STORAGE TANKS

1. INTRODUCTION

2. GENERAL

3. DESIGN CODES

4. TYPE OF TANKS

5. SELECTION OF TANKS

6. MATERIAL SPECIFICATIONS

7. DESIGN OF COMPONENTS
Shell design
Bottom Plate design
Wind girder design
8. SEISMIC
9. ANCHORAGE REQUIREMENT

10. VENTING OF TANKS

11. ROOF TO SHELL JOINT DETAIL

12. REINFORCEMENT REQUIREMENT

13. ROOF STRUCTURE DESIGN

14. FOUNDATION DESIGN CONSIDERATION

15. TYPE OF FLOATING ROOF AND ITS ACCESSORIES

16. CALCULATION OF THICKNESS BY VARIABLE POINT METHOD

 INTRODUCTION

Throughout the chemical, petrochemical and refineries gases,

liquids and solids are stored, accumulated or processed in
vessels of various shapes and sizes.
Such a large number of storage vessels or tanks are used by
these industries that the design, fabrication and erection of these
vessels have become a specialty of a number of companies.
Only very few companies in process industries now design
storage vessels having large volumetric capacity.
However, the design of this equipment involves basic principles
which are fundamental to the design of other types of
equipment.
 GENERAL
Storage tanks are designed for internal pressure approximating
atmospheric pressure, or internal pressure not exceeding the weight
of the roof plates.

Higher internal pressure upto 2.5 psi is permitted when additional

requirement are met.

Maximum operating temperature of 90º C is allowed however for

higher temperature upto 260 º C allowable stress modification to be
done.

Tank designed for one product can store other product of differing
relative density(always of lesser density)

Height-to-diameter ratio is often a function of the processing

requirements, available land area and height limitations.
 DESIGN CODES
Following are the codes for the design of welded steel storage tanks,
API 650
BS 2654 For non-refrigerated, above ground storage
IS 803

API 12F For tanks for storage of Production liquids (upto 120m 3)

API 653 For tank inspection, repair, alteration and reconstruction

API 620 For low-pressure storage tanks

IS 10987 For under-ground/above-ground storage of petroleum

products

For design of reinforced tanks

BS 4994 For tanks in reinforced plastics
 TYPES OF TANKS

The above ground storage tanks of large capacity are categorised based
on the type of roof as follows,

Storage Tank

Fixed roof Floating roof

Cone Roof Dom e Roof O pen top Closed top

Sim ply Supported Single Deck Single Deck

Internal rafter type Double Deck Double Deck
Internal truss type
Rafter with Central colum n
 SELECTION OF TANK
Selection of specific type of tank and type of roof depends upon the
intended service conditions, such as the product being stored, its vapor
pressure and corrosive nature and anticipated weather and loading
conditions.

Cone roof tanks are recommended for products with lower vapor
pressure or with less emission control requirement.
Even for products with higher vapor pressure, cone roof tanks can be used
if the product capacity is less and necessary venting and blanketing
arrangements are provided.
Cone roof tanks are cheaper and easier to construct. Maintenance is very
simple.
Floating roof tanks are recommended for storing products of higher
volatility. The steel deck provide good insulation over the entire surface of
the liquid.
 MATERIAL SPECIFICATIONS

Following are the common plate material used for construction of tanks,
A 36 upto 40 mm
A 283 Gr C upto 25 mm
A 285 Gr C upto 25 mm
A 131 Gr A upto 12.5 mm
A 131 Gr B upto 25 mm
A 516 Gr 55,60,65,70 upto 40 mm
A 537 Cl1, Cl2 upto 45 mm

The minimum tensile strength of materials used in construction of tanks are

between 55000 psi to 85000 psi.

Carbon content between 0.15% to 0.25%

Low carbon steels are soft and ductile, easily sheared, rolled and
formed into various shapes easily. Easy for welding and gives joints of
uniform strength relatively free from localised stresses.

Low alloy, high strength steels are also used but it is more difficult to
fabricate, because they have low ductility.

Plates shall be semi killed as minimum and fully killed and made to
fine grain practice or normalised as required.

For material with minimum tensile strength upto 80 ksi, the manual
metal arc-welding electrodes shall conform to E60 and E70
classification series.

