Design, Analysis And Fabrication Of Firewater Storage Tank
Research ArticleDesign, analysis and fabrication of firewater storage tankH. K. Sachidananda1· Shalvi Dubey1 · M. Veera Kumar1 Springer Nature Switzerland AG 2018AbstractThis research article focuses on the design, fabrication and analysis of firewater storage tank in order to assess tankintegrity and maintaining compliance with industry and regulatory standards. The storage tank is considered of fixedcone roof firewater tank considering carbon steel as the material of the tank. The analysis has been carried out usingCFD and finite element analysis. The results of the study shows that the designed tank is safe from the failure mode andthe seismic energy transferred and accumulated in the structure.Keywords Firewater tank · ANSYS · Design · FabricationList of symbolstd Design shell thickness (mm)tt Hydrostatic test shell thickness (mm)D Nominal tank diameter (m)G Design specific gravity of liquidCA Corrosion allowance (mm) 1.50Sd Maximum allowable stress (MPa)St Maximum allowable stress for hydrostaticcondition (MPa)Di Inside diameter of tank (m)Ht Hydrotest liquid level (m)HL Design liquid level (m)Vn Maximum wind speed (km/h)Sp Peak ground acceleration for seismicanalysis 0.30I Importance factor 1.25Lf Minimum roof live load (MPa)Ys Minimum yield stress (MPa)Uts Ultimate tensile stress (MPa)E Modulus of elasticity (GPa)Cf Yield stress reduction factorFy Minimum yield stress (MPa)W1 Force in annular plate (N)tar Minimum thickness without corrosion (mm)tba Minimum thickness of annular plate (mm)t Top shell core thickness (mm)H2 Height of the tank (m)Pw Wind pressure (MPa)V Wind speedPe Design vacuum pressureEd Young’s modulus at design temperature andambient temperature (MPa)Dv Design vacuum pressure (MPa)CF Correction factor for velocity and vacuumHL Maximum height of unstiffened shell (m)Ea Young’s modulus at ambient temperatureAv Vertical seismic coefficientµ Friction coefficient for tank slidingGe Effective specific gravityWi Effective impulsive weightWp Weight of tank contact (N)Xi Center of action (m)Xc Center of attraction (m)Xs Height of the bottom of the shell to shell CG(m)Wr Total weight of the roof framing (N)Xr Height from top of shell to roof CG (m)J Anchorage ratioWrs Roof loading acting on the shell per meter(N/m)* H. K. Sachidananda, sachidananda6@gmail.com; Shalvi Dubey, shalvidubey@gmail.com; M. Veera Kumar, veerakumar16@gmail.com 1Department of Mechanical Engineering, School of Engineering and IT, Manipal Academy of Higher Education, Dubai Campus, Dubai,United Arab Emirates.SN Applied Sciences (2019) 1:81 https://doi.org/10.1007/s42452-018-0071-2Received: 11 October 2018 / Accepted: 19 November 2018 / Published online: 4 December 2018Vol.:(0123456789)
Research ArticleSN Applied Sciences (2019) 1:81 https://doi.org/10.1007/s42452-018-0071-2Wtr Transposed width of each shell course (mm)W Actual width of shell course (mm)tuniform Corroded thickness of top shell (mm)tactual Ordered thickness of each shell (mm)Ht Height of transposed width (mm)Hf Height of product level (mm)H Maximum design liquid level (m)Ci Coefficient of impulsive periodtu Average thickness of shell (mm)Ti Impulsive natural period, sSp Peak ground accelerationRi Response reduction factorQ Scaling factorFa and FV Site coefficientN Number of boltPf Failure pressure, MPaMW Wind moment (N-m)Fba Bearing pressure (MPa)Dbo Annular bottom plate diameterWo Operating weight (N)tbr Annular bottom plate thickness (mm)tb Annular bottom plate thickness (mm)nc Effective width of the gusset (mm)tcr Thickness of chair plateNb Projection in chair plateC Spacing between the gussetsP Bolt load on gussetf Bolt hole diameter (mm)Ms Seismic overturning momentWi Effective impulsive weight of liquid (N)Ws Weight supported by shell (N)1 IntroductionStorage tanks are used to store water, liquid petroleum,petroleum products and similar liquids. These tanks aredesigned as crack-free structures to eliminate any leakage. Oil storage tanks are susceptible to fire as it containsvarious hydrocarbons in it. Therefore, firewater tanks areinstalled in