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Storage Tanks 140705141053 Phpapp01 PDF
Storage Tanks 140705141053 Phpapp01 PDF
1. INTRODUCTION
2. GENERAL
3. DESIGN CODES
4. TYPE OF TANKS
5. SELECTION OF TANKS
6. MATERIAL SPECIFICATIONS
7. DESIGN OF COMPONENTS
Shell design
Bottom Plate design
Wind girder design
8. SEISMIC ANALYSIS
9. ANCHORAGE REQUIREMENT
Tank designed for one product can store other product of differing relative
density(always of lesser density)
API 12F For tanks for storage of Production liquids (upto 120m3)
The above ground storage tanks of large capacity are categorised based
on the type of roof as follows,
S to ra g e T a n k
F ix e d r o o f F lo a t in g r o o f
S im p ly S u p p o r te d S in g le D e c k S in g le D e c k
In te rn a l ra fte r ty p e D o u b le D e c k D o u b le D e c k
In te rn a l tru s s ty p e
R a fte r w ith C e n tr a l c o lu m n
SELECTION OF TANK
Selection of specific type of tank and type of roof depends upon the
intended service conditions, such as the product being stored, its vapor
pressure and corrosive nature and anticipated weather and loading
conditions.
Cone roof tanks are recommended for products with lower vapor
pressure or with less emission control requirement.
Even for products with higher vapor pressure, cone roof tanks can be
used if the product capacity is less and necessary venting and
blanketing arrangements are provided.
Cone roof tanks are cheaper and easier to construct. Maintenance is
very simple.
Floating roof tanks are recommended for storing products of higher
volatility. The steel deck provide good insulation over the entire
surface of the liquid.
MATERIAL SPECIFICATIONS
Following are the common plate material used for construction of tanks,
A 36 upto 40 mm
A 283 Gr C upto 25 mm
A 285 Gr C upto 25 mm
A 131 Gr A upto 12.5 mm
A 131 Gr B upto 25 mm
A 516 Gr 55,60,65,70 upto 40 mm
A 537 Cl1, Cl2 upto 45 mm
Low alloy, high strength steels are also used but it is more difficult to
fabricate, because they have low ductility.
Plates shall be semi killed as minimum and fully killed and made to fine grain
practice or normalised as required.
For material with minimum tensile strength upto 80 ksi, the manual metal
arc-welding electrodes shall conform to E60 and E70 classification series.
Hydrostatic Condition:
tt = 2.6 D(H-1)G
St
Variable design point method is used for tanks above 60 m dia and if L/H
ratio is less than or equal to 2, where L = (6Dt)0.5 where ‘t ‘ is the thickness
of bottom shell course.
This method normally provides a reduction in shell-course thickness and
hence total material weight. Variable design point method is explained
separately.
After the maximum height of the unstiffened shell, H 1 has been determined,
the height of the transformed shell shall be calculated as follows:
Change the actual width each shell course into a transposed width of each
shell course having the top shell thickness:
Wtr = W((tuniform/tact)5)0.5
where Wtr = Transposed width of each shell course, (in.)
W = Actual width of each shell course (in.)
tuniform = ordered thickness of top shell course (in.)
tact = ordered thickness of shell course for which transposed width is
calculated (in.)
Add the transposed widths of the courses. The sum of the transposed widths
of the courses will give the height of the transformed shell
If half the height of the transformed shell exceeds the than H 1 a second
intermediate wind girder shall be used to reduce the height of unstiffened
shell to a height less than the maximum.
The design procedure considers two response modes of the tanks and its
contents:
a. The relatively high-frequency amplified response to lateral ground motion
of the tank shell and roof, together with the portion of the liquid contents that
moves in unison with the shell.
b. The relatively low-frequency amplified response of the portion of the
liquid contents that moves in fundamental sloshing mode.
