UHDE INSTRUCTION September 2011

UI
Erection
9252-02
Site-welded equipment
Copyright reserved Page 1 of 18
Montage; Baustellengeschweißte Ausrüstungen Supersedes 2008-02

UHDE INSTRUCTION
UF 19 ST-F01 M03 E 2010-12

01.09.11 Rapior 01.09.11 Hochstein 01.09.11 Fellner 01.09.11 Hasenbein

Date Prepared Date Checked Date Standardization Date Approved
 September 2011

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9252-02
Site-welded equipment
Page 2 of 18

Contents
Page
1 Scope .................................................................................................................................................................... 3
2 Units, abbreviated terms ..................................................................................................................................... 3
2.1 Units....................................................................................................................................................................... 3
2.2 Abbreviated terms.................................................................................................................................................. 3
3 Technical documents .......................................................................................................................................... 3
4 Storage and transport ......................................................................................................................................... 3
4.1 Storage .................................................................................................................................................................. 3
4.2 Transport ............................................................................................................................................................... 3
5 Foundations ......................................................................................................................................................... 3
6 Machining of plates on site ................................................................................................................................. 4
7 Erection ................................................................................................................................................................ 4
7.1 General requirements ............................................................................................................................................ 4
7.1.1 Scaffolding and erection aids ................................................................................................................................. 4
7.1.2 Tanks with bottom insulation.................................................................................................................................. 5
7.1.3 Storm rigging.......................................................................................................................................................... 6
7.2 Requirements for weld sequences......................................................................................................................... 7
7.3 Assembling and welding of plates.......................................................................................................................... 7
7.3.1 Annular plates ........................................................................................................................................................ 7
7.3.2 Bottom plates ......................................................................................................................................................... 8
7.3.3 Shell plates ............................................................................................................................................................ 9
7.3.4 Roof plates........................................................................................................................................................... 11
7.4 Steel structures .................................................................................................................................................... 12
8 Grouting.............................................................................................................................................................. 12
9 Dimensional tolerances..................................................................................................................................... 12
9.1 Bottom ................................................................................................................................................................. 12
9.2 Shell..................................................................................................................................................................... 13
9.3 Roof ..................................................................................................................................................................... 13
10 Measurement of settlements, leakage testing................................................................................................. 14
10.1 General notes ...................................................................................................................................................... 14
10.2 Measurement of settlements................................................................................................................................ 14
10.3 Leakage testing.................................................................................................................................................... 15
10.3.1 Filling operation.................................................................................................................................................... 16
10.3.2 Extended leakage test ......................................................................................................................................... 16
10.3.3 Leakage test of double-shell tanks....................................................................................................................... 16
10.4 Determination of the tightness ............................................................................................................................. 17
10.5 Measures to be taken after the leakage test ........................................................................................................ 17
11 Calibration .......................................................................................................................................................... 17
12 Documentation................................................................................................................................................... 17
Reference standards ......................................................................................................................................................... 18
Amendments ...................................................................................................................................................................... 18
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Erection
9252-02
Site-welded equipment
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1 Scope
This Uhde instruction (UI) shall apply to the design and construction of industrial and chemical plants. It
applies to the welding of equipment on site (hereafter named site-welded equipment), such as tanks and
silosand contains generally applicable requirements. It does not apply to floating-roof tanks and spheres.

2 Units, abbreviated terms

2.1 Units
Table 1. Units
General SI units
Concentration ppm
Dimensions mm
Pressure bar, mbar
Bearing capacity kN/m²
Gripping capacity kN
Temperature °C

2.2 Abbreviated terms

UF = Uhde form
ppm = Parts per million

3 Technical documents
Technical documents related to the erection of site-welded equipment and associated work are provided by
the Orderer, such as drawings, bills of material, specifications and procedures.

UI 9252-06 shall be applied. The Contractor shall prepare the weld sequence plan.

4 Storage and transport

4.1 Storage
For the storage of plates, pipes, flanges, filler metals and any other items pertaining to the site-welded
equipment, UI 9250-01 shall apply.

The material code numbers and heat numbers stamped on the plates shall be properly marked with
weatherproof paint. The marking shall be clearly visible and durable to ensure material traceability.

4.2 Transport
The plates shall be transported in such a manner as to prevent damage and contamination. Special care shall
be taken by Contractor to prevent machined edges being damaged.

