Above-ground fire-resistant storage tank system and fabrication method

Abstract

An improved fire-resistant above-ground storage tank for flammable and combustible materials is fabricated from steel plates of at least 10 gauge, the sheets being made from a ferrous alloy having a maximum of approximately 0.15% carbon and a maximum of approximately 0.8% manganese and the steel plates welded in a specific way resulting in a tank that can withstand a 2000° F. environment for a minimum of two hours.

What is claimed is:  
     
       1. An improved above-ground fire-resistant storage tank system for storing flammable and combustible material, such as gasoline, comprising: 
       a plurality of storage tank sheet steel pieces assembled to form a storage tank, with each said storage tank sheet steel piece having at least one edge, each said edge being adjacent to a neighboring edge, said storage tank sheet steel pieces being approximately 10 gauge or thicker, having a maximum of approximately 0.15% carbon and a maximum of approximately 0.8% manganese, one or more joints where each said edge is in contact with said neighboring edge, said joints being selected from the group consisting of joggle joints and butt weld joints and at least one weld contains weld metal having a maximum of approximately 0.15% carbon and a maximum of approximately 1.4% manganese; and  
       at least one tank fitting.  
     
     
       2. The storage tank system according to claim  1 , wherein: 
       said storage tank sheet steel pieces having approximately 0.04% phosphorus and approximately 0.05% sulfur, and  
       said weld metal having approximately 0.05% carbon, approximately 1.28% manganese, approximately 0.5% silicon, approximately 0.013% phosphorus, and approximately 0.009% sulfur.  
     
     
       3. The storage tank system according to claim  1 , wherein: 
       said storage tank sheet steel pieces are approximately 7 gauge or thicker; and  
       said system further comprises:  
       a plurality of secondary containment tank sheet steel pieces constructed to form a secondary containment tank, each said secondary containment tank sheet steel piece having at least one edge, each said edge fabricated to be adjacent to a neighboring edge, said secondary containment tank sheet steel pieces being approximately 10 gauge or thicker, having a maximum of approximately 0.15% carbon and a maximum of approximately 0.8% manganese, at least one joint where each said edge is in contact with said neighboring edge, said joint being selected from the group consisting of joggle joints and butt weld joints; and at least one weld contains weld metal having a maximum of approximately 0.15% carbon and a maximum of approximately 1.4% manganese; and  
       said storage tank and said secondary containment tank constructed and arranged such that said storage tank can reside inside said secondary containment tank, thereby forming an interstitial space between said storage tank and said secondary containment tank.  
     
     
       4. The storage tank system according to claim  1 , wherein: 
       said storage tank sheet steel pieces having approximately 0.04% phosphorus and approximately 0.05% sulfur;  
       said weld metal of said storage tank having approximately 0.05% carbon, approximately 1.28% manganese, approximately 0.5% silicon, approximately 0.013% phosphorus, and approximately 0.009% sulfur;  
       said secondary containment tank sheet steel pieces having approximately 0.04% phosphorus and approximately 0.05% sulfur; and  
       said weld metal of said secondary containment tank having approximately 0.05% carbon, approximately 1.28% manganese, approximately 0.5% silicon, approximately 0.013% phosphorus, and approximately 0.009% sulfur.  
     
     
       5. A method of fabricating an improved above-ground fire-resistant storage system for storing combustible material, such as gasoline, comprising the steps of: 
       providing sheet steel of approximately 10 gauge or thicker, said sheet steel having a maximum of approximately 0.15% carbon and a maximum of approximately 0.8% manganese;  
       cutting and shaping from said sheet steel into a plurality of storage tank sheet steel pieces with at least one edge, said storage tank sheet steel pieces constructed such that when assembled and welded they form a storage tank with each said edge in contact with a neighboring edge to form at least one joint, said joint being selected from the group consisting of joggle joints and butt weld joints, at least a weld fusing each said joint;  
       assembling and welding said storage tank sheet steel pieces to form said storage tank, said welding being performed with a welding technique selected from the group consisting of:  
       submerged arc welding using a L 61 weld wire and a 761 flux, operating with 225 to 280 amps; and  
       dual shielded wire feed welding shielded by carbon dioxide and operating with 180 to 220 amps, using a flux core weld wire having a maximum of approximately 0.15% carbon and approximately 1.4% manganese;  
       installing a test fitting to said continuous storage tank wall; and  
       pressure testing said storage tank, identifying and rewelding any leaks.  
     
