2018 Product Award Menu
2018 Field Erected Tank Entries
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liquid storage tank
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vessel storage
| Product / project title: | ASME Pressure Vessel Storage – Two (2) 50,000 BBL Spheres |
| Product / project owner: | Mark West Energy Partners |
| Product / project location: | Hopedale, OH |
| Date completed: | December 2018 |
| Construction standard (if any): | ASME Section VIII Div. 2 |
| Overall height / length (feet, inches): | (2) 81’ -10” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | (2) 81’ -10” |
| Capacity (US gallons): | 4,120,000 |
| Steel tonnage used (US tons): | 1,293 |
| Steel thickness (inches): | 1.11” to 1.30” |
The two (2) pressure spheres were designed and built in accordance with ASME, Section VIII Division 2, 2015 Edition to hold 50,044 barrels (BBLS) of Isobutane (pictured on the far right) and 50,044 BBLS of Y Grade (pictured on the far left in the foreground) under pressure at 100 psig and 150 psig respectively.
The Isobutane sphere is 81’-10” diameter designed for 100 psig pressure, 10 psig vacuum, 150 degrees F to hold 50,044 BBLS or 2,100,000 gallons of product. All full penetration welds on the sphere were 100% Ultrasonic Tested (UT) for quality prior to being hydrotested at 143 psig. Following hydrotest, the sphere pressure boundary was painted in the field with an epoxy patch coat and urethane finish coat as well as the support columns were patch primed and fireproofed prior to being placed in service by the owner.
The Y Grade sphere was also 81’- 10” diameter, but designed for 150 psig pressure, 0 psig vacuum, 150 degrees F to hold 50,044 BBLS or 2,100,000 gallons of product. All full penetration welds on this sphere were also 100% Ultrasonic Tested (UT) for quality prior to being hydrotested at 215 psig. Similarly to the Isobutane sphere and following hydrotest, the epoxy patch coat and urethane finish coats were applied to the sphere pressure boundary as well as columns were patch primed and fireproofed prior to being placed in service by the owner.
The Scope of Work for the two spheres also included the design and construction of pier / ring foundations; design, fabrication and installation of the steel support columns, including the Pyrocrete 241 fireproofing; design and installation of a multi-ring deluge fire protection spray/deluge system; design, fabrication and construction of the two spheres ranging in steel thickness from 1.11 inches thick to 1.30 inches thick; galvanized stairways; shop applied priming of all column and pressure boundary surfaces; and field paint of the finalized spheres.
The two spheres, which are in addition to the sixteen (16) ASME Section VIII Div 2 spheres already constructed at this facility, used a total of 1,293 tons or 2,586,000 pounds of steel plate and demonstrates the capability and flexibility of steel to store various products at very high pressures and vacuum – making steel the repeat material of choice!
| Product / project title: | Isobutane Sphere for the Valero Houston C4 Alky Project |
| Product / project owner: | Valero Houston Refinery |
| Product / project location: | Pasadena, TX |
| Date completed: | September 2018 |
| Construction standard (if any): | ASME Section VIII, Div. 2 |
| Overall height / length (feet, inches): | 57’ -0” |
| Column height (feet, inches): | 31’ -6” |
| Diameter (feet, inches): | 51’ -0” |
| Capacity (US gallons): | 509,000 |
| Steel tonnage used (US tons): | 192 |
| Steel thickness (inches): | 1.006” |
Concurrent and as part of a C4 Alky Project, this refinery expansion included the Engineering, Procurement, Fabrication and Construction (EPFC) of (1) one Isobutane Sphere designed to ASME Section VIII Div 2. The sphere was designed for 12,000 BBLs net working capacity, used over 190 tons of steel, and incorporated plates just over one inch thick.
Included in this scope were the following:
1) Design and installation of the augercast piling system
2) Engineering and construction of the pier foundations atop the supporting piling
3) Design, fabrication and installation of the fire protection system (top deluge and lower spray)
4) Non-destructive examination per ASME and client’s specifications
5) Hydrostatic testing
6) Shop prime and field painting (Self-Performed)
The 51′ DIA sphere was designed for 128.0 PSIG pressure at 150 degrees F and 14.7 PSIG vacuum. The stairways were a double stringer with an equator and a top platform. The hydrostatic test was performed at 215 PSIG.
One of the client challenges for this project was the window allotted for removal and rerouting of utility poles from the work area. Thusly, the coordination of mobilization as well as the start-to-finish duration on site became even more critical for the overall project’s success. The sphere project scope of works were executed in less time than the original schedule, providing turnover to the client prior to their need date. This was accomplished by sub-assembling portions of the sphere prior to erection and also by closely scheduling the painting activities immediately sequential with the hydrostatic test.
This sphere project was completed with zero incidents, recordable, or lost time incidents.
| Product / project title: | Spheres for HDPE3 Expansion |
| Product / project owner: | Formosa Plastics |
| Product / project location: | Point Comfort, TX |
| Date completed: | February 2018 |
| Construction standard (if any): | ASME |
| Overall height / length (feet, inches): | 100’ -0” |
| Column height (feet, inches): | 40’ -0” |
| Diameter (feet, inches): | (2) 60’ -0” |
| Capacity (US gallons): | 3,113,800 (Total) |
| Steel tonnage used (US tons): | 711 (Total) |
| Steel thickness (inches): | 1.274” |
The Owner required two (2) additional spheres – one for butane and one for hexane – to facilitate expansion of their High Density Polyethylene (HDPE) unit. Both spheres were designed to ASME Section VIII Div 1; a capacity of 19,725 BBLs net working capacity each, which corresponds to 60′-0” in diameter; a 110 psig design pressure; and 7.5 psig vacuum. The spheres were hydrostatically tested to 143 psig, used over 710 tons of steel and incorporated plates over 1 1/4″ thick.
The scope of work included the Engineering, Procurement, Fabrication and Construction of the spheres as well as:
1) Design, fabrication and installation of the fire protection system
2) Detailing, fabrication and placement of the double stringer stairways and platforms
3) Ultrasonic examination per ASME
4) Hydrostatic testing
5) Shop prime and field coatings (Self-executed)
6) Shop prime and field painting (Self-Performed)
The spheres were successfully hydro-tested, completed, and turned over to the customer meeting high standards of excellence in both quality and schedule delivery. The total length of welds for this project was approximately 3,500 feet with a weld acceptance rate of over 99.5%. And despite the effects of Hurricane Harvey during the construction period, the sphere project was completed ahead of the original schedule.
