Above-Ground Storage Tanks

By:
Tribhuwan Kumar,
DGM(O)
NRPL,Panipat
A GLIMPSE ON TOPICS TO BE DISCUSSED
1.Different types of storage tanks
2. Design codes
3. Design basis for tanks
4. Safety features in tanks design
5. Corrosion resistance system
6. Some important fittings in tank design
 TYPES OF ABOVEGROUND TANK

Fixed roof Fixed cum internal Floating roof

(Cone , floating
Umbrella,
Dome)
Single Deck Double deck
Generally for high
Volatile products like (Crude)
(HSD, SKO,
MS
LDO)
 FIXED ROOF TANKS
Cone roof Umbrella roof

Dome roof
 TYPES OF STEEL TANK
(FLOATING ROOF)
 To store volatile products
 For tanks having big volumes

 According to their position:

- external floating roof
- internal floating roof

 According to their construction:

- single deck floating roof;
- double deck floating roof.
INTERNAL FLOATING ROOF TANKS
 EXTERNAL FLOATING ROOF

Annular pontoon Double deck

ADVANTAGES OF IFR OVER DDFR
DIFFERENT TYPES OF ROOF AND BOTTOM
 TANK ROOF
FLOATING ROOF - EITHER SINGLE DECK OR DOUBLE DECK

TOP DECK
SUPPORTING
SEAL AREA
LEGS
ROOF DRAIN

BOTTOM DECK
 TANK BOTTOM
Shape of the bottom
Cone up
Cone down
Flat with slope
Flat without slope
 TANK BOTTOM

SLOPING TOWARDS CENTER TOP DECK

SUPPORTING
SEAL AREA
LEGS
ROOF DRAIN

BOTTOM DECK
 TANK BOTTOM

SLOPING TOWARDS SHELL

TOP DECK
SUPPORTING
SEAL AREA
LEGS
ROOF DRAIN

BOTTOM DECK
DESIGN CODES
 API STD 650 : SCOPE

 The standard is meant for design, selection of

materials, fabrication, erection & testing
 Vertical, cylindrical, above ground, closed and

open top, welded steel storage tanks.

 Internal Pressure approximating to atmospheric

pressure.
 The tanks entire bottom is uniformly supported.
 The tanks are in non refrigerated service and

maximum temp of 93 deg C.

15
FACTORS TO BE SPECIFIED FOR DESIGN

 Metal Temp
 Specific gravity
 Corrosion allowance for each component
 Wind velocity
 Special consideration to foundation.
DESIGN CONSIDERATION
 Dead Load : Weight of the tank or tank component
 External Pressure : Atmospheric
 Hydrostatic load: load due to filling the tank with water to
the design liquid level
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 SAMPLE DATA SHEET
Design Code API-650 11th. Edition
Design /Operating Pressure ATM.
Design temperature 55 Deg C
Operating temperature Ambient
Stored product Crude oil/ MS/Diesel/SKO/Naphtha
Specific gravity Taken as per product
Wind pressure As per IS : 875 (Part-3) 1987
Wind speed 50-65 meter/ second depending on location
Design rain fall intensity As per data from metrological department
Seismic load As per IS : 1893, 1984 & depending on location
Corrosion allowance Shell 1.5-3mm; Bottom 1.5mm & Roof- Nil
Radiography As per API-650, Section-8
Joint efficiency factor 1 (For shell design calculation)
Testing As per tender spec. & API-650
Nominal capacity As per tender
Effective operation capacity Tank designer to submit
Type of roof DDFR/ IFR/ Cone roof
Diameter & Height of tank As per tender specification
 SAMPLE MATERIAL SPECIFICATIONS
Shell ASTM-A-537-Class 1/ IS 2062 Gr. B
Annular plate ASTM-A-537-Class 1
Bottom/ roof plate IS 2062 Gr. B
Manhole necks ASTM-A-537-Class 1
Manhole flanges ASTM-A-537-Class 1
Nozzle necks ASTM-A-53 GR.B/ API 5L GR.B
Nozzle flanges A-105 Gr. 1
Gasket CAF (IS 2712)
Bolting for structural IS : 1363
External gusset IS 2062 Gr. B
Stairway, platform IS 2062 Gr. B
Handrail IS : 1239 (GI)
Wind girder, pipe support IS 2062 Gr. B
Pipe fitting SA 234 Gr. WPB
Name plate bracket SS 304
Gauge hatch Aluminum/ Brass
Gauge well pipe ASTM-A-53 GR.B/ ASTM- A 106 GR. B
TANK CAPACITY

