STORAGE TANKS Improve selection and sizing of storage tanks Guidelines help engineers select the best tank design for plant applications A. HEYDARI GORJI and H. KALAT JARI, SAZEH Consultants, Tehran, Iran further processing into end-products. Within the plant, the feedstocks and raw materials undergo several processes steps by various operating units. Because the flow of feedstocks and other raw materials is not exactly instantaneous, tanks are necded to hold various product streams. Finally, storage tanks ate used to hold and store finished products until distribution, Storage tanks are classified in different ways. Tanks are clas- sified depending on the nature of the product to be stored (atmospheric, low pressure and medium pressure), operating, temperature (ambient and low temperacure) as well a the type of construction (aboveground or underground and double wal) A significant factor to consider when selecting storage tank is effects from vapor pressure created by the stored product at the ambient temperatures S ‘torage tanks are used to receive and hold raw materials for Atmospheric and low-pressure tanks. Six basic tank designs ae used for liquid storage vessels fixed roof (vertical and horizontal) external floating roof, domed external (or covered) floating roof, internal floating roof, variable vapor space and. medium pressure. A brief description of each tank is provided here: Fixed roof. The fixed-roof tank when compared to an open- top tank, which is used mainly in water and wastewater teat- ‘ment, contains product vapors with reduced potential for fir. Since the liquid surface is exposed, the tank-vapor space results, significant product evaporation occurs. Fixed-roof tanks are generally used to store products that do not readily vaporize at ambient or stored temperature con- ditions. For instance, fixed-roof tanks can be used to handle. non-volatile products such as gasoil, lubricating oils, asphalt and fuel oil, Regarding emission control, ixed-roof tanks without vapor- recovery facilities are restricted to materials with a crue vapor pressure (TVP) of less than 1.5 psia at the tank operating tem- perature. This type of rank consists of a cylindrical steel shell ‘with a permanently fixed roof, which may vary in design from cone or dome shaped to flat. Each type can be further sub- divided into non-pressure, low-pressure and high-pressure fixed- roof tanks: + Non-pressure fixed-roof tanks are used for storage at atmo- spheric pressure and are provided with open vents. + Low-pressure and high-pressure fixed-roof tanks are used for storage at a low. and high-internal pressure or vacuum ype of tanks Design presure/vacuum, mbar (gauge) Non pressor 75/25, Tow pressure 20/60 igh pressore 50760 respectively. They are provided with pressure/vacuum relief valves (breather valves) that should be set to be fully open at the design pressures “Table 1 summarizes the maximum design conditions foreach ‘ype of fixed-roof tanks. Atmospheric tanks should not be used to store liquids at temperatures at or above its boiling point. Losses from fixed-roof tanks are caused by changes in tempera ture, pressure and liquid level. Fixed-roof tanks should be either freely vented or equipped with a pressure/vacuum relief valve. Floating roof. For this tank type, the roofis not fixed to the shell, bur “floats” on the liquid; so, no vapor space is created. Because the floating roof rests directly on the liquid surface, it significantly diminishes stock evaporative losses and reduces the hazards associated with handling a large, possibly combustible tank vapor space. Floating-roof tanks are utilized when the TVP of the stored liquid at operating temperacure is less than L1.1 psia. For TVPs greater than 11.1 psia, a medium-pressure storage tank or vapor- recovery system is mandatory. There is 2 preference for floating roof over fixed-roof tanks as the size ofthe tank can be increased, as the vapor pressure of the stored liquid increases, and the flash point is below the storage temperature. Floating-roof tanks are preferred to store products susceptible to high electric charge