This project demonstrates another example of steel being the material of choice for various product high pressure storage applications – serving the Owner for many years to come similar to their other ASME spheres which have remained in service since their initial construction in the early 1980s.
| Product / project title: | LACC 1000 KTA Ethane Cracker Project |
| Product / project owner: | Four (4) 35′ Diameter ASME Spheres / LACC LLC (JV between Axiall Corp. and Lotte Chemical Corp.) |
| Product / project location: | Lake Charles, LA |
| Date completed: | February 2018 |
| Construction standard (if any): | ASME |
| Overall height / length (feet, inches): | 46’ -5.625” |
| Column height (feet, inches): | 28’ -11” |
| Diameter (feet, inches): | (4) 35’ -0” |
| Capacity (US gallons): | 657,049 (Total) |
| Steel tonnage used (US tons): | 433 (Total) |
| Steel thickness (inches): | 1.425” (Max) |
The four (4) spheres are an integral storage component of a 2 billion pounds per year grassroots ethylene production facility in which the Site Owner invested billions of dollars to build in the U.S. Gulf Coast. The spheres were needed to store two important products at pressure for use in the petrochemical facility. Two of the spheres were designed to store a Mixed (C4) Butane product at 75 psig while the other two spheres were designed to store Refinery Grade Propylene (RGP) at a much higher 300 psig.
The scope of work for the project included the engineering, procurement, fabrication and construction (EPFC) of the four (4) spheres, which were all 35′-0 in diameter. These spheres were built in accordance with ASME Section VIII, but uniquely the 75 psig spheres were designed to the Division 1, 2015 Edition of the code while the 300 psig spheres were designed to the Division 2, 2015 Edition of the code. This difference in design code usage allowed for better design economics for the lower pressure, thinner wall spheres versus the higher pressure, thicker wall spheres.
In addition to the EPFC of the four (4) sphere structures themselves, also included in the scope of work were:
1) Design of the sphere foundations;
2) Design, supply and installation of a fire water system for each sphere;
3) The external coatings for each sphere (self-executed);
4) The fireproofing of the sphere columns to meet a 2 hour fire rating;
5) Hydro-testing with customer provided water. The fire water system provided for each sphere was a unique design that included for a top deluge installation to protect the top half of each sphere and a bottom spray ring system, consisting of multiple circular spray rings, to protect the bottom half of each sphere in the event of a fire. The fire water systems were designed in accordance with API 2510. The sphere plates all received a full field blast prior to the application of the exterior coatings. As an extensive dry field blast was discouraged by the Site Owner due to concerns of blast residue affecting the already congested site, the execution plan was uniquely adapted for water blasting. This adjustment went so successfully that it improved the project cost / schedule in addition to satisfying the Site Owner.
| Product / project title: | Butane Sphere Construction Project – (2) 69ft Diameter Butane Spheres |
| Product / project owner: | Buckeye Partners |
| Product / project location: | Freeport, Grand Bahama |
| Date completed: | February 2018 |
| Construction standard (if any): | ASME Section VIII, Div. 2 |
| Overall height / length (feet, inches): | 75’ -0” |
| Column height (feet, inches): | 40’ -6” |
| Diameter (feet, inches): | (2) 69’ -0” |
| Capacity (US gallons): | 2,520,000 (Total) |
| Steel tonnage used (US tons): | 672 (Total) |
| Steel thickness (inches): | 0.875” |
The project consisted of engineering, foundation design, procurement, fabrication and erection of (2) 69′-0 Diameter (30,000 BBL) Butane Spheres for a bulk liquids storage terminal in Freeport, Grand Bahama.
The spheres were designed to ASME Section VIII Div. 2 with a design pressure of 100 psi and maximum sustained wind speed of 160 mph. The design utilized SA738 Gr B material sourced from the United States. The spheres were fabricated in Houston TX, trucked to Ft. Lauderdale FL, then shipped to Grand Bahama Island.
A blend of experienced foreign supervisors and local Bahamian craft/laborers were mobilized to construct the spheres. Since the construction phase was during the entirety of the 2017 hurricane season, the main focus was to complete erection of the two spheres as quickly as possible without jeopardizing safety and quality of work. To minimize work at heights, the plates were welded on the ground in sub-assemblies. These assemblies were then lifted in place, fit up and welded out.
The NDE requirements consisted of 100% examination of the weld seams (4,300 ft) by performing radiographic testing during the night. The spheres were successfully hydro-tested at 143 psi. Certified ASME Inspectors witnessed the fabrication, erection and testing of the spheres and certified them upon completion.
Despite the very congested work area and hot environment, the project was completed with zero incidents which demonstrates the values and professionalism of the construction crew.
Additionally, the project logistics of sourcing and fabricating materials in the US Gulf Coast and shipping ocean freight for construction in a Caribbean location, attests to the flexibility of and economics for steel construction in remote offshore locations.
| Product / project title: | Two (2) Revolution Pipeline Spheres |
| Product / project owner: | Energy Transfer |
| Product / project location: | Houston, PA |
| Date completed: | April 2018 |
| Construction standard (if any): | ASME |
| Overall height / length (feet, inches): | 93’ -11” |
| Column height (feet, inches): | 46’ -11” |
| Diameter (feet, inches): | (2) 81’ -10” |
| Capacity (US gallons): | 4,200,000 (Total) |
| Steel tonnage used (US tons): | 1,919 (Total) |
| Steel thickness (inches): | 1.945” |
The owner required two (2) Propane Plus spheres to receive, store and load the product pipeline. Both spheres were designed to ASME Section VIII Div. 2; a capacity of 50,040 BBLs net working capacity each, which corresponds to 81′-10 in diameter; a 250 psig design pressure; and 15.0 psig design vacuum. The two spheres used over 1,900 tons of steel and incorporated plates that were just shy of two inches thick with the 1/16″ owner-specified corrosion allowance.
Due to the unusually high design pressure and large storage capacity, all pressure boundary welds required 100% examination per ASME Div. 2. Additionally due to the resultant thicknesses, the spheres required field Post Weld Heat Treatment (PWHT) by holding each sphere at 1,140 degrees F for two hours. Following field PWHT, the spheres were then successfully hydrostatically tested to 358 psig.
The scope of work beyond the Engineering, Procurement, Fabrication and Construction (EPFC) of the spheres additionally included the design, fabrication and installation of a top deluge / lower multi-ring spray fire protection system and the detailing, fabrication and placement of the double stringer stairway with top platform. Despite the challenging winter weather conditions of the northeast and a very aggressive owner driven schedule, mechanical completion which excluded paint and the hydrostatic test was achieved earlier than the original date. Field painting was then completed by others in the spring of 2018. Furthermore, the project was completed with zero incidents, recordable, or lost time injuries.
These two spheres employed an impressive 3,838,000 pounds of steel plate and required nearly 6,000 feet of field welding – demonstrating the capability and flexibility of steel to store products at very high pressures making steel – the material of choice!
Entry #7
TARSCO
Spring, TX
| Product / project title: | Baytown, TX ASME Sphere |
| Product / project owner: | Private |
| Product / project location: | Baytown, TX |
| Date completed: | October 2018 |
| Construction standard (if any): | ASME |
| Overall height / length (feet, inches): | 78’ -0” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | 72’ -0” |
| Capacity (US gallons): | 1,470,000 |
| Steel tonnage used (US tons): | 340 |
| Steel thickness (inches): | 1.06” |
To meet anticipated growth in the Ethylene to Butene-1 industry, the site owner of a Baytown, TX petro chemical facility wanted to store and supply Butene-1 from the co-located existing Ethylene facility. The site owner decided to build a process manufacturing plant which opened in 2018 to accomplish this objective. The $200 million facility provides co-monomer for polymer plant producing Polyethylene and converts petrochemical feedstock into the final olefin product, Butane-1, by dimerizing Ethylene.
