SEQUENTIAL LIFTING OF TANK SHELL USED

TO REPAIR FLOORS
The sequential lifting method has been successfully used to repair storage tanks when other
methods were not recommended, or considered impossible. It provides a practical, economical
approach to lifting storage tanks of different types and sizes.
Many of the bulk liquid storage tanks that were built in the early sixties now need major overhaul.
This normally entails replacement of the corroded floor annulus ring. A few methods have been
implemented recently to replace the floor annular plates by lifting or cutting the tank shell to
provide the necessary access to perform the work.
LIFTING TECHNIQUES
Unlike floor rectangular and sketch plates, the replacement of the floor annular plates requires a
special technique. This is because the annular plates are the linking members between the tank
vertical shell and horizontal floor.
The annulus rings of storage tanks are currently being replaced by one of the following methods:

 Direct total lifting of the tank

 Partial lifting of the tank shell
 Cutting the bottom of the tank shell.

TOTAL LIFTING
The method of direct total lifting of storage tanks has been efficiently executed in many
applications (OGJ, Nov. 4, 1991, p. 76).
It is normally used when full repair or rebuild of the tank foundation is required in addition to
repair of the floor.
A number of special types of hydraulic jacks are required to be spread along the circumference
of the tank.
The significant costs involved in this method may not be justifiable if the repair of the tank is
limited to the replacement of the floor annulus ring.
PARTIAL LIFTING
The method of partial tank lifting is simpler than direct full lifting, as only a portion of the tank
shell is lifted to provide access for replacement of the annular plates. The number of jacks
utilized is greatly reduced compared to a total lift, and ordinary jacks can be used.
Also, the installation of a supporting structure is not needed because the tank is made stable by
the action of the unlifted portion of the shell.
The major drawback of this approach is the possibility of insufficient access for the replacement
of the annular plates. The gap created between the tank shell and annular plates is always
restricted by the amount of local stresses on the shell.
In most cases the foundation beneath the shell-to-annular junction must be cut to increase the
gap. Appropriate repair to this critical part of the foundation cannot be guaranteed because of the
lack of proper compaction at the confined available opening.
SHELL CUTTING
The method of cutting a strip at the bottom of the tank shell to provide access for floor plate
replacement is normally applied to small tanks where the high quality of the shell-to-annulus (T)
joint is not required and the modification to the connecting pipework is minimal.
The use of this method on medium and large tanks is restricted because of the presence of shell
makeup sections and cleanout doors on the cutline.
SEQUENTIAL LIFTING
The sequential lifting method for replacing floor annulus rings is based on progressive lifting of
the tank shell from zero level to the required height, with respect to the tank foundation. It
involves consecutive steps of tank partial lifting using hydraulic jacks, until the required gap
between the shell and tank foundation is obtained.
The shell vertical displacement gained per step is estimated so that the maximum allowable
bending stress on the tank shell at the jacking locations does not exceed the allowable limits.
The total number of steps and lifting cycles depends on the diameter of the tank and the
available number of hydraulic jacks used in the lifting process.
Practically, the tank shell can be lifted up to 2-3 in. This is more than adequate for convenient
replacement or upgrading of the annular plates, and for carrying out the necessary tests. These
tasks are accomplished without cutting the tank shell or the foundation.
This method can be used for repairing both fixed and floating-roof tanks.
REPAIR PROCEDURE
Note: It is assumed that the tank is in a clean and gas-free condition, and that an engineering
analysis, which will be covered later, has been performed.

