Aboveground Storage Tanks: Types,

Components, Design Aspects, and Erection

A Storage Tank is a piece of static equipment that is used to store products (liquids)
in atmospheric pressure conditions. As there is no moving part, storage tanks are
called static or stationary equipment similar to pressure vessels. However, there is a
distinct difference between a storage tank and a pressure vessel; Pressure
vessels hold fluid at a higher pressure than storage tanks.

Storage Tanks can be split into two types

 Site-built Tanks
 Smaller Tanks (transported to the site fully assembled)
In general, site-built tanks are designed as vertical cylinders however smaller tanks
may be either vertical/horizontal cylinders or rectangular/square in shape.

Large Storage Tanks are constructed on-site, on prepared foundations as they are too large
to transport.
To reduce site work and the amount of equipment required, the component parts of the tank
are normally pre-fabricated or pre-formed prior to delivery.

Applications of Site-Built Storage Tanks

Site-built Large Storage tanks are used widely to store various products in the
following industries.

 Refinery and Petrochemical

 Fertilizer
 Oil and Gas
 Chemical
 Water
Type of Storage Tank
Storage Tanks can be defined into three types

 Cone Roof Storage Tank: A Cone Roof Storage Tank has vertical sides and is equipped
with a fixed cone-shaped roof that is welded to the sides of the tank.
 Open Top Floating Roof Storage Tank: An Open Top Floating Roof Storage Tank is
similar to the cone roof tank in construction but with the exception that it has no fixed roof.
A pontoon-type roof floats directly on the flammable liquid surface.
 Internal Floating Roof/Covered Floating Roof Storage Tank: An Internal Floating
Roof/Covered Floating Roof Storage (see “red” dome) Tank is a combination of both the
cone roof or dome and the open-top floating roof tank. The tank has a cone roof but with
the addition of an internal floating roof or pan, that floats directly on the fuel surface.
 Fig. 1: Cone Roof and floating Roof Storage Tank

Locating Storage Tanks

Storage Tanks are mostly located inside a Tank Farm area inside a bunded area
(Fig. 2).

Storage Tanks are mostly located inside a Tank Farm area inside a bunded area (Fig. 2).

Bunded area is necessary around a storage tank when the potential environmental
and economic risk of tank spillage is great. Its function is to contain spillage so that
subsequent damage to adjacent tanks and surrounding areas can be minimized.

Fig. 2: Tank location inside Bund Area

Component of a Storage Tank

Typically a Tank consists of three components (Fig. 3).

 Tank Shell: A cylindrical portion that is resting on the bottom plate and covered by the
roof.
 Tank Bottom Plate: A welded flat bottom plate that is placed beneath the cylindrical
shell.
 The roof of the Tank: The fixed roof tank is mostly provided with a conical top roof.
Larger diameter conical roof tanks are supported by roof structures or columns and the
open-top tank is mostly provided with a floating roof.

Fig. 3: Components of a Storage Tank

Construction of Tank Shell
Tank shell is constructed by butt welding steel plates of specified length and width at
their edges in order to form a cylindrical shell.

Construction of Tank Bottom

The bottom of a tank is constructed from flat plates. Plates are arranged with
rectangular plates in the center and sketch plates (cut to suit radius) around the
perimeter.

Construction of Storage Tank Roof

The top of a tank is constructed from flat plates. Plates are arranged with rectangular
plates in the center and sketch plates (cut to suit radius) around the perimeter.

Type of Tank Roof Support Structures

 Fixed Conical or Dome roof tanks are provided with internal rafters or trusses (Fig. 4).
 Some larger diameter Conical or Dome roof tanks are also provided with column
supports.
Fig. 4: Various types of roof Supports
Storage Tank Design Standards
The main design codes for vertical cylindrical storage tanks are:

 BS EN 14015:2004 “Vertical Steel Welded Storage Tanks with Butt-Welded Shells for the
Petroleum Industry”
 API 650 “Welded Steel Tanks for Oil Storage”
 DEP 34.51.01.31-Gen and DEP 64.51.01.31-Gen
Storage Tank Design Aspects
The design aspects of the storage tank can be divided into the following:

Design standards: The storage tank can be designed by using different International
standards like API 650 and BS EN 14015.

Tank Shell Plate Size: Although the physical size of the shell plates is a function of
the height and diameter of the tank, the actual size is also dependent upon material
availability, fabricators’ facilities, and handling/logistic issues. A large plate is more
difficult to form and handle, however, a large plate requires less welding during tank
erection. The plate size must, therefore, be considered on a case-by-case basis to
achieve the most economical design. For example, for a 10m high tank, the most
practical and economical plate width would be 2.5m so as to achieve four shell
courses. Plates 3.33m wide are large and nonstandard.

