Storage Tank Design as per IS 803 / API 650

Storage Tank Classification

A storage tank is a construction or a container, usually holding liquid's, sometimes for gases. According to NFPA (National Fire Protection Association), atmospheric storage tanks are defined as those tanks that are designed to operate at pressure between atmospheric pressure and 6.9 Kpa gage, as measured at the top of the tank. Such tanks are builds in two basic design the fixed roof design & External floating roof design.

Storage Tank Classification

(Contd.)

Fixed roof design:

Fixed-roof tanks consist of a cylindrical shell with a permanently welded roof that can be flat, conical or dome-shaped. Such Tanks are used to store materials with a true vapor pressure of less than 10.3 KPa absolute.

External-Floating Roof Design.

In floating-roof storage tanks, the roof is made to rest on the stored liquid and is free to move with the level of the liquid. These tanks reduce evaporation losses and control breathing losses while filling. They are preferred for storage of petroleum products with a true vapor pressure of 10.3 to 76.5 KPa absolute.

DESIGN OF
CONE ROOF TANK, 200 m3
(Design and Construction Code: IS 803 / API 650 )

Diameter: (D)= 6.0 m Height:= 7.5 m Design Liquid Height (H)= 7.5 m Design Pressure : (h)=Hydrostatic+150 mm WC, and 50 mm WC (vacuum) Design Temperature=75 C Operating Pressure=Ambient, Hydrostatic Operating Temperature=4-50 C Design Specific Gravity: (G)=0.85 Product Stored :Crude oil Corrosion Allowance: (CA)= 1.6 mm for Shell and Bottom, 0 mm for roof Basic wind speed : (Vb)= 47 m/sec (As per IS 875 Pt 3) Seismic loads :IS 1893 Zone III Joint efficiency:0.85 Test Pressure:Full of water MaterialShell, Bottom & Roof: IS 2062 Gr A Yeild Strength: (fy)250 MPa (2549.3 Kgf/cm2 ) Tensile Strength: (T)410 MPa (4180.8 Kgf/cm2 ) Roof slope:1:5 Shape Factor=0.7

Drawing of Storage Tank

Design Condition as Per IS 803

S1 = 0.7 (Yield Strength)

= 0.7 x 250 MPa = 175 MPa = 1784.5 Kgf/cm2 = 25381.6 psi

S2 = 0.4 (Tensile strength)

= 0.4 x 410 MPa = 164 MPa = 1672.3 Kgf/cm2 = 23786.2 psi Allowable Stress, S = Minimum of S1 or S2 = 164 MPa = 1672.3 Kgf/cm2 = 23786.2 psi

DESIGN OF SHELL PLATES (Reference: IS 803-CI 6.3.3)

Plate Thickness:
The minimum thickness of shell plates should not be less than calculated from following formula. t= (4.9 (H-0.3) D.G / S. E) + CA Where, t= minimum thickness in mm; D= nominal diameter of tank in m; H= height from the bottom of the course under consideration to top of curb angle m; G= specific gravity of liquid to be stored, but in no case less than 1; S= allowable stress; and E= joint efficiency factor.

DESIGN OF SHELL PLATES(contd.)

1st Shell Course from bottom

t1 = (4.9 (H-0.3) D.G / S. E) + CA = (4.9 (7.5-0.3) 6 x 0.85 / (164). (0.85)) + 1.6 = 2.89 mm Provide 8 mm thick for 1500 mm height for bottom first shell course.

2nd Shell Course from bottom

H = 7.5-1.5 = 6.00 m t2 = (4.9 (H-0.3) D.G / S. E) + CA = (4.9 (6.00-0.3) 6 x 0.85 / (164). (0.85)) + 1.6 = 2.62 mm Provide 6 mm thick for 1500 mm height for bottom 2nd shell course.

DESIGN OF SHELL PLATES(contd.)

3rd Shell course

H = 7.5-3 = 4.5 m t3 = (4.9 (H-0.3) D.G / S. E) + CA = (4.9 (4.5-0.3) 6 x 0.85 / (164). (0.85)) + 1.6 = 2.35 mm Provide 6 mm thick for 1500 mm height for 3rd shell course.

