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200 Bottom Selection and Design

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

Single Bottom vs. Double Bottom Characteristic Differences

220

Bottom Design

221

Bottom Plate Thickness

222

Shell-to-Bottom Joint

223

Reinforcing Pads

230

Bottom Construction

231

Bottoms for New Tanks

240

Bottom Repair or Replacement

241

Philosophy

242

Repair Alternatives

243

Bottom Replacement

244

Bottom Replacement Requirements

250

Leak Detection and Containment

251

Background and Scope

252

Definitions

253

Performance Criteria for Leak Detection and Leak Containment

254

Undertank and Double Bottom Spacer Material Considerations

200-5

200-1

200-9

200-10

200-17

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200 Bottom Selection and Design

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255

Miscellaneous Design Considerations

256

Design Variations

260

Membrane Design and Selection

261

Introduction

262

Elastomeric Liner

263

Membrane Materials for Tank Secondary Containment

264

Design and Construction

265

Inspection

266

Approved Manufacturers and Installers

270

References

200-27

200-32

200-2

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200 Bottom Selection and Design

210 Bottom Selection


Tank Bottom Selection
If the tank is to store petroleum crude or products and if water is present in the
contents, then a means for removing the water must be provided. How the water is
removed determines the type of bottom. Small tanks where water drawing is not a
problem have flat bottoms. Flat bottoms are inexpensive to build and may be
supported on a concrete ring or flat pad-type foundation.
Larger tanks usually have a cone up or cone down bottom. The cone up bottom is
the more common and is the less expensive of the two. The cone up bottom permits
the use of a bottom outlet or waterdraw basin at the edge of the tank. The primary
disadvantage of the cone up bottom is that water tends to stand along the edge of the
bottom rather than drain to the waterdraw outlet. The standing water can cause
severe corrosion on the bottom near the edge and the lower two to three inches of
the shell.
The cone down bottom offers better drainage and removal of water since the bottom
slopes toward the center of the tank, but installing piping to center of tank is costly
and could be difficult. This type of design is not recommended.
Single-slope bottoms are used on tanks where the ability to draw water and clean
the tank is important and where the center sump is not practical.
Figure 200-1 summarizes basic configurations for tank bottoms and arrangements
for piping and drain connections. The advantages and disadvantages of the different
designs are listed. The designs shown deal only with tank structure and do not
show any means for corrosion prevention or leak detection such as linings, double
bottoms, cathodic protection, etc. See Sections 600 and 250 for information on
corrosion prevention and leak detection.
Note

Figure 200-1 appears at the end of this section.

Choice of bottom is influenced by: 1) operating requirements for the product to be


stored, 2) maintenance considerations, and 3) characteristics of the support soil
(unless a piled foundation is to be used). Typical operating requirements include:

Keeping a layer of water on the bottom in some services.

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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211 Single Bottom vs. Double Bottom Characteristic Differences


Characteristic

Single Bottom

Double Bottom

Mean life

25 years

Approximately 35 years (a 40-50%


increase over single bottoms)

Costs

Initial installation costs are lower


than double bottoms

Lower total cost of ownership

Higher inspection costs

Reduced by longer in-service run


time intervals

Potential for high environmental


clean up costs

Lower operating factor. Repair scope


is less.

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

Leak detection

Leaks often not detectable and go on for


years resulting in future cleanups

Leaks are detected early and results in


minimal, if any, environmental damage

Corrosion

Most serious from underside of tank


bottom because of:

Underside attack reduced substantially


by changing underside conditions

Variable soil conditions and chemistry

Moisture and oxygen variation

Elevated aboveground so less moisture

Salts, dirt, debris, scale

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

Exemptions for Double Bottom Tanks


The following are examples of exemptions on the Use of Double Bottoms for
aboveground storage tanks (ASTs).
Exemption based on use of a release prevention barrier (RPB). Any tank which
is fitted with an RPB or will be fitted with an RPB is exempt from the requirement
to use a double bottom. An RPB is an elastomeric, impermeable membrane placed
in or under a tank which acts to stop the migration of a leak downward and to direct
it to the perimeter of the tank where it can be visually detected. It is essentially
equivalent from the perspective of environmental performance to a double bottom
tank.

