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Abstract
This section of the manual discusses the design requirements and Company and industry specifications for atmospheric storage tank bottoms. It provides data required to determine the most cost-effective new tank bottom and/or replacement or repair for existing tanks. The advantages and disadvantages of the different types of new designs are addressed. Included is a cost benefit methodology for determining the most cost-effective bottom for a particular site. Leak detection and containment are also discussed.
Contents
210 211 220 221 222 223 230 231 240 241 242 243 244 250 251 252 253 254 Bottom Selection Single Bottom vs. Double Bottom Characteristic Differences Bottom Design Bottom Plate Thickness Shell-to-Bottom Joint Reinforcing Pads Bottom Construction Bottoms for New Tanks Bottom Repair or Replacement Philosophy Repair Alternatives Bottom Replacement Bottom Replacement Requirements Leak Detection and Containment Background and Scope Definitions Performance Criteria for Leak Detection and Leak Containment Undertank and Double Bottom Spacer Material Considerations
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255 256 260 261 262 263 264 265 266 270
Miscellaneous Design Considerations Design Variations Membrane Design and Selection Introduction Elastomeric Liner Membrane Materials for Tank Secondary Containment Design and Construction Inspection Approved Manufacturers and Installers References 200-32 200-27
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Maintenance considerations include accessibility of piping and connections, underside and stockside bottom corrosion, and need for regular cleaning. Section 220 details bottom design and Section 300, foundation design.
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Single Bottom
25 years Initial installation costs are lower than double bottoms Higher inspection costs Potential for high environmental clean up costs Lower operating factor. Repair scope is less.
Double Bottom
Approximately 35 years (a 40-50% increase over single bottoms) Lower total cost of ownership Reduced by longer in-service run time intervals Lower material costs due to a smaller safety factor against leaks (bottom thickness can be less) Reduced inspection costs by reducing inspection frequency Minimal environmental cleanup costs (Secondary benefits) Can retrofit slopes, coating, etc., for improved product integrity
Leaks often not detectable and go on for years resulting in future cleanups Most serious from underside of tank bottom because of: Variable soil conditions and chemistry Moisture and oxygen variation Salts, dirt, debris, scale
Leaks are detected early and results in minimal, if any, environmental damage Underside attack reduced substantially by changing underside conditions Elevated aboveground so less moisture Clean uniform contact with concrete Concrete is a corrosion inhibitor Reduces the variance of oxygen concentration, moisture and electrolytes because they provide a uniform surface, elevating the new steel bottom out of the mud and dirt Concrete is itself a corrosion inhibitor and reduces underside corrosion rates
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Exemptions based on liquids stored. The following tanks do not need to be considered for implementation of double bottoms: Chemical tanks less than 100 feet in diameter Lubricants Asphalt tanks
Exemptions based on site. Certain sites such as the Pascagoula Refinery have settling or shifting soil conditions which weigh against the use of a double bottom tank or a release prevention barrier. In this case, the entire refinery is exempt from using double bottom tanks. However, for new tanks or tanks which will be retrofitted with double bottoms, consideration should be given to installation of RPBs. In order to determine whether a site is exempt, an engineering analysis should be performed, documenting the considerations which weigh against the use of the double bottom practice. The use of double bottoms should also be evaluated in areas of high humidity and/or low water table. Exemptions based on analysis. Any tank may be exempted from the requirement of a double bottom provided that: An analysis is documented which shows why the tank does not need to have a double bottom, or The benefits of the double bottom are so marginal as to not justify the costs of the double bottom.
Tanks which may not be exempted. Any tank which stores motor fuels or fuels with MTBE or TAME or pure oxygenates shall be put onto a schedule which implements an RPB or a double bottom.
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Concrete Spacer While sand, steel or other media may be used Chevron has chosen concrete as the spacer material upon which to install the new or second bottom. This material gives good control over the slope of the tank bottom allowing for better water drainage and reduced corrosion due to stagnant water in the tank bottom. The main reason for the selection of concrete, however, is that it is alkaline and it actually reduced corrosion from the underside. In many inspections, we have found the concrete to extend the life of the tank bottom by a factor of 25 to 50 percent due to reduced underside corrosion attack.
