Comparative Analysis of Manual Strapping Method (MSM) and

Electro-Optical Distance Ranging (EODR) Method of Tank

Calibration.

Submitted in partial fulfillment of the requirements for the award of the degree
of
Bachelor of Science in Mechanical Engineering.

Submitted by
1.Md. Shadikul Huq Shezan (BME-1702012100)
2.Shaharia Alam (BME-1702012262)
3.Mahmudul Hasan Tareq (BME-1702012082)
4.Md. Musharof Hosen (BME-1702012081)

Under the guidance

of
Md. Ahatashamul Haque Khan Shuvo
Lecturer & Asst.Coordinator
Department of Mechanical Engineering
Sonargaon University (SU)

To the
DEPARTMENT OF MECHANICAL ENGINEERING
Sonargaon University (SU)
147/I, Green Road, Tejgaon, Dhaka-1215
April: 2021
Enrolled Semester : Summer-2017

Department of Mechanical Engineering

Sonargaon University (SU)
 DECLARATION
We hereby certify that the work which is being presented in the project entitled “Comparative
Analysis of Manual Strapping Method (MSM) and Electro-Optical Distance Ranging (EODR)
Method of Tank Calibration” in partial fulfillment of the requirement for award of degree
Bachelor of science submitted in department of Mechanical Engineering Sonargaon University
(SU).

The matter presented in this report has not been submitted for the award of any others degree of this
or any other university. This is to certify the above statement made by the candidate’s is correct and
true to the best of our knowledge and belief.
 ACKNOWLEDGEMENTS
We have taken efforts in this project. However, it would not have been possible without the kind
support and help of many individuals and the department. We would like to extend my sincere
thanks to all of them.
We want highly indebted to Md. Ahatashamul Haque Khan Shuvo for his guidance and constant
supervision as well as for providing necessary information regarding the project and also for his
support in completing the project. We also would like to express my gratitude towards our parents
and all the members of Department of Mechanical Engineering along with Md. Mostofa Hossain
(Head of the Department Mechanical Engineering).
We would like to express our special gratitude and thanks to skilled workshop personals for giving
us such attention and time, without whom we cannot demonstration our ideas. Our thanks and
appreciation also goes to Our friends and every individual who have willingly helped us out with
their abilities and skills.
Finally, last but not the least we apologize all other unnamed who helped us in various ways to have
successful and satisfactory project work.
On behalf our thesis group.

1.MD. SHADIKUL HUQ SHEZAN

SU ID: BME-1702012100
-----------------------------------
2.SHAHARIA ALAM
SU ID: BME-1702012262
-----------------------------------
3.MAHMUDUL HASAN TAREQ
SU ID: BME-1702012082
-----------------------------------
4.MD. MUSHAROF HOSEN
SU ID: BME-1702012081

i
 APPROVAL OF SUPERVISOR

This is to certify that the thesis entitled “Comparative Analysis of Manual Strapping Method
(MSM) and Electro-Optical Distance Ranging (EODR) Method of Tank Calibration” had been
prepared under my supervision to be accepted in partial fulfillment of the requirements for the award
of the degree of Bachelor of science in mechanical engineering.

Supervisor
--------------------------
Md. Ahatashamul Haque Khan Shuvo
Lecturer & Asst. Co-ordinator.
Department of Mechanical Engineering
Sonargaon University (SU)

ii
 ABSTRACT

Oil storage tanks are mandated for calibration before putting to use and to be recalibrated as a
statutory requirement at every five year interval. Oil tanks could be calibrated by geometrical
methods such as Manual Strapping Method (MSM) and Electro-Optical Distance Ranging (EODR)
method. This study compares both MSM and EODR in terms of cost incurred, duration of calibration
and efficiency. Both methods were found to be efficient as they satisfied 95% minimum efficiency as
stated by API MPMS 2.2 standard when compared with the wet method of tank calibration; though
the cost of EODR was slightly higher than MSM but this was compensated with higher efficiency
and reduced duration/time of calibration.

iii
 TABLE OF CONTENT

1. ACKNOWLEDGEMENTS…………………………………………………………………..i

2. ABSTRACT…………………………………………………………………………………..ii

3. TABLE OF CONTENT……………………………………………………………………..iii

4. LIST OF FIGURE…………………………………………………………………………...vi

5. LIST OF TABLES………………………………………………………………………….vii

6. LIST OF ABBREVIATION………………………………………………………………viii

CHAPTER 1, INTERODUCTION
1.1 GENERAL ….……………….……………………………………..……………………….…….1
1.2 PLASTICS …………………………...……………………………...…………………....……... 2
1.3 SELECTION OF WASTE PLASTICS ….....................................................................................3

