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2
inch wc), which
is about 1/3 the weight of conventional 3/16 inch thick
carbon steel roofs.
The live load is 25 psf or greater if required by the
regulatory agencies or building codes. API 650, Ap-
pendix G includes requirements for unbalanced loads,
panel loading, and concentrated loading. It also gives
requirements for the load combinations such as dead-
load-plus-seismic. The suppliers are required to run
through a series of load combinations to assure that
the roof is structurally adequate for the application. If
there is any internal pressure, that number must be in-
cluded in the load calculations.
One of the design-loading conditions that requires
good communication between the purchaser and the
supplier is the means of transferring the roof loads
to the tank shell. The tank and foundation must be
checked to assure that they are adequate to assume
the increased loading from the added roof. Since the
top of an existing tank is rarely round, the dome
must be constructed to accommodate this tolerance
problem. This is done by the allowance for large tol-
erances made at the support points. It must also accom-
modate thermal expansion of the roof within a
temperature range of 120F. For existing tanks, the
easiest way to handle some of these problems is to de-
sign the roof to shell junction with a sliding surface so
that only vertical loads are transferred to the tank shell.
For new tanks, the tank rim is often strengthened suf-
ficiently so that the roof is rigidly attached to the shell
which is designed to take all of the roof loadings. When
tanks have internal pressure, the preferred design is to rig-
idly affix the roof to the shell. If a sliding joint is used,
a sealing fabric must be installed to contain the internal
pressure. This design is more subject to failure than the
fixed-base design.
Shell Buckling
Local and general shell buckling must have a mini-
mum safety factor of 1.65. General shell buckling
can be determined from:
NOTES:
1. SUPPORT POST TRANSFERS REACTIONS
TO THE WINDGIRDER TO PREVENT OVER-
STRESSING OF THE TOP OF THE TANK
SHELL AT POINTS OF ATTACHMENT.
2. FREEBOARD IS ENCLOSED BY ROLL
FORMED SIDEWALL PANELS WHICH ARE
ATTACHED TO SUPPORT POSTS.
3. POST ELEVATES DOME ABOVE TOP OF
TANK.
X47207.HPG
TAM90013.GEM
Fig. 900-13 Tension Ring
900 Construction Tank Manual
900-14 June 1994
W 2258 x 10
6
I
x
A
(SF) LR
2
(Eq. 900-1)
where:
W = allowable live load, psf
I
x
= moment of inertia of beam about the
strong axis, in
2
A = cross section area of beam, in
2
R = spherical radius of dome, in
L = average dome beam length, in
SF = safety factor
= 1.65
Tension Ring Area
The minimum tension ring area is determined from:
A 11
D
2
ntansin
|
.
180
n
`
,
F
t
(Eq. 900-2)
where
A = net area of tension beam, in
2
D = tank diameter, ft
n = number of dome supports
=
1
2 the central angle of the dome or
the roof slope at the tank shell
F
t
= allowable stress of the tension ring, psi
Roof-Shell Junction
A dome roof is never considered to be frangible. How-
ever, internal pressure would probably blow out dome
panels or destroy the roof long before the shell or bot-
tom would be affected and could therefore be an ef-
fective means of preserving the integrity of the tank
contents during an over-pressure situation.
Temperature Limits
API establishes a maximum operating temperature for
aluminum dome roofs of 200F.
Wind Loading
Unless specified by the tank/owner operator, the de-
fault wind loading condition is 100 mph.
Seismic Loading
The seismic loading is presumed to act uniformly over
the dome and the design basis for the dome is:
F .24ZIW
r
(Eq. 900-3)
where
F = horizontal force
Z = zone coefficient
I = essential facilities factor
= 1.0 for most cases
W
r
= weight of tank roof, lb
Testing
For atmospheric applications the roof is simply hosed
down and checked on the underside for the evidence
of leakage. When the tank is designed for internal pres-
sure, it should be pressurized with air and soap-bubble,
and leak tested.
Appurtenances
Roof hatches are optional. However, most tank appli-
cations use only 1 hatch. If there is a rolling ladder
left in a tank, a hatch is often supplied for it. Figure
900-14 shows the details of a roof hatch.
Roof nozzles should be constructed per Figure 900-15.
They are used for high level alarms or for thief hatch
purposes. Many applications do not have any roof noz-
zles.
Skylights are optional See Figure 900-16. However,
they provide natural lighting for the interior and also
provide a means to do visual inspection of roof seals
that are required to be performed annually by EPA.
They are recommended and they should be provided at
a rate of 1% of the projected area of the dome.
Tank Manual 900 Construction
June 1994 900-15
Dome roofs are vented by the gap between the roof
and the shell, making peripheral shell vents unneces-
sary. One center vent at the top is required per API
650 (Appendix 11), usually an 8 inch vent. Typically,
there is no special access provided for this hatch.
Internal Rolling Ladders
When an existing tank is retrofitted with a dome, the
existing rolling ladder can be left in place. Because the
dome usually interferes with the operation at the top
of the ladder, the dome manufacturers often reattach
the ladder to the structural members of the dome. This
requires that the bottom of the rolling ladder be ex-
tended to suit the modifications.
