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ABSTRACT
y Storage tanks are used for intermediate and final y y y y
product storage Petroleum products and chemicals are stored Used for mixing, blending, precipitation and setting process For storing Furnace Oil we use Cone Roof type Storage Tanks Efficient storage and better safety are to be concentrated while designing storage tanks
BPCL ,Ambalamugal
y Formerly known as Kochi Refinery is now owned by Bharat Petroleum Corporation Limited y Location : Ambalamugal in Kochi y Refining Capacity : 9.5 million metric tons per annum y Products : LPG, Petrol, diesel, kerosene, ATF, FO(Furnace Oil), Naphtha, Benzene, Rubberized bitumen, MTO(mineral turpentine oil), SPBS(Specialized Boiling point Solvent) & Bitumen emulsion
product storage in process plant or for storing petroleum products and chemicals at terminals y Can be used for Mixing, blending, precipitation and setting process or as chemical reactor vessels y Tanks are classified on the basis of product which is to be stored
FURNACE OIL
y Class C Petroleum product y Bunker fuel, furnace oil , Fuel oil are other names for
vessels
y They have a conical top and are used for storing less
volatile products
y Asphalt, vaccum gas oil, fuel oil, seal oil etc can be
stored
FOAM SYSTEM
y Foam for firefighting purposes is an aggregate of air filled bubbles formed from aqueous solutions and is higher in density than the lightest flammable liquid Used to form a floating blanket on flammable and combustible liquids lighter than water and prevents or extinguishes fire by excluding air and cooling the fuel
pressure y Products like benzene and toluene are stored y Prevent the product from contamination and are used to store class A and class B products y There are 13 floating cum cone roof tanks in BPCL Kochi
and they don t get vaporized fast. So we can use cone roof type since its more economical
A537 For Shell plates ,The most cost effective material has been decided as ASTM A537 CLASS 1
y Minimum Tensile Strength : 385 Mpa y Minimum Yield Strength : 485 Mpa
y For bottom plates, annular plates : IS2062 grade A y Minimum Tensile Strength : 247.6 Mpa y Minimum Yield Strength : 410.6 Mpa
thickness of 6mm exclusive of corrosive allowance y Bottom plates : 6 + CA = 6 + 2 = 8 mm y As the available size of plates in markets are 6m ,8mm, 10mm etc we have to consider 8 mm thickness for bottom plates y Available sizes of plates are of width 1.5m, 2m, 2.5, etc.
SHELL PLATES
SHELL DESIGN
y If the diameter is in the range 36 to 60m the nominal
5.3.1.3
The design shell thickness shall be computed on the basis that the tank is filled to a level H (design liquid level) with a liquid that has a specific gravity specified by the purchaser. The hydrostatic test shell thickness shall be computed on the basis that the tank is filled to a level H (design liquid level) with water. The calculated stress for each shell course shall not be greater than the stress permitted for the particular material used for the course. No shell course shall be thinner than the course above it.
5.3.1.4
5.3.1.5
5.3
5.3.3
5.3.3.1 5.3.3.2
The I-foot method calculates the thickness required at design points 03 m (I ft) above the bottom of each shell course. The required minimum thickness of shell plates shall be the greater of the values computed by the following formulas:
In SI units:
td = 4.9D(H Sd t t = 4.9D(H St
0.3)G
+ CA
03)
5.3 where
td = design shell thickness, in mm, tt = hydrostatic test shell thickness, in mm, D = nominal tank diameter, in m r of the top joined (that is, the shell plate or the bottom H = design liquid level, in .mm, = height from the bottom of the course under consideration to the top angle, if any; to the bottom of any overflow that of the shell including the top limits the tank filling height; or to any other level specified by the purchaser, restricted by an inter-nal floating roof, or controlled to allow for seismic wave action, G = design specific gravity of the liquid to be stored, as specified purchaser, CA = corrosion allowance, in mm, as specified by the purchaser Sd = allowable stress for the design condition, in MPa St=allowable stress for the hydrostatic test condition, in MPa
