DESIGN CALCULATION
FOR
HCl STORAGE TANK
(2500 X 4300mm(T/T) L) BASED ON BS49941987
Rev Date Revision Description Prepared by:
1 15062011
a. Design Data Operating Pressure and Temperature
ERM
b. Tank Capacity 26m
3
to 25m
3
c. Nozzle Loading onto N1 & N9
d. Live load on Platform 1000Pa to 2500 Pa
e. Inclusion of Handrail Design
2 28072011 Cage(Truss) web members rearrangement ERM
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FRP TANK DESIGN BASED ON BS 4994 (1987)
A) Design Data
Shape of tank: Cylindrical, horizontal, dish end. (0.30 SemiEllipse)
Di = 2500mm .
L: 4300mm (T/T)
Fluid handle: HCl, 9.9% concentration
Specific gravity: 1.05
Operating temperature: Ambient.
Design temperature: 20
0
C(min) to 60
0
C(max)
Operating pressure: 0.015 barg (0.0015MPa)
Design pressure: 0.34barg (0.034MPa)
Design vacuum: 0.05barg (0.005MPa)
B) Material Data
I. Material Properties:
Type of resin: Isopthalac resin.
Ultimate tensile unit Strength, UTUS = 200 N/mm (CSM)
= 250 N/mm (WR)
= 500 N/mm (Unidirectional Filament)
Unit modulus = 14,000 N/mm (CSM)
= 16,000 N/mm (WR)
= 28,000 N/mm (Unidirectional Filament)
Maximum allowable strain, c = 0.2%. (Clause 9.2.4)
Note: Material strengths were based from minimum values provided in the
BS 4994: 1987 Table 5.
C) Design Factor
K= 3 x k1 x k2 x k3 x k4 x k5 (EQ 1)
where:
3: represents a constant which allows for the reduction of
material strength caused by long term loading.
k1: Handwork : 1.5
k2: Without thermoplastic lining: 1.6
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k3: Heat distortion temperature of resin: 1.0
k4: Cyclic loading: 1.1
k5: Without post cure: 1.5
= pDi/2 (EQ 7)
SG of liquid = 1.05
P = 0.034N/mm
2
Di = 2500mm
Q
=
2
) 2500 ( 034 . 0
= 42.50N/mm
Use 8 layers of CSM as chemical barrier, 2 layer of WR and 4 layers of filament
roving as reinforced layer.
Check:
Circumferential U
LAM
= (8 x 0.45 x 16.8) + (2 x 0.80 x 19.2) + (4 x 1.1 x 9.60)
= 133.44N/mm > Q
 OK!
ii) Longitudinal unit load, Q
x
=
4
pDi
+
2
4
Di
M
t
(EQ11)
Tank Empty Weight = 1,530 kg (FRP Tank)
Liquid Weight (full) = 1.05 x 1000kg/m
3
x 25m
3
= 26,250 kg
Total Operating Weight = 27,780 kg
W = 27,780kg x 9.81m/s
2
= 272,522N
Uniform load, w = 272,522N/5800mm
= 46.99N/mm
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39.71 kNm
19.38 kNm
39.71 kNm
61.09 kN
50.29 kN
14.50 kNm 14.50 kNm
24.89 kN
24.88 kN
61.09 kN
50.29 kN
9.93 kNm 9.93 kNm
1300mm 1600mm 1600mm 1300mm
Pressure due to liquid, p = 0.034N/mm
2
:
Q =
4
pDi
2
4
Di
M
t
Q =
4
) 2500 ( 034 . 0
2
6
) 2500 (
) 10 71 . 39 ( 4
t
Nmm x
Qx = 29.34N/mm ; 13.16 N/mm
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Pressure due to vacuum, p = 0.005N/mm
2
:
Q =
4
pDi
2
4
Di
M
t
Q =
4
) 2500 ( 005 . 0
2
6
) 2500 (
) 10 71 . 39 ( 4
t
Nmm x
Qx = 4.96N/mm ; 11.21 N/mm
Using 8 layers of CSM, 2 layer of WR and 4 layers of filament roving,
U
LAMX
= (8 x0.45 x 16.8) + (2 x 0.80 x 19.2) + (4 x 1.1 x 2.64)
= 102.82N/mm > Qx  OK!
iii) Compressive unit load.
a) Due to Shear on saddle support:
Q
c
=
L
V
=
2500 360 / 120
380 , 111
x x
N
[
= 42.54 N/mm
b) Due to weight onto nozzle N1 and N9:
Q
c
=
4
pDi
;
where p is computed from 20kg over effective area supporting
nozzle (consider smaller area, so pressure is maximum)
since N1 is smaller with Diameter = 80mm, effective diameter
is 92mm;
Effective area =
4
92
2
x mm
= 6,648mm
2
Therefore p =
2
2
648 , 6
/ 81 . 9 20
mm
s m kgx
= 0.030 N/mm
2
Q
c
=
4
pDi
=
4
2500 030 . 0 x
=18.75 N/mm
Since compressive unit load due to saddle support (Qc= 42.54 N/mm) is
greater than Qc due to nozzles N1 and N9 and also greater than Qx due to vacuum,
therefore consider compressive load due to Shear on saddle supports.
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Permissible compressive unit load
Qp =
FDo
tX
LAM
6 . 0
(EQ 13)
Qp =
) 14 2 2500 ( 4
) 4 1 . 1 400 , 4 2 80 . 0 000 , 16 8 45 . 0 000 , 14 )( 14 ( 6 . 0
x
x x x x x x
+
+ +
= 79.22N/mm > Qc  OK!
iv) Check minimum permissible thickness, t
m
, to prevent buckling due to
external pressure or vacuum:
L = 0.4 x 750 + 4300 = 4,900mm
D
o
= 2500+2x14 = 2,528mm
p
vacuum
= 0.005 N/mm
2
F = 4
E
LAM
=
14
4 10 . 1 400 , 4 2 80 . 0 000 , 16 8 45 . 0 000 , 14 x x x x x x
t
X
LAM
+ +
= (EQ14)
= 6,811.43
94 . 1
2528
900 , 4
= =
o
D
L
;
77 . 11
4 005 . 0
43 . 811 , 6
35 . 1 35 . 1
17 . 0
17 . 0
= 
.

