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Improving Industry Needs Construction of New Storage Tanks

according to API 650

November 29&30, 2011ISTANBUL - TURKEY

FE RT GNGRM BUREAU VERITASOil & Gas, Energy Supervisor API 653 AUTHORIZED INSPECTOR


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2Tankstorage presentation Turkey 30/11/2011

Bureau Veritas at a Glance

Established in 1828

Providing one-stop service andinnovative solutions in QHSEmanagement, whatever the asset,product or business sector

- 48,000 employees, 930 officesand 330 laboratories in 140countries

- 400,000 clients- 8 global businesses withleadership positions- 2010 revenue: 2.9 billion

- Quality- Health- Safety- Environment- Social responsibility

Broad Geographic Presence 1


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Bureau Veritas at a Glance


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A Balanced Portfolio of Activities

Industry

Marine

Inspection & In-ServiceVerification (IVS)

Health, Safety and

Environment (HSE)

Construction

Certification

Consumer Products

Government Servicesand International Trade(GSIT)

Ship classification, ship and marine equipment certification, technical assistance and outsourcing services

Conformity assessment of industrial equipment and installations to regulatory or client specifications fromfeasibility stage to de-commissioning

Services include design review, shop inspection, site inspection, asset integrity management, productcertification and related testing services such as non-destructive testing

Periodic inspection of equipment and installations to assess conformity with regulations or client-specificrequirements

Services apply to electrical installations, fire safety systems, lifts, pressure and lifting equipment, and machinery

Inspection, audit, measurement and testing services in the areas of environment and health and safety Technical assistance and consultancy services to help companies define their HSE management strategy and

improve their performances

Conformity assessment of construction projects to local regulations and construction standards, from designstage to completion

Services include design review, code compliance, technical control, on-site safety coordination, testingof construction materials, asset management and technical due diligence services

Certification of management systems and processes in the areas of quality, health and safety, environmentand social responsibility based on public standards

Second party auditing services based on customer-specific or Bureau Veritas standards

Testing, inspection and certification of consumer goods including textile, hardlines, toys, electrical andelectronics

Factory audits, social responsibility audits and training services

Government Services: Pre-Shipment Inspection, X-Ray Scanning, Verification of Conformity of importedproducts

International Trade: Commodity quantity/quality assurance, automotive services

Eight global businesses providing strong growth and cross-selling opportunities


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CONTENT of PRESENTATION

1. Improving Industry Needs2. Design - Basic design approach and verification

3. Fabrication - Important points for fabrication at workshopsor site

4. Erection - Methods and their advantages/disadvantages

5. Testing - NDT, Pneumatic & Hydrostatic testing


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1. Improving Industry Needs

Global improvement on industry is going on

with increasing population and technology. To solve raw material needs for serialproduction increasing number of storage tank isunavoidable.

Increasing number of vehicle in traffic causes

construction of new storage tanks. Old storage tanks, generally built up before1970s need to be replaced with new ones duecorrosion on material and wrongmanufacturing/erection techniques in past.

Natural reasons such as eartquake, wind, snowalso cause new storage tanks or reinforcementon in-service tanks

Change in service or operation cause newstorage tanks or change in tank structure orgeometry.

API 650


7/297Tankstorage presentation Turkey 30/11/2011

CONTENT of PRESENTATION

Othervise;



1. Improving Industry Needs

Locally there are two refinery projects in Turkey, and one storage terminal forchemical or nutrition liquid storage.

Countries especially in Middle East, Africa needs new storage tanks

To standardize and share lessons learnt by other API was established in 1919.Issued first standart in 1924.

For storage tanks beginning with API 12C, API 650 - Welded Tanks for OilStorage code describes and defines rules for construction of new storage tanks.Recently 11th Ed. of API 650 is on the market.

Mainly; materail, design, fabrication, erection, inspection of joints, weldingrequirements and marking were defined in API 650.

Understanding of API 650 an follow its requirements can lead owners to avoidany failure/loss experienced by others.