For material with minimum tensile strength of 80 ksi to 85 ksi,

electrodes shall conform to E80 series.
 DESIGN OF TANK COMPONENTS

SHELL DESIGN:As per Clause 3.6.3

Shell thickness is calculated for two conditions, design conditions
and hydrotest condition
Design Condition:

td = 2.6 D(H-1)G + CA
Sd

Hydrostatic Condition:
tt = 2.6 D(H-1)G
St

where, td is the design thickness required in inches

tt is the hydrostatic thickness required in inches
D is the diameter of the tank in feet
H is the height of the tank in feet
G is the specific gravity of the product
CA is the corrosion allowance in inches
Sd is the allowable stress for design condition in psi
St is the allowable stress for test condition in psi
Method explained above is one-foot method of
calculating the shell thickness.
This method is very conservative method and gives a
higher thickness.
For tanks above 60 m dia, this method is not preferred.

Variable design point method

is used for tanks above 60 m dia and if L/H ratio
is less than or equal to 2,
where L = (6Dt)0.5
where ‘t ‘ is the thickness of bottom shell course.

This method normally provides a reduction in shell-

course thickness and hence total material weight.

Variable design point method is explained separately.

BOTTOM PLATE DESIGN:
As per clause 3.4.1 of API 650

All bottom plates shall have a minimum nominal

thickness of 6 mm, exclusive of corrosion allowance.

Annular bottom plate design:

For calculating the thickness of annular bottom
plate the hydrostatic test stress in first shell course
shall be calculated as given below

St = 2.6 D(H-1)G
t
where ‘t’ is thickness of first shell course.
Thickness of annular plate shall be obtained from the table given
below.
Radial width of annular plate at any point around the circumference of
the tank shall be either Aw1 or Aw2, whichever is greater
Aw1= X + t + Y + L
where, X = 24 “ or as per Appendix E.4.2 X=0.0274 WL/GH
whichever is greater
t = Provided thickness of the lowest course
Y = Projection of annular plate outside the shell
L = Annular-sketch plate lap
WL = Weight of tank contents
Aw2= 390 tb/ (HG)0.5
where, tb = Thickness of the annular plate
WIND GIRDER DESIGN:
As per Clause 3.9.7
Tanks of larger diameter may not have the necessary inherent
rigidity to withstand wind pressure without deforming and
excessively straining the shell. To avoid this suitable stiffening
or wind girders are provided.
The maximum height of unstiffened shell H1 shall be calculated
as follows:
H1 = 600,000 t ((t/D)3)1/2 (100/V)2 (As per Clause 3.9.7)
where, t = as ordered thickness of the top shell course(in.)
D = nominal tank diameter(ft)
V = wind velocity (mph)
WIND GIRDER DESIGN:As per Clause 3.9.7

After the maximum height of the unstiffened shell, H 1 has been

determined, the height of the transformed shell shall be
calculated as follows:
Change the actual width each shell course into a transposed
width of each shell course having the top shell thickness:
Wtr = W((tuniform/tact)5)0.5
where Wtr = Transposed width of each shell course, (in.)
W = Actual width of each shell course (in.)
tuniform = ordered thickness of top shell course (in.)
tact = ordered thickness of shell course for which transposed
width is calculated (in.)
Add the transposed widths of the courses. The sum of the transposed widths of the
courses will give the height of the transformed shell

If Wtr is greater than H1 an intermediate wind girder is required.

For equal stability above and below the intermediate wind girder, the girder should be
located at the mid height of the transformed shell.

If half the height of the transformed shell exceeds the than H 1 a second intermediate
wind girder shall be used to reduce the height of unstiffened shell to a height less than
the maximum.

Overturning stability considering wind load shall be checked as follows:

Overturning moment from wind pressure shall not exceed two-thirds of the dead load
resisting moment.
M less than or equal to 2/3(WD/2) for unanchored tanks
where, M = overturning moment from wind pressure
W = shell weight available to resist uplift, less any CA, plus dead weight supported
by the shell minus simultaneous uplift from operating conditions such as internal
pressure
 SEISMIC ANALYSIS

The design procedure considers two response modes of the tanks

and its contents:
a. The relatively high-frequency amplified response to lateral
ground motion of the tank shell and roof, together with the portion
of the liquid contents that moves in unison with the shell.
b. The relatively low-frequency amplified response of the portion of
the liquid contents that moves in fundamental sloshing mode.

The design requires the determination of the hydrodynamic mass associated

with each mode and the lateral force and overturning moment applied to the
shell as a result of the response of the masses to lateral ground motion.

