Click here to see all the 2017 awards entries
Product / project title:
Product / project owner:
Product / project location:
Construction standard (if any):
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Column height (feet, inches):
Diameter (feet, inches):
Capacity (US gallons):
Steel tonnage used (US tons):
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Spheres Project - Powder Springs Logistics, LLC
Powder Springs, GA
PRODUCT/PROJECT DESCRIPTION AND SPECIAL FEATURES:
Butane is commonly added to gasoline to increase its volume through a process called oxygenation. The region’s climate, where butane is stored and oxygenated, determines when this process can best be completed with the least amount of vapor created. Adjusting gasoline vapor pressure for a regional climate can enhance the profitability of a terminal and pipeline operation.
The site owner wanted to construct two large spheres so they could receive and store butane year round and then inject it into gasoline during the winter months when vapors would be at their lowest.
The contractor provided an Engineering, Procurement, Fabrication, and Construction package to the following specifications and scope.
Size: (2) Butane ASME pressure vessels (spheres 90’ diameter each – 100 psi)
Specifications: ASME Section VIII Division 2, NFPA 58, and API 2510
Capacity barrels: 68,000 barrels each / 136,000 total
Capacity gallons: 2,856,000 gallons each / 5,712,000 gallons total
Shell thickness: 1.33 inches
Steel tonnage: 750 tons each / 1,500 tons total
Additionally, the scope of work included the sphere foundations and piling, fire protection system (deluge and spray rings), stairs and platforms, ultrasonic or radiograph testing, internal and external coatings and fireproofing of the support columns. The total number of feet welded in this project topped out at 7,500 feet.
This project schedule presented some challenges because the spheres owner needed to begin operations during fall/winter months in order to take advantage of the opportunity to tailor the vapor pressure of gasoline for their cooler climate.
The contractor successfully completed this project without any recordable accidents and over 100 days ahead of schedule.
NH3 Anhydrous Ammonia Tank - API 620
Rock Spring, WY
The J. R. Simplot Company in Rock Springs, WY wanted to expand its ammonia plant to improve its long-term sustainability in the phosphate marketplace. Ammonia is a key raw material in the production of fertilizer. With this new plant that supplies both the Rock Springs, WY and the Pocatello, ID phosphate fertilizer production locations, output significantly enhances Simplot’s ability to be self-sufficient. This new plant was constructed adjacent to its existing phosphate fertilizer complex.
The contractor provided the engineering, procurement, fabrication, and construction of:
(1) API 620 Annex R Anhydrous Ammonia Tank (114'-6" diameter x 92'-6" high)
Capacity of 150,000 bbl of NH3 anhydrous ammonia
In addition to the actual construction of the tank, the scope of work included the tank foundation, installation of the heating system, insulation, and coating.
The 6,500-foot elevation, high winds, cold temperatures, and snow presented challenges with the project schedule. The roof's main platform was another challenge because of its size and that it could not be supported on the roof due to contraction concerns by the client.
The contractor met this challenge by constructing a large girder to span across the whole roof and connecting it to the compression bar. The contractor utilized its roof air raising technology by constructing the dome roof near the bottom of the tank and then air raising it to the final position. Experienced personnel then fit and welded the roof connection to the compression bar. By constructing the roof at a low elevation, the contractor limited workers’ exposure to dangerous heights.
Personnel safety was always paramount during this procedure the same as it was in all aspects of the project. The contractor utilized services within its company structure to provide a complete single source solution on this project. Despite all of the challenges, the entire project was completed with zero incidents.
City Campus Thermal Energy Storage Tank
University of Nebraska – Lincoln
1.124” to .3125”
PRODUCT / PROJECT DESCRIPTION AND SPECIAL FEATURES:
This unique, very large and aesthetically pleasing welded steel tank serves the University of Nebraska at Lincoln as a cost effective Thermal Energy Storage (TES) tank that holds 8,291,000 gallons (120’ diameter x 100’ shell height) and uses 1,516,000 pounds of steel plate.
The TES tank stores chilled water produced at night when electricity rates are low and uses the chilled water during the heat of the day to economically air condition a number of campus buildings when electricity rates are high. With an estimated annual utility bill savings of up to $900,000 per year, the tank will ultimately pay for itself!
The tank foundation design was complicated due to the poor soils at the site requiring a thick pile cap supported by (295) 18" auger cast piles drilled to a 60+ foot depth. The internal flow diffusers were specifically designed for this tank based on the temperatures differences and the flow rates of the water coming in and out of the tank that will stratify the water and provide 52,000 Ton-Hours of cooling.
The TES tank was wedged onto a very small site and built between a new mechanical building and an active railroad spur line making construction challenging.