5 Foundations
Prior to erection, the Contractor shall check the dimensions and elevations of the foundations as well as the
correct position of the anchor holes, anchor bolts or flat-bar anchors already grouted. The Orderer shall be
notified in writing if any dimensional discrepancies are found.

The foundations shall have adequate strength, shall be dry and free from contamination.

For the dimensional tolerances of the foundations, the data contained in UN 9281-02 Part 1 shall apply. For
the levelness of foundations and the bottom insulation in the area of the shell-to-bottom joint, the tolerance
group G6 shall apply. For the remaining foundation area, the tolerance group G5 shall apply. The data
contained in the construction drawings shall take precedence.

The levelness of foundations, supports of sectional steel, and the bottom insulation shall be determined with
the aid of a level instrument in the area of the shell-to-bottom joint. The spacing of the measuring points shall
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not exceed 4 m. The measured levels shall be entered into a measuring record. The level differences between
the reference level and the other measuring points as well as the level differences between adjacent
measuring points shall be recorded.
Spacing of the measuring points
1 to 2

Reference level

1 2 3 4 5 6 7 8 9 1

Circumference

Figure 1. Determination of levelness

For supports of sectional steel, the deviation from the specified levelness shall not exceed:
• 2 mm at a spacing of ≤ 4 m,
• 5 mm at a spacing of > 4 m.

6 Machining of plates on site

For the dimensional tolerances of the machined shell plates, section 7.3.3 shall apply. For the preparation of
weld bevels the applicable drawings apply. If strips of up to 800 mm width are to be cut, two parallel cutting
torches shall be employed simultaneously to avoid distortion. Undercuts and cutting slag shall be removed by
grinding. The depth of the undercuts shall not exceed 0.5 mm.

The ends of the shell plates shall be adequately pre-formed under a press prior to rolling. During rolling, the
radius of the plates shall be regularly checked by means of a template of approximately 1 m in length.

Prior to rolling the plates of austenitic chromium-nickel steel the roller surfaces shall be cleaned from rust,
grinding dust, and other contamination. Contractor shall submit an invitation / request to the Orderer for
inspection in writing at least one day in advance. Rolling shall not be started until the Orderer has checked
and accepted the condition of the rollers. If the rollers cannot be cleaned sufficiently, the plate surfaces shall
be protected by plastic sheets or other suitable and adequate means.

7 Erection
After the Contractor has confirmed acceptance of the foundation to the Orderer, erection work shall
commence.

7.1 General requirements

Prior to the erection, the centrelines of the site-welded equipment shall be marked on the foundation. The
Contractor shall be responsible to protect anchor bolts against corrosion, damage, and soiling.

For site-welded equipment which is to be coated or rubber-lined after erection, special requirements shall
apply to the finishing of inside surfaces and welds. The standards specified for the performance of this work
shall be ob-served. The acceptance of this work will be performed jointly by the Orderer and the contractor
who applies the coating or rubber-lining.

7.1.1 Scaffolding and erection aids

For erection and welding work, only scaffolding shall be used which require non or a small number of weld-on
clamps. The Contractor shall provide the required erection aids (e.g. clamps, spacer plates, wedges, clamping
devices, shims, welding clamps for aligning the weld joints) for the assembly of the site-welded equipment.
For site-welded equipment of austenitic chromium-nickel steel, erection aids of unalloyed and low-alloy steel
shall not be in direct contact to any site-welded equipment material.
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Welding of erection aids to items of site-welded equipment (e.g. shell plates, bottom plates) shall be subject to
approval by the Orderer. The type of material of weld-on erection aids shall be the same as the material of the
item of site-welded equipment they are welded to. Welds between erection aids and items of site-welded
equipment of fine-grained steel shall be welded in two runs and shall be approximately 40 mm in length. The
second run shall not surface-fuse the base material.

A
Weld-on clamp

Shell plate
A
Weld-on clamp

≥ 50

Wooden block

Figure 2. Erection scaffolding (safety measures not shown)

Erection aids shall be removed after erection. Knocking-off, bending-off, chiselling-off or flame-cutting of
erection aids is prohibited. The weld areas shall be ground flush. For these areas, the Orderer may demand
from the Contractor the performance of a surface test. Costs for these tests shall be borne by Contractor.
Damaged plate surfaces shall be repaired according to the directions of the Orderer.