CHAPTER 2, LITERATURE REVIEW ON PLASTIC PYROLYSIS…………...6

2.1 FACTORS AFFECTING PLASTIC PYROLYSIS….……………….……………………..……7

2.2 CHEMICAL COMPOSITION OF FEEDSTOCK….……………….………………………...…7

2.3 CRACKING TEMPERATURE AND HEATING RATE.……………….………………………9

2.4 TYPE OF REACTOR ….……………….………………………………………………………11

2.4.1 Batch, Semi-Batch and Continuous Reactors….……………….………………………11

2.4.2 Fixed bed, Fluidized bed and screw kiln reactors….……………….……………….…12

2.5 RESIDENCE TIME….……………….…………………………………………………………12

iv
2.6 USE OF CATALYST….……………….……………………………………………………….14

2.6.1 Advantages of using catalyst….……………….…………………………………….…14

2.6.2 Catalyst classification….……………….………………………………………………15

2.7 PRESSURE….……………….…………………………………………………………………15

2.8 OTHER INFLUENCING FACTORS….……………….……………………………….………17

2.8.1 Multi-factor effect on pyrolysis process….……………….…….……………………17

2.9 REVIEW OF PYROLYSIS MONITORING AND PRODUCT ANALYSIS….………………18

2.9.1 Pyrolysis process monitoring….……………….…………………..…………………18

2.9.2 Product analysis method….……………….…………………………………………..18

2.10 COMPARISON OF DIESEL WITH PLASTIC DERIVED FUELS….………………………19

2.11 EXISTING COMMERCIAL PLASTIC PYROLYSIS TECHNOLOGIES

AND PROCESSES………………..………………………………………………………….20

2.12 FEEDSTOCK EFFECTS….……..………….…………….…………………………………..21

2.12.1 Technology….………………...……………………………………………………..21
2.12.2 Feeding system….……………….……………………………………………..……21
2.13 PYROLYSIS….……………….……………………………………………….………………22
2.13.1 Product Separation and Collection….……………….…………………...…………22

CHAPTER 3, BASIC COMPONENT PLASTIC PYROLYSIS

3.1 PYROLYSIS REACTOR …………………………………….……………………….………...23

3.2 CONDENSER …………………………….…………………………..…….…………….….…23

3.3 PRESSURE GAUGE ………………………………..…… ……………………………..........23

3.4TEMPERATURE SENSORE AND DISPLAY……………………….………………...………24

3.5 BURNER ……………………………………..………………..………………………………..24

3.6 LPG GAS CYLINDER ……………………..…………………………..……………….………24

3.7 CAST IRON PIPE…………………….………………………………………………...………24

v
CHAPTER 4, METHODOLOGY
4.1 DESIGN OF PYROLYIS REACTOR……….………………………………………………….25

4.1.1 Determination of the amount of raw materials………………………………………..25

4.1.2 Determination of vessel geometry…………………………………………………….25

4.2 FABRICATION OF PYROLYSIS REACTOR………………………………………………....25

4.3 DESIGN OF CONDENESER………………………………………………………….………..26

4.4 FABRICATION OF CONDENESER …………………………………………………….…….27

4.5 PYROLYSIS PROCESS ………………………………………………………….…………….28

4.5.1 Scope of Liquid Fuel……………………………………………………………………28

4.5.2 Production Method………………………………………………………………………28

4.5.3 Filtration & Purification…………………………………………………………………31

4.5.4 Fuel Testing and Analysis……………………………………………………………….31

CHAPTER 5, RESULT INTERPRETATION ………………………………..….32

CHAPTER 6, CONCLUSION & FUTURE SCOPE

6.1 CONCLUSION …………………………………………………………………………………35
6.2 FUTURE SCOPE ……………………………………………………………………………….35
6.3 REFERENCES….……………….………………………………………………………...……36

vi
 LIST OF FIGURE

Sr.n Name of Figure page

o
1. Figure 1.1 SPI code 2
2. Figure 2.1 Influence of temperature on product distribution 10
3. Figure 2.2 GC analysis results of plastic pyrolysis liquid 11
4. Figure 2.3 Influence of residence time on the production of gaseous product 14
(from HDPE thermal and catalytic cracking)
5. Figure 2.4 Effect of pressure on the distribution of PE pyrolysis Products 16
6. Figure 2.5 Effect of pressure on the yield of gas at different temperature. 16

7. Figure 4.1 Pyrolysis Reactor 26

8. Figure 4.2 Shell and Tube condenser 27
9. Figure 4.3 Polypropylene Granules 29
10. Figure 4.4 Schematic diagram of a production plant of Plastics derived fuel 30

