T

E
A

ANK
NGINEERING
ND
ANAGEMENT

M
CONSULTANTS, INC.
PRESENTATION
ON

HYDROPNEUMATIC TANKS
BY

JAM E S E.PAN D OLPH, P.E.

WATER STORAGE TANKS

ARE CRITICAL TO THE EFFICIENT
OPERATION OF ANY WATER
DISTRIBUTION SYSTEM

PURPOSE OF STORAGE
VOLUME
PRESSURE

TYPES OF STORAGE
GROUND STORAGE TANKS OR RESERVOIRS

PROVIDE LARGE VOLUMES OF WATER, USUALLY

FOR LARGER WATER SYSTEMS

DO NOT PROVIDE PRESSURE TO THE SYSTEM

UNLESS:
1. BUILT ON A HILL
2. PUMPED TO AN ELEVATED TANK.
3. USE OF HIGH SERVICE PUMPS TO PROVIDE
PRESSURE TO THE SYSTEM

INSERT A GROUND STORAGE TANK HERE

ST. PETE OBERLY

TYPES OF STORAGE
STAND PIPES

ESSENTIALLY A GROUND STORAGE TANK WHOSE

HEIGHT WILL PROVIDE ADEQUATE SYSTEM
PRESSURE.
ONLY UPPER VOLUMES ARE AVAILABLE TO
PROVIDE ADEQUATE PRESSURE
1. CAREFULL CIRCULATION IS REQUIRED TO
PREVENT STAGNATION, STRATIFICATION &
OTHER PROBLEMS.
2. PROPER SOIL BEARING IS MANDATORY.

ELEVATED STORAGE TANKS

HCL ESTABLISHES
MAX PRESSURE
HEAD RANGE
(HR)

HR CONTROLS
Pressure variation

HT. TO
HCL
HT. TO
LCL

LCL ESTABLISHES
MIN PRESSURE

ELEVATED STORAGE TANKS

ELEVATED STORAGE TANKS

HYDROPNEUMATIC TANKS
Hydropneumatic tanks (or pressure tanks) are very
common in small water systems that use wells to
supply drinking water. The hydropneumatic system
combines the energy from a pump (usually the well
pump) with the principle of air pressure to force
water into the distribution system. These tanks are
installed between the well pump and distribution
system and are intended to:

Maintain an adequate and relatively even

pressure in the distribution system
Reduce the number of times the well pump
turns on and off

Hydropneumatic tanks are usually not large enough to

provide sufficient water storage for fire fighting.
Availability of alternate water sources must be considered
when selecting a hydropneumatic system for a municipal
supply.
Because the volume of stored water is minimal,
operational failures that occur with hydropneumatic tank
systems can result in the water system customers being
completely out of water within a matter of minutes. It is
therefore important for all operators of these systems to be
familiar with basic troubleshooting steps to identify and
correct problems with the water system.

Types of Hydropneumatic Tanks

While the number and size of hydropneumatic tanks
may vary widely from system to system, there are
four basic styles of tanks. Depending on the type and
size, these tanks can be installed vertically or
horizontally. The general differences between the
four styles (shown below) involve the method of
separating the air and the water inside the tank.
Operators should be familiar with the type of tank(s)
in their system.

TYPICAL HYDROPNEUMATIC TANK

Conventional tank WITH AIR COMPRESSOR

The air cushion is in direct contact with the water. Because air can
dissolve in the water, an air volume controller is necessary as well
as an air compressor system

AIR
WATER

MAJOR COMPONENTS OF A HYDROPNEUMATIC TANK SYSTEM

COMPONENT

PURPOSE

Water Source

The Well and pump. Includes

Check Valve, Air relief & Meter.

Steel Tank

Tank
Foundation

Air Volume
Controller

Stores water and air. Pressurized

vessel. Florida requires periodic
cleaning & Inspection.
Supports the tank and insures that
the tank will not tip over and break
a main water supply line.
Regulates air volume in tank
(controls compressor)

MAJOR COMPONENTS OF A HYDROPNEUMATIC TANK SYSTEM

COMPONENT
PURPOSE
5 Air Compressor Supplies air to the tank to maintain
air cushion. Unit should be oil
free type or be fitted with filters to
prevent oil from entering the water.
6

Pressure Relief
Valve

Prevents excessively high pressure

in the tank. Generally 100 psi
maximum.

Inlet/Outlet
Piping

Allows flow of water in and out of

tank. Both should be fitted with
gate valves and inlet pipe should be
fitted with a check valve.

MAJOR COMPONENTS OF A HYDROPNEUMATIC TANK SYSTEM

COMPONENT
8 Sight Glass
(Tube)

PURPOSE
Allows direct observation of airto-water ratio. Generally the ratio
should be 1 to 2, i.e.: 1/3 air to 2/3
water.

For monitoring pressure inside the

tank and on the distribution system.
Controls cut-in (start) and cutout (stop) cycles of the well pump.

Pressure
Gauges
10 Pump/Motor
Controls

MAJOR COMPONENTS OF A HYDROPNEUMATIC TANK SYSTEM

COMPONENT
11 High/Low
Pressure
Controls

PURPOSE
Regulates the pump/motor controls
based on pre-set cut-in and cut-out
points. These are adjustable but
adjustments should be performed only
by qualified personnel. The settings
should generally provide a minimum of
40 psi and a maximum of 70 psi
throughout the distribution system. The
pressure should never be allowed to
drop to below 20 psi. Alarms should be
provided to notify the operator in the
event of a system failure (low water
pressure)

MAJOR COMPONENTS OF A HYDROPNEUMATIC TANK SYSTEM

COMPONENT

PURPOSE

12 High/Low Water Regulates water level in the tank.

Level Controls

13 Master Water
Flow Meter
14 Cycle Counter

Measures quantity of water

pumped.

