COURSE OVERVIEW

Above-ground storage tanks are essential facilities in the oil, gas, petrochemical, and chemical industries, where safe containment and structural integrity are critical. This five-day training course provides a practical and comprehensive introduction to the key requirements of API 650 – Welded Tanks for Oil Storage, covering the major engineering, fabrication, erection, repair, inspection, and testing considerations for atmospheric storage tanks.

The course focuses on fundamental principles of storage tank design, including material selection, shell and bottom design, roof configurations, wind and seismic considerations, nozzles and appurtenances, and corrosion protection. It also addresses practical aspects of tank fabrication and field erection, including welding, quality control, non-destructive examination, repair of damaged or deteriorated areas, hydrostatic testing, and settlement monitoring.

Through technical presentations, practical examples, discussions, and case studies, participants gain a clear understanding of how API 650 requirements and related industry practices are applied throughout the lifecycle of a storage tank, from initial design through fabrication, construction, repair, inspection, testing, and final acceptance.

TARGET AUDIENCE

Mechanical Engineers
Civil and Structural Engineers
Tank Inspectors
QA/QC Engineers and Inspectors
Fabrication and Construction Supervisors
Welding Engineers and Inspectors
Maintenance and Integrity Engineers
Project Engineers and Project Managers
Technical Consultants involved in oil, gas, petrochemical, and chemical facilities
COURSE OBJECTIVES

After completion, participants will be able to:

Understand the scope, application, and fundamental requirements of API 650.
Identify major components and configurations of above-ground storage tanks.
Select appropriate materials based on service conditions and design requirements.
Understand basic design principles for tank shells, bottoms, and roofs.
Apply fundamental principles of shell thickness calculations.
Evaluate fixed and floating roof configurations.
Understand wind, seismic, and stability considerations.
Identify requirements for nozzles, manways, and major appurtenances.
Understand principal fabrication, welding, and erection requirements.
Understand basic principles of storage tank repair, including cutting, plate replacement, and repair welding.
Identify key inspection and NDE/NDT requirements for fabrication and repair activities.
Understand corrosion protection and internal lining considerations.
Understand hydrostatic testing, settlement monitoring, and final tank acceptance.
Recognize the relationship between new tank construction requirements and repair/inspection practices for existing tanks.
COURSE OUTLINE

DAY 1 – API 650 FUNDAMENTALS, TANK CONFIGURATION & MATERIALS

Introduction to API 650 Storage Tanks

Scope and application of API 650
Basic design philosophy and terminology
Types and applications of above-ground storage tanks
Major tank components and functions
Design conditions and tank data requirements
Relationship between API 650 and other relevant industry standards
Tank Configurations

Fixed-roof storage tanks
Cone and dome roof configurations
Open-top tanks
External and internal floating roof tanks
Selection of tank configuration based on service requirements
Materials of Construction

API 650 material requirements
Material selection and service conditions
Design temperature and material toughness
Corrosion allowance
Material certification and traceability
Practical Discussion

Review of a typical API 650 tank data sheet
Identification of major tank components
Selection of appropriate tank configuration for different products
DAY 2 – SHELL, BOTTOM & ROOF DESIGN

Shell Design

Shell construction and shell course arrangement
Hydrostatic pressure and liquid loads
Shell thickness requirements
One-Foot Method
Variable Design Point Method
Minimum thickness and corrosion allowance
Shell joint and welding considerations
Bottom Design

Tank bottom configuration
Bottom and annular plates
Bottom slope and drainage
Bottom-to-shell connection
Corrosion considerations for tank bottoms
Roof Design

Fixed cone roofs
Dome roofs
Supported and self-supporting roofs
Internal and external floating roofs
Roof loads and basic stability considerations
Practical Exercise

Basic shell thickness calculation
Comparison of fixed and floating roof applications
Review of typical tank design drawings
DAY 3 – WIND, SEISMIC DESIGN & TANK APPURTENANCES

Wind and Structural Stability

Wind loads on storage tanks
Tank stability and overturning
Wind girders and stiffening requirements
Anchored and unanchored tanks
Basic shell stability considerations
Seismic Design

API 650 seismic design principles
Seismic forces and tank response
Liquid sloshing considerations
Overturning and anchorage requirements
Introduction to API 650 Annex E
Nozzles, Manways & Appurtenances

Nozzle types and applications
Nozzle sizing and location
Manways and access openings
Reinforcement requirements
Vents, drains, overflow, and instrumentation connections
Ladders, platforms, and other tank attachments
Practical Exercise

Basic nozzle reinforcement example
Review of tank nozzle and appurtenance arrangements
Seismic and stability case study
DAY 4 – FABRICATION, WELDING & TANK ERECTION

Tank Fabrication

Fabrication planning and sequence
Plate cutting, forming, and rolling
Shell course fabrication
Bottom and roof fabrication
Nozzle and appurtenance fabrication
Dimensional control and tolerances
Welding Requirements

Welding processes used in tank construction
WPS, PQR, and welder qualification
Welding consumables and quality requirements
Shell, bottom, and roof welding
Welding sequence and distortion control
Weld repair and quality control
Tank Erection

Foundation preparation and inspection
Bottom plate installation
Shell erection and alignment
Shell course welding sequence
Roof erection and installation
Installation of nozzles and appurtenances
Construction quality and safety considerations
Practical Exercise

Review of a typical tank erection sequence
Identification of common fabrication and welding issues
Basic tank construction quality checklist
DAY 5 – REPAIR, INSPECTION, NDT, CORROSION PROTECTION & TESTING

Tank Repair Principles

Common causes of storage tank damage and deterioration
Identification and assessment of damaged or corroded areas
Repair planning and preparation
Cutting and removal of damaged plate sections
Plate replacement and patch repair concepts
Repair of shell, bottom, and roof components
Fit-up, alignment, and dimensional considerations
Repair welding requirements and quality control
Welding procedures and welder qualifications for repair work
Inspection & NDE/NDT

Inspection requirements for tank fabrication and repair
Visual inspection of repaired areas
Weld inspection and acceptance criteria
Radiographic Testing (RT)
Ultrasonic Testing (UT)
Vacuum Box Testing
Other applicable NDE/NDT methods
Inspection before, during, and after repair activities
Identification and correction of weld defects
Corrosion Protection

Common corrosion mechanisms in storage tanks
Internal and external corrosion
Corrosion allowance
Coating and painting systems
Internal lining
Cathodic protection considerations
Hydrostatic Testing & Final Acceptance

Pre-test inspection requirements
Hydrostatic testing procedures
Tank filling and draining considerations
Settlement monitoring
Leak detection and evaluation
Post-repair and post-test inspection considerations
Final inspection and acceptance
Documentation and commissioning requirements
Practical Case Study

Review of a damaged or corroded storage tank
Identification of areas requiring repair
Selection of appropriate repair approach
Review of cutting and plate replacement sequence
Welding and NDT inspection sequence
Hydrostatic test and settlement monitoring case study
Final tank acceptance checklist
TRAINING METHODOLOGY

A highly interactive combination of lectures, technical discussions, practical examples, case studies, and problem-solving exercises will be used to maximize transfer of knowledge and practical experience.

The course is intensive and practical, emphasizing the application of API 650 requirements to real-world storage tank design, fabrication, construction, repair, inspection, and testing. Participants are encouraged to discuss their experience, raise technical questions, and participate in developing appropriate engineering and inspection solutions.

Materials: PowerPoint presentations, technical illustrations, engineering examples, learning videos, case studies, and supporting reference materials.

Evaluation: Knowledge checks, practical exercises, discussions, and final assessment.