PT.

ZUG INDUSTRY INDONESIA

MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
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CLIENT :

PROJECT TITLE : CIREBON 2, 1x1000MW COAL FIRED POWER

PLANT, INDONESIA

LOCATION : CIREBON , WEST JAVA

PO. No :

EQUIPMENT NAME : SWRO PERMEATE TANK

ØE

ØD

ØC

ØB

ØA Issued for Information 30/12/2019

PREP. CHKD APVD
REV. DESCRIPTION DATE
PT. GRAHA FORTUNA PURNAMA
 PT. ZUG INDUSTRY INDONESIA

MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
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REVISION HISTORICAL SHEET

Rev. No Date Description

A 30/12/19 Issued for Information
 PT. ZUG INDUSTRY INDONESIA

MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
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I. Size of Tank
ID = 13,3 ft = 160,0 in. = 4000 mm
H = 18,3 ft = 220,0 in. = 5500 mm
HD = 2,3 ft = 27,2 in. = 680 mm

II. Calculation of Tank Shell

PD 0.036 HD
tsh = =
2SH 2ETZ

Wheres :
tsh = Minimum thickness of tank shell, in.
P = Pressure = 0.036 H, psi + 0,142 psi (0.98 kPa) ( Note : As per client spec. )
D = Inside diameter, in.
SH = Hoop Stress, psi
H = Fluid head, in.
= Specific gravity of fluid = 1,20 ( Note : As per client spec. )
ET = hoop tensile modulus of filament wound = 2,32E+06 psi --------> Helical
( Note : 40%Winding 70 degree.
HLU + 60% Helical winding. )
Z = Allowable strain = 0,001 in./in.

For H1 = 73,3 in.

( 0,036 . 1,20 . 73,333 + 0,142 ) 160

tsh-1 = = 0,114 in. = 2,9 mm.
2 . 2,3E+06 . 0,001

Corrosion barier = 3,50 mm

Total thickness = 2,9 + 3,50 = 6,4 mm
-----------> Proposed design tsh-1 = 7,0 mm

For H2 = 146,7 in.

( 0,036 . 1,20 . 146,67 + 0,142 ) 160

tsh-2 = = 0,223 in. = 5,7 mm.
2 . 2,3E+06 . 0,001

Corrosion barier = 3,50 mm

Total thickness = 5,7 + 3,50 = 9,2 mm
-----------> Proposed design tsh-2 = 10,0 mm

For H3 = 220,0 in.

( 0,036 . 1,20 . 220 + 0,142 ) 160

tsh-3 = = 0,333 in. = 8,4 mm.
2 . 2,3E+06 . 0,001

Corrosion barier = 3,50 mm

Total thickness = 8,4 + 3,5 = 11,9 mm
-----------> Proposed design tsh-3 = 13,0 mm

For H4 = 0,0 in.

( 0,036 . 1,20 . 0 + 0,142 ) 160

tsh-4 = = 0,005 in. = 0,1 mm.
2 . 2,3E+06 . 0,001
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MECHANICAL DESIGN CALCULATION OF FRP TANK

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Corrosion barier = 0,00 mm

Total thickness = 0,1 + 0,0 = 0,1 mm
-----------> Proposed design tsh-4 = 0,0 mm

For H5 = 0,0 in.

( 0,036 . 1,20 . 0 + 0,142 ) 160

tsh-5 = = 0,005 in. = 0,1 mm.
2 . 2,3E+06 . 0,001

Corrosion barier = 0,00 mm

Total thickness = 0,1 + 0,0 = 0,1 mm
-----------> Proposed design tsh-5 = 0,0 mm

For H6 = 0,0 in.

( 0,036 . 1,20 . 0 + 0,142 ) 160

tsh-6 = = 0,005 in. = 0,1 mm.
2 . 2,3E+06 . 0,001

Corrosion barier = 0,00 mm

Total thickness = 0,1 + 0,0 = 0,1 mm

-----------> Proposed design tsh-6 = 0,0 mm

The maximum allowable external pressure (Pa) between stiffening elements of cylindrical shells shall be computed as per
para 3A-310 such as follows