Often the tank owner/operator does not wish to make
the modifications or there are no modifications that can
be made to accommodate the new dome and the full
travel range of the floating roof. In these cases the lad-
der is removed and tank owners do one of two things
for access to the internal roof:
1. They use a rope ladder for access when needed.
2. They wait until the floating roof is at its high level
X47201.HPG
TAM90014.GEM
Fig. 900-14 Typical Access Hatch Detail
X47202.HPG
TAM900-15.GEM
Fig. 900-15 Typical Nozzle Section at Duct
Penetration with Flanged Connection
X47203.HPG
TAM900-16.GEM
Fig. 900-16 Skylight Panel Detail
900 Construction Tank Manual
900-16 June 1994
in the tank and simply access the top of the roof
by stepping onto it.
Access to the internal roof is required periodically for
seal, appurtenance and roof condition inspections.
Platforms and Walkways
In existing tanks retrofitted with domes, some problems
related to the tank gagers platform often arise. In these
cases modification must be made to raise or relocate
the platform to clear the dome.
Walkways are rarely used on domes as there is really
no reason to access the top of the dome. The center
vent at the top does not need maintenance in most
cases. However, when many tanks are located near one
another, walkways have been used to provide access
as shown in Figure 900-17.
Construction
Domes can be constructed on operating tanks that are
filled with flammable materials since there is no hot-
work involved. The typical construction sequence be-
gins with the loading of the structural materials and
sheet panels onto the top of the floating roof. The roof
structure is assembled using jackstands with bolted and
other types of fasteners. The entire roof fits within the
shell space. The roof can be raised until the dome is
higher than the top of the tank shell and then lowered
onto its support points. The support points have suffi-
cient radial adjustment to accommodate the typical out-
of-round that exists in tank shells near the top.
Typical construction times will be according to Figure
900-18.
Costs. For rough estimating purposes for aluminum
domes, refer to Figure 900-19.
950 TANK HOLD POINTS CHECKLIST
Figure 900-20 is a tank hold points checklist to be used
when constructing a tank.
990 REFERENCES
1. Morovich, The Use of Aluminum Dome Tank
Roofs, Proceedings of the 2nd International Sym-
posium on Aboveground Storage Tanks, January
14-16, 1992, Houston Texas, Materials Technology
Institute, 1992
2. Barnes, New Tank Roofs Capture Evaporating Va-
pors, Louisiana Contractor, 12/1992
3. Barrett, Geodesic-dome Tank Roof Cuts Water
Contamination, Vapor Losses, Oil and Gas Journal,
7/10/1989
Diameter, ft Time, Weeks
30 - 70 1
70 - 100 2
100 - 120 3
TAM9018.WP
Fig. 900-18 Aluminum Dome Roof Construction
Period
Diameter, ft Installed Cost, $/ft
3
0 - 50 20 - 40
50 - 100 15 - 20
100 - 200 10 - 15
Fig. 900-19 Costs for Aluminum Domes
TAM90019.WP
TAM90017.TIF
Fig. 900-17 Aluminum Dome Roof Walkways
(Courtesy of Conservatek)
Tank Manual 900 Construction
June 1994 900-17
TANK HOLD POINTS CHECKLIST
The items below are inspection hold points for the construction of ____ Tank in the ____________ Tank Field
and are part of the contract. Company Engineer or Company Representative will initial this checklist after each
item has been satisfactorily completed. Contractor will notify Company when these items are ready for inspec-
tion. Company will have the time length indicated to inspect and approve or disapprove each item. Repairs
and/or delays necessary to make each installation satisfactory will be at Contractors expense and will not
constitute delay by Company.
Item Engr. Initial
Company Rep.
Initial
1. Ringwall Installation
(8 Dayshift hours after completion)
2. Soil Compaction & Sand Fill
(8 Dayshift hours after completion)
3. Membrane Installation
(8 Dayshift hours after completion)
4. Concrete Pad Placement
(8 Dayshift hours after completion)
5. Concrete Cure Time/Clean Up
(8 Dayshift hours after completion)
6. Bottom Plate Vacuum Test
(8 Dayshift hours after completion)
7. Annular Ring Diesel Test
(48 Dayshift hours after completion)
8. Shell 1st Course Inserts Installation and X-Ray
(8 Dayshift hours after completion)
9. Shell 2nd Course Installation and X-Ray
(8 Dayshift hours after completion)
10. Shell 3rd Course Installation and X-Ray
(8 Dayshift hours after completion)
11. Shell 4th Course Installation and X-Ray
(8 Dayshift hours after completion)
12. Shell 5th Course Installation and X-Ray
(8 Dayshift hours after completion)
13. Shell 6th Course Installation and X-Ray
(8 Dayshift hours after completion)
14. Shell 7th Course Installation and X-Ray
(8 Dayshift hours after completion)
15. Shell 8th Course Installation and X-Ray
(8 Dayshift hours after completion)
16. Roof Plate Vacuum Test
(8 Dayshift hours after completion)
17. Hydrotest Tank & Install Roof Seal
(8 Dayshift hours after completion)
18. AQMD Roof Seal Inspection
(8 Dayshift hours after completion)
TAM90020.WP
Fig. 900-20 Tank Hold Points Checklist
900 Construction Tank Manual
900-18 June 1994
1000 IN-SERVICE ABOVEGROUND STORAGE TANKS: GUIDELINES
FOR INSPECTION, REPAIR, ALTERATION, AND
RECONSTRUCTION
Abstract
This section covers the inspection, repair, alteration, and maintenance of in-service, aboveground storage tanks
(ASTs) welded and riveted, non-refrigerated, and atmospheric and focuses on the American Petroleum In-
stitutes (API) Standard 653 relating to these activities. A synopsis of this recently released standard is included
as Figure 1000-1 of this chapter.
