Project Description

FUEL STORAGE TANKS | ENGLAND

FOUNDATIONS, CONTAINMENT & INFRASTRUCTURE

Project Details

CLIENT:  FUEL TERMINAL, ENGLAND

new build storage tanks
new build storage tanks
new build storage tanks

The Challenge

Following the successful delivery of an options appraisal to identify cost-effective secondary containment bund configurations, IKM was appointed to undertake the engineering design and detailing works for:

  • new reinforced concrete tank foundations
  • new reinforced concrete floor
  • bund wall
  • associated tank infrastructure

The design needed to accommodate and support two proposed 15m diameter by 10m high diesel storage tanks on a constrained, brownfield site within a live fuel storage terminal.

The Solution

The storage facility is a Control of Major Accident Hazard (COMAH) establishment due to the quantity and hazardous nature of substances stored.
IKM undertook all design works to comply with relevant legislation, standards and industry good practice. The containment design was undertaken in accordance with CIRIA C736. This provides industry good practice guidance on containment systems and helped our client meet their statutory obligations.
To inform the design, IKM’s geotechnical team provided geo-environmental assistance in the form of:
• conducting a ground investigation
• waste classification works
• in-situ soil sampling and testing

IKM prepared a Basis of Design document, in advance of the works, which allowed our client to engage with the Environment Agency early along with our scheme design.
The project comprised the detailed design and construction detailing of:

• reinforced concrete bund walls
• floor
• tank foundations
• bund gate
• isolated bund drainage system

We also worked collaboratively with a third-party mechanical, electrical and control designer to coordinate and provide the associated civil and structural design services for the tank access and infrastructure. IKM also provided technical support throughout the EXECUTE stage of the works.

The secondary containment system was designed as a water retaining structure. Consideration was given to crack control, with the design carried out to BS 8007 ‘Code of practice for the design of concrete structures for retaining aqueous liquids’. This included the specification of appropriate movement and construction joints with fire-resistant sealants and cast in water stopping systems. The bund walls were also provided with a “recurved” wall head detail to mitigate overtopping effects in the event of a tank failure and product surge.

Due to the phased construction programme careful consideration was given to the design criteria for the new bund floor / hardstanding. The concrete bund floor with associated joints was designed to withstand 40-tonne vehicular movements within the bund area and maximum crane outrigger loads of up to 750kN.

The concrete bund floor was graded to allow surface water run-off to drain to perimeter drainage channels before entering an internal collection sump. The bund collection sump was connected to a shut-off valve chamber located external to the bund before being tied into a new drainage Interceptor.
The treated surface water run-off was then directed into the existing site drainage network and SUDS system.

Tank foundations were designed and detailed as reinforced concrete cone down raft foundations. The new foundations were designed as water retaining and provided with integrated leak detection systems.

Throughout the design of the bund wall and floor, IKM also collaborated with a specialist sub-contractor for the specification and construction detailing of a floodgate access system. Due to the nature of the tank bund, fire and hydrocarbon attack resistant sealants were also specified where the floodgate was tied in with the new concrete bund wall.

IKM carried out a study to determine the requirement for additional tertiary containment due to site constraints and nearby receptors. This included computational fluid dynamic modelling being carried out to calculate overtopping volumes for various catastrophic tank failure scenarios. Once determined, overland flow models were generated to allow potential improvements to be detailed ensuring the environmental integrity and the health and safety of site personnel and future site operations.

Due to the phased construction programme careful consideration was given to the design criteria for the new bund floor / hardstanding. The concrete bund floor with associated joints was designed to withstand 40-tonne vehicular movements within the bund area and maximum crane outrigger loads of up to 750kN.

The concrete bund floor was graded to allow surface water run-off to drain to perimeter drainage channels before entering an internal collection sump. The bund collection sump was connected to a shut-off valve chamber located external to the bund before being tied into a new drainage Interceptor.

The treated surface water run-off was then directed into the existing site drainage network and SUDS system.

Tank foundations were designed and detailed as reinforced concrete cone down raft foundations. The new foundations were designed as water retaining and provided with integrated leak detection systems.

Throughout the design of the bund wall and floor, IKM also collaborated with a specialist sub-contractor for the specification and construction detailing of a floodgate access system. Due to the nature of the tank bund, fire and hydrocarbon attack resistant sealants were also specified where the floodgate was tied in with the new concrete bund wall.

IKM carried out a study to determine the requirement for additional tertiary containment due to site constraints and nearby receptors. This included computational fluid dynamic modelling being carried out to calculate overtopping volumes for various catastrophic tank failure scenarios. Once determined, overland flow models were generated to allow potential improvements to be detailed ensuring the environmental integrity and the health and safety of site personnel and future site operations.

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