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200 Bottom Selection and Design

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:

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.

220 Bottom Design


Refer to Section 210 for the selection of bottom configuration, and Section 300 for
foundation design.
The design of bottoms for cylindrical storage tanks at atmospheric pressure does not
involve a direct consideration of the hydrostatic pressure for the design fill height at
the bottom of the tank. The weight of the liquid contained in the tank is assumed to
be supported by the foundation upon which the bottom rests, and no significant
stress is developed in the bottom plates attributable to the hydrostatic pressure. In
other words, the tank bottom serves as a simple liquid-tight membrane, with no
significant structural strength required. The exception is the outer edge of the
bottom under the tank shell, for an annular width of approximately 2 feet. This
highly stressed location has been the site of many tank failures. Therefore, the shellto-bottom welds and the annular ring, when one is required, are the primary design
considerations.

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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.

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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200 Bottom Selection and Design

Reasons for not using closed design:


1.

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.

221 Bottom Plate Thickness


The minimum thickness for bottom plates required by API 650 is inch exclusive
of any corrosion allowance that may be required (API 650, Paragraph 3.4.1). Singlewelded lap joints with full-fillet welds are normally used for bottom plates;
however, single-welded butt joints with backing plates are an acceptable alternative
(API 650, Paragraph 3.1.5.4 through 3.1.5.7) as shown in Figure 200-2. It is
preferred that bottom plates over 3/8-inch thick be butt welded.

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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200 Bottom Selection and Design

Fig. 200-2

Tank Manual

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.

222 Shell-to-Bottom Joint


API Standard 650 requires double fillet welds for the shell-to-bottom joint (API
650, Paragraph 3.1.5.7), as illustrated in Figure 200-3. The stress in this joint is
dependent on the hydrostatic pressure at the design fill height and the diameter of
the tank. The minimum size of the fillet welds required by API 650 is based upon
the thickness of the lowest shell course, as given in API 650, Paragraph 3.1.5.7. In
this manner, the size of the fillet welds is increased in proportion to the hydrostatic
pressure acting on the shell-to-bottom joint, without making separate design
calculations.
Fig. 200-3

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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223 Reinforcing Pads


Pads, at least 3/8 inch thick, should be provided under columns that support fixed
roofs and under the legs for floating roofs. The pads for floating roof legs should be
wide enough to accommodate the maximum horizontal roof movement. Pads at
least inch thick should be installed to serve as wear plates under mixers and inlet
nozzles and under any bottom-mounted appurtenances, including gauge wells. The
pads prevent high local loads from developing in the bottom plates and tend to
minimize localized corrosion of the bottom plates. All pads should be welded to the
bottom plates with continuous inch fillet welds. See Section 700 for additional
appurtenance design guidelines.
Fig. 200-4

Configuration of Lap-welded Bottom Plates Under Shell (From API 650, Figure 33B.) Courtesy of the American Petroleum Institute

230 Bottom Construction


This section covers field installation of steel bottoms.

231 Bottoms for New Tanks


Bottoms Not Requiring Annular Rings
The new bottom sheets are tacked into place, then welded. Watch for excessive
overlapping of plates and grinding down of the upper plate to hide a less-than-full
fillet weld. Before welding, check that enough plate extends beyond the outside
edge of the shell radius to meet the specified overlap.

Cone up Bottoms Requiring Annular Rings


The annular ring plate should be installed first. Annular plate must be welded with
full penetration welds. As many plates as can be handled may be back welded into a
single section for installation. Welding these assembled sections together in place
requires the use of backup strips (see Figure 200-5). After installation of the annular

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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

Details of Annular Ring Butt Weld and Backup Strip Installation

Cone down Bottoms with Annular Rings


The preferred method of installing a new cone down bottom with annular ring is to
install the bottom deck plate first, shingled toward the center (i.e., the row of plates
running through the center is placed first). The annular ring is then placed on top of
the deck plate with its installation being the same as detailed above. Installing the
annular ring first traps a small amount of liquid near the edge of the shell. The
finished fillet weld attaching the annular ring to the bottom deck plate should, as a
minimum, be equal to the bottom deck plate thickness. If the surface is to be coated,
the weld should be ground to a smooth radius.