Contents Page Page
1010 Background 2
1011 Industry Standards
1012 Intent of API 653
1013 Responsibility and Compliance
1014 Implementation: Time and Costs
1015 Other Considerations
1016 Recommended Implementation
1020 Preventing Failures: API 653 6
1030 Assessing Suitability for Service 6
1031 Reasons for Assessing Suitability for
Service
1032 Physical Considerations
1040 Inspection 7
1041 Inspection Philosophy
1042 Three Types of Periodic Inspections
1043 General Requirements for
Post-installation Inspections
1044 Inspection Methods
1045 Typical AST Bottom Inspection
Techniques
1046 Other Inspection Methods and Tools
1047 Leak Detection Methods of Inspection
1050 API 653 Repair and Alteration
Guidelines
24
1051 Repairs of AST Components
1052 Welding
1053 Shell Plates and Penetrations
1054 Bottom Plates and Slumps
1055 Roofs and Foundations
1056 Hot Taps
1057 Hydrostatic Testing of Repaired,
Altered, or Reconstructed ASTs
1058 Dismantling and Reconstruction
1060 The Mechanical Integrity Element
of OSHA 29 CFR 1910.119
34
1070 API Recommended Practice RP 575 35
1080 References 35
1090 Other Resources 35
Tank Manual 1000 Inspection and Testing
March 1993 1000-1
T
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T
S
1010 BACKGROUND
Recent incidents involving ASTs have caused public
and legislative bodies to view them as environmentally
hazardous equipment. The most notable event occurred
in 1988 in Floreffe, PA, when a sudden and cata-
strophic spill released over one million gallons of fuel
oil into the Monagahela river, a drinking water source
for several municipalities.
Such episodes have contributed to the current attitude
of local, state, and federal agencies toward ASTs: i.e.,
any leak or spill that contaminates subsurface or navi-
gable waters often results in:
Severe financial and legal penalties, and
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7
1045 Typical AST Bottom Inspection
Techniques
AST bottom integrity and leak prevention is probably
the single, most important issue facing the majority of
AST facility owner/operators who are considering
compliance with API 653.
Bottom-assessment difficulties have led many
owner/operators to ignore this item unless there is evi-
dence of a leak. API 653, however, states that leaks in
tank bottoms are not acceptable while tanks are in-
service and also requests that, when replacing an
ASTs bottom, the owner/operator consider installing a
leak-detection system.
API has intentionally made allowances for improving
technology or advanced inspection practices to increase
the basic inspection intervals if the owner/operator has
other means of determining suitability for service. In
no case, however, is the interval allowed to exceed 20
years.
The owner/operator must conduct a quantitative evalu-
ation of the ASTs bottom plates to determine the cor-
rosion allowance, corrosion rate, and internal
inspection intervals required by API 653. When the
corrosion rates are unknown and records of similar
service experience are unavailable, the maximum inter-
val between internal inspections is decreased from 20
years to a maximum of 10 years.
The underside of AST bottoms that rest on pads or on
the soil cannot be inspected readily from the outside
for corrosion or other damage; however, there are sev-
eral methods practiced:
Tunneling
When the AST is empty, a tunnel may be cut under it
but only near the edge as it is difficult to refill a tunnel
properly. Clean sand or crushed limestone are the best
types of fill material for tunnels. Coupon cutting, dis-
cussed later in this section, is safer and usually a
quicker method of inspection.
Damming
The following methods are used very infrequently and
may require hydrostatic testing of the AST after in-
spection. In each case, a temporary clay dam or seal
is placed around the base outside the AST. Going over
the entire bottom of the AST with an air-operated ham-
mer improves the effectiveness of these methods. The
sharp jarring of the bottom plates frequently causes
sufficient scale to pop out of pits to make them leak
detectably. Seek guidance by consulting with CRTC
personnel and with contractors experienced in these
methods.
Soap Solution. The inside surface of the ASTs bottom
is coated with soap solution; a hose applies air pressure
(less than three inches of water) under the bottom of
the AST through the clay seal or through a drilled and
tapped hole (or holes) in the bottom. The bottom is
then inspected for soap bubbles that indicate leaks.
Water Leaks. Water is pumped under the AST (held
by the clay dam) to a depth of approximately six
inches above the level of the highest point of the
ASTs bottom. Vents are required to allow trapped air
to escape. Leaks are then evident if the water seeps
through to the inside of the AST. This approach can
cause the ASTs pad to wash out or shift, depending
on its construction. To build the air pressure to the de-
sired value may involve considerable plastering of the
clay seal.