Storage Tank Loading Conditions:

External / Internal loads: External loads on a tank may result from adjoining piping
or structures. These loads may be due to for example their static weight or as a
result of thermal growth. Due to the use of relatively thin and therefore flexible steel
plates, tanks have a poor ability to resist external loads and therefore measures
should be taken to minimize all external loads. Methods to analyze external pipe
loads can be found in API 650.

Wind / Earthquake Loads: Wind and earthquake loads depend greatly on the
environmental conditions of the proposed site. Guidance on how to analyze wind and
earthquake loads can be found in the appropriate design codes however particular
attention should also be given to the risk of wind and earthquakes during tank
erection where the full stability of the tank is not yet available and temporary facilities
have to be deployed.

Loads in Storage Tank due to Pressure / Vacuum Condition: Although the

maximum external design pressure of tanks is very low (6 mbar), it should be noted
that tanks are inherently very poor at resisting partial vacuums. Care must be taken
to ensure that vacuum breaker valves are correctly sized to prevent a partial vacuum
from forming during for example liquid draw off/draining. See the below slide for an
example photo of a tank collapse due to a vacuum.

Storage Tank Foundations: Although a fabricated tank is relatively light for its
physical size, due to the static head from the liquid contents the overall load onto the
foundations can be considerable. The design of the foundations is especially
important where the ground conditions are soft or inconsistent which could result in
the risk of sinking or uneven settlement which could cause the failure of the tank. To
prevent this problem from occurring it is important that a soil survey of the proposed
site is performed early in the project and the foundations designed to suit. This
analysis may be performed by a civil engineering contractor.

On tanks where there is a potential for uplift caused by for example wind loading, the
base of the tank should be anchored to the ground using foundation bolts. This is
normally done by providing a concrete ring beam around the perimeter of the tank.
On smaller tanks the entire foundation may be made from reinforced concrete
however due to the cost, a ring beam is more economical. Uplift can also result from
internal pressure bowing the floor when empty and high-pressure tanks should
always be provided with foundation bolts. The area under the tank floor is typically
compacted ground covered with a layer of bitumen-coated sand which helps
‘bedding-in’ of the floor plates and as a means of corrosion protection.

The layout of Storage Tanks: The layout of tanks depends upon a number of
parameters such as the number of tanks, ground conditions, process duty, etc

Example of vacuum collapse of Storage Tanks

This collapse occurred following the accidental draining of the contents whilst the
vacuum valve was blocked by plastic tape during paint refurbishment.
 Fig. 5: Example of Vacuum Collapse

Tank Material of Construction

Storage tanks are normally manufactured from the following materials

 Carbon steel
 Stainless Steel
 Duplex Stainless steel
Typical Method of Storage Tank Erection
There are four main methods of tank erection:

 Progressive
 Complete Assembly
 Jacking
 Flotation
Progressive assembly and welding: In the progressive assembly method, the
bottom plates are assembled and welded first. Thereafter the shell plates are
erected, held in place, tacked, and completely welded. This shall be done course by
course, working upwards to the top curb angle. No course shall be added as long as
the previous course has not been entirely welded. The erection and completion of
the roof framing and roof plates then follow.

Complete assembly followed by welding of horizontal seams: In the complete

assembly method, the bottom plates are assembled and welded first. Thereafter the
shell plates are erected, held in place, and tacked, and only the vertical seams are
completely welded, leaving the horizontal seams un-welded. This shall be done
course by course, working upwards to the top curb angle. No course shall be added
as long as the vertical seams of the previous course have not been entirely welded.
The erection and completion of the roof framing and roof plates then follow. Finally,
the horizontal seams are welded, working upwards from the bottom course or
downwards from the top curb angle.

Jacking-up method: Some contractors employ a system of erection in which the

bottom plates are completed, The top course is erected on the bottom plates, the
roof framing and sheeting are completed and a number of jacks are then assembled
around the structure. By means of these jacks, the completed top course together
with the roof framing and sheeting is lifted to a height sufficient to insert the next
lower course. The jacking method and the supporting of the partly erected shell shall
have no adverse effect on the roundness of the shell. The welding is completed at
each stage of lift until all courses of the shell plates have been inserted and the
finished height is reached. The final operation is the welding of the bottom course to
the bottom plates.

