DESIGN CALCULATION

FOR
HCl STORAGE TANK
(Ø2500 X 4300mm(T/T) L) BASED ON BS-4994-1987

Rev Date Revision Description Prepared by:

a. Design Data – Operating Pressure and Temperature
b. Tank Capacity 26m3 to 25m3
1 15-06-2011 c. Nozzle Loading onto N1 & N9 ERM
d. Live load on Platform 1000Pa to 2500 Pa
e. Inclusion of Handrail Design
2 28-07-2011 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 Semi-Ellipse)

Di = 2500mm Ø.
L: 4300mm (T/T)
Fluid handle: HCl, 9.9% concentration
Specific gravity: 1.05
Operating temperature: Ambient.
Design temperature: 200C(min) to 600C(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,  = 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

 K=3 x 1.5 x 1.6 x 1.0 x 1.1 x 1.5 = 11.88

D) Design Unit Loading

1. Design unit loading, UZ

a) Determine the Load limited allowable unit loading, uL.

u
uL = K (EQ 2)
where u is UTUS from Table 5.

200
uL,CSM = 11.88 = 16.84 N/mm per kg/m2 glass.

250
uL,WR = = 21.04 N/mm per kg/m2 glass.
11.88
500
uL,FW = 11.88 = 42.09N/mm per kg/m2 glass.

b) Allowable strain,  = 0.2%

c) Strain limited allowable unit loading, uS.

uS = Xz  (EQ. 3)
where Xz is the unit modulus from Table 5.

uS,CSM = 14,000 x 0.2/100 = 28.0 N/mm per kg/m2 glass.

uS,WR = 16,000 x 0.2/100 = 32.0 N/mm per kg/m2 glass.

uS,FW = 28,000 x 0.2/100 = 56.0 N/mm per kg/m2 glass.

d) Design unit loading Uz.

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 Since UL < US, then the strain for each layer concerned shall be
determined. (clause 9.2.6 b)

uL
XZ
= (EQ. 4)

16 .84
CSM = 14 ,000 x 100

= 0.12%

21 .04
WR = x 100
16 ,000

= 0.13%

42 .09
FW = 28 ,000 x 100

= 0.15%

Therefore, the allowable strain, d = 0.12%. (Least of the two

values)

The Design unit loading for each layer, uZ, shall be determined
from the formula below:

uZ = Xz d (EQ. 5)

uZ,CSM = 14,000 x 0.12/100 = 16.8 N/mm per kg/m2 glass.

uZ,WR = 16,000 x 0.12/100 = 19.2 N/mm per kg/m2 glass.

uZ,FW = 28,000 x 0.12/100 = 33.6 N/mm per kg/m2 glass.

degrees) to the tank axis, the following formulas should be used:

In circumferential direction:

uZ = Xø d Fø (EQ. 5a)

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 In longitudinal direction:

uZ = XX d FX (EQ. 5b)

From Table 7, filament at winding angle 65°.

Fø = 0.5, FX = 0.5

From Figure 3, we can obtain the Unit modulus for winding

angle 680,

Xø = 18,000N/mm and XX = 4,400N/mm

Therefore,

(i) Circumferential uZ = Xø d Fø (EQ 5a)

= 16000 x 0.12/100 x 0.5

= 9.60 N/mm per kg/m2 glass.

(ii) Longitudinal uZ = XX d FX

= 4400 x 0.12/100 x 0.5 (EQ 5b)

= 2.52 N/mm per kg/m2 glass.

Summary of Design unit loading:

For CSM, uZ,CSM = 16.8 N/mm per kg/m2 glass.

For WR, uZ,WR = 19.2 N/mm per kg/m2 glass.

For Filament Winding,

Circumferential uZ = 9.60 N/mm per kg/m2 glass.

Longitudinal uZ= 2.64 N/mm per kg/m2 glass.

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E) Design For Construction.

1) Tank Shell Design.

i) Circumferential unit load, QØ = pDi/2 (EQ 7)
SG of liquid = 1.05
P = 0.034N/mm2
Di = 2500mm
0.034(2500)
QØ = = 42.50N/mm
2
Use 8 layers of CSM as chemical barrier, 2 layer of WR and 4 layers of filament
roving as reinforced layer.

