Vessel and Tank PEM Sem I 2021

TM3407 Perancangan Tangki dan 15/10/20
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Storage Tank
Dr. Rachman Setiawan
Introduction
 Vertical, aboveground atmospheric-pressure storage
tanks are commonly used in processing facilities.
 For more than a century, storage tanks have been in use
within the petrochemical industry, fulfilling their intended
purpose: to store products
 By definition, an atmospheric tank has a design pressure
less than 2.5 psig
 Most ASTs are
constructed out of welded
steel plates. Older tanks
have riveted or bolted
seams and newer tanks
are welded.
Rachman Setiawan 2020 1

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Tank vs Pressure Vessel
 Tank, Storage tank, atmospheric tank
 Pressure vessel, tank, column, drum
Tank vs Pressure Vessel
Tank Pressure Vessel

 Atmospheric pressure  Having significant internal
(approx. 0 barg, max. 2.5 pressure or external
psig) pressure
 Fluid: liquid with a certain  Fluid: either gas, liquid, or
SG both (mix)
 Main load: hydrostatic  Main load: static
pressure, dead weight, pressure, dead weight,
live load live load

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Applicable Codes
API Std. 650 API Std. 620

 Internal pressure: 0 – 2.5 psig  Internal pressure: 2.5 – 15 psig
(atmospheric pressure) (may contain small internal
 Application for safe and pressure)
economical OIL storage tanks  Application: to hold or store a)
liquids with gases or vapors
above their surface or, b)
gases or vapors alone,
including refrigerated fluid
Scope of Mechanical Design

 Tank Sizing: diameter, height
 Basic configuration
 Material selection
 Wall thickness calculation: thickness for each course
 Other components design: bottom plate, roof, column,
rafter, etc.

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Design Process
Capacity Consideration
 Nominal capacity: capacity as printed on the tank wall
 Geometry capacity: the volume of vertical cylindrical
section
 Storage capacity: the volume from the tank bottom to
the maximum design level
 Net working capacity: the volume between HLL and
LLL or HHLL and LLLL

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 The overfill protection capacity of a tank is that between max.
operation level (H2) and the design liquid level (H1).
 The design liquid level is set higher than the normal operating
liquid level to provide a safety margin for upsets.
 The overfill section is filled with vapor under normal operating
conditions
Tank Capacity

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 For an in-process tank, net working capacity = required
retention time of the liquid x flowrate.
 For large, off-site storage tanks, the net working capacity is
determined by performing an economic analysis, including
items such as the savings in bulk transportation costs, the
size and frequency of shipments, and the risks of a plant
shutdown.
 In some cases, use multiple
tanks, if the size of a single tank
is physically unrealistic, or if
separate tanks are needed for
other reasons, such as
dedicated service or rundown.
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Tank Capacity

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Tank Capacity
Classification
 Tangki penyimpanan bawah tanah

(Underground storage tank, UST)
 Tangki penyimpanan diatas tanah

(Aboverground storage tank, AST)

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Classification
 Jenis-jenis AST
 Vertical Cylinder
 Horizontal Cylinder
 Spherical
Classification
 Jenis-jenis Atap (AST Vertikal)
 Fixed roof
 Dome
 Conical
 Umbrella
 Floating roof

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Classification
Classification

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Roof Type Selection
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Roof Type Selection

 Cone Roof Tank (CRT)
 This type is used for liquid whose vapor pressures are
relatively low such as Gas oil and heavier, water,
chemicals and lubricating oil
 Reffering to the graphs above, if the contents are
stored in the lean area at the maximum expected
storage temperature, CRT can be applied
 If the contents belong to the rich area, yet using CRT,
nitrogen/gas blanket shall be applied.
 This tank type shall also be used for non-flammable
liquid such as chemicals, water. However, the vapor
pressure shall be checked by the same way of
flammable liquid.
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Roof Type Selection

 Floating Roof tank (FRT)
 This type is usually used for storing liquid having high
vapor pressure such as Crude oil, Gasoline and
naphtha.
 In a tropical atmosphere, Kerosene may be stored in
this type
 This tank type has no vapor space, so vapor loss can
be minimized, however small amount of rain water
contamination through the roof seal is unavoidable,
unless using internal floating roof.
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Roof Type Selection