11. Figure 5.1 Comparison of Polypropylene oil Vs diesel 32

vii
 LIST OF TABLES

Sr.n Name of Tables page

o
1. Table 1.1 Product types of some plastics 04
pyrolysis
2. Table 1.2 Comparison of Carbon footprint 05
3. Table 2.1 Types of Chain Structures 09
4. Table 2.2 Pyrolysis processes and target products 13
5. Table 4.1 Specifications of Pyrolysis Reactor 25
6. Table 4.2 Specifications of Condenser 27
7. Table 5.1 Polypropylene Oil and Diesel comparison 32
8. Table 5.2 FTIR Test Results 33
9. Table 5.3 GC/MS Test Results 33
10. Table 5.4 Hydrocarbon Range in Commercial Fuels 34

viii
 LIST OF ABBREVIATION

SPI Society of Plastic Industry

PE Polyethylene

HDPE High density polyethylene

LDPE Low density polyethylene

PP Polypropylene

PS Polystyrene

PVC Polyvinyl Chloride

PET Polyethylene Terephthalate

GC Gas chromatography

MS Mass spectrometry

TGA Thermo gravimetric analysis

LPG Liquefied petroleum gases

MW Molecular weight

ix
x
CHAPTER 1
INTERODUCTION

1.1 Tank Calibration

Tanks are containers used in storing liquids or compressed gases. Though it can be in various
shapes such as cubic/cuboidal shape and spherical shape or spheroid, but the acceptable shape
in oil industry is cylindrical shape. Upright cylindrical storage tanks used in oil industries are
calibrated at an interval as directed by the regulatory agency of various countries. For instance,
oil storage tanks are calibrated at five (5) years interval In Bangladesh.

Basically, tank calibration can be classified as a wet or dry calibration. Wet calibration
involves transfer of a known quantity of liquid into a tank or withdrawal of a known quantity
of liquid from a tank .Though, wet method of tank calibration is adjudged to be the most
accurate method however it is only practicable in the calibration of small-sized tanks. Dry
calibration is known as the geometrical method of tank calibration which involves the accurate
measurement of tank dimensions so as to use mathematical formulae and relations to
determine its capacity Dry/Geometrical method of tank calibration is sub-divided mainly into:
Manual Strapping Method and Electro-Optical Distance Ranging Method.

Manual strapping method (MSM) is the oldest geometrical method of determining tank
volume. When using this method, a strapping tape (steel tape) is wound firmly round the
circumference of each course of the tank to obtain the actual value of the circumference Other.
Measurements such as height of the tank, thickness of each course, temperature, specific
gravity of the product to be stored, deadwoods in the tank and their locations; are also required
to determine the tank capacity. MSM could be modification Optical Reference Line Method
(ORLM) and Optical Triangulation Method (OTM). BSTI™ All Used Microsoft Excel in
generating calibration chart for horizontal petroleum storage tanks. It was revealed that the
results of comparison done between Microsoft Excel program and Society General de
Surveillance (SGS software) was found to be in statistical controlled limit. In the study, only
manual strapping method (MSM) was used to obtain the field data. Electro-optical Distance
Ranging (EODR) involves the use of surveyor’s total station to internally scan about eight (8)
or more points round the circumference of each course of the tank. Unlike MSM, EODR
eliminates the use of scaffold to obtain circumferential measurements and also saves time .
There are recent studies in advanced method of tank calibration such as 3D scanning of storage
tanks using 3D scanner to determine its capacity as well as the automation of tank calibration
process. EODR, which has been on ground for a while, now is yet to gain total a total
acceptance in Bangladesh because of the fear of high cost, efficiency and technical knowledge
of the calibrators. It is on this note that this study was carried out in comparing MSM and
EODR in terms of the efficiency of the generated calibration chart, cost of calibration and
duration with safety requirement.

1
 Figure 1.1: Oil Storage Tank

1.2 Various Petroleum and chemical storage tanks:

• Vertical Tanks
• Horizontal Tanks
• Spherical Tanks
• Cylindrical Tanks
• Double-wall Tanks
• Fixed Roof Tanks
• Floating Roof Tanks
• LNG Tank Calibration

2
 1.3 Types of storage tank calibration:

• Horizontal and Vertical Land Tanks Calibration

• Internal and external tank calibration by EODR (Electro-Optical Distance Ranging)
• Pipeline Volume Calculations
• Custody Transfer Systems (CTS)
• Ship and Barge Tank Volume Calculations

Measurements include detailed assessments of tank verticality, tank shell out of roundness and
shape, along with roof and floor profiles. Tank calibrations are conducted to the exacting
requirements of the appropriate international standards published by the International Standards
Organization (ISO) or by the American Petroleum Institute (API). Detailed volumetric tables are
compiled for each tank and can be formatted according to the client’s requirements. Comprehensive
tables can incorporate any standard units of measure for size, volume or both.

1.4 Objectives:

The most importance of accurate tank calibration.

Calibration is the science of determining the exact true volume of a containment system
corresponding to a certain measurement value. ... Without accurate calibration tables, even the best
gauging systems and the most accurate manual measurements are of little value.

3
CHAPTER 2
INTRODUCTION OF MAKEING TANK:
Crude oil, the feed to all petroleum refineries, is received and stored in tanks to build up enough
inventory prior to processing. This takes care of contingencies like delays in crude receipt and avoids
interruptions in crude oil processing. Tanks are also provided to store intermediate products/finished
products prior to transfer to terminals for further distribution. Ultimately, distribution of petroleum
products is done by trucks/pipeline/tankers/ barges etc.