industries in case of emergency. The commonmaterials used to construct firewater storage tanks arecarbon steel, structural steel and concrete. Reservoir is acommon term applied to liquid storage structure and itcan be below or above the ground level. Reservoirs belowthe ground level are normally built to store large quantities of water, whereas those of overhead type are builtfor direct distribution by gravity flow and are usually ofsmaller capacity. Based on firewater tank, some of the literature reviews are as follows.Scholz [1] has studied firewater storage, treatment,recycling and management. They reviewed firewatermanagement and recycling of firewater in order to reduceVol:.(1234567890)water use. Also, they reviewed the health risk of firewaterto firefighters and also to protect environment from pollution. Aware and Mathada [2] have studied cylindrical liquidstorage tank using finite modeling techniques. They studied the seismic performance of various heights elevatedwater tanks using STAAD-PRO software, and they concluded that their study will be useful for civil engineers tounderstand the effects of various heights water tank. Kronowitt [3] has suggested an insulated water storage tankmade of plastic along with associated piping and seriesof valves which is directly connected to the regular watersupply which can be bypassed when not in use. Ali [4] hasstudied procedures for designing and assessing the firewater storage tank. They analyzed the procedure used ingravel pad foundation of firewater storage tank. They recommended conducting regular maintenance and installing instruments to monitor the settlement of the sand onwhich firewater storage tank is constructed. Palmer [5] hasstudied stresses in storage tanks. According to them, thesettlement around the circumference of the foundationbelow the firewater storage tank can cause stressing anddistortion resulting in deflections and stresses in the shelland the primary wind girder.In this research paper, design and analysis of fixed coneroof firewater tank has been studied. The analysis of thistank has been performed using ANSYS static structural andCFD workbench for stress and pressure analysis, respectively, and validated. This analysis has been carried out forfirewater tank considering steel, concrete and structuralsteel material.2 MethodologyThe firewater storage tank considered in this work is fixedcone roof tank. The material considered is carbon steel forthe various parts such as shell courses, the roof plates, bottom and annular plates, wind girders and anchor bolts.3 Standards and specificationsAmerican petroleum institute (API) 650 [6] This standardestablishes minimum requirements for material, design,fabrication, erection and inspection for vertical, cylindrical, aboveground, closed- and open-top, welded storagetanks in various sizes and capacities for internal pressuresapproximating atmospheric pressure, but a higher internal pressure is permitted when additional requirementsare met. This standard applies only to tanks whose entirebottom is uniformly supported and to tanks in non-refrigerated service that have a maximum design temperatureof 93 C (200 F) or less.
Research ArticleSN Applied Sciences (2019) 1:81 https://doi.org/10.1007/s42452-018-0071-2National fire protection association (NFPA) 22 [7] Thisstandard provides requirements for the design, construction, installation and maintenance of tanks and accessoryequipment that supply water for private fire protection.Coverage includes provisions for: (1) gravity tanks, suctiontanks, pressure tanks and embankment-supported coatedfabric suction tanks, (2) towers, (3) foundations, (4) pipeconnections and fittings, (5) valve enclosures, (6) tank filling and (7) protection against freezing.American water works association (AWWA) D100 [8] Thepurpose of this standard is to provide guidance to facilitatethe design, manufacture and procurement of welded carbon steel tanks for the storage of water. This standard doesnot cover all details of design and construction because ofthe large variety of sizes and shapes of tanks.The main method used for determining