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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.
Chevron Corporation
Contents
Page
210
Bottom Selection
200-3
211
220
Bottom Design
221
222
Shell-to-Bottom Joint
223
Reinforcing Pads
230
Bottom Construction
231
240
241
Philosophy
242
Repair Alternatives
243
Bottom Replacement
244
250
251
252
Definitions
253
254
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255
256
Design Variations
260
261
Introduction
262
Elastomeric Liner
263
264
265
Inspection
266
270
References
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Removing water frequently to keep the contents of the tank dry. This can be
important for quality control or when the tank feeds an operating unit.
Changing service or specifications. In this case, you would want a design that
would enable you to completely drain the product in the tank.
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
Double Bottom
Mean life
25 years
Costs
Leak detection
Corrosion
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Exemptions based on OPCO. All Production tanks are exempt from requirements
to apply double bottoms or RPBs.
Exemptions based on liquids stored. The following tanks do not need to be
considered for implementation of double bottoms:
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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This section is a briefing of why we have several different double bottom designs.
Although there are several different designs, they are all functionally equivalent.
That is, they perform the function of secondary leak detection and containment. All
of these designs have the following functional components in them:
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.
All of these systems are of the open design. We do have a few closed systems which
are described below.
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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.
2.
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 non-destructive
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.
3.
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.
4.
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.
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.
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Bottom Plate Welds (From API 650, Figure 3-3A.) Courtesy of the American
Petroleum Institute
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.
Bottom-to-shell Joint (From API 650, Figure 3-3A.) Courtesy of the American
Petroleum Institute
Figure 200-4 illustrates how lap welded bottom plates under the shell are configured for the shell-to-bottom joint.
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Configuration of Lap-welded Bottom Plates Under Shell (From API 650, Figure 33B.) Courtesy of the American Petroleum Institute
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ring, the bottom plate is tack welded in place and then welded. The plates should
shingle toward the low point, i.e., the outside row of plates should be installed first
with the higher center plate row installed last.
Fig. 200-5
241 Philosophy
Repair is recommended over replacement when:
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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.
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Fig. 200-6
Step 1
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).
Step 2
Gauge the depth of the deepest stockside pitting not to be patched during the shutdown and record.
Deepest Pitting: 0.
Step 3
No_____
Step 6
inch
Determine whether the stockside bottom is to be protective coated. If it is, stockside pitting rate in
Step 5 is zero.
Yes_____
Step 5
inch
Gauge the depth of the deepest pit on the underside of the bottom by measuring turned coupons.
Deepest Pitting: 0.
Step 4
inch
0.
0.
0.
=
=
=
=
=
=
inch/yr
inch/yr
inch/yr
0.
0.
0.
0.
0.
0.
Total
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1.
2.
Before welding, plug holes to prevent moisture from leaking into the tank from
under the bottom. Normally, wood plugs are used, but anything that will stop
the seepage long enough to complete the weld all around the patch is
acceptable. Preventing moisture leakage keeps the fillet weld on the patch from
cracking.
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3.
Spot weld pits half way or more through the plate if the pit is not greater than
1 inch in diameter and is surrounded by substantially full thickness material.
Shallower pits may be filled with special epoxy compounds, if necessary, prior
to the application of internal coatings.
4.
Patch pitted areas of larger than 1 inch diameter with pieces of -inch plate full
fillet welded all around. Time can be saved by supplying patch material
consisting of random-sized square and rectangular pieces with dimensions from
12 to 30 inches sheared from scrap plate. Sheared patches must be small
enough to pass through the shell manway or existing opening.
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.
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.
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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.
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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.
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 200-2.
3.
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 200-2.
4.
Install membrane under roof supports. Form around fixed roof supports and
wrap floating roof legs as discussed in Specification TAM-MS-1.
5.
Install the membrane liner as discussed in Section 260 and shown on Drawing
GD-D1120.
6.
7.
Remove 6-inch spacers between slots, install annular ring through shell slots
and install bottom plate.
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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stockside weld. It should be used wherever the bottom design does not include a
thick welded annular ring.
Bottoms equipped with annular rings cannot be welded this way. Making the stockside weld first causes the annular ring plate to rotate about the bottom edge of the
shell. For this reason, the outer weld must be made first and tested before the inner
weld is made.