 Dome Roof tank (DRT)
 This type is used to store liquids having around 1
kg/cm2 absolute vapor pressure, because it is
applicable for higher design pressure up to 0.15
kg/cm2 gauge (1500 mm of water column). Therefore,
this type is mainly used for refrigerated liquid storage.
 This type may also be used for liquids having low
vapor pressure instead of cone roof type, if the tank
cost is lower than the cone roof type.
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Oil/Fuel Storage Facility

 Pump & Piping
 Pump & piping is used to transfer liquid:
 from the delivery source to the ASTs at the facility (transfer or
fill piping),
 between tanks and dispensing pump (manifold piping),
 and from facility tanks to other associated tanks and other
sources (distribution piping).
 Pipes are buried or aboveground. Aboveground
piping should be supported up off the ground and
protected from moving vehicles such as trucks.
 Valves control the flow of oil between tanks and other
tanks, delivery barges and other sources. The most
common type of valves are ball valves and gate
valves.

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 Secondary Containment
 The purpose of secondary containment is to prevent
petroleum products from flowing onto the land or into
the water if there is a spill through dikes.
 The following must be met:
 Large, high and strong enough to hold the contents of the
largest tank plus 10% for local precipitation.
 constructed or lined with material that will hold products and
prevent them from seeping into the ground, e.g. high-density
polyethylene (HDPE),
 May use additional concrete walls and slabs, along with a
leak detection system

 Secondary Containment

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 Auxillary Equipment
 Fencing: lockable, to keep unauthorized people,
vandals and animals out.
 Lighting: sufficient lighting to prevent vandalism and
help detect spills at night.
 Signs: “No-smoking” signs must be posted around the
facility so they can be seen from every side of the
tank farm. Also “Danger”, “Warning” or “Authorized
Personnel Only” signs must be posted to warn
unauthorized individuals from entering the facility.
Operating Condition
 Operating Temperature
 Density of the contents in a tank is defined by the
Operating temperature and is used as the base for
tank sizing and the tank wall thickness calculation
 Operating temperature shall be selected from:
 Run-down temperature from process units
 Ambient air temperature (annual mean or annual highest
mean temperature)
 Receiving temperature from a tanker (if the contents receives
from a tanker)
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Operating Condition
 Operating Temperature
 Density at the highest operating temperatures is used
for tank sizing
 Density at the lowest operating temperatures is used
for the tank wall thickness calculation.
 However, in the following cases, the density at the
highest temperature shall be used for both tank
sizing, and wall thickness calculation
 The tank has a heater to maintain the storage temperature.
 The tank only receives run-down fluid from process units.
 The tank has a temperature compensating level indicator.
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Operating Condition
 Operating Temperature (cotd.)
 The maximum and the minimum storage
temperatures shall clearly be mentioned in the offsite
design basis.
 Operating Pressure
 Forstorage tanks, Operating pressure is
approximately atmospheric pressure.
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Design Condition
 Design Temperature
 Design temperature = 10°C + maximum operating
temperature (jika temperatur maksimum selama
operasi normal tidak dapat diperkirakan), dan dipakai
untuk perancangan mekannikal (wall thickness calc.)
bukan penentuan ukuran dasar (tank sizing)
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Design Condition
 Design Pressure
 Design pressure ditentukan berdasarkan tekanan
untuk venting system.
 Standard setting pressures dari venting system
adalah sbb:
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Design Consideration
 Design factors:
 design metal temperature
 design specific gravity,
 corrosion allowance (if any),
 design wind velocity.
 Special considerations:
 Foundation, soil condition
 Service conditions, e.g. H2S, Weld hardness,
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Tank Components
 Shell
 Roof
 Rafter
 Column
 Top Angle
 Bottom Plate
 Welding Joint
 Nozzles & Manhole
 Anchor Bolts
 Venting
 Gauging
 Ladder

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Shell
Collumn & Rafter
Top Angle
Components Design
 Shells
 Shells are usually made of mild steel, e.g. A-36, with
sufficient corrosion allowance is added to the
thickness of the structure.
 If product contamination due to corrosion cannot be
tolerated, then the tank material is upgraded to
stainless steel or a high alloy.
 Alternatively, carbon steel tanks can be lined with
corrosion-resistant materials such as rubber, plastic
or ceramic tile.