7.1.2 Tanks with bottom insulation

The bottom insulation (e.g. insulation blocks) shall be checked for damage jointly by the Contractor and the
Orderer prior to placing the annular bottom plates. Thereafter, the Contractor shall be responsible for the
protection of the bottom insulation against damage and the influence of weather. If the bottom insulation gets
damaged while placing the annular bottom plates the Orderer shall be informed immediately.

If strips are used for backing the molten pool at the bottom annular-plate joints and not being removed after
welding, the insulation blocks shall be recessed in the area of the backing strips.

If rain water might collect in the space encircled by the insulation blocks, a sufficient number of rain water
drains (e.g. plastic hoses) shall be placed below the insulation blocks. The rain water drains shall be checked
regularly for proper function. The rain water drains shall remain in place and shall be properly shortened be-
fore the insulation of the shell outside surface is applied.

Supporting plates for rigging masts to be placed on the bottom insulation shall be adequately sized to reduce
the bearing pressure.
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Figure 3. Bottom insulation in the area of the annular bottom plates

7.1.3 Storm rigging

If the erection of site-welded equipment is performed according to this UI, a provision has to be made for
storm rigging (e.g. bracing or guy ropes) after erection of the third shell course to secure the statically unstable
site-welded equipment shell. In the erection progress the storm rigging shall be extended or shifted. It shall not
be removed until the roof rafters have been installed and welded. If the Contractor selects bracing as storm
rigging, details of its design and stability analysis shall be submitted to the Orderer for approval.

Figure 4 shows a recommended storm rigging by using 12 mm diameter steel guy ropes. The rope ends and
the gripping devices used for tensioning the ropes shall be properly anchored in the ground. The distance
between the anchorage and the shell shall be 1.4 × shell height. The ropes shall be attached to the shell by
using quick-release clamps. The anchoring point, the connecting point of the quick-release clamp and the
centre of the tank shall be in line. The gripping capacity of the gripping devices shall be at least 15 kN.

If an erection procedure is selected which requires the filling of the tank with water during erection, no storm
rigging is necessary. The distance between the water level and the upper edge of each last shell course shall
not exceed 3 times plate width.

Figure 4. Storm rigging by means of steel guy ropes

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7.2 Requirements for weld sequences

All fillet welds shall be welded with minimum 2 passes. Interpass temperatures shall be observed.

Shell plate
3
1
3
1 2
2

Flat-bar anchor Annular bottom plate

3 Shell plate

Flat-bar anchor
4

Figure 5. Weld sequence for flat-bar anchors

The weld sequence according to Figure 5 shall be observed. At the starting points, the runs shall be lap-
welded.

7.3 Assembling and welding of plates

Contractor shall take shrinkage and distortion due to welding into consideration as well as given dimensional
tolerances for the preparation and fit-up works and the selection of weld sequences.

7.3.1 Annular plates

The annular bottom plates shall not be laid in place until the tolerances of the foundation and bottom insulation
have been checked according to section 5.

Laying out, tack welding, and welding of the annular bottom plates should be performed without interruption.
Welding shall be performed by an even number of welders and be arranged in axes (see Figure 6). With only
one welder performing the work, the weld sequence also given in Figure 6 shall be observed.
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A1 A1
A2 A3 A 10 A6

C3 D2 A8 A 11

C1 D1 A4 A3

C2 D3 A 12 A7

B3 B2 A5 A9
B1 A2

Figure 6. Weld sequence for annular bottom plates (left: by 4 welders, right: by one welder)

In the area of the shell-to-bottom joint, the weld reinforcement shall be ground flush.

After welding, the annular bottom plates in the area of the shell-to-bottom joint shall be aligned as accurately
as possible with the aid of shims. The material of shims shall be the same as for the annular bottom plates.
The spacing of the shims shall ensure continuous contact between the annular bottom plates and the
foundation or the bottom insulation.

7.3.2 Bottom plates

Installing the insulation and laying out the bottom plates in the central section of a tank should not be
performed until the shell and the roof have been erected.

The plates for the central section of the bottom shall be rectangular and sharp-edged. To achieve a bottom
surface as plane as possible, suitable holding and clamping devices shall be used for laying out and welding
the plates. In the central section of the bottom and especially at the transition from this central section to the
annular bottom plates, welding shall not be performed until the bottom has been protected from solar radiation
(e.g. after erection of the roof).

