Vertical Cylindrical

Cylindrica l Storage Tank

Tank Calibration
Calibration
Technologies and Application

Srini Sivaraman
SK Japan
March 2012
API Conference
Conference & Expo Singapore
Singapore 2012

1
 Calibration Overview - 1
• Process by which the volume in a tank in relation to the liquid height (up
to maximum fill height) is established
e stablished
 –  The diameter of the courses is determined by field measurements using
following technologies

• Reference Standards :

 –  API Chapter 2.2 A: Manual

 –  API Chapter 2.2 B: Optical Reference

Reference Line Method (ORLM)

 –  API Chapter 2.2 C: Optical Triangulation

riangulati on Method (OTM)

 –  API Chapter 2.2 D: Electro Optical Distance Ranging Method (EODR)

 –  API Standard 2555: Liquid Calibration

2
 Calibration Overview - 1
• Process by which the volume in a tank in relation to the liquid height (up
to maximum fill height) is established
e stablished
 –  The diameter of the courses is determined by field measurements using
following technologies

• Reference Standards :

 –  API Chapter 2.2 A: Manual

 –  API Chapter 2.2 B: Optical Reference

Reference Line Method (ORLM)

 –  API Chapter 2.2 C: Optical Triangulation

riangulati on Method (OTM)

 –  API Chapter 2.2 D: Electro Optical Distance Ranging Method (EODR)

 –  API Standard 2555: Liquid Calibration

2
 Calibration Overview - 2

• All new tanks must undergo calibration

 –  Have access to internal for accurate deadwood determination
 –  Datum plate (reference plate at the bottom) flatness and level check and
correction as necessary
 –  Calibration after successful hydrostatic test

• All tanks in service must undergo recalibration or re computation

 –  Recalibration at set frequency or after repair
 –  Either set by customs or local regulations
 –  General informative guidelines per API Chapter 2.2 A
 –  Re computation only under certain conditions

3
 Frequently Asked Questions
• Do you have to empty the tanks for re calibration
 –  NO
• Can you calibrate the tank at any liquid level
 –  Yes
• Can you calibrate the tank when the tank is moving (receiving or
discharging)
 –  No, you cannot calibrate the tank while the tank is in motion. The tank level
must be steady and no movement in and out of the tanks
• Does product temperature impact volume
 –  Yes. It results in expansion of tank shell wall and the additional volume can be
significant
• Can calibration be undertaken over the insulation
 –  No, not for custody transfers and inventory

4
 Frequently Asked Questions
• Can you calibrate the tank when the tank is full of water for hydro test
 –  Yes . Once the test is completed you can calibrate the tank full of water,
de-stress the tank to zero stress condition and re-stress the tank for the actual
gravity of the product
• What is the impact of gravity in tank calibration
 –  For a given liquid level the hydrostatic pressure is a function of gravity and this
results in tank expansion . If not accounted for it could impact the tank volume
significantly depending on diameter and thickness of shell
 –  Also FR must be compensated for buoyancy that is function of gravity
 –  Gravity of course is needed for VCF
• Do you need traceability for working tape calibration
 –  Working tape is calibrated by master tape and master tape is calibrated per National
Standards

5
 Calibration Process Parameters
• Following operational parameters must be supplied by the tank owners
to the calibration contractor
 –  Product Temperature
 –  Product Gravity
 –  Roof Leg Position for FR ( Critical Zone: Figure 1)
• Zone needed for FR to float fully from rest position (no custody gauging
in this zone)
 –  Ambient Temperature
 –  Maximum Fill Height ( depends on safety rules)

• These must not be decided by or assumed by the calibration contractor

6
Note: Critical Zone Position varies with FR position

Roof Legs
CZ
Floating Roof

CZ

FR in Maintenance Position FR in Operating Position

Floating Roof Position

7
 Calibration by Manual Method
• Manual Method
 –  API Chapter 2.2A
• Often is referred to as the Referee Standard (basis for all other methods)
 –  Circumference measured with a working tape at various courses
• Working tape is Calibrated against a master tape and applicable tension determined
for actual application
• Master tape readings generally are at 68 deg F
 –  Tape is maintained physically in perfect contact with shell
• Tape is maintained in horizontal plane
• Stroke the straps two or thee times to ensure perfect contact with the shell
 –  Single strap or multiple straps may be used
• Multiple straps with a smaller length tape are preferred as they are easy to handle
• They are easy to maintain control, contact with shell and horizontality
 –  All circumference measurements are external
• Tank shell surface must be clean