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Component Design
 Shell Design (API 650 section 3.6)
 Beban utama adalah tekanan hidrostatik  bervariasi
terhadap ketinggian dari alas
 Dua alternatif perhitungan:
 One-foot method
 Variable-design point
Stepped thickness
plate
Hydrostatic pressure
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Component Design
 Shell Design
 One-foot method
Tebal minimum dari 1 course pelat dihitung berdasarkan tekanan
hidrostatik pada 1 ft di atas batas bawah pelat
pressure at 1 ft
Real pressure distribution 1 ft
Design Shell Thickness Hydrostatic Test Shell Thickness
4,9 D ( H  0,3)G 4,9.D(H  0,3)

td   CA tt 
Sd St
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 Variable-Design-Point Method
Untuk tangki yang relatif langsing L 1000
 ; L  6 Dt in
H 6
Tebal desain Tebal hydrostatic Test

Shell
bawah
Shell atas
Symbol Keterangan
D Nominal Tank Diameter (mm)
H Maximum Design Liquid (mm)
G Design Specific of the Liquid (gram/cm3) Perhitungan berulang
CA Corrosion Alowance (mm) diperlukan untuk
Sd Allowable Stress for the Design Condition (MPa) mendapatkan x yang
optimum
St Allowable Stress for The Hydrostatic Test (MPa)
Ikuti Prosedur 5.6.4
x point at which the pressure is considered to be API 650
the optimum 39
Component Design
 Minimum plate thickness (Guideline API 650):
Tank Nominal Diameter (m) Nominal Plate Thickness (mm)
D ≤ 15 5
15 ≤ D ≤ 36 6
36 ≤ D ≤ 60 8
60 < D 10
40

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Components Design
 Fixed Cone Roof
 supported cone roof is a roof formed to approximately
the surface of a right cone that is supported
principally either by rafters on girders and columns or
by rafters on trusses with or without columns.
 self-supporting cone roof is a roof formed to
approximately the surface of a right cone that is
supported only at its periphery.
Components Design
 Fixed Cone Roof
 supported cone roof is a roof formed to approximately the
surface of a right cone that is supported principally either by
rafters on girders and columns or by rafters on trusses with or
without columns.
 The slope of the roof shall be 1:16 or greater
 Max allowable rafter span:
Collumn & Rafter

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Rafter
 Stresses occur at the rafter :
 Due to supported roof plate
+
 Due its weight
=
 Total stresses
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Components Design
 Fixed Roof
 Self-supporting dome roof is a roof formed to
approximately a spherical surface that is supported
only at its periphery.
 Self-supporting umbrella roof is a modified dome roof
formed so that any horizontal section is a regular
polygon with as many sides as there are roof plates
that is supported only at its periphery.

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Column
 Allowable compression stress on pipe column, based on
AP1 650 section 3.10.3.4 : Symbol Keterangan
 1   L/r   Fy
  0.5 E Modulus Elasticity (Ksi)
 2π E 
2
2


2 
2C C  C C   

Fy Yield stress of column (Ksi)
3  L/r   L/r 
3  Fy  w Dead weight (kg/m)
5/3   3
A Pipe section area (cm2)
8C C 8C C
Fa  r Radius of gyration (mm)
1.6   L/200r  L Unbalance length (mm)
When l/r exceed Cc, Fa Allowable compression stress (MPa)
 Compression stress on pipe column :
WC  R1  N  w  L
WC
C   Fa
A
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Top Angle
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Top Angle
 Maximum design pressure at the shell base
0.00127 w 0.00382M
Pmax   0.08 th 
D3 D3
Q  qDH
M  QH 2
Simbol Keterangan
w Total weight of the shell and any framing (but not roof plate) supported by the
shell and roof (N) = 511.222 N
M Wind Moment (Nm)
th Roof plate thickness (mm) = 5 mm
D Tank Diameter (m) = 13,50 m
q Wind drag force per unit area (kg/m2) = 25 kg/m2
H Maximum design liquid level (m) = 13,97 m
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Top Angle
 Reqired compression area at the roof to the shell junction :
D 2 P  0.08 th 
  compression area
1.1tanθ 
 Compression area :
A  WC t c  Wh t h  A1
WC  0.6R C t C 
0.5
0.5
R 
Wh  0.3 C t h 
 sinθ 
Symbol Keterangan
WC Maximum width of participating shell (mm)
Wh Maximum width of participating roof (mm)
RC Inside radius of tank shell (mm)
tC Thickness of shell plate (mm) example
A1 Cross section angle (mm2), for exampe L75x75x9 = 12.69
mm2
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Stability Against Wind Load