15 Elapsed Time
Meter

Records total hours of water supply

pump operation.

Records number of pump cycles.

Should be limited to a maximum of
10-15 cycles per hour. Cycles can
adjusted by high/low pressure
controls.

TYPICAL HYDROPNEUMATIC TANK

WITH AIR COMPRESSOR

Water Level
Site Gage

Pressure Release

1/3 air

Air Compressor

HYDROPNEUMATIC TANK

Well Pump

2/3 water
Air Relief
Master Meter

Well
Inlet

Foundations
Check Valve

Outlet

Types of Hydropneumatic Tanks

FLOATING WAFER TYPE
There is a floating wafer (usually
constructed of a ridged material,
flexible rubber, or plastic) that
separates the air and water. This
wafer, however, does not
completely separate the air and
water, and therefore some
dissolving of air is expected.
These tanks require occasional
recharging with air

wafer

Types of Hydropneumatic Tanks

Tanks with Flexible Separator: These tanks provide a
complete separation of the air and water. A separator is
fastened around the inside of the tank (diaphragm type) or a
bag is provided for containing the air (air bladder). These
units may be charged with air at the factory, however most are
fitted with an air valve (similar to a tire), which the operator
can use to adjust the pressure inside the tank. Care must be
taken when adding air to these tanks in order to avoid overpressurization and a possible rupture of the separator.
Manufacturers literature must be consulted before adding air
to these tanks and the procedure should be performed only by
qualified personnel

Types of Hydropneumatic Tanks

DIAPHRAM TYPE
AIR
DIAPHRAM

WATER

BLADDER TYPE
AIR

BLADDER

WATER

DESIGN CODE ASME SECTION VIII

CODE STAMPED VS. NON CODE STAMPED PRESSURE

VESSELS

CODE
STAMPED
YES
Design
Drawings
Traveler
Receiving Report
Authorized Inspection
Heat No. Transfer
Weld Map

X
X
X
X
X
X
X

NO

ASME
No Stamp
YES

NO

X
X
X
X
X
X
X

CODE STAMPED VS. NON CODE STAMPED PRESSURE

VESSELS

CODE
STAMPED
Weld Procedures
Welder Qualifications
Weld Visual Inspection
NDT
Hydro Test
Data Report
Stamping

YES
X
X
X
X
X
X
X

NO

ASME
No Stamp
YES

NO
X
X
X
X
X
X
X

CODE STAMPED VS. NON CODE STAMPED PRESSURE

VESSELS

CODE
STAMPED
Final Inspection
MTR's
Weld Wire Certs
Traceability
P.O. Review by Q.C
National Board Registration

YES
X
X
X
X
X
X
OPTIONAL

ASME
No Stamp

NO YES NO
X
X
X
X
X
X

HYDROPNEUMATIC TANK
CONSTRUCTION
WELDING
TYPES OF JOINTS
JOINT EFFECIENCY

BUTT WELDS
E = 100% IF FULL X-RAY
E = 85% IF SPOT X-RAY
E = 70% IF NO X-RAY
TYPES OF WELD JOINTS

LAP WELDS

E = 55% IF DOUBLE LAP

E = 45% IF SINGLE LAP

Lap Welded Construction

Lap Welds

HYDRO PNEUMATIC TANK CONSTRUCTION

FOUNDATIONS

Tank saddles
Steel
Concrete

GROUND SUPPORT

Water weighs 8.33 lbs/gallon a 30,000 gallon tank will

weigh about 250,000 lbs or 125 Ton.

Soil bearing must allow for this load.

HYDROPNEUMATIC TANK CONSTRUCTION

HEAD TYPES
HEMISPHERICAL
ELLIPSOIDAL
TORISPHERICAL

ACCEPTBLE TANK HEAD TYPES

HEMISPHERICAL
R= 1/2D
ELLIPSOIDAL
r1 + R2 = K

TORISPHERICAL

Tank Diameter (D)

R usually =D

DOME

SHELL

SHELL

UNACCEPTABLE HEAD TYPES

FLAT HEAD
SHELL

SHELL

PRESSURE VESSEL INSPECTION CODE:

MAINTENANCE INSPECTION, RATING,
REPAIR, AND ALTERATION
API 510

NO SADDLE

SUPPORT PIER AND SADDLE

Unsealed saddle

Note saddle overhang

Concrete pier

Improper head Radius

Poor Weld

Air from Compressor

Factory Installed
Pressure MW

All Butt Welded

Joints
Code Stamp

Sight Glass

This aftermarket 24 MH does not meet

ASME Code and can be very dangerous

Severe dent may affect tank

integrity

This tank blew its lid

Patch Plate

Lap welded Head

Not welded inside

Severe corrosion

No saddle

CONCLUSION

Hydropneumatic tanks are pressure vessels.

As such they should:
1. Be ASME Code Stamped Vessels.
2. Be pressure rated on the stamp
3. Be Inspected by qualified Inspectors who know the
pressure vessel code
4. Upgrades and repairs must be designed by engineers
and work performed by qualified welders.

CONCLUSION
Water Storage tanks are necessary for every water
system.
Although relatively smaller, hydropneumatic tanks must
be treated respectfully. They can cause considerable
damage if improperly operated.

Proper maintenance is necessary for continued

safe operation.
A system failure of a hydropneumatic tank could

result in being completely out of water within a

matter of minutes.

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