Butene-1 is a colorless gas having an aromatic, gasoline odor and is slightly soluble in water. It is an important commercial chemical that is used in gasoline and rubber compounds and to make other chemicals. To store the Butene-1, the general contractor for the project hired an industrial construction company to build an ASME sphere to store the Butene-1 product. The project included the following activities:
(1) Sphere constructed to ASME standards
35,000 barrels of product capacity
Engineering
Procurement
Fabrication
Construction
Fireproofing
Exterior coating
Staircase
Top platform
The project began in July of 2017 and was ready for service by October 2018. The site owner has already secured long-term fee-based offtake agreements with multiple buyers that had committed to take nearly all of the nameplate 100,000 t/y Butene-1 capacity. The completion of this sphere provides much needed product storage to enable the owner to meet the demand for Butene-1.
liquid storage tank
| Product / project title: | 830 MG LIN Tank Project |
| Product / project owner: | Linde LLC. |
| Product / project location: | Hillsboro, OR |
| Date completed: | March 2018 |
| Construction standard (if any): | API 620 |
| Overall height / length (feet, inches): | 70’ -5” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | 61’ -0” |
| Capacity (US gallons): | 830,000 |
| Steel tonnage used (US tons): | 229 |
| Steel thickness (inches): | .315” (Max) |
This API 620 Appendix Q project included the engineering, fabrication and construction of an unusually large (830,000 gallon capacity) Liquefied Nitrogen (LIN) tank built in the upper Northwest for a well-known cyber companies’ use. The design of this double walled tank had to handle regionally high seismic and snow loads along with the -325 deg F cryogenic temperatures of the product being stored.
The inner tank, constructed of 201LN stainless steel to resist brittle fracture from the extremely cold product, was designed as 53′-0 diameter and included a 4′-6 freeboard above the overflow for the seismic sloshing wave. The inner tank was also designed for a 5 psig internal pressure. The outer tank was designed with A36 carbon steel with a 4′-0 annular space for both insulation and for constructability. Outer tank shell dimensions were 61′-0 diameter by approximately 62′ high. Both the inner and outer tanks have independent self-supported dome roofs constructed of the same steel material as the tank shells.
In addition to design and construction of the tank, the project scope included:
1) Detail engineering and installation of relief valves and annular piping,
2) Installation of the perlite insulation in the annulus between the two tanks,
3) Internal tank cleaning specific to liquid oxygen / liquid nitrogen service,
4) Hydro-pneumatic testing, and
5) Shop prime and field painting of the exterior of the outer tank (self-performed).
Nearly 230 tons of 201LN stainless and A36 carbon steel plate went into the fabrication and construction of this special API-620 structure during late 2017, with the tank going on line in early 2018. Erection of the twin shell(s) and roof(s) took place on an elevated pile cap foundation roughly 10 to 12 feet above the sloped grade and on a quite restrictive site, making it an even more challenging project when dealing with the winds and rain typical of this location. Despite the inclement weather and non-optimal, tight site conditions, the project was completed ahead of schedule and with zero incidents, recordable, or lost time injuries.
oil storage tank
| Product / project title: | Sasol World Scale Petrochemical Project Field Erected Tanks |
| Product / project owner: | Sasol |
| Product / project location: | Westlake, LA |
| Date completed: | November 2018 |
| Construction standard (if any): | API 650 |
| Overall height / length (feet, inches): | (41) Tanks up to 50’ -0” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | Up to 77’ -0” |
| Capacity (US gallons): | 22,000,000 |
| Steel tonnage used (US tons): | 4000 |
| Steel thickness (inches): | ¼” to 7/16” |
In 2015 Sasol Chemicals decided to triple their US production and build a world scale chemical complex adjacent to their existing plant in Lake Charles, LA. In addition to expanding and adding chemical production lines, they installed an ethane cracker that will produce 1.5 million tonne of ethylene annually. Overall the project is projected to cost $10 billion. For this we built Forty-One (41) Field Erected, Steel Welded Tanks.
With a project this size we built a wide range, size, and styles of tanks made out of different materials that were spread out over the 5 square mile plant. Included in our scope was tank design, fabrication, and erection, tank coatings, tank insulation, passivation, eductor and steam heater design and install, foundation installation, mechanical equipment installation, and aluminum internal floating roofs. Overall we used 7,000,000 pounds of Carbon Steel, 1,000,000 lbs of Stainless Steel, and built a combined storage of over 22,000,000 gallons.
For the Ethylene Glycol Tanks we built seven (7) carbon steel tanks with a total capacity of 2,500,000 gallons that required no tank internals and a heavy duty two coat, epoxy novolac coating system due to the chemicals stored inside the tanks. These tanks ranged in size from 52′ by 48′ to 25′ x 16′ and were all carbon steel and dome roof.
For the Chemical Storage Tank Terminal we built twenty-four (24) carbon steel tanks ranging in size from 77′ by 48′ to 23′ by 24′ with a total capacity of over 17,000,000 gallons. These tanks were a mix of self-supported dome roof, self- supported cone roof, and supported cone roof tanks. The majority of these tanks were insulated with polyisocyanurate and had two (2) coats of Epoxy Phenolic under the insulation. Uninsulated Tanks receive a three coat system of Zinc, Epoxy, and Polyurethane.
For the Ethylene Unit Tanks, we constructed ten (10) tanks stainless steel tanks ranging in size from 48′ by 50′ to 15′ by 26′ with a total capacity of 2,000,000 gallons. These tanks were all dome roof. Two (2) of the tanks had an exterior carbon steel shell roof and bottom for double containment.
One key component of the site was building these tanks while billions of dollars of other construction was also underway. To coordinate with other contractors we ended up building multiple tanks in an offsite laydown yard and using large equipment to move completed tanks across the site and then set in place. For the coatings we used a Wet Ring Blasting system that enabled us to reduce the issues on construction projects resulting from uncontained blasting, and it was a more efficient process than power tool cleaning.
| Product / project title: | Thermal Energy Storage Tank |
| Product / project owner: | National Institute of Health |
| Product / project location: | Bethesda, MC |
| Date completed: | August 2018 |
| Construction standard (if any): | API 650 |
| Overall height / length (feet, inches): | 100’ -3” |
| Column height (feet, inches): | 96’ -0” |
| Diameter (feet, inches): | 120’ -0” |
| Capacity (US gallons): | 7,755,000 |
| Steel tonnage used (US tons): | 694.4 |
| Steel thickness (inches): | 1.017” |
The tank height was limited by FAA restrictions due to the adjacent helipad at the Walter Reed National Military Medical Center, which provides medical care for the President of the United States. As such, the TES structure was constructed in a 33′-0 deep concrete pit. Internal to the tank are 84′-0 diameter internal radial plate diffusers to ensure stratification. Based on a maximum discharge/charge rate of 24,000 gpm, the tank provides a thermal capacity of 47,500 ton hours of cooling. Additionally the tank utilized a horizontal insulation system uniquely positioned to provide an architecturally pleasing finish, in conjunction with a stone wall and vegetation screen, to integrate the aesthetics of this tank into the overall campus. Uniquely at night, the tank is also illuminated with patterned lighting to highlight it’s beauty. The tank was executed as a subcontract to the General Contractor who was responsible for the 33 foot deep pit, the pump house and the associated mechanical equipment.