The overturning moment due to seismic forces applied to the bottom of the shell
shall be determined as follows:
M = ZI (C1WSXS + C1WrXt+ C1W1X1 + C2W2X2)
where, Z = seismic zone factor
I = Importance factor as per Appendix E
 C1 C2 = lateral earth quake force coefficients
WS = Total weight of the tank shell(lb)
XS = Height from the bottom of the tank shell to the shell’s CG(ft)
Wr = Total weight of the tank roof(lb)
Ht = Total height of tank shell(ft)
W1 = Weight of the effective mass of the tank contents that move in
unison with the tank shell(lb)
X1 = Height from the bottom of the tank shell to the centroid of
lateral seismic force applied to W 1 (ft)
W2 = Weight of the effective mass of the tank contents that move in
unison in first sloshing mode(lb)
X2 = Height from the bottom of the tank shell to the centroid of
lateral seismic force applied to W 2 (ft)

Resistance to the over turning moment at the bottom of the shell may
be provided by the weight of the tank shell and by anchorage of the
tank shell or for unanchored tanks, the weight of a portion of the tank
contents adjacent to
the shell.
 WL = 7.9tb(FbyGH)1/2
where, WL = maximum weight of the tank contents that may be used to resist
the shell overturning moment, in lb/ft of shell circumference.
tb = thickness of the bottom plate under the shell(in.)
Fby = minimum specified yield strength of the bottom plate under
the shell (lb/in.2)
G = design specific gravity of the liquid to be stored

Now, calculate Wt, weight of tank shell & portion of fixed roof supported by
the shell, in lb/ft of shell circumference.

When M/[D2(Wt + WL )] is greater than 1.57 the tank is structurally unstable.

When the tank is unstable any one of the following measures shall be carried
out:
a. Increase the thickness of the bottom plate tb under the shell.
b. Increase the shell thickness, t.
c. Change the proportions of the tank to increase the diameter and reduce the

height.
d. Anchor the tank.
 ANCHORAGE REQUIREMENT

Tank anchorage shall be provided if there exists a tendency for the

shell and the bottom plate, close to the shell, to lift off its foundations
due to the following reasons,
Uplift on an empty tank due to internal design pressure
counteracted by the effective weight of roof and shell.
Uplift due to internal design pressure in combination with
wind loading counteracted by effective weight of roof and shell,
plus the effective weight of product considered .

The anchorage shall not be attached to the bottom plate only but principally to
the shell.
The design shall accommodate movements of the tank due to thermal changes
and hydrostatic pressure and reduce any induced stresses in the shell to a
minimum.
If an anchored tank is not properly designed, its shell can be susceptible to
tearing.
Care should be taken to ensure that the strength of the anchorage attachments is
greater than the specified minimum yield strength of the anchors so that the
anchors yield before the attachment fail.
The spacing between anchors shall not exceed 10ft. On tanks less
than 50ft in diameter, the spacing between anchors shall not
exceed 6ft.

Minimum diameter of anchor bolts shall be 1in. excluding

corrosion all.
 VENTING OF TANKS

Venting is required for all tanks.

The venting system provided shall cater for the following:
a) normal vacuum relief
b) normal pressure relief
c) emergency pressure relief
Normal venting is accomplished by a pressure relief valve, a vacuum relief valve,
a pressure vacuum(PV) valve or an open vent with or without a flame-arresting
device.
Emergency venting is by means of the following:
 Larger or additional valves or open vents.
 A gauge hatch that permits the cover to lift under
abnormal internal pressure.
 A manhole cover that lifts when exposed to abnormal
internal pressure.
 By means of frangible joint.
Vent sizing is as per API 2000

Inbreathing (Vacuum Relief)

Required venting capacity for liquid movement out of tank : iQ1
5.6 ft3/hr for each 1 bbl/hr of maximum emptying rate
Required venting capacity for thermal inbreathing : iQ2
1 ft3/hr for each 1 bbl of tank capacity or 2ft3/hr for each 1 ft2 of total shell
and roof area.
Required total venting capacity for inbreathing : iQt = iQ1 + iQ2

Outbreathing (Pressure Relief)

Required venting capacity for liquid movement into tank : oQ1
6 ft3/hr for each 1 bbl/hr of maximum filling rate
Required venting capacity for thermal outbreathing : oQ2
Should be 60% of the inbreathing requirement .
Required total venting capacity for outbreathing : oQt = oQ1 + oQ2
Now select any standard venting device like open vent, open vent
with flame arrester or Pressure/Vacuum valve
Once the type and size of venting device is selected, the flow capacity
of the device iQc, oQc will be known.