240 Bottom Repair or Replacement


This section discusses the justification for replacing a bottom versus a less costly
repair. It also gives guidance on the types of replacement bottoms along with the
repair methods available and where they are applicable.

241 Philosophy
Repair is recommended over replacement when:

July 2000

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

200 Bottom Selection and Design

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.

Procedure for Determining the Remaining Life of a Tank Bottom


Gauge bottom plate thickness in multiple locations where there is no bottom pitting observed on the
stockside or indicated on the underside. Average the readings.
Average Reading: 0.

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_____

Determine the following rates:


General Corrosion Rate:
Stockside Pitting Rate:
Underside Pitting Rate:

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

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:

If total is equal to or less than zero, the bottom should be replaced.

0.
0.
0.
=
=
=
=
=
=

inch/yr
inch/yr
inch/yr
0.
0.
0.
0.
0.
0.

Total

242 Repair Alternatives


Weld Repair and Plate Patching. These methods are for repairing mechanical
damage and stockside pitting. Patching is also done to repair openings in the bottom
resulting from turning coupons. The following guidelines are suggested:

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1.

Repair holes by welding on patches, rather than by spot welding.

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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200 Bottom Selection and Design

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.

243 Bottom Replacement


Specification. A bottom replacement specification, TAM-MS-1, is included in this
manual.
Types of Replacement Bottoms. The considerations in selecting a replacement
bottom are generally the same as for new construction. These are discussed in
Section 210.
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.

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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.

244 Bottom Replacement Requirements


For a complete description of the requirements for replacing tank bottoms, see the
commented version of Specification TAM-MS-1, Tank Bottom Replacement, and
the discussion above. Below is a summary of the procedure to follow for tank
bottom replacement for small and large tanks.

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.

Remove internal appurtenances, supports, and brackets.

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.

Install the concrete spacer. Complete concrete around supports as discussed in


the specification.

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.

Bottom-to-Shell Weld Seam


Minimum weld thickness is specified in API 650, Paragraph 3.1.5.7. There is no
increase in strength by exceeding the thinner plate thickness dimension with the
weld. However, since this particular weld is subject to considerable potential corrosion, on cone up bottoms in particular, some extra corrosion allowance in the weld
is useful.
Procedure. The ideal step-by-step procedure in making and testing the bottom-toshell welds is to weld the inside weld first, leak test the weld by applying diesel oil
or penetrant to the un-welded side and visually inspecting for leakage on the interior of the shell. The exterior weld is then made. This method ensures a leak-free

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Fig. 200-7

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Slot Configuration for Replacement Bottom

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.

Vacuum Testing of Weld Seams


Vacuum testing of weld seams is often done as the bottom seam welding progresses;
however, this practice is not recommended. Sometimes slag inclusions occur in the
welds, particularly at stop and start weld points. Vacuum testing immediately after
welding does not give these inclusions enough time to open up. For this reason,
vacuum testing of bottom welds should be delayed for 4 or more days (if possible)
after welding. Failure due to hydrogen cracking should be evident after 1 day.

Pads and Reinforcing Plates


All pads or reinforcing plates welded to the tank bottom should be, as a minimum,
seal welded all around. No clip, support, bracket, etc., should be welded to the
bottom plate without a pad between the item welded on and the bottom plate. This
precaution avoids concentrated loads that might tear the bottom.

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250 Leak Detection and Containment


251 Background and Scope
Contamination of surface and subsurface waters by leaks and spills from storage
tanks can be prevented by the use of leak detection, leak containment, secondary
containment, cathodic protection and internal linings. In this section, leak detection
and leak containment are addressed. See Section 650 for details of cathodic
protection. Refer to the Coatings Manual for details of coatings and linings.
The Oil Pollution Act of 1990 required EPA to conduct a liner study to determine
if leak detection and containment can be effectively implemented using liners in an
effort to address the problem of surface and subsurface contamination by
aboveground storage tank leaks and spills. The American Petroleum Institute has
responded to this call to safeguard the environment by issuing a new Appendix I to
API Standard 650, Undertank Leak Detection and Subgrade Protection. In addition,
because of various accidents, leaks and spills, the trend in the industry has been to
install systems aimed at reducing the chance for undetected leaks and spills. Many
states now have some form of regulation that requires undertank leak detection and
leak containment.
Undertank leaks, especially small ones, can go undetected for years contaminating
the aquifer and accumulating liability for the owner. In large tanks, the threshold for
leak detection is about 350 gallons per hour by tank gauging methods. This is
considered unacceptable for leak detection. Leak detection methods, leak
containment methods, cathodic protection, and linings for new and existing storage
tanks should be considered where the bottom is being replaced.
Examples of tanks with leak detection/containment are shown in Figure 200-8.
These examples are discussed in detail in Section 256.
Note