 Maximum height of the unstiffened shell :
H1  9.47 t  t/D   
3 0.5
 160/V 
2
Simbol Keterangan
H1 Maximum heght of unstiffened shell (mm)
t Thickness of the top shell course (mm)
D Nominal tank diameter (m)
V Wind Velocity (m/s)
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Stability Against Wind Load
 Height of transformed shell :

5
 TUniform
H  W  W   
Shell
W TUniform T Actual Wtr
Course
tr
 TActual  #1 2400 5 8 741.16
#2 2400 5 6 1521.45
#3 2400 5 6 1521.45
Simbol Keterangan #4 2400 5 5 2400.00
Wtr Transposed width of each shell course (mm) #5 2400 5 5 2400.00
TUniform Thickness of the top shell course (mm) = 5 mm #6 2400 5 5 2400.00
TActual Thickness of the shell course (mm) #7 2400 5 5 2400.00
#8 2400 5 5 2400.00
Total 6184.06
Because H1 = 83,139 mm > Σ Wtr = 6,184 mm

so intermediate wind girder / stiffener is not required
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Shell Stability Againts Earthquake

 Overtuning Moment
M  ZIC1WS XS  C1Wr Ht  C1W1X1  C2W2 X2 
Z = Seismic zone
I = Importance Factor
C1 = Lateral force coefficient
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 C2 = function of the natural period of the first sloshing
T = kD0.5 = 2.15
k = faktor from fig E-4 = 0.585
C2 = (0.75 x S)/T = 0.523

S = site coefficient from tale E-3 = 1.5
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 WS = Total weight of tank shell
 XS = height from the bottom to the center gravity
 Wr = total weight of the roof
 WT = total weight of the tank contents
 W1 = weight of the effective mass of the tank contents
that move in unsion with the tank shell, from fig E-2
 W2 = weight of the effective mass of the tank contents
that move in the first sloshing mode, from fig E-2
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 X1 = height from the bottom of the tank shell to the centroid

of the lateral seismic forceapplied to W1, from fig E-3
 X2 = height from the bottom of the tank shell to the centroid
of the lateral seismic forceapplied to W1, from fig E-3
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 Resistance to overtuning
Weght of tank contents that may be used to resist shell overtuning moment:
wL  99t b Fby GH
Symbol Keterangan
G Specific gravity (kgm/m3) = 866.30 kgm/m3
H Maximum design liquid level (m) = 13.97 m
D Nominal tank diameter (m) = 13.50 m
Fby Minimum specified yield strength (MPa) = 250 MPa
tb Thickness of the bottom plate under shell (mm) = 8
mm
wL shall not exceed than 196 G.H.D
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Stress Analysis
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Stress Analysis
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Allowable External Load on Shell Opening