Required number of device Ni shall be as follows:

For inbreathing Ni = iQt/iQc
For outbreathing No = oQt/oQc

Sample design of Roof Vent:

Condition:
Tank capacity : 11,200 m3
Tank diameter : 35,000 mm (114.8 ft)
Tank height : 15,400 mm (50.5 ft)
Max. filling rate : 2,600 m3/hr (16,354 bbl/hr)
Max. emptying rate : 2,150 m3/hr (13,524 bbl/hr)
For Inbreathing(Vacuum relief)

Required venting capacity for liquid movement out of tank : iQ1

iQ1 should be 5.6 ft3/hr for each 1 bbl/hr of maximum emptying
rate.
iQ1 = 5.6 x 13,524 = 75,734 ft3/hr
= 2,145 m3/hr
Required venting capacity for thermal inbreathing : iQ2
iQ2 should be 2 ft3/hr for each 1 ft2 of total shell and roof area.
(A=55,450 ft2 )
iQ2 = 2A = 2 x 55,450 = 110,900 ft3/hr
= 3,140 m3/hr
Required total venting capacity for inbreathing : iQt
iQt = iQ1 + iQ2
= 2,145 + 3,140
= 5,285 m3/hr
For Outbreathing (Pressure relief)

Required venting capacity for liquid movement out of tank : oQ1

oQ1 should be 6.0 ft3/hr for each 1 bbl/hr of maximum filling rate.
oQ1 = 6.0 x 16,354 = 98,124 ft3/hr
= 2, 779 m3/hr

Required venting capacity for thermal outbreathing : oQ2

oQ2 should be 60% of the inbreathing requirement
oQ2 = 0.6 x 110,900 = 66,540 ft 3/hr
= 1,884 m3/hr
Required total venting capacity for outbreathing : oQt
oQt = oQ1 + oQ2
= 2,779 + 1,884
= 4,663 m3/hr
Venting Device capacity
Select a 12” Pressure/vacuum valve having the following
capacity
iQc = 3,366 m3/hr
oQc = 5,600 m3/hr

Required set of PV valve:

For inbreathing : Ni (number required)
Ni = iQt/iQc = 5,285/3,366 = 1.57

For outbreathing : No (number required)

No = oQt/oQc = 4,663/5,600 = 0.84

Then, 2 (> 1.57) sets of the above 12” venting device shall be
provided for this tank.
 ROOF TO SHELL JOINT

Roof plates shall be attached to the top angle of the

tank with a continuous fillet weld on the top side only.
Frangible joint design:
In the event of excessive internal pressure build up
failure occurs first in the roof to shell joint protecting
the bottom to shell joint.
In most cases cone roofs are designed as frangible
joints only.
 ROOF TO SHELL JOINT
Following are the design conditions for a frangible joint:

a. The continuous fillet weld between the roof plates and the top
angle does not exceed 5 mm
b. The roof slope at the top-angle attachment does not exceed 1:6
c. The roof to compression-ring details are limited to those
shown in figure.
d. Cross-sectional area of the roof-to-shell junction, A should be
less than value calculated by the following Aa=W/201,000 tan θ
where
W= Total weight of the shell & roof framing (but not the roof
plate) supported by shell & roof
 REINFORCEMENT REQUIREMENT
Openings in tank shells larger than a NPS 2 nozzle shall be
reinforced.
The minimum cross sectional area of the required reinforcement
shall not be less than the product of the vertical diameter of the
hole cut in the shell and the required plate thickness.
Reinforcement may be provided by one or any combination of
the following:
a. The reinforcing plate
b. The portion of the neck
c. Excess shell-plate thickness.
d. The material in the nozzle neck. The area in the neck available for
reinforcement shall be reduced by the ratio of allowable stress in the
neck to shell.
 REINFORCEMENT REQUIREMENT

Reinforcement may be provided by one or any

combination of the following:
a. The reinforcing plate
b. The portion of the neck
c. Excess shell-plate thickness.
d. The material in the nozzle neck. The area in the neck
available for reinforcement shall be reduced by the ratio
of allowable stress in the neck to shell.
 REINFORCEMENT REQUIREMENT
The effective area of reinforcement provided by the neck is
as follows,
a. The portion extending outward from the outside surface
of the tank shell plate to a distance equal to four times the
neck-wall thickness
b. The portion lying within the shell-plate thickness.
c. The portion extending inward from the inside surface of
the tank shell plate to a distance equal to four times the
neck.
 REINFORCEMENT REQUIREMENT
Sample case:
Manhole opening size : 511 mm
Manhole neck thick : 10 mm
Shell thickness required:5.958 mm, say 6 mm
Shell thick provided : 10 mm