the shell thickness of the liquid storage tanks designed is in conformance with API standard 650 is the one-foot method whichis the most effective method for tanks with a smallerdiameter.The thickness of the cylindrical shell using one-footmethod can be estimated as follows:td 4.9D(H 0.3)G CASd(1)tt 4.9D(H 0.3)St(2)where td design shell thickness (mm), tt hydrostatictest shell thickness (mm), D normal tank diameter (m),H design liquid level (m), G design specific gravity of liquid to be stored, CA corrosion allowance (mm), Sd allowable stress for design condition (MPa), St allowable stressfor the hydrostatic test condition (MPa) and the minimumthickness of shell as per API 650 Cl.5.6.1.1 5.00 mm.The cylindrical shell designed for the tank comprisesof five shell courses, the roof plate, the bottom plate andthe annular plate. The details of the specifications are asfollows:Type of roof used is cone roof, contained fluid is firewater, specific gravity G of the fluid is 1, operating pressure isatmospheric (1.01325 bar), operating temperature 65 C,design temperature 0 minimum and maximum 85 C,inside diameter of tank (uncorroded), Di 12.50 m, tankheight up to top of curb angle Ht 12.5 m, design liquidlevel Hl 12.5 m, tank filling height Hf 12 m, nominalcapacity 1543 m3, stored capacity 1473 m3, corrosionallowance (CA) for the shell, roof and bottom is 1.50 mm,radiography for shell as per API 650 CL 8.1.2, maximumwind speed Vn 190 km/h, peak ground acceleration forseismic analysis Sp 0.30, importance factor I 1.25 andminimum roof live load Lf 0.0012 MPa.4 Material specifications (A36)and allowable stresses4.1 For bottom shell courses and balance shellcourses (As per A36) for shell design conditionMinimum yield stress (Ys) 250 MPa, ultimate tensile stress(Uts) 400 MPa, maximum allowable stress (Sd) 160 MPa,modulus of elasticity (E) 200 GPa, yield stress reductionfactor (Cf ) 6.40 and hydrotest temperature is taken as17 C (Table 1).4.2 For bottom shell courses and balance shellcourses (As per A36) for shell hydrostaticconditionMinimum yield stress (Ys) 250 MPa, ultimate tensilestress (Uts) 400 MPa and maximum allowable stress(St) 171 MPa (Fig. 1, Tables 2, 3).4.3 Annular plateMaterial for the annular plate is selected as per A36 (GroupIII), minimum yield stress (Fy) 250 MPa. Maximum designliquid level (H) 20 m, force in annular plate (Wl) due toliquid as per C1.5.11.2 19,389 N/m, product stress in firstshell course as per C1.5.5.3 115.04 MPa, hydrostatic teststress in first shell course as per C1.5.5.3 93.47 MPa, minimum thickness without corrosion allowance (tar) 6 mm,minimum thickness as per C1.5.11.2 (tar) 4.65 mm, corrosion allowance for annular plate (CA) 1.50 mm. Therefore, tar CA 7.50 mm, provided thickness of annularplate (tba) 8 mm, mean diameter D 12.508 m, minimumannular bottom plate width inside of shell 600 mm, lapof bottom annular plate 50 mm, minimum requiredradial width 708 mm, required annular bottom platewidth 384.60 mm and provided width of annularplate 720 mm.Table 1 Maximum allowable stress for bottom shell course (design condition) (Sd should be the smallest of A, B and C.)ABCSd 32 Cf Ys 1066.67 MPaSd 25 Uts 160 MPaSd (API 650) 160 MPaVol.:(0123456789)
Research ArticleSN Applied Sciences (2019) 1:81 https://doi.org/10.1007/s42452-018-0071-2Fig. 1 Firewater tank elevation and shell courses4.4 Bottom plateCorrosion allowance for bottom plate(CA) 1.50 mm, minimum required thickness as perC1.5.4.1 6 mm CA 7.50 mm, provided thickness ofbottom plate 8 mm and resisting downward force dueto bottom plate corroded weight 51.03 kg/m3.4.5 Roof plateType of roof used is cone roof and the roof slope/angle 4.76 , nominal diameter of tank D 12.508 m, corrosion allowance for roof plate (CA) 1.50 mm and theload considered is 0.002171 MPa.The minimum thickness (C1.5.10.5.1) for self-supportingcone roof is calculated as given in equation below.