Flotation method: The flotation method is used for floating roof tanks. After the
completion of the bottom plating and erection and welding of the two lower courses
of the tank, the floating roof is assembled on the tank bottom and completed. The
tank is then filled with water and, using the floating roof as a working platform, the
third and subsequent courses are erected and welded, water being pumped in as
each course is completed. Regular checks on the vertical alignment and roundness
are required. This method may only be used at locations where soil settlement is
very limited and with the agreement of the Principal. The predicted soil settlements
of the soil investigation report shall be taken into account. A small crane is usually
erected on the floating roof for hoisting the shell plates into position.

Tank Foundations:
Tanks are usually supported on concrete ring wall foundation or pad-type foundation.
Fig. 6: Tank Foundations
Venting of Storage Tanks:
Tank Venting is very important due to the low design pressure of tanks. They must
consider:

 In/outflow of tank
 Thermal venting
 Number of independent breather valves
 Birds/blockage
 Roof Profile
Floating roof tanks have minimum vent losses

Consideration must be given to the maximum inflow into the tank (causing over-
pressurization) and also the maximum outflow (causing partial vacuum). These may
result from the action of pumps and/or process upsets such as gas blow-by from a
vessel.
The type and selection of the relief valves also depend upon if there is a vapor
blanket within the tank. For example, this may be a nitrogen blanket or a fuel gas
blanket. Fuel gas should not be vented into the atmosphere and where practical
should instead be recovered.

Tanks are also provided with simple emergency vents (blow-out covers), the purpose
of which is to prevent tank damage in the event of for example a process upset
condition.

Tank roofs are inherently designed to be weaker than the shell so that in the event of
over-pressurization and the failure of the venting system, the roof will fail and the
shell will remain intact thus preventing spillage/loss of the contents.

Small Tanks
Smaller Tanks, defined here, as those transported to the site fully assembled may be
cylindrical or rectangular in shape.

They are used for many purposes such as:

 Water storage
 Fuel storage
 Settling or separation of fluids (e.g. oily water treatment)
 Lubrication oil storage
 Chemical storage
 Drains tanks
Small tanks can be supplied as individual items to the site or more commonly they
are supplied on packaged skids.

Tanks may also be fabricated from concrete.

Rectangular Storage Tanks

These are very common on packaged skids as they offer the greatest volume within
a confined package space envelope.

For example:

 Lubrication of oil tanks on pump/compressor skids

 Chemical storage on chemical injection skids
There is no definitive design standard for rectangular tanks and they are usually
designed from first principles or “good engineering practice”.

Rectangular tanks may be made from flat or corrugated plates. Depending on the
tank’s size, flat plates are normally provided with internal or external stiffeners to
prevent plate deflection.
Rectangular tanks are often provided with internal partition plates so that two or
more separate storage volumes are provided within a compact arrangement.

Due to a large amount of stiffening required, it is not economic to make rectangular

tanks. In such cases, alternative designs, such as a cylinder, should be considered.
 Storage Tank Erection: Conventional vs
Jacking Method
Two types of storage tank erection methodology have become widely accepted and
popular. The first one is the Conventional Method of Tank Erection & the other is the
Tank Jacking method. Both of these tank erection methods are accepted by the API
650 and the constructor. The selection of the tank erection method basically
depends on the site location or workshop where we are making these tanks.

There is a popular myth that API 650 guides us to adopt the tank erection
methodology. But that is not true. API 650 only guides us in the design, fabrication,
welding, hydro testing & inspection of storage tanks.

Conventional Method of Tank Erection

In conventional methods, cranes are used for tank erection as a sheet-by-sheet
method. At first, the bottom and annular plates are erected. Then the lower course
shell is erected and finally, the upper course shell is erected. Refer to Fig. 1 which
shows an example of a double-deck floating roof Tank erection by the conventional
method. Suppose there are a total of 9 shells in a Tank so the tank erection
sequence shall be 1st shell coarse, 2nd shell coarse, 3rd, and then in last 9th shell
coarse.

Fig. 1:
Double deck floating roof tank erection by a conventional method

In the case of a small diameter Tank, the tank is fabricated at the workshop and then
brought to the site by a trailer for erection. But the handling should be proper to avoid
buckling, bending, and any damage.
 Fig. 2:
Tank erection by the conventional method.

In the case of Shop fabrication, the tank fabrication, erection, & assembly is done
by EOT (electric overhead traveling) crane at the shop and then shifted to the site
by a trailer.

Fig. 3: Tank Fabrication at shop

Fig. 4: Mobilizing fabricated tank to the construction site

Tank Erection by Jacking Method

A jacking method is an advanced form of tank erection. The jacking method uses the
technology of the Swedish Company Bygging Uddemann AB. A number of hydraulic
Jacks are placed inside the tank to be erected. Refer to Fig. 5. In recent times this
method is widely used in all developed countries.