H = 7.5-4.5 = 3.0 m t4 = (4.9 (H-0.3) D.G / S. E) + CA = (4.9 (3.0-0.3) 6 x 0.85 / (164). (0.85)) + 1.6 = 2.22 mm Provide 6 mm thick for 1500 mm height for 4th shell course.

4th Shell course

DESIGN OF SHELL PLATES(contd.)

5th Shell course

H = 7.5-6 = 1.5 m t5 = (4.9 (H-0.3) D.G / S. E) + CA = (4.9 (1.5-0.3) 6 x 0.85 / (164). (0.85)) + 1.6 = 1.82 mm

Provide 6 mm thick for 1500 mm height for 5th shell course.

As per Cl. 6.3.3.2 Shell thickness provided are above minimum nominal thickness recommended.

DESIGN OF SHELL PLATES(contd.)

Summary of Tank shell plates

No of shell course from bottom

Height of course (mm)

Calculated thickness (mm)

Thickness required as per design (mm)

Thickness provided (mm)

t1 t2 t3 t4 t5

1500 1500 1500 1500 1500

2.89 2.62 2.35 2.2 1.82

5 5 5 5 5

8 6 6 6 6

Shell Development and Weld Detail

Bottom plate thickness:

Refer IS 803 Cl. 6.2 for bottom plate uniformly resting on foundation or ground. Min. thickness = 6 mm + CA = 6 mm + 1.6 mm = 7.6 mm Provide 8 mm thick bottom plate.

Bottom Plate Development

Self Supporting Conical Roof Curb angle:

As per IS 803 CI: 6.3.6.2, minimum size of top curb angle required is 65 x 65 x 6 mm. Provide top curb angle of 75 X 75 X 10 mm all round the tank. Area of Curb angle, Ac provided = 14.02 cm2 Area of Curb angle, Ac required = (PD2/117500 tan G) 0.1Ws.ts - 0.1Wr.tr Where P is upward pressure on tank roof (allowing for roof self weight) in N/m2. Internal Pressure of Tank, Pi = 150 mm WC = 1500 N/m2 Weight of Roof Plate = 1130 kg Weight of rafter (ISWB 150) with Accessories = 450 kg Weight of rafter (ISWB 150) with Accessories = 450 kg

Self Supporting Conical Roof Curb angle (contd.):

Equivalent Weight Downward Pressure = (11300 N +4500 N)/ 28 m2 = 560 N/m2 Effective Internal Pressure on roof, P = (1500 560) N/m2 = 940 N/m2 Tank Diameter, D = 6 m Roof Slope from horizontal, G deg = tan -1 (0.2) =11.3 deg Ws = Shell width in compression region = 0.19 (Rs. ts)0.5 = 0.19 (300 cm x 6 mm)0.5 = 8.1 cm ts = Shell thickness = 6 mm Wr = Width of roof in compression region = 0.095 (Rr. tr)0.5 = 0.095 (300 cm x 5 mm)0.5 = 3.68 cm tr = Roof Thickness = 5 mm (Adopted, Cl. 6.4.5) Ac (required) = ((940 x 62 / 117500 x 0.2) 0.1 x 8.1 x 6 0.1 x 3.68 x 5) cm2 = (1.44 4.86- 1.84) = (-) 5.26 cm2 ( Hence no curb angle is basically required.) Ac (required, for self supporting cone roof, refer Cl. 6.4.5) = D2/ 40 sin G = 62/ 40 sin 11.3 = 36/ (40 x 0.196) = 4.6 cm2 ,which is more than the provided.