The plates of the central section of a tank bottom shall be laid out in strips, starting from one bottom
centreline, with an overlapping of approximately 50 mm. Thereafter, the transverse joints may be tack-welded
and welded. The welding of the transverse joints shall proceed from the plate centre alternately to either side
to avoid transverse and longitudinal shrinkage of the plate strips to the greatest possible extent. After welding
the transverse joints, two plate strips may then be joined by tack welding and welding. The longitudinal joints
shall be back step welded from the centre of the plate strips alternately to either side. The resulting plate strips
of double width shall then be joined in the same way. For tanks with a diameter of more than 20 m, two or four
straightening seams might be specified. Details of these straightening seams shall be agreed upon with the
Orderer.

For three-plate lap joints, the top plate shall be heated up to 600 to 700 °C and contoured to the lower plate
(see Figure 7).
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0
≈5

50

Figure 7. Three-plate lap joint

After welding the transverse and longitudinal joints, the plates of the central section of the bottom shall be cut
to size to obtain an overlapping with the annular bottom plates of at least 50 mm. The joint with the annular
bottom plates shall not be tack-welded until the shell-to-bottom joint has been welded. The joint shall be
welded with an even number of welders and be arranged in axes (see above).

For laying out, tack welding and welding of the bottom plates which are to be butt-welded, the Orderer may
provide special working instructions. In principle, the procedure shall be similar to that one described for lap-
welded plates. To achieve a bottom surface as plane as possible, the straightening seams (mostly longitudinal
seams) shall not be welded until the shell-to-bottom joint has been welded.

7.3.3 Shell plates

Erection of the shell plates shall not be started until the elevation of the annular bottom plates has been
checked and accepted by the Orderer.

Shell plates supplied cut to size shall be checked for dimensional accuracy. The longitudinal edges of the shell
plates shall be parallel. The transverse edges shall be perpendicular to the longitudinal edges. Unless
otherwise specified, the following tolerances shall not be exceeded:
• plate width: specified dimension ± 1.5 mm,
• plate length: specified dimension ± 1.5 mm,
• difference of the diagonals: ≤ 3 mm.
Plate length ± 1.5

50 ± 3
Reference line
Plate width ± 1.5

50 ± 3

al Diagon
Diagon al

Figure 8. Dimensional tolerances of shell plates

Deviations from the permissible plate width shall be corrected by grinding or overlay welding (with subsequent
grinding). If plates of excessive length are used for a shell course, the circumference shall be corrected at the
plate to be installed last.

Each plate shall be marked in such a manner that the correct erection position is indicated. The elevation of
stiffening rings, the joints of the stiffening rings, and the rafter connections shall also be marked. The markings
shall be re-checked and re-measured after erection and the required welding has been completed.
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Prior to the erection of the shell plates, the bottom centre, the main centrelines, and the shell joints shall be
marked on the foundation and on the annular bottom plates. The inside radius of the shell plates minus 10 mm
shall be marked on the annular bottom plates (e.g. by punching). For the erection of the shell plates and the
weld sequence, the following sequence of operations shall be maintained:
• Erect first shell course.
• Adjust, align shell plates and tack weld vertical joints.
• Erect and align second shell course. Tack weld vertical joints.
• Weld vertical joints of the first shell course.
• Erect and align third shell course. Tack weld vertical joints.
• Weld vertical joints of the second shell course.
• Align, tack and weld circumferential joint first to second shell course.
• Install the following shell courses similarly.
• Welding of vertical joints of any shell course shall be carried out when the next course is erected, aligned
and tack welded.
• Weld the shell-to-bottom joint.

The first shell course shall be aligned with a more stringent dimensional tolerance than given in section 9 to
facilitate easy erection of the following shell courses. For aligning the first shell course, auxiliary plates (same
material type as annular bottom plates) shall be tack-welded to the annular bottom plates at a spacing of
approximately 1.50 m as shown in Figure 9. The following shell courses shall be erected in accordance with
the drawings.

The alignment of each course shall be measured by a surveyor. Readings shall be taken per plate closed to
the circumferential joints:
• Four measuring points on the lower circumferential joints and
• Four measuring points on the upper circumferential joints.

Additionally per course shall the tank centreline be measured by a surveyor.

All vertical joints shall be aligned with the aid of spacer plates and wedges and then tack-welded at a spacing
of up to 300 mm. During tack welding, the spacer plates shall be removed. Alignment of the horizontal joints
shall be performed with the aid of spacer plates. The spacing of the spacer plates should be approximately 0.5
m.