3/4 1/4 5/2

KD 0.8531 ϒ E hf Eat t
Pa = 3/4 3/2
( 1 - vx vy ) L (Do / 2 ) F

Where :
Pd = Design external pressure = 0,98 kPa = 0,14214 psi ( Note : As per client spec. )
Do = Outside diameter of shell = 160,6 in.
Eat = Axial tensile modulus = 8,7E+05 psi
Ehf = Hoop flexural modulus = 2,3E+06 psi
Eaf = Axial flexural modulus = 8,7E+05 psi
F = Design factor = 5
KD = 0,84 a knockdown factor to cover all data points using the rigorous equations
L = Design length of a vessel section = 73,3 in. ( Note : The longest unsupported shell)
t = Nominal Wall thickness = 0,28 in. = 7,0 mm

vx = Flexural poisson's ratio in the axial direction = 0,27

vy = Flexural poisson's ratio in the hoop direction = 0,23
ϒ = Reduction factor developed to bettter correlate the oretical predictions and test results
= 1 - 0.001 Zp, if Zp < 100
= 0.9 , if Zp > 100

3/2 1/2 2
Ehf Eat 1/2 L
Zp = 2 ( 1 - vx vy )
Eaf ( Do t / 2 )

= 4,37 ( 0,968 ) 243,083

= 1028,7 > 100

= 0,9
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MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
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0,84 0,8531 .
. 0,9 ( 2,3E+06 ) 3/4 . ( 8,7E+05 )
1/4
( 0,28 )
5/2
Pa = 3/4 3/2
( 1 - 0,27 . 0,23 ) 73,3 ( 160,6 / 2 ) . 5

46658,25
= = 0,19 psi > 0,14 psi
251341,44
-----------> Design is acceptable !

III. Calculation of Bottom Head

- Thickness of flat bottom head.

Refer to ASTM D 3299-00 std, clausa 6.3.2
The minimum thickness for a fully supported flat bottom head for Type I tank for diameter over 6 to 12 ft ( 1,8 ~ 3.7 m ) =
0.255 in. (6,4 mm)

-----------> Proposed design tB = 13,0 mm

- Thickness of bottom knuckle.

Refer to ASTM D 3299-00 std, clausa 6.3.2.3
The minimum thickness of radiused section shall be equal to the combined thickness of the shell wall and the bottom.

t knuckle = 13,0 + 13,0 = 26,0 mm

IV. Calculation of Top Cover

Refer to ASTM D 3299-00 std, clausa 6.3.1

The top head, regardless of shape, shall be able to support a single 250 lbf (113.4 kg) load on a 4 by 4-in. (100 by 100 mm
) area without damage and with maximum deflection of 1/2% of the tank diameter at the area the load is applied.

The minimum thickness shall be 0.1876 in (4.76 mm)

For torispherical heads, this requirement can be satisfied by using method presented in Appendix NM-11 - ASME RTP-1.

Take assumption :
tc = Thickness of crown = 0,31 in. = 8,0 mm
R = Inside radius of the crown of the head = 160,0 in.
F = Design factor = 5
2
P = Design pressure = -15,63 psi = (250 lb/16 in )
Su = Ultimate tensile strength of laminates = 15000 psi
S1 = Stress on the upper surface of the head, psi
S2 = Stress on the lower surface of the head, psi
G = Stress function, lb

1/2
(Rtc) = 7,1

From Fig. NM 11-1 :

G upper = -180 lb
G lower = 100 lb
2 2
S1 = G/t = -180 / ( 0,31 ) = -1815 psi
S1 < Su / F = 15000 / 5 = 3000 psi
-1815 < 3000 psi -----------> Design is acceptable !

2 2
S2 = G/t = 100 / ( 0,31 ) = 1008 psi
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MECHANICAL DESIGN CALCULATION OF FRP TANK

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S2 < Su / F = 15000 / 5 = 3000 psi

1008 < 3000 psi -----------> Design is acceptable !

-----------> Proposed t top cover = 10,0 mm

145

-240

7,1

V. Calculation of Lifting Lugs

Weight of empty tank (W) :

- Top Head
2 3
W = A (m ) x t (m) x SG ( Kg/m )
2) 3
= 15,70 (m . 0,010 (m) . 1600 (Kg/m ) = 251,2 Kg
( SG : 100 % HLU Std Type II laminates )
- Shell - 1
2 3
W = A (m ) x t (m) x SG ( Kg/m )
2) 3
= 23,03 (m . 0,007 (m) . 1800 (Kg/m ) = 290,1 Kg
( SG : 60 % HLU + 40 % FW )

- Shell - 2
2 3
W = A (m ) x t (m) x SG ( Kg/m )
2) 3
= 23,03 (m . 0,010 (m) . 1800 (Kg/m ) = 414,5 Kg
( SG : 60 % HLU + 40 % FW )

- Shell - 3
2 3
W = A (m ) x t (m) x SG ( Kg/m )
2) 3
= 23,03 (m . 0,013 (m) . 1800 (Kg/m ) = 538,8 Kg
( SG : 60 % HLU + 40 % FW )
- Shell - 4
2 3
W = A (m ) x t (m) x SG ( Kg/m )
2) 3
= 23,03 (m . 0,000 (m) . 1800 (Kg/m ) = 0,0 Kg
( SG : 60 % HLU + 40 % FW )
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MECHANICAL DESIGN CALCULATION OF FRP TANK