The welded steel tank met all of the challenges proposed by this site as well as provided additional benefits to the Campus including:
• A 100% leak tight storage tank to eliminate risk of any leakage to the adjacent campus buildings.
• Display of the flexibility of steel design and construction for site imposed space and height restrictions,
• Accommodations to not only blend in with but to highlight the tank’s aesthetic beauty,
• Provision of the lowest initial capital cost as well as the lowest maintenance & life cycle cost.
This tank promotes and demonstrates the flexibility and aesthetics of welded steel tanks to be built in constricted sites while dually serving back up cooling and assurance for years to come that the Campus can properly maintain its multi-decades of electronic research in the event of power outage.
| Product / project title: | P66 Phase II & III Crude Projects – (8) Tanks Total |
| Product / project owner: | P66 Gulf Coast Properties LLC |
| Product / project location: | Nederland, TX |
| Date completed: | December 2018 |
| Construction standard (if any): | API 650 |
| Overall height / length (feet, inches): | 52’ -0” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | 250’ -0” |
| Capacity (US gallons): | 140,626,000 (Total) |
| Steel tonnage used (US tons): | 10,850 (Total) |
| Steel thickness (inches): | 1.068” (Thickest) |
The Scope of Work for the Phase II (not pictured) & III (three tanks pictured in the foreground) Crude Project in Nederland, TX included the engineering, procurement, fabrication and construction (EPC) of over 2.8 million barrels of crude oil storage consisting of eight (8) 250′ DIA x 52’H External Pontoon Type Floating Roof tanks. These tanks were built in accordance with API 650 12th edition and applicable Customer specifications.
Included in this scope were:
1) Design and installation of foundations including cathodic protection;
2) EPC of the foam systems;
3) Hydro-testing with Customer provided water – which was re-used in moving from tank to tank, when able to accommodate by schedule, to conserve consumption; and
4) The internal and external coatings for all tanks (Self-Executed).
Both of these phases were challenging with extreme weather and aggressive Customer in-service dates. The project required close coordination with the Customer for adjacent on-site activities, and it was necessary to take advantage of overlapping work scopes to recover schedules impacted by Hurricanes Harvey and other extensive rain events. Weld quality was also a critical focal point to assist in the prevention of re-work that could impact the schedule. The weld percentage goal of 98% was exceeded on both phases, with a total of just over 4,750 radiography shots taken. At completion, both phases were finished safely and on or ahead of schedule, achieving the Customer’s original in-service dates for each of the eight tanks.
The Phase II and III tank project achieved over 100,000 man-hours executed without an incident, recordable, or Lost Time Incident (LTI). This contributed to the Customer’s successful completion of over 1,000,000 man-hours at this facility without a recordable or LTI, but also company-wide in 2018.
These safety milestones, an achievement of weld quality of over 98%, and the successful fabrication and erection of over 10,850 tons of steel on or ahead of the Customer’s in-service dates is a testament to the flexibility of steel design which will dually meet the Customer’s bulk storage needs for many years to come.
| Product / project title: | Fuel Oil Storage Tanks (2) |
| Product / project owner: | Duke Energy |
| Product / project location: | Trenton, OH |
| Date completed: | October 2018 |
| Construction standard (if any): | API 650 |
| Overall height / length (feet, inches): | 50’ -0” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | 92’ -0” |
| Capacity (US gallons): | 2,300,000 |
| Steel tonnage used (US tons): | 635 |
| Steel thickness (inches): | 5/8, 1/2, 3/8, 5/16 & 1/4” |
(2) 92′ diameter x 48′ shell height field erected carbon steel tanks. Supported cone roof with center column & rafters. Spiral stair assembly that led to a 10′ wide x 12′ long platform assembly at top tank perimeter. Weight 635,000 lbs. each. Capacity 2,300,000 gallons each. Designed and fabricated per API-650 for atmospheric pressure @ 120 Degrees F. with a 1/16″ corrosion allowance. Exterior of tanks painted with three coat epoxy system with a urethane top coat. Interior of tank coated with a three coat epoxy system.
1. Tanks were constructed to incorporate (2) foam box fire protection systems that mounted high through the tank shell and provided fire protection to the inside of the tanks.
2. Duel sump system installed.
3. Tank had (2) tank bottoms that sandwiched 1 1/4″ thick grating to allow for installation of (4) electronically monitored leak detection systems. The (4) leak detection systems were evenly spaced across the tank bottom. The electronic monitoring allowed the customer to watch the system from inside the building for the earliest possible moment should a problem occur.
Entry #5
FISHER TANK COMPANY
Leesville, SC
| Product / project title: | API 650 Double Wall Fuel Oil Storage Tank |
| Product / project owner: | PSEG |
| Product / project location: | Bridgeport, NJ |
| Date completed: | September 2018 |
| Construction standard (if any): | API 650 |
| Overall height / length (feet, inches): | 74’ -1 1/16” |
| Column height (feet, inches): | 56’ -0” Shell |
| Diameter (feet, inches): | 135/150’ -0” (Total) |
| Capacity (US gallons): | 5,728,300 |
| Steel tonnage used (US tons): | 912.75 |
| Steel thickness (inches): | 25” to .895” |
This 5,708,000 fuel oil tank serves a combined-cycle power plant on the East coast. The tank contractor provided fabrication of the tank double bottom, double shell and roof, as well as ladders, platforms, handrails and clean out doors. The tank contractor also provided interior and exterior shop priming for the tank shell and roof.
The tank was constructed in the middle of a congested, very busy power generation project, making tank erection especially challenging. The tank contractor developed a site-specific construction plan to address the unique challenges of the site. The tank team worked closely with the other contractors in the general area, who were actively building other structures, pouring concrete and digging and installing underground utilities. The tank contractor erected one ring of the dike tank and then one ring of the fuel oil tank, repeating that process as the rings went up so that there was no need to reach out over the fuel oil tank to build the dike tank. The 116 ton roof was erected inside the tank and lifted into place with a 750 ton DeMAG 3800 crane. Temporary structure needed to construct the huge 135′ diameter roof was removed once the roof was welded out and ready to be hung. The extensive exterior structure on the tank roof provides the support required by the roof design and the snow load requirements.
Entry #6
TARSCO
Spring, TX
| Product / project title: | Terminal Expansion – (6) API 650 Storage Tanks |
| Product / project owner: | Transmontaigne |
| Product / project location: | Collins, MS & Brownsville, TX |
| Date completed: | December 2018 |
| Construction standard (if any): | API 650 |
| Overall height / length (feet, inches): | 64’ -0” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | 100 – 180” |
| Capacity (US gallons): | 49,560,000 |
| Steel tonnage used (US tons): | 3,954 |
| Steel thickness (inches): | 68” to 1.07” |
Two terminal locations owned by the same company experienced significant demand for additional bulk storage (Collins, MS and Brownsville, TX). This need prompted the site owner to expand the bulk storage in both terminals. Both terminals provide terminalling, storage, transportation, and related services for refined products (gasoline, diesel, jet fuel).