The university's Aesthetics Review Committee wanted this tank to tie in well with the new mechanical building. After rendering numerous color patterns for the tank, they chose a staggered, vertical pattern in a light gray and white finish for the exterior of the aluminum jacketing. The aesthetically pleasing finished product can be seen from certain parts of this large campus.
The welded steel tank met all of the challenges proposed by this site as well as provided additional benefits to the University including:
• A 100% leak tight storage tank to eliminate any risk of any leakage to the adjacent campus buildings.
• Displayed the flexibility of steel design and construction in tight sites with poor soil conditions,
• Displayed the flexibility to meet even the most concerned customers needs to be aesthetically pleasing.
• Provided not only the low initial capital cost but also the lowest maintenance & life cycle cost.
This tank promotes and demonstrates the flexibility and aesthetics of welded steel tanks to be built in tight sites, pay for themselves in a few years and will continue to save the Owner money for many years to come.
1 MMG Waterspheroid / 1st Street Elevated Water Storage Tank
City of Ocean City, MD
Ocean City, MD
Striving to create an iconic landmark for their Summer beach visitors, the town of Ocean City, Maryland prepared its specifications to give its newest water tower a "Beach Ball" appearance. The colorful paint scheme now welcomes the throngs of sand and water fun loving tourists as they arrive onto the southern end of the island. Standing at nearly 120' tall, it creates many a smile for those seeing it for the first time.
While the "Beach Ball" nickname is certainly appropriate, the builders gave it a second moniker - "The Cell Tower That Holds Water". This is because the tank had to be designed to accommodate the (52) incoming cellular and municipal antenna cable systems (which were being relocated from two older multi-leg tanks slated for demolition)! In order to meet this need, the tank's bell includes a massive shop fabricated insert plate to hold the four dozen six inch diameter penetrations. Inside the tank, there is also a complex system of conduit routing and support systems, topped by a custom access tube extension on the roof. This extra wide tube allows the operators to actually exit onto the tank dome via a steel door (vs std roof hatch). It also provides adequate turning space for the thick cables, as they are directed towards the three heavy duty antenna support railing systems.
Another special feature of this tank relates to its support structure. With the tank's location being situated on soft barrier island sands, a deep pile foundation was an obvious necessity. However, this area of the island also routinely floods during nor'easters, and so the engineer smartly designed the site's layout, such that the elevation of the final grade would be four feet above the surrounding properties. Thus, the tank's ringwall was extended and the entire site backfilled with four feet of compacted fill upon the tank's completion. This ensures that if (hmmm, when) the neighborhood floods, that the City's control systems within the tank's base remain dry. All in all, this colorful tower gives new meaning to the local sign, "High Water"!
Reservoir 4606-1 Construction (Mission Hills Pressure Zone)
Coachella Valley Water District
Coachella Valley, CA
186’ – 0”
0.3125” to 0.9788”
This tank was under consideration to be built via concrete or welded but the design team performed a Life cycle cost analysis and overall bid the job as a welded steel tank. It was designed to meet the new demands of an ever growing city as well as supplement future demand of additional housing tracks. This asset will be a critical part of their system for decades/ centuries to come.
The tank was designed in accordance with AWWA D-100 section 14 in order to be as cost effective as possible; but due to high seismic load’s and the tank being located just feet away from the San Andres Fault line there were many precautions taken in the design/supply of the reservoir. The tank as a whole weighed more than 1.2 million pounds and was constructed during the Santa Ana winds. The effects of the high winds were amplified by the fact that it’s located on a mountain range which regularly sees winds in excess of 60 mph on any given day. Although there were many days which the crew had to work split shifts or submit a weather delay, we were still able to complete the job on time with a satisfied customer and a safe crew. This was due to the construction sequencing of a welded steel tank and the ability to start / stop as needed in order for the crew to safely follow all applicable safety regulations.
Paradise Meadows 5.0 MG Tank
Eastern Municipal Water District
157’ – 0”
0.25” to 0.78”
The work comprises construction of a 5.0 MG Potable Water Storage Tank and appurtenances including but not limited to the following: furnishing, delivery and erecting a 5.0 MG welded steel tank and appurtenances; all precise grading and construction of the tank pad, detention basin and access road; including 18-inch dia. Detention basin drain pipe and riser; furnishing, delivery and installation of 24-inch dia. welded steel (CML/C) water pipeline and appurtenances; including all welded joints, valves, blowoffs, and air valves; connections to existing water mains with valves and associated removals as needed; trench sheeting, shoring and bracing per California Labor Code; pavement and PCC curb and gutter; valve enclosure; electrical panel and SCE service panels/conduits; all electrical and SCADA equipment; implementation of the mitigation measures identified from the Mitigation Monitoring and Reporting Program; comply with SCAQMD Rule 403 to actively prevent, reduce or mitigate fugitive dust emissions; chain link fencing and gates; painting and coating; all system shutdowns and piping tie-ins; hydrotesting, miscellaneous testing, chlorination/disinfection and field start-up and testing.