2.1 TERMINALS:
Terminals consist of tanks which receive crude/products from oil tankers, rail cars, truck tankers,
pipelines as well as loading or unloading facilities for dispatch or receipt of products. A terminal
could be part of a refinery/production unit or a separate marketing facility or a cross country pipeline
installation.

2.2 SLOP:
Off-specification products obtained during plant start- up, shutdown or upset conditions and draining
etc. from various equipments/tanks/pumps containing oil – water mixture from process plants /
marketing / pipeline installations are called slops. Slops containing large quantity of free water are
known as wet slop. When free water content is low enough to process the slop in plant, in a
controlled manner, it is known as dry slop.

2.3 Loading Bays:

In order to handle large number of rail cars / trucks for loading or unloading, facilities called loading
bays are provided. These consist of loading/unloading headers with loading/unloading points with
hoses/arms, walkways, railings, set stop ramping / up ramping down (opening in steps and closing in
steps) automatic cut-off valves, approach platforms, metering station, rail tracks etc.

2.4 LOW PRESSURE STORAGE TANK:

Storage tanks are defined as "ATMOSPHERIC STORAGE TANK" and "LOW PRESSURE
STORAGE TANK".
Tanks designed as per API Code 650 or equivalent is called ATMOSPHERIC STORAGE TANKS.
These tanks can also be sub-divided into two categories:
 Atmospheric storage tanks with open vent to atmosphere i.e. goose neck type vent
 Atmospheric storage tanks with blanketing facilities

4
Tanks designed as per API Code 620 or equivalent is called LOW PRESSURE STORAGE TANK.
Products having slightly higher vapor pressure are stored in these types of tanks.

2.5 TANK CAPACITY :

 Nominal Capacity of a Tank
Nominal capacity shall mean the geometric volume of the tank from bottom up to curb angle in case
of fixed roof tanks and the underside of roof deck up to the maximum floating position of floating
roof in case of floating roof tanks.

 Gross Capacity of a Tank

Gross capacity (stored volume) is the capacity of the tank up to the maximum safe filling height of
the tank.

 Net Capacity
Net capacity is the net pump able capacity of the tank during operation after subtracting the volume
of tank bottom contents up to the top of normal pump out nozzle from safe filling capacity of the
tank.

2.6 CLASSIFICATION OF PETROLEUM :

Petroleum products are divided into three classes based on their flash points as follows:
Class A - Flammable liquids having flash point below 23oc.
Class B - Flammable liquids having flash point of 23oC and above but below 65oC.
Class C - Flammable liquids having flash point of 65oC and above but below 93oC.
Excluded Liquids having flash point of 93 degree C Petroleum.

5
2.7 TANK STANDARDS AND SPECIFICATIONS:

2.7.1 DESIGN CONSIDERATIONS FOR STORAGE TANKS –

Figure 2.1: Tank Inner Indication With code & Standard

2.7.2 ROOFS :
Tanks are classified based on their roof design. Normally, atmospheric tanks are of fixed roof or
cone roof or floating roof or fixed cum floating roof (with or without Nitrogen blanketing) type tanks
and low pressure Nitrogen blanketed tanks.

2.7.3 Floating Roof-

Floating roof may be single deck pontoon roof, double deck or pan roof. Pan roof shall not be used
as these are unsafe. For designing these tanks, API 650 guidelines may be followed,

6
2.7.4 Fixed Roof -
Fixed roof may be of cone type or dome shaped. The tank may be pressurized (to a few inches of
water) type with breather valves. Alternatively, tanks may be provided with fuel gas or inert gas
blanketing to prevent oxygen/moisture ingress. Fixed roof tanks for light products (e.g. Motor Spirit)
breathing into a neoprene balloon is not acceptable. For designing atmospheric/low pressure tanks,
API 650 or API 620 may be followed based on the type of the tank.

2.7.5 Fixed Floating Roof –

These tanks have a fixed roof over a floating roof. They are used for products having very stringent
water content specifications like Aviation Turbine Fuel and products sensitive to oxygen like light
intermediate feed tanks. Where oxygen ingress is to be avoided, it is preferable to provide Nitrogen
blanketing.

 Selection of Roof

Selection of type of roof generally depends on ambient conditions and the product handled.

 Ambient Temperature

Ambient temperature statistics shall be taken for the past at least 15 years. Maximum average daily
temperature for four (4) summer months for each year shall be considered.

 Product Handled

Following guidelines should be used for specific cases:

(i) Tanks used to store finished Aviation Gasoline/ Turbine Fuel shall be floating fixed roof to avoid
entry of water into product.
(ii)Where product degradation due to air/moisture ingress is a problem and fixed roof tanks are used,
such tanks should be provided with inert gas blanketing.
(iii)Nitrogen blanketing for internal floating roof tanks/fixed roof tanks should be considered for
storing hazardous petroleum products like benzene etc.

