CONCENTRATED SULPHURIC ACID

TANK

TANK STRENGTH CALCULATION

Rev. 0 (For approval)

Date : 4/4/2015

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SUMMARY OF RESULTS
3
Tank Volume : 6000 m

Tank Inside Diameter (D) : 22.6 m

Tank Height (H) : 15 m

Roof Slope : 0.7 : 10

Shell Plate Thickness : 25/10 mm

Bottom Plate Thickness : 16 mm

Roof Plate Thickness : 6 mm

Tank Empty Weight : 210 Ton

Tank Operating Weight : 10544 Ton

Tank Test Weight : 5827 Ton

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 Thickness Calculation

1- Tank Design Data :

Tank Type : Supported Cone Roof Without Columns

th
Design Code : API 650 , 12 Edition, Addendum 2014
Tank Service : Concentrated Sulphuric Acid Tank
Fluid : Concentrated Sulphuric Acid 98.5%
Fluid Density (ρf)
3
: 1840 kg/ m
3
Total Volume : 6000 m
3
Max. Operating Capacity : 5600 m
Tank Inside Diameter (Di) : 22600 mm
Tank Height (H) : 15000 mm
Max. Operating Level (Ho) : 14000 mm
Design Temperature : 60 ºC
Design Internal Pressure (Pi) : Atm
Internal Lining : NA
Corrosion allowance (C.A) : 4 mm
Materials for fabrication:
- Shell : St. 37
- Bottom : St. 37
- Roof : St. 37
- Nozzle Neck : SA-106 Gr B
- Flanges : SA-105
- Manway Neck/Flange : St. 37

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2- Shell Plate Thickness

Shell Plate Width (h) : 1500 mm

Shell Plate Material : St. 37-2 (Equivalent to A-283 C)
Max. Allow. Design Stress (Sd) : 137 Mpa
Max. Allow. Test Stress (St) : 154 Mpa
Corrosion Allowance (C.A) : 4 mm

Number of shell courses (n) = H/h

= 10 Courses
Note : Course order shall be from bottom to top of the shell.

[2.a] Plate thickness for first course (t1) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t1 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t1 = 24.38 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t1 = [4.9 D (Ho - 0.3) / St] + C.A
t1 = 13.85 mm

* Min. Thickness of shell course as per API 650, Art. 5.6.1.1

for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t1 = 25 mm

[2.b] Plate thickness for second course (t2) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t2 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t2 = 22.15 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t2 = [4.9 D (Ho - 0.3) / St] + C.A
t2 = 12.77 mm

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 * Min. Thickness of shell course as per API 650, Art. 5.6.1.1
for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t2 = 23 mm

[2.c] Plate thickness for third course (t3) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t3 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t3 = 19.91 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t3 = [4.9 D (Ho - 0.3) / St] + C.A
t3 = 11.69 mm

* Min. Thickness of shell course as per API 650, Art. 5.6.1.1

for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t3 = 20 mm

[2.d] Plate thickness for fourth course (t4) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t4 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t4 = 17.68 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t4 = [4.9 D (Ho - 0.3) / St] + C.A
t4 = 10.62 mm

* Min. Thickness of shell course as per API 650, Art. 5.6.1.1

for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t4 = 18 mm

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[2.e] Plate thickness for fifth course (t5) :
* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t5 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t5 = 15.45 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t5 = [4.9 D (Ho - 0.3) / St] + C.A
t5 = 9.54 mm

* Min. Thickness of shell course as per API 650, Art. 5.6.1.1

for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t5 = 16 mm

[2.f] Plate thickness for sixth course (t6) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t6 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t6 = 13.22 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t6 = [4.9 D (Ho - 0.3) / St] + C.A
t6 = 8.46 mm

* Min. Thickness of shell course as per API 650, Art. 5.6.1.1

for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t6 = 14 mm

[2.g] Plate thickness for seventh course (t7) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t7 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t7 = 10.99 mm

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 * Thickness at Test conditions (API 650, Art. 5.6.3.2):
t7 = [4.9 D (Ho - 0.3) / St] + C.A
t7 = 7.38 mm

* Min. Thickness of shell course as per API 650, Art. 5.6.1.1

for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t7 = 12 mm

[2.h] Plate thickness for eighth course (t8) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t8 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t8 = 8.76 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t8 = [4.9 D (Ho - 0.3) / St] + C.A
t8 = 6.3 mm

* Min. Thickness of shell course as per API 650, Art. 5.6.1.1

for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t8 = 10 mm

[2.i] Plate thickness for ninth course (t9) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t9 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t9 = 6.53 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t9 = [4.9 D (Ho - 0.3) / St] + C.A
t9 = 5.22 mm

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 * Min. Thickness of shell course as per API 650, Art. 5.6.1.1
for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t9 = 10 mm

[2.j] Plate thickness for tenth course (t10) :

* Thickness at Design conditions (API 650, Art. 5.6.3.2):
t10 = [4.9 D (Ho - 0.3) * G / Sd] + C.A
t10 = 4.3 mm