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- Shell - 5
2 3
W = A (m ) x t (m) x SG ( Kg/m )
2) 3
= 23,03 (m . 0,000 (m) . 1800 (Kg/m ) = 0,0 Kg
( SG : 60 % HLU + 40 % FW )
- Shell - 6
2 3
W = A (m ) x t (m) x SG ( Kg/m )
2) 3
= 23,03 (m . 0,000 (m) . 1800 (Kg/m ) = 0,0 Kg
( SG : 60 % HLU + 40 % FW )
- Bottom
2 3
W = A (m ) x t (m) x SG ( Kg/m )
2) 3
= 13,82 (m . 0,013 (m) . 1600 (Kg/m ) = 287,4 Kg
( SG : 100 % HLU Std Type II laminates )

- Accessories tank ( Joint bottom & top-head, Nozzles, Lifting lugs, Anchor lugs, etc)
W = 25 % of ( W top-head + W shell + W bottom)( Note : take assumption )
= 0,25 ( 251,2 + 1243,4 + 287,4 ) = 445,5 Kg +

Total Weight = 2227,5 Kg

Weight of empty tank (w) = + 2227,5 kg

For design , w = 2,0 . 2227,5 = 4455,0 kg = 9.823 lbs ( Note : Design factor = 2 )

Qty of Lifting lugs = 4 pcs

So, Load of each lifting lugs = 2.456 lbs
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MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
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- Stress Analysis On The Local Area of Tank Shell

t shell = 7,0 mm = 0,28 in.

w laminate = 400,0 mm = 15,75 in.
allowable = 868 psi ( Note : Axial stress for 40 % HLU + 60 % FW hoop laminates )

2
= F /A = 2456 Lbs / ( 0,28 . 15,75 ) in =
= 565,9 < 868,0 psi -----------> Design is acceptable !

- Stress Analysis On The Overlay Laminates of Lifting Lugs

t laminates = 10,0 mm = 0,39 in.

w laminate = 400,0 mm = 15,75 in.
L laminate = 600,0 mm = 23,62 in.
w steel = 150,0 mm = 5,91 in.
L steel = 250,0 mm = 9,84 in.
allowable = 1500 psi ( Note : Axial stress for 100 % HLU laminates )
allowable = 200 psi ( Note : shear stress for 100 % HLU laminates )

2
= F /A = 2456 Lbs / ( 0,39 . 15,75 ) in
= 396,1 < 1500,0 psi -----------> Design is acceptable !

2
= F /Ashear = 2456 Lbs / ( 15,75 . 23,62 - 5,91 + 9,84 ) in
= 6,5 < 200,0 psi
-----------> Design is acceptable !

- Stress Analysis On The Steel Plate of Lifting Lugs

t steel = 16,0 mm = 0,63 in.

w steel = 80 - 40 mm = 40,0 mm = 1,57 in.
L welded = 100,0 mm = 3,94 in.
t welded = 8,0 mm = 0,31 in.
allw axial = 21000 psi
( Note : Mat'l SS 400)
σ allow shear = 10500 psi

2
= F /A = 2456 Lbs / ( 0,63 . 1,57 ) in .
= 2475,6 < 21000,0 psi -----------> Design is acceptable !
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MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
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2
= F /Ashear = 2456 Lbs / ( 3,94 . 0,31 ) in .
= 1980,5 < 10500,0 psi -----------> Design is acceptable !

VI. Seismic Loading on Vessels ( As per Appendix NM-3 , ASME RTP-1 )

- Spectral Parameters
Location tank : Cirebon - West Java
Latitude : -6,376
Source : puskim.pu.go.id/Aplikasi/design_spektra_indonesia_2011
Longitude : 106,965

Ss = Mapped, maximum considered earthquake, 5 % damped, spectral response acceleration parameter at short
periode (0.2 sec), %g.
= 73,90 % Source : puskim.pu.go.id/Aplikasi/design_spektra_indonesia_2011
S1 = Mapped, maximum considered earthquake, 5 % damped, spectral response acceleration parameter at short
periode (1.0 sec), %g.
= 31,20 % Source : puskim.pu.go.id/Aplikasi/design_spektra_indonesia_2011

Fa = Acceleration-based site coefficient ( at 0.2 sec period ) = 1,209

Fv = Velocity -based site coefficient ( at 1.0 sec period ) = 1,775
Notes :
- Source : puskim.pu.go.id/Aplikasi/design_spektra_indonesia_2011
- Value of F a & F v are use Site Class D, because no inforamation related site soil specification.