This 5.4 million gallon tank was built at 157’ diameter by 40’ tall, with a knuckle roof, and overlooks the new housing development of Audie Murphy, but can be seen from surrounding communities to the west. One of the unique things about this tank is that, when you’re looking for it from the east end of town, it is painted to blend in with the hillside that it was built into, so you really have to scan to find it. In order to make room for this site footprint, and to set the tank at the proper elevation, over 25,000 cubic yards of dirt /rock had to be blasted and removed. As a customer preference the reservoir was designed with a modified structure to support the large roof platform as the additional weight required rafters, poles and a girder to be increased in thickness. Along with their preferred platform design, this customer is extremely particular about operator safety, so they design all of their tanks to have 360 degree handrail, roof tie off cables, and fall resistant grading shields, located on all roof access hatches. As you can see in the picture, the tank is fitted with 5 custom aluminum roof vents, which really standout against the dark color of the tank and hillside.
1,000,000 Gallon Elevated Tank Raise
Pennsylvania State University
State College, PA
1” to 3/16”
GMP 7 - Thermal Energy Storage Tank
Fort Worth, TX
Given that this standpipe was to be built in an existing and operating Lockheed Martin plant, the space taken up by the standpipe had to be absolutely minimized. Therefore, we had to size the standpipe to have the smallest diameter possible, while still meeting the ton-hour of storage required for the standpipe. We were able to provide 16,000 Ton Hours of Thermal Energy Storage in a 45' diameter by 105' tall Chilled Water Standpipe.
Included in the scope of supply was the foundation, which consisted a 3' pile cap and (37) 3' diameter drilled piers over 25' deep.
This standpipe and the diffuser within it, had to be built, painted, and insulated in an urban, plant environment with many other existing, occupied buildings and in use parking lots, immediately adjacent to the standpipe. In any urban environment, paint application is difficult, and this project presented an especially challenging work site. The parking lot on the west side of the standpipe was within 15', and on the east side of the standpipe was an existing standpipe within 5'. To the south of the standpipe was a production building, within 40', and to the north, was a production building, within 100'. Deliveries and major lifts involved significant communications with Lockheed Martin so as to not impede plant operations.
Most importantly, the building 40' to the south of the standpipe was where Lockheed Martin paints their fighter jets. Because of this, numerous steps to ensure cleanliness had to be taken. This included hourly checks for Foreign Object Debris (FOD), where all construction waste had to be immediately placed in a sealed receptacle. All sparks produced during welding had to be contained. This especially is challenging for a hundred foot tall standpipe.
The interior of the standpipe received two coats of epoxy, and the exterior received one coat of epoxy. This was touched up in the field with the welds, and damaged areas being power tool cleaned, to minimize the dust, and then the coatings were applied with brush and roller for the exterior surfaces, to eliminate overspray issues.
Despite the challenges, we were able to provide this Thermal Energy Standpipe to Lockheed Martin ahead of schedule and with a storage capacity exceeding that of the performance guarantee.
Stainless and Carbon Steel Columns
Customer in TX
A 140 ft. tall column, a 120 ft. tall column and six other pressure vessels and reactors established the core of this grass roots project constructed in south Texas. STI/SPFA Affiliate Members were crucial in the success and supplied close to 750,000 lbs. of steel required to build these units.
Water Utility Project
Procter and Gamble Manufacturing Company
5-40,000 gallon 12' diameter x 49'-6" vertical water treatment tanks were fabricated, insulated and transported to our customer's facility.
1-10,000 gallon 8' diameter x 27' vertical water treatment was fabricated, insulated and transported to the job-site.
1-10,000 gallon 12' diameter x 12' vertical water treatment tank was fabricated, insulated and transported to the job-site.
All the tanks incorporated a flat sloped bottom and cone top made of carbon steel. Internal welds were ground smooth. Tanks were designed for 2.5 psig with -.2 psig vacuum with a design temperature of -20 to 275 degrees Fahrenheit, built and stamped for API-650. The tanks were lined with an epoxy two coat lining system. Tanks include anchor chairs, caged ladder with intermediate step-off platform and top platform with handrail.
Special shipping rings were designed and attached to the tank to allow shipping with the insulation pre-installed at the manufacturing plant then transported to the site.
Customer in SC
PRODUCT/PROJECT DESCRIPTION AND SPECIAL FEATURES:
This unique stainless steel unit with complex internals was fabricated on an expedited basis for a Customer in South Carolina. The internal draft tube tolerances were FARO laser critical with parallelism to the shell wall and trueness to the top agitator mounting flange.