The Collins, MS terminal is strategic and desirable given its dual connectivity to two U.S. major pipelines and is the last injection point on the two pipelines to up-load product at full line rates to U.S. locations. To facilitate transportation of more products, increased storage capacity was needed.
The terminal expansion was planned to roll out in two phases with Phase I completed and put into service in 2017. The expansion plan for Phase IIA increased that capacity by an additional 2 to 5 million barrels of product storage. As a component of Phase IIA, a tank construction company was contracted by the site owner to build three new 650 tanks that would store 870,000 barrels of refined petroleum (gasoline, diesel, jet fuel) for a major oil company. Phase IIA improvements have resulted in significant increased flexibility for the owner’s customers. The improvements resulted in significant increased flexibility for the Collins Terminal’s customers including the simultaneous receipt and delivery of gasoline.
The Brownsville, TX terminal operates a refined product terminal with approximately 0.9 million barrels of aggregate active storage capacity. It processes refined petroleum products, chemicals, vegetable oils, naphtha, wax and propane on behalf of and provides integrated terminalling services to customers engaged in the distribution and marketing of refined products and natural gas liquids.
The Brownsville, TX location needed to expand its storage capacity of gasoline, diesel and additives for further transportation by truck and the Diamondback Pipeline to the U.S./Mexico border. To increase its capacity, the site owner secured agreements with third parties for the construction of new facilities in Brownsville for the storage of these products. They hired the same full service tank construction company to build three new 650 tanks having a storage capacity 310,000 barrels.
Entry #7
TARSCO
Spring, TX
| Product / project title: | Pasadena Terminal Expansion – (10) Tanks Total |
| Product / project owner: | MVP Terminalling |
| Product / project location: | Pasadena, TX |
| Date completed: | September 2018 |
| Construction standard (if any): | API 650 |
| Overall height / length (feet, inches): | 60’ -0” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | 139’ -0” |
| Capacity (US gallons): | 970,000 BBL |
| Steel tonnage used (US tons): | 3,150 |
| Steel thickness (inches): | 0.89” |
The demand for refined products from the Gulf Coast continues to grow. To meet this increasing demand, the site owner partnered with another energy company to expand and own a new marine storage terminal along the Houston Ship Channel. The $820 million Pasadena, TX terminal mostly will store and handle fuel products like gasoline, diesel, jet fuel, and more. The site would eventually connect to nearby refineries in Houston and Texas City with outbound capacity on existing pipelines. The expansion initially included 5 million barrels of storage, truck-loading facilities, and two ship docks.
In Phase Two of this project the site owners needed to construct 10 welded steel tanks with total capacity of 1 million barrels of storage and a dock capable of handling a Panamax-size vessel. The owners needed the 10 tanks completed and ready for service by early 2019.
The construction activities were carried out to meet permit requirements and environmental regulations. The contractor provided the engineering, procurement, fabrication, construction, and coating of all tanks in a lump sum contract. The steel plate was processed in house and included burning, beveling, rolling, and priming before being shipped to the project site.
■ Tank specifications: API 650
■ Total capacity: 970,000 bbls
■ Total tonnage: 3,150 tons of steel, maximum of 0.89” thick
■ Roofs: Geodesic and cone roofs with steel internal floating roofs
■ Size: (5) 139’x60Ø geodesic roof tanks
Capacity barrels: 162,163 barrels
■ Size: (1) 98’x60Ø cone roof tank
Capacity barrels: 80,607 barrels
■ Size: (1) 85’x60Ø cone roof tank
Capacity 60,640 barrels
■ Size: (3) 44’X40Ø cone roof tanks
Capacity: 10,833 barrels
Strict adherence to the schedule was important in order to meet the in-service deadline. With many other contractors on the terminal site at the same time this project was underway, there was always a concern for the safety of all personnel. The project began in February 2018 and was completed in September 2018. All progress objectives were met, and there were no safety recordables during the entire project.
tank
| Product / project title: | 750,000 Gallon Waterspheroid / Holstein Pattern Storage Tank |
| Product / project owner: | Newton County Regional Water & Sewer District |
| Product / project location: | Morocco, IN |
| Date completed: | August 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 132’ -0” |
| Column height (feet, inches): | 86’ -6” |
| Diameter (feet, inches): | 64’ -8” |
| Capacity (US gallons): | 750,000 |
| Steel tonnage used (US tons): | 198 |
| Steel thickness (inches): | 1.25” (Max) |
In conjunction with Fair Oaks Farms, Newton County Regional Water wanted to create an iconic landmark for their many visitors to this working farm featuring birthing barns, milking parlor, pig arena, crop production adventure and on-site restaurants, shops and hotel. Tourists and bus loads of school children come for an exciting and learning experience in a country setting.
The “Holstein” cow pattern on the tank greeting the visitors as they arrive is a prelude to what they will see on their ensuing tours. The Holstein breed is known for its excellent production of quality milk.
This 750,000 gallon single pedestal spheroid style tank with a 126′-0 top capacity line and 40′-0 head range provides excellent water pressure for the needs of the farm campus, restaurant, hotel and nearby treatment plant. Additionally, the bottom bell of the tank houses an insulated and heated area for the telemetry controls and valves to maintain the clean aesthetics of the park like setting.
All finish coating was completed in a high quality, long lasting fluoropolymer polyurethane finish which should continue to enhance the appearance of this “udderly” attractive landmark for many years to come.
| Product / project title: | 750,000 Gallon Single Pedestal Elevated Tank/ Contract #1- Phase V |
| Product / project owner: | West Carteret Water Corporation |
| Product / project location: | Carteret County/ Newport, NC |
| Date completed: | March 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 182’ -3” |
| Column height (feet, inches): | 120’ -10 3/8” |
| Diameter (feet, inches): | 64’ -8” |
| Capacity (US gallons): | 750,000 |
| Steel tonnage used (US tons): | 254 |
| Steel thickness (inches): | 1.1875” to .25” |
This project was bid in August of 2016 and a Notice to Proceed issued in September of 2016. The Owner and General Manager already had an “all steel” multi- leg elevated tank and an “all steel” fluted column elevated tank all in her existing water system. She had studied but did not like the looks or appearance of the Composite style tank and did not want one in her system. She excluded the Composite style tank from consideration. She did include an “all steel” single pedestal elevated tank for further consideration.
The project was funded by USDA. It was bid with the three alternate and competitive “all steel” styles of elevated tanks. The owner selected the single pedestal elevated tank based on price and overall appearance for the planned location. She paid a slight premium for the single pedestal tank but reasoned it was a better tank based on long term maintenance cost associated with less painted surface area and the tank location being in a harsh coastal environment with strong ultra violet light from the sun, high heat, high humidity and the salty atmosphere from the coastal shores and winds.