7
2.8 TANK BOTTOM

Tank bottoms may have conical shape or inverted cone shape, also known as "Apex down". Tanks
used to store finished Aviation Turbine Fuel shall have bottoms coned downwards towards the center
with a sump of adequate size at the center of the tank bottom and a siphon drain. The outside of pipe
shall be epoxy coated.

Figure 2.2: Tank outside Indication

8
CHAPTER 3

EQUIPMENT & COMPONENTS

3.1 Surveyor's wheel

The surveyor's wheel is marked in fractional increments of revolution from a reference position.
Thus its current position can be represented as a fraction of a revolution from this reference. If the
wheel rotated a full turn (360 angular degrees), the distance traveled would be equal to the
circumference of the wheel. Otherwise, the distance the wheel traveled is the circumference of the
wheel multiplied by the fraction of a full turn. In the figure on the right, the blue line is the reference
starting point. As the wheel turns during measurement, it is seen that the wheel sweeps out an angle
of ¾ π radians, which is equal to 135 degrees or 3/8 of a full turn.

Figure 3.1: Surveyor's wheel

3.2 Water pump:

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical action,
typically converted from electrical energy into hydraulic energy. Pumps can be classified into three
major groups according to the method they use to move the fluid..

9
 Figure 3.2: Water pump

3.3 Ultrasonic thickness gauge

In the field of industrial ultrasonic testing, ultrasonic thickness measurement (UTM) is a method of
performing non-destructive measurement (gauging) of the local thickness of a solid element
(typically made of metal, if using ultrasound testing for industrial purposes) based on the time taken
by the ultrasound wave to return to the surface. This type of measurement is typically performed
with an ultrasonic thickness gauge

Figure 3.3: Ultrasonic thickness gauge

10
3.4 Dip Tape

The oil sounding tape consists of handle, tape frame, crank, measuring tape, brass drawing weight,
oil wiper, bracket and connector.The scale direction of the tape faces the handle.

Figure 3.4: Dip Tape

3.5 Laser meter

Distance measurement, refers to the many ways in which length, distance, or range can be measured.
The most commonly used approaches are the rulers, followed by transit-time methods and the
interferometer methods based upon the speed of light.

Figure 3.5: Laser meter

11
CHAPTER 4
METHODOLOGY

4.1 Method

Three categories of storage tanks were considered: i. Small size tanks (1,000,000liters), ii. Medium
size tank (1,000,001 – 10,000,000 liters) and iii. Large size tanks (10,000,001 – 20,000,000 liters). A
representative tank was chosen for each of the afore-mentioned categories, of which the dimensions
and volumes are presented in Table 1.

Table 4.1: Representative tanks considered in this study

Nominal
Tank Nominal Volume Categories of
S/N
ID Dimensions (m) (Litres) Tank

1 Tank A 10D x 12.3H 966,000 Small size

2 Tank B 22.49D x 15.1H 5,999,000 Medium size
3 Tank C 29.96D x 20.99H 14,799,000 Large size
Note that ‘D’ is the nominal diameter and ‘H’ is the nominal height

Four calibration vendors were contacted to give their best quotations for the calibrations of Tanks A,
B and C. Two separate quotations, one each for MSM and EODR were obtained from the four
vendors and the average cost for each of the method was computed.

Tanks A, B and C were calibrated by both MSM and EODR while noting their durations and costs.
The efficiency of each of the method was determined by comparing the calibrated volume with the
volume obtained by wet method at different levels up to 2 m height. The efficiency was calculated
using Equation (1). Wet volume and the corresponding level was obtained by using FMC-80 Smith
Flowmeter to meter in/flow in a known quantity of water or liquid [4]. After metering in a known
quantity of water, a dip tape coated with water paste was inserted to indicate the level of water
metered in. Efficiency = 100 × 100

12
4.2 Manual Strapping Method

The strapping tape was wound round the circumference of each course shell at 20% height and 80%
height of the course to determine the average circumference for each course as shown in Figure 2.
Pocket measuring tape was used to measure the height of each course while the bottom survey was
conducted on the floor of the tank by surveyor’s leveling instrument as shown in Figure 3. Bottom
survey is conducted to determine the volume at the datum (dead stock/zero volume). Plate thickness
of each course was also determined using UTM machine. Internal diameter ‘d’ was determined using
Equation (2) after putting into consideration the effects of temperature, tape rise and plate thickness

Internal diameter ‘’ = 2 (2)

where c is the average circumference for each course shell and ‘t’ is the plate thickness for each
course.

Strapping tape

Strapping rod

Figure 4.1: Strapping of tank shell

Figure 4.2: Bottom survey with leveling instrument

13
Commonly encountered bottom profiles as described by Dan are spherical, ellipsoidal and conic is
as shown in Figure 5. After establishing the profile of the bottom, exact mathematical equations
(Equations (3) – (8)) as given by Dan was then adopted to compute the volume at any level/height.