\

=


.

\

x
x
pF
E
LAM
;
Since
o
D
L
<
17 . 0
35 . 1


.

\

pF
E
LAM
, then
t
m
=
40 . 0
4 . 0


.

\

o LAM
o
D
L
x
E
pF
D (EQ 16)
40 . 0
528 , 2
900 , 4
43 . 811 , 6
4 005 . 0 4 . 0
528 , 2 
.

\

= x
x x
= 13.98mm < 14mm, OK!
Therefore, the proposed construction of 8 layers CSM, 2 layers WR and 4 layers
filament roving for shell is SAFE!
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2) Dish End Design.
i) Against internal pressure:
Assume
Di
t
s 0.005 and
Di
hi
= 0.3
Conservatively, use
Di
hi
=0.25 K
s
values from Table 11.
Use Ks = 1.30 for semi ellipsoidal dome.
Q
= 55.25 N/mm
But Q
> U
1
, M
1
, N
1
+ U
2
+ M
2
+ N
2
+
Using 11 layers of CSM + 3 layers of WR:
Qact = 16.8x0.45x11 + 19.2x0.80x3
= 129.24 N/mm > Q
= 56.93 N/mm
2
< Fv  OK!
b. Tensile Stress Analysis
Allowable Tensile of plate, Ft = 0.60Fy
= 0.60(248)
= 148.80 N/mm
2
Actual Tensile stress on plate =
A
P
=
12 ) 40 225 (
30 . 572 , 37
= 16.92 N/mm
2
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Welding Check
a. Total welding length of Lifting lug to base plate,
l
LL
= 2 x 225mm = 450mm
Effective length = 0.70 x 450 = 315mm
b. Total welding length of base plate to Cage,
l
BP
= 200 + 2x 100 + 100 = 500mm
Effective length = 0.70 x 500 = 350mm
Using E60 electrode(Fu = 414MPa), Fw = 0.38Fu = 157.32 N/mm
2
Since Fw of weld is higher than allowable shear capacity of plate, use
plates value to be conservative.
Therefore, Fw = Fv = 99.20 N/mm
2
Throat of weld = 0.70 x 6mm
Required length of weld =
xthroat f
P
w
=
) 6 70 . 0 ( 20 . 99
30 . 572 , 37
x x
= 90.18 mm < effective length both on base
plate and Lifting lugs, therefore, SAFE!
Since plate and weld check shows it can carry the weight, therefore
material provided are SAFE!
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D. Handrail Design
Load applied to handrail = 0.75 kN/m
1000 1000 1000
1100
550
550
Check for Horizontal Rail:
M =
8
2
wL
=
8
1000 / 75 . 0
2
mm mmx N
= 93,750 Nmm
Sx
Reqd
=
fb
M
=
MPa x
Nmm
248 66 . 0
750 , 93
= 572.80 mm
3
= 0.57cm
3
Check for Vertical Rail:
M = P x L = (0.75N/mm x 1000mm) x 1100mm
= 825,000 Nmm
Sx
Reqd
=
fb
M
=
MPa x
Nmm
248 66 . 0
000 , 825
= 5040 mm
3
= 5.04cm
3
Use of 40mm x 4mm Thk CHS (Sx = 5.92cm
3
) is SAFE!