The overturning moment due to seismic forces applied to the bottom of the
shell shall be determined as follows:
M = ZI (C1WSXS + C1WrXt+ C1W1X1 + C2W2X2)
where, Z = seismic zone factor
I = Importance factor as per Appendix E
C1 C2 = lateral earth quake force coefficients
WS = Total weight of the tank shell(lb)
XS = Height from the bottom of the tank shell to the shell’s CG(ft)
Wr = Total weight of the tank roof(lb)
Ht = Total height of tank shell(ft)
W1 = Weight of the effective mass of the tank contents that move in
unison with the tank shell(lb)
X1 = Height from the bottom of the tank shell to the centroid of
lateral seismic force applied to W 1 (ft)
W2 = Weight of the effective mass of the tank contents that move in
unison in first sloshing mode(lb)
X2 = Height from the bottom of the tank shell to the centroid of
lateral seismic force applied to W 2 (ft)
Resistance to the over turning moment at the bottom of the shell may be
provided by the weight of the tank shell and by anchorage of the tank shell or
for unanchored tanks, the weight of a portion of the tank contents adjacent to
the shell.
WL = 7.9tb(FbyGH)1/2
where, WL = maximum weight of the tank contents that may be used to resist
the shell overturning moment, in lb/ft of shell circumference.
tb = thickness of the bottom plate under the shell(in.)
Fby = minimum specified yield strength of the bottom plate under the
shell (lb/in.2)
G = design specific gravity of the liquid to be stored
Now, calculate Wt, weight of tank shell & portion of fixed roof supported by the
shell, in lb/ft of shell circumference.
height.
d. Anchor the tank.
ANCHORAGE REQUIREMENT
Tank anchorage shall be provided if there exists a tendency for the shell and
the bottom plate, close to the shell, to lift off its foundations due to the
following reasons,
Uplift on an empty tank due to internal design pressure counteracted by
the effective weight of roof and shell.
Uplift due to internal design pressure in combination with wind loading
counteracted by effective weight of roof and shell, plus the effective
weight of product considered .
The anchorage shall not be attached to the bottom plate only but principally to
the shell.
The design shall accommodate movements of the tank due to thermal changes
and hydrostatic pressure and reduce any induced stresses in the shell to a
minimum.
If an anchored tank is not properly designed, its shell can be susceptible to
tearing.
Care should be taken to ensure that the strength of the anchorage attachments
is greater than the specified minimum yield strength of the anchors so that the
anchors yield before the attachment fail.
The spacing between anchors shall not exceed 10ft. On tanks less than 50ft in
diameter, the spacing between anchors shall not exceed 6ft.
For outbreathing : No
No = oQt/oQc = 4,663/5,600 = 0.84
Then, 2 sets of the above 12” venting device shall be provided for this tank.
ROOF TO SHELL JOINT
Roof plates shall be attached to the top angle of the tank with a continuous
fillet weld on the top side only.
Frangible joint design:
In the event of excessive internal pressure build up failure occurs first in the
roof to shell joint protecting the bottom to shell joint.
In most cases cone roofs are designed as frangible joints only.
Following are the design conditions for a frangible joint:
a. The continuous fillet weld between the roof plates and the top angle does
not exceed 5 mm
b. The roof slope at the top-angle attachment does not exceed 1:6
c. The roof to compression-ring details are limited to those shown in figure.
d. Cross-sectional area of the roof-to-shell junction,A should be less than
value calculated by the following Aa=W/201,000 tan θ
where W= Total weight of the shell & roof framing (but not the roof
plate) supported by shell & roof
REINFORCEMENT REQUIREMENT
Sample case:
Manhole opening size : 511 mm
Manhole neck thick : 10 mm
Shell thickness required:5.958 mm, say 6 mm
Shell thick provided : 10 mm
B. By manhole neck
Neck thickness t = 10 mm, 4t = 40
Shell thickness = 10 mm
Reinforcement provided by manhole neck = (40x10)+(10x10)
= 500 mm2
All roofs and supporting structures shall be designed to support dead load
plus a uniform live load of not less than 25 lb/ft2 of projected area.
Rafters shall be spaced so that in the outer ring, their centers are not more
than 2л feet apart measured along the circumference of the tank.