     
       6. A system made according to the method of claim  5 . 
     
     
       7. The method according to claim  5 , wherein: 
       said storage tank sheet steel pieces having approximately 0.04% phosphorus and approximately 0.05% sulfur, and  
       said weld metal having approximately 0.05% carbon; approximately 1.28% manganese, approximately 0.5% silicon, approximately 0.013% phosphorus, and approximately 0.009% sulfur.  
     
     
       8. The method according to claim  7 , wherein: 
       said storage tank is of a substantially cylindrical shape having a storage tank circumference and a storage tank diameter;  
       said cutting and shaping further comprises cutting said sheet steel such that at least one of said storage tank sheet steel pieces is a rectangular storage tank sheet having two side edges approximately equal in length to said storage tank circumference and two end edges and rolling said rectangular storage tank sheet into a storage tank ring, thereby butting said end edges;  
       said cutting and shaping further comprises cutting said sheet steel such that at least one of said storage tank sheet steel pieces is a storage tank end panels of substantially circular shape having a storage tank end panel diameter approximately equal to said storage tank diameter, and  
       said assembling and welding further comprising assembling said storage tank rings and said storage tank end panels into said storage tank such that said end edges of said storage tank ring are not adjacent to said end edges of a neighboring storage tank ring.  
     
     
       9. A system made according to the method of claim  8 . 
     
     
       10. The method according to claim  5 , wherein: 
       said storage tank sheet steel pieces are approximately 7 gauge or thicker, and  
       said cutting and shaping further comprising cutting from said sheet steel a plurality of secondary containment tank sheet steel pieces with at least one edge, said secondary containment tank sheet steel pieces constructed such that when assembled and welded they form a secondary containment tank with each said edge in contact with a neighboring edge to form at least one joint, said joint being selected from the group consisting of joggle joints and butt weld joints, at least a weld fusing each said joint;  
       said assembling and welding further comprising welding said secondary containment tank sheet steel pieces to form said secondary containment tank which surrounds said storage tank, thereby forming an interstitial space between said storage tank and said secondary containment tank, said welding being performed with a welding technique selected from the group consisting of:  
       submerged arc welding using a L 61 weld wire and a 761 flux, operating with 225 to 280 amps; and  
       dual shielded wire feed welding shielded by carbon dioxide and operating with 180 to 220 amps, using a flux core weld wire having a maximum of approximately 0.15% carbon and approximately 1.4% manganese; and  
       installing said tank fitting to said storage tank such that said tank fitting protrudes through said secondary containment tank wall and said storage tank and said secondary containment tank are substantially leak-free when said tank fitting is closed.  
     
     
       11. A system made according to the method of claim  10 . 
     
     
       12. The method according to claim  10 , wherein: 
       said storage tank sheet steel pieces having approximately 0.04% phosphorus and approximately 0.05% sulfur;  
       said weld metal of said storage tank having approximately 0.05% carbon, approximately 1.28% manganese, approximately 0.5% silicon, approximately 0.013% phosphorus, and approximately 0.009% sulfur;  
       said secondary containment tank sheet steel pieces having approximately 0.04% phosphorus and approximately 0.05% sulfur; and  
       said weld metal of said secondary containment tank having approximately 0.05% carbon, approximately 1.28% manganese, approximately 0.5% silicon, approximately 0.013% phosphorus, and approximately 0.009% sulfur.  
     