Sms = Fa x Ss / 100 = 1,21 . 73,90 / 100 = 0,893

Sm1 = Fv x S1 / 100 = 1,78 . 31,20 / 100 = 0,554

Sds = The design, 5 % damped, spectral response acceleration parameter at short periods ( T = 0.2 sec period ) based
on ASCE 7 method, %g.

= 2/3 x Sms = 2/3 . 0,893 = 0,596

Sd1 = The design, 5 % damped, spectral response acceleration parameter at short periods ( T = 1.0 sec period ) based
on ASCE 7 method, %g.

= 2/3 x Sm1 = 2/3 . 0,554 = 0,369

Ts = Sd1 / Sds = 0,369 / 0,596 = 0,620

- Sloshing Period ( Tc )

α = Aspect ratio of D / Hc = 13,33 / 18,33 = 0,727

0,578 0.5 0,578 0.5

Tc = 0.5 ( D) = 0.5
( 13,33 )
[ tanh ( 3.67 / α)] [ tanh ( 3.67 / 0,727 )]

= 2,111 sec.
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MECHANICAL DESIGN CALCULATION OF FRP TANK

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- Weight and Mass Fractions

Wc = Weight of content , lb
2
= 0.785 (D) (Hc) (62.4) 2(Ƴ)
= 0.785 ( 13,33 ) 18,33 ) ( 62.4 ) ( 1,20 ) = 191.581,9 lb
(

Wfc = Fixed mass fraction, lb

Wfc
= 1 - 0.218 α for α < 1.333
Wc

Wfc tanh (0.866 α )

= for α > 1.333
Wc 0.866 α

α = 0,727
= ( 1 - 0,218 . 0,727 ) 191.581,9

= 161.207,43 lb

Wsc = Sloshing mass fraction, lb

Wsc Wfc
= 1 -
Wc Wc
= 1 - 0,841 = 0,159

= 0,159 . 191581,867 = 30.374,43 lb

- Centroidal Locations for Fixed and Sloshing Mass

Hfc = Fixed mass centroid

Hfc
= 0,5 - 0.094 α for α < 1.333
Hc

Hfc
= 0,375 for α > 1.333
Hc

α = 0,727
= 0,432 . 18,33 = 7,91 ft

Hsc = Sloshing mass centroid

-1
Hsc 3,67 3,67 3,67
= 1 - cosh ( ) - 1 sinh ( )
Hc α α α

= 0,804

= 0,804 . 18,33 = 14,7 ft

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MECHANICAL DESIGN CALCULATION OF FRP TANK

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- Base Shear (Vb) and Moment (Mb)

For Tc < Ts

Vb = (0.7) (0.24 Sds I ) ( W sh + W h + W c )

Mb = (0.7) (12) (0.24 Sds I ) [ W sh (H/2) + W hH + W c (Hc/2) ]

For Ts < Tc < 4.0

Vb = ( 0.7 ) ( Vbf + Vbs )

Vbf = (0.24 Sds I ) ( W sh + W h + W fc )

Vbs = 0.8 Sds I ( 0.75 / Tc ) Ts W sc

Mb = (0.7) (12) [ (0.24 Sds I) (Wsh H/2 + WhH + WfcHfc) + VbsHsc ]

For Tc > 4.0

Vb = ( 0.7 ) ( Vbf + Vbs )

Vbf = (0.24 Sds I ) ( W sh + W h + W fc )

2
Vbs = 0.71 Sds I ( 3.72 / Tc ) Ts W sc

Mb = (0.7) (12) [ (0.24 Sds I) (Wsh H/2 + WhH + WfcHfc) + VbsHsc ]

Ts = 0,620 < Tc = 2,111 < 4,0

I = Importance factor = 1,00 ( Note : As per ASCE 7, table 1.5-2 )

W sh = Weight of shell = 2.740,5 lb
Wh = Weight of head = 553,6 lb

Vbf = ( 0.24 . 0,596 . 1,0 )( 2.740,5 + 553,6 + 161.207,43 )

= 23.515,86 lb

Vbs = 0,80 . 0,596 . 1,0 )( 0,75 / 2,111 ) 0,620 . 30.374,4

= 3.187,91 lb

Vb = 0,7 ( 23.515,86 + 3.187,91 )

= 18.692,6 lb

Mb = 0.7 (12) [( 0.24 . 0,596 . 1,0 )( 2.740,5 . 18,3 / 2 + 553,6 . 18,3

+ 161.207,43 . 7,91 ) + 3.187,91 . 14,7 ]
= 8,4 [ 0,143 ( 25122 + 10150 + 1275688,149 ) + 47011 ]
= 1.969.092 in. lb
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MECHANICAL DESIGN CALCULATION OF FRP TANK

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- Hold Down Force

1.695 Mb - 1.46 ( Wsh + Wh ) R

Fh =
R
R = Vessel radius = 80,0 in.