Water In/Air Under. Approximately six inches of
water are pumped into the AST, and nine inches wc
of air are pumped under the AST. (The water must be
pumped into the AST before applying air pressure un-
der the AST.) Leaks are identified by air bubbling
through the water in the AST.
Hammer Testing
Usually, the hammer is a brass ballpeen that weighs 16
to 18 ounces. When an experienced inspector wields a
hammer to strike the steel, the sound, vibration, dent-
ing, and movement produced can reveal such defects
as reduced thickness in the AST walls, loose joints,
and intergranular cracking. Primarily a means for ex-
amining the interior of the ASTs bottom and the ex-
terior chime area, hammer testing is usually useful only
for determining gross flaws and imminent failure as it
has many limitations:
Lights spark-proof.
Document inspections.
Figure 1000-25 does not provide details, designs, nor
procedures but merely represents a list to start devel-
oping compliance tailored to the facility in question; it
is not intended to:
Change of service
or remove sludge to
improve tank opera-
tion or product qual-
ity.
Remove sludge. No
final cleaning
required.
Tank out-of-service
well before its due
date. Quick visual in-
spection requested;
no repairs antici-
pated.
Remove sludge.
Remove scale if it
impedes inspection.
Tank out-of-service
on normal mainte-
nance interval (10
years). Detailed in-
spection needed.
Remove sludge.
Remove scale for
thorough inspection.
Welding required
in the tank.
Remove sludge.
Remove scale.
Clean oily film off of
metal.
Coating required.
Remove sludge.
Clean oily film off
metal. Abrasive
blast surface to rec-
ommended finish.
TAM11006.WP
Fig. 1100-6 Summary of Levels of Cleaning
Tank Manual 1100 Maintenance
June 1994 1100-7
1131 Bottom Replacement or Repair
This section discusses the justification for replacing a
bottom versus a less costly repair. It also gives guid-
ance on the types of replacement bottoms along with
the repair methods available and where they are appli-
cable.
Philosophy
Repair is recommended over replacement when:
Mechanical damage
Cracking of welds.
Uniform Settlement
Planar Tilt
Differential Shell Settlement
Global Dishing
Edge Settlement
Uniform Settling. In this type of settling the soil con-
ditions are relatively uniform, soft or compressible, and
astorage tank will slowly, but uniformly sink down-
ward as shown in Figure 1100-11. Uniform settling
poses no significant problems; however, there are two
important side effects:
1. Water Ingress occurs when a depression or water
trap is formed around the tanks periphery where
it meets the soil. When it rains, moisture accumu-
lates under the tank bottom near the shell or chime
region and corrodes the bottom.
2. Piping connected to the tank will eventually be-
come over stressed by the tank movement.
To assess the degree of uniform settlement, simply
monitor elevations at the base of the tank.
Planar Tilt. In this mode the tank tips as a rigid struc-
ture. (See Figure 1100-12). Often planar tilt accompa-
1100 Maintenance Tank Manual
1100-22 June 1994
nies uniform settlement. Planar tilt can be assessed
from an external tank inspection conducted by taking
elevation readings at the base of the tank. The follow-
ing may occur as the tilt becomes severe:
1. Appearance. The human eye is sensitive to verti-
cal lines. With a relatively small angle of tilt the
appearance of a tank begins to look strange. The
public or employees may begin to question the
safety of the tank and the operating and mainte-
nance practices of the owner. Planar tilt limited to
D/50 is a reasonable plumbness specification that
provides an acceptable tank appearance.
2. Hydrostatic Increase. The tilt of the tank results
in an increase in hydrostatic head as shown in Fig-
ure 1100-12.
If the increased stress causes the shell to exceed
the design-allowable stress, there are several solu-
tions:
Lower the liquid level.
2
S
i
(Eq. 1100-1)
where:
i = station number of elevation reading taken
at base of tank
r = radial shell displacement at top of tank
N = number of stations or readings
H = shell height at which radial
displacements are calculated
D = tank diameter
S =
measured settlement at ith location
x = circumferential shell coordinate
2. Shell Stresses. Non-planar, differential settlement
may generate shell stress near the top of the tank
and may result in buckling of the upper shell
courses. In the past, the amount of differential set-
tlement allowed was determined by arbitrarily lim-
iting the differential settlement to a constant,
which represented a ratio of the settlement to the
span between consecutive settlement measure-
ments. Figure 1100-15 shows how various struc-
tures, particularly buildings, are damaged when the
slope represented by the deflection-to-span ratio
exceeds some value.
X47105.HPG
TM110014.GEM
Fig. 1100-14 Problems Resulting from Shell Out-of-
Roundness Due to Nonuniform Settle-
ment
X47107.HPG
TM1100-15.GEM
Fig. 1100-15 Limiting Angular Distortion
1100 Maintenance Tank Manual
1100-26 June 1994
One commonly used limit [2] is
S
1
450
(Eq. 1100-2)
where:
l = length between settlement readings, feet
S =
allowable settlement
Local slopes limited to approximately l/450 to l/350
applied to tank have proven conservative, and result in
tanks being releveled when further settlement could
have been tolerated.