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SPECIFICATION FOR STEEL
PLATE
 HR coils
• shall be rolled from continuous cast slabs
• made by Open Hearth/ Basic Oxygen/ Electric Arc furnace
steel process.
Plates shall be
• fully killed & made to fine austenitic grain size requirement of
specification ASTM A 20/20M.
• Fully killed plates shall be heat treated to produce grain
refinement by normalizing.
Tests and inspections to be carried out on steel plates are :
Tests ASTM A 537 IS 2062

Tensile test √ √

Bend test √ √

Charpy V-notch Impact test √ √

Ultrasonic testing √ √

Dimensional check √ √
 STORAGE TANK DESIGN

 CONSISTS OF 4 MAIN SECTIONS

◦ SHELL DESIGN

◦ BOTTOM DESIGN

◦ ROOF DESIGN

◦ FOUDATION DESIGN
SHELL DESIGN
 DESIGN CRITERIA OF API STD 650
◦ API Std 650 is based on maximum Principal stress
theory.

◦ Thickness of tank shell is calculated by stress due to

hydrostatic pressure + internal vapor pressure.

◦ Allowable Stress : Design Condition (Sd)

Min of 2/3 of Yield Stress or 2/5 of ultimate tensile stress
whichever is less

◦ Allowable Stress : Hydrostatic Condition (St)

Min of 3/4 of Yield tress or 3/7 of ultimate tensile stress
24
whichever is less
 TANK SHELL DESIGN
Various stresses to which the shell of a tank is subjected to are as follows:
 Hoop Stress : Major stress in the shell is hoop tension which is caused by

the head of product in the tank, together with any overpressure in the roof of
a fixed roof tank

 Axial compression: This stress is made up of the following component:

◦ The self-weight of the tank, comprising the shell, the roof, the
superimposed load on the roof and any attachments to the tank.

◦ The compressive load due to any internal vacuum in the tank.

◦ Wind load acting on the shell of the tank causes a overturning effect and
hence induces a compressive load on the shell.

◦ Where a tank is located in a geographical area which is subject to

earthquakes, then compressive stresses due to seismic action can be
transmitted to the shell.
 SHELL DESIGN

Shell stress Top and 1.Stability check

design which is intermediate against the wind
to size up the stiffener ring 2. Seismic load
shell wall 3. Requirement
thickness of the anchor
bolt
SHELL WALL THICKNESS
CALCULATION
 1-FOOT METHOD
◦ The most common method of shell thickness
calculation
◦ The 1-foot method calculates the thickness
required at design points 0.3 m (1ft) above the
bottom of each shell course
◦ The required minimum thickness of shell plates
shall be the greater of the value computed as per
API 650
◦ 1-foot equation shows that the minimum required
shell thickness is directly proportional to the liquid
static height.
◦ It is used up to tank dia. of 61 M.
SHELL THICKNESS CALCULATION
4.9D (H-0.3)G + CA
td =
Sd

4.9D (H-0.3)
tt =
St
td : Design shell thickness in mm
tt : Hydro-test shell thickness in mm
Sd : Allowable stress of the shell plate material for
design condition in MPa
St : Allowable stress of the shell plate material for
hydro-test condition in MPa
D : Nominal Diameter of tank in m
H : Design liquid Level in m
G : Design specific Gravity of the liquid to be stored
CA : Corrosion allowance in mm
 TANK COMPONENTS
SHELL THICKNESS