Corner Lock Design In the original El Segundo Design, the liner is simply spread out and trimmed at the inside diameter of the tank. A caulk bead is then applied between the dead shell and the liner to seal the double bottom space and create leak containment. However, Chevron has recognized that the integrity of the system could be improved by making a continuous bathtub out of the HDPE liner. To do this we have used the CBI PROPRIETARY corner lock method is described as follows. This design uses a perforated angle iron. To this angle iron is attached a short segment of HDPE liner. This is extruded into the angle so that the flap can be used to heat weld the basic liner to the angle. This provides the same bathtub effect that the Chevron In-house design does.
Chevron In-House Design (Batten Strip Design) In this design we use a steel batten strip to seal the liner to the dead shell. This involves using stud welding to bolt the batten strip to the shell. By using this technique a bathtub is created by heat seaming all seams up to the point at the top of the batten strip. In this system we do not depend on caulking to provide a tight joint.
All of these systems are of the open design. We do have a few closed systems which are described below. Open vs. Closed System Chevron does not support the use of a closed double bottom system in general (with few rare exceptions). The closed system is defined as one in which the leak detection ports are valved closed and the junction between the dead shell (the stub of the shell under the new bottom) and the new bottom is sealed by caulking or seal welding. In an open system the leak detection ports are either open, or if they have valves, the valves are left open and the area under the dead shell is left open.
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Reasons for not using closed design: a. Making a weld that would actually seal the space is difficult if not impossible. In most cases there is inadequate room to make the weld. It is therefore of poor quality and would not keep water out and leaks in. Due to the difficulty of making this weld and due to the nature of fillet welds it is prone to having cracks and flaws. As this is the most highly stressed region in the tank, it makes the possibility of a catastrophic failure much more likely. From the principle of fracture mechanics, crack growth or sudden propagation occurs in the presence of flaws and stress. Both are likely with this weld. It is for this reason that API Standard 650 makes such stringent nondestructive examination requirements for the topside fillet welds in this highly stressed area. It would be basically impossible to verify the integrity of the underside weld at this location. c. It was originally thought that water and thus corrosion could be minimized on the underside of tank bottoms to reduce underside attack. However, due to the large size of the tank double bottom space and the humidity of the air, if the bottom is sealed into a closed system, water will actually condense on the underside of the tank bottom plates, causing accelerated corrosion. This is similar to the crawl space of a house in which moisture will damage the flooring unless adequate ventilation is provided. For this reason, the open system is superior in that it allows for this ventilation to occur, removing any moisture that does enter the space. Even if the bottom could be perfectly sealed and constructed with no moisture, the concrete itself has moisture which evaporates from it and would create a humid corrosive environment were the space not allowed to breathe. The closed system also defeats the purpose of leak detection. By closing the system, a leak cannot be viewed as soon as it occurs. Since leaks tend to start very slowly and increase with time, the best way to protect the environment is to detect leaks as early as possible.
b.
d.
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Fig. 200-2
Bottom Plate Welds (From API 650, Figure 3-3A.) Courtesy of the American Petroleum Institute
Annular Ring
In general, annular rings are required by API Standard 650 Section 3.5 when steel with tensile strengths of 65,000 psi or higher is used for the lowest shell course. Additionally, the Company requires annular rings for all 100,000-bbl or greater tanks and tanks greater than 100 feet in diameter, regardless of the strength of the steel being used. Butt welds with full penetration and complete fusion are required to join the plates that form the annular ring. However, the butt welded plates in the annular ring can be lap welded to the bottom plates. The required thickness of the plates for the annular ring is determined by the hydrostatic stress and thickness of the lowest shell course (API 650, Paragraph 3.5.3), as given in Table 3.1 of API 650. Width of annular rings must be able to support the column of liquid above it at design fill height, in the event of foundation settlement. The minimum width allowed is 24 inches. However, a greater width may be needed as calculated by the formula given in Paragraph 3.5.2 of API 650. In addition, seismic design requires checking the thickness of the annular ring, as discussed in Section 530.
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Fig. 200-3
Bottom-to-shell Joint (From API 650, Figure 3-3A.) Courtesy of the American Petroleum Institute
Fig. 200-4
Configuration of Lap-welded Bottom Plates Under Shell (From API 650, Figure 3-3B.) Courtesy of the American Petroleum Institute
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241 Philosophy
Repair is recommended over replacement when: Corrosion and pitting are not severe and patching or weld repairs can be accomplished economically. The maximum depth of unrepaired stockside pits and underside pits will not exceed the plate thickness before the end of the next run. Figure 200-6 gives the procedure for determining the remaining life of a bottom. Corrosion and pitting are localized to a specific area (i.e., annular ring corrosion due to water standing around the inside edge of the shell). Most of the pitting is underside, and external cathodic protection is being installed to minimize this pitting.