The API 653 formula uses a factor of safety of two
times:
S .011
y
1
2
2EH
(Eq. 1100-3)
Global Dishing. The entire tank bottom settles relative
to the shell. This may occur singly or in combination
with other forms of settlement. There is no one form
of global settling, however, the majority of tank bot-
toms do tend to form a dished shape as shown in Fig-
ure 1100-16. There are several other common global
settling patterns and investigators have recommended
criteria for each type as shown in Figure 1100-17. [3]
The problems associated with general global settling
are:
Piping flexibility
If possible, use an N
2
smothering system. This sys-
tem eliminates a large source of moisture in the
tank. Size the system to make the tank inert in 10
minutes. Use this system only to smother a fire.
If steam smothering is required, mount the control
valve as close to the tank as possible to eliminate
the chance of a deadleg of condensate building up
downstream of the valve.
Blanketing
Evaluating a tanks safe capacity based on API seismic criteria and a method developed by George Manos
[2].
Seismic zone 4
An S
3
soil site
If the tanks specific gravity is greater than 1.0, rests on an S4 soils site, or has an unusually thin shell (D/t >
2000), the tank may satisfy Figure C-3 but not pass API 650 criteria. Tanks in this category should be evaluated
numerically by using API 650 Appendix E. An example of how to use the seismic requirements in API 650
Appendix E is shown in Chapter 460 of this manual.
Tanks That Fail API Criterion
Tanks that have a stability ratio greater than 1.57 should have their safe seismic fill height calculated. This height
can be found iteratively by using different fill heights until the stability ratio is just less than 1.57.
Tanks that fail API 650 criterion can alternatively be evaluated using method developed by George Manos. This
method is presented in detail in section C2.3.
It should be realized that Tanks with thinner than average shells may pass API 650 criteria but fail the Manos
method. This is because the Manos method is more sensitive to the tanks shell thickness than API 650. The
difference becomes more pronounced for tanks with high strength steels and when a thickened annular ring is
used. See section C2.3 for more detail.
C2.3 Manos Stability Requirements
Introduction
For most tanks API 650 Appendix E conservatively estimates their seismic performance. This is because API 650
considerably underestimates the amount of bottom plate uplifted during an earthquake. The API approach assumes
the bottom plate develops plastic hinges and does not recognize the important role played by the in-plane stresses
in the bottom plate during uplift. By underestimating the amount of bottom plate uplifted, API 650 underestimates
the resisting liquid on the uplifted bottom plate. This causes API 650 to calculate stability ratios that are too high
and therefore, fail some tanks for being unstable that are seismically safe. This effect becomes more pronounced
with small diameter tanks.
As an alternative to the API 650 approach, Manos [2] has developed an approach based on experimental studies
that better predicts tank seismic performance for most tanks. Instead of trying to model the complex dynamic
uplifting plate behavior, Manos assumes a stress distribution at which the shell buckles and solves for the accel-
eration. This acceleration, C
eq
, is the response acceleration at which the tank wall buckles and the tank becomes
unstable. Comparing C
eq
to the peak spectral acceleration, C
ex
, specifies if the tank is stable.
Foundation stiffness can have a considerable effect on tank performance. Since a flexible foundation allows for
more rigid-body motion it has more uplift, radial displacement and penetration. The compressive stresses in the
tank shell are decreased as the foundation becomes more flexible and is accounted for by a foundation deformability
coefficient in the seismic resistance equation.
Appendix C Tank Manual
C-6 June 1994
Evaluation Procedure
The equation for determining the tanks seismic resistance is:
C
eq
.372 SEt
s
2
w
GRH
2
|
.
m
1
m
t
`
,
1
|
.
R
H
`
,
n
|
.
t
s
t
p
`
,
0.1
(Eq C-1)
The above equation only considers the impulsive liquid for the earthquake forces. Since the tanks shell and
roof only make a small contribution to the earthquake forces, this omission constitutes only a small inaccuracy.
The sloshing liquids absence is compensated for by increasing the moment arm X
1
/H for the impulsive liquid.
The variables are explained below:
Ceq
Cex
= Maximum impulsive acceleration at which the tank is stable (g)
= Peak horizontal spectral acceleration at 2% damping (g)
E
G
H
R
|
.
m
1
m
t
`
,
Wt
Fc
S
n
tp
ts
w
= Youngs modulus of the tank shell material (lb/ft
2
)
= Contents specific gravity
= Liquid height (ft)
= Tank radius (ft)
= Ratio of impulsive to total mass (Figure E-2 from API 650 Appendix E)
= Total weight of the tanks contents (lbs)
= Total summed compressive force in the tanks shell (lbs)
= Foundation deformability coefficient
= 0.1 + 0.2 H/R 0.25
= Annular ring or bottom plate thickness (ft)
= Tank-wall thickness (ft)
= Unit weight of water (lb/ft
3
)
Graphical Procedure
Figure C-4 depicts a graphical representation of the Manos equations that can be used to facilitate rapid evaluation
of the tanks seismic stability. The nomenclature and units for the terms involved in the evaluation is the same
as just described for equation C-1. The procedure may be used to determine the safe seismic fill height for the
tank. A step by step procedure follows.
1. Determine the maximum operating fill height, H, of the tank. If this information is not available from tank records
or other sources, calculate it using the procedure described in subsection 434 or section 1150 of this manual.