Required shell thickness shall be the greater of the design shell

thickness, including any corrosion allowance, or the hydrostatic test
shell thickness, but the shell thickness shall not be less than the
following:

Nominal dia of Tank Min. Nominal Plate thickness

<15 M 5 mm
15 M to 36 M 6 mm
36 M to 60 M 8 mm
>60 M 10 mm

Shell plates are limited to a maximum thickness of 45 mm

Tank shell to be checked for stability against buckling from the design
wind speed. If required for stability, intermediate girders, increased 30
shell plate thickness or both shall be used.
TANK COMPONENTS- VARIABLE-
DESIGN-POINT METHOD
FOR TANK DIAMETER GREATER THAN 61 M.

31
INDICATIVE SKETCH OF SHELL THICKNESS
Different shell course with different
thickness is used. The use of courses
with diminishing thickness means
following:
At the joint between two adjacent
courses, the thicker lower course
provides some stiffening to the top
thinner course.

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TANK COMPONENTS: TANK FABRICATION & ERECTION
Typical Joints :

33
 DIMENSIONAL TOLERANCES
• Plumpness : Top of shell relative to bottom not to
exceed 1/200 of total tank height.
• Roundness : Radii measured at 1 ft above the
bottom corner weld shall not exceed the following :
Tank Dia. Radius Tolerance
< 12 m +/-1/2’’
12 to 45m +/- ¾’’
45 m to 75 m +/- 1’’
>=75 m +/- 1.25’’

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 TANK SHELL ATTACHMENTS

Foam guard

Wind girder
Cooling rings Foam line

Water Stirrer Shell Manhole

draw-off

A Tank shell opening that is larger than 2’’ to be suitably reinforced.

 TANK COMPONENTS: TOP & INTERMEDIATE WIND
GIRDER
• Open Top Tanks to be provided with stiffening rings to maintain
Roundness at or near the top of the course preferably at outside.

• When Wind girders are located more than 0.6M below the
top of the shell, the shell to be provided with a top curb angle -
size 64 x 64 x 4.8 mm for shell 5 mm thick and angle size of 76 x
76 x 6.4 mm for shell more than 5 mm thk

• Stiffening Ring or wind girder can be used as walkway.

Width of walkway not to be less than 24 inch.

• Location of Primary wind girder at about 1100mm from top of

shell.

36
 PRIMARY WIND GIRDER

Hand rail Curb angle

Mid rail

Shell
Toe board

Shell patch plate

Walk way
 SECONDARY WIND GIRDER
Depending on the wind speed, height , diameter,
secondary/tertiary wind girder is decided.

Secondary wing girder

Opening for stair case Toe board

Shell
 BOTTOM PLATE DESIGN

 All bottom plates shall have a corroded thickness of not less than 6
mm. Add 1.5 CA, bottom plate thickness is usually taken 8mm.
 Butt-welded annular bottom plates are used normally. Annular bottom
plates shall have a radial width that provides at least 600 mm (24 in.)
between the inside of the shell and any lap-welded joint in the
remainder of the bottom.
 Annular plate width=(215XTb)/ (HG)0.5 ; where Tb is width of Annular
plate in mm, H is max. design ht in mtr. , G is specific gravity of liquid.
 Selected width of annular plate to be higher of the above two.
 ANNULAR PLATE

•Annular Bottom Plate thickness:

6-9 mm. if 1st Shell course is less than 19 mm.
6-11 mm. if shell course is between 19-25 mm
6-14 mm if shell course is between 25-32 mm
8-17 mm if shell course is between 32-38 mm
9-19 mm if shell course is between 40-45mm
Variation in thickness of annual bottom plate thickness is
due to 1st shell course stress value/Material of
construction.
 TANK BOTTOM
Shell Course

Bottom Plate Annular Plate

Short Seam

Long Seam
ROOF DESIGN
 TANK COMPONENTS: ROOF DESIGN
Fixed Roof :
• Dead Load : (a) Self weight of members including the weight of
joints & connections.
(b) Weight of covering plates
(C) Weight of bracing members
(d) Weight of nozzles and attachments etc.
• Live Load : Roofs and all supporting members to carry a
uniformly distributed live load of 125 kg/m2. This
includes wind load and internal vacuum load also.
• Seismic Load : Basic seismic coefficient are given in IS 1893-
1984. These loads are to be considered in
conjunction with the self and live load.

