Floating Roof Work Safety

2006 Storage Tank Conference and Safe Entry Workshop

Presented by Mark Baker

Types of Floating Roofs

Pan Roof

Internal Steel Pan Roof

Types of Floating Roofs

Steel Annular Pontoon

Internal Steel Pontoon Roof

Types of Floating Roofs

Internal Steel Annular Open Pontoon

Types of Floating Roofs

Steel Double Deck Floating Roof

Internal Double Deck Roof

Types of Floating Roofs

Internal Aluminum Skin and Pontoon Floating Deck

Types of Floating Roofs

Internal Aluminum Full Contact Floating Deck

Types of Floating Roofs

There are many other types

Floating Roof Work Safety

o Incidents have occurred working under floating roofs o People who work around floating roofs need to be aware of proper safety procedures

API RP 2016
Guidelines and Procedure for Entering and Cleaning Petroleum Storage Tanks

First Edition, August 2001

API RP 2016
o Covers potential hazards associated with internal and external floating roofs o Potential failure mechanisms o Highly divergent risks o Procedures to prevent or mitigate roof collapse o Procedures for inspecting floating roofs

Applicability
o Flat bottom, vertical cylindrical storage tanks with internal or external floating roofs
n Built to API Std. 650 or API 12 C n Repaired to API Std. 653

Applicability
o All types of:
n Aluminum n Steel pan n Steel annular pontoon n Double deck n High center deck roofs

Floating Roof Stability

o Support
n Adequately attached to the floating roof n Pins capable of carrying roof weight n Legs should be:
o Straight o Free from severe corrosion o Pinned properly

n Roof in reasonable condition

Floating Roof Stability

o Lateral Movement
n Small lateral movements increase risks n Typical rim gap is 6 to 12 inches n Lateral movement restrained by:
o Certain types of seals o Wedges o Bracing

Floating Roof Stability

o Rotation
n Roof must be stabilized against rotation n Rotational stability may be provided by:
o Sampling well pipe (typically 6 10 inch) o Anti-rotation cable (aluminum decks) o Other devices

Floating Roof Stability

o Legs
n Typically 3 to 4 inch diameter pipes n Some have holes drilled in the pipe for setting the height n Roof design can impact leg stability

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Floating Roof Stability

o Pan or single deck

Floating Roof Stability

o Pan or single deck

Note: Deck is weak in bending and allows easy lateral deflection of the support leg.

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Floating Roof Stability

o Double deck or Annular Pontoon

Note: To deflect a leg in this section requires actual failure of the support leg by bending.

Floating Roof Stability

o Other IFR Decks
n Aluminum n Composite

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Roof Failure and Collapse

o Excessive Loading
n External Floating Roofs - 25 lb/ft2 n Internal Floating Roofs 12.5 lb/ft2 n IFR with roof drains 5 lb/ft2

o The roof at weakest state when on legs

Roof Failure and Collapse

o Excessive Loading
n Liquid in Pontoons
o Product o Water

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Roof Failure and Collapse

o Excessive Loading
n Leg Pinning
o Not Pinned o Not Uniformly Pinned

Roof Failure and Collapse

o Stability
n Dependant upon vertical support n Rotational resistance
o Seals o Anti-rotation device

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Roof Failure and Collapse

Roof weight is directed vertically down the roof leg

Roof Failure and Collapse

Roof weight is directed down the roof leg and a horizontal component of force is generated

The magnitude of the horizontal force is dependant upon the weight of the roof and the angle of the leg

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Roof Failure and Collapse

o Stability
n Anti-rotation device
o Corrosion o Weld Failure o Missing

n Work on top of the roof

o May add excessive weight o May add excessive movement

Roof Failure and Collapse

o Stability
n Roof Seals o Wiper Seals o Foam Log o Mechanical Shoe Seals

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Inspections
o Above the roof Inspections
n At the top of the tank n Without entry into the confined space

Inspections
o Inspect:
n Water or Product on the Roof n Floating Roof Legs
o Check for vertical alignment o All pinned properly

n Anti-Rotation System
o Verify working anti-rotation device o Check floating roof fitting for damage

n Rim Seals
o Check seal condition

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Inspections
o Below the roof Inspections
n From outside the tank n Without entry into the confined space

Inspections
o Inspect:
n Floating Roof Legs
o Misalignment o Buckling o Corrosion

n Anti-Rotation System n Rim Seals

o Check primary seal o Check for wiper seals

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Before Cleaning Tanks

o Minimize Exposure - Atmosphere is Hazardous o Condition of the roof is often unknown o Install a temporary roof support

After Cleaning Tanks

o Inspect Leg Condition
n UT, Hammer

o Cribbing
n Ensures that the entry manhole will remain clear and open during a roof collapse n Serves as a guide to the exit n Protects personnel inside the tank within ~30 ft radius of the manhole

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After Cleaning Tanks

o Cribbing
(Baker Comments)

n The strength of wood timbers is dependant upon type of wood and its condition n Compressive strength ranges from 200 PSI to 1,000 PSI. n Engineer should design a cribbing stack

After Cleaning Tanks

o Lateral Movement Backup
n Wedges n Radial steel beams
o Extending to within 1 inch of the shell o Used only on clean and gas freed tanks

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After Cleaning Tanks

o Anti-Rotation Backup
n Required unless a guide pole is present, the seal is a shoe seal and in good condition n Wooden wedges 4 places n Other systems may be required

Cable Suspended Roofs

o Not specifically covered in API RP 2016 o Principles can be applied

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Cable Suspended Roofs

o Risks Reduced for
n Lateral Movement n Rotation

o Other Concerns which should be checked:

Cable Suspended Roofs

o Condition of the cable o Condition of fixed roof node

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Cable Suspended Roofs

o Excessive Loading of the Fixed Roof
n High external loads may reduce load carrying ability of the roof

o Excessive loading of the floating roof

n Trapped product n Water on the roof

o Damage or deterioration of the Roof Structure

Other Standards
o API Publication 2026, Safe Access/Egress Involving Floating Roofs of Storage Tanks in Petroleum Service o Confined Space Entry 29 CFR1910.146

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Conclusions
o The risk of incidents can be minimized implementing API RP 2016 o The likelihood of a failure is not the same for all roof designs o Backup protection schemes should be reviewed to determine applicability

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