Fabrication of fuel storage tank

INTRODUCTION:
This report:a) Discusses fabrication of two each 10000 cubic meters fuel
storage tank and reported the progress of fabrication work
being done by TEPC at 1180MW CCPP, Bhikki Sheikhupura.
b)Investigate the material, dimensions of plates, working speed,
number of manpower and equipment being used.
c) Illustrate the technical requirements for tank fabrication.

MAIN FABRICATION AND INSPECTION DATA:

Design life of the tank
Design life of internal
floating roof
Filling height (m)
Bottom joint L.T
Working pressure (KPag)
Design pressure (KPag)
Working temperature
Design temperature (C)
Minimum climate
temperature (C)
Flash point temperature (C)
Fluid property
Density (Kg/m3)
Joint efficiency
Corrosion allow (mm)
Total volume (m3)
Effective volume (m3)
Design roof live load (Pa)
Empty weight (kg)
Operating weight (kg)
Weight of full water (kg)
Shell plate dimensions (cm)
Diameter (m)
Bottom to highest position
of floating deck (m)
Bottom to peak of dome
(mm)
Top to primary wind girder
(m)
Top to second wind girder
(m)
Plates in a shell

30 years
30 years
18
API 650 8.6
1
2 / -0.6
30
50
4
60 (min)
Flammable
820 ~ 870
0.85
3
22619
20000
1200
552110
~17974658
~20584251
910*260*1
40
16.3
~23477
4.4
4.4+5.6
14

Rows of plates

8.5

TECHNICAL REQUIREMENTS:
This tank is fabricated, inspected and accepted according to
code API 650 edition 2013
Before the tank body erection, the tank foundation shall be
checked and accepted according to the requirements of API
650 and civil basis drawing.
Plates shall be ordered with a 0mm under tolerance.
All nozzles provided with an inside corner radius of 3mm
minimum.
The welded joints and size shall in accordance with API 650,
fillet welding root as per thinner thickness.
All the opening on the shell shall avoid shell seams. The
distance between opening rim and butt seam of shell shall be
8 times of thickness and no less than 250mm.
The entire butt welding shall be full penetration.
Magnetic particle inspection of shell to bottom plate welds
shall be performed. The radiographic test for shell butt welds
must be performed.
Vacuum testing is required for bottom plate per API 650 para
8.6.3 a partial vacuum of 21 KPag to 35 KPag shall be used for
the test. A second partial vacuum test will be required for
each vacuum test, after erection and after hydro test a second
partial vacuum test of 56 KPag to 70 KPag shall be performed
for the detection of very small leaks.
When the entire tank is completed it shall be filled with water
to the top angle for testing any leakage between the welds.
After hydrostatic test the equipment shall be dried and
cleaned

 Floating roof movements should be smooth, steering

mechanism, seal device and automatic vent valve without
jamming phenomenon such as pillar.
The welding slag of shell inside surface must be removed, in
case of damage of floating plate seal.
A guide system shall be provided to prevent the roof from
rotating.
The internal floating roof for this tank metallic internal floating
roofs on floats have their deck above the liquid supported by
closed pontoon compartments for buoyancy. The roof is
constructed of aluminum alloys.
The pontoon diameter is not less than 200mm, the thickness
is not less than 1.3mm and the material for pontoon and
aluminum plate is 303H24 ( high manganese aluminum alloy)
or equal.
All the connection parts of pontoon for internal floating roof
should be joined by austenitic stainless bolts.
The seal type of internal floating shall be resilient seal; the
seal design life is not less than 6 years.
Cathodic corrosion protection should be set.

CURRENT ACTIVITY:
Three and a half shells have completed of tank on west side.

 Two and a half shell have completed of tank on east side.

We have two CAT generators each of 275KVA working on site.

 Fifteen ZX7-400STG Welding machines are installed on each

tank; rated input consumption for each machine is 18.4 KVA.

Primary wind girder is installed below 4.4 meters from top

shell plate.

 30 to 35 welders are working on both tanks, every welder has

their helpers, and around 150 people are working on both
tanks in day and night shift.
It takes about 4 to 5 days to complete one shell.

MATERIAL DESCRIPTION:
DESCRIPTION
Bottom
Platform & ladder for
manway
Shell manway
30
M1b manhole core
Shell

MATERIAL

QUANTITY

A-36
Composite

1
1

Composite
Composite
Composite

2
1
1

Inner floating roof

Spray water coil
support
Top ring beam
Reticulated shell
structure
Platform and spiral
stair
Grounding lug
Rain skirt
Anchor bolt chair
Anti-wind ring
L180*110*10
Pipe
114.3*6.02

Drawings:

Aluminum alloys
Composite

1
1

Composite
A-36 A-285 Gr.C

1
1

Composite

SS304
A-36
Composite
A-36

6
1
60
2

A-106 Gr.B