Gauge the depth of the deepest stockside pitting not to be patched during the shutdown and record. Deepest Pitting: 0. inch
Gauge the depth of the deepest pit on the underside of the bottom by measuring turned coupons. Deepest Pitting: 0. inch
Step 4 Step 5
Determine whether the stockside bottom is to be protective coated. If it is, stockside pitting rate in Step 5 is zero. Yes_____ Determine the following rates: General Corrosion Rate: Stockside Pitting Rate: Underside Pitting Rate: Perform the following calculation: Remaining bottom general thickness: Less general bottom corrosion rate X years next operating run: Less deepest unrepaired stockside pitting: Less deepest underside pitting: Less stockside pitting rate X years next operating run: Less underside pitting rate X years next operating run: 0. 0. 0. = = = = = = 0. 0. 0. 0. 0. 0. inch/yr inch/yr inch/yr No_____
Step 6
Total
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3.
4.
Annular Ring Replacement. Water accumulating around the inside edge of the shell can cause accelerated corrosion on the bottom in this area. For tanks over 100 feet in diameter, it is often less costly to replace the annular ring than the entire bottom. See Section 300 and API 650 for annular ring design and installation. Laminate Reinforced Coating. Section 640 discusses the various internal coating systems available for tanks. Company Specification COM-MS-4738 is a standard specification to use for thin film, glass flake, or laminate-reinforced coatings. Because properly applied laminates have some structural strength, they can be an effective tool for prolonging the life of a tank bottom which has moderate underside corrosion. However, they must be used cautiously. Laminates should not be used in the following situations: Where a hole has worn through the bottom plate and it remains unrepaired Where the bottom plate will hole through before the end of the next run and no leakage can be allowed Where general corrosion has caused loss of structural strength in the annular ring area. A rule of thumb is not to coat the annular ring if there is a 20% general reduction in plate thickness over any 2-square foot area of the annular ring
Thin Film or Glass Flake Coatings. Thin film or glass flake coatings can be used in conjunction with bottom repairs or a new bottom to prolong the life of the bottom. They should not be put on over a bottom with severe internal or external corrosion or pitting.
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Section 640 discusses the use of these coatings. Specification COM-MS-4738 specifies the materials and application procedures. Section 100 of the Coatings Manual discusses in more detail the factors that affect the type of coatings selected. Thin film coating is most effective when used with internal cathodic protection. See Specification TAM-MS-3. External Cathodic Protection. Cathodic protection can be used to stop underside bottom corrosion of existing tanks. If there is no portland cement concrete slab, asphaltic concrete pavement, or penetration macadam pavement under the tank, properly applied cathodic protection will almost always be effective in preventing further corrosion. However, a concrete slab or pavement under the tank may make cathodic protection ineffective. An impermeable pavement will prevent the flow of cathodic protective current to the bottom steel. Cathodic protection will be effective where there are permeable areas or breaks in the pavement and will prevent moisture-caused corrosion at these locations. However, cathodic protection cannot eliminate corrosion due to moisture migrating under the tank from permeable to impermeable areas. Similarly, cathodic protection cannot completely control corrosion caused by moisture penetration beneath the tank from the periphery due to breathing. It is very difficult to determine conclusively from short term field tests whether cathodic protection will be helpful for a specific situation. Section 650 and the Corrosion Prevention and Metallurgy Manual discuss cathodic protection in more detail. Bottom Repairs. New tank bottoms should be installed by cutting horizontal slots in the shell above the existing bottom and slipping in new bottom plates. The new bottom must be joined to the shell with a fillet weld on both the inside and outside. The area between the new and old bottom must be filled with sand or concrete. Refer to Specification TAM-MS-1, Tank Bottom Replacement and Membrane Placement. Bottom patch plates, when used, should have full fillet welds all around except when they are butted together. Full penetration welds should join patch plates when butted together. When a patch plate is within 6" of the shell, the patch plate shall be tombstone shaped. The sides of the patch plate shall intersect the shell-to-bottom joint at approximately 90. When bottom patch plates are added directly below the shell, the shell should be slotted immediately above the old bottom and the plate inserted. Fillet weld the patch plate to the shell on both the inside and outside. A continuous fillet weld should join the patch plate to the old bottom, including the section under the shell. For additional information, consult API 653 Section 7.10.