Check:
Circumferential ULAMØ = (8 x 0.45 x 16.8) + (2 x 0.80 x 19.2) + (4 x 1.1 x 9.60)
= 133.44N/mm > QØ ------ OK!

pDi 4M
ii) Longitudinal unit load, Qx = + (EQ11)
4 Di 2

Tank Empty Weight = 1,530 kg (FRP Tank)

Liquid Weight (full) = 1.05 x 1000kg/m3 x 25m3

= 26,250 kg

Total Operating Weight = 27,780 kg

W = 27,780kg x 9.81m/s2
= 272,522N

Uniform load, w = 272,522N/5800mm

= 46.99N/mm

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 1300mm 1600mm 1600mm 1300mm

39.71 kN-m 39.71 kN-m

19.38 kN-m

14.50 kN-m 14.50 kN-m

9.93 kN-m 9.93 kN-m

61.09 kN
50.29 kN

24.89 kN

24.88 kN

50.29 kN
61.09 kN

Pressure due to liquid, p = 0.034N/mm2:

pDi 4M
Q= 
4 Di 2

0.034(2500) 4(39.71x106 Nmm)

Q= 
4  (2500) 2
Qx = 29.34N/mm ; 13.16 N/mm

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 Pressure due to vacuum, p = -0.005N/mm2:

pDi 4M
Q= 
4 Di 2
 0.005(2500) 4(39.71x106 Nmm)
Q= 
4  (2500) 2
Qx = 4.96N/mm ; -11.21 N/mm

Using 8 layers of CSM, 2 layer of WR and 4 layers of filament roving,

ULAMX = (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:

V 111,380 N
Qc = =
L 120 / 360 x  x 2500

= 42.54 N/mm

b) Due to weight onto nozzle N1 and N9:

pDi
Qc = ;
4
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;

92 mm 2 x 
Effective area = = 6,648mm2
4
20 kgx9.81m / s 2
Therefore p = 2
= 0.030 N/mm2
6,648 mm
pDi 0.030x 2500
Qc = = =18.75 N/mm
4 4

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
0.6tX LAM
Qp = (EQ 13)
FDo
0.6(14 )(14 ,000 x0.45 x8  16 ,000 x0.80 x 2  4,400 x1.1x 4)
Qp =
4(2500  2 x14 )
= 79.22N/mm > Qc ------- OK!

iv) Check minimum permissible thickness, tm, to prevent buckling due to

external pressure or vacuum:

L = 0.4 x 750 + 4300 = 4,900mm

Do = 2500+2x14 = 2,528mm
pvacuum = 0.005 N/mm2
F=4
X 14,000x0.45x8  16,000x0.80 x 2  4,400x1.10 x 4
ELAM = LAM  (EQ14)
t 14
= 6,811.43

L 4,900
  1.94 ;
Do 2528

0.17
E 
0.17
 6,811.43 
1.35 LAM   1.35x   11.77 ;
 pF   0.005x 4 

0.17
L E 
Since < 1.35 LAM  , then
Do  pF 
 0.4 pF L 
0.40

tm = Do  x  (EQ 16)
 E LAM Do 
 0.4 x0.005x4 4,900 
0.40

 2,528 x 
 6,811.43 2,528 

= 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:

t hi
Assume  0.005 and = 0.3
Di Di
hi
Conservatively, use =0.25 Ks values from Table 11.
Di
Use Ks = 1.30 for semi ellipsoidal dome.

QØ = 0.5pDi Ks (EQ 43)

= 0.5(0.034)(2500)(1.30)

QØ = 55.25 N/mm

But QØ  U1, M1, N1 + U2 + M2 + N2 + …

Using 11 layers of CSM + 3 layers of WR:

Qact = 16.8x0.45x11 + 19.2x0.80x3

= 129.24 N/mm > QØ = 55.26 N/mm ---------OK!

ii) Check minimum permissible thickness against buckling, tm:

pF
t m  1.7 Ro (EQ 19)
E LAM

But Ro  0.5Do K e (EQ 46)

and Ke = 1.50 (from Figure 15, BS4994:1987)

Ro  0.5 x 2,528 x1.50  1,896

X LAM 14,000x0.45x11  16,000x0.80 x3

ELAM = 
t 14
= 8,975

Therefore,

pF 0.034x4
t m  1.7 Ro  1.7 x1,896 =12.55 mm < 14mm, OK!
E LAM 8,975

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 iii) Check against vacuum, p =-0.005 N/mm2

QØ = 0.66pDi Ks (EQ 43)

= 0.66(0.005)(2500)(1.30)
= 10.725 N/mm < Qact, OK!

3) Mild Steel Saddle Support.

764

2800

A. Check Legs for compression:

Total weight of tank, W = 272,522 N

Factor of safety = 2
Design weight of tank = 545,044 N
Load on each support set = 545,044 / 3
= 181,681 N

Using 4 numbers of C-Channel 150 x 75 x 6.5

Maximum compressive load that center Leg will carry:
= 66,617 N

Allowable compression stress = 0.6Fy

= 0.6 x 248
Fc = 148.8N/mm2

P
Actual compression stress =
A
2
Where A = 2280mm (C-Channel cross section)

P 66,617
c = =
A 2280mm 2
= 29.22N/mm2 < Fc ------- OK!