8
 Field Measurements-1
Calibration in the field involves following physical measurements

• Circumference measurement of each course (Figure 2)

 –  Using working tape calibrated with appropriate tension
 –  Multiple straps or single strap at each course
 –  Typical tape length of 100 ft may be used
 –  Number of Straps required = π  * D( ft )
100(  ft )
• Plate Thickness
 –  Measured ultrasonically all around in each course (8 to 12 data points) and
averaged for each course
• Diameter
 –  Computed from the measured circumference and the thickness

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 Note: Ideally scaffolding fixed or portable needed to maintain tape in contact
with shell
C

   t
    f
A    4
   6
   o
   t
   8
   4

AB, BC, CA : Three straps (An example)

A to A : Single Strap (heavy)
Multiple Straps easier to handle

Manual Calibration : API Chapter 2.2A

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 Field Measurements-2
• Reference height and reference gauge point (Figure 3)
 –  Critical component of calibration
 –  For new tanks easily established
 –  For old tanks the bottom access to datum plate may not be possible as bottom
maybe filled with solid sludge or other foreign materials
• If access is not available one should not try and measure RH but use the
RH from previous calibration table
 –  Gauge point is the point from which gauging should be undertaken
• The gauge point should be clearly marked on the stilling well
• Critical Zone (Figure 1)
 –  On empty tanks roof leg position can be verified physically
 –  On tanks in service , information may be taken from the last tank calibration
table
 –  Typically this is in the range of 6 to 12 in but could be as high as 18 in
depending on FR design

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 Field Measurements-2
• Deadwood
 –  All internal piping and other structures inside are physically measured and
their volumes distributed vertically from the datum plate
 –  This is necessary to subtract the volume of the deadwood as tank table is
developed (volume Vs height)
 –  This is possible only when entry is permitted into the tank, if not it should be
taken from the most recent calibration data
• FR Weight
 –  During calibration FR weight is collected either from old table data or
physically measured and computed. But computation could potentially carry
large uncertainty
 –  Number of welding rods that are used in the FR fabrication must be taken into
account or else could understate the FR deadweight
 –  Best obtained from the fabricator and documentation on file maintained for
all future calibration

13
 Field Measurements-3
• Maximum Shell Height
 –  This height is measured and documented as part of the development of the tank table
 –  Measured externally from the base

• Maximum fill Height

 –  Depends on local conditions
 –  Earthquake zones ; 4 to 6 feet below the top rim
 –  Others limited by FR height

• Bottom Calibration
 –  Tank bottom could be flat, cone up or cone down
 –  Tank bottoms are measured by physical survey when entry is allowed
 –  Tank bottoms may also be calibrated with liquid (water)
 –  When in service the zero gauge volume is copied from old tables
• Zero gauge volume is the volume below the datum plate
• Tilt
 –  Measured optically or manually by plumb line

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 Capacity Table Development
• The capacity table is simply a table that gives the volume of the tank at
any given height
• In the development of the table following corrections should be applied

 –  FR buoyancy correction

 –  Tank tilt correction
 –  Hydrostatic correction
 –  Shell temperature correction
 –  Master tape correction
 –  Working tape correction
 –  Other correction such as tape rise

15
 Corrections – 1
FR Buoyancy Correction
 –  Correction is based on gravity of the product and FR weight
 –  FR correction (volume units) must be subtracted from the total volume at any
given level as long as FR is fully floating
 –  In critical zone the FR correction is distributed over the range of the zone
 –  Below the critical zone FR correction is zero
 –  Tank table carries the base FR correction for a given gravity and incremental
correction for variations in base gravity
Tilt Correction
 –  No correction needed when tilt is less than 1 in 70
 –  Tilt correction is requires when tilt exceeds the above value
 –  Maximum tilt should be less than 2.4 in 100

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 Corrections -2
• Hydrostatic Head correction
 –  Hydrostatic head (liquid pressure) causes expansion of the tank shell
 –  Additional volume from pressure expansion may be as high as 0.08%
depending on plate thickness
 –  Expansion function of plate thickness and gravity for a given tank
 –  API 2.2 A provides detailed procedure for calculating the incremental volume
and the total volume for pressure correction
• The additional incremental and total volume is generally included in the
capacity table for a given gravity of the product
 –  Variation in gravity of +/- 5 deg API will have negligible impact on the
computed volume
 –  If the gravity changes by more than 10 deg API the table must be rechecked