* Thickness at Test conditions (API 650, Art. 5.6.3.2):

t10 = [4.9 D (Ho - 0.3) / St] + C.A
t10 = 4.14 mm

* Min. Thickness of shell course as per API 650, Art. 5.6.1.1

for tank diameter (22.6 m) is 6 mm

Selected Nominal Plate Thickness t10 = 10 mm

[2.k] Stability of Shell Against Buckling (API 650 , Art. 5.9.7)

3 0.5 2
Max. Height of Unstiffened Shell (H1) = 9.47 t ((t/D) ) (190/V)
(Considering wind velocity V=160 km/h)
H1 = 88.8 m

Transposed widths of shell courses (API 650, Art. 5.9.7.2) :

5 0.5
Wtr = W [(Tuniform/Tactual) ]

- Course #1 : Wtr(1) = 152 mm

- Course #2 : Wtr(2) = 187 mm
- Course #3 : Wtr(3) = 265 mm
- Course #4 : Wtr(4) = 345 mm
- Course #5 : Wtr(5) = 463 mm
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- Course #6 : Wtr(6) = 647 mm
- Course #7 : Wtr(7) = 951 mm
- Course #8 : Wtr(8) = 1500 mm
- Course #9 : Wtr(9) = 1500 mm
- Course #10 : Wtr(10) = 1500 mm

Tank Transformed Height (Htr) = Wtr(1) + Wtr(2) + .... + Wtr(10)

Htr = 7.51 m
Htr < H1

Therefore, tank shell does not require an intermediate stiffening girder and
plates thicknesses are satisfactory to withstand buckling.

[2.m] Summary of Shell Courses Thicknesses :

Req. Req. Nominal

design Test
Thick. Thick. Thick. Course
Allow. Allow.
for for Used Material
Stress Sd Stress St
Design Test (mm)
Course #1 24.38 13.85 25 St. 37 137 Mpa 154 Mpa

Course #2 22.15 12.77 23 St. 37 137 Mpa 154 Mpa

Course #3 19.91 11.69 20 St. 37 137 Mpa 154 Mpa

Course #4 17.68 10.62 18 St. 37 137 Mpa 154 Mpa

Course #5 15.45 9.54 16 St. 37 137 Mpa 154 Mpa

Course #6 13.22 8.46 14 St. 37 137 Mpa 154 Mpa

Course #7 10.99 7.38 12 St. 37 137 Mpa 154 Mpa

Course #8 8.76 6.30 10 St. 37 137 Mpa 154 Mpa

Course #9 6.53 5.22 10 St. 37 137 Mpa 154 Mpa

Course #10 4.30 4.14 10 St. 37 137 Mpa 154 Mpa

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3- Bottom Plate Thickness

(A) As per API 650, Art. 5.4.1 :

Min. bottom plate thickness (tb) = 6 mm + corrosion allowance
tb = 10 mm

(B) As per API 650, Art. 5.5.5, and Table 5.1a :

All bottom plates shall be butt welded, i.e annular plates are not used.
- Product Stress = ((td - CA) / corroded t) (Sd)
= 132 MPa

- Hyd. Test stress = (tt / Nominal t) (St)

= 85.3 MPa

So, Required Bottom Plate thickness as per (Table 5.1a) = 6 mm

Selected Nominal Thickness of Bottom Plates tb = 16 mm

4- Roof Plate Thickness

Tank Inside Diameter (D) : 22.6 m

Corrosion Allowance (C.A) : 4 mm
Slope of roof plates : 0.7/10
Roof Cone Height (Hr) : 0.79 m
Steel density (ρs)
3
: 7850 kg/m
Minimum Yield Strength (Fy) : 205 MPa
Number of rafters (n) : 36 (Recommended)
Rafter section : (to be specified by steel designer)

* Roof plates weight Wp = π * D/2 * (D /4 + Hr ) * tr * ρs

2 2 0.5

Wp = 18940 kg

Using No. 36 rafters:

Weight of rafters Wr = 10000 (Assumed) kg
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* Dead load DL = (WP+Wr) g / (πD / 4)
2

DL = 0.708 kPa

* Live load on roof (Lr) : 1 kPa (API 650, Art. 5.2.1- f)

* Gravity Loads (API 650, Art. 5.2.2):

e1 = DL + Lr + 0.4 Pe
e1 = 1.708 kPa

e2 = DL + 0.4 Lr + Pe
e2 = 1.108 kPa

p = the greater of e1 and e2 = 1.708 kPa

* Spacing between rafters at the shell periphery (b) = π D/n

(b) = 1972 mm

Calculating roof plate thickness as per (API 650, Art. 5.10.4.4):

b = t (1.5 Fy/p)1/2
t = b/(1.5 Fy/p)1/2
t = 4.65 mm

Roof plate thickness as per (API 650, Art. 5.10.2.2):

min. roof plate thickness = 5 mm

Selected Nominal Thickness of Roof Plates tr = 6 mm

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5- Top Angle
5.1- Top Angle Size (API 650, Art. 5.1.5.9.e) :
D = 22.6 m
Minimum Top Angle Size: 75 x 75 x 10 mm

Selected Top Angle Size : 100 x 100 x 10 mm

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