Drawing Detail of CURB ANGLE

Design Wind Speed for Wind Pressure Calculation: (Refer IS 875 Part 3)

Basic wind speed (Vb) = 47 m/sec (Refer Clause 5.3, Fig 1, Table 1 of 5.3.1, 5.3.2, 5.3.3) K1 =1 (General structure, for 50 years of service, Table 1) K2 =1 (Category 2, Class A, Table 2) K3 =1 (Topography factor, for planar terrain upwind slope shall be less than 3 deg) Design wind speed, VZ =(Vb) (k1) (k2) (k3) =47 m/sec Wind pressure, N/m2 = 0.6 Vz2 = 0.6 (47)2 =1325.4 N/m2

Stability Check for Tank shell:

Maximum Height, H1 (m) of un-stiffened shell = (14700 t / p) ((t/D)3)0.5 Where t = (6 mm 1.6 mm CA) = 4.4 mm D= 6 m p1 = 50 mm WC , vacuum = 500 N/m2 ( excludes external wind pressure) p2 = Wind pressure, N/m2 = 1325.4 N/m2 p = p1 + p2 = (500 + 1325.4) = 1825.4 N/m2 H1 = (14700 x 4.4/ 1825.4). ((4.4/ 6)3)0.5 = 35.43 x 0.63 = 22.32 m Hence the tank shell of 7.5 m height without stiffening ring will be safe and stable under vacuum and external loads.

Weight Calculation Tank Shell

Dia of Tank (m) Ht of course Tactual (mm) Uncorroded weight,ws CA Corroded weight,Wsc

6 6 6 6 6 Total

1.5 1.5 1.5 1.5 1.5

6 6 6 6 8

1331 1331 1331 1331 1775 7100(Kg) approx

1.6 1.6 1.6 1.6 1.6

976 976 976 976 1420 5324(KG) approx

Weight Calculation (Contd.)

Bottom Plate
Slope = 1:50 ;Diameter = 6.2 Area = 30.18 M2 ;Thickness = 8 mm Weight = 1960 Kg (approx), Uncorroded Weight= 1568 kg (approx.), Corroded

Roof plates & Structures

Slope: 1:5, Dia:6.0 M; Area: 28.8 M2 Weight: 1130 Kg (approx) Structure & Rafter = 450 kg (approx) Total = 1580 kg ; Thickness : 5 mm

Weight Calculation (Contd.)

Curb Angle
ISA 75 X 75 X 10 @ 11 KG/M X 19 m = 209 kg

Stair way, Railings & platform:

Structural & plate work @ 210 Kg/M (approx) Height = 1575 Kg

Nozzle & flanges : 870 Kg (approx) Hand Rail on roof @ 22 Kg/M run : 420 Kg (approx)

Stability of Tanks against wind load, Operating Condition and Empty:

(Ref: API-650, Cl. 3.11.3)

Design wind speed (Vb)

=47 m/sec =169.2 Km/hr Corresponding Wind pressure, p2 = 1325.4 N/m2 = 135.2 Kgf/m2 Wind force acting on the tank shell = p2. D.H.(SF) = 135.2 X 6 X 7.5 X 0.7 = 4259 Kgf Where D= 6M, Height= 7.5M, Shape factor (SF)= 0.7 Corresponding Wind Moment at base Mw = 4259 X 7.5/2 = 15972 Kg.m

Roof Development
NOTES 1. All the dimensions are in mm unless otherwise specified. 2. The dimensions of the cut pieces of roof plate can be adjusted to meet the site febrication requirements.

B1 B2

ROOF DEVELOPMENT

DETAILS OF JOINT NO 2.

13-06-07

SUBMISSION FOR APPROVAL

SDJ MSJ

DETAILS OF JOINT NO 1.

DETAILS OF JOINT NO 3.

APPVD. CHK'D. DRN. DATE

N K Roy MSJ SACHIN 13-06-07

SCALE DRAWING NO: N.T.S. SHEET:

CCPL/1084-T2-GGS I SOBHASAN-005

REV. 0

1 OF 1

Stability of Tanks against wind load, Operating Condition and Empty (Contd.):
(Ref: API-650, Cl. 3.11.3)

Weight of the Corroded tank to resist the Moment (empty condition): Shell: Stairway & platform: Nozzle: Roof plate: Roof structure: Wind girder: Curb girder: Hand rail on roof: Bottom Plate: Total: 5324 Kg (approx) 1575 Kg (approx) 870 Kg (approx) 1130 Kg (approx) 450 Kg (approx) - Kg (approx), Not Required 209 Kg (approx) 420 Kg (approx) 1568 Kg (approx) 11546 Kg (approx)

Stability of Tanks against wind load, Operating Condition and Empty (Contd.):
(Ref: API-650, Cl. 3.11.3)

Resisting Moment: MR = 11546 x D/2

= 9508 x 6/2 = 34638 Kg.m Refer API 650 CI 3.11.2 for stability check under wind load; (2/3 MR) > Mw (2/3) MR = (2/3) (34638) = 23092 Kg.m >Mw,15972 Kg.m Hence the Tank is stable against over turning by wind.