2. Determine the following data from tank records or other appropriate sources:
- The tank diameter D
- The specific gravity of the tanks fluid contents, G, i.e., the ratio of the density of the fluid contents
to the density of water
- The thickness of bottom course of the tank shell, ts
- The thickness of the tanks annular ring or bottom plate if the tank doesnt have an annular ring, tp
- The tank shell materials yield strength, Fy
- The foundation deformability coefficient, S
S = 1.2 for tanks supported on crushed rock, wood planks, asphalt pads or soil foundation
S = 1.0 for tanks supported on concrete rings or pads
Tank Manual Appendix C
June 1994 C-7
J
S
T
N
0
5
A
0
.
H
P
G
T
A
M
A
P
C
4
.
G
E
M
F
i
g
u
r
e
C
-
4
M
a
n
o
s
T
a
n
k
S
e
i
s
m
i
c
S
t
a
b
i
l
i
t
y
A
p
p
e
n
d
i
x
C
T
a
n
k
M
a
n
u
a
l
C
-
8
J
u
n
e
1
9
9
4
3. Calculate the lateral seismic acceleration Cex (in gs), as follows.
(a) If site specific DBE (Design Basis Earthquake, typically corresponding to a return period of 475
years) response spectra is available, then Ceq is taken as the peak of the 2% damped spectrum (2%
damping is considered to be appropriate for the impulsive liquids response of unanchored tanks). A
site specific response spectrum shows the accelerations structures would experience for different struc-
tural natural periods. The response spectrum is site specific, that is, it takes into account the sites dis-
tance to known faults and its soil profile. Response spectrum are usually produced by a soils
consultant. If a response spectrum exists for some damping value other than 2%, the peak can be
scaled to the 2% value as follows (see [4] for further details):
C
ex
S
a
()
3.66
4.38(1.04(Ln))
]
]
]
(Eq C-2)
where:
= damping ratio (in percent) for which the peak response spectrum acceleration is available
S
a
()
peak spectral acceleration for damping ratio of
For example, if the peak of the 5% response spectrum is known to be 0.95g, then = 5.0, Sa () =
0.95g and Cex, the peak response for 2% damping is:
C
ex
0.95g
3.66
4.381.04(Ln 5.0)
]
]
]
1.28g
(b) If a site specific response spectrum is not available, then use the values listed in Figure C-5. These
values are shown in the paper by Manos using the amplification factor of 4.3 he recommends S1, S2,
and S3 are soil types defined in the UBC [3].
SOIL TYPE
UBC Seismic
Zone (3) S1 S2 S3
1 0.19 0.23 0.29
2A 0.39 0.46 0.58
2B 0.52 0.62 0.77
3 0.77 0.93 1.16
4 1.03 1.24 1.55
TAMAPC-5.WP
Figure C-5 Peak Spectral Values Cex
Tank Manual Appendix C
June 1994 C-9
4. Using the values for D, G, Cex, ts, tp and S from Steps (1) through (3), calculate F(D) from the following equation:
F
(D)
D
2
GC
ex
(t
s
t
p
)
0.1
t
s
S
(Eq. C-3)
5. Calculate D/ts. Using Figure C-4 and entering the curve corresponding to the calculated value of D/ts at the
appropriate F(D) value, determine the value of H/D. Note that if D/ts lies between two values for which
curves are supplied, interpolate linearly between those two curves when determining the upper bound value
from Figure C-4. Also, low D/ts valves are limited by the tank shells yield stress.
6. Find the upperbound on H/D for the Cex value found in step 3. The vertical (i.e., constant H/D) lines in
Figure C-4 represent upper bound values of H/D for different values of Cex. If the value of Cex found in
Step (3) does not coincide with any of the values shown in Figure C-4, then the upper bound on H/D can
be interpolated or calculated from equation C-4.
H
D
1.52
C
ex
+ 0.22
(Eq. C-4)
7. Take the lower of the H/D values found in steps 5 and 6 and multiply by D to get H. This is the seismic
safe fill height. If it is greater than the tanks operating height, the tank is stable. If it is less then the tanks
operating height then the tank is unstable at the tanks operating safe oil height.
Example
For an example of the above procedure, consider a 36 foot diameter by 35 foot high tank at the El Segundo
Refinery. It is required to determine the seismic safe fill height for the tank.
1. Take H = Current Operating Safe Oil Height = 34.5 ft.
2. Tank Diameter D = 36 ft.
Liquid specific gravity G = 1.0
Bottom course shell thickness ts = 0.29 inches = 0.0242 feet
Bottom plate thickness tp = 0.25 inches = 0.0208 feet
Tank shell Yield strength Fy = 36 Ksi
Foundation rigidity factor S = 1.0 (Concrete Pad)
3. Following the procedure described above and using the 5% damped site specific response spectrum for the
El Segundo site, which has a peak of 0.95g, Cex = 1.28g.
4. Calculate F(D)
F
(D)
D
2
G C
eq
(t
s
t
p
)
0.1
t
s
S
(36)
2
1.0 (1.28)
(0.0242
0.0208)
0.1
0.0242 (1.0)
F
(D)
6.75 X 10
4
5. D/ts = 36/0.0242 = 1487. Since 1487 is almost 1500 use the D/ts = 1500 curve. From Figure C-4, the allowable
H/D is about 0.75.