due to friction such as light products, kerosine and crude oi External floating-roof tanks. This tank type is designed to work at atmospheric pressure. Although normally recom- mended only for diameters of 15 m and greater, this does not exclude applying this design for smaller-diameter tanks under special circumstances, At minimum, the diameter of an external floating-r00f rank should be equal to its height to enable using a normal rolling ladder for roof acces. ‘A typical external floating-roof tank consists of an open topped cylindrical ste! shell equipped with a roof that floats on the surface of the stored liquid. The floating roof consists of a dec, fittings and rim-seal system. YOROCARBON PROCESSING OCTOBER 2006 | 95STORAGE TANKS Era Tank diameter, m 7a 0 Ts ear Flash pomtless High ad lw presse Tigh and low pressure cone External foatng rook Trterna oating ook than 21°C cane roof and dome rootexteral and ——_(preferablyilowrpressre intemal foating oof cone and dome oof Fisch part 21°C and Lowe pressore Gone ook Tawepresire cone and dame Exiernal and internal floating Exeral Hosting root higher but less rooffexteal and internal roof preferabyMow pressure than 5% floating root ‘cone and dome roof Flashpoint 35° Tor pretre cone root Tor pressure cone and Tior-presure coe and Tenpressre cane root ™ and higher dome oof ome rot aim dana ornon pare creo Floating decks are of wo general types: pontoon and double- dec. Typical pontoon external floating-roof tanks are shown in Fig. 1. With all ypes of external floating-roof tanks, the roof falls, and rises with the liquid level within the tank. Extemal floating decks are equipped with a rim-seal system, which is attached t0, the deck perimeter and contacts the tank wall. The purpose of the floating roof and rim-seal system is to reduce evaporative loss of the stored liquid. Internal floating-roof tanks. This tank design was devel- coped in the mid-1950s to provide protection of the floating roof from elements, including lightning strikes. The tank vapor space, which is located above the floating roof and below the fixed roof, includes circulation vents to allow natural ventilation, thus reduc ing accumulation of product vapors and mitigating the formation, of a combustible mixcure (Fig. 2). ‘Such tanks can be used when: + Snow loading on a floating oof may be a problem since snow ‘or water on the floating roof will affect the operating buoyancy * Contamination by rainwater of the liquid stored in a floating roof tank is unacceptable + Environmental or vapor loss problem with fixed-roof tanks are evident * Contact of the stored liquid with air should be avoided. Internal floating roof can be installed in existing tank as well as new tanks. 196 | croREn 206 xOROCARION POCESSNG “There are wo basic types of internal floating-roof tanks: + Tanks in which the fixed roof is supported by vertical col- ‘umns within the tank «Tanks with a self-supporting fixed roof and no internal sup- port columns. Installing 2 floating roof minimizes evaporative loses of the stored liquid. Evaporative losses from floating roofs may develop from the deck fitings, non-welded deck seams and annular space between the deck and tank wall. In addition, these tanks are freely, vented by circulation vents at the top of the fixed roof. The vents ‘minimize the accumulation of organic vapors in the tank vapor space in concentrations approaching the flammable range. An internal floating-roof tank that isnot freely vented is considered a pressure tank Domed external floating-oof tanks. Domed external (or covered) floating-roof tanks have a heavier deck used inthe exter- nal floating-roof tanks as well asa fixed roof at the top of the shell, such as an internal floaing-oof tank. Domed external floating roof tanks usually result from retrofitting an external floating roof tank with a fixed roof. The function of the fixed roof in the domed external floating-roof tank is not to act as a vapor barrier. However it should block the wind. Like the internal floating-roof tanks, these tanks are frely vented by circulation vent at the top of the fixed roof. A