Figure 4.3: Commonly encountered bottom profile

Conical bottom Profile

Calibrated volume for conical bottom profile Calibrated volume for conical bottom profile =
= when when< ! (3) (4)

Ellipsoidal bottom Profile

Calibrated volume for ellipsoidal bottom profile Calibrated volume for ellipsoidal bottom profile =
= when when ! < (5) (6)

Spherical bottom Profile

Calibrated volume for spherical bottom profile Calibrated volume for spherical bottom profile "" ==
2 +# +$ when when ! < (7) (8)

where C is the average circumference of each course; t is the plate thickness of each course; a is the
assistance between the datum point and the deepest point at the centre of the tank floor; h is the
calibrated height/level; D is the internal diameter of the course shell; Vc is the calibrated volume for
conical bottom profile; Ve is the calibrated volume for elliptical bottom profile; Vs is the calibrated
volume for spherical bottom profile

4.3 Electro Optical Distance Ranging

14
Surveyor’s total station and its ancillary equipment were set at the center or near the center at the
tank floor. A series of target points (minimum of 8 points) were struck at 25% and 75% height of
each course height. This was done from the first course through to the last course. The coordinates x,
y, z generated round the internal circumference of all the courses were transferred to AUTOCAD
2017 to generate the circular section so as to determine its cross-sectional area (Figure 6). The cross-
sectional area generated from each course was multiplied by the corresponding height to obtain the
calibrated volume at a particular level. Figure 7 shows the circular section for course shell generated
from coordinates supplied into AUTOCAD 2017. The volume calibrated using EODR can be
determined using Equation (9).

Figure 4.4: Use of EODR for tank calibration

Circumference of Course Shell

Figure 4.5: Circular section generated from each course shell

CHAPTER 5

15
DISCUSSION AND CONCLUSION

5.1 Results

Table 5.1 shows the cost of calibration and the time taken to calibrate for both MSM and EODR.
Tanks A, B and C illustrate the small, medium and large sample tanks based on their dimensions,
respectively. The costs of calibration of the three categories of storage tanks as well as the time taken
to perform the calibration using the two methods were reported as shown in Table 5.1. The costs of
calibration for both methods range from 117,258.50 to 604,942.92. Calibration costs for both
methods for small storage tank is below 200,000; for medium storage tank is below 300,000 and for
large storage tank is below 610,000. An assumption that calibration personnel’s could only perform
their duties for close to 8 hours was used in this study. Hence, the time to calibrate the small tank
(Tank A) for the MSM and EODR are 7.6 h (1 day) and 4.1 h (1 day), respectively. Calibration time
taken for Tank B and Tank C for MSM and EODR are 13.3 h (2 days) and 7.5 h (1 day),
respectively; and 19.7 h (3 days) and 10.4 h (2 days), respectively.

Table 5.1: Cost of calibration and time taken for calibration

Cost of calibration (#) Time taken (hour/Day)

Tank Nominal
S/N
ID Dimensions (m)
MSM EODR MSM EODR

1 Tank A 10D x 12.3H 117,258.50 198,685.99 7.6h/1 day 4.1h/1 day

2 Tank B 22.49D x 15.1H 228,470.37 285,885.41 13.3h/2 days 7.5 h/1 day
3 Tank C 29.96D x 589,627.66 604,942.92 19.7 h/3days 10.4h/2 days
20.99H
Assumption is that the calibration personnel could only work for a maximum of eight hours

From Table 5.1, it was observed that the cost incurred while adopting EODR was slightly higher than
that of MSM when compared for each tank under study. However, the duration of calibration was
reduced in EODR when compared with MSM for each tank under study. Therefore, it can be said
that EODR is faster and slightly expensive than MSM for usage for each tank level.

MSM and EODR calibrated volume at different level/height up to two metres (2 m) for the three
tanks are shown in Table 5.2. The bottom profile for the tanks A, B and C are flat, cone and cone,
respectively. For both methods, calibrated volume increases as the level or height increases.
Moreover, calibrated volume in EODR was higher than MSM at every level considered for all the
three tanks. This indicates that EODR can be said to be more accurate in volume calibration of
storage tanks than MSM as supported by BSTI.

16
Table 5.2: Calibrated volume at various levels

MSM (Calibrated volume at different EODR Calibrated volume at different

level/height in Litres) level/height in Litres)
Bottom
Tank ID 0
profile
1m 1.5 m 2m 0m 1m 1.5 m 2m
m
Tank A Flat 341 78,891 118,166 157,441 350 79,930 119,735 160,120
797
Tank B Cone 405,288 603,943 802,598 7990 406,090 605,440 804,990
8
200 2001
Tank C Cone 725,062 1,077,592 1,430,121 725,095 1,782,715 3,192,875
02 5

Table 5.3: Efficiency at the datum level and at the highest calibrated level

MSM EODR
Wet calibration MSM EODR
Tank ID Efficiency Efficiency
0m 2m 0m 2m 0m 2m 0m 2m 0m 2m
Tank A 358 164,910 341 157,441 350 160,120 95.3 95.5 97.1 97.1
Tank B 8,305 824,720 7,978 802,598 7,990 804,990 96.1 97.3 96.2 97.3
Tank C 20,806 1,472,183 20,002 1,430,122 20,015 1,430,17 96.1 97.1 96.2 97.1
5

Table 5.3 gives a further analysis of Table 5.2, where the efficiency of both MSM and EODR was
determined. The wet calibration values and dry calibration values based on MSM and EODR for
datum and highest calibrated levels were as shown in Table 5.3. The efficiencies for MSM and
EODR were obtained based on Equation (1) for each of the tank. The efficiencies obtained show the
accuracy of the methods.