Figure 9. Alignment of first shell course

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300
A-A

< 500

50
½
3
Wedge
Plate width

50
A A Spacer plate
Tack weld
½

50

B
300

Spacer plate with wedges

B Annular bottom plate

Figure 10. Alignment and tack welding of vertical joints

Prior to welding the vertical joints, the wedges on the spacer plates in the horizontal joint shall be loosened but
not removed. In the case of the first shell course, the wedges between the auxiliary plates (on the annular
bottom plates) and the inside of the shell shall be loosened as well. To achieve the shrinkage of a shell course
as uniform as possible, all vertical joints should be welded simultaneously, i.e. one welder per joint. Otherwise
the number of available welders shall be even and be arranged in axes (see above). Figure 6 applies in
analogy for welding of vertical joints of shell plates.

Prior to welding, the horizontal joint shall be aligned by reseating the loosened wedges on the spacer plates.
Tack welds shall be provided in the centre between the spacer plates. Thereafter, the spacer plates shall be
removed. The number of welders shall be even and be arranged in axes (see above).

The shell-to-bottom joint shall not be welded until at least four shell courses have been welded completely.

For double-shell tanks, the outer shell shall be erected by analogy to fit into the sequence of operations. Inner
and outer shell shall not be joined during erection. The scaffolding shall only be attached to the inner shell.

Stiffening rings shall not be installed and welded until the associated shell course has been welded completely
and the specified non-destructive tests have been performed.

With the approval of the Orderer, an opening (door sheet) may be cut into the first shell course during the
erection of the upper shell courses to facilitate easy access to the tank interior. If the stability of the shell is
jeopardized by this opening, suitable temporary supporting elements shall be provided by Contractor.

During the erection of the shell plates, the following measurements of settlements shall be performed, taking
into consideration the data contained in section 10.2:
• 1st measurement after placing the annular bottom plates,
• 2nd measurement after erection of half the shell courses,
• 3rd measurement after erection of the last shell course.

If settlements are detected, the Orderer shall be informed immediately. The root gap shall not be corrected by
pulling or cutting off the shell plates. Raising the annular bottom plates (by means of shims) shall be
performed according to the instructions of the Orderer.

7.3.4 Roof plates

Erection of the roof plates shall not be started until the top shell course has been checked and accepted by
the Orderer.
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In the case of a roof with rafters, the crown ring shall be raised by suitable means (e.g. on a mast) to the
specified level.

Site-welded rafters shall be assembled according to the drawing. All rafters shall be marked to identify the
location of the polygon connections and of the roof plate joints. The rafters shall be placed on the brackets,
which are welded to the top shell course and to the crown ring. Thereafter, the rafters shall be aligned and
welded.

After erection of the rafters, the annular roof plates shall be laid out with the specified root gap and aligned
with the aid of spacer plates and wedges. While the annular roof plates, and the rafters to the annular roof
plates are being welded, the other roof plates may be laid out. The joint between the roof plates and the
annular roof plates shall be welded at last.

In the case of spherical roofs, the plates shall be laid out in the shape of a ring starting from the centre. In the
case of conical roofs the Contractor may select the erection sequence.

The permissible load of the rafters shall be observed when laying out the plates (e.g. by piling up of plates for
storage purposes).

7.4 Steel structures

For the erection of light steel structures (operating platforms, ladders, railing) UN 9281-03 Part 1 shall apply.

8 Grouting
Grouting of anchor holes and pipe sleeves is normally performed by a civil contractor.

If the grouting of anchor holes is included in the scope of services of the Contractor, UN 9281-02 Part 1 shall
apply to the performance of this work.

Masonry bolts shall not be tightened until the grout has cured to the required strength, but not earlier than
seven days after grouting.

9 Dimensional tolerances
The site-welded equipment shall be erected in accordance with the dimensions given in the drawings. The
Orderer shall be informed in a timely manner of any discrepancies found in the drawings. The tolerances
indicated in the drawings or in the specified standards shall take precedence over this UI.

The dimensions of site-welded equipment shall be checked prior to the leakage test and the application of
coatings, insulation and rubber linings. When measuring, the influence of temperature and wind shall be taken
into consideration.

9.1 Bottom
For bottoms with a diameter of up to 40 m, local bulging of 0.25 % D of the bottom plates is permissible. For
bottoms with a diameter of more than 40 m, bulging shall not exceed 100 mm.

0.25 % D, max. 100

Figure 11. Permissible deviations of the bottom from the true shape
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9.2 Shell
The deviation of individual shell courses or the shell from the vertical line shall not exceed ± 5 mm per meter
of plate width HP or shell height HS, respectively.