Seismic Analysis
( Ref. API 650-APPENDIX- E)

Nominal Tank Diameter (D): 6 m (19.69 ft) Total shell height (Ht): 7.5 m (24.61ft) Max. Liquid Height (H): 7.5 m (24.61 ft) Shell Material: IS 2062 A Yield stress: (Fby) = 250 MPa = 2549.3 Kgf/cm2 = 36259.4 psi Height of shell bottom course (h1):1.5 m= 4.92 ft Design specific Gravity of liquid (G): 0.85 Corrosion Allowance (Shell only) (CA): 1.6 mm = 0.063 in

Seismic Analysis (contd.)

( Ref. API 650- APPENDIX- E) Overturning Moment due to Seismic effect applied to the bottom of shell is determined by
M= Z.I {(C1 Ws Xs) + (C1 Wr Xt) + (C1 W1 X1) + (C2 W2 X2)} While Z =Seismic Zone Factor = 0.20 (IS 1893 Table 2 For Seismic zone III) I =Importance Factor = 1.50 C1 =Lateral Earthquake Coefficient = 0.60 (Refer API 650, E-3.3.1)

Seismic Analysis (contd.)

( Ref. API 650- APPENDIX- E)

D = 19.69ft H = 24.61ft D/H = 0.8 Factor K=0.58 , (Ref. API 650 FIG-E4) Natural Period of the first Sloshing mode in seconds; T = K(D)0.5 = 0.58 (19.69)0.5 = 2.57 sec < 4.5 sec. Site Coefficient S = 1.5 (For soft to medium Clay, API 650, Table E-3) Hence Lateral Force Coefficient C2 = 0.75 S/(T) (for T <4.5 sec) = (0.75) (1.5) / (2.57) = 0.4377

Constants

Seismic Analysis (cont)

(Ref. API 650-APPENDIX-E)

WT = Total Weight of tank content = 200 m3 Crude Oil = 200x1000x (0.85)= 170,000 kg = 374786 lbs H = Max Design liquid level (height) = 24.61 ft Refer FIG E 2 API 650; For D/H value of 0.8, Effective Masses are; W1/WT= 0.82; W1= 0.82 WT = (0.82) (374786) = 307325 lbs W2/WT= 0.22; W2= 0.22 WT = (0.22) (374786) = 82453 lbs Refer FIG E 3 API 650; For D/H value of 0.8, Cancroids of seismic forces are; X1/H = 0.42; X1= (H) (0.42) = (24.61) (0.42) = 10.34 ft. X2/H = 0.75; X2= (H) (0.75) = (24.61) (0.75) = 18.46 ft. Ws = Total weight of Tank shell (un-corroded) = 7100 kg= 15653 lbs

Seismic Analysis (cont)

(Ref. API 650-APPENDIX-E)

Calculation of CG of shell
H1 of course (cm) Thickness (cm) Area (a) Distance of CG (cm2) (y) from bottom (cm)

Shell Course

ay

t1 t2 t3

150 150 150

0.8 0.6 0.6

120 90 90

75 225 375

9000 20250 33750

t4
t5

150
150

0.6
0.6

90
90

525
675

47250
60750

Total

480

171000

Seismic Analysis (contd.)

(Ref. API 650-APPENDIX-E)

Calculation of CG of shell (Contd.)