Minimum c/s area of reinforcement required = 511 x 6

= 3066 mm2
Reinforcement provided:
A. By excess plate thickness
Reinforcement provided = 511 x (10-6) = 2044 mm2
B. By manhole neck
Neck thickness t = 10 mm, 4t = 40
Shell thickness = 10 mm
 REINFORCEMENT REQUIREMENT
Reinforcement provided by manhole neck = (40x10)+(10x10)
= 500 mm2

Reinforcement provided by A & B = 2044 + 500 = 2544 mm2

Balance required reinforcement = 3066 - 2544 = 522 mm2
Now the reinforcement plate OD can be selected such a way the total
reinforcement area provided is higher than reinforcement required.

OD of RF plate as per code = 1055 mm

Selected OD of pad (to avoid fouling with weld seam) = 800 mm

Reinforcement provided by RF pad = (800 - 511) x 6 = 1734 mm2

which is greater than 522 mm2
Therefore provided reinforcement is OK
 ROOF STRUCTURE DESIGN
All roofs and supporting structures shall be designed to
support dead load plus a uniform live load of not less than 25
lb/ft2 of projected area.
Rafters shall be spaced so that in the outer ring, their centers
are not more than 2л feet apart measured along the
circumference of the tank.
Step 1:
calculate the total load/unit area W acting on the roof.
a. Live load & Vacuum load
25 lb /ft2 as per API 650 + any vacuum load if any
b. Dead load - Weight of roof plate and roof structures
Step 2:
Now minimum number of rafters required shall be calculated.
Say, a tank of 15 meter dia.
Then minimum number of rafters required shall be (л x 15)/1.915 =
24.6 nos
Now say 30 rafters are provided.
Provide 15 primary rafter and 15 secondary rafter.
Step 3:
Calculate the total load acting on the primary rafter
Area of roof x W gives total load say P
Now P/15 gives the load per rafter
Since the roof is of cone type, loading is zero at the center and
maximum at the periphery of the tank roof and is uniformly
increasing nature from center to periphery.
This condition can be considered as hinged end condition. Ra =
P/15

Step 4:
C
P/15 P/15
ht
Ha Hb
Ra D/2=r Rb
Sum of the moments about end C equal to zero
Ha x ht. + load x r x 2/3 = Ra x r
Get value of Ha

 Maximum bending moment M = 1/3 x r x

load - 1/3 Ha x ht
 Minimum section modulus required =
(M / All.Stress)
 Now select a structural member with higher
sectional modulus than required.
Step 5:
Now check for Induced compressive axial stress and
bending stress

Induced compressive axial stress =Ha/Ar

where Ar = cross sectional area of the member selected

Induced bending stress = M/Z

where Z = section modulus of the member selected.

If induced stress is less than allowable stress, then member

size selected is OK

For allowable stress values refer table 5.1 and 6.1 of IS-800
Typical Roof Structure Pattern:
 TANK FOUNDATION DESIGN
CONSIDERATIONS
Providing adequate foundations is an important part of
ensuring an economical and safe liquid storage tank
installation.
Uneven foundation settlement on floating roof tank is a
special problem as compared to fixed roof tank foundations.
The seals of floating roof tanks will compensate for
reasonable variation in the tank diameter such as out-of-
roundness of the shell.
Extreme conditions will impair roof seal efficiency or cause
jamming of the roof, which can be corrected by releveling
the tank.
Proper foundation design will avoid this problem.
 TANK FOUNDATION DESIGN
CONSIDERATIONS
 At any tank site, the subsurface conditions must
be known to estimate the soil bearing capacity and
settlement that will be experienced.
 The subgrade must capable of supporting the
load of the tank and its contents.
 The total settlement must not strain connecting
piping or produce gauging inaccuracies, and the
settlement should not continue to a point at which the
tank bottom is below the surrounding ground surface.
 The tank grade or surface on which a tank
bottom will rest should be constructed at least 0.3 m
above the surrounding ground surface.
 TANK FOUNDATION

Clean washed sand 75 to100 mm deep is recommended as

a final layer because it can be readily shaped to the bottom
contour of the tank to provide maximum contact area and
will protect the tank bottom from coming into contact
large particles and debris.
The finished grade shall be crowned from its outer
periphery to its center at a slope of one inch in ten feet.
The crown will partly compensate for slight settlement,
which is likely to be greater at the center.
It will also facilitate cleaning and the removal of water
and sludge.
 TANK FOUNDATION

Typical foundation types are earth foundation without a

concrete ring wall and earth foundation with a concrete
ring wall.