Step 1:
calculate the total load/unit area W acting on the roof.
a. Live load & Vacuum load
25 lb /ft2 as per API 650 + any vacuum load if any
b. Dead load
Weight of roof plate and roof structures
Step 2:
Now minimum number of rafters required shall be calculated.
Say, a tank of 15 meter dia.
Then minimum number of rafters required shall be (л x 15)/1.915 = 24.6 nos
Now say 30 rafters are provided.
Provide 15 primary rafter and 15 secondary rafter.
Step 3:
Calculate the total load acting on the primary rafter
Area of roof x W gives total load say P
Now P/15 gives the load per rafter
Since the roof is of cone type, loading is zero at the center and maximum at
the periphery of the tank roof and is uniformly increasing nature from center
to periphery.
This condition can be considered as hinged end condition. Ra = P/15
Step 4:
C
P/15 P/15
ht
Ha Hb
Ra D/2=r Rb
Sum of the moments about end C equal to zero
Ha x ht. + load x r x 2/3 = Ra x r
Get value of Ha
Maximum bending moment M = 1/3 x r x load - 1/3 Ha x ht
Minimum section modulus required = M/All.Stress
Now select a structural member with higher sectional modulus than required.
Step 5:
Now check for Induced compressive axial stress and bending stress
Induced compressive axial stress =Ha/Ar
where Ar = cross sectional area of the member selected
Induced bending stress = M/Z
where Z = section modulus of the member selected.
If induced stress is less than allowable stress, then member size selected is OK
For allowable stress values refer table 5.1 and 6.1 of IS-800
Typical Roof Structure Pattern:
TANK FOUNDATION DESIGN
CONSIDERATIONS
Typical foundation types are earth foundation without a concrete ring wall
and earth foundation with a concrete ring wall.
Foundation without a ring wall shall be adopted for small size tanks and on
surface where adequate bearing capacity is available.
Tanks with heavy or tall shells and/or self-supported roofs impose a
substantial load on the foundation under the shell.
Advantages of Concrete ring wall
Provides better distribution of the concentrated load of the shell to produce a
more uniform soil loading under the tank.
Provides a level, solid starting plane for construction of the shell.
Provides a better means of leveling the tank grade, and it is capable of
preserving its contour during construction.
The centerline diameter of the ringwall should equal the nominal diameter of
the tank.
TYPE OF FLOATING ROOFS AND ITS
ACCESSORIES
Pan type floating roof is the first type used in the industry. As the name
indicates, this roof looked very much like a shallow pan. The single deck
sloped to the centre for drainage.
The pan roof could sink under heavy loads of water or snow or from leaks in
the deck or drain. Since the single-deck was in direct contact with the stored
liquid, the more volatile liquids would sometimes boil from the sun’s heat.
Pontoon type floating roof has a single deck with an annular pontoon divided
by bulkheads into liquid-tight pontoon compartments.
The pontoon area was in excess of 50% of the total roof area. The top deck of
the pontoon shaded the bottom deck which is in contact with the liquid.
The single deck area was designed to balloon upward to contain vapors
produced by boiling. This reduced considerably the heat input and further
boiling.
Double deck floating roof has two deck, one top and one bottom deck.
These two decks are separated by rim plates and bulk heads to form liquid-
tight pontoon compartments.
The top deck provides an insulating air space over the entire area and boiling
losses are held to a minimum.
The deck slopes to one or more drainage points and open emergency
overflow drains protect the roof from excessive water loads.
Internal floating roofs is a fixed roof tank with a floating roof inside.
The fixed roof provides a shade from the sun, protection from the wind and
also keeps the rain and snow off the floating roof.
Pontoon design:
Floating roofs shall have sufficient buoyancy to remain afloat on liquid with a
specific gravity of 0.7 and with primary drains inoperative for the following
conditions:
a. 250 mm(10 in.) of rainfall in a 24-hour period with the roofs intact, except
for double-deck roofs provided with emergency drains to keep water to a
lesser volume that the roofs will safely support. Such emergency drains shall
not allow the product to flow onto the roof.
b. Single-deck and any two adjacent pontoon compartments punctured in
single-deck pontoon roofs and may any two adjacent compartments
punctured in double-deck roofs, both roof types with no water or live load.