6. The upper bound on H/D for Cex = 1.28 is found by interpolating between the vertical lines of Cex = 1.2
and Cex = 1.4. From Figure C-4 upper bound is about H/D = 1.4.
7. H/D = 0.75 from step 5 is the lower value and controls in this case. The seismic safe fill height is then:
0.75 (36) = 27 ft.
Appendix C Tank Manual
C-10 June 1994
Since this is less than the current operating safe fill height, the tank is unstable at the tanks operating safe oil
height.
Numerical Procedure
If increased accuracy is desired, the tanks seismic safe fill height can be solved for numerically using an iterative
process. The procedure uses equation C-1 with the following modifications.
1. The Manos method uses 75% of the theoretical buckling stress. For small diameter tanks with low D/ts, this
stress may exceed the yield stress. The buckling stress is therefore limited to the shells yield stress. This is
taken into account by calculating an additional variable, , which relates the tank shells yield stress to its
buckling stress.
yield
buckle
(Eq C-5)
buckle
0.454E(t
s
)
R
(Eq C-6)
If
buckle
yield
1.0
2. The Manos method sums up the stresses in the shell to calculate an overturning moment. However, for small
tanks summing the compressive shell stresses may yield a force (F
c)
which can be greater than the total tank
weight including contents (W
t
). To correct this problem, an additional variable, , which relates the tank
contents weight to the summed compressive force is introduced.
W
t
F
c
(Eq C-7)
Where:
W
t
62.4 G( H D
2
)
4
(Eq C-8)
F
c
0.38SEt
s
2
(
R
H
)
n
(t
s
t
p
)
0.1
(Eq C-9)
If W
t
F
c
Then 1.0
C
eq
is calculated from equation C-1 and multiplied by the smaller of or to get a modified C
eq
. If C
eq
> C
ex
then the tank is stable. When C
eq
= C
ex
the fill height used, H, is the seismic safe fill height. To get this fill
height, equation C-1 is checked with different fill heights until C
eq
= C
ex
.
Tanks that Fail API and Manos Criteria
A tank that has a C
eq
less than the peak acceleration which the tank would be expected to see in an earthquake
C
ex
, is unstable and should have its safe seismic fill height calculated. The safe seismic fill heights from API 650
and Manos can be compared and for most cases, the safe seismic fill height based on the Manos method should
be used. This is usually the higher of the two. The Manos Method is more sensitive to the tanks shell thickness
than API 650 Appendix E. This may be particularly important for tanks which have thinner than average shells
such as tanks with high-strength steels. For these tanks the Manos Method may calculate a lower safe seismic
fill height than API 650.
While the Manos Method is more sensitive to tank shell thickness than API 650 Appendix E, it is less sensitive
to a tanks annular ring thickness. A thicker annular ring allows the tank to mobilize more fluid as the tank shell
uplifts and can have an important stabilizing affect on tank stability. For tanks with annular rings thicker than
1/4 inch, Appendix E of API 650 is thought to be more appropriate.
Tank Manual Appendix C
June 1994 C-11
To reduce the seismic vulnerability of a tank, the maximum operating fill height should be reduced to the safe
seismic fill height, or, alternately, a tank can be retrofitted. Section C3.0 and C4.0 discuss retrofit options in more
detail.
Legal Considerations
Many states require that new tanks be built in accordance with good engineering practice or applicable design
codes. The governing standard is often API 650 and in these cases the seismic design requirements listed in
Appendix E have been used.
For assessing existing tanks, the applicable seismic standard becomes less clear. API 653 is the only standard that
covers in service storage tanks. This standard does not specifically address which design code or standard should
be used to perform a seismic evaluation. Instead, it directs the tank engineer to consider and evaluate all anticipated
load conditions, including seismic loads. Because this standard does rely heavily on the principles of API 650
one may presume that Appendix E may be used to evaluate an existing tank if nothing better exists. However,
there is nothing to prevent the tank engineer from using other standards or codes. Since the various seismic codes
and standards give differing results it is natural to choose the method that provides the lease costs to implement.
Of course, prudent engineering judgment should always be used.
From a legal viewpoint, the important thing to do is for the engineer to document not only the basis for selecting
the method of analysis to be used but to document the rationale for the design conditions and to show that
consideration was given to the risks associated with the proposed designs.
C3.0 APPROPRIATE RETROFIT DECISIONS
Once a tank has been identified as being seismically vulnerable, a choice needs to be made as to how to best
mitigate the tanks seismic vulnerability. Some possible options are:
4
inch in diameter or less.
Adhesive anchors are temperature sensitive and may not be appropriate for heated tanks containing wax or asphalt.
Stainless steel through-bolts go through the foundation and use the entire foundation depth to get the maximum
concrete pullout strength. In through-bolt construction a hole slightly larger than the bolt diameter is drilled through
the foundation and a bolt with both ends threaded and without a head is placed in the hole. To prevent the bolt
from pulling out, a cover plate and nut are placed on the lower threaded end. This requires access to the underside
of the foundation which may be difficult for a combined foundation or foundations without piles. Since the bolt,
nut, and plate are permanently in contact with the ground, stainless steel is used to prevent corrosion. To minimize
the loads on the anchor chairs and foundation, a mild strength steel should be used.