Tank A which has the smallest nominal capacity had its MSM efficiency lower than Tanks B and C.
It was observed that for Tank A that the EODR efficiency maintained same value of 97.1 m at datum
and highest calibrated level. This might be due to uniform cross-sectional area between the datum
and the highest calibrated level for this study. Furthermore, it could be opined that there are no local
deformations such as bulges and dents. More so, the efficiency at 2 m was slightly higher than the
MSM and EODR efficiencies at the datum (zero level) for all the tanks. From the foregoing, it could
be inferred that the efficiencies increase with an increasing level. Higher efficiency with shorter
duration observed when using EODR corroborated the work of Knyvaet al. . It could also be said that
the results of calibration of both methods are efficient because they satisfied the minimum
requirement of 95% efficiency when compared to wet calibration .

17
5.2 Future scope

The present document is applicable to safety in the design philosophies and operating procedures
pertaining to the storage and handling of crude oil and petroleum products at crude oil exploration &
production, refineries and pipelines installations which are normally stored in above ground
atmospheric pressure or low pressure storage tanks and underground tanks. This does not cover the
storage and handling of propane, LPG, butane etc. which requires pressurized / cryogenic storage.

5.3 Conclusion

The comparative analysis of Manual Strapping Method and Electro-Optical Distance Ranging
method of tank calibration has been carried out. The results confirmed that both methods were
efficient. The cost of utilizing EODR for calibration is a bit higher than MSM but compensated with
higher efficiency and a shorter duration when compared with MSM which shows longer duration
with lower cost. Due to the shorter duration involved in EODR, the study suggests that the method
can viably be used in Bangladesh for storage tanks calibration. More so, based on the analyzes done
for both methods, the study has offered the decision makers opportunity to make choice of
calibration method they preferred to use; considering the cost, efficiency and duration.

CHAPTER 6

18
CERTIFICATION OF CALIBRATION

Table-6.1

TANK OWNER Orion Power Sonargaon Limited

153-154, Tejgaon Industrial Area,
P.O. Tejgaon – 1208, P.S. – Tejgaon, Dist. – Dhaka.
TANK LOCATION Orion Power Sonargaon Limited at
Chorgoaldi, Hossainpur, Post Code-1441, Sonargoan, Narayanganj

TANK TANK NO: 01

PRODUCT: HFO STORAGE TANK
TANK INNER DIA: 19215 MM
TOTAL TANK HEIGHT: 14103 MM
ACTUAL CAPACITY: 4102831.959 LITERS

SAFE HEIGHT 12,692 MM ( 36,92,399.899 Litters)

ISSUING AUTHORITY BANGLADESH STANDARDS & TESTING INSTITUTION

(BSTI)
Divisional Metrology Inspectorate, 116/A, Tejgaon Industrial Area,
Dhaka-1208

CALIBRATED BY Group-18 Team Member

CALIBRATION DATE 29-03-2020 TO 02-04-2021

VALIDITY OF CHART 05 (FIVE) YEARS FROM THE DATE OF CALIBRATION

NATURE OF CALIBRATION PHYSICAL CALIBRATION

METHOD OF CALIBRATION STRAPPING METHOD

This certificate of calibration is issued without prejudice and to the best of our knowledge and ability
and our responsibility is limited to the exercise of due care and attention.

CALIBRATION & SUPERVISED CERTIFIED BY

19
 ORION POWER SONARGAON LIMITED
CHORGOALDI, HOSSAINPUR, POST CODE-1441, SONARGAON, NARAYANGANJ.
CALIBRATION CHART OF HFO TANK -02