1. Disconnect all tank attachments and piping connections.

2. Remove all sketch-to-annular plate welds (sketch plates normally require replacement as well).
3. Mark the location of the jacking brackets on tank shell external. The elevation of the brackets should be as low as possible,
depending on the height of the jack. Avoid locating the brackets on shell vertical welds.
4. Perform an ultrasonic test on the shell at the locations of shell-to-bracket welds to ensure that the shell plates are lamination-
free before welding the brackets.
5. Weld the brackets to the shell and apply the magnetic particle inspection (MPI) test to all welds. (It may be necessary to
preheat the tank shell before welding the brackets to the shell).
6. Install subjack foundations (if required) in tank berm and/or install spreader plate to properly distribute the jack reactions on
the tank foundations.
7. Install the available number of hydraulic jacks (usually 6-8) on the spreader plates against the corresponding set of
successive brackets on the portion of the tank shell where the initial jacking will take place. (Fig. 1 shows the jack and
bracket arrangement with respect to the tank shell and foundation.)
8. Connect the jacks to a central oil-feeding pump by means of high-pressure hoses.
9. Mark a reference point just above each jack bracket and install a pressure gauge (or load gauge) on each jack connection at
the tank.
10. Carefully operate the hydraulic pump (manual operation is recommended) and note the load on each jack and the
corresponding shell relative evaluation using the theodolite. Stop the pump when the load on any jack or the level of the tank
shell reaches the specified limits per cycle of tank lifting.
11. Replace the jacks with prepared supports (normally double extra-strong pipes). As necessary, insert shims between the
bracket and the support before removing the jacks to keep the shell at the attained elevated position.
12. Reinstall the jacks under the successive set of brackets according to the direction of the shell lifting cycle, i.e., clockwise or
counterclockwise.
13. Repeat Steps 8-12 until a shell lifting cycle is completed. All shell reference points at this stage should be equally elevated
to the specified lift for the first cycle, as determined in Step 10.
14. If the required lift is not attained by the first cycle of shell lifting, repeat Steps 7-13 once or twice until reaching the required
level.
15. Prepare the new floor annular plates with dimensions similar to the existing ones (the thickness of the new annular plates
can be increased if upgrading of the original design is required).
16. Prepare the edges of the new annular plates for butt welds and weld the backing strips at the specified end of each plate.
17. Remove the existing shell-to-annular double fillet weld of an annular plate plus 1 m of the preceding and succeeding annular
plates, with respect to the adopted replacement direction. Also remove the existing butt weld and backing strips between this
plate and the preceding and succeeding existing ones.
18. Withdraw the redundant annular plate and prepare the shell edges for a new weld.
19. Fit a new annular plate in place of the redundant one through the aperture between the shell and the foundation, as shown in
Fig. 2. Local repair of the tank foundation can be carried out as necessary before fitting the new annular plate.
20. Use wedges to raise the new annular plate until it is in contact with the tank shell and tack it into position.
21. Weld the new annular plate to the shell from both sides, leaving 1 m at both ends to be welded later, as shown in Fig. 2.
Apply the MPI test to the full length of the fillet weld.
22. Repeat Steps 17-20 to fit an adjacent new annular plate as shown in Fig. 2. (Note that the preceding plate is a new annular
plate, assuming replacement in a clockwise direction.) Therefore, no butt weld to the preceding plate is to be removed.
23. Apply the butt weld between the adjacent new annular plates and perform the full X-ray test to the joint to fulfill design code
requirements.1 2 (The flimsy end of one of the annular plates and the free end of the other greatly facilitate performing this
work within the available access between the shell and the tank foundation.)
24. Grind flush, then apply the MPI test to the length of the annular butt weld under the shell. Next, complete the shell-to-
annular double fillet weld for a set of two adjacent annular plates, leaving 1 m at the end unwelded. (Fig. 2 illustrates the
order of applying all associated welds.)
25. Repeat Steps 17-24 for further installation of a set of two annular plates following the specified replacement direction.
Continue until all annulus ring plates are installed.
26. Remove all wedges that are used for construction and lower the tank shell, along with the new annulus ring, following in
reverse the lifting procedure, using the same hydraulic jacks.
27. Remove all lifting brackets and grind flush all remaining welds; then apply the MPI test to the shell at the location of the
removed welds.
28. Weld the new annular plates to the floor sketch plates.
29. Carry out other repairs on the floor and the shell, then hydrotest the tank to the full design height per the applicable design
code.
ENGINEERING ANALYSIS
Before applying the sequential lifting method, the necessary engineering analysis must be
carried out to ensure that the site work will be accomplished correctly and safely (see sample
calculations box).
The following calculations are usually incorporated in the engineering analysis:

 Calculating the maximum jacking load

 Calculating the maximum jacking span and number of lifting cycles
 Designing the lifting brackets
 Checking the stress on the shell at the jacking points
 Checking the stability of the tank against the wind load.

MAXIMUM JACKING LOAD

The estimation of the jacking load in tank sequential lifting is different than in direct total lifting
because the load of the tank is not equally distributed among all jacking points around the
circumference. In sequential lifting, only the weight of the physically lifted portion of the shell is to
be considered in the calculation of the jacking load.
To determine the length of the shell lifted portion, the initial jacking step is simulated as shown in
Fig. 3.
The shell is represented by a continuous beam which carries the weight of the upper sections of
the shell plus its own weight. The ends of this beam are assumed to be fixed, and the
midsupport represents two jacking points combined in a single support, which is elevated above
the fixed ends.
Equation 1 (equations box) is the resultant deflection equation of the beam, as shown in Fig. 3.
Analyzing the reactions and vertical loads produces Equation 2.
Equation 3 is the result of resolving the moments created by vertical loads. And application of the
theory of three moments produces Equations 4 and 5.
Equations 1-5 are independent, and functions of dB, 1, RA, RB, MA, and MB, which are
unknown. Solving Equations 1-5 by letting dB = dC yields Equation 6.
If dC is assumed, the corresponding 1 can be obtained from Equation 6 and, consequently, RB
can be calculated by Equation 1. Equation 7 is the result of the fact that the vertical reaction at B
simulates the action of two jacks.
MAXIMUM JACKING SPAN
To expedite the lifting procedure, more than two jacks are used for each lifting step. Thus the
lifted portion of the shell can be simulated as shown in Fig. 4.
It is assumed that the deflection of the beam along the span QD is negligible, which means that
the shell load between Q and D is equally distributed among the intermediate jacks, as shown in
Equations 8 and 9.
By reducing Ljs to a workable length-Lj-Equations 10, 11, and 12 are obtained.
LIFTING BRACKETS
Fig. 5 illustrates the arrangement of a lifting bracket that is composed of a structure element and
reinforcing pad welded to the shell. Equation 13 calculates the jacking moment.
Equation 14 calculates the bending stress on the structure element. The bracket-to-shell fillet
weld length is calculated by Equation 15.
JACKING POINT STRESS
The longitudinal section of the shell that is effectively resisting the jacking moment is extended
above and below the reinforcing plate by approximately 12 ts, as shown in Fig. 5 (Equations 16
and 17).3
Equation 18 calculates the bending stress on the shell.
WIND LOAD
In checking the stability of the tank against wind load, Equations 19, 20, and 21 must be solved.
Sliding resistance is calculated by Equation 22, and overturning resistance is calculated by
Equation 23.1
REFERENCES

1. API 650, American Petroleum Institute, "Welded Steel Tanks for Oil Storage," November 1988.
2. British Standard Institution BS 2654, "Manufacture of Vertical Steel Welded Non-Refrigerated Storage Tanks," 1989.
3. Von Karman, "Analysis of Some Thin-Walled Structures," ASME paper AER-55-19C, Aer. Eng., Vol. 5, No. 4, 1933.
4. JIS, B-8501, "Welded Steel Tanks for Oil Storage," 1979.