Foundation without a ring wall shall be adopted for small

size tanks and on surface where adequate bearing capacity
is available.

Tanks with heavy or tall shells and/or self-supported roofs

impose a substantial load on the foundation under the
shell.
 TANK FOUNDATION – Concrete Ring

Advantages of Concrete ring wall

 Provides better distribution of the
concentrated load of the shell to produce a more
uniform soil loading under the tank.

 Provides a level, solid starting plane for

construction of the shell.

 Provides a better means of leveling the tank

grade, and it is capable of preserving its contour
during construction.
 TANK FOUNDATION – Concrete Ring

Disadvantages of Concrete ring wall

It doesn’t conform to differential settlements
which may lead to high bending stress in the bottom
plates adjacent to the ringwall.

1 Ringwall shall not be less than 300 mm thick.

2 The centerline diameter of the ringwall should

equal the nominal diameter of the tank.
 TYPE OF FLOATING ROOFS
AND ITS ACCESSORIES
Pan type floating roof
is the first type used in the industry.
As the name indicates, this roof looked very much like
a shallow pan.
The single deck sloped to the centre for drainage.

The pan roof could sink under heavy loads of water or

snow or from leaks in the deck or drain.

Since the single-deck was in direct contact with the

stored liquid, the more volatile liquids would
sometimes boil from the sun’s heat.
 TYPE OF FLOATING ROOFS
Pontoon type floating roof has a single deck with an
annular pontoon divided by bulkheads into liquid-tight
pontoon compartments.
The pontoon area was in excess of 50% of the total
roof area.
The top deck of the pontoon shaded the bottom deck
which is in contact with the liquid.
The single deck area was designed to balloon upward
to contain vapors produced by boiling. This reduced
considerably the heat input and further boiling.
 TYPE OF FLOATING ROOFS

Double deck floating roof has two deck, one top and
one bottom deck.
1 These two decks are separated by rim plates
and bulk heads to form liquid-tight pontoon
compartments.
2 The top deck provides an insulating air space
over the entire area and boiling losses are held to a
minimum.
3 The deck slopes to one or more drainage points
and open emergency overflow drains protect the roof
from excessive water loads.
 TYPE OF FLOATING ROOFS
AND ITS ACCESSORIES

Internal floating roofs is a fixed roof tank with a floating

roof inside.

The fixed roof provides a shade from the sun,

protection from the wind and also keeps the rain and
snow off the floating roof.
 TYPE OF FLOATING ROOFS

Pontoon design:
Floating roofs shall have sufficient buoyancy to remain
afloat on liquid with a specific gravity of 0.7 and with
primary drains inoperative for the following conditions:
1 250 mm(10 in.) of rainfall in a 24-hour period with the roofs
intact, except for double-deck roofs provided with
emergency drains to keep water to a lesser volume that the
roofs will safely support. Such emergency drains shall not
allow the product to flow onto the roof.
2 Single-deck and any two adjacent pontoon compartments
punctured in single-deck pontoon roofs and
3 may any two adjacent compartments punctured in double-
deck roofs,
4 both roof types with no water or live load.
 TYPE OF FLOATING ROOFS
ACCESSORIES
Following are the accessories of floating roofs:
1. Roof drain
2. Emergency drain
3. Bleeder vent
4. Rim vent
5. Foam seal
6. Supporting legs
7. Anti-rotation devices
8. Automatic tank gauging
9. Rolling ladder
 TYPE OF FLOATING ROOFS
ACCESSORIES
Roof drain:
Roof drains are for removing water from floating roofs in open
top tanks.
These drains are made out of pipes with swing joint assembly.
These pipe drains are also called as flexible pipe drains as these
pipes extends and shrinks with the varying level of the roof which
depends on the product height.