Figure 200-8 is a foldout appearing at the end of this section.

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.

253 Performance Criteria for Leak Detection and Leak Containment


In order to satisfy the requirements for leak detection outlined in API 650,
Appendix I the following criteria must be adhered to:

July 2000

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.

254 Undertank and Double Bottom Spacer Material Considerations


When tank bottoms are replaced most of them are done by the shell slotting
method referenced to in API 653, 7.10.2.1.2 The details of this construction are
shown in Figure 200-9. Using this method requires that a spacer material be placed
between the old and the new bottom. Some options for this material are discussed
below.
Fig. 200-9

Shell Slotting Removal of Existing Bottom

Spacer Material for Double Bottoms


For double bottom designs a common question is whether concrete or sand should
be used. Although concrete is much more costly on a volumetric basis it has a
number of advantages. Concrete has essentially zero void space, whereas sand has a
void space of approximately 40 percent. This means that any leak that occurs will
come to the tell-tale holes at the perimeter faster with the concrete system than with
the sand system.
Also, sand as a filler material between the two bottoms may be considered a
hazardous material if contaminated with product leaks. The removal of the sand will
probably be more difficult. There is also a much greater volumetric quantity of
product leakage to remove from a sand layer than from a concrete layer.
Concrete is advantageous from an installation viewpoint because its slope and
flatness can be specified and permanently controlled in the construction

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specifications. It is easy to create an accurate surface with concrete. Sand, on the


other hand, is not easy to slope or control because it is too easily disturbed by men
and equipment pathways. The concrete acts as a rigid foundation and aids in the
process of laying down and forming the bottom plates. This is especially true when
forming requires impacts, cutting, and welding operations. Sand is hard to keep out
of the weld joints and can contaminate welds. Dragging plates across the sand has
caused the plate to dive down through the sand and cut the liner on occasion. The
elastomeric liner under the sand can more easily be damaged during construction
than if placed under concrete.
Although the concrete system cannot accept a cathodic protection system, the
concrete itself is considered to be a factor in inhibiting corrosion since it is alkaline.
Sand should be considered where concrete may not be feasible. This occurs when
the tank is relatively large and the soil is subject to settlement. The settling concrete
can crack causing failure of the elastomeric liner.
Another problem with concrete can occur when settlement pockets introduced by
non-uniform settlement may cause pockets of water to form in the grooves under the
tank and accelerate corrosion.
Also, acoustic emissions testing companies claim that a concrete pad makes finding
leaks more difficult for them than does a sand pad or filler.

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
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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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.

255 Miscellaneous Design Considerations


Double Bottom Tanks
The design engineer should evaluate the condition of the dead shell that will exist
between the old bottom and the new bottom. In most cases, the dead shell is in good
condition with little corrosion except at the very bottom. However, should it be
severely thinned or pitted the following may apply. A weakened dead shell may
not transfer the dead loads or seismic loads to the foundation. It may buckle or
warp. It also might not withstand a build up of hydrostatic pressure that could occur
should there be a severe leak in the new bottom.
A common error in the installation of new bottoms is to attempt to install the new
bottom inside the tank, fillet welding it to the interior surface of the shell as shown
in Figure 200-10. This is prohibited by API 653. This type of joint is subject to shell
rotation and will fail either on first filling or after fatigue of the new fillet weld.
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

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Fig. 200-10 Retrofitting an Existing Tank with a New Double Bottom

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:

July 2000

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.

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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.