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 TANK COMPONENTS: ROOF DESIGN

Fixed Roof
(1) Roof plate shall have a minimum nominal thickness of
5 mm.
(2) Roof plates shall be attached to the top angle of the
tank with continuous fillet weld on top side only.
(3) A roof is considered not rigid if shell to roof joint fails
prior to the shell to bottom joint in the event of
excessive internal pressure.
(4) Slope of the roof at the top angle attachment does not
exceed 1 in 6.

44
TANK COMPONENTS: ROOF SUPPORT
Supported Fixed Roof
(1) Minimum thickness of any structural member,
including any CA on the exposed side or sides shall not
be less than 6 mm for columns, knee braces and
beams.
(2) It shall be 4 mm minimum for any other members.
(3) For columns the value of L/rc (maximum slenderness
ratio) shall not exceed 180.
(4) For all other members except tie rods, the L/rc shall
not exceed 300.
where, L = unbraced length, rc = least radius of
gyration of column and r = governing radius of
gyration.
45
TANK COMPONENTS: ROOF SUPPORT
( TYPICAL COLUMN BASE DETAILS)

46
 TANK COMPONENTS: EXTERNAL
FLOATING ROOF
Deck : Roof in corrosive sour services such as Crude Oil should be
contact type designed to eliminate the presence of any air-vapour
mixture under the deck.
(1) All deck plates shall have minimum nominal thickness of 5 mm.
(2) Pontoon : Pontoon Design shall be based on a liquid with a
specific gravity of 0.7 and with primary drain inoperative for the
condition as under:
 250 mm of rainfall in 24 hours period .
 Single deck and any two adjacent pontoon compartments
punctured and flooded.
Double deck and any two adjacent compartment punctured and
flooded without any water or live load.
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 TANK COMPONENTS: EXTERNAL
FLOATING ROOF
• Ladders : A ladder to be provided for access to the roof. All deck
plates shall have minimum nominal thickness of 5 mm.
• Roof Drains : Shall be not less than 3 inch for tank dia up to 36
M and for tank dia more than 32 M, the roof drain shall be 4 inch
NB. Drain shall be provided with an NRV.
• Emergency Roof drain : Min. 3 nos. drains to be provided in
double deck design to take care of severe rainfall.
• Vents: To prevent overstressing of the roof deck or seal
membrane, automatic bleeder vent is furnished.
• Supporting Legs : Size >= 2 inch NPS

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TANK ROOF ACCESSORIES
 ROOF ATTACHMENTS

Foam pourer

Foam cylinder

Bleeder vent
Foam dam

Pontoon manhole Roof supports

TANK COMPONENTS: EXTERNAL FLOATING ROOF
• Roof Manholes : Minimum diameter of 24 inch.

•Number of Manholes in the Roof shall be as follows:

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FOUNDATION DESIGN
Foundation design depends on
 Soil condition, Seismic zone, height of tank
 Type of tank -cone roof/ floating roof
 Dead load- Weight of tank + Weight Of liquid+ Weight Of cone roof /
floating roof
 Soil Settlement
 Soil investigation and study are required to monitor the soil settlement.
Soil settlement is a common problem in compressible soil
 At location where weak, compressible layers are present in the subsoil,
excessive soil settlement may occur due to the weight of the tank and
its liquid content.
 Excessive soil settlement can affect the integrity of tank shells and
bottoms.

53
 STONE COLUMN FOUNDATION
 Used in places where soil is compressible
 Vibro replacement stone columns are a ground improvement
technique to improve the load bearing capacity and reduce the
settlement of the soil.
 The stone column consists of crushed coarse aggregates of various
sizes.
 The crushed aggregates in the definite proportion are to be placed
into the soil at regular intervals throughout the area of the land
 This is done either by using the dry or the wet top feed vibrators
 The vibrating probe breaks down the pores of the surrounding soil,
thereby making the soil dense. The crushed aggregates or the gravel
that is poured in takes the place of the soil and keeps up the
pressure on the soil that was created by the vibrating probe.
 These columns are made across the area to be built on in a grid
pattern at regular intervals.