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Secondary Containment and Leak Detection Bottoms. If future leakage cannot be tolerated, then a retrofit bottom, which includes secondary containment and leak detection, should be installed (see Standard Drawing GD-D1120, sheets 1 and 2). A membrane (HDPE) liner is placed over the existing steel bottom and overlaid with a concrete slab. The new steel bottom is then placed above the slab. This retrofit design works best where you expect minimal bottom settlement. If large settlement is expected, a membrane liner with a sand cushion over it and cathodic protection system should be installed. The old steel bottom may need to be removed in this case due to the amount of storage volume lost to the sand cushion. This approach is generally not recommended because of the sand shifting and causing voids. (See Standard Drawing GD-S1121, sheets 1 and 2). Refer to Section 260 for membrane design and selection. Non-leak Detection Bottoms. An important item to consider when secondary containment and leak detection are not included is that the new steel bottom will be anodic to the old steel bottom. This galvanic effect accelerates corrosion of the new bottom and has produced bottom failures in as little as four years. Therefore, it is essential either to remove the old corroded bottom before putting in the new bottom, or else to provide a good dielectric shield to stop current flow between the two. An asphalt pad between the old and new bottoms provides a good dielectric shield, but it may not entirely stop water migration to the tank bottom. However, in a retrofit situation, there will be a semi-intact old bottom beneath the asphalt, and most of the tank settling will have already occurred, so the chance for success of asphalt is much greater than in the case of new construction. Therefore, if secondary containment is not required, asphalt may be a viable alternative. See TAM-EF-364 for asphalt pad foundation design. Replacement Bottom Installation. The replacement bottom plates should be installed in accordance with API 653 and API 650. Generally, the replacement sketch plates (bottom plates upon which the shell rests) or annular ring plates are slid through a slot cut in the shell. The new bottom is continuously welded to the shell, both inside and outside, using fillet welds on the top. Intermittent fillet welds for strength are made between the new bottom and the lower part of the old shell. The weld size should be enough to develop the full strength of the bottom plates in bending. Undercutting at the toe of the fillets should be avoided. Care must be taken to be sure the new pad fully supports the new bottom next to the shell. Annular ring plates are butt welded together using a 1/8 inch thick compatible backing strip, 2 inches wide, under the joint where it passes through the shell. Inside, the bottom plates are welded with a 1 inch lap and a full fillet lap weld as for new API tanks. In either case, it is necessary to notch (rat hole) the shell over this joint in the tank bottom to permit the welder to make a good weld through the shell. See Figure 200-5 for details of the annular ring installation in a replacement bottom.
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Small Tanks
Small tank bottom replacement is best done by lifting (or jacking up) the tank, placing a prefabricated bottom on the foundation, then lowering the tank to within 2 inches of the new bottom, cutting the tank shell just above the old bottom weld, sliding the old bottom out and then lowering the shell and roof into place. The shell is then welded into place and tested.
Large Tanks
For replacing the bottoms of large tanks, follow the steps described below for each of the replacement phases: preparation, bottom-to-shell welding, weld seam testing, and welding of pads and reinforcing plates to bottom.
Preparation Phase
To prepare the shell for bottom replacement follow these steps: 1. 2. Remove internal appurtenances, supports, and brackets. Cut horizontal slots in the shell. These slots are usually about 5 to 8 feet long with 6 inches of shell left between the slots. The height of the slot should be inch. The lower face of the slot should be relieved (notched out) for butt welded annular ring backup strips. The bottom edge of the slot will act as a form for the concrete spacer. See Figure 200-7. Weld square C-shaped support clamps (or dogs) of heavy steel to the shell so that the open area of the C allows the new bottom plate to slip through the shell with the required overhang. See Figure 200-7. Install membrane under roof supports. Form around fixed roof supports and wrap floating roof legs as discussed in Specification TAM-MS-1. Install the membrane liner as discussed in Section 260 and shown on Drawing GD-D1120. Install the concrete spacer. Complete concrete around supports as discussed in the specification. Remove 6-inch spacers between slots, install annular ring through shell slots and install bottom plate.
3.
4. 5. 6. 7.
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Fig. 200-7
Relieving Shell over Bottom Plate Weld. A portion of the shell plate directly over the field welded bottom lapped plate or butt welded annular ring joint should be notched in order to permit completion of the weld under the tank shell. Each of the lap welded bottom plates or butt welded annular ring joints under the shell should be inspected before the notch can be welded up. Failure in this weld joint can produce a bottom leak almost impossible to track down. See Figure 200-5.
