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January 18, 2009 Ref: SH/D52/18/1/09

M/s. Cumberland Subject Size : Acid Wash Tank Design Calculations : 1250mm x 2050mm (Total height)

Design Standard BS 4994, ASTM D 3299 Design Conditions: Design Pressure : Hydrostatic + 25000 Pa Design Vacuum Directly vented. Design Temperature 55oC Specific Gravity 1.24 Diameter 1250mm Shell height 2050mm Contents Hydrochloric Acid Configuration Vertical, Flat Bottom, Flanged Flat top Wind Loading 160 Km/hr Design Factor (K) K = 3 x K1 x K2 x K3 x K4 x K5 Where K1 = 1.5 for filament winding & hand lay up process. K2 = 1.2 K3 = 1.22 K4 = 1.1 K5 = 1.1 K = 7.97 = 8 Pressure = P = 1.24 x 1000 x 9.81 x 2.05m + 25000 = 0.5 bar Q = 0.05 N/mm2 = PDi 2

= Circumferential unit load = 0.05 x 1250 = 31.25 N/mm. 2

Maximum allowable strain CSM strain = UL x 100% where UL = U XZ K = 2000 x 100% 8 x 14000 500 x 100% 8 x 28000 = 0.17% = 0.17%

Filaments strain = Design strain d Allowable loads 1) CSM 600 g/m2

= 0.22%

U = 14000 x 0.0017 x 0.6 = 14.3 N/mm 2) Unidirectional filaments per Kg/m2 for 89o U UX = 26000 x 0.0017 x 1 = 44.2 N/mm =0

Proposed Construction Two layers of 600g/m2 CSM 6.5 Kg/m2 of 89o filaments Thickness 10 nos. of Radial 2400 Tex.

= 3mm + 10 x 0.5 = 8 mm = = 316 N/mm Q 28.6 N/mm QX (See page 4)

ULam = 2 x 14.3 + 6.5 x 44.2 ULamx = 2 x 14.3 + OK. Wind Load

Reference : BS CP3 Chapter V, Part 2. 2

VS = V S1 S2 S3 Where VS = Design wind speed V = Basic wind speed =160 Km/hr = 45m/s S1 = Topography factor S2 = Ground roughness & height factor S3 = Statistical factor VS = 45 m/s = 1221 N/m2 =1 =1

q = 0.603 x 452 Cf shell Cp top

= 0.7 Pshell = 855 N/m2 = 0.8 Ptop = 977 N/m2 = 2245 N = 2245 x 1.05 = 2360 Nm = (D0 D14) 64
4

Wind shear force = 855 x 1.25 x 2.1 Wind overturning moment

Moment of Inertia

=I

= (12664 - 12504) 64 = 6.25 x 109 mm4 = My x t = 2 N/mm = longitudinal loading due to bending under wind pressure I = longitudinal loading due to shelf weight of shell + Top cover = (3.14 x 1.25 x 8 x 2.2 x 2.1 + 3.14 x 1.452/ 4 x 15 x 1.5 x 1.1) x 1.24 x 9.8) 3.14 x 1250 = 0.7 N/mm QX OK. 3 = 2.7 N/mm Ulamx (See page 3)

QX1 QX2

Flat Top Head Design Consider external load of 200 Kg/m2 = 2500 N/m2 In addition to the wind load of P total = 1962 + 977 = 2940 N/m2 Refer to equation BS 4994 eqn. (52) P45 MCSM = Where: MCSM P Db tg = Total mass of glass per unit area (in Kg/m2) = Pressure = 6221 N/m2 = 0.00294 N/mm2 = Bolt Circle diameter = 1390mm P Db2 5.33 tg UCSM

= Thickness per unit mass of glass = 2.125 mm per Kg/m2

UCSM

= Design unit loading = 14000 x 0.0017 x 0.45 = 10.7 N/mm

Mcs t

= 6.845 Kg/m = Mcsm = 15mm. 0.45

Hence 15 layers of CSM 450g/m2 is sufficient for Top head cover. Flat bottom design Since bottom fully supported on concrete, choose same thickness of shell, t = 8mm Bund Design 2400mm x 800mm height P = 1.24 x 1000 x 9.81 x 0.8 + 25000 4

= 34, 732 N/mm2 Q

= 0.035 N/mm2

= PDi = 0.035 x 2400 = 42 N/mm 2 2 2 CSM 600 g/m2 + 65 Kg/m2 of 89o filaments which will give Ulam = 316>Q

Proposed Construction t = 8mm OK.

Bund flat bottom thickness

= 8mm

For bund top flange design refer to table 2 page 6 of ASTM D 3299 Flange dimension required width = 51mm x 8mm thick, instead use 100mm wide x 8mm thick.