Distance of CG from Bottom; Xs = a1y1 + a2y2 + --- as ys / a1 + a2 ---as = 171000/480 = 356.25 cm = 11.69 ft Ht = Actual height of Tank = 24.61 ft Wr = Weight of Roof = 1130 + 450 + 209 = 1789 kg = 3944 lbs Overturning Moment due to seismic effect, M M = Z1 [(C1 Ws Xs) + (C1 Wr Xt) + (C1 W1 X1) + (C2 W2 X2) ] Z1 = 0.20 x 1.50 = 0.3 C1 Ws Xs = (0.6) (15653) (11.69) = 109790 C1 Wr Xt = (0.6) (3944) (24.61) = 58237 C1 W1 X1 = (0.6) (307325) (10.34) = 1906644 C2 W2 X2 = (0.4377) (82453) (18.46) = 666215 Sum = 2740886 Over-turning moment applied to the bottom of the shell M = (0.3) (2740886) = 822266 lb.ft

Seismic Analysis (contd.)

( Ref. API 650- APPENDIX- E)

Resistance to overturning (Ref. API 650-E-4) wL = Max weight of tank content that may be used to resist the shell overturning moment = 7.9 tb (Fby. G.H)0.5 Where tb = Corroded Thickness of bottom plate = 8 mm 1.6 mm (CA) = 6.4 mm = 0.252 in (Corroded) Fby = Min. yield strength of bottom plate under the shell = 36259.4 psi G = Specific Gravity of stored liquid = 0.85 H = Design liquid level = 24.61 ft wL = (7.9) (0.252) ((36259.4 x 0.85 x 24.61)0.5) = 1733.8 lb per ft of shell circumference wL shall not exceed 1.25 GHD. 1.25 GHD = (1.25) (0.85) (24.61) (19.69) = 514.86 lb per ft shell circumference Hence adopt wL = 514.86 lb per ft of shell circumference.

Seismic Analysis (contd.)

( Ref. API 650- APPENDIX- E)

Resistance to overturning (Contd.) (Ref. API 650-E-4) Weight of the New tank to resist the Moment: Shell: 7100Kg (approx) Stairway & platform: 1575 Kg (approx) Nozzle: 870 Kg (approx) Roof plate: 1130 Kg (approx) Roof structure: 450 Kg (approx) Wind girder: - Kg (approx), Not required Curb girder: 209 Kg (approx) Hand rail on roof: 420 Kg (approx) Bottom Plate: 1960 Kg (approx) Total: 13714 Kg (approx) wt = 13714 Kg / Shell circumference = 30234 lbs / ( 19.69 ft) = 489 lb/ft of shell circumference (wt + wL) = 489 + 514.86 = 1003.86 lb per ft of shell circumference. M / D2 (wt + wL) = 822266/ (19.69)2 (1003.86) = 822266/ 389192.6 = 2.11 Since M / D2 (Wt + WL) = 2.11 > 1.57, The tank has to be provided with anchorage as per API 650 E-5.1 (d), E-6.

Seismic Analysis (contd.)

( Ref. API 650- APPENDIX- E)

Check for Safe Compressive Stress (Anchorage Tank) (Ref. E 5.2, Anchored tanks)
Value of maximum compressive longitudinal force at the bottom of the shell;
b

= wt + (1.273 M/ D2) = 46 0.4 + ((1.273) x (822266 ) / (19.6 9)2) = 46 0.4 + 2700 = 316 0.4 lb per foot of shell circumference Ma xi mum Longi tud inal Compressive stress in shell; b/12tb = 3160.4/ (12). (0.252) = 1045.1 lb/in2 GHD2/t2 = (0.85) (24.61) (19.69)2 / (0.252)2 = 127709 < 106 Max Allow Compression stress in shell, Fs = 106 (t/2.5 D) + 600 (GH)0.5 = 106 (0.252/ 2.5 x 19.69) + 600 ( 0.85 x 24.61)0.5 = 5119.3 +2744 = 7863.3 psi The tank is stable under compression as the maximum longitudinal compressive stress is less than the allowable, Fs.

Seismic Analysis (cont)

( Ref. API 650- APPENDIX- E)

Anchorage(Ref. API 650, E- 6.2.2)

Diameter of tank = 6 m = 19.69 ft Anchor spacing shall be less than 6 feet. Minimum size of anchor bolts shall be M24. Min. number of anchor required = x 19.69 / 6 = 10.30 Nos. Provide 12 Nos. anchor bolts 0f IS 2062 Gr C of M29 size.