typical domed external loating-roof tank is shown in Fig. 3.oe ec ee ene Medium-pressure tank. Spherical-shaped storage tanks are used to store products with high vapor pressure in very large capacity (Fig, 4). Spherical storage tanks can be 10 times larger than baller ranks. Bullet eanks are long cylindrical (usually horizontal) pressure HYDROCARBON PROCESSING STORAGE TANKS ra eee vessels most frequently used for liquid petroleum gas (LPG). ‘The working pressure ofthese tanks can be from 1 t0 70 barg ot greater. These tanks often have hemispherical head. High-pressure ‘material such as propane and ammonia can be stored in these tanks at ambient temperature.Sphere, hemispheroid and spheroid are rarely used in petro- eum and petrochemical industri Selection of vertical tanks. Table 2 summarizes the types and ranges of tanks recommended to store different classes of liquid products. Some important factors such as evaporation losses, pumping loses, climatic conditions. air pollution, soil conditions and local regulations shall also be considered when selecting che ‘most suitable type(s) and size(). Sizing and design procedure. The presented procedure includes method to calculate the diameter and height of afixed- roof and external and internal floating-roof tanks, minimum, liquid level and maximum liquid level in the atmospheric and low-pressure tanks.Forfloating-roof tanks, rank capacity depends on the type of floating roof, roof seal, roof cover and internal rank. construction that may affec chese guidelines Nominal capacity of the tank. Nominal tank capacity, assumes thatthe flac-bottom rankis filed tothe ropof the shell plate and is calculated by summing the net capacity ofthe tank (net work- ing capacity), dead capacity of che tank and liquid volume pumped ‘outof the tank in three minutes (beeween LLL and LLLL). ‘The later item is important from an operational point of view, because the operator will switch off the pump three min- ‘utes after hearing the alarm or interlock shutdown system will, switch off the pump. xD” Vy =(Hi+ Hy +h) 4M Vy @ Hy = Tank dead height Hz = Vapor space height of maximum safe working level V; = Net working capacity ofthe tank V4 = liquid volume pumped out ofthe tank in three minutes. Diameter and height of the tank. The following steps list the assumptions and operations to find the diameter and height, of the tank: 1. Assume the first larger value of net working capaciey (V;) from Table 3 (considering as V= V;) 2. Read the related diameter to V from Table 3. Consider that the diameter of a floating roof shall at least be equal to its, height. 3. Caleulate the nominal tank capacity (Vj) from Eq, 1 using this diameter. 4, Compare calculated nominal tank capacity (Vy) with Vi * If Vy V, chen select the related diameter and height of V from Table 3 as diameter and height of the tank. “TE Vyy> Ve then pick the next greater value for Vfrom the ‘Table 3 and go to Step 2 until Vy V. ‘Tank-height calculation for a fixed-roof tank. To find the tank for afxed-roof tank, follow these steps: Bottom dead height. Tank dead height isthe distance between tank outlet nozale (connected to pump suction) and tank floor. Consider the height needed to prevent vortexing in the connec- tion poinc of the outlet nozzle with the rank on the outlet line [This height is assumed equal to outlet line diameter (4) ] STORAGE TANKS ce cra en Cree In this regard, cank dead height (LLLL) is calculated by: Habe ed, @ 2 where: b= dy +5 in. Please note that che minimum size of His 24 in. (sce Fig, 5). ‘Vapor space height of the tank can be calculated by: 3 Hy= 34, 8) where: = overflow line diameter. ‘The minimum value of Hp is 18 in, Note: If the level switch high-high is considered in a fited-roof tank, then the overflow nozale is not installed. Floating roof. To find the tank fora floating-roof tank, follow these steps: Bottom dead height. The same procedure used for the fixed- roof tank should be applied. However, designers should consider that the roof must be supported approximately 1.2 m from the bottom for external floating roof and 1.6 m of the bottom for internal floating-roof tank, to keep the roof floatings therefore: HyOROCARBON PROCESSING OCTOBER 2006 | 992 = z = S 3 = 2 a WU Ge OES UTS CY ULE SEM MTR OR GER Ws Ban e808 airy = BHD WTB Sos Levee Give One wR Gam wwe Loe wea HEH wears Wer % Cee OGRE KLSTE vaOOF GIN GSE GONE SVE TIVE vive Lao WEL aL tS HY @ GOES BESS VOEOE ivaww OLWGE GREE GlVOE OWS GEE oWNw) oassI [o0EI eeLOL 91ers Lae % BLESS GREE vey GUT —OOOBE eee peo SaUGL SIE IOGLI war Elva wocOl eee LeEo WUE Te 7% ans9s SETS VOWS oGvOR U6ISE WOwIE SUCE WORE EOE wOTLL Tee 5. 