[()( )0.5 ]TD CA 32.67 mm(3)4.8 sin 4.76 2.2This thickness is not practical and hence supportedcone roof is considered for which minimum roof platethickness considered is 8 mm.4.6 Intermediate wind girders (API‑650 C1.5.9.7and M.6)The tank nominal diameter (D) 12.508 m, corrosion allowance for the shell (CA) 1.50 mm, top shell course thicknesscorroded t 4.50 mm, height of tank including free board(H2) 12.50 m, maximum wind velocity (Vm) 190 km/h,design wind speed as per 5.2.1 1.2 V 228 km/h,w i n d p r e s s u r e ( Pw) o n c y l i n d r i c a l p a r t V V 1000 1238.40 mN2 , design vacuum pressure0.86 190190(Pe) 0.00 N/m2, total external pressure (Pw Pe) 1238.40 N/m2, design temperature (T) 85 C, Young’s modulus atdesign temperature and ambient temperature Ed 200 GPa,design vacuum (Dv) 0.000 MPa, the vacuum already considered as per C1.5.9.7.1.1 0.00024 MPa, correction factor(CF) for velocity and vacuum 0.720, maximum height (H1)of unstiffened shell in corroded condition (C1.5.9.7.1)Table 2 Maximum allowable stress for bottom shell course (hydrostatic test condition) (St should be the smallest of A, B and C.)ABCSt 43 Cf Ys 1200 MPaSt 73 Uts 171.43 MPaSt (API 650) 171 MPaVol:.(1234567890)
Research 2.506.175.224.263.302.34Required thickness (tt) (mm)H (requiredheight)12.5010.007.505.002.50H 250025002500123456.175.224.263.302.34Ht (requiredheight)Shell course no.Course width (m)tactual (m)Wtr 9972.5002.5002.5002.500 t3d3EdEa 12.772 m and transposed width of 5tuniformwhereeach shell course C1.5.9.7.2 Wtr W t5 actualW actual width of shell course (mm), tuniform corrodedthickness of top shell 4.5 mm and tactual ordered thickness of each shell course (mm) (Table 4).Since the height of transformed shell (Ht) is equal to thesum of the transposed width of the courses and since H1is less than Ht, intermediate wind girder is required as perCL.5.9.7.3. So number of wind girders required will beequal to one. Therefore, distance between IWG and topangle H 1 (5.50) m, required modulus of section(Z) D 2 H117 V1902 50.60 cm3 and the provided modu-lus of section 97.89 cm3.Course width Design(mm)Ho (requiredheight)Required thickness (td) (mm)HydrotestTable 4 Thickness of each course shell and transposed width 9.47 Course no.4.7 Seismic analysis (API 650)Height of product level (HF) 12 m, ratio D/H 1.042, ratioH/D 0.959, coefficient of impulsive period (Ci) 6.14,average thickness of shell (uncorroded) tu 6.40 mm andimpulsive natural period (as per C1E4.51.1) is calculatedas follows:Ti 12.5010.007.505.002.50Table 3 Thickness of shell courses (Tp thickness provided and Tr thickness required)Thickness required is less Thickness prothan td or tt (mm)vided (mm)Tp TrTp TrT p TrT p TrT p TrRemarkSN Applied Sciences (2019) 1:81 https://doi.org/10.1007/s42452-018-0071-2Ci H𝜌0.5t 0.5 0.163 s(4)20000.5 Du0.5 E 0.5Similarly, peak ground acceleration (Sp) 0.340, responsereduction factor (Ri) 3 and scaling factor q 1, S1 0.260and S 8. The site coefficient Fa and Fv as per table E-1, E-2is considered as 1 and 1.5, impulsive horizon seismic coefficient (Ai) is calculated using 2.5 Q Fa Sp RI 0.283,vertical seismic coefficient (Av) 0.1190, convective (sloshing) period (Tc) is calculated using TC 1.8KS D0.5 as perC1.E.4.5.2-a 3.6827 Sec, Ks 0.578() 0.5785, K 1.5,tanh3.68HDTl 8 s, Ts 0.4588 s, friction coefficient for tank slidingµ 0.40, convective horizontal seismic coefficient forTc 4 s, effective specific gravity (Ge) G(1 0.4Av) 0.95and effective impulsive weight of liquid as per E6.1.1 isVol.:(0123456789)
Research ArticleSN Applied Sciences (2019) 1:81 ted using Wi 1 0.218 DH Wp where Wp is theweight of tank content 14,445,195 N, but D/H 1.333 asper E.6.6.6. Similarly, the center of action for ringwall found at i [o n a s p e r ] E 6 . 1 . 2 . 1 i s c a l c u l ate d u s i n gXi 0.5 0.094 DH H 4.824 m, effective convectiveweightper E6.1.1 is calculated using( c) as )][ of liquid (WHDWc 0.23 H tanh 3.67 D Wp 345,699 N, center ofattraction (Xc) for [ringwall foundation is calculated as ]per)(1() HE 6 . 1 . 2 . 1 Xc 1 cosh 3.67 H HHD3.67 D Sinh 3.67 D 8.788 m, the seismic overturning moment (MS) at theb a s e o f t h e t a n k f o r r i n(g w a l l c o n)d i t i o n[ ()]2)]2 0.5[ (MS Ai Wi Xi WS XS Wr Xr Ac Wc Xc 16,062,990N-m, shear force due }to seismic{ ()2( )2 0.5FS Ai Wi Ws Wr Wf (Ac Wc 3,315,745N,MsAnchorage