418

A New

Method

for Replacing

Plates

Wataru

of

TSUDA*1),

Akira

Oil

Petrol.

Inst., 26,

Corroded

Storage

ISEDA*2)

J. Japan

(6),

418-423

(1983)

Bottom

Tanks

and

Koichi

YAMAZAKI*2)

The bottom plates of oil storage tanks sometimes need to be replaced due to corrosion or
rivetted-joint leakage. This replacement work usually involves lifting the tank with hydraulic
jacks, a costly and time-consuming exercise. Nippon Petroleum Refining Co. and Niigata
Construction Co. have jointly developed a new non-jacking method that allows the tank
bottom plates to be replaced by supporting the tank with simple jigs. Engineering analysis
and strain gauge measurements have proved that the method does not generate unacceptable
stress levels in the tank even from earthquake and wind loads during the replacement work.
The method has been successfully applied to the bottom plate replacement of more than 260
tanks, and when compared with the conventional Jack-up method, it has demonstrated remarkable cost and time savings.

1. Introduction
Strict regulations concerning the acceptable bottom plate thickness for large oil storage tanks are
now enforced throughout Japan. These regulations, which resulted from the oil spillage accident
at a Japanese refinery in 1974, are required by
the local government agencies for regular and
systematic inspection of all tank bottom plates.
The Jack-up Method is conventionally used for
bottom plate replacement work, involving jack
mounting attachments to the tank and localized
foundation reinforcements under the jacks. This
method is labor-intensive, it requires costly hydraulic jacking equipment, and it is time consuming.
A simpler method referred to as the "Support
Piece method" was introduced jointly by Nippon
Petroleum Refining Co. and Niigata Construction
Co. in 1977 after two years of developments. One

Fig.

Installation

of

Reinforcing

Aword

of

Ring

2.

Received June 8, 1983.

1981

Technical

*1) Nippon

Progress

Petroleum

Refining Co.,

Isogo-ku, Yokohama 235)

*2) Niigata Construction Co., Ltd.
koen, Minato-ku,

of the outstanding merits of the Support Piece

Method is a typical 30% reduction in both repair
costs and time consumed when compared with the
conventioned Jack-up Method. More than 260
storage tanks of all types and sizes, including tanks
in the 100,000 kiloliter range, have been successfully
repaired by the Support Piece Method.

JPI.

Ltd.

(1-1, Otori-cho,

(4-1, 2-chome,

Shiba-

Tokyo 105)

J. Japan

Petrol.

On-site

Procedure

2.1 Reinforcing
the Shell
A reinforcing ring is normally installed around
the inner or the outer circumference of the shell
plates (Fig. 1). This prevents any distortion of
Inst., Vol.

26,

No.

6,

1983

419

the shell plates from residual stresses, which may

have accumulated during construction and service,
and retains the correct circular profile during the
rectification work.
2.2 Marking Off
A cutting line is normally marked a minimum
of 1" (25mm) above the base of the shell plates.
This dimension is governed by the following:
-Working space for replacing the annular plates.
-Welding and inspection of new annular plate
butt joints.
-Removing
the existing weld metal from the
shell and annular plate joint.
-The
extent of corrosion at the base of the
shell plates.
-The position of reinforcement for existing nozzles.
The false marker line for the automatic gas
oxygen flame cutting equipment together with a
transient line are marked at the same time (Fig.
2). Before marking, any paint, rust, and oil close
to the marking area are thoroughly removed. The
automatic gas cutting machine is then installed
against one of the marker lines, taking care to
ensure the straightness and angle of the cutting
plane.
2.3 Cutting the Shell Plates
An opening cut 30 ft (9m) in length is made
around the shell plates (Fig. 3). All shell cutting
work needs to be done accurately and carefully
because the cut surfaces become the new joint
faces between the shell and annular plates.
2.4 Annular Plate Replacement
and Temporary Supports
The first annular segment of the tank bottom
plate complete with the heel of the shell plate
is then cut out and withdrawn through the side
plate aperture, taking care not to damage the shell
plate or the tank foundation. A replacement annular plate, precisely cut to size in the shop, is

Fig.

Cut
to

Fig. 4

next
into

Shell

and

9 Meters

Fig.

through

4 shows
which

the

are

The

temporary

then

support

shell plates

and

shape

supported

of the

and

Marker

Line

for

the

Automatic

Marker
Flame

the first

welded

to the

at
the
tank

on the replace-

loading

stresses

and

lowered

to guide

onto

the

These guide plates also

movement
by wind force
plate

annular

the

gap

safety

segments

at regular

the

them
new

when
annular

prevent
any horiwhen all the bot-

have

precaution,

from

plate.
the correct

been

wedges

replaced.

are

inserted

intervals.

removing

segment
and tacking

the old bottom

the

new

bottom

plate
plate

Line
Cutting

Equipment

are

via shoes

shell plates

is later

annular
-inserting
Transient

mea-

with

over the new annular

are installed to maintain

This procedure
of:
-cutting
out and

Line,

support

starting

These are positioned

suit the weight
of

pieces

distribute
pieces
plates

tank

into

Cutting

tacked

the

and

support
Guide

As a final

of

tank

taken,

and

tions

tom

Marking

These shoes protect

the new
subsequent
gas cutting
opera-

plates.
zontal

in

ment annular
plate.
annular
plates from

the

Fig.