The deviation of the shell radius from the specified dimension shall be checked approximately 0.3 m above
the bottom level. The following values are permissible:
• ± 0.1 % D for a diameter D of ≤ 40 m,
• ± 40 mm D for a diameter D of > 40 m.

Local deviations (bulges) of the shell from the vertical line and from the true shape (horizontal) shall not
exceed ± 15 mm per 1 m. For aluminium shells, a deviation of ± 25 mm per 1 m is permissible.

The vertical centreline of the shell shall also be checked, if specified. The deviation from the vertical line shall
not exceed 2 mm per meter of the shell height HS.

Figure 12. Permissible deviations of the shell from the true shape

For double-shell tanks, the above tolerances apply to both shells.

9.3 Roof
For fixed roofs with rafters, the roof height may fall short by not more than 30 mm per meter of the roof height
HR. Exceeding the specified dimension is admissible.

Level differences of opposite rafters shall not exceed 4 mm per meter of the radius RR. Level differences of
adjacent rafters shall not exceed 3 mm per meter of the spacing DR. The level differences shall be measured
at the centre of the rafters (e.g. by means of a hose levelling instrument).

Curved polygon bars, and curved shape-stabilising bars of at least 1.5 m length which are not attached to the
rafters may deviate from the theoretical curvature by ± 3 mm per meter of the bar length SL.

Figure 13. Permissible deviations of the roof from the true shape
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10 Measurement of settlements, leakage testing

10.1 General notes
Prior to the measurement of the foundation settlements and the leakage testing the following work shall be
completed:
• welding work including the specified examinations and necessary repairs,
• heat treatment according to UF 9252-01,
• dressing the welds of site-welded equipment which is to be provided with coating or rubber lining,
• inside cleaning of the site-welded equipment,
• checking the dimensional tolerances according to section 9,
• grouting and tightening of the anchor bolts,
• leakage testing the nozzles provided with reinforcing plates at a test pressure of ≤ 0.5 bar,
• first vacuum test of the bottom welds.

Prior to installation the safety valves shall be tested for proper function at site on a test bench.

Sufficiently wide safety zones shall be cordoned off prior to testing the tanks. During the leakage test, other
work within these safety zones shall be restricted, work at the tank shall be interrupted. During the test, only
the personnel assigned to the testing work shall be permitted to be present in the immediate vicinity of the
tank.

Vacuum testing of the bottom welds at a test pressure of not more than 500 mbar shall be performed before
as well as after the leakage test. If leaks are detected during the second vacuum test, the vacuum test shall
be repeated after elimination of the leaks. Repeating the leakage test is not required.

Flat-bar anchors shall not be connected until the water has been filled in and the annular bottom plates rest
uniformly on the foundation.

Test filling level shall be the maximum filling level or overflow level of the site-welded equipment, as
applicable, unless otherwise specified.

Welds shall not be coated or insulated until the leakage test has been performed.

10.2 Measurement of settlements

For the measurement of settlements, measuring points shall be uniformly distributed and marked (e.g. by
inserting a bolt) at a spacing of up to 10 m around the circumference of the foundation. The reference point
aside of the foundation will be determined by the Orderer. The measurements shall be performed as follows:
• 1st reading prior to filling,
• 2nd reading approximately 24 h after attaining ¼ of the filling level (± 500 mm),
• 3rd reading approximately 24 h after attaining ½ of the filling level (± 500 mm),
• 4th reading approximately 24 h after attaining ¾ of the filling level (± 500 mm),
• 5th reading approximately 24 h after attaining the specified filling level,
• 6th reading after emptying.

The same measurements of settlements shall be performed in the case of a double-shell tank with the annular
space empty. One additional reading has to be carried out before emptying, at the specified filling level of the
tank proper and the specified filling level of the annular space.

In case of differential settlements of the foundation of at least 15 mm (referred to 10 m circumference) or

uniform settlements of at least 10 mm in 24 hours, the filling operation shall be interrupted. Only after an
assessment by the Orderer the filling operation shall be resumed under continuous observation by Contractor
with due consideration to special instructions.
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Extended leakage test Leakage test of outer shell

Filling level (m)

Leakage test and measurement of settlement Pressure Vacuum Draining

20

15
/h
m³
25

10 /h
m³
30

90
/h
Inner shell

m³

m³
/h
90
³/h
m

5
70

Outer shell
³/h
m
60

Time
0
1 2 3 4 5 6 7 (Weeks)
2nd reading

3rd reading

5th reading

6th reading

7th reading
1st reading

4st reading

Figure 14. Typical filling diagram

10.3 Leakage testing

The testing agent will be specified by the Orderer. The testing agent shall only be replaced by another one if
approved by the Orderer in writing.