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 B. Check Base against Compression:

Total Compressive force to carry = 181,681 N

Allowable compressive stress, Fc = 0.60Fy = 0.60x248MPa = 148.80 N/mm2

P 181,681N
Actual Compressive stress, c = = = 6.49N/mm2 <Fc, OK!
A 2800mmx10mm

4) Design of M/S Cage

2800

1300 1600 1600 1300

5800

A. Platform Beam support

FRP Grating, accessories loading = 150 Pa

Live Load = 2,500 Pa
=========
Total = 2,650 Pa = 0.00265 N/mm2
Safety Factor = 2
Maximum distance between beams = 1,600 mm
Beam length, l = 2,800 mm

Design uniform load, w = 0.00265N/mm2 x 1,600mm x 2

w = 8.48 N/mm

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 wl 2 8.48 x 2,800 2
Max bending Moment, M = = =8,310,400 N-mm
8 8
M 8,310 ,400 N  mm
SxReqd = = =50,772mm3 = 50.77cm3
0.66 Fy 0.66 x 248 MPa

Use C-channel 125x65x6.0mm Thk (Sx = 89.40cm3>SxReqd), is OK!

B. Design of Truss Members

a. Truss self weight

Assuming members using L100x100x6mmT,

Mass per meter of member = 12.2kg/m x 9.81m/s2
= 119.68 N/m

b. Handrails, and other accessories = 300Pa = 0.0003 N/mm2

Uniform load onto Top Chord of truss,
w = 0.0003N/mm2 x 2800mm/2
= 0.42 N/mm

c. Loading from Platform beam support:

Reactions from beam support

P1 = 0.00265N/mm2 x 2(SF) x 650mm x 2800mm / 2 = 4,823 N

P2 = 0.00265N/mm2 x 2(SF) x 1450mm x 2,800mm / 2 = 10,759 N
P3 = 0.00265N/mm2 x 2(SF) x 1600mm x 2,800mm / 2 = 11,872 N

d. Tank assembly load

Saddle support weight = 2,000 N per support

Tank Empty weight = 1,530 kg

Uniform load from empty tank = 1,530x9.81/5,800mm
= 2.59 N/mm

Support Reactions for saddle (see Shear Diagram on p. 14)

R1 = 2,770 N + 3,370 N = 6,140 N

R2 = 1,370 N + 1,370 N = 2,740 N

Total load transferred to joints of truss:

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 T1 = R1 + 2,000N = 8,140 N
T2 = R2 + 2,000N = 4,740 N

1300mm 1600mm 1600mm 1300mm

3.37 kN

2.77 kN

1.37 kN

1.37 kN

2.77 kN

3.37 kN

At Tank Operation:

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SUPPORT REACTIONS:

JOINT FORCE-Y (kN)

2 12.01
3 26.01
4 12.01

MEMBER END FORCES

Unit: Force: kN
MEMBER JT AXIAL SHEAR-Y SHEAR-Z

1 1 2.58 -.02 .02

2 -2.58 .13 -.13

2 2 .00 .09 -.09

3 .00 .04 -.04

3 3 .00 .04 -.04

4 .00 .09 -.09

4 4 2.58 .13 -.13

5 -2.58 -.02 .02

5 6 .00 .16 -.16

7 .00 .33 -.33

6 7 -6.15 .32 -.31

8 6.15 .29 -.29

7 8 -6.15 .29 -.29

9 6.15 .32 -.32

8 9 -.01 .33 -.33

10 .01 .16 -.16

9 1 5.39 .00 .00

6 -5.06 .00 .00

10 2 11.69 .01 -.01

7 -11.36 -.01 .01

11 3 13.04 .00 .00

8 -12.70 .00 .00

12 4 11.69 -.01 .00

9 -11.36 .01 -.01

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 13 5 5.39 .00 .00
10 -5.05 .00 .00

14 1 -5.95 .06 -.06

7 6.28 .05 -.05

15 3 7.34 .07 -.07

7 -7.01 .07 -.06

16 3 7.34 .07 -.07

9 -7.01 .07 -.06

17 5 -5.94 .06 -.05

9 6.28 .05 -.06

Maximum Axial Load = 12,700 N

Maximum Shear = 330 N

Check Member against Axial Load(Tension):

Cross-sectional area = 1,560mm2

P 12 ,700 N
T = = = 8.14 N/mm2
A 1,560 mm 2
Allowable Tensile stress, fT = 0.60Fy
= 0.60 x 248 MPa = 148.80 N/mm2> T, OK!