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Replacement Bottoms. After the bottom-to-shell weld has been completed and tested, the dogs supporting the shell are removed and the tank permitted to settle down on the spacer pad.
Tank Manual
252 Definitions
Leak Detection. Aside from product loss considerations, leaks in ASTs are unacceptable because they may go on for years undetected while contaminating subsurface waters. Leak detection is the detection of leaks soon after they occur. In the performance criteria outlined in API 650, Appendix I, a leak must be directed to the perimeter of the tank where it shall be capable of detection by visual examination. Other methods including sensors are acceptable but do not supplant the visual method. Also supplementary to the perimeter system of leak detection are all of the other methods including ultra sensitive hydrostatic gauging, acoustic emissions, tracer compounds blended with stored product, ground penetrating radar, slant drilling, etc. Leak Containment. Referred to as Subgrade Protection in Appendix I of 650. Leak containment is the prevention of leaks from spilling onto the ground. Generally, this is meant to apply to ASTs that have an elastomeric liner that prevents leakage under a tank from entering the groundwater system. Double bottom tanks and tanks with liners that can contain a small fraction of the tank contents usually qualify as having leak containment systems. Secondary Containment. Secondary containment refers to impounding of the tank contents. Most of the regulations such as NFPA 30 or SPCC require that the dikes be sized to contain the largest AST volume plus some freeboard for rainwater. Secondary containment is not covered in this section. Cathodic Protection. External cathodic protection (CP) is becoming more and more widespread throughout the industry, both as a means to meet federal and local regulations regarding groundwater protection (some of which are already in place and some of which are still being written), and as a cost-effective method of prolonging the service life of tank bottoms between scheduled shutdowns. Internal cathodic protection is common for corrosion protection of crude tank bottoms or tanks containing water. For smaller tanks (less than 50 feet in diameter), sacrificial zinc or magnesium anodes are generally used for external CP, and require no maintenance. For larger tanks it is more economical to use mixed metal oxide grids which require some maintenance to keep them in working order. In either case, good tank bottom protection can be had for as little as one to two dollars per square foot of steel protected. External cathodic protection systems are covered by the new API Recommended Practice 651. Internal cathodic protection is usually provided by aluminum anodes attached to the tank bottom. In order to work properly, the anodes must be submerged in a conductive medium, such as the water layer at the bottom of a crude oil tank. See Section 650 for further discussion of cathodic protection.
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4. 5.
6.
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Undertank Materials
Concrete has most of the advantages that are listed above for double bottom fill materials such as: Reduced corrosion Quicker bottom plate layout and installation Slope and flatness control The ability to install leak detection grooves, and Low void space.
Sometimes, concrete is indispensable as a liner thus fulfilling the need for a leak detection barrier when an elastomeric liner will not suffice. This is the case for hot
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tanks. Since the liner should be designed for the stockside temperature which may be well above any ordinary elastomeric liner design limits, the concrete, if reinforced may be considered a liner. Sand or soil as an undertank material has the advantage of reduced material costs. However, the washed sand or soil should be selected with minimal amounts of minerals and salts that could accelerate corrosion rates. Sand or soil under a tank can accommodate large amounts of local settlement without any adverse affects. Clay. There are a lot of concerns with the usage of clay. First, it must meet the permeability standards required by API Standard 650, Appendix I. Clay can crack when dry and lose its properties as a liner. The cracks caused by shrinkage in the clay would allow large quantities of groundwater to migrate up to the bottom of the liner of the tank causing potential problems. It is recommended that a geotextile fabric be installed between the clay and the liner because the effects of clay shrinkage in direct contact with the liner on the integrity of the liner are not known. A lot of experience does not exist for clay liners. Claymax bentonite liners which have been used extensively for diking requirements are subject to changing permeability when exposed to certain conditions of pH or chemistry. Some states do not allow clay to be used as a liner because of its known expansion and contraction problems affecting liner integrity. Clay is a poor conductor of electricity when dry and therefore will have a variable effect on any cathodic protection systems that must pass current through the clay. Also, it is hard to visualize a good method of assuring a leak proof joint between the ringwall and the clay when shrinkage contraction occurs.