For leakage testing, water shall normally be used as testing agent. The water shall be free of dirt, iron oxides
and organic substances. The quality of the water shall be evidenced by an analysis prior to use. If the Con-
tractor is responsible for the supply of the testing agent he shall provide this analysis. He shall always perform
the interim analyses regardless of the supply if the same water is used several times.

The following testing agents can be used for leakage testing:

WSN = sea water with a chloride ion content of more than 10 000 ppm,
WSB = brackish water with a chloride ion content between 1000 and 10 000 ppm,
WSDB = water with a chloride ion content between 200 and 1000 ppm,
WSDA = drinking water with a chloride ion content between 50 and 200 ppm,
WSD = drinking water with a chloride ion content between 1 and 50 ppm,
WDS = de-mineralised water (e.g. condensation) with a chloride ion content of less than 1 ppm,
WCl = drinking water with a chloride ion content between 50 and 200 ppm and a corrosion inhibitor
(e.g. 2 % by volume of sodium carbonate).

With the approval of the Orderer, WSN, WSB or WSDB may be used, if the following details have been
agreed upon in writing prior to testing:
• the residence time of the saltwater in the site-welded equipment,
• the measures for the prevention of corrosion,
• the measures for cleaning of the site-welded equipment after the test.

WSDA or WCI should be used for site-welded equipment of unalloyed or low-alloy steel. For pumping and
storing the water, equipment and piping of unalloyed or low-alloy steel shall not be used unless their surfaces
coming in contact with the water are protected (e.g. by rubber lining).
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WSD or WCI shall be used for site-welded equipment of austenitic chromium-nickel steel or nickel alloys.

10.3.1 Filling operation

Prior to filling in the testing agent, the blind flanges shall be removed from all roof nozzles. The filling rate
should not exceed 0.2 m water level per hour. Depending on the number and the nominal diameter of the roof
nozzles as well as on the soil conditions, it might be necessary to reduce the filling rate to 0.1 m water level
per hour. For site-welded equipment with a diameter of not more than 12 m or in case of soils with a bearing
capacity of at least 300 kN/m² the filling rate may be increased appropriately. Higher filling rates are permitted
for the annular space of double-shell tanks. Details shall be agreed upon between the Orderer and the
Contractor in a timely manner.

For the measurement of settlements according to section 10.2, the filling operation shall be interrupted. During
filling, the shell shall be checked for deviations from the vertical line.

The flat-bar anchors shall be welded and the anchor bolts re-tightened after the specified filling level has been
attained.

Adequate redundant provisions to display the testing agent level during the filling operation outside the tank
(e. g. transparent hose and pressure gauge) shall be made by the Contractor.

10.3.2 Extended leakage test

For tanks which are designed for a slight positive pressure and for vacuum, an extended leakage test might
be specified. Pressure and vacuum shall be measured with the aid of a U-tube manometer with an adequate
measuring range. The U-tube manometer shall be provided by Contractor and approved by the Orderer.

The specified safety measures (e.g. a water seal) shall be checked prior to the test. The pressure range of the
water seal shall be in line with the specified test pressure. The vent nozzle shall have a diameter of at least
DN 200. During the test, no other work shall be performed within the safety zones. It shall be possible for the
personnel assigned to the testing work to take up safe positions when the pressure is being increased.

Testing shall not commence until the temperature equalization between shell and water fill has taken place.
The water should have a temperature of at least 15 °C. During testing, Contractor shall observe permanently
the influence of solar radiation and the corresponding pressure increase.

Filling up to the specified filling level shall be performed in accordance with section 10.3.1. The roof nozzles
shall be closed by blind flanges and on the vent nozzle a manual operated valve shall be installed after
attaining the specified filling level. The pressure in the free space above the water level shall be increased
gradually by blowing in air. When about 50 % of the test pressure has been attained, the shell and the roof
shall be checked for distortions. After the specified test pressure has been attained, the welds above the water
level shall be checked (e.g. by using a foaming agent). Minimum holding time for the leakage test shall be one
hour, unless otherwise specified.