ACCESSORIES:
Following are the accessories of floating roofs:
Roof drain
Emergency drain
Bleeder vent
Rim vent
Foam seal
Supporting legs
Anti-rotation devices
Automatic tank gauging
Rolling ladder
Roof drain:
Roof drains are for removing water from floating roofs in open top tanks.
These drains are made out of pipes with swing joint assembly.
These pipe drains are also called as flexible pipe drains as these pipes extends
and shrinks with the varying level of the roof which depends on the product
height.
Emergency drain:
Water automatically drains into the tank when it reaches a certain level on
the roof. Rainwater cannot collect on the roof to endanger the safety of the
floating roof .
Bleeder vent:
Vents the air from under a floating roof when the tank is being filled initially.
After the liquid rises enough to float the roof off its supports the vent
automatically closes. When the tank is being emptied the vent is
automatically opened just before the roof lands on its support.
Rim vents:
Rim vents are provided to release any excess pressure in the rim space after
the roof is floating.
Foam seals:
One of the important component of a floating roof is the primary seal
between the floating roof and the tank shell.
A good seal closes the space effectively, yet permits normal roof movement
while protecting against evaporation loses.
Supporting legs:
Floating roof shall be provided with supporting legs.
Legs fabricated from pipe shall be notched or perforated at the bottom to
provide drainage.
The length of legs shall be adjustable from the top side of the roof.
The operating and cleaning position levels of the supporting legs shall be
specified of fixing the adjustable positions.
The legs and attachments shall be designed to support the roof and a uniform
live load of at least 1.2 kPa(25 lb/ft2)
Steel pads shall be used to distribute the leg loads on the bottom of the tank.
Anti-rotation device:
Required to prevent floating roofs from rotating and damaging rolling
ladder, pipe drains and seal.
A guided pole is used as anti-rotation device. The pole is fixed at the top and
bottom and passes through a well. The guide pole can additionally used as
gauging or sampling device.
Rolling ladder:
Rolling ladder provides safe and easy access from top of the tank to the
floating roof.
On floating roof a runway is provided, over this runway the ladder provided
with spark proof wheels will travel.
These ladders are provided with self-leveling treads.
CALCULATION OF THICKNESS BY VARIABLE POINT
METHOD:
Design by this method gives shell thickness at design points that
results in the calculated stresses being relatively close to the actual
circumferential shell stresses.
The bottom shell course thickness t1d and t1t for the design and
hydrostatic test condition shall be calculated using the following
formulae:
t1d = (1.06 - (0.463D/H)(HG/Sd)0.5 (2.6HDG/ Sd) + CA
t1t = (1.06 - (0.463D/H)(H/St)0.5 (2.6HD/ St)
First trial:
Course # 3
H= 49.212
tu = (2.6D(H-1)G)/Sd
1.216132
tl = 1.501837
As explained earlier repeat the steps and calculate the third shell course
thickness.
Similarly, shell thickness of other courses are calculated
ONE-FOOT METHOD DESCRIPTION:
This method of calculating the thickness of the shell is based on the
assumption that the tank is filled with water and the tension in each ring is
calculated at a point 12 in. above the center line of the lower horizontal joint
of the horizontal row of welded plates being considered.
The hydrostatic pressure varies from a minimum at the top of the upper most
course to a maximum at the bottom of the lowest course.
In determining the plate thickness for a particular course, a design based
upon the pressure at the bottom of the course results in over-design for the
rest of the plate. A design based upon the pressure at the top of the course
would result in under-design.
However, some consideration should be given to the additional restraint
offered by the plates adjoining a particular course.
In the lowest course, the plates of the vessel bottom offer considerable
restraint to the bottom shell course.This additional restraint of the bottom
edge is effective for an appreciable distance or height from the bottom of the
lowest course.
In an intermediate course with a course of heavier plates below, the top of the
heavier will be understressed.
Therefore, a design based upon the pressure at a height of 1 ft from the
bottom of the course may be considered conservative.