Emergency drain:
Water automatically drains into the tank when it reaches a
certain level on the roof. Rainwater cannot collect on the roof to
endanger the safety of the floating roof .
 TYPE OF FLOATING ROOFS
ACCESSORIES
Bleeder vent:
Vents the air from under a floating roof when the tank is being
filled initially.
After the liquid rises enough to float the roof off its supports the
vent automatically closes. When the tank is being emptied the
vent is automatically opened just before the roof lands on its
support.
Rim vents:
Rim vents are provided to release any excess pressure in the rim
space after the roof is floating.
Foam seals:
One of the important component of a floating roof is the primary
seal between the floating roof and the tank shell.
A good seal closes the space effectively, yet permits normal roof
movement while protecting against evaporation loses.
 TYPE OF FLOATING ROOFS
ACCESSORIES

Supporting legs:
Floating roof shall be provided with supporting legs.
Legs fabricated from pipe shall be notched or perforated at
the bottom to provide drainage.
The length of legs shall be adjustable from the top side of
the roof.
The operating and cleaning position levels of the supporting
legs shall be specified of fixing the adjustable positions.
The legs and attachments shall be designed to support the
roof and a uniform live load of at least 1.2 kPa(25 lb/ft 2)
Steel pads shall be used to distribute the leg loads on the
bottom of the tank.
 TYPE OF FLOATING ROOFS
ACCESSORIES

Anti-rotation device:
Required to prevent floating roofs from rotating and
damaging rolling ladder, pipe drains and seal.
A guided pole is used as anti-rotation device. The pole is fixed
at the top and bottom and passes through a well. The guide
pole can additionally used as gauging or sampling device.

Rolling ladder:
Rolling ladder provides safe and easy access from top of the
tank to the floating roof.
On floating roof a runway is provided, over this runway the
ladder provided with spark proof wheels will travel.
These ladders are provided with self-leveling treads.
CALCULATION OF THICKNESS BY VARIABLE POINT
METHOD:
Design by this method gives shell thickness at design points that
results in the calculated stresses being relatively close to the actual
circumferential shell stresses.

To calculate the bottom-course thickness, preliminary values t pd and

tpt for the design and hydrostatic test conditions shall first be
calculated from the 1-foot method formula.

The bottom shell course thickness t1d and t1t for the design and
hydrostatic test condition shall be calculated using the following
formulae:
t1d = (1.06 - (0.463D/H)(HG/Sd)0.5 (2.6HDG/ Sd) + CA
t1t = (1.06 - (0.463D/H)(H/St)0.5 (2.6HD/ St)

To calculate the second-course thickness for both the design condition

and the hydrostatic test condition, the value of the following ratio shall
be calculated for the bottom course:
 h1/(rt1)0.5 where,
h1 = height of the bottom shell course
r = nominal tank radius
t1 = actual thickness of the bottom shell course, less any
thickness added for CA used to calculate t 2
If the value of the ratio is less than or equal to 1.375,
t2 = t 1
If the value of the ratio is greater than or equal to 2.625,
t2 = t2a
If the value of the ratio is greater than 1.375 but less than 2.625,
t2 = t2a + (t1 - t2 a)[2.1-(h1/1.25(rt1)0.5]
where, t2 = minimum design thickness of the second shell
course excluding any CA
t2a = thickness of the second shell course as calculated
for an upper shell course as calculated as described below
Second Shell Course
The preceding formula for t2 is based on the same allowable
stress being used for the design of the bottom and second
courses.
For tanks where the value of the ratio is greater than or
equal to 2.625, the allowable stress for the second course may
be lower than the allowable stress for the bottom course.
To calculate the upper-course thickness for both the design
condition and hydrostatic test condition, a preliminary value
tu for the upper course thickness shall be calculated by the 1-
foot method and then the distance x of the variable design
point from the bottom of the course shall be calculated using
the lowest value obtained from the following:
x1 = 0.61(rtu)0.5 + 3.84 CH
x2 = 12CH
x3 = 1.22(rtu)0.5
 Second Shell Course (cont.)
where,
tu = thickness of the upper course at the girth joint
C = [K0.5(K-1)]/(1+K1.5)
K = tL/tu

The minimum thickness tx for the upper shell courses

shall be calculated for both the design condition (tdx)
using the minimum value of x obtained as explained
above
tdx = (2.6D(H-x/12)G)/ Sd) + CA
ttx = (2.6D(H-x/12)G)/ St)

The steps described above shall be repeated using the

calculated value of tx as tu until there is little difference
between the calculated values of tx in succession.
Design Data

Type of Tank: Double deck floating roof

Diameter of Tank 'D' :92 m

Height of Tank 'H' :20m

Product Stored: Crude Oil

Design specific gravity 'G': 0.9

Corrosion Allowance 'C.A.' :0.03937 inches = 1 mm

Course width: 2.5 m

Capacity of Tank : 132952.2 cu.m = 836176.3

barrels
The bottom shell course thickness:
t1d = [ 1.06 - (0.463 D/H) sqrt(HG/Sd) ] (2.6HDG/Sd