Progressively

the aperture

support
pieces and shoes.
appropriate
intervals
to
tank.

Plate

Support Piece, other Jigs and Initial Welding

of Annular Plate

maneuvered
position.

sures

Annular
Increment

J. Japan

segment
-installing

Petrol. Inst., Vol.

26,

into
the

No.

6,

position
support

1983

pieces,

support

plates,

420
guide plates and wedges
is continued around the circumference of the tank
until all the bottom plate annular segments have
been replaced. The tank is then competely supported on the new annular plates via the support
pieces.
2.5 Setting down the Tank
Before lowering the tank, the annular plates are
butt-welded radially over a length of about 12"
(300mm) inwards from the outer circumference
and the weld surface is ground flat as shown in
Fig. 4. This gives the finished surface on which
the tank shell plates will sit. A magnetic particle
or liquid penetrant examination is done on this
surface.
All the wedges are then removed and controlled
lowering of the tank onto the new annular plates
is achieved in small stages by cutting 3/8"(10mm)
out of the support pieces in a progressive sequence
until the cut-back shell plates are completely supported on the replacement annular plates. When
internal-roof-support structure exists, its length is
also adjusted during the setting-down operation.
2.6 Welding
After the tank has been lowered onto the new
annular plates, and the jigs have been installed
for any adjustment to the curvature of the bottom
shell plates, the T-joint between the shell and
annular plates is welded. This welding operation
also narrows the unwelded radial gap between
adjacent annular plates and sometimes can cause
cracking to the existing weld bead end. So, before
completing the butt weld between adjacent annular
plates, remaking of the groove and inspection of
the existing weld bead end are essential. The final
welding operation is the joint between the annular
plates and the bottom plates. Fig. 5 shows the
order of these individual welding operations.
2.7 Finishing
After the welding work has been completed, all

the support pieces, guide plates, and jigs are finally

removed and their temporary weld marks are finished flat by grinding.
2.8 Testing
The new bottom is tested in accordance with
the testing methods specified in API. Std. 650,
5.3. Additionally, a magnetic particle or liquid
penetrant examination is conducted.
3.

Engineering

Analysis

All tanks are checked by engineering analysis

before starting the work. As an example of this
analysis, a tank with the following specifications
was used for both calculations and field measurements:
1. Tank Duty
a. Content:
Crude
b. Type:
F.R.T.
C. Capacity:
96,00kl
d. Outside diameter: 91,135mm
e. Height:
15,846mm
2. Tank Weight
Shell
690.8 ton
Accessories
136.2ton
Total

W=827.0ton

The stress induced in the shell plate during this

operation must be lower than the stresses in the
support pieces and must also be at an acceptable
level to comply with the legal safety standards and
codes of practice.
3.1 Calculations
3.1.1 Earthquake
Load (horizontal)1),2)
Ps=kW

Ps: earthquake

load

k:

earthquake

factor=0.1

W:

tank weight

3.1.2

=82.7ton
=827ton

Wind Load (horizontal)3),4)

Pw=CqA(1)
A=hD(2)
q=1/2V02(h1/h0)1/2(3)
Fig.

Procedure

of

Welding

Pw:

Work

J. Japan

Petrol.

Inst., Vol.

wind

26,

No.

load

6,

=315ton

1983

421

C: wind factor
A: projected wind area

=1.0
=1,444m2

h: tank height
D: tank diameter

=15.846m
=91.135m

q: air pressure

=218kg/m2

=0.115kgsec2/m4

air

density

V0: design wind speed

h0: const. height
h1: height from ground
3.1.3

Sliding

Rw=W

(1)

K=t/12(2)
Pc/Psu
=3.3>1.5

=60m/sec
=15m
=16.346m

Pc: max. compressive load

=10.8 ton
A: support piece cross-sectional area
=6.4cm2

Resistance

f:
n:
a:
l:
K:
t:

Rw:

sliding

W:

tank

When

resistance

=413.5ton

weight

coefficient

RwPs

is maintained

=827
of

or Pw,

friction

the

tank

ton

=0.59)

is safe

from

horizontal

sliding. (If opposite, action must be taken to

increase Rw.)
3.1.4 Overturning
Resistance

(3)

compressive strength
constant (safety factor)
Rankine factor
support piece length
first moment of area
support piece thickness

=3,400ton/cm2
=1/4
=1/7,500
=20.0cm
=0.46cm
=1.6cm

Fillet weld joint strength between shell and

support piece6).

F=Psu/2Cl0236L2+l02(1)

Mr=WD/2(1)

M0=Rs(Pw)H(2)

C=S/2(2)

H=1/2h(3)
Mr:

overturning

moment

resistance
=37,684tonm

M0:

overturning

H:

height

moment

above

=2,496tonm

ground

of center

of gravity

=7.923m
When

MrM0,

the

tank

is safe

from

overturning.