Pump Discharge Header:
Pipe: 3/8" thick x 50 3/4"OD x 31'-8 1/8" long
Spigot end x plain end for a restrained flex coupling
Flanged Outlets: (3) 3/8" thick x 30"OD x 6'-7 1/4" long 45 degree laterals with (3) 30" AWWA Class D ring flanges & (1) .365" thick x 10"nom x 6" long with (1) 10" AWWA Class D ring flange.
Outlet Reinforcements: (3) 1-3/4" thick crotch plates weighing approximately 2.6 tons each.
AWWA M11 Ring/Ring Harness: 5/8" thick x 8-3/4" wide ring x ring fabricated for (10) 1-3/8" diameter tie rods for restraint of the flex coupling.
Product / project title:
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Grandfather Falls Penstock Replacement
Wisconsin Public Service
132” & 156”
Two wooden penstock lines, (1) 11 foot OD & (1) 13 foot OD ran side by side and supplied water to the Grandfather Falls Hydroelectric Plant. Built in 1975 the wooden penstocks had exceeded their life span and leaks developed in the pipe causing massive loss of water at more than 7000 gallons per minute. So, when it came time to replace the wooden pipelines, steel was the obvious choice. Both sizes, 132"OD x 1/2" and 156"OD x 9/16" were run in our state of the art, spiral mill. This spiral mill is one of just a very few in the United States that is capable of running 13 foot diameter pipe. ASTM A516, GR60 steel coils were brought in to make the pipe. Shop welds were 100% ultrasonically tested and spot radiographically tested. Pipe was coated with 25 mils of Polyurethane and furnished with bell & spigot ends. As an added service to the contractor, every lap joint (60) was shop fit tested to insure proper and speedy fit-up in the field. Pipe joints were shipped in 42 foot lengths. 74 permitted & escorted trucks were required to get the 11 foot and 13 foot diameter pipe delivered to the jobsite.
A major concern was the need for the pipeline to be able to expand and contract due to temperature changes. We manufactured and provided (12) expansion joints (6 each line) to allow the penstock to expand or contract 5" either direction at each expansion joint. The expansion joints included an internal 316L stainless steel slip plate to allow the pipe to slide, and internal lubricated packing to seal the joint.
Time was critical with the demolition of the wooden penstock and installation of the new steel penstock. While the plant was not in operation it was not generating electric, which was costly in of its self. But, with the cooperation of all parties involved, the plant was back on line in a minimal amount of time and on schedule as originally planned.
Spanish Fork Santaquin Pipeline
Central Utah Water Conservancy District
Spanish Fork, UT
This is a 66" Dismantling Joint produced with a special extra thick flange. The Spanish Fork - Santaquin Pipeline Project consists of installing 8,480 ft. of 60 in. steel pipeline. The project is also installing jacked casing under two Union Pacific Railroads, while also making improvements to the existing infrastructure. The pipeline is to deliver water to cities in South Utah County for outdoor systems.
Dismantling Joints are a double-flanged pipe fitting. Dismantling Joints allow for easy installation and continued maintenance of the fitting. Typical applications include pumping stations, water treatment works, sewage treatment works, plant rooms, meter chambers, power generation equipment and gas distribution stations. Dismantling Joints can accommodate custom longitudinal adjustment dependent on the diameter and also allows for up to 2° of misalignment. Once adjusted the Dismantling joints movement can be restricted by using the supplied tie rods. Dismantling Joints are designed such that the restraint system does not extend outside of the flange diameter. Dismantling Joints can be easily installed with minimal special equipment needed.
Design Pressure: 440 PSI
Working Pressure: 390 PSI
Test Pressure: 660 PSI
Product: DuraPlate 8200
Steel pipe fabricators and shop fabricated tank members continue to ask: is there a tank lining that can be applied directly to prepared steel without a primer, that cures quickly, that can withstand severe chemical immersion and high temperatures, that can be used in combination with cathodic protection systems, and - most important of all - can be applied with the equipment our shop already has so that we do not need to buy new equipment?
The answer is now YES!
A product is now available (DuraPlate 8200) that has been formulated to supply one coat protection up to 35 mils and rapid return-to-service: 24 hours. It is solvent-free and low odor and is made for pipelines, process vessels, and tanks that convey or store petrochemical products. In addition, it resists temperature and pressure gradients as defined in NACE TM 0174 Atlas Cell, and NACE TM 0185 Autoclave and often required by global petrochemical companies.
As desired by pipe and tank shops, this product (DuraPlate 8200) can be applied with standard airless spray equipment and has no additional financial burden for new equipment or training.
If you fabricate steel pipelines or storage tanks for the oil & gas or petrochemical industry, require cathodic protection-resistant linings that are unaffected by temperature and pressure gradients, do not shrink after application (requiring more thickness) nor require heated equipment to apply, this new product (DuraPlate 8200) is perfect for you and your customers.