54
55
56
TANK BOTTOM CP
C.P SYSTEM FOR TANK BOTTOM PROTECTION
• Long Line Polymeric Anodes with inbuilt Coke Breeze is
provided for protecting the earth side of tank bottom plates.
• 100% area of tank bottom is considered bare, although it is
black high build bitument coated at the soil side
• Only soil side is protected with Impressed Current Cathodic
Protection system
• The cable strings are laid parallel below the tank bottom at
approximate depth of 1000 mm
• Design life of anodes considered is 35 years
• Minimum Protection current=10mA/Sqm of tank Bottom
plate
SAFETY CONSIDERATIONS
IN DESIGN
 ADEQUATE FIRE PROTECTION FACILITY IS BEING
CONSIDERED IN LINE WITH THE STIPULATIONS OF OISD-117
FOR STORAGE TANKS.
 AFFF based modular type rim seal fire protection system for all
the tanks.
 Fixed foam protection system with centralized foam station,
carrier pipes, foam makers etc for all tanks.
 Multiple cooling ring main for cooling of tank shell.
 Fire hydrant network covering the entire tank farm area with fire
hydrant valves, fire water monitors.
 For fire water storage over ground storage tanks are considered
with fire water pumps, jockey pump etc.
 A separate Fire station with all facilities including mobile Foam
Tender is provided.
 Electrical contact between the roof & ladder, shell & ladder, roof
& shell.
 Adequate earthing of the shell.
 Provision of primary and secondary seals
 RIM SEAL FIRE PROTECTION SYSTEM –
PRIMARY PROTECTION

• For primary fire protection against rim seal fire, foam

based modular type rim seal fire protection system
with metal-tube, linear heat detection system is
considered.
• This is a self actuating and instant extinguishing
system. Additionally, the alarm signals generated
shall be used for actuation of Secondary fire
protection system
RIM SEAL SYSTEM
AUTOMATIC FOAM FLOODING SYSTEM
 FOAM POURER SYSTEM –
SECONDARY PROTECTION
•Fixed Foam system has been considered as secondary fire
protection measure for the storage tanks.

•The system has centralized foam stations accommodating foam

concentrate tanks, foam proportioners, foam solution carrier pipes,
riser pipes, foam makers and foam pourers.

•The actuation of the system is from sensors.

•The system can be actuated with the alarm signal provided by the
rim-seal fire protection system.
SEMI FIXED FOAM SYSTEM
 SEMI FIXED FOAM SYSTEM

Injection of foam from near the bottom (Fixed roof tanks)

 SEMI FIXED FOAM SYSTEM

Foam injection for internal floating roof tanks (like ATF)

 COOLING WATER RINGS
 Cooling water ring mains around the shell at
different elevations for even distribution for
cooling of tanks on fire @ 3 litre per minute.
 Spray the water on the tank on fire as well as on
tank in same dyke area simultaneously @ 3 litre
per minute.
 For other tanks, which is not in same dyke
cooling is to be provided @ 1 litre per minute.
 2/3 rings are provided depending on water
requirement, spray nozzle type
SAFETY CONSIDERATIONS IN DESIGN
PRIMARY SEALS

Foam type
 SECONDARY SEALS

Compression plate Double seal

type secondary seal
FLEXIBLE ROOF DRAIN SYSTEM
 BREATHER VALVES

Pressure Relieving
Device

Vacuum Relieving
Device

Flame Arrestor

Erected view of the P&V Valve

TANK MIXERS
TANK RADAR GAUGE
ANTI ROTATIONAL DEVICE
FAULTY DESIGN LEADS TO
DISASTER
STORAGE TANK COLLAPSED DUE TO
HEAVY WIND

82
STORAGE TANK COLLAPSED DUE TO
HEAVY WIND
Seismic effect
causes damage
to shell
 NEW CONCEPTS ON DEAD STOCK REDUCTION IN
STORAGE TANKS(INVENTORY REDUCTION)

 Nominal capacity- The gross volume of the tank

cylinder.