17
 Corrections - 3
• Shell Temperature Expansion Correction
 –  Shell expands due the combined effect of product and ambient temperature
 –  The impact on total volume could be 0.05% and higher
 –  The shell temperature determination equation has been modified from the
old API Standard 2550
• It is no longer the mean of ambient and product temperature
• In the new equation product temperature dominates
 –  Tanks which are insulated, the shell temperature equals product temperature
 –  The temperature expansion factor may be included in the main capacity table
for a give product and ambient condition or
• The capacity table may be established at 60 deg F or 15 deg C and the shell temperature
expansion factor may be applied externally for each batch received or discharged from the
tank with actual field temperatures
• The capacity table may also be accompanied by a temperature expansion factor table when
the capacity table is at 60 deg F

18
 Corrections - 4
• New Shell Temperature Equation
7 * T L + T A
T S  =
8
T L = Liquid Temperature
T A = Ambient Temperature

• Master Tape Correction

 –  Tape carries calibration to 68 deg F
 –  Measured lengths should be corrected to 60 deg F
• Other Corrections
 –  Tape rise correction, if needed, should be applied

19
 Recalibration Frequency
• Informative Appendix in API Chapter 2.2 A provides guidelines
• Recalibration is required on all tanks if internals are modified
• Recalibration may also be mandated by local regulations or customs
• Recalibration is required if the tank bottom repair work is undertaken
• 5/15 rule for tanks in Custody Service
 –  Bottom course verified once every 5 years for diameter, thickness and tilt
 –  Variations in D, t, and tilt (from previous calibration) are computed and impact
on volume determined
 –  If variation in volume is in excess of 0.02% recalibration is recommended
 –  If variation in volume is within 0.02% , 5 year verification is continued until 15
years when total recalibration is recommended

20
 Working Tape Re calibration
• Working Tape should undergo re calibration after application on 20 tanks,
once every 20 tanks

• Working tape should undergo re calibration if it is to be used on a tank or

tanks whose circumference(s) vary by more than 20%  the circumference
of the tank on which the tape was originally calibrated

• Master tape should be re certified once every two years .

21
 Re Computation
• Re computation/Verification of table required when gravity changes by 10
deg API or higher

 –  Diameters from the last calibration may be used to compute the new volumes
for gravity changes

• Re computation required when average product temperature has changed

by 20 deg F or higher (if the temperature correction is built into the table)

• Capacity table revised to reflect New RH if the stilling well is extended on

top with a nozzle for alternate gauging devices.

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 Capacity Table and Raw Field Data
• All raw data collated in the field should be made available to the tank
owner along with main capacity table
• Capacity table should generally contain following information at the very
minimum:
 –  Product ID, RH, Nominal Diameter
 –  Product Gravity, Product temperature
 –  Critical Zone
 –  FR total and incremental correction
 –  Shell Temperature correction table if capacity table at 60 deg F
• Appropriate foot note if corrections are already built into the table

 –  RH and Reference gauge point location

 –  Method of calibration and date of calibration
 –  Certificate of calibration of working tape and master tape
 –  Signature of the certifying authority
 –  API Standard number (e.g. 2.2A) used in the calibration

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 Optical Reference Line Method (ORLM)
• Reference Standard: API Chapter 2.2B
• This method establishes diameters of the courses by optical method
• The method can be applied internally or externally (external easier)
Procedure (Figure )
• Tank divided into horizontal and vertical stations
 –  Number of stations horizontally vary from 8 to 36 depending on diameter
• Magnetic trolley with graduated scale moved vertically
• Reference circumference of bottom course by manual method (API Chapter 2.2A)
• Reference offset is measured optically at the same height where the reference
circumference is measured
• At each horizontal station, course offsets are measured (Two per course) optically
• Deviations in course offsets from the reference offset are averaged for each course
 –  Using the reference circumference and deviations the course diameters are
established

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 E

F D

Optical Device

G • C

H B

A , B ….Horizontal Stations
A Optical Reference Line

HORIZONTAL STATIONS A
B
OPTICAL REFERENCE LINE METHOD
Vertical Station:Typical Optical Reference Line

h/5
NOTE: Plan view shown for 8 stations
Course Height ‘h’

h/5

Weld Seam

Magnetic Trolley

Scale Reference Diameter

300 mm
Reference Offset

Optical Device

Optical Reference Line Method (ORLM)