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A common question that arises with the design is whether to caulk or weld the underside of the new bottom (See Figure 200-10). Unfortunately, this issue is far from simple and involves a number of parameters. API 650 Appendix I states that welding or caulking a double bottom under the new bottom is required. However, the discussion in I.4.1 of the Appendix requires that an analysis and evaluation be performed if the new double bottom is not uniformly supported both inside and outside of the shell. The intent of the caulk/weld is to seal out moisture which may enter by a number of mechanisms. Rainfall may flow around the new chime and by capillary action migrate into the leak containment space. If the foundation is in a flood area, the flood level may rise above the new tank floor and flood the underside of the new bottom. Slight thermal variation may cause a breathing of moisture laden air and cause a moisture pumping under the tank. Most people agree that this space needs to be sealed off from the atmosphere. A single 3/16 inch fillet weld pass would be the most economical weld to make. However, accessibility to the weld and control of the gap space can often be a problem. To really do it right may require the welder to use mirrors, slowing down the weld speed considerably. A proper weld should have a life expectancy approximately equal to that of the service life of the tank. Whether or not this is attained in practice is debatable. Most of our facilities do seal weld this juncture.
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To reduce initial capital expenditures, an alternative to seal welding is to seal the joint with caulking. If this choice is considered, Sherwin Williams Steel Seam 920-W-974 products are recommended. Caulking probably does not have the life span of seal welding and is sensitive to surface preparation, flexure of the joint, sunlight, chemical environment effects, etc. However, it is probably cheaper to install on an initial cost basis compared to seal welding the floor to the dead shell. Here are some comparisons between the two methods of sealing this space: Seal welding will have a longer life than caulking. The life of the caulking is dependent on a number of factors as mentioned above. With a caulked joint the position of the top shell and dead shell should be monitored periodically to make certain that the tank shell is directly supported by the foundation through the dead shell. Caulking should be used only where concrete is used as a filler material between the old and new bottom. When sand or gravel are used there is too much probability that insufficient filler material near the old dead shell will act to load the floor directly at the point of the old dead shell. Any misalignment could cause failures. This has occurred in some non Company facilities. Where high temperatures or varying temperatures of stored product are used, caulking should not be considered because the caulking will tear away as the shell grows radially outward. In this case seal welding would act to keep the upper and lower shells aligned. Where large amounts of settlement are expected, caulking should not be used as the seal will be broken. After hydrostatic testing, and on first filling, the caulking should be checked for its integrity against leaks. The effect of uplift caused by seismic events on a welded joint versus caulked joint is not really known. Further study is needed.
Triple Bottoms
In several refineries, not only have second bottoms been installed but additional bottoms including up to as many as four bottoms have been installed. Although it is certainly possible to add three or more bottoms, it should be realized that if the old bottoms ever have to be removed the work will be more costly and difficult. As the number of bottoms increases, the likelihood of having to relocate tank appurtenances will increase and, of course, the usable volume of the tank is reduced. Although the structural effects are not really understood, the proof that they do not seem to be adverse is the large number of operating years experience with three or more bottoms. One problem that has occurred is the oldest bottoms continue to deteriorate, and since the void space is filled with sand it washes out. This causes buckling of the dead shells and results in a very difficult repair job. If it is determined that the second bottom is deteriorating and a new bottom required, consideration should be given to more effective corrosion prevention techniques.
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locations are more prone to corrosion from atmospheric moisture. In some samples that were checked (in tanks with approximately seven years of service) in Richmond this was not observed to be the case. What is far more of a potential problem is backing up of condensing atmospheric moisture or of ground moisture that cannot escape because the tell-tale holes are plugged. Debris either in the grooves of the leak detection slab or plugged tell-tale holes can cause extremely accelerated corrosion rates on the bottom underside. The slab elevation should be high enough so that the water table or flood level virtually never exceeds it. One major drawback with this design is that if used on soft or un-compacted soils subject to settlement, the concrete slab can crack. The cracked slab can damage, tear or puncture the liner thus voiding the leak detection system. So far, this design has not been tried on soft ground in Chevron. Locations which pump sand under tank bottoms to replenish supporting soils are also unlikely to be able to use this design. Designs 2N, 4N, and 6N. Design 2N and 6N are similar except that 6N does not use a ringwall. As an alternate, a crushed rock ringwall maybe used. These designs are similar to foundation type D on Company Standard Drawing TAM-EF-364. The choice of whether or not to construct a ringwall for a new foundation is best decided on a location-by-location basis. In most locations, a compacted soil ringwall will not withstand erosion from heavy rains and may allow too much settling of the bottom to assure the integrity of the leak detection system. In a few dry locations with hard soils, going without a ringwall may be an alternative. A ringwall also minimizes differential peripheral settlement which causes the need for repairs to be made. The question of whether or not to use a sacrificial anode system depends on cost. Both systems can be installed in any tank. Using todays relative costs of zinc or magnesium (for a sacrificial anode system) versus typical mixed-metal anodes (for an impressed current system), the critical tank diameter size is about 35 feet. Tanks of less than about 35 feet diameter are constructed with a sacrificial anode system, while tanks larger than this are generally constructed using an impressed current system. A definite advantage to designs 2N and 6N is that they incorporate not only leak prevention (the cathodic protection system) but they have leak detection (the telltale system). Designs 3N and 5N. Designs 3N and 5N include clay as a form of liner beneath the tank bottom. These designs can be used for new tanks or for retrofits if the existing tank soil is excavated first. Not very much experience on these designs is available. Locations which might find this design suitable are locations with soft, moist soil where settlement is a problem. Small chemical tank foundations might be able to use these designs. Design 7N. This design is a reinforced mat foundation extended at the perimeter to act as a ring wall. The middle section relies on a liner and sand to support the bottom.