App. P API 650
 Due to piping loading, shell opening experience
external load, in various direction:
 Radial load, FR
 Longitudinal load, FL
 Longitudinal Moment, ML
 Torsional Moment, MT
 Circumferential Moment, MC
 Analysis to obtain piping loading can be done using
Piping stress analysis software, e.g. CAESAR II.
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Allowable External Load on Shell Opening
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Venting
 Venting Capacity
 Due to air temperature:
 The venting quantity shall be calculated based on the
maximum vapor volume of the tank, in other words the vapor
space at the minimum operation liquid level,
 Reference to API Std 2000 "Venting Atmospheric and Low-
pressure Storage tanks" (or JIS 8501 Design of Steel Tanks)
 Tank filling and emptying operation
 Equivalent air flow rate to the maximum liquid filling rate and
emptying rate are the capacity requirement
 of out-breathing and in-breathing respectively
 TotalCapacity: summation from 2 above  ‘Normal
max. venting capacity requirement’
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Venting
 Emergency venting:
 Emergency venting requirement:
 Emergency vent(s) or pressure relief devices
 Weak roof-to-shell attachment (frangible joint )
 The emergency venting capacity requirement for fire
exposure can be calculated by API STD 2000 "
Venting Atmospheric and Low-pressure Storage
tanks"
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Gas Blanket
A nitrogen or fuel gas blanket is applied to avoid
oxygen contact at the surface of stored liquid in a
cone or dome roof tank.
 The capacity is given by the maximum inbreathing
requirement as calculation above.
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Welding
 Typical Weld Joints:
 Vertical Shell Joints  Butt joint with complete
penetration & complete fusion from double welding or
equivalent
 Horizontal Shell Joints  Complete penetration and
complete fusion. Top angles may be attached to the
shell by a double-welded lap joint.
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Welding
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Welding
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Tugas Pembahasan API 650

1. 5.1
2. 5.4 – 5.5
3. 5.7.1
4. 5.7.2
5. 5.9
6. 5.10
7. 5.11

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Tank Basic Inspection

 Soundness
 Visibleleaks? Must be stopped & repair
 Stains on the ground around the tank?
 Seams & weld
 Corrosion protection
 Any sign of rust/corrosion?
 If using sacrificial anode: make sure there is sufficient
metal left
 If using ICCP: make sure the proper amount of
electricity is flowing
Tank Basic Inspection

 Tank signs: tank no., product, capacity, flammable(?)
 Vents: clear, no debris plugging them
 Paint: Check for peeling, blistering or chipping.
 Foundation:
 If using beams, is there crack or deformation?
 Concrete: crack, settlement
 Gauges & overfill devices:
 working?
 test overfill alarms
 Test shut-off devices

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Maintenance & Repair (API653)

 API 653 provides minimum requirement for maintaining
integrity of welded or riveted, non-referigerated,
athmospheric pressure, aboveground storage tank (API
650 tanks) after they have been placed in service.
 It covers: maintenance inspection, repair, alteration,
relocation and reconstruction of tanks

Suitability for Service:
Roof, Shell, Bottom plate, Foundation
Inspection:
Frequency, external inspection, internal
inspection, bottom thickness, Records
Tank Repair & Alteration:

Removal & Replacement of shell plate; Repair
of defects in shells; defective welds, tank
bottoms, roof, hot taps
Documentation:
Marking, record keeping, certification

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 General Evaluation of Suitability for Service
 Internal corrosion due to product or water bottoms
 External corrosion due to environment
 Stress level vs allowable stress
 Properties of the stored product
 Metal design temperature
 External roof live load, wind and seismic loadings
 Tank foundation, soil & settlements
 Chemical analysis & mechanical properties of material
 Distortions
 Operating conditions, e.g. filling/emptying rates & frequency

 Tank Roof Evaluation
 Roof support systems (rafters, girders, columns &
bases) shall be inspected against corrosion and
damage especially center column.
 For floating roof, check for crack, puncture, or pitting
corrosion.

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 Tank Shell Evaluation
 Shells corrosion occurs in form of uniform loss of
metal over a large area or in localised areas.
 Pitting may occur. It does not represent a significant
threat unless close to one another.

 Method of evaluation againts corrosion
1. From inspection, determine
the least min. thickness in
entire area, t2
2. Calculate L =
3. Inspect the average
thickness over a length, L
4. Safe if:
t1  t min
t 2  0.6t min
where
2.6 DH  1G
t min  if D  200feet
SE
t min 

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 The thinning due to corrosion shall also be evaluated
against other loads, if applicable, e.g.
 Wind-induced buckling
 Seismic loading
 Operation at temperature over 200F
 External loading due to piping
 Vacuum-induced external pressure
 Wind-induced overturning
 Loads due to settlements

 Distortions
 Example: Out-of-roundness, buckled areas, flat spots.
 Causes: foundation settlements, over- or under-pressure,
high wind, poor shell fabrication or repair
 Flaws/Cracks
 Shell weld
 Shell openings
 Shell stiffeners

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 Tank Bottom Evaluation
 Main inspection: Leakage!
 Mitigation plan:
 Shorter inspection intervals
 Bottom lining
 Upgrading/repair
 Replacement

