Construction and erection of tanks

Certification

Installation works are performed in accordance with the "Certificate of admission to specific types of works that affect the safety of capital construction facilities, including highly dangerous and technically complex ones."

Three steps of tank installation

Preparation stage

Includes the full fledged foundation for aboveground or underground steel vessel, for example, of horizontal installation, designed to bear the weight of the structure.

The surface of the site for future installation of the tank for oil products storage is marked, according to the foundation plan (axes layout), using surveying instrument.

The foundation is arranged not only on the basis of the equipment weight calculation, but also taking into account the foundation settlement, which can not be avoided due to considerable dimensions of the system. The degree (speed) and uniformity of the settlement depends directly on the quality of the “bedding” and the bearing capacity of soil.

Loose soil is stabilized, in case soil stabilization is not possible, the soil is replaced, rammed down and treated to reduce the risk of future soaking.

Prior to the erection of the vessel, the preparation of the construction site, the erection of the necessary facilities, arrangement of the transport routes and the utilities tie-in are carried out.

The arrangement of the basement and foundation is an important stage, since it affects the speed and uniformity of steel structures shrinkage, and, therefore, the preservation of its geometry and stability. Basement and foundation preparation technology depends on the weight of steel structures and the quality of soil. In case soil bearing capacity is not sufficient, the soil stabilization, compaction, or even replacement is performed along with groundwater removal.

Typically, tanks with a volume of up to 5000 m3 are installed on a soil bedding at a slope of 1:50 from the center to the periphery with a sand pad (up to 2 m thick) and a hydrophobic (waterproofing) layer of a mixture of soil, bitumen, tar oil, tar or fuel oil (up to 200 mm thick)

Tanks over 10,000 m3 capacity are installed additionally on reinforced concrete ring foundation, arranged along the perimeter of the wall to bear its load

For loose soil, it is possible to install pile foundations covered with reinforced concrete slabs.

The erection of the vessels can be carried out only after the basement and the foundation are accepted.

Tank erection

Technique is determined based on the vessel type, dimensions and design features. In the selection of tank erection method, we are governed by the current Russian Federation regulatory system:

VSN 311-89 "Erection of vertical steel tanks for oil and oil products storage with the capacity of 100 to 50000 m3"

GOST 31385-2016 "Vertical cylindrical steel tanks for oil and oil products. General technical specifications"

STO-SA-03-002-2009 "Rules for engineering, manufacturing and erection of vertical cylindrical steel tanks for oil and oil products"

GOST 17032-2010 "Horizontal steel tanks for oil products. Technical specifications"

Testing

Includes the simulation of future operating conditions — imposing loads on the tank shell to detect defects and deficiencies of the designed system prior to the first start.

Testing is carried out according to the project process flow diagram (it describes in detail the parameters and specifications of the devices used).

All works are carried out in accordance with the process flow diagram, method statement (MS) and construction design, as part of the detailed design. Principal as-built documentation for all installation phases includes logs and work completion certificates, test and inspection certificates, as-built drawings.

Method Statement (MS) is elaborated on the basis of the Structural steel design. MS contains rules and procedure of overall installation and welding operations including necessary equipment, tests, measures to ensure the required accuracy and quality of welding, steel structures assembly, safety at the facility, etc.

Featuring all aspects of oil tanks erection

Tank erection technology is defined depending on the tank weight, volume, location and type. Today most industrial facilities use horizontal systems, although vertical tanks for oil products are more common for high pumping volumes. The first type includes 2 types of tanks — aboveground and underground options. Standard vessel capacity estimates to 100 m3 (less frequent — 200 m3).

Our company performs full cycle construction of horizontal and vertical tanks, including site preparation and foundation construction. Vertical tanks specific features differ depending on the system.

The basement for the aboveground steel tank for oil products is usually made of reinforced concrete or metal. The top shall correspond to the shape of the vessel installed.

Underground tanks are installed directly on the prepared soil. Before the installation of oil product tank, the area of the tank erection is waterproofed (sand pad or special isolation by bedding). In case the soil is wet, the underground tank for oil product is installed on a prepared foundation. The foundation has embedded parts to fix the vessel of underground location. Vertical steel tank installation is performed directly on the construction site. The erection method of such type of tank is selected depending on the structure (roof design — fixed, pontoon, floating roof).

Three methods of oil product tanks erection

The erection of an underground or aboveground tank for oil products is performed by one of the following methods: rolling or sheet-by-sheet method, in accordance with the manufacturing technology of the structure. Technology selection defines tank installation activities features. Rolling method involves assembling of steel walls at the installation site, steel walls are manufactured at the plant and delivered in rolls to site. First, the bottom is welded (by separate parts), the walls are mounted onto the bottom by welding. The fixation of the shell usually requires rigid bracing and use of machinery.

Vertical Steel Tanks (VST) rolling method erection.

Rolling method involves delivery of the rolled up wall to the construction site. The bottom may also be delivered in a roll form (diameter up to 12 m) or as preassembled elements like the roof. Preliminary welding of the steel structures of the wall, bottom and roof is carried out at the plant, which significantly reduces the work period. First, the bottom elements are installed, fastened and welded onto the concrete or soil base: first, the edges (i.e. peripheral sheets) and then, the central part. Next, the wall is installed in a vertical position. Permanent or temporary brace strut is fixed in the center to install the fixed roof: permanent brace strut for VST of up to 5000 m3, temporary brace strut for VST of 10000-20000 m3 volume. Then the wall is unfolded along the perimeter and welded by vertical and two-sided T-butt weld, maintaining the design position of the wall and its stability by the fixation by rolled angle clamps stops. At the same time the installation of the fixed roof sheets is performed. The floating roof and the pontoon are mounted immediately after the bottom installation. If necessary, reinforcing rings are installed along the perimeter of the upper edge of the tank. All lifting operations are performed by heavy equipment: tractors, haulers, mobile and crawler cranes.