256 Design Variations


Leak detection/containment may be installed on new tanks or existing tanks.
Appendix I of API 650 applies to new installations since the standard is applicable
to new tank construction only. API 653, Tank Inspection, Repair, Alteration, and
Reconstruction, which applies only to tanks that have been in service makes only a
brief reference to leak detection/containment: If a tank bottom is to be replaced,
consideration should be given to installing a leak detection (tell-tale) system that
will channel any leaks in the bottom to a location where it can be readily observed
from the outside of the tank (API 653 Paragraph 2.4.5 Bottom Leak Detection). It
was the intent of the API Committee to allow the criteria from Appendix I of API
650 to be used for either new or existing construction.
Company practice has generally been to install double bottom tanks on existing
tanks where the bottom is being replaced and to use one of the single bottom details
where a new tank is being installed. This probably has the greatest economic payout
if all things are considered. However, there are cases where double bottoms are
installed on new installations. Sometimes this is the result of local regulatory
compliance or the opinion that the double steel bottom offers the best, longest
lasting means for achieving effective leak detection.

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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.

Designs for New Installations


Design 1N. This design is shown in more detail as Foundation Type E, in
Standard Drawing TAM-EF-364. It can be used on flat bottom or sloped bottom
tanks of any size.
The design incorporates ringwall foundations fitted with a grooved concrete slab.
The grooves act to direct the leak to the perimeter of the tank where it can be
observed. An 80-100 mil HDPE liner beneath the concrete slab acts to contain
the leak.
Since the concrete is slotted, there are strips of tank bottom underside which are not
in contact with the concrete (it is doubtful that the areas adjacent to the bottom plate
fillet welds are in contact with the concrete either). It has been postulated that these
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 uncompacted 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.

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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.

Designs for Retrofitting Existing Tanks


Design 1R. This design has been used in many locations within Chevron. It is the
Standard Bottom Replacement for Existing Tanks, which is shown in more detail
on Standard Drawing GD-D1120.
The concept behind this design is to use the existing bottom four to six inches of the
tank as a form in which to pour concrete. A new bottom is then placed upon the
concrete producing a new tank that is reduced in height by approximately four to six
inches. The old bottom is generally in pretty bad shape. In order to satisfy the
requirements of leak detection/containment, an HDPE liner is placed over the old
bottom. The liner also acts to insulate the spacer concrete from infiltration of ground
moisture and to electrically insulate the new bottom from the old bottom. It is
probably a good idea to place a geotextile fabric over the old bottom prior to
placement of the liner to protect the liner from damage by the old bottom.
The concrete is typically reinforced with a polypropylene fiber in lieu of welded
wire mesh because it is quicker and less costly to install, will not set up galvanic
cells for corrosion, and does prevent formation of hairline cracks. It also allows for
installation of thinner sections of concrete than would be possible with welded wire

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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.

Tank Bottom Selection Criteria


Figure 200-11 lists a number of criteria as they apply to the various designs shown
in Figure 200-9. The figure shows that the Company really only has experience with
designs 1R, 1N and 2N. However, there are conditions where another design might
be appropriate for other reasons. As an example, design 2R for small shop
fabricated chemical tanks storing extremely hazardous materials that can be
detected with electronic sensors might be appropriate.

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260 Membrane Design and Selection


261 Introduction
This section discusses the selection and installation of impermeable tank bottom
membranes used for secondary containment on both new tanks and old tanks
requiring new bottoms. The membranes are installed beneath supporting slabs (slabs
are covered in Section 310 of this manual) as shown on Standard Drawings GFS1121, Standard Secondary Containment and Leak Detection Details for Storage
Tanks, and GF-D1120, Standard Bottom Replacement for Existing Cone-up and
Cone-down Bottom Tanks Including Secondary Containment and Leak Detection.
The slabs are grooved on top to channel leaking fluid. The membrane provides the
impermeable layer to prevent the leaking fluid from reaching groundwater.
This section discusses only membranes appropriate for tank bottom secondary
containment. Refer to Section 600 of the Civil and Structural Manual, titled Ponds
and Basins, for a detailed and complete discussion of geomembranes for other
applications.

262 Elastomeric Liner


The primary function of this liner is to serve as a release prevention barrier. The
liner directs the leaks to the perimeter, serving as a leak detector while at the same
time, the liner prevents groundwater contamination. The liner is a backup system to
the original steel bottom, which also serves this function. In addition, the liner
functions to prevent galvanic corrosion between the new steel and old steel bottoms.

