API 650 TANKS - Engineers Australia

1 api 650 TANKSINSTALLATION and COMMISSIONINGINSTALLATION and COMMISSIONINGbyMike Raine BSc MSc MIEAust AFIAM Director, Engineering ManagerFuel Tank and PipeProcess Water TanksFMG Cloudbreak Mine-site5/27/2009 FUEL TANK & PIPE2 api 650 TANKS INSTALLATION TANK BUNDS FOUNDATIONS/RING BEAMS WELDING PROCEDURES COMMISSIONING TANK STRAPPING NDT HYDROTESTING PV VENTS5/27/2009 FUEL TANK & PIPE3 WELDING PROCEDURES FLOOR PLATE LAYOUT STRAKE LAYOUT ROOF CONSTRUCTION ROOF LIFT NOZZLE INSTALLATION SURFACE PREPARATION TOLERANCES PV VENTS CONTROL PHILOSOPHY INSTRUMENTSP rocess Water TANKS , Diesel Storage TANKS , Cloudbreak5/27/2009 FUEL TANK & PIPE4 TANK BUNDS AS1940 mandates bunded storage for hydrocarbon storage facilities. Bund volume shall not be less than 110% of the volume of storage. For multiple TANKS , multiple products the storage volume is 110% of the largest tank.

2 Although each tank must be independent and fully isolatable from the other TANK & PIPE5independent and fully isolatable from the other TANKS . Bund Construction Earthen bund fully lined with a composite Geo-Fabric, Welded HDPE liner, Geo Fabric Membrane installed on a select fill base Bund walls with a 45 Degress angle of repose covered with a concrete filled revetment mattress. Revetment mattress can either be painted or covered with a layer of concrete. Bund liner is pneumatically leaked tested on the overlapping welded BUND HDPE Lined filled revetment mattress prior to final select fill providing a metre of cover over the Geo-Fabric HDPE TANK & PIPE6cover over the Geo-Fabric HDPE Bund Construction 5/27/2009 FUEL TANK & PIPE7 Other forms of Bunding Self Bunded TANKS Limits storage volume and results in multiple TANKS . Concrete Bunds5/27/2009 FUEL TANK & PIPE8 Effective for a tank farm with an array of small TANKS .

3 Both methods cost prohibitive on large volume storage courtesy of DRA TankFoundation Ring Beam Construction Tank foundations at typically of 3 types. Concrete Ring Wall Asphalt Sand-pad5/27/2009 FUEL TANK & PIPE9 Sand-pad FT&P almost exclusively build TANKS on a concrete ring wall Ring Beam design Ring beams perform a variety of functions. A critical aspect of ring beam design is whether holding down bolts are required for wind overturning stability. Factors influencing the needs for holding down 5/27/2009 FUEL TANK & PIPE10 Factors influencing the needs for holding down bolts include; Cyclonic region and prevailing wind speeds. (AS/NZS :2002) Weight of Tank (excluding roof and contents) Aspect ratio of the tank, tall versus squat to achieve the same storage Client Wall Components Reinforcing Bars Re-bar comprises ligatures placed on an angular pattern with a maintained TANK & PIPE11spacing.

4 A total 8 to10 rolled circumferential lace bars located on the internal and external diameters of the ligatures. Plywood board and rolled tubes make up the remainder of the Wall Components 30mm PVC pipes are installed at 4 angular locations to provide weep holes leaking product. Tank earthing is facilitated by connecting the tank shell to the rebar. The ring wall is back filled with select fill and compacted to 95% TANK & PIPE12compacted to 95% mdd. Diesel is sprayed on the fill to prevent corrosion of the underside of the floor plate. Bitumen board installed on top of the ring wall providing a compressive membrane between it and the floor of Ring Wall Ring beam foundation is excavated after the liner has been installed and the bund has been backfilled. A 50mm layer of blinding is installed to provide a stable base for the construction of the formworks.

5 Establishing a stable level base/foundation is critical to 5/27/2009 FUEL TANK & PIPE13 Establishing a stable level base/foundation is critical to achieving tight tolerances on the overall tank Wall Construction5/27/2009 FUEL TANK & PIPE14 Ring Wall Construction5/27/2009 FUEL TANK & PIPE15 Holding Down Bolts Analysis5/27/2009 FUEL TANK & PIPE16 Wind Forces, Overturning Moments5/27/2009 FUEL TANK & PIPE17 Wind Forces, Overturning Moments5/27/2009 FUEL TANK & PIPE18 design of Anchor Bolts5/27/2009 FUEL TANK & PIPE19 Holding Down bolt ArrangementRing Beam for HD BoltsInverted Tee Ring Beam5/27/2009 FUEL TANK & PIPE20 Holding Down Bolt ArrangementFEA of HD ArrangementShell Bolting Arrangement5/27/2009 FUEL TANK & PIPE21 Weep Hole, Earthling Strap5/27/2009 FUEL TANK & PIPE22 Floor Plate Layout Typically floor plate ranges in thickness from 6-10mm without the addition of corrosion allowance.

6 FT&P generally utilise an offset over lapping 5/27/2009 FUEL TANK & PIPE23 FT&P generally utilise an offset over lapping plate arrangement. Alternatively, an annular plate arrangement is often used which allows for thicker plate at the shell interface and simplifies floor Plate Layout5/27/2009 FUEL TANK & PIPE24 Floor Plate5/27/2009 FUEL TANK & PIPE25AS1692 and Applicable Welding Code For Cylindrical Vertical TANKS greater than in diameter AS1692 nominates a Category 6 tank. Category 6 Tank Category 6 Tank AS1692 nominates either BS EN 14015 API620 or API650. Welding Standard AS1692 allows an Australian Standard to be nominated in place if both purchaser and contractor are TANK & PIPE26 Welding Standard Which code FT&P use ? AS3992 and Pre-qualified Procedures? AS1554 AS1210 AS1210 API650 5/27/2009 FUEL TANK & PIPE27 Welding Standard API650 derives the welding code from Section IX of the ASME code.