Tank Others Information

1 Datum Plate (150X150X10) mm, to Frist shell Plate Distance -

2 Tank Datum Plate Submersed after filling of water 3475 Ltr

3 Tank Bottom plate submersed after filling Liters of water 17437 ltr

4 Tank Bottom plate submersed after filling, dip found. 56 mm

5 Total tank height in Load condition 14103 mm

6 Total tank height in Empty condition 14100 mm

7 Manhole: Dia-600 mm, Length-227 mm from Bottom Plate 475 mm

8 Tank Return Line: Dia 75 mm, Length-14300 mm (Inside of Tank) -

9 Tank Loading Line: Dia-200 mm, Length-14300 mm (Inside of Tank) -

10 Tank Overflow Line: 150 mm (Out of Tank) -

11 Sounding Line: Dia-150 mm, Length- 14300 mm (Inside of Tank) -

12 Tank Drain Line: Dia-150 mm, (Inside of Tank) -

13 Tank Heater with Delivery line: Delivery Line Dia-200 mm (Out of Tank) -
and Heater Dia-600 mm

14 Height of Sounding Line from roof plate: E- 90, W-123, N-120, S-100 mm

15 Shell plate welding joint: 17+16+15+15+13+11 = 87 mm -

Table-6.2

CALIBRATION & SUPERVISED CERTIFIED BY

Table-6.3
20
 ORION POWER SONARGAON LIMITED
CHORGOALDI, HOSSAINPUR, POST CODE-1441, SONARGAON, NARAYANGANJ.
CALIBRATION CHART OF HFO TANK -02
Tank Others Information
1 Datum Plate (150X150X10) mm, to Frist shell Plate Distance -
2 Tank Datum Plate Submersed after filling of water 3475 Ltr
3 Tank Bottom plate submersed after filling Liters of water 17437 ltr
4 Tank Bottom plate submersed after filling, dip found. 56 mm
5 Total tank height in Load condition 14103 mm
6 Total tank height in Empty condition 14100 mm
7 Manhole: Dia-600 mm, Length-227 mm from Bottom Plate 475 mm
8 Tank Return Line: Dia 75 mm, Length-14300 mm (Inside of Tank) -
9 Tank Loading Line: Dia-200 mm, Length-14300 mm (Inside of Tank) -
10 Tank Overflow Line: 150 mm (Out of Tank) -
11 Sounding Line: Dia-150 mm, Length- 14300 mm (Inside of Tank) -
12 Tank Drain Line: Dia-150 mm, (Inside of Tank) -
13 Tank Heater with Delivery line: Delivery Line Dia-200 mm (Out of -
Tank) and Heater Dia-600 mm
14 Height of Sounding Line from roof plate: E- 90, W-123, N-120, S-100 mm
15 Shell plate welding joint: 17+16+15+15+13+11 = 87 mm -

21
CALIBRATION & SUPERVISED CERTIFIED BY

ORION POWER SONARGAON LIMITED

CHORGOALDI, HOSSAINPUR, POST CODE-1441, SONARGAON, NARAYANGANJ.
CALIBRATION CHART OF HFO TANK -02
TANK STRAPPING WORKS
TANK NO-02
TANK STRAPPING WORKS CARRIED OUT WITH 100-METER-LONG STEEL TAPE
SHELL PLATE TANK OUTER SHELL PLATE SHELL PLATE REMARKS
CIRCUMFERENCE
NUMBER HEIGHT THICKNESS
FROM IN mm
IN mm IN mm
BOTTOM
1 (One) T-60312 2015 14
M-
B-60366
2 (Tow) T-60302 2015 12
M-60295
B-60301
3 (Three) T-60301 2016 12
M-60306
B-60299
4 (Four) T-60292 2011 10
M-60301

22
 B-60300
5 (Five) T-60297 2011 10
M-60308
B-60303
6 (Six) T-60292 2012 8
M-60299
B-60303
7 (Seven) T- 2023 6
M-60293
B-60299

Table-6.4

Table-6.5

Physical Calibration
Description Dip in Found Quantity Quantity Remarks
Filled Filled in
mm
mm / Liters (Total)
Liters
Datum Plate Submersed 0 mm – 0 mm - 3475.00

Bottom Plate Submersed 0 mm – 38 mm 223.54 12082.152

Bottom Plate Submersed 0 mm – 56 mm 249.31 17,437.329

Datum Plate to Water High 0 mm – 187.5 mm 278.70 55592.774

56 mm – 187.5 290.155 38,155.445

mm
= 131.50 mm
Datum Plate to Water High 0 mm – 238 mm 280.88 70325.988

187 mm – 238 mm 291.76 14733.988

= 51 mm
Datum Plate to Water High 0 mm – 305.75 283.18 90059.374

23
 mm
238 mm – 305.75 291.26 19733.38
mm
= 67.75 mm

CALIBRATION & SUPERVISED CERTIFIED BY

Table-6.6

Course Applicable Range in MM Per mm/Liter

No.
1 Datum Plate 0 3475.00
0 mm To 38 mm 223.54
38 mm To 56 mm 249.31
56 mm To 187.5 mm 290.155
187.5 mm To 238 mm 291.76
238 mm To 306 mm 291.26
306 mm To 2015 mm 290.71
2 2015 mm To 4030 mm 290.62
3 4030 mm To 6046 mm 291.12
4 6046 mm To 8057 mm 290.85
5 8057 mm To 10,068 mm 290.79
6 10,068 mm To 12080 mm 290.88
7 12080 mm To 14,103 mm 290.88

24
CALIBRATION & SUPERVISED CERTIFIED BY

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[10] Knyva, V. &Knyva, M. (2012). New method for calibration of horizontal fuel tanks.
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