The tank was built on a small, tight site and the single pedestal base had the advantage of the smallest foundation foot print of the three styles of tanks. All the tank foundations included driven deep pile foundations into the deep coastal sands. After award, the owner elected to eliminate the outside valve vault and piping and move all the piping inside the base of the tank above grade on a concrete slab. This move eliminated the exterior maintenance issues associated with the exterior vault.
Being located on the coast of North Carolina , the tank was designed to resist hurricane force winds. Shortly after being put in service, Hurricane Florence hit North Carolina in September of 2018 with full force hurricane winds and torrential rain fall. Land fall was made just south of Newport with damaging winds of over 140 mph, extensive flying debris thru out the area and major coastal flooding. The tank weathered the storm as designed and is now getting a new and fresh coat of exterior paint.
It is truly a great looking elevated tank and a testament to the strength and durability of “all steel ” elevated tank designed to weather strong hurricane force winds and extreme coastal conditions and will be providing many years of service to the owner and citizens of the community for years to come.
| Product / project title: | 1.5 Million Gallon Elevated Tank / Madera Valley Water Tank |
| Product / project owner: | Madera Valley Water |
| Product / project location: | Madera, CA |
| Date completed: | December 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 157’ -2” |
| Column height (feet, inches): | 104’ -0” |
| Diameter (feet, inches): | 90’ -0” |
| Capacity (US gallons): | 1,500,000 |
| Steel tonnage used (US tons): | 461.8 |
| Steel thickness (inches): | 2.3125″ (Max) |
Madera Valley Water first began serving approximately only 75 households in 1977, but has grown over the last forty years to serve over 1,900. With the significant growth of their system and realization that continuous pumping to provide pressure to its customers was not a viable solution, they began planning for their first elevated water storage tank more than a decade ago.
In viewing elevated tanks of adjacent communities, Madera Valley Water Company was attracted to the clean vertical architectural lines of the “all-steel”, single-pedestal fluted-column type structure. Additionally, the larger diameter base of this tank style lends itself to a more economical design for the higher seismic conditions of California.
The water company resolved to add a 1,500,000 gallon capacity tank, 144′-0 to the top capacity line with a 40′-0 head range to serve their current and future water capacity and pressure demands. More importantly based on Madera Valley’s conservative estimate for constructing an elevated tank over continuous pumping, they are anticipating to realize $2.41 million dollars in maintenance and operations savings in their system over the next twenty years in addition to lessening the impact of rising energy costs by filling the tank off peak of electricity demand. Furthermore, the new elevated tank would much improve the reliability for fire flow in the system.
In addition to the engineering, fabrication and construction of the all-steel, fluted column style elevated tank, the scope of work included design and construction of a spread footer foundation with ground improvement as a more economical alternative to a deep pile foundation; shop priming and field paint of the structure; design and installation of a zero operating cost in-tank mixing system to reduce microbial growth and related tastes and odors; and installation of electrical lighting. Madera Valley additionally elected to showcase their water company name on the side of the tank with their city logo as the tank sits at the base of the Sierra Mountains.
This tank promotes and demonstrates the flexibility and aesthetics of welded steel tanks in high seismic regions while dually reducing operations and maintenance costs as well as improved fire flow while serving Madera Valley – likely longer than its forty-plus years that the water company has been in existence.
| Product / project title: | 750,000 Gallon Waterspheroid / Marion Road Water Tower |
| Product / project owner: | City of Oshkosh |
| Product / project location: | Oshkosh, WI |
| Date completed: | August 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 172’ -0” |
| Column height (feet, inches): | 125’ -0” |
| Diameter (feet, inches): | 64.5’ -8” |
| Capacity (US gallons): | 750,000 |
| Steel tonnage used (US tons): | 242 |
| Steel thickness (inches): | 1.25″ (Max) |
This two-tone, 750,000 Gallon all-steel single pedestal elevated tank replaces an all-steel 750,000 Gallon multi-leg elevated tank that had been serving the city since 1936. It is located downtown just north of the river and not far from where the original OshKosh B’gosh Clothing Brand was founded.
The 165′-0 top capacity line tank is supported on a ringbeam foundation on 36 concrete filled steel pipe piles. The bottom bell of the tank houses a large 11′ x 20′ x 9′ deep vault that contains bypass valving and telemetry controls. And, all the telecommunication antennas on the roof are uniquely concealed by a 32′ diameter by 10′ high screen for an aesthetically pleasing view.
In addition to the selection of a more modern smooth curved single pedestal style tank, the City of Oshkosh also chose to prominently highlight their city logo on two sides of the tank. The tank was then finish coated with a high quality, long lasting fluoropolymer polyurethane to ensure the appearance of this downtown iconic tank will be distinctly on display for many, many years.
The eighty-plus year old multi-legged tank, which reached its useful life, was unfortunately removed from the downtown skyline as part of the project scope. But, this all-steel structure stood the test of time, and the new tank – without all the lattice-braced structural columns, cross bracing and exterior balcony of the multi-legged tank as well as with the improvements in coating technology – will be much more economical to maintain over the next eighty-plus years this tank will serve the community.
| Product / project title: | Purposed Bathhouse and Water Tank |
| Product / project owner: | Warrior Met Coal |
| Product / project location: | Brookwood, AL |
| Date completed: | March 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 203’ -0” |
| Column height (feet, inches): | 170’ -0” |
| Diameter (feet, inches): | 32’ -0” |
| Capacity (US gallons): | 150,000 |
| Steel tonnage used (US tons): | 150 |
| Steel thickness (inches): | 1/4” to 7/16” |
When the Warrior Met Coal Company decided they needed an elevated water storage tank to support a new 10,000 foot deep coal mine with potable water for 400 miners and fire protection water to be COMPLETE IN 90 DAYS, they knew just who to call – steel plate fabricators! To add to the extreme schedule challenge, the site required the utilization of ground improvement technologies to make the foundation suitable for the loads imparted by an elevated water storage tank that is OVER 200 FEET in total height. The underlying geotechnical conditions, the foundation system and the height of the tank make this project extraordinary.
To add the extreme challenge of reducing what is a typical schedule of about a year to just three months, timely meeting all compliance regulations of the Mine Safety and Health Administration’s strict requirements, made this project truly remarkable. The outstanding responsiveness and skill of steel suppliers, safety personnel, designers and of course fabrication, construction and coatings personnel, together made this fastest track project a wonderful success in support of home-grown energy supply.
| Product / project title: | Elevated Water Storage Tank Four Seasons at Kent Island |
| Product / project owner: | K. Hovnanian Homes |
| Product / project location: | Kent Island, MD |
| Date completed: | September 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 130’ -3” |
| Column height (feet, inches): | 93’ -9” |
| Diameter (feet, inches): | 55’ -6” |
| Capacity (US gallons): | 500,000 |
| Steel tonnage used (US tons): | 156 |
| Steel thickness (inches): | 1/4” to 1 3/16” |
Originally planned nearly twenty years ago, but moving forward when the economic conditions were just right, this very high profile Pedesphere-style tank soars prominently above Kent Island in the middle of Chesapeake Bay. There were many discussions on what the height of this tank was going to be to accommodate the water pressure required for the new housing development that was going to be constructed.