7 FT&P almost exclusively use procedures qualified to qualified to API650. API650 Visual Examination permissible limits are commensurate with the build TANK & PIPE28 Visual Examination5/27/2009 FUEL TANK & PIPE29 Vertical Down API650 Procedure5/27/2009 FUEL TANK & PIPE30 Welding Procedures Weld Procedures Defined under ASME IX FCAW/Machine Welded Horizontals Vertical Down MMAW Verticals5/27/2009 FUEL TANK & PIPE31 Vertical Down MMAW Verticals MMAW butt weld with backing plate for fillet to butt weld transition as the floor approaches the shell. MMAW Iron Powder for fillet Welds on floor, roof, wind girder, compensating Plate ThicknessAppendix A, Determination of Shell Thickness 5/27/2009 FUEL TANK & PIPE32 Tank Aspect Ratio Tank Aspect Ratio is significant in the overall design of the tank. In respect of tank holding down bolts, a squatter tank is favourable.

8 Increasing height increases static head which influences shell thickness. Volume is proportional to Diameter Squared. Thus changes in diameter have a great influence on height. Squatter TANKS are more economical on material. (Calculus minima question in TEE) Increasing diameter is often restricted by space. Plate heights in either 3m or thus preference for TANKS over 6m high5/27/2009 FUEL TANK & PIPE33 Aspect Ratio for 600kL Tank5/27/2009 FUEL TANK & PIPE34 Shell Plate ThicknessAppendix A, Optional design Basis for Small TANKS . appendix A allows joint efficiencies of either or If is used 42% additional plate thickness is Joint efficiency of provides a relaxation on NDT. Documented in Clause of API650. By agreement of contractor and TANK & PIPE35 Radiography RequirementPlate Thickness <=10mm5/27/2009 FUEL TANK & PIPE36 Radiography RequirementPlate Thickness <=25mm5/27/2009 FUEL TANK & PIPE37 Radiography RequirementPlate Thickness >25mm5/27/2009 FUEL TANK & PIPE38 Radiography RequirementPlate Thickness <=10mm5/27/2009 FUEL TANK & PIPE39 Radiography RequirementRadiography Notes:5/27/2009 FUEL TANK & PIPE40 Strake Layout5/27/2009 FUEL TANK & PIPE41 Key Plates5/27/2009 FUEL TANK & PIPE42 Location of Plates Shell plate horizontal and vertical plate clearances are maintained by key plates, shims and wedges.

9 Key plates are secured to the TANK & PIPE43 Key plates are secured to the shell. Driven wedges maintain the gaps for welding Shims maintain the clearance on the horizontal Welder This style of welder used for horizontal welds. The welding process is controlled by an oscillator. A range of patterns and 5/27/2009 FUEL TANK & PIPE44 A range of patterns and welding parameters can be controlled. The welder runs along a magnetic flexible steel track. Viable on larger Strakes5/27/2009 FUEL TANK & PIPE45 Roof Construction5/27/2009 FUEL TANK & PIPE46 Roof Construction Fuel Tank & Pipe often build the roof on the ground and lift this on to the completed strakes. Fully engineered lift studies are 5/27/2009 FUEL TANK & PIPE47 Fully engineered lift studies are generated using Spacegass and other analytical methods. Lifting lug design Spacegass FEA TANK & PIPE48 Lifting Lug Design5/27/2009 FUEL TANK & PIPE49 Finished Roof Can5/27/2009 FUEL TANK & PIPE50 Roof Lift5/27/2009 FUEL TANK & PIPE51 Tolerances and DeviationsAPI 650 provides client requirements Circumference x D/1000 +30mm Diameter5/27/2009 FUEL TANK & PIPE52 Diameter x D/1000 +20mm Height and Horizontality of Plate Edge 40mm Local Deviations Buckle height floor/roof plate D/1000 x (t+20)/t Verticality of the TankTolerances and Deviations5/27/2009 FUEL TANK & PIPE53 Tank Survey5/27/2009 FUEL TANK & PIPE54 Tank Survey5/27/2009 FUEL TANK & PIPE55 COMMISSIONING Tank Strapping Tank Strapping is a method of measuring the deviation of the tank from its cylindrical form.

10 The method employs a laser and provides an accurate circumferential profile of the tank at 5/27/2009 FUEL TANK & PIPE56accurate circumferential profile of the tank at different heights up the tank. Strapping data is then entered into the tank gauging system providing an accurate means of interpolating the tank volume. Strapping Data5/27/2009 FUEL TANK & PIPE57 Non Destructive Engineering FT&P employ the following methods on tank welds. Vacuum box testing. Radiography (Usually on Tee's intersections of vertical and horizontal welds) RT is only required if the joint efficiency exceeds 5/27/2009 FUEL TANK & PIPE58 RT is only required if the joint efficiency exceeds 70%. ( api 650 ) Magnetic Particle Inspection (100% of Joints) Dye Penetrant (100% of Joints) Air Testing of compensating of Tank Welds5/27/2009 FUEL TANK & PIPE59 HYDROTESTING Hydro testing Subject to availability of clean water.