263 Membrane Materials for Tank Secondary Containment


HDPE
Company Standard Drawings GF-S1121 and GF-D1120 specify 80-100 mil thick
high density polyethylene (HDPE) as the appropriate membrane material for tank
secondary containment. This recommendation is based the tough physical properties
required of the membrane and on immersion testing of membrane materials in crude
oil and finished product by the CRTC Materials and Equipment Engineering Unit.
(See References [1] through [5] in the Reference Section of this manual.)
California law requires that these membranes be at least 40 mil thick. This
requirement is based on the membrane being reinforced with a scrim (such as
Hytrel, described below). 80 to 100 mil HDPE is specified because HDPE is
unreinforced (no scrim) and the extra thickness is required for strength and
toughness. Richmond and El Segundo have used 100 mil HDPE because they have
found that wrinkling 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).

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Fig. 200-11 Tank Bottom Selection Criteria


Design Number (See Fig. 500-11)
Criteria

1R

2R

3R

4R

1N

Retrofit Design

New Tank Design

Cathodic Protection

X
X

Concrete Inhibits Corrosion

Leak Detection

Reasonable Track Record

2N

X
X

(1)

Moist Soil Conditions Required


X

Cracking Concrete Can Cause Liner Failure

4N

6N

X
X

(1)

Foundation Washout Potential

Relatively Small Diameter Only


Releveling Difficult

5N

Potential Hazardous Waste Disposal

Stable Soil/Foundation Required

3N

X
X

Releveling May Damage Leak Prevention

X
X

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

X
X

(1) Deep-well cathodic protection possible

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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264 Design and Construction


Design
The membrane layout should be in a pattern that minimizes the number and length
of seams. Use the largest pieces that you can from HDPE rolls which come in 22foot widths and are several hundred feet long. Using odd-shaped, smaller pieces of
scrap results in a membrane that resembles a quilt. This patchworking is
unacceptable because it increases the number of seams and the total weld length,
and also results in weld intersections (often called weld Ts or Ys due to their
appearance) that are much more likely to leak or tear if stressed. On cone up and
cone down bottoms, the seams should be oriented down-slope to minimize stresses.

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.

Anchoring and Sealing


The liner is anchored with studs around the circumference of the liner near the tank
wall. A sealant is then applied to the membrane which covers the studs and seals the
edge of the membrane to the tank wall [see Reference 6 at the end of this section].
All of this work should be performed when the liner is cool and shrinkage will not
be a problem.

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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.

266 Approved Manufacturers and Installers


Manufacturers
Company specifications should require testing of every roll of liner used to ensure
that we are getting only top quality material. Consult with the CRTC Materials and
Equipment Engineering unit for approved manufacturers.

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.

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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.

Cummiskey, B. J., Impoundment Liner Testing - Western Producing Oil


Cleaning Plant, June 30, 1983, Materials and Equipment Engineering Unit
File 25.6.

2.

Klein, L. J., Storage Tank Containment Membrane TestsEl Segundo,


December 7, 1983, Materials and Equipment Engineering Unit File 6.85.

3.

Stofanak, R. J., Storage Tank Containment Membrane TestsEl Segundo, April


3, 1985, Materials and Equipment Engineering Unit File 6.85.

4.

Rippel, T. E., Permeability Testing Flexible Membrane Liners, February 28,


1986, Materials and Equipment Engineering Unit File 25.06.01.

5.

Rippel, T. E., Immersion Testing of Flexible Membrane Liners for Secondary


Containment, May 30, 1986, Materials and Equipment Engineering Unit
File 6.85.

6.

Kmetz, J. H., Adhesives Testing for Secondary Containment Membrane


Systems, December 3, 1987, Materials and Equipment Engineering Unit
File 56.1.

7.

Environmental Protection Agency, Document EPA-600/2-88/052, Lining of


Waste Containment and Other Impoundment Facilities, Appendix K

200-32

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Fig. 200-1

100 General Information

Bottom Designs for Storage Tanks

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Fig. 200-8

100 General Information

Tank Bottoms with Secondary Containment, Leak Detection and Cathodic Protection (New or Retrofitted)

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