 Working capacity- The available product in the tank for

flow into process, etc.

 Inventory- Volume of unused product or “dead stock”

under the floating roof- determined by the low leg height
settings on the floating roof.
 NEW CONCEPTS ON DEAD STOCK REDUCTION IN
STORAGE TANKS(INVENTORY REDUCTION)

 Working capacity increase attempts to enhance the total volume of

the tank available for use. It typically includes inventory reduction.

 This strategy typically provide a favorable ROI. For a 79m tank,

each 100mm reduced inventory adds approximately $315k to
working capital assuming a crude price of $100/bbl.

 Dead stock or unusable inventory

that must remain in the bottom of the
tank while operating.

Unusable Inventory
 NEW CONCEPTS ON DEAD STOCK REDUCTION IN
STORAGE TANKS(INVENTORY REDUCTION)

 Under Bottom Sump(Drain Dry sump)- The idea is to

put the large nozzles, such as fill/suction nozzles below
the shell. The shape of the sump acts as a diffuser,
although additional velocity reduction can be added as
well. It also can serve as the water draw off sump as
well, eliminating another shell nozzle.
 NEW CONCEPTS ON DEAD STOCK REDUCTION IN
STORAGE TANKS(INVENTORY REDUCTION)

Advantages of Drain Dry sump

 Allows floating roof to travel much lower by removing
interference from shell nozzles which are
now moved to an elevation below the tank bottom.
 Greatly reduces inventory
 Increases working capacity.
 NEW CONCEPTS ON DEAD STOCK REDUCTION IN
STORAGE TANKS(INVENTORY REDUCTION)

Drain Dry sump- Constraints & Challenges

 For the tanks, the “cone up“ bottom design needs to be

changed to allow flow into the drain dry sump. (Flat or
sloped down design)
 Water will accumulate in the under bottom sump & shall
be mixed/pumped with the product.
 As per API 650, under-bottom connections may be
potentially problematic in areas where high lateral
impulsive ground motion may cause the tank to slide.
The tank sliding may cause a bottom failure.
 NEW CONCEPTS ON DEAD STOCK REDUCTION IN
STORAGE TANKS(INVENTORY REDUCTION)

CONCEPT OF PLATEAU BOTTOM – DESIGN CONSIDERATIONS

 Sufficient distance should be allowed around the perimeter for mixers and propellers,
water draw off, drain nozzles and other operational considerations.
 Slope up can be gradual or more steep as shown.
 Slope area bottom fill material needs to be protected from degradation. Keeps the
slope intact.
 Care should be taken in the placement of the EFR support legs so that they do not
land on the slope, but have relatively flat bearing.
 Similar to the water bottom concept discussed but without the difficulties of multiple
liquids being stored in the tank.
 NEW CONCEPTS ON DEAD STOCK REDUCTION IN
STORAGE TANKS(INVENTORY REDUCTION)

Plateau Bottom Design

 It is strictly for inventory reduction. Does not change the
working capacity of the tank.
 Raised bottom that displaces significant amounts of
inventory- 60 to 70% reduction in inventory possible
 Ideal for use with mixers or other perimeter equipment
without utilizing mixer notches
 Fill/suction nozzles can remain in shell if desired.
 NEW CONCEPTS ON DEAD STOCK REDUCTION IN
STORAGE TANKS(INVENTORY REDUCTION)

Plateau Bottom Design- Constraints & Challenges

 As support legs of the floating roof can not be placed in
slope area, support legs re-engineering is to be done.
 Roof drain flexible hose pipe can not be accommodated
in 300 mm space .
 Roof drain manhole climb down ladder is about 1300
mm projected inward from lower deck of the floating roof.
THANK YOU