1,695 . 1.969.092,4 - 1,46 ( 2.740,5 + 553,6 ) 80,0

=
80,0
= 36.910,6 lb

- The combined axial stresses at the vessel base are found to below :

1 -w
σ = 2 ( + Mb ) +
πR t 2πRt w = Weight of empty tank = 3.294,19 lb
t = Thickness of shell = 0,51 in.

1 3.294,19
= (+ 1.969.092,4 )+
π ( 80,0 )
2
0,51 2π . 80,0 . 0,51

= 9,7226E-05 (+ 1.969.092,4 )+ 12,81

= 204,3 psi and -178,64 psi

- The short - wave buckling stress on the compressive side

0.3 Et 0,3 . 2,3E+06 . 0,51

σcrit = = = 4.452,8 psi
R 80,0

The buckling safety factor = 4.452,8 / 204,3 = 21,80

- And the average cross sectional shear is :

Vb 18.692,6
= = 72,70 psi
2πRt 2π . 80,0 . 0,51

- Using the methods given in Kovalevski and Rish's " Structural Analysis of Shells " Sec. 10.3, the critical stress for shear
buckling is given by :

Et
ζ crit = Cs 0.25
R (Zs)

Cs = function of the parameter R/t, from fig. NM3-4 = 0,63

2 2
Zs = L /Rt for 100 < Zs < 78 (R/t)
2
= ( 220,0 ) /( 80,0 . 0,51 ) = 1182,08

2,3E+06 . 0,51
ζ crit = 0,63 0.25
= 1594,73 psi
80,0 ( 1182,08 )
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0.63
R/t = 156,31

101,6

- Safety Factor (Fs)

1594,73 --------------> Design is acceptable !

Fs = = 21,9 > 5
72,70

VII. Wind Loading on Vessels ( As per Appendix NM-3 , ASME RTP-1 )

Empty Cantilevered Vessel Under Wind Load

- Uniform Wind Load (U)

U = (SF) q D
SF = Shape factor = 0,8 ( per Table 23-G UBC, NM3-321 Example )
2 2
q = wind pressure = V /16 Kgf/m
V = Wind speed = 125 KPH 34,73 m/sec
2
= 75,36 Kgf/m ( Note : As per Client Spec )
2
= 753,64 N/m
= 16,0 psf

= 0,80 . 16,0 . 13,33 = 170,67 lbf of height

- Bending moment at the base of the vessel ( Mw )

2
M w = 0.5 U H
2
= 0,5 . 170,67 ( 18,33 ) = 28.681,5 ft.lb = 344.177,78 in.lb

- Total lateral force ( W )

W = UH
= 170,67 . 18,33 = 3.128,89 lbf

- Axial stress at the base of vessel ( f a )

Total vessel weight = 4.909,45 lb
Weight of bottom = 633,37 lb
Weight transmitted through the shell at the base = 4.909,45 - 633,37 = 4.276,08 lb
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MECHANICAL DESIGN CALCULATION OF FRP TANK

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fa = -4276,075613 / [ π . 160,0 . 0,51 ] = -16,63 psi

- Flexural stress at the base of vessel ( f b )

f b = - Mw C / I
4 4
I = moment of inertia = π/64 (Do - Di )
4 4
= π / 64 [ ( 161,02 ) - ( 160,0 ) ]
4
= 830.758,3 in.
C = distance of neutral axis = 80,512 in.

= [ -344177,78 . 80,51 ] / 830.758,3 = -33,36 psi

- Total axial stress f a + f b = -16,63 + -33,36 = -49,99 psi

- Shear stress ( fv )

fv = 3.128,89 / [ π . 160,0 . 0,51 ] = 12,2 psi < 200 psi

-------------> The design is acceptable.
- Allowable stress ( Fa )

Take assumption, the tank is built of filament wound laminate, for which,
Su = Ultimate tensile strength = 8.680 psi ( Note : axial strength of 60 % HLU + 40 % helical FW )

F = Design factor for operating load = 10

= Design factor for wind, seisimic, snow = 8,33

Fa = Su / F = 8.680 / 8,33 = 1042 psi

fa + fb = 16,63 + 33,36 = 50,0 psi < 1042,0 psi

-------------> The design is acceptable.