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Designs 3R and 4R. These designs should be considered the backup design to 1R. We have experience with them and they do not seem to present significant problems. It is our opinion that the impressed current anodes are more effective at delivering the required current to all sections of the tank bottom rather than sacrificial anodes systems when the tank diameter exceeds about 35 feet. If the anodes are covered with sand, they can be exposed or destroyed if the new tank bottom plates are dragged across the sand.
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Fig. 200-11 Tank Bottom Selection Criteria Design Number (See Fig. 500-11) Criteria
Retrofit Design New Tank Design Cathodic Protection Concrete Inhibits Corrosion Leak Detection Reasonable Track Record Potential Hazardous Waste Disposal Moist Soil Conditions Required Stable Soil/Foundation Required Cracking Concrete Can Cause Liner Failure Foundation Washout Potential Relatively Small Diameter Only Releveling Difficult Releveling May Damage Leak Prevention High Number of Barriers to Leakage Sand Pumping Can Damage Liner or Tank Bottom Leak Containment Space Reduces Tank Volume Company Has Experience With This Design Quick Leak Detection Response
(1) Deep-well cathodic protection possible
1R
X
2R
X X
3R
X
4R
X
1N
X X
2N
3N
X
4N
5N
X
6N
X X
X X(1)
X X(1)
X X
X X X X X X
X X X X X X
X X X
X X
X X X
X X
X X
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
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caused by thermal expansion is less with 100-mil HDPE than with 80-mil HDPE during installation. The proper ordering description is 100-mil thick HDPE liner conforming to EPA standards (see Reference 7 at the end of this section). Two other membrane materials Fueltane and Hytrel are considered good alternatives and are preferred when design cannot eliminate potential installation problems encountered with the thicker, stiffer HDPE. Fueltane (Seaman Corp.) is a urethane-coated polyester membrane, and Hytrel (DuPont) is a polyester elastomer membrane which has been used by the Company for service station piping secondary containment.
Other Materials
Substrate
New Tanks. The Standard Drawing GF-S1121 for new tanks shows four inches of sand or compacted fill as the membrane substrate. This substrate is ideal as it separates the liner from the subgrade and helps protect it from any potential damage if the foundation settles or shifts. Existing Tanks. For retrofitting old tanks, the membrane is often installed over the old steel floor as shown in Standard Drawing GD-D1120. Most often, this provides a good, stable substrate for the membrane. However, if the floor is badly corroded and/or riveted, the possibility of puncturing the membrane increases. A high quality 10-to-16 ounce geotextile can be deployed under the liner to help protect the liner from puncture and abrasion. The obvious burrs and edges should be ground flush prior to the installation of the geotextile. Floating roof tanks have internal support legs that sit on the tank floor if the fluid level in the tank is low or empty. For existing tanks with the roof already in place, circular pieces of membrane, roughly two or three feet in diameter, are precut and slid under the roof support legs while the roof is being temporarily supported. Then the rest of the membrane is installed and welded to the circular pieces under the stands.