Verify that all traces of diesel oil or penetrant are removed by detergent washing
from the opposite side prior to making the weld.
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.
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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
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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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1.
Leaks through the bottom must be directed to the perimeter where they are
visually detectable. If a leak does occur it must be collected.
2.
Electronic sensors and detectors may be used but they must be in addition to
the requirements for leak detection at the perimeter.
3.
Materials used for leak detection must be compatible with the range of products
and the stockside temperature ranges and material in contact with the subgrade
must be suitable for below grade service.
4.
The permeability of the liner shall be less than 10-7 cm (400 mils) per second.
5.
The leak barrier shall be of single-piece construction, or the joints shall satisfy
leak tightness, permeability, and chemical resistance requirements of the base
material. The manufacturer and a complete description of materials used shall
be identified to the tank owner.
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6.
The installation of sumps and pipes below the tank bottom is acceptable;
however, the required leak detection and leak tightness shall be maintained.
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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
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
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
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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.
To reduce initial capital expenditures, an alternative to seal welding is to seal the
joint with caulking. If this choice is considered, Sherwin Williams Steelseam 920W-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:
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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.
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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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Figure 200-8 shows most of the designs that are being used by various oil
companies today. The figure is divided into R figures, meant to cover the retrofit
designs where a new bottom is required because the old bottom must be replaced
and N figures, meant to cover the designs that include leak detection for new
installations.
Chevron has used the Figure 1R and 1N in the vast majority of cases. These designs
are proven with over 10 to 12 years experience and have shown no special
problems. They are competitive with the other designs from a cost standpoint. This
manual also has detailed drawings and specifications that are based upon these
designs.
Because of the numerous factors and pros and cons associated with each of the
various designs, it is not a simple task to select the most optimal leak
detection/containment system for a given site. Probably the best way is to
coordinate the available knowledge by bringing in input from operations, tank
building contractors and Company experts.
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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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mesh. In this application, the concrete is not designed for any structural
requirements but is simply a spacer.
After the concrete is hardened, leak detection grooves are sawcut into the slab in
radial patterns as applicable to the type of sloped bottom being used and dependent
on diameter. These patterns are shown on Standard Drawing GD-D-1120.
Design 2R. This design depends on grating, mesh, angles, I-beams, or other
structural steel shapes to form the spacer between the old and new bottoms. With
this design any leaks and spills should quickly flow to the leak detection points
located around the periphery of the tank. With this design hydrocarbon sensors can
presumably pick up vapors relatively quickly for sensing leaks.
However, this design has been installed in so few cases in the industry that there is
really no experience with it. It was created for relatively small diameter tanks only
on concrete foundations. If some moisture accumulates in the space between the
bottoms, it is not known if accelerated corrosion will be experienced at contact
points with the structural members due to galvanic action.
If this design is chosen, the filler material must be both structurally adequate in
itself and configured so as not to overstress any other component of the tank. It must
provide the same characteristics as normal tank foundations, i.e., it must provide
uniform support to the new bottom as well as transfer the loads uniformly to the old
bottom and foundations. At least two potential problems must be addressed. First,
the material must have the ability to support the new bottom without buckling or
crushing due to the hydrostatic weight of the liquid above. Second, the bending
stresses in the new bottom must be limited to prevent cracking. Since lap welded
bottom plate construction is subject to failure where the welds are in excessive
bending, the bottom plates must be laid out such that the high bending stresses
caused by the hydrostatic head do not concentrate in long lengths of the bottom
fillet welds.
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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1R
2R
3R
4R
1N
Retrofit Design
Cathodic Protection
X
X
Leak Detection
2N
X
X
(1)
4N
6N
X
X
(1)
5N
3N
X
X
X
X
X
X
Other Materials
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.
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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.
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
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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 overlap
required 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
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.
July 2000
200-30
Chevron Corporation
Tank Manual
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
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 CRTCs 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.
Chevron Corporation
200-31
July 2000
Tank Manual
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
July 2000
1.
2.
3.
4.
5.
6.
7.
200-32
Chevron Corporation
Tank Manual
Fig. 200-1
Chevron Corporation
200-33
July 2000
Tank Manual
Fig. 200-8
Tank Bottoms with Secondary Containment, Leak Detection and Cathodic Protection (New or Retrofitted)
Chevron Corporation
200-35
July 2000