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 ORLM
• Important Considerations
Optical device stability is critical
 – 

Device must be in level in all directions

 – 

The optical ray must be vertical throughout the height of the tank (within
 – 

limits)
At each station reference offset is rechecked b after the full vertical traverse
 – 

The optical device is checked randomly at three locations for perpendicularity

 – 

by rotating the device 360 deg

In extreme windy condition , when it is difficult to maintain the trolley in
 – 

contact with the shell, calibration should not ne undertaken

• Other Measurements
Identical to manual method API Chapter 2.2 A
 – 

• Development of the Capacity table

Per API Chapter 2.2A
 – 

• Advantages
Much easier, no scaffolding and reference circumference is easier to control
 – 

being at the base

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 Optical Triangulation Method (OTM)
• Reference Standard : API Chapter 2.2 C
• This method establishes diameters of the courses by optical method
• The method can be applied internally or externally (internal easier)
Procedure (Figure 5)
• Tank is divided into horizontal and vertical stations for both internal and external
methods
• Tank profile is established by triangle at each target point and hence the name
OTM
• For internal method reference distance “D” is established optically using
temperature compensated Stadia typically 2 m long
• Subsequently tank coordinates A(x, y) are measured optically using two
theodolites
• For external method the tangential angles are measured along with the distance
between the two theodolites ( T 1 T2 )
• Diameters are computed using mathematical computational proce dures

27
 X

T, L = Theodolites
A(x, y)
A(X,Y) : Coordinates •

T1
+ T α
D Y
• •

T2 +
*
AN * A2

Target Points T1 , T2 …. For External Calibration *

(A1…..AN) A1
T…D, For Internal Calibration A1, A2….AN Horizontal Stations

Ring 3 D = Reference Distance

h
, : Coordinate Angles

Ring 2

h/5 A1 A2 AN
Ring 1

h/5
OTM: Internal and external
Figure 5
Vertical Stations

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 OTM
• Important Consideratio ns
 –  Optical devices stability is critical
 –  Devices must be in level in all directions
 –  Distance D for internal method should be measured again at the end
• Other Measurements
 –  Identical to manual method API Chapter 2.2 A
• Development of the Capacity table
 –  Per API Chapter 2.2A

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 Electro Optical Distance Ranging Method
(EODR)
• Reference Standard: API Chapter 2.2 D
• This method is for Internal application only
• Like ORLM and OTM the method establishes diameters of all courses
Procedure (Figure 6)
• Establish a reference target on the bottom course and note the reference distance
and reference angle
• Spherical coordinates are measured using distance ranging device (r, α, β) for each
target point
• Tank profile is thus established from bottom to top
• The reference distance of the target and the reference angle of the target at the
end are rechecked
• Using standard mathematical procedures, diameter of courses is computed
• With an on line computer, diameters can be determined instantaneously

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 r, , : Spherical Coordinates

: Vertical angle

: Horizontal angle to reference target

Target Points

+ + + + +

Ref. Target
+

Optical Device

Electro Optical Distance Ranging Method : EODR

Figure 6
31
 EODR
• Important Considerations
 –  Optical device stability is critical
 –  Device must be in level in all directions
 –  The measurements at the reference target at the end of the tank traverse
should be repeatable
• Other Measurements
 –  Identical to manual method API Chapter 2.2 A
• Development of the Capacity table
 –  Per API Chapter 2.2A

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 Liquid Calibration
• Reference Standard: API Standard 2555
• Level Vs Volume is established directly
• Volume Q 1 is metered ( volume through meter that is calibrated prior to start of the tank
calibration) and corresponding level L1 is measured
• Increments will depend on tank diameter and generally should be 6 in to a foot
• Recalibration of the meter at the conclusion is required
• In liquid calibration hydrostatic correction is not necessary as at each level the tank is
already in an expanded state
• Alsothe deadwood correction is not necessary
• RH must be measured per API Chapter 2.2A
• Liquid used: Product to be stored in tanks or water
 –  If water is used, then adjustments to the volume by courses is necessary due to the
gravity variation between water and the product
• Time consuming and may take as much as two days
• This standard is an old standard and will be revised in future

33