It should be noted that the foundation may be slightly thicker than shown on the existing drawings. Unless a
field investigation is done to determine the footings actual thickness, the bolt should be a few inches longer than
what is required for design.
As an alternative to stainless steel through bolts, grouted-in-place A-307 bolts may be used. For grouted in place
bolts, a hole, (one inch in diameter greater than the anchor bolt head) is drilled in the foundation and the bolt is
placed in the hole which is then filled with a non-shrink epoxy grout. These bolts do not require access to the
underside of the foundation but the embedment depth is limited to the foundation depth minus the required concrete
cover.
Since grouted-in-place bolts require a larger drilled hole than through-bolts or adhesive anchors, they will have
a larger eccentricity with respect to the tank shell than other alternatives. This larger eccentricity will require a
higher chair and may limit the anchor bolt size.
Anchor Chairs
Anchor chair distribute the anchor bolt load to the tank shell so that the stresses are within their allowables. The
chair is designed so that the bolt yields well before the chair or tank shell. This is met by designing the chair
for the yield strength of the anchor bolt as specified by API 650 E.6.2.1. Although not required for existing tanks,
anchor chairs should be located so that their weld spacings meet the requirements of API 650 3.8.1. When the
tank shell material is not one of the types listed in 3.8.1, the weld spacings should still be met but may be relaxed
for special circumstances. Specifically, for chairs near the manway reinforcing plate, the weld spacing requirements
are impractical and, therefore, these anchor chairs may be placed on the reinforcing plate so long as the new
welds do not cross existing welds. Anchor chair design is covered in more detail in Chapter 460 of this manual.
When chair height becomes excessive an alternative to using anchor chairs is to use a continuous ring which
distributes the forces more efficiently. A continuous ring must continue around the entire tank without any breaks.
This requires the continuous ring to miss any appurtenances, some of which may need to be moved. Also, experience
has shown that tanks are slightly out of round and may necessitate varying the ring width slightly.
Foundation
The foundation transfers the loads from the anchor bolts and tank to the piles or soil. The foundation must be
designed for these loads.
For tanks with existing foundations, the foundation is typically extended to confine the anchor bolts. Holes are
drilled horizontally into the foundation with reinforcing steel epoxied into place to tie the new concrete to the
existing foundation. New and existing concrete is bonded together by roughening up the existing concrete surface
and either applying a coat of epoxy or wire brushing the new concrete into the existing concrete just before the
concrete pour.
Tank Manual Appendix C
June 1994 C-19
If piles are added, they must be tied into the foundation to resist the uplift forces. For driven piles or caissons
the uplift connection is made with reinforcing steel attached to the pile and embedded in the foundation. For helix
piles, the compression and tension are resisted by a plate welded to the pile and embedded in the concrete as
shown in Figure C-7. The foundation is designed for the Concrete bearing pressures under the plate and the
punching shear.
Piles
Retrofitting tanks to resist earthquake forces will often require piles to resist the uplift forces. Piles bring the
earthquake uplift forces down into the soil. Typical piles that can resist tension are:
Driven Piles
Caissons
Helix Piles
Generally, driven piles are more expensive than the other two options and usually require more accessibility to
the site. Caisson piles, although less expensive and easier to install have limited uplift capacity. Chapter 230 in
the Civil and Structural Manual describes driven piles and caissons in more detail.
Because of their economy and ease of installation, Helix piles are usually the best alternative when retrofitting a
tank.
Helix piles are a metal shaft with one or more circular plates, 8 inches to 14 inches in diameter, attached in a
helical pattern. Unlike other piles, helix piles are torqued into place. This allows helix piles to be installed with
smaller equipment than other pile types.
Pile pullout resistance comes from the soil bearing on the circular plates. For piles with shallow embedments
defined as less than five circular plate diameters the failure mode is a cone of soil projecting to the surface
from the circular plate. For piles with deep embedments, the failure mode is a plug of soil starting at the circular
plate. A deep anchor is preferred since it will have a ductile failure mode. Very dense soils or soils with large
boulders make torquing helix piles into place difficult and may prevent their use entirely.
It is impractical to use piles to resist the uplift loads for tanks that are founded on rock or have a very shallow
soil profile. For these situations, rock bolts are an acceptable alternative.
Appendix C Tank Manual
C-20 June 1994
C6.0 REFERENCES
1. American Petroleum Institute, API Standard 650, Ninth Edition, Welded Steel Tanks for Oil Storage,
Appendix E, Seismic Design of Storage Tanks, July 1993.
2. Manos, George C., Earthquake Tank-Wall Stability of Unanchored Tanks, American Society of Civil
Engineers, Journal of Structural Engineering, Vol. 112, No. 8, August 1986.
3. International Conference of Building Officials, Uniform Building Code, 1991.
4. Newmark, N.M., and Hall, W. J., Earthquake Spectra and Design, Earthquake Engineering Research
Institute, 1982.
Tank Manual Appendix C
June 1994 C-21