2. Design - Basic design approach and verification

2.1 Types of Atmospheric Storage Tank Roofs The most common type of atmospheric storage tank is the fixed cone roof tank, Theseroofs are normally supported by internal structural but can be fully self-supporting in smallerdiameters (typically, 60 ft [3 m] diameter or less). up to 300 ft (91.5 m) in diameter & 64 ft(19.5 m) in height (larger diameter tanks have been built, mostly outside the U.S.)




2.1 Types of Atmospheric Storage Tank Roofs

The floating-roof tank is designed to minimize filling and breathinglosses by eliminating or minimizing the vapor space above the storedliquid. The shell and bottom of this type of tank are similar to those ofthe fixed roof tanks, but in this case, the roof is designed to float on thesurface of the stored liquid. Older styles of floating roofs include single

steel deck details without annular pontoons. Such roofs have no reservebuoyancy and are susceptible to sinking in service. Annular-pontoonand double-deck; roofs are external floating roof tanks.Some floating-roof tanks have fixed aluminium geodesic dome roofsinstalled on top of the tank shell to reduce product vapor loss or to

eliminate the need to drain rainwater from the roof. These areconsidered internal floating roofs is a tank with a fixed steel cone roofover a floating roof.





Double-Deck Annular Pontoon





Low-pressure storage tanks are those designed to operate with pressures intheir gas or vapor spaces exceeding the 2.5 lbf/in.2 (18 kPa) gauge permissiblein API Std 650, but not exceeding the 15 lbf/in.2 (103 kPa) gauge maximumlimitation of API Std 620.

Plain Hemispheroids Vapor Dome Roof




2.2 Materials used in construction

Section 4 of API 650 define materials can be used in construction of a storagetank. Accoding to this section mainly below materials can be used;

Also design metaltemperature should be takeninto account according tolocation of storage tank.

Material type of shapes andpipe is also deifned insection 4.

Welding electrode for;

Material has Ut550 MPa,E80 series




2.3 Basic Design Approach and Verification

2.3.1 Correct thickness?Shell thickness easliy can be verified by 1-foot method;

td: design thicknesstt: hydrotest thicknessD:nominal tank diameterH:design liquid levelG:specific gravity of productSd:allowable stress for designSt:allowable strss for

hydrotestCA:corrosion allowance

In any case min thicknesses as follows;

Bottom plates shall be minimum 6 mm thick exclusive of CA unless othervisespecified. API 650 offers 1800 mm width plates.




2.3 Basic Design Approach and Verification Annular plate thickness shall be decided acc. to below table;

The ring of annular plates shall have a circular outside circumference, but may have aregular polygonal shape inside the tank shell, with the number of sides equal to the number of annular plates.


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2.4 Opennings in correct location?

Tank design review can prevent many imperfection duringfabrication or erection.



3. Fabrication - Important points for f abricat ion at workshops or si t e

During fabrication of tank material in workshop or site maximumcare shall be taken not to cause failure during erection or service.

Edges of plates may be sheared, machined, chipped, or machine gas cut.Shearing shall be limited to plates less than or equal to 10 mm thick used for butt-welded joints and to plates less than or equal to 16 mm thick used for lap-weldedJoints

Shaping of shell plates before erection should be done according to belowfigure;



3. Fabrication - Important points for f abricat ion at workshops or si t e

Good engineering design can accelerate erection by pre-drilled

openning. Drilling of telltale holes shall be done before erection

Radius and weld bevel control during fabrication can prevent anytime/effort loss during erection

Proper marking of shell/bottom plates with a prestudied drawing cansave time and effort during erection.

Plates and tank material shall be loaded in a manner that ensuresdelivery without damage

Shop primer on plates and protective oil on flange faces canprevent material from corrosion till final process




4.1 After foundation works and laying bottom/annular plates, there are

mainly two different erection method for storage tanks;1. Conventional method: Starting from bottom course and raising tankputting upper courses on top of bottom one via crane.




2. Jacking method: Starting from top course and raising bottom courses

on bottom of top one via hydrojacking.