The (original) safety valves shall be tested in sequential order by raising the test pressure, as detailed above,
to the set pressure of the safety valves. Each safety valve shall be checked minimum twice.

After testing the pressure shall released slowly by venting the air.

If approved by the Orderer, the welds may be subjected to a vacuum test. The vacuum test shall only be
carried out if the site-welded equipment has been filled up to the maximum specified filling level. The vacuum
in the free space above the water level shall be produced by slowly lowering the water level to the response
pressure of the (original) vacuum safety valves. Each vacuum safety valve shall be checked minimum twice.

10.3.3 Leakage test of double-shell tanks

The inner tank shall be tested according to sections 10.3.1 and 10.3.2.

The annular space shall only be tested for leaks if specified and if the bottom insulation can be protected from
the testing agent. Details shall be determined on site. The test shall then be performed according to section
10.3.1. The annular space shall be filled with water to the maximum level which the fluid will reach in case of a
leakage of the inner tank. During the test of the annular space, the inner tank shall be filled up to the specified
filling level.
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If the annular space has to be gas-tight, the test shall be performed according to the specified standards.

The leakage test of the annular space shall be performed prior to the installation of the shell insulation.

10.4 Determination of the tightness

The tests according to section 10.3 shall be considered as passed, if no inadmissible distortions (on the shell
and roof) and no leakage have been detected. The response pressure of the safety valves may deviate from
the specified pressure by ± 5 %.

10.5 Measures to be taken after the leakage test

After testing, the blind flanges and safety valves shall be removed from the roof nozzles and the site-welded
equipment shall be drained. The drainage rate of the water shall be controlled to preclude the formation of a
vacuum. In the case of double-shell tanks, the annular space shall be drained first.

After drainage, the site-welded equipment shall be cleaned and dried. Loose adhering mill scale, rust, debris
and other foreign matters detrimental for plant operation shall be removed from all internal surfaces of the tank
and internal stiffeners. Manhole covers and blind flanges shall be installed at last.

11 Calibration
If specified, the site-welded equipment shall be calibrated and adequate marking shall be applied to the
outside of the shell. Calibration can be performed by the following methods:
• Calculation of the volume taking the actual dimensions of the site-welded equipment into consideration.
• Filling or draining the site-welded equipment and measuring the incoming or effluent liquid.

If the volume is determined by calculation, the leakage test with water shall be performed first.

Surveying equipment for measuring shall be preferred. Steel measuring tapes used shall permit a reading
accuracy of 1 mm. If measuring tapes are employed, permissible pulling forces shall be observed. The
measuring accuracy shall be verified with a calibrated measuring rule.

If the volume of the site-welded equipment is to be determined by measuring a liquid, measuring the testing
agent during drainage after the leakage test shall be performed. Depending on the required measuring
accuracy, the results of measurements shall be corrected according to the specified standard.

The flow meter used for measuring shall be calibrated immediately before use. The effects of the testing
agent’s temperature changes shall be minimised. The testing agent temperature shall preferably be ambient
temperature. Flow meters, hoses, valves and all other accessories required for measuring shall be arranged
as close as possible to the site-welded equipment and in such a manner that no vacuum or air bubbles might
develop in the measuring system. After the tank’s volume has been determined, the flow meter shall be re-
calibrated.

12 Documentation
For each site-welded equipment a documentation shall be prepared by Contractor in accordance with the
specified design code under consideration of this Uhde Standard, applicable laws and acts and further
contractual requirements. A documentation shall consist of, but is not limited to:
• Material certificates, if material was supplied by Contractor
• Inspection reports
• Measurement reports
• Analysis certificate of testing agent
• Leakage test report
• Tightness test report
• Calibration report
• Welding documentation according to UI 9252-06
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Reference standards
Uhde standards:
UI 9250-01 : 2007-09
UI 9252-06 : 2011-09
UN 9281-02 Part 1 : 2006-06
UN 9281-03 Part 1 : 2006-09
Uhde forms:
UF 9252-01 : 2011-03
Construction; Material flow and Warehousing on Site
Erection; Welding and weld examination of site-welded equipment
Civil works; Concrete and reinforced concrete
Construction; Steel structures; Erection
Erection; Welding data sheet for site-welded equipment

Amendments
In comparison with UI 9252-02 : 2008-02, the following amendments have been made:
a) Section 7.3.3 have been revised.
b) Reference standards have been updated.