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Flash point: 32°C Input parameters: Net working capacity: ‘Withdraw rate: 180 m#fhe Inlet/outletioverfiow nozzles: 10 in./12 in/12 in. Ait foc a lectesCacueadperaeten had + Sin =t2in. Sin =17in : Heats dani 115 (4ln)a36m. <0 y= 2dy 15 (12m) = 181-487 mm From Table 3: D = 25,000 mm and H; = 20,000 mm for Va 9817m? as eae 183 mm ca hy = HLL — (Hy + hy) = 136 mm V.= 66.7 From 8q. 1: Vy = 9,817 mh? (Vy = V) Final results: D = 25,000 mm Hrs 20,000 mm HULL = 19,543mm HLL = 19,360 mm LLL = 1,026mm LLL = 890mm External floating-roof tank: Hy = 1.2m Internal loating-roof tank: H; = 1.6m. Maximum safe working level. Maximum safe working level is allevelin which any additional produce will overflow and contact, ‘or damage will occur. This level is taken approximately 0.6 - 0.8 mbelow the top curb angle. External loating-roof tank: Fly = 0.8m Internal loating-roof tank: H=0.6m for D<15 H,=08m forD=15. Low-liquid level in the tanks. Low. liquid level (LLL) in fixed and floating, roof tanks isthe summation of tank dead head (#1) and height of the liquid in three-minute suction (4), which can be calculated as below: 929 iat xD (thy = HILL — (Hh + hg)» whichever is greater where Pump discharge flowrate, m?/hr STORAGE TANKS Fank diameter, m iquid height above LLLL in three-minute suction, m, High-liquid level in the tanks, After calculating H;, high- liquid level (HLL) height from tank bottom for fied- and float- ing-roof tanks can be calculated as HLL= (Ha +h) 6 +, is the height between high-high liquid level (HHLL) and HLL and calculated as: oy ‘shall be at least 100 man. Note: Some internal parts such as heating coils inside tanks ‘may affect the height and liquid levels. Overflow-liquid line sizing, The overflow line inside diam- cer is determined as 4 (24 ae) o AP p where: W «Vessel inflow, kg/see AP = Pressure drop (pa), [as experience, 996 Pa can be used] N = Friction los (for simple overflow p= Density, kg/m? y= Overflow internal diameter, m. 5) LITERATURE CITED * American Petroleum Intute, "Welded Stel Tanks for Oil Seorage,” 10th ed, ‘Scandard 650, Washington, DC, 1998. 2 Mead, J, The Engelpeia of Chemical Pocos Equipment, Reihold Publching, [New York, 196, pp. 941-956 2 Burk, H. Sy ety *Conceprual Design of Refinery Tankage,” Chemical Engineering, No. 88, Vol. 17, Aug 24, 1981, pp. 107-110. ‘ranian Petoleum Standard, Procest design of liquid and gas traner and storage,” December 1997, ACKNOWLEDGMENT ‘The authors woul ke wo thank the Board of Directors and Process Division Director of Sneh Consultants Company for their soppore iakbar Heydari Gorjt isa senior process engineer at SAZEH Consukats in Tran, an, He 2 PhO student of chem | cal engnering and olds 8S and MS degrees in ceric engi- = neering al om the Amrkabir Unversity of Technolgy (eran Peitechni) He sof speciation has nuded ges separation vith membranes and hi indus experience has focused on simulation, bas and detail design of gas and petrochemical plans. He can be reached a emai a eycari@sazehcoie Hamid Reza Kalat Jarl isa serior process engineerin the process department of SAZEH Consultants in Tehvan, ta. Mr Keats been with SAZEH Process dpartnt fr fou years. Previous he worked or our years wit Total Fina Bt and ght years with National ranian Gas Company a a process engineer {and proces conto engineer He helde 385 degree in cherical engineering fom the Sharif Univesity of eehoogy and an MS degree in chemical engreerng fom “bat Modares Uiversiy He can be reached ate: hkalajari@saze cit tnvonocanson pRocrssine OcrOUER 206 | 101