by the
In page 3.6.1.1
CASE 1 I Can be divided into 6 courses as 2 II 2 III 2.50 IV 2.5 V 2.5 VI 2.5
Course 1 Nominal Tank Diameter in meters D = Height from bottom of the course = under consideration to the top of shell H Design stress to be considered Sd = Corrosion Allowance = Specific Gravity G = Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t Width of shell course W = = = = = = = 36.00m 14.00m
194Mpa 2.00mm 0.95 208Mpa 13.80m 11.60m 13.80mm 14mm 0.014m 2.00m 3.17
Course omi l i meter i meters Hei t from ottom of t e course under consider tion to t e top of s ell H Desi n stress to e considered d Corrosion llowance Specific ravit ax d stress to e considered . m = = = = = = = 1 . m 1 pa
Max t ic ness
12.08mm
= = = =
Course 3 Nominal Tank Diameter in meters D Height from bottom of the course under consideration to the top of shell H Design stress to be considered Sd Corrosion Allowance Specific Gravity G Ma hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Ma thickness Thickness selected t = = 36.00m 10.00m
= = = = = = = = =
194Mpa 2.00mm 0.95 20 Mpa 10.36m .21m 10.36mm 12mm 0.012m 2.50m 3.39
= =
Course 4
Nominal Tank Diameter in meters D Hei ht from ottom of the course under consideration to the top of shell H Desi n stress to e considered Sd
= =
36.00m . 0m
194Mpa
Corrosion Allowance
2.00mm
Specific Gravity G Max hyd stress to e considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t
= = = = = = =
= =
Height from bottom of the course under consideration to = the top of shell H
194Mpa
Corrosion Allowance
2.00mm
Specific Gravity G Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t
= = = = = = =
= =
Height from bottom of the course under consideration to = the top of shell H
194Mpa
Corrosion Allowance
2.00mm
= = = =
Max thickness
3.90mm
Thickness selected t
= =
Width of shell course W = Volume of Shell course V6 = 3.14 * D * W * t Total Volume V = V1+ V2 + V3+V4+V5+V6 =
I 1.5
II 1.5
III 2.50
IV 2.5
V 2.5
VI 3.5
Height from bottom of the course under = consideration to the top of shell H Design stress to be considered Sd Corrosion Allowance Specific Gravity G Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St = = = = = =
= = =
= =
Course 2 Nominal Tank Diameter in meters D Height from bottom of the course under consideration to the top of shell H Design stress to be considered Sd = = 36.00m 12.50m
194Mpa
Corrosion Allowance Specific Gravity G Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t
= = = = = = = =
2.00mm 0.95 208Mpa 12.51m 10.33m 12.51mm 14mm 0.014m 1.50m 2.37m3
= =
Course 3 Nominal Tank Diameter in meters D = = Height from bottom of the course under consideration to the top of shell H 36.00m 11.00m
194Mpa
Corrosion Allowance
2.00mm
Specific Gravity G Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t
= = = = = = =
= =
Height from bottom of the course under consideration to the = top of shell H
194Mpa
Corrosion Allowance
2.00mm
Specific Gravity G Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t
= = = = = = =
= =
Course 5 Nominal Tank Diameter in meters D Height from bottom of the course under consideration to the top of shell H Design stress to be considered Sd Corrosion Allowance Specific Gravity G Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t Width of shell course W Volume of Shell course V5 = 3.14 * D * W * t = = = = = = = = = = = = = 36.00m 6.00m 194Mpa 2.00mm 0.95 208Mpa 6.91m 4.83m 6.91mm 8mm 0.008m 2.50m 2.26m3
Course 6 Nominal Tank Diameter in meters D Height from bottom of the course under consideration to the top of shell H Design stress to be considered Sd Corrosion Allowance Specific Gravity G Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t Width of shell course W olume of Shell course 6 = 3.14 * D * W * t Total olume : 1+ 2+ 3+ 4+ 5+ 6 = = = = = = = = = = = = = = 36.00m 3.50m 194Mpa 2.00mm 0.95 208Mpa 4.76m 2.71m 4.76mm 8mm 0.008m 3.50m 3.17m3 16.39m3
Case 3