This 500,000 gallon single pedestal tank is visible from the extremely heavily traveled Chesapeake Bay Bridge and serves the new housing development on the north side of the Island. The tank logos prominently feature the Maryland crab, highlighting the area’s world renown claim to fame, and the Kent Island logo, displaying the four seasons of Kent Island. The tank consists of over 156 tons of steel and nearly 26,500 square feet of painted steel surface. It also included a hydrodynamic mixing system to improve the water quality and a cathodic protection system to help control corrosion of the submerged surfaces inside the tank. With the high end coating system and use of cathodic protection, this tank will be a predominate steel structure on the island for years to come.
tank
| Product / project title: | Jamestown Reservoir Replacement Project |
| Product / project owner: | Tuolumne Utilities District |
| Product / project location: | Jamestown, CA |
| Date completed: | November 2018 |
| Construction standard (if any): | AWWA Section 14 |
| Overall height / length (feet, inches): | 32’ -2” |
| Column height (feet, inches): | 28” -7” |
| Diameter (feet, inches): | 75’ – 0” |
| Capacity (US gallons): | 1,000,000 |
| Steel tonnage used (US tons): | 139 |
| Steel thickness (inches): | .250” |
Project consisted of design, procurement, fabrication and erection of a new welded steel tank with foundation and coatings. Previously the district had many issues with the faying surfaces in the vapor space of their tanks so they had extreme concern with mitigating future corrosion. Therefore the bid required a competent contractor which could successfully design a reservoir to prevent the future corrosion with an innovative design.
The district had previously seen the benefits of utilizing our design on steel tank roofs because they replaced a roof with an external press brake system the previous year and have been nothing but satisfied with its results. If it wasn’t for steel’s unique characteristics and ability to be shaped / formed this roofing system would not be possible.
| Product / project title: | Robin Hood Lakes Water Tank Project |
| Product / project owner: | Aqua Pennsylvania, Inc |
| Product / project location: | Polk Twp, PA |
| Date completed: | October 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 10’ -6” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | 24’ -0” |
| Capacity (US gallons): | 35,000 |
| Steel tonnage used (US tons): | 14 |
| Steel thickness (inches): | 1/4” |
Just as Robin Hood stood and worked for the little man, this mighty little tank stands and works in the green hillsides above the small eastern Pennsylvania community of Robin Hood Lakes. Upgrading from a pumped system with no storage capacity, this new 35,000 gallon steel reservoir tank provides much needed water reliability for the neighborhood down in the valley. With a high water level of only 10′ 6″ and a tank diameter of only 24′, this tank is small, yet mightily important in its service.
Situated on a blind curve off a windy switch back of Scenic Drive / Route 534 in Eastern Pennsylvania, and down a steep hill, the ingenuity of construction, safety and trucking personnel were put to the test. There was no good road to the site, and maneuvering tractor trailers and construction equipment in and out of steep wooded zigzag curves by tank and painting crews, demonstrated the can-do abilities of field personnel for all aspects of this tank project – foundation and tank construction, and painting.
The fun part of the work was hearing the comments of field crews, that they “felt like giants” being able to see the top detail of the tank up close, as they are so used to constructing much larger and taller reservoirs. Well, they are gigantically important to the community of Robin Hood Lakes and their efforts stand tall for the people in need.
Entry #3
PASO ROBLES TANK
Hemet, CA
| Product / project title: | Flat Top Tank Replacement Project |
| Product / project owner: | Virgin Valley Water District |
| Product / project location: | Mesquite, NV |
| Date completed: | May 2018 |
| Construction standard (if any): | AWWA Section 14 |
| Overall height / length (feet, inches): | 40’ -0” |
| Column height (feet, inches): | 37’ -0” |
| Diameter (feet, inches): | 93’ -0” |
| Capacity (US gallons): | 2,000,000 |
| Steel tonnage used (US tons): | 175 |
| Steel thickness (inches): | .250” |
Project consisted of replacing an existing leaking (non-welded) water tank on Flat Top Drive with a new 2 MG welded steel tank. Scope of work included demolition of existing tank, design, erection & coatings of new welded steel tank with appurtenances, site work, fence installation, drainage, and grading. Because the tank they were replacing was less than 15 years old, the district would only accept a welded steel tank which they know will last them for generations to come. The customer wanted to make sure that they could maximize time in between coatings cycles due to the important nature of this tank so they specifically called out for 100% seal welding of all interior lap joints as well as structure to roof plate interfaces. This increases the time in between coatings cycles by 20%-30%.
Entry #4
PASO ROBLES TANK
Hemet, CA
| Product / project title: | Blue Heron Circle Reservoirs Project |
| Product / project owner: | City of Anacortes |
| Product / project location: | Anacortes, WA |
| Date completed: | October 2018 |
| Construction standard (if any): | AWWA Section 14 |
| Overall height / length (feet, inches): | 48’ -0” |
| Column height (feet, inches): | 46’ -0” |
| Diameter (feet, inches): | 80’ -0” |
| Capacity (US gallons): | 3,000,000 |
| Steel tonnage used (US tons): | 344 |
| Steel thickness (inches): | .250” to .5” |
The primary scope of work on this project was to replace an older storage tank with two new reservoirs at half the original capacity each for future maintenance cycles. The previous reservoir was still in serviceable condition but the customer wanted to install two new internal roofs with metal formed by press brakes and which are fully seal welded in order to extend the life of their assets by eliminating all inaccessible areas.
tank
| Product / project title: | Collinsville, IL Water Treatment Plant – (8) Tanks |
| Product / project owner: | City of Collinsville |
| Product / project location: | Collinsville, IL |
| Date completed: | December 2018 |
| Construction standard (if any): | AWWA |
| Overall height / length (feet, inches): | 30’ -2” |
| Column height (feet, inches): | 29’ -2” |
| Diameter (feet, inches): | (2) 47’ -0” (Cones) |
| Capacity (US gallons): | 140,763 (Cones Only) |
| Steel tonnage used (US tons): | 158 (Total of all (8) Tanks) |
| Steel thickness (inches): | 0.25” |
In 2016 the City of Collinsville began the process of replacing their 50 year old water treatment plant. The new plant, situated across the street from the existing plant, will be an updated plant designed to treat 5 million Gallons of Water per Day (MGD).
The main process unit in the new plant is the ClariCone, a Solids Contact Clarifier with no moving parts. The ClariCone is a hydraulically driven unit that softens and cleans the water prior to distribution to the Customer. Invented in 1980, there are over 300 ClariCones in operation throughout the United States treating over 600 MGD of water.