 Failure Causes:
 Internal pitting
 Corrosion of weld joints
 Weld joint cracking history
 Roof support loads
 Underside corrosion
 Inadequate drainage
 The lack of annular bottom plate
 Uneven settlement
 Inadequate pre-conslodation
 Inadequate support sumps

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 Effectiveness of cathodic protection (API 651)
 Lining (API 652)
 Main inspection: Leakage!  leak detection system

 Bottom plate thickness measurement
 Calculation of “Remaining thickness for tank bottom
at the end of the in-service period (normally 10 years)
Inspected corrosion In-service period
Original thickness Corrosion rate

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 ifthis remaining thickness is less than bottom renewal
thickness (table below), then:
 Shorter inspection intervals
 Bottom lining
 Upgrading/repair
 Replacement

 Annularplate thickness measurement
 Minimum thickness:

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 Tank Foundation Evaluation
 Principal causes:
 Settlement
 Cracking and deteriation of concrete. Initiated by calcining,
attack by underground water, frost, alkalies & acids.
 Concrete pads, ringwalls, and piers, showing spalling,
cracks, or general deteriotion, shall be repaired to
prevent water from entering the concrete structure
and corroding the reinforcing steel.
 Anchor bolts, check for:
 Distortion
 Excessive crack of concrete structure
Maintenance Management
 Inspection/maintenance periods
 formal visual external inspection at least every 5 yrs
or at the quarter corrosion-rate life of the shell
(whichever less)
 Insulation may be remove for inspection of the
exterior wall or roof
 Cathodic protection system requires periodic surveys
acc. API RP 651
 Tank electrical grounding shall be visually checked

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Maintenance Management
 Inspection/maintenance periods
 Reference of code for inspection:
 API standard 653, “Tank inspection, repair, alteration and
reconstruction, 3rd edition, December 2001.
 API Recommended Practice 575, “Inspection of atmospheric
and low-pressure storage tanks, 1st edition, November 1995.
 EEMUA Publication No. 159, “User’s guide to the inspection,
maintenance and repair of above-ground vertical steel
storage tanks”, Volume 1 and 2, 3rd edition, 2003
*EEMUA: Engineering Equipment and Materials Users’ Association
References
 API Std 650
 API Std 653
 API RP 575
 Aboveground Storage Tank Operator Handbook,
Second Edition, Alaska Department of Environmental
Conservation
 A vision on tank maintenance costs, by Jan de Jong

Vessel and Tank PEM Sem I 2021

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Vessel and Tank PEM Sem I 2021

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TM3407 Perancangan Tangki dan 15/10/20

Dr. Rachman Setiawan

Rachman Setiawan 2020 1

Tank vs Pressure Vessel

 Tank, Storage tank, atmospheric tank

 Pressure vessel, tank, column, drum

Tank vs Pressure Vessel

Tank Pressure Vessel

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API Std. 650 API Std. 620

Scope of Mechanical Design

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 Tangki penyimpanan bawah tanah

 Tangki penyimpanan diatas tanah

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Roof Type Selection

Roof Type Selection

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Roof Type Selection

Roof Type Selection

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Oil/Fuel Storage Facility

Oil/Fuel Storage Facility

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Oil/Fuel Storage Facility

Oil/Fuel Storage Facility

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Oil/Fuel Storage Facility

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Collumn & Rafter

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Real pressure distribution 1 ft

Design Shell Thickness Hydrostatic Test Shell Thickness

4,9 D ( H  0,3)G 4,9.D(H  0,3)

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Tebal desain Tebal hydrostatic Test

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Collumn & Rafter

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 Due to supported roof plate

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 Compression stress on pipe column :

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Stability Against Wind Load

Stability Against Wind Load

 Height of transformed shell :

TUniform Thickness of the top shell course (mm) = 5 mm #6 2400 5 5 2400.00

TActual Thickness of the shell course (mm) #7 2400 5 5 2400.00

Because H1 = 83,139 mm > Σ Wtr = 6,184 mm

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Shell Stability Againts Earthquake

Shell Stability Againts Earthquake

C2 = (0.75 x S)/T = 0.523

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