Course 1 I Can be divided into 6 courses as 1 = = = = = = = = = = = = = II 1.5 III 2.50 36.00m 14.00m 194Mpa 2.00mm 0.95 208Mpa 13.80m 11.60m 13.80mm 14mm 0.014m 1.00m 1.58m3 IV 2.5 V 3 VI 3.5
Nominal Tank Diameter in meters D Height from bottom of the course under consideration to the top of shell H Design stress to be considered Sd Corrosion Allowance Specific Gravity G Max hyd stress to be considered Td=((4.9*D*(H-0.3)*G)/Sd))+CA Tt =(4.9D(H 0.3))/St Max thickness Thickness selected t Width of shell course W Volume of Shell course V1 = 3.14 * D * W * t
Course 2 Nominal Tank Diameter in meters D = Height from bottom of the course under consideration to the top of shell H = Design stress to be considered Sd = Corrosion Allowance = Specific Gravity G = Max hyd stress to be considered St = Td=((4.9*D*(H-0.3)*G)/Sd))+CA = Tt =(4.9D(H 0.3))/St = Max thickness = Thickness selected t = = idth of shell course = Volume of Shell course V1 = 3.14 * D * * t = 36.00m 13.00m 194Mpa 2.00mm 0.95 208Mpa 12.94m 10.75m 12.94mm 14mm 0.014m 1.50m 2.37m3
Course 3 Nominal Tank Diameter in meters D = Height from bottom of the course under = consideration to the top of shell H Design stress to be considered Sd = Corrosion Allowance = Specific Gravity G = Max hyd stress to be considered St = Td=((4.9*D*(H-0.3)*G)/Sd))+CA = Tt =(4.9D(H 0.3))/St = Max thickness = Thickness selected t = = Width of shell course W = Volume of Shell course V1 = 3.14 * D * W * t = 36.00m 11.50m 194Mpa 2.00mm 0.95 208Mpa 11.65m 9.48m 11.65mm 12mm 0.012m 2.50m 3.39m3
Course 4 Nominal Tank Diameter in meters D = Height from bottom of the course under = consideration to the top of shell H Design stress to be considered Sd = Corrosion Allowance = Specific Gravity G = Max hyd stress to be considered St = Td=((4.9*D*(H-0.3)*G)/Sd))+CA = Tt =(4.9D(H 0.3))/St = Max thickness = Thickness selected t = = Width of shell course W = Volume of Shell course V1 = 3.14 * D * W * t = 36.00m 9.00m 194Mpa 2.00mm 0.95 208Mpa 9.50m 7.37m 9.50mm 10mm 0.010m 2.50m 2.83m3
Course 5 Nominal Tank Diameter in meters D = Height from bottom of the course under = consideration to the top of shell H Design stress to be considered Sd = Corrosion Allowance = Specific Gravity G = Max hyd stress to be considered St = Td=((4.9*D*(H-0.3)*G)/Sd))+CA = Tt =(4.9D(H 0.3))/St = Max thickness = Thickness selected t = = Width of shell course W = Volume of Shell course V1 = 3.14 * D * W * t = 36.00m 6.50m 194Mpa 2.00mm 0.95 208Mpa 7.34m 5.25m 7.34mm 8mm 0.008m 3.00m 2.71m3
Course 6 Nominal Tank Diameter in meters D = Height from bottom of the course under = consideration to the top of shell H Design stress to be considered Sd = Corrosion Allowance = Specific Gravity G = Max hyd stress to be considered St = Td=((4.9*D*(H-0.3)*G)/Sd))+CA = Tt =(4.9D(H 0.3))/St = Max thickness = Thickness selected t = = Width of shell course W = Volume of Shell course V1 = 3.14 * D * W * t = Total Volume V1+V2+V3+V4+V5+V6 = 36.00m 3.50m 194Mpa 2.00mm 0.95 208Mpa 4.76m 2.71m 4.76mm 8mm 0.008m 3.50m 3.17m3 16.05m3
CASE 1 Total volume of shell plate required in m3 = Density in kg/m3 The total weight of shell plates = V * density Material cost of shell plates Overall material cost of shell plates Weight * Cost = = = = 17.07m3 9.50 162.16tonnes 40000.00 64.86lakhs
CASE 2
16.39m3
Density in kg/m3
9.50
density
155. 1tonnes
40000.00
62.29lakhs
CASE 3
16.05m3
Density in kg/m3
9.50
152.49tonnes
40000.00
61.00lakhs
= 61.00
lakhs
= CASE 3
1st shell course thickness 2nd shell course thickness 3rd shell course thickness 4th shellcourse thickness th shell course thickness 6th shellcourse thickness
= = = = = =
2,
2,
2. 0,
2. ,
2. ,
2.
Conclusion
y
Thus e are i t esi a c e r f st ra e ta st ra e f fur ace il as er the re uire e ts f The calculati s f shell thic ee c lete The calculati
y y y y y y y y y y y y
f r the , chi
y y
ess a e e are
tt
lates have
s f arts t
ular tt lates a ial i th f tt late esi f ri ary ec ary i ir er I ter e iate i ir er (if ecessary) a syste iser i e a hole olts ozzles ater rai ra off umps ooli ater system
References
y API 650 STANDARDS (11th EDITION) y BOOK OF ABOVE GROUND STORAGE TANKS y www.bpcl.co.in
Thank you .