Vertical Steel Tanks (VST) sheet-by-sheet erection:

Sheet-by-sheet erection involves step by step assembly of separate parts of the wall of 2000×8000 mm or 1500×6000 mm. Assembly of tank rings starts from the bottom ring. The elements can be preassembled on construction site: for example, two sheets are first welded together on a stand and then welded to the mounted wall. Sheet-by-sheet erection method — shell, bottom, roof are assembled from the sheets at the tank installation site. The assembly procedure is as follows: first, the installation of the bottom is performed (originally, it is a rolled billet); the shell is built up by electric ark welding by "rings" that are prepared in advance by bending the sheets according to the given radius; a column is installed in the center; the supports are installed along the exterior perimeter of the shell with the roof half-trusses fixed on them; half-trusses are connected by traverse beams; roof steel sheets are lap welded separately; a continuous girth weld is made outside the roof, along the perimeter connecting its sheets with the shell corner; to ensure maximum reliability and tightness of the future structure, the roof elements are welded with supporting parts (beams and half-trusses), using spot arc weld at a given interval.

Completion of installation works

Process equipment installation

Anti-corrosion treatment

Statutory testing

Facility handover to the Client

Our experience

We have been executing challenging tank cleaning projects since 2008.

Tanks of all types and sizes at oil refineries, pumping stations, product and raw material bases, oil terminals, power plants and boiler houses, including damaged and emergency tanks, as well as tanks with damaged bottom, with flooded and dropped to the bottom pontoons.

Заказчик: BP Raffinaderij Rotterdam B. V. 2015г.

Тип резервуара: 120 000 м³
Объем шлама: 6 500 м³
Сроки реализации: март-апрель 2015

Сложность проекта заключалась в том, что зачистка не производилась в течении 12 лет, в высокой температуре плавления нефтешлама, а также в большом объеме резервуара.

На протяжении длительного времени ни одна подрядная организация не справилась с поставленной задачей.

Нефтеосадок был приведен в жидкое состояние с помощью мобильного парогенератора. Высокоточные газовые анализаторы были установлены внутри и снаружи резервуара для обнаружения любых выбросов в атмосферу - выбросов не обнаружено.

Заказчику было возвращено 100% нефтепродукта

Заказчик: BP Raffinaderij Rotterdam B. V. 2015г.

Тип резервуара: 120 000 м³
Объем шлама: 6 500 м³
Сроки реализации: март-апрель 2015

На протяжении длительного времени ни одна подрядная организация не справилась с поставленной задачей.

Заказчику было возвращено 100% нефтепродукта

13 Years of experience

1300+ Specialists in the company

400+ Successful projects

References

All petroleum derived organic residues were removed by pumps and used by the Client as feedstock in main production processes, and the whole scope of works was performed in accordance with high quality standards and within the agreed timeframe. The technology of tank solid sludge cleaning, developed and implemented by NNIAT LLC, is safe, cost effective, environmentally friendly, reduces work performance time, and can be recommended for wide use.

S.V. Gavrin — Chief Mechanical Engineer

Organic part of the sludge was completely removed by pumps and disposed by transportation by the Client tank trucks. The whole scope of works was performed in accordance with high quality standards and within the agreed timeframe. The tank is prepared for hot works.

V.V. Osipov — Chief Engineer

The whole scope of cleaning operations was performed in accordance with high quality standards and ahead of schedule. The tank solid sludge cleaning technology, developed and implemented by NNIAT LLC, can be recommended for wide application.

V.V. Osipov — Chief Engineer

Отзыв Департамента капитального строительства

All petroleum derived organic residues were removed by pumps and used by the Client as feedstock, and the whole scope of works was performed in accordance with high quality standards and within the agreed timeframe.

The new technology of tank solid sludge cleaning, developed and implemented by NNIAT LLC, is safe, cost effective, environmentally friendly, reduces work performance time, and can be recommended for wide use.

A.V. Kochemaskin — Director of Capital Construction and Reconstruction Department

Oil sludge tank cleaning technology, developed and applied by NNIAT LLC, is cost effective and safe.

A.A. Shipitsyn — Deputy Manager of Fuel Production Plant

The works have been executed ensuring high quality surfaces cleaning, sufficient for hot works and diagnostics. High level of Occupational health and Safety has been ensured.

A.Yu. Yakovlev — Production Manager

Licenses and certificates

Guaranteed safety at the facility

Compliance with all standards and requirements

Works at the facility are performed in compliance with safety requirements established by the Russian Federation laws, international standards, as well as safety requirements of the Client.

Hazardous facilities operating licenses

NNIAT LLC is licensed by RosTechNadzor (RTN) for the operation of industrial facilities with explosion, fire and chemical hazards of I, II and III class. Occupational health and Industrial safety Management system is in compliance with OHSAS 18001 requirements.

Exhaustive staff training and protective equipment

The personnel is duly qualified and certified, undergoes all the necessary types of trainings, briefings, internships and knowledge assessments. The personnel is fully equipped with personal and collective protective equipment, undergoes preliminary and regular medical examination.

Safe patented technology

Tank cleaning is carried out under a patented technology that minimizes the risks of incidents and accidents.

Construction and erection of tanks of any capacity and complexity

Request a quote for tank construction and erection