     
       13. The method of according to claim  12 , wherein: 
       said storage tank is of a substantially cylindrical shape, having a storage tank circumference and a storage tank diameter;  
       said secondary containment tank is of a substantially cylindrical shape, having a secondary containment tank circumference and a secondary containment tank diameter;  
       said cutting and shaping further comprises cutting said sheet steel such that at least one of said storage tank sheet steel pieces is a rectangular storage tank sheet having two side edges approximately equal in length to said storage tank circumference and two end edges and rolling said rectangular storage tank sheet into a storage tank ring, thereby butting said end edges;  
       said cutting and shaping further comprises cutting said sheet steel such that at least one of said secondary containment tank sheet steel pieces is a rectangular secondary containment tank sheet having two side edges approximately equal in length to said secondary containment tank circumference and two end edges and rolling said rectangular secondary containment tank sheet into a secondary containment tank ring, thereby butting said end edges;  
       said cutting and shaping further comprises cutting said sheet steel such that at least one of said storage tank sheet steel pieces is a storage tank end panel of substantially circular shape having a storage tank end panel diameter approximately equal to said storage tank diameter;  
       said cutting and shaping further comprises cutting said sheet steel such that at least one of said secondary containment tank sheet steel pieces is a secondary containment tank end panel of substantially circular shape having a secondary containment tank end panel diameter approximately equal to said secondary containment tank diameter;  
       said assembling and welding further comprising assembling said storage tank rings and said storage tank end panels into said storage tank such that said end edges of said storage tank ring are not adjacent to said end edges of a neighboring storage tank ring; and  
       said assembling and welding further comprising assembling said secondary containment tank rings and said secondary containment tank end panels into said secondary containment tank such that said end edges of said secondary containment tank ring are not adjacent to said end edges of a neighboring secondary containment tank ring and said secondary containment tank surrounds said storage tank.  
     
     
       14. A system made according to the method of claim  13 . 
     
     
       15. An improved noninsulated above- around fire - resistant storage tank system for storing flammable and combustible material, such as gasoline, comprising:    
         a plurality of storage tank sheet steel pieces assembled to form a storage tank, each of said storage tank sheet steel pieces having at least one edge, each said edge being adjacent to a neighboring edge, said storage tank sheet steel pieces having thicknesses that are sufficient to have enough mass to maintain the integrity of the storage tank in an environment of at least  2000  degrees F. for a period of time of at least two hours, said sheet steel pieces being fabricated of a steel that has a brittleness that is substantially no more than a brittleness of a steel having a maximum of approximately  0 . 15   %  carbon and a maximum of approximately  0 . 8   %  manganese; one or more joints where each said edge is in contact with said neighboring edge, said joints being selected from the group consisting of joggle joints and butt weld joints; and at least one weld comprising a weld metal that has a coefficient of expansion that is similar to that of the steel from which the sheet steel pieces are fabricated; and    
       
         at least one tank fitting.  
       
     
     
       16. A system according to claim  15 , wherein said storage tank sheet steel pieces have a thickness of at least  10  gauge. 
     
     
       17. A system according to claim  15 , further comprising at least one skid member attached to said storage tank for supporting the storage tank with respect to an underlying surface, said skid member being fabricated from a material having a similar coefficient of expansion as the steel from which the sheet pieces are fabricated. 
     
     
       18. A system according to claim  15 , wherein said sheet steel pieces are assembled to form a storage tank and a secondary containment tank, and wherein said sheet steel pieces forming the storage tank have a similar coefficient of expansion as said sheet steel pieces forming the secondary containment tank. 
     
     
       19. An improved noninsulated above- ground fire - resistant storage tank system for storing flammable and combustible material, such as gasoline, comprising:    
       
         a plurality of storage tank sheet steel pieces assembled to form a storage tank, each of said storage tank sheet steel pieces having at least one edge, each said edge being adjacent to a neighboring edge, said storage tank sheet steel pieces having a minimum thickness that is sufficient to have enough mass to maintain the integrity of the storage tank in an environment of at least  2000  degrees F. for a period of time of at least two hours, one or more joints where each said edge being in contact with said neighboring edge, said joints being selected from the group consisting of joggle joints and butt weld joints and at least one weld, said weld comprising a weld metal that has a coefficient of expansion that is similar to that of a steel from which the sheet steel pieces are fabricated; and  
       
       
         at least one tank fitting.  
       