A system of hydraulic pressure hoses interconnects the hydraulic jacks which are
energized by the action of a hydraulic pump.
 Fig. 5:
Tank Erection by Jacking Method

This method is just the opposite of the conventional method. The construction
sequence is just the reverse of the conventional one. If there are a total of 9 shell
courses, the erection in the jacking method will start from the 9th, then the 8th, 7th,
and in the last 1st shell course will be erected.

The number of hydraulic jacks is decided based on the total weight of the roof & shell
courses except for the bottom courses. Standard practice is to keep a 3000 mm
distance between two jacks. However, the number of hydraulic jacks can be
increased to meet additional wind load. Fig. 8 shows a typical jack used for tank
erection.

Tank Jacking Procedure

The following steps are followed while erecting tanks by jacking procedure:

 Tank pad to be checked and tolerances to be verified.

 Since jacks are to be mounted on the annular plates, these need to be placed.
 Annular plate joints are to be aligned and welded.
 Next, erect the floor plates and align the joints to complete the welding of the
bottom seams.
 After that, Erect the top 2 courses. Align properly and weld. All the works on these
two courses including the erection of the curb angle, wind girder for Floating Roof
Tanks (or) roof structure, and roof for Cone Roof Tanks, hand railing, etc to be
completed.
 Next, Place the hydraulic jacks along the circumference of a circle drawn about
100 mm from the shell plate circle. The maximum arc distance between the two
Jacks shall not exceed 3000 mm.
 Jacks are available in 8 T / 12T capacities. So arrange hydraulic jacks of
predetermined quantities before starting the erection. Anchor the jack supporting
columns to the base plate.
 When, the sub-assembly consisting of the top 2 courses, roof structure/roof (or
wind girder) railing, etc. is lifted, erect the shell plates of the third course from the
top, after lifting the entire subassembly to the required height.
 Align the vertical joints and weld. Next, the sub-assembly is lowered to complete
the alignment and welding of the girth seam.
 The hydraulic jacks can be released and lowered after the alignment of the girth
seam,
 In a similar way, erect the other shell courses till all courses are erected.
 Finally, Align the shell to the bottom joint and check for the verticality of the
completed tank. Weld the shell to the bottom joint.
 Now, all other balance works like fixing and welding of shell manholes, nozzles,
etc. can be completed.
Various terms are used while erecting tanks as mentioned below:

Fig. 6: Stay Pipe and Powerpack machine

 Power Pack Machine (Fig. 6): This Machine is used to lift the Jack. This machine
Pumps the oil to Jack through the hose pipes to lift the jack.
 Stay Pipes (Fig. 6): Also known as supporting pipes; These pipes provide
support to jack and trestle pipes. Basically, these pipes are supporting the vertical
trestles to maintain verticality.
 Trestle Pipes (Fig. 7): These are the vertical members in the Jacking system that
carries loads of Jacks. While installing this assembly we need to take extra care of
these vertical members so that the verticality of the Tank is maintained. Jacks
Move over the Trestles by teeth. These get support from base plates in the Tank
bottom.
Fig. 7: Example of Trestles

Difference between the Conventional and Jacking Methods

The main differences between the conventional tank erection and jacking tank
erection methods are provided in a tabular format below:
 Fig. 8: Typical Jack for Jacking Method

Conventional Tank Erection Method Tank Erection by Jacking Method

Large diameter tanks with higher plate thickness requiring

Suitable for all types of tanks with any diameter and
sided welding are not possible to erect by this method. No
height
feasible for double-wall tanks.

Very good dimensional control is possible: Shell and

bottom shapes obtained can be close to the designed Dimensional control is comparatively less.
dimensions.

Erection time is comparatively more Erection time is less.

Safety issues as working at height Safe erection as working at ground level. So lower risks.

Resource requirement is more, hence more costly Economical erection.

Protective tank roofs and wind girders eliminate the possi

Possibility of wind damage while erection.
wind damage.

Inspection Access is difficult Easily accessible

Lower productivity Better productivity

High-capacity cranes are required The involvement of high-capacity cranes is comparatively

Difficult operation with less efficiency Smooth operation with high efficiency
Conventional Method vs Jacking Method

To summarize, the tank erection methodology by jacking method has many

advantages over the conventional ones which include easy to operate, safe and
reliable, accurate control of the weld gap and the height of the lifting rod, good
quality of the project, and providing an outstanding economic benefit.

References and Further Studies:

 https://www.iqpc.com/media/8544/24895.pdf
 https://3.imimg.com/data3/TQ/MO/MY-3035455/tank-erection-jack.pdf
 https://whatispiping.com/storage-tank-erection-conventional-vs-jacking-method/ (this
Page)