Check Member against Shear:

P 330 N
V = = = 0.21 N/mm2
A 1,560 mm 2
Allowable ==Shear stress, fV = 0.40Fy
= 0.40 x 248 MPa = 99.20 N/mm2 > V, OK!

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During Lifting of Tank:

SUPPORT REACTIONS:

JOINT FORCE-Y (kN)

7 14.00
9 14.00

MEMBER END FORCES

Unit: Force: kN
MEMBER JT AXIAL SHEAR-Y SHEAR-Z

1 1 .38 .06 -.06

2 -.38 .05 -.05

2 2 .37 .05 -.05

3 -.37 .08 -.08

3 3 .37 .08 -.08

4 -.37 .05 -.05

4 4 .38 .05 -.05

5 -.38 .06 -.06

5 6 .02 .20 -.20

7 -.02 .30 -.30

6 7 .00 .32 -.32

8 .00 .29 -.29

7 8 .00 .29 -.29

9 .00 .32 -.32

8 9 .02 .30 -.30

10 -.02 .20 -.20

9 1 .62 -.01 .01

6 -.28 .01 -.01

10 2 -8.28 .00 .00

7 8.62 .00 .00

11 3 1.15 .00 .00

8 -.82 .00 .00

12 4 -8.28 .00 .00

9 8.62 .00 .00

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 13 5 .62 .01 -.01
10 -.28 -.01 .01

14 1 -.80 .05 -.05

7 1.14 .06 -.06

15 3 -3.58 .07 -.07

7 3.92 .07 -.07

16 3 -3.58 .07 -.07

9 3.92 .07 -.07

17 5 -.80 .05 -.04

9 1.14 .06 -.07

Maximum Axial Load = 862 N

Maximum Shear = 320 N

Check Member against Axial Load(Tension):

Cross-sectional area = 1,560mm2

P 862 N
T = = 2
= 0.55 N/mm2
A 1,560 mm
Allowable Tensile stress, fT = 0.60Fy
= 0.60 x 248 MPa = 148.80 N/mm2> T, OK!

Check Member against Shear:

P 3260 N
V = = = 0.20 N/mm2
A 1,560 mm 2
Allowable =Shear stress, fV = 0.40Fy
= 0.40 x 248 MPa = 99.20 N/mm2 > V, OK!

C. Lifting Lugs Check

Plate Check

4 nos of Lifting Lugs to be weld connected to the Truss (Cage)

Total Weight of Empty tank c/w M/SCage, ladder, hand rails etc:

Empty Tank = 1,530 kg

M/S Cage = 2,300 kg
========
Total Lift Weight = 3,830 kg

Factor of Safety =4

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Design Loading per Lifting Lugs,
P = 3,830kg x 4 x 9.81m/s2 / 4 nos
= 37,572.30 N

Using 12mm thick M/S Plate(A36 steel, Fy = 248MPa)

a. Shear Stress Analysis

Allowable Shear of plate Fv = 0.40Fy

= 0.40(248)
= 99.20 N/mm2

P 37 ,572 .30
Actual Shear stress on plate = =
A (75  20 )12
= 56.93 N/mm2 < Fv --- OK!

b. Tensile Stress Analysis

Allowable Tensile of plate, Ft = 0.60Fy

= 0.60(248)
= 148.80 N/mm2

P 37 ,572 .30
Actual Tensile stress on plate = = = 16.92 N/mm2
A (225  40 )12

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Welding Check

a. Total welding length of Lifting lug to base plate,

lLL = 2 x 225mm = 450mm

Effective length = 0.70 x 450 = 315mm

b. Total welding length of base plate to Cage,

lBP = 200 + 2x 100 + 100 = 500mm

Effective length = 0.70 x 500 = 350mm

Using E60 electrode(Fu = 414MPa), Fw = 0.38Fu = 157.32 N/mm2

Since Fw of weld is higher than allowable shear capacity of plate, use

plate’s value to be conservative.

Therefore, Fw = Fv = 99.20 N/mm2

Throat of weld = 0.70 x 6mm

P 37 ,572 .30
Required length of weld = =
f w xthroat 99 .20 x(0.70 x6)

= 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

550

1100

550

Check for Horizontal Rail:

wL2 0.75 N / mmx 1000 mm 2

M= = = 93,750 N-mm
8 8

M 93,750 Nmm
SxReqd = = = 572.80 mm3 = 0.57cm3
fb 0.66 x 248MPa

Check for Vertical Rail:

M = P x L = (0.75N/mm x 1000mm) x 1100mm

= 825,000 N-mm

M 825,000 Nmm
SxReqd = = = 5040 mm3 = 5.04cm3
fb 0.66 x 248MPa

Use of 40mm x 4mm Thk CHS (Sx = 5.92cm3) is SAFE!

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