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4.2 Advantages/Disadvantages of Each Method

Conventional method needs crane which costs huge amount iferection works delay( generally occurs)

Jacking method is safer especially against site accidents Conventional method provide less temporary welds and eventually

less cleaning and NDT works.

Jacking method provides generally working on ground level and highweld quality

Conventional method is faster if no repair works retrospectively. Jacking method helps worker for inside work during raising of tank. Conventional method complicate final inspections

Jacking method needs NDT results and repairs(if exist) before puttingbottom one Conventional method complicate NDT works Jacking method needs more workmanship during raising operation. Convetional method is more dependent on climatic conditions


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4.3 Important points during erection

Welding procedures and welder certificatesshall be prepared according to ASMESec.9. For welds on non-pressure partsAWS D1.1 can be used.

The welding of the shell to the bottom shallbe practically completed before the weldingof bottom joints that may have been leftopen to compensate for shrinkage of anywelds previously made is completed.

Upper plate at a horizontal butt joint shall

have a 4:1 taper when its thickness is morethan 3 mm greater than the lower plate


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4.3 Important points during erection

Misalignment during shell welding, vertical or horizontal, shall becontrolled. Limits around 1,5 and 3 mm, respectively.

After first pass of shell-to-bottom weld from outside weld shouldbe checked against leakage with suitable manner.

Shell butt welds shall be examined with either RT or UT. Plumbness and roundness control shall be taken into account

before hydrotest. Foundation requirements shall be provided to achive other

dimensional tolerances.


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5. Testing NDT, Pneumatic and Hydrostatic Testing. 5.1 Pneumatic and Hydrostatic Testing

Welds of bottom shall be checked with vacuum box with air pressurebetween 20kPa and 70 kPa.

Before hydrotest pads shall be tested pneumatically with air up to100 kPa

During hydrotest water level shall be increased at least 50 mmabove the weld of roof-to-shell(top angle) connection

For carbon steel equipment where water contact exceeds 14 days,including filling and draining owner may consider adding an oxygenscavenger and a biocide, and raise the pH by the addition of caustic.

Aim of hydrotest is checking welds against leaking as well settlementcontrol.

Roof plates shall be tested by vacuum box or bubble test. If bubbletest is used, before draining water after hydrotest volume abovewater level shall pressurized with air not exceeding weight of roofplates.


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5. Testing NDT, Pneumatic and Hydrostatic Testing. 5.2 NDT(Non-Destructive Test)

Number of RT film on shell welds shall be decide from below figure;


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5. Testing NDT, Pneumatic and Hydrostatic Testing. 5.2 NDT(Non-Destructive Test)

We offer shortly; one spot from each first vertical, each T joint, onespot per 20 m vertical weld and one spot per 40 m horizontal weld .

Annular plate butt weld shall be examined via RT RT shall be applied according to ASME Sec. 5 and evaluated

according to ASME Sec 8. Penalty films shall be taken into account carefully. Magnetic and Liquid penetrant testing shall be applied according to

ASME Sec 5. and evaluated according to ASME Sec.8. Moreoveroperator shall have eye vision capability test report not older than1-year.

Reinforcement of welds and undercut shall be xamined carefully

according to limits given in Sec. 8 of API 650. Arc strikes are generally evaluated as harmless or ignored. Howeverthey can initiate big failure. Those shall be cleaned carefully.


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Bureau Veritas Turkey Services for Storage Tanks

API 650 DESIGN REVIEW PREPARATION WELDER QUALIFICATION & PQR REVIEW OF WELDING PROCEDURE SPECIFICATIONS 3.PARTY INSPECTION OF ERECTION &

MANUFACTURING OCCUPATIONAL HEALTH & SAFETY DURING

CONSTRUCTION API 653 - IN-SERVICE & OUT OF SERVICE INSPECTIONS AUTHORIZE INSPECTOR SERVICES NON-DESTRUCTIVE TESTS SETTLEMENT SURVEYS TANK BOTTOM SCAN BY MFL AND FLOOR SCANNER CERTIFICATION OF HYDROSTATIC TEST TRAINING ABOUT INSPECTION & CONSTRUCTION


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