(If opposite, action must be taken to increase

Mr.)
3.1.5
(1)

Support

F:

combined longitudinal, bending and

shear stress
=0.78ton/cm2
C: throat of fillet weld
=0.56cm
S: fillet weld size
=0.8cm

Pieces

Load

Psu=W/N+M0/Z(1)
Z=N

/Z(2)

Psu: support piece load

N: number of support pieces

=3.31ton/piece
=284

M0:

=2,496tonm

Z:

(2)

overturning

modulus

moment

tank

of support

radius

piece

weld

L:

upper

efficiency

width

=0.857)

of support

piece
=5.0cm

l0: length
p:

of fillet

permissible

weld

=12.0cm

shear

stress

fillet

weld

=950kg/cm2

(ASTM A570 Gr. 33)8)

section
=6,471m

When

F<p,

this

joint

is safe.

3.2 Field Measurements

3.2.1 Measured Stresses
A three-dimensional finite element analysis pro-

=45.57m

Buckling load5)

gram was used for shell stress calculation. Ideally

elastic deformation and rigid foundations were assumed. In addition, Fig. 6 shows the measured
results with strain gauges during reconditioning of
a 96,000KL floating-roof tank. These results are
for support pieces #283 and #284, and for the
shell plates immediately adjacent to them. The
support pieces were cut progressively in numerical
order from the first (#1) to the last (#284). The

J. Japan

Petrol.

Inst., Vol.

26,

No.

6,

1983

422

--

#.283

--Shell
--

#.284

--Shell

Fig.

Stresses

in

Shell

Plates

and

stress level reached a maximum when the unsupported length was 30-40 meters. Although the
calculated stress continued to increase in proportion
to this length, in practice minor elastic deformation
of the shell limited the maximum unsupported
span to 23 meters. Beyond this length, the support
pieces were brought into contact with the annular
plate and the stress level was contained within
competely acceptable limits. The maximum shell
stresses were 19.3 (compressive), 13.1(tensile), and
7.1(shear)kg/mm2 adjacent to support piece positions #283 and #284 before the support piece
was cut at a circumferential distance of about 45
meters round from these positions. One support
piece (#284) was loaded to beyond its elastic
limit without buckling.
3.2.2 Evaluation of Imposed Stress Intensity
From the measured results, the imposed stress
intensity was evaluated. ASME Boiler and Pressure Vessel Code Section VIII Division 2 stipulates
that (Pm+Pb+Q)
shall not exceed 3Sm.
where
Pm is the general primary membrane stress
Pb is the primary bending stress
Q is the secondary stress
and
Sm is the lesser of 1/3Su (tensile strength) or
2/3Sy (yield strength)
Su and Sy for this shell material (ASTM A
633GrC) are 53 & 36kg/mm2, respectively. Thus
3Sm
stresses

is

53kg/mm2.

corresponding

The
to

maximum

Pm+Pb+Q

measured
were

2maxi-

mum shearing stress (14.1kg/mm2), so that a safety

factor of 3.8 existed, without creating any distortion
or safety hazards.

J. Japan

Petrol.

Support

4.

support
adjacent

to #.283

support

to

during

Principal

support

piece

support

piece

piece

adjacent

Pieces

piece

#.284

Operation

Advantages

of the New Method

(1) Simple and repetitive work procedures with

minimal needs of specialized equipment and manhours. Consequently, a typical 30% reduction in
both costs and out-of-service time is achievable
when compared with the Jack-up Method.
(2) Gravity does all the tank moving, giving good
inherent safety to the method. Moreover, the tank
support measures taken-support
pieces, guide
plates and wedges-are many, so that tank stability
is maintained throughout the work.
(3) Complete replacement of the bottom plates
and reconditioning of certain tank foundations can
be done at the same time.
(4) The tank dike is not damaged because all
work takes place inside the dike and additional
ground reinforcement is unneccessary.
References

1) Sub-sect. 19 of sec. 4 of Notification concerning technical standard for controlling dangerous objects of the
FDB (Japan).
2) 3.1.2. (5) "Welded steel tanks for oil storage" JIS
B-8501 (1979).
3) Sub. sect. 20 of sec. 4 of Notification concerning technical standard for controlling dangerous objects of the
FDB (Japan).
4) 3.1.2. (6) "Welded steel tanks for oil storage" JIS
B-8501 (1979).
5) Rankin's formula.
6) Enomoto, K., "Yosetsu-Kogaku", p. 219 (1971), Keirin
Tosho.
7) 3.5.2. (1) "Welded steel tanks for oil storage" JIS
B-8501 (1979).
8) 3.9.2. (4.1) "Welded steel tanks for oil storage" JIS
B-8501 (1979).
9) Appendix IV "Welded steel tanks for oil storage" JIS
B-8501 (1979) p. 120.
Inst., Vol.

26,

No.

6,

1983

423

*1),

*2),

*2)

, ,

) ,

, (

, ,

*1)

*2)

(235

(105

1-1)

2-4-1)

Keywords
Bottom

plate,

Oil

storage

tank,

Support

piece

J. Japan

method,

Petrol.

Replacing

Inst., Vol.

26,

No.

6,

1983