The entire water treatment process, including the process tanks, is located within a building. The scope of work for the process tanks included the engineering, fabrication and construction of the following:
1) One (1) 5′-0 bottom Dia X 10′-0 top Dia X 43′-0 H with 2′-6 transitional cone field erected Head Tank and Aerator (Not visible in the picture)
2) Two (2) 9′-6 bottom Dia X 47′-0 top Dia X 30-2 H with 19′-2 transitional cone field erected ClariCones (One pictured in the foreground with the second partially visible in the rear)
3) One (1) 13′-0 bottom Dia X 3′-6 top Dia X 30′-2 H HeliCarb Unit (pictured on the right side)
4) Four (4) 21′-0 bottom Dia X 16′-6 top Dia X 15′-6 H with 12′-6 transitional cone field erected Decelerating-Flo Filters (Not visible in the picture)
Construction of the field erected tanks was completed in September of 2017. Upon completion of the field erection of the tanks, a General Contractor performed finish painting of the shop primed tanks and enclosed the tanks within a building. Process piping and the instruments & controls were installed in time for a December 2018 project completion. Plant personnel expect to complete the switchover from the existing plant to the new facility this Spring and decommission the 50 year old existing water plant.
The uniqueness in the engineered configurations of the above process tanks is a testament to the flexibility of steel design and construction which should serve the City of Collinsville with proper maintenance for longer than the half century fulfilled by their existing plant.
| Product / project title: | JMWSA Lexington County Standpipe |
| Product / project owner: | Joint Municipal Water and Sewer Commission, Lexington County, SC |
| Product / project location: | Lexington, SC |
| Date completed: | October 2018 |
| Construction standard (if any): | AWWA D100, Section 14 |
| Overall height / length (feet, inches): | 82’ -8 15/16” |
| Column height (feet, inches): | 72’ -0” (Shell) |
| Diameter (feet, inches): | 69’ -0” |
| Capacity (US gallons): | 2,013,900 |
| Steel tonnage used (US tons): | 193.96 |
| Steel thickness (inches): | .25” to .56” |
This welded steel knuckle umbrella roof standpipe became an instant icon occupying a well traveled corner in the county it serves. The tank holds just over two million gallons of water for a water and sewer commission that serves a rapidly growing area.
The tank contractor provided the tank foundation design and installation, as well as tank design, fabrication and construction. The tank contractor also provided tank painting, including the beautiful execution of the commission’s logo. An interior circulation system keeps the water moving inside the tank, prohibiting stagnation.
Entry #1
T BAILEY, INC.
Anacortes, WA
| Product / project title: | Log Cabin Road Reservoir |
| Product / project owner: | City of Olympia |
| Product / project location: | Olympia, WA |
| Date completed: | November 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 156’ -0” |
| Column height (feet, inches): | 144’ -0” |
| Diameter (feet, inches): | 80’ -0” |
| Capacity (US gallons): | 5,200,000 |
| Steel tonnage used (US tons): | 660 |
| Steel thickness (inches): | 1/4” to 1 3/8” |
Construction of a 5.2 million gallon Standpipe 80′ diameter x 144′ shell height per AWWA D100 Section 14 Standard including an inverted “T” concrete foundation. Foundation included over 155 tons of reinforcing steel along with eighty-five (85) 4″ diameter x 9′-6″ anchor bolts and 1,750 cubic yards of high strength concrete. Lower shell course vertical seams were welded with the electroslag process averaging less than 6 hours elapse time per joint providing a 100% full penetration weld. A double head 3 o’clock welding fixture was utilized with the submerged arc process simultaneously welding both sides of the joint achieving full penetration horizontal joints. The standpipe included a self-supported, fully seal welded, carbon steel knuckle/dome roof which was assembled/welded on the ground and set as one piece weighing over 20 tons. The project included complete site preparation, nearly a mile of improved road access, pump house, electrical, standby generator, and connection the City’s main waterline. Standpipe accessories included spiral stairway and full perimeter roof handrail along with an array of nozzles and other miscellaneous standpipe accessories.
| Product / project title: | Treasure Lake Water Storage Tank Project |
| Product / project owner: | Aqua Pennsylvania, Inc. |
| Product / project location: | Sandy Twp., PA |
| Date completed: | December 2018 |
| Construction standard (if any): | AWWA D100 |
| Overall height / length (feet, inches): | 57’ -0” |
| Column height (feet, inches): | – |
| Diameter (feet, inches): | 40’ -0” |
| Capacity (US gallons): | 520,000 |
| Steel tonnage used (US tons): | 60 |
| Steel thickness (inches): | 5/16” |
With the need to improve drinking water quality and service reliability throughout its water and wastewater operations, Aqua Pennsylvania, Inc. called on steel construction experts to build a new 520,000 gallon, 40’-0” diameter standpipe tank in the beautiful Treasure Lake community in Dubois, Pennsylvania. Situated high in the Allegheny Mountains and just adjacent to an existing 500,000 gallons steel Standpipe, the new Standpipe doubles the water capacity for this growing community, increases water reliability. Over 60 feet tall, and utilizing over 50 tons of steel, this new tank construction provides system flexibility to prevent service interruption to this 9,000 acre community.
Constructed with a unique combination of active and a passive vertical internal mixing system, the tank mixing performance was verified with real-time performance testing, ensuring proper water turnover and high-quality water for the system’s customers. This tank was also provided with a 100% solids coating system on its interior to eliminate the volatile organic compounds, and topped with a roof handrail to provide safe access to tank top performance monitoring components.
The existing steel 500,000 gallon standpipe (inset photo) is retrofitted with the same active and passive mixing configuration of the new standpipe, and a new roof handrail, emphasizing the inherent flexibility that a steel structure exhibits, with its ability to be easily modified as performance enhancements and Owner requirements develop over time.
Entry #4
FISHER TANK COMPANY
Leesville, SC
| Product / project title: | Jackson Township Standpipe |
| Product / project owner: | Jackson Township, NJ |
| Product / project location: | Jackson Township, NJ |
| Date completed: | August 2018 |
| Construction standard (if any): | AWWA D100, Section 14 |
| Overall height / length (feet, inches): | 134’ -1/8” |
| Column height (feet, inches): | 125’ -11” (Shell) |
| Diameter (feet, inches): | 52’ -0” |
| Capacity (US gallons): | 2,000,300 |
| Steel tonnage used (US tons): | 276.22 |
| Steel thickness (inches): | .25” to .875” |
This 125′ -11” tall knuckle umbrella roof standpipe holds over two million gallons of water for a New Jersey township. The huge standpipe required an equally impressive slab foundation. The tight site was also very challenging. On one side of the tank was a busy road leading to a school; on the other side was another storage tank.
The tank contractor provided foundation design and installation (with a subcontractor). The foundation design was a key issue. The tank contractor worked with the customer to develop an alternative foundation design that would work for the site and would support the tank. The tank contractor designed a unique reinforcement system with rebar in a radial spoke design. This eliminated the complex web of rebar in the center of the foundation indicated in the original design. The radial spoke design permitted the concrete with aggregate to flow evenly throughout the rebar system.
The tank contractor provide fabrication of the tank shell and knuckle roof, and tank erection in the very close quarters of the project site. The location of the tank and proximity to a school and other highly populated areas dictated full containment for blasting and painting the tank. The final design includes a prominent logo and the completed tank serves as an impressive community ambassador.
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