= 1.59256 inches
= 40.45102 mm
Where,
D = Tank Diameter = 301.8336
H = Tank Height = 65.616
G = Product Specific Gravity = 0.9
Sd = Allowable stress for design condition
of bottom course = 28000
adding 0.03937 inches as corrosion allowance

t1d = 1.63193 inches

41.45102 mm
The second shell course thickness:

h1/(rt1) 0.5 = 1.8327322

Where,
h1 = bottom course height = 98.424 inches
r = nominal tank radius = 1811.002 inches
t1 = bottom course thickness = 1.63193 inches

From API 650 Cl.3.6.4.5

h1/ (rt1)0.5 applicable formula
1.375-2.625 t2 = t2a + (t1 - t2a)(2.1 - h1/1.25sqrt(rt1))
> 2.625 t2 = t2a
< 1.375 t2 = t1

Since h1/(rt1) 0.5 = 1.8327322

t2 = t2a + (t1 - t2a)(2.1 - h1/1.25sqrt(rt1))
where,
t2 = minimum design thickness for second shell
t2a = thickness for second shell course as calculated for an upper course
First trial:
Course # 2
H = 57.414 ft.
tu = (2.6D (H-1) G)/Sd
= 1.423024 inches
tl = 1.59256 inches
K = tl/tu = 1.119137
C= k^0.5 (k-1) / (1 + K^1.5)
= 0.05771
a = (rtu)^0.5
50.76514 inches
x1 = 0.61a + 3.84CH
= 43.69006 inches
x2 = 12CH
= 39.7604 inches
x3 = 1.22a
= 61.93347 inches
x = min ( x1, x2, x3)
= 39.7604 inches
x/12 = 3.313367 inches
tdx = (2.6D (H-x/12)G) / Sd
= 1.36467 inches
Second trial:
H= 57.414
tu = 1.36467
tl = 1.59256
K= tl/tu = 1.166992
C=k^0.5 (k-1) / (1 + K^1.5) = 0.079798
a= (rtu)^0.5 = 49.71338
x1 = 0.61a + 3.84CH = 47.91824
x2 = 12CH = 54.97837
x3 = 1.22a = 60.65032
x= 47.91824
x/12 = 3.993187
tdx = (2.6D (H-x/12)G) / Sd = 1.347522
Third trial:
H = 57.414
tu = 1.347522
tl = 1.59256
K= tl/tu = 1.181843
C=k^0.5 (k-1) / (1 + K^1.5) = 0.086522
a= (rtu)^0.5 = 49.40005

x1 = 0.61a + 3.84CH = 49.2095

x2 = 12CH = 59.61084
x3 = 1.22a = 60.26806
x= 49.2095
x/12 = 4.100791
tdx = (2.6D (H-x/12)G) / Sd = 1.344808
t2a = 1.344808
t2 = t2a + (t1 - t2a)(2.1 - h1/1.25sqrt(rt1)) = 1.502
in. = 38.14665 mm
Adding 0.0625 in. corrosion allowance
t2 = 1.541207 in. = 39.14665 mm

The third shell course thickness:

First trial:

Course # 3
H= 49.212
tu = (2.6D(H-1)G)/Sd = 1.216132
tl = 1.501837

As explained earlier repeat the steps and calculate the third

shell course thickness.
Similarly, shell thickness of other courses are calculated
ONE-FOOT METHOD DESCRIPTION:

This method of calculating the thickness of the shell is based

on the assumption that the tank is filled with water and the
tension in each ring is calculated at a point 12 in. above the
center line of the lower horizontal joint of the horizontal
row of welded plates being considered.
The hydrostatic pressure varies from a minimum at the top
of the upper most course to a maximum at the bottom of the
lowest course.
In determining the plate thickness for a particular course, a
design based upon the pressure at the bottom of the course
results in over-design for the rest of the plate. A design
based upon the pressure at the top of the course would
result in under-design.
ONE-FOOT METHOD DESCRIPTION:

However, some consideration should be given to the

additional restraint offered by the plates adjoining a
particular course.
In the lowest course, the plates of the vessel bottom offer
considerable restraint to the bottom shell course.This
additional restraint of the bottom edge is effective for an
appreciable distance or height from the bottom of the
lowest course.
In an intermediate course with a course of heavier plates
below, the top of the heavier will be understressed.
Therefore, a design based upon the pressure at a height of 1
ft from the bottom of the course may be considered
conservative.