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Installation
Refer to the Engineering Specifications of this manual for bottom replacement specification TAM-MS-1. This specification also includes membrane placement. The steps to be followed when installing a membrane are summarized below: Preparation. Before deploying any membrane, remove all debris from the supporting surface. The surface should also be dry. Cement grout can be used to develop a smooth surface for the liner. A geotextile may be used in the grouted areas beneath the liner to prevent abrasion damage. Membrane Deployment. Deploy the membrane in a pattern to minimize the number and length of the seams. The best method is to unroll the membrane into position so that all seams are parallel. The membrane can be cut so that it conforms to the tank circumference. As the membrane is being placed into position, the seams should be hot air tack welded using a hot air gun (Liester). This will hold the membrane in place until the seams are welded. The ideal sequence is to install the liner in the afternoon when temperatures are the warmest and the liner will be at its maximum expansion. This procedure will reduce the problem of wrinkles. However, do not fasten the liner to the shell until it cools down to prevent tearing due to shrinkage. If the liner does wrinkle, it may become necessary to splice the liner and remove the wrinkle. If this is done, repair the liner using an oversized patch that is at least six inches larger than the cut at all locations. Merely welding the cut will not be acceptable because it is impossible to obtain the minimum three inch overlaprequired by the specificationat the ends of the cut. Seam Preparation. Bevel the top, overlying membrane edge at roughly 45 degrees. This is necessary on thicker HDPE membranes (80 mil and up) to achieve a good fusion weld. Just prior to extrudate welding, the seams should be lightly sanded or ground to remove the thin layer of oxide that builds on the surface and then wiped or air-blown to remove grindings, dust, or any other contaminants. Weld Qualification. Prior to production seam welding, the installation technician must weld a qualifying test strip. Two test specimens from separate points on the test strip must be cut and pulled to failure in peel as shown in Figure 200-12.
Fig. 200-12 Peel Test
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To pass the peel test, the membrane material, not the weld, must fail. If the weld breaks or if it peels off of the membrane, the test is a failure. The weld must be stronger than the membrane material.
265 Inspection
Non-Destructive Inspection
The Company inspector should visually inspect the liner during and after installation. He should verify that: The seams are being lightly ground and cleaned prior to welding The proper testing is being done The liner is the correct thickness, and Sound construction practices are being enforced.
The installer must vacuum test the seams for pinhole leaks. The vacuum test machine must pull at least 5 psi vacuum. Some installers prefer using a spark test, which is also acceptable. Every inch of weld must be inspected by one of these methods, including patches.
Destructive Inspection
Destructive samples are cut from the installed liner and tested in peel as described above. The frequency of testing is usually one sample per seam. Often, two destructive samples are also taken from the first 20 feet of seam welding to ensure that the weld guns are operating properly. The holes are patched with a circular piece of liner welded to the membrane.
Installers
The Company does not maintain an official list of approved installers because the quality of the installation depends on the on-site crew installing the system and that can vary widely within individual companies. Instead, we give guidance on the
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experience level required for the site foreman and crew. On large pond projects, we usually require two years experience in the specific position (field foreman, CQA foreman, technician, etc.), a predetermined number of square feet installed, and job references with contacts and phone numbers. For tanks, require a set number of tank installations and ask for references with contacts and phone numbers. The performance history of a particular company and crew is also very helpful. Obviously, request the good ones and reject the poor ones. You may also contact ETCs Materials and Equipment Engineering Unit for assistance. This Unit is involved with liner jobs and projects throughout the Company and has direct experience with many manufacturers and installers of membranes.
Standard Drawings
GF-S1121, Standard Secondary Containment and Leak Detection Details for Storage Tanks. GD-D1120, Standard Bottom Replacement for Existing Cone-up and Cone-down Bottom Tanks Including Secondary Containment and Leak Detection.
270 References
1. Cummiskey, B. J., Impoundment Liner Testing - Western Producing Oil Cleaning Plant, June 30, 1983, Materials and Equipment Engineering Unit File 25.6. Klein, L. J., Storage Tank Containment Membrane TestsEl Segundo, December 7, 1983, Materials and Equipment Engineering Unit File 6.85. Stofanak, R. J., Storage Tank Containment Membrane TestsEl Segundo, April 3, 1985, Materials and Equipment Engineering Unit File 6.85. Rippel, T. E., Permeability Testing Flexible Membrane Liners, February 28, 1986, Materials and Equipment Engineering Unit File 25.06.01. Rippel, T. E., Immersion Testing of Flexible Membrane Liners for Secondary Containment, May 30, 1986, Materials and Equipment Engineering Unit File 6.85. Kmetz, J. H., Adhesives Testing for Secondary Containment Membrane Systems, December 3, 1987, Materials and Equipment Engineering Unit File 56.1. Environmental Protection Agency, Document EPA-600/2-88/052, Lining of Waste Containment and Other Impoundment Facilities, Appendix K
2. 3. 4. 5.
6.
7.
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