     
     
       20. A system according to claim  19 , wherein said sheet steel pieces are assembled to form a storage tank and a secondary containment tank, and wherein said sheet steel pieces forming the storage tank have a similar coefficient of expansion as said sheet steel pieces forming the secondary containment tank. 
     
     
       21. A system according to claim  19 , wherein said storage tank sheet steel pieces have a thickness of at least  10  gauge. 
     
     
       22. A method of making a noninsulated above- ground fire - resistant storage tank for storing combustible material such as gasoline, comprising steps of:    
       ( a )  providing a plurality of sheet steel pieces, each of said sheet steel pieces having a minimum thickness;    
       ( b )  assembling and welding the sheet steel pieces to form a storage tanks said assembling and welding being performed so as to form at least one joint that is selected from the group consisting of joggle joints and butt weld joints;    
       ( c )  installing a fitting on the storage tank; and    
       ( d )  pressure testing the storage tank,    
         and wherein said minimum thickness of said sheet steel pieces is sufficient to have enough mass to maintain the integrity of the storage tank in an environment of at least  2000  degrees F. for a period of time of at least two hours.    
     
     
       23. A method according to claim  22 , wherein step ( a )  is performed with each of said sheet steel pieces having a thickness of at least  10  gauge.   
     
     
       24. A method according to claim  22 , wherein the welding in step ( b )  is performed with a welding metal that has a similar coefficient of expansion as said sheet steel pieces.   
     
     
       25. A method according to claim  22 , further comprising a step of attaching at least one skid member to the storage tank for supporting the storage tank with respect to an underlying surface, said skid member being fabricated from a material having a similar coefficient of expansion as the steel from which the sheet pieces are fabricated. 
     
     
       26. A method according to claim  22 , wherein step ( b )  is performed so that said sheet steel pieces are assembled to form a storage tank and a secondary containment tank, and wherein said sheet steel pieces forming the storage tank have a similar coefficient of expansion as said sheet steel pieces forming the secondary containment tank.   
     
     
       27. A method of making a noninsulated above- ground fire - resistant storage tank for storing combustible material such as gasoline, comprising steps of:    
       ( a )  providing a plurality of sheet steel pieces having a composition, each of said sheet steel pieces having a minimum thickness;    
       ( b )  assembling and welding the sheet steel pieces into joints with at least one weld metal to form a storage tank; and    
       ( c )  installing at least fitting on the storage tank; and wherein    
         the configuration of said joints, the composition and thickness of said sheet steel pieces and the composition of the weld metal are selected and combined such that the storage tank is able to withstand an environment of at least  2000 degrees F. for a period of time of at least two hours.  
     
     
       28. A method according to claim  27 , wherein said sheet steel pieces being fabricated of a steel that has a brittleness that is substantially no more than a brittleness of a steel having a maximum of approximately  0 . 15 %  carbon and a maximum of approximately  0 . 8   %  manganese.   
     
     
       29. A method according to claim  27 , wherein step ( b )  is performed so as to form more than one butt joint extending longitudinally with respect to an axis of the storage tank, and wherein said butt joints are positioned so as to be nonaligned.   
     
     
       30. A method according to claim  27 , wherein said joints are is selected from the group consisting of joggle joints and butt weld joints. 
     
     
       31. A method according to claim  27 , wherein step ( a )  is performed with each of said sheet steel pieces having a thickness of at least  10  gauge.   
     
     
       32. A method according to claim  27 , wherein the welding in step ( b )  is performed with a welding metal that has a similar coefficient of expansion as said sheet steel pieces.   
     
     
       33. A method according to claim  27 , further comprising a step of attaching at least one skid member to the storage tank for supporting the storage tank with respect to an underlying surface, said skid member being fabricated from a material having a similar coefficient of expansion as the steel from which the sheet pieces are fabricated.