- Critical buckling stress ( f cra )

f cra = 0.3 Et /R = 0,3 . 2,3E+06 . 0,51 / 80,0 = 4.452,8 psi

- Critical stress for buckling from bending under the wind moment ( fcrb )

f crb = 1.3 f cra = 1,3 . 4452,76 = 5.788,58 psi

- Critical buckling stress due to shear ( f crv )

1.25 0.5
fcrv = 0.695 (E) (t/R) (R/H)
1.25 0.5
= 0,695 . 2,3E+06 ( 0,51 / 80,0 ) ( 80,0 / 220,00 )
= 1759,26 psi

- Buckling interaction equation :

2
fa F / fcra + fb F / fcrb + (fv F / fcrv ) < 1
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MECHANICAL DESIGN CALCULATION OF FRP TANK

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F = Design factor = 5
2
16,63 . 5 / 4452,8 + 33,36 . 5 / 5788,6 + ( 12,17 . 5 / 1759,26 ) < 1
0,049 < 1
-------------> The design is acceptable.

- Conclusion
The design is acceptable for wind load on the empty tank, as far as strength is concerned.

Flat-Bottomed Vessel Under Operating Condition And Wind Load

The hoop stress due to hydrostatic pressure must be combined with the axial stress caused by wind and weight, using a design
factor ( F = 10 / 1.2 = 8.33 )
- Hoop stress ( fh)

Su = 15.000 psi ( Note : 100 % HLU lamination )

PDi 0.0361 (H) (SG) (Di) 0,0361 . 220,00 . 1,20 . 160,0

fh = = =
2t 2t 2 . 1,02

= 744,8 psi < 15.000 / 8,33

= 744,8 psi < 1800,7 psi -------------> The design is acceptable !

- Total axial Stress fa

fa = fa + fb = 16,63 + 33,36 = 49,99 < 15.000 / 8,33

50,0 < 1800,7 psi
-------------> The design is acceptable !

- Shear Stress ( f v )

fv = 12,2 psi < 200 psi -------------> The design is acceptable !

- Conclusion
The design is acceptable for wind load on the tank under operation condition.

VIII. Calculation of Anchor Lugs ( As per Appendix NM-4 , ASME RTP-1 )

- Approximate vessel weight

Weight of empty tank (w) = + 2227,5 kg = 4911,7 lbs

- Calculate wind uplift on roof of vessel (U)

U = At . PG . G

At = Plan area of vessel top, sq ft

G = Wind velocity pressure = 16,0 psf
PG = Uplift Coefficient = 0,95 ( From Fig. NM 4-4 ASME RTP-1, D/H = 0,73 )
2
.
2
= ( /4)(D ) . PG . G = (π / 4) ( 13,33 ) . 0,95 16 = 2.121 lb uplift
 PT. ZUG INDUSTRY INDONESIA

MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
Page 16 of 20
1-074-9/DKP/18 02 -

- Uplift Coefficient
0,95

0.58

- Calculate the wind overturning moment (MQ)

2
MQ = 0.5SfGDH + 0.25GDHD ( H + HD /3 )

Sf = Wind shape factor , dimensionless

= 0,8 ( for cylinder vessel )

MQ = (0.5 . 0,8 . 16 . 13,33 . 18,3 2 ) + 0,25 . 16 . 13,33 . 2,27 . ( 18,33 + 2,27 /3)
= 3,10E+04 ft.lb

- Net uplift (Unet) is :

Unet = U - W + 4 MQ/D
= 2.121 - 4.912 + 4 3,10E+04 / 13,33
= 6506,31 lb < 36.910,6 lb (Hold-down force by seismic)

So, the load (F) per lugs will use of the value of hold-down force by seismic.

F = 4613,83 lb/lug Assume the Qty of anchor lugs (N) = 8 pcs

- Bending Moment (M)

M = Fe
e = Load eccentricity = 3,0 in.
= 4.613,83 . 3,0
= 13.841,5 in-lb
M/Z = Bending stress
S = Allowable bending = 20.000 psi ( Note : Mat'l SS400 + FRP LIned )

3
Z = Section modulus, in .
3 2
bd w t lug
=
6
= 6
 PT. ZUG INDUSTRY INDONESIA

MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
Page 17 of 20
1-074-9/DKP/18 02 -

Drawing sketch of anchor lugs

tw

tk

w
h1

h
tb

e
w

3
Zmin = Minimum required section modulus , in . From dwg skecth of anchor lugs
= M/S w = 10,0 in.
3
= 13.841 / 20.000 = 0,69 in . h = 15,0 in.

1/2
t lug = ( 6Zmin / w )
= ( 6 . 0,69 / 10 ) 1/2
= 0,64 in.
-----------> Proposed design tlug = 0,63 in. = 16 mm

- Height of lug (h)

0.5
6DoWeML
h = 2
NSat k
Do = outside diameter = ID + 2 ts = 160,0 + 2 ( 0,51 )
= 161,02 in.
W = Total load, lb. = Unet = 36.910,6 lb
ML = 0,019 (from fig NM4-3 : w/Do = 10,0 / 161,02 = 0,062 , and
assuming 8 lugs
Sa = Allowable tensile stress = 1.500 psi

0.5
6 . 161,02 . 3,69E+04 . 3,0 . 0,019
=
8 . 1.500 . 1,02 2

= 12,7 in. -----------> Proposed design h = 15,0 in. = 381 mm

- Unit radial load on overwrap (W max)

2
W max = 3Fe / h
2
= 3 . 4.614 . 3,0 / 15,0 = 184,55 lb/in.
 PT. ZUG INDUSTRY INDONESIA

MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
Page 18 of 20
1-074-9/DKP/18 02 -

- Radial load due to moment (P)

P = W max h / 2
= 184,55 . 15,0 / 2 = 1384,1 lb.

- Calculate the tensile perimeter

hl = 19,0 in. ( height of lugs laminates)
w = 10,0 in. ( width of lugs)

2hl + w = 2 . 19,0 + 10,0

= 48,0 in.

- Tensile perimeter load = P / tensile perimeter

= 1384,1 / 48,0 = 28,8 lb/in < 50 lb/in
-----------> Design is acceptable !

0.019

0.066

The minimum required area of secondary RTP bond overlay on the vessel wall shall not be less than :

AR = W / 200 N
2
= 3,7E+04 / 200 . 8 = 23,07 in / lug

Actual area of secondary RTP bond overlay (A) w lam = 28 in.

2 2
A = ( 19,0 . 28 - 16,0 . 10,0 ) = 372,0 in / lug > 23,07 in /lug
-----------> Design is acceptable !
 PT. ZUG INDUSTRY INDONESIA

MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
Page 19 of 20
1-074-9/DKP/18 02 -

- Overlay hoop load (Ttot)

Ttot = PRm / w
Rm = mean radius of overlay
= (Di + 2 tk) / 2 = [ 160,0 + 2 ( 1,02 ) ] / 2 = 81,02 in.

= 1384,15 . 81,02 / 10,0 = 11215 lb

- Overlay hoop tensile stress ( )

= Ttot / hl . tl tl = 0,71 in. ( thickness of overlay )

= 11214,87 / 19,0 . 0,7087 = 833 psi < 3.000 psi

-----------> Design is acceptable !

- Shear across vessel wall ( w)

w = P / tk w
= 1384,15 / 1,02 . 10,0 = 135,2 psi < 200 psi
-----------> Design is acceptable !

- Coefficient of bending in vessel wall ( )

1/2
= 1.28 / (Rm . tk )
1/2 -1
= 1.28 / ( 81,02 1,02 ) = 0,141 in.

- Unit radial loading (P*)

P* = P / w
= 1384,15 / 10,0 = 138,4 lb/in.

- Bending load

Max = P* / 4
= 138,4 / 4 ( 0,141 ) = 246,20 in-lb/in.

Mhp = v Max
v = poisson ratio = 0,3
= 0,3 . 246,2 = 73,86 in-lb/in.

- Bending stress
2
ax = 6 Max / t l = 6 . 246,20 / 0,71 2 = 2.941 psi < 4.400 psi
-----------> Design is acceptable !

2
hp = 6 Mhp / t l = 6 . 73,9 / 0,71 2 = 882 psi < 4.400 psi
psi < -----------> Design is acceptable !

IX. Calculation of Anchor Bolts

F uplift = Uplift load per anchor bolt = 4.613,8 lb

F shear = Shear load per anchor bolt = 2.306,9 lb ( assumed = 1/2 Fuplift)
fc = Specified comprossive strength of concrete at end 28 days = 3000 psi
Fp = Allowable bearing stress on concrete = 0.25. fc = 750 psi
D = Diameter of bolt, in.
 PT. ZUG INDUSTRY INDONESIA

MECHANICAL DESIGN CALCULATION OF FRP TANK

Document No. Rev. Project No.
Page 20 of 20
1-074-9/DKP/18 02 -

Ls = Length of anchor bolt required for resisting shear force on bolt , in.
= 12D (Assumed)
2
Ac = Area of concrete in compression, in .
2
= Ls . D = 12 D

- Concrete resistance for shear

2 2 2
F shear = 1/2 Fp Ac = 6Fp D = 6 . 750 D = 4500 D

1/2 1/2
----> D = ( Fshear / 4500 ) = ( 2306,9 / 4500 ) = 0,72 in.

----> Ls min = 12 . 0,72 = 8,59 in.

---------> Proposed of bolt size = 1 in. (D) x 16 (L) in.

- Check bolt stress

Fy = Yield stress of anchor bolt materials = 35.000 psi (for SA 307 )
Fv = Allowable shear stress = 0.3 Fy = 10.500 psi
Ft = Allowable tensile stress = 0.6 Fy = 21.000 psi
2 2
Ag = Gross area of anchor bolt, in = ( /4) (D) = 0,79 in .
2
At = Tensile stress area of anchor bolt, in .
= 0.75 Ag ( AISC Spec. Sect, 1.5.2.1)
2
= 0,589 in .
fv = Actual shear stress in anchor bolt, psi
= Fshear / Ag = 2.306,9 / 0,79 = 2.939 psi << 10.500 psi
-----------> Design is acceptable !

ft = Actual tensile stress in anchor bolt, psi

= Fuplift / At = 4.613,8 / 0,59 = 7.837 psi < 21.000 psi
-----------> Design is acceptable !

m = Bending moment due to Fshear at the level of top of grout

= Fshear x a -------------> a = gap between anchor lug & top of foundation = 0,5 in.
= 2.306,9 . 0,5 = 1.153,5 lb-in.

Fb = Allowable bending stress in anchor bolt, psi

3
= m / [ ( /32) (D) ]
3
= 1.153 / [ ( π /32 ) ( 1,00 ) ] = 11754,98 psi

( 1/1.33 ) ( ft +Fb ) = 0,752 ( 7.837 + 11754,98 )

= 14.731 psi < 21.000 psi
-----------> Design is acceptable !
Cirebon 2, 1x1000MW Coal Fired Power Plant Project, Indonesia Rev. : 2

Title : Datasheet, GA for GRP Tank - WT Page :

TECHNICAL DATA SHEET FOR BWRO PERMEATE TANK

DESIGN DATA
EQUIPMENT NAME UNIT BWRO PERMEATE TANK
EQUIPMENT TAG NO. P2GCF50 BB001
QUANTITY 1 Nos
MATERIAL GRP
TYPE VERTICAL CYLINDRICAL
TOP/ BOTTOM FLAT
FLUID BWRO PERMEATE
SPECIFIC GRAVITY 1.01
DESIGN VOLUME m3 15
NET VOLUME m3 15
DETENTION TIME Day 10
TANK DIAMETER mm 2600
TANK HEIGHT mm 3800
GROSS VOLUME m3 20.17
DESIGN CODE BS EN 13121-3 : 2008
WORKING PRESSURE bar ATM
DESIGN PRESSURE bar ATM
HYDRO TEST PRESSURE bar FULL OF WATER
WORKING TEMPERATURE ℃ AMBIENT
DESIGN TEMPERATURE ℃ 60.0
CORROSION ALLOWANCE mm 2
FLANGE STANDARD ANSI B16.5 150#
NOZZLE DETAIL AS PER DRAWING
MATERIAL OF CONSTRUCTION
SHELL & DISH END GRP
NOZZLE FLANGE GRP
BOLTS & NUTS ASTM A307 Gr.B / A563 Gr.B HD GALVANISED
HANDRAIL & LADDERS STEEL SCH 40
 ORIENTATION

ELEVATION

1/4

A3
 DETAIL OF N3, N4 & N5 INSIDE OUTSIDE

DETAIL OF N1 & N2A DETAIL OF N2B

FRONT VIEW SIDE VIEW

DETAIL OF EXT. LADDER

DETAIL OF LIFTING LUGS

SECTION OF A - A TOP VIEW

DETAIL OF ANCHOR LUGS

2/4
DETAIL MH1 (TOP MANHOLE)

DETAIL OF MH2 (SIDE MANHOLE) SECTION OF B_- B

A3
 ORIENTATION FOUNDATION PLAN

SECTION OF D - D

3/4

DETAIL PENAHAN PASIR DETAIL ANCHOR BOLT

A3
 BWRO PERMEATE TANK
CODE BS EN 13121-3 : 2008
DESIGN PRESS ATMOSPHERIC
HYD. TEST PRESS FULL WATER
DESIGN TEMP.
DIMENSION 2600 (ID) X 3800 (H)
CAPACITY 20
MATERIAL FRP ISOPTHALIC POLYESTER
DATE AUG-19 SERIAL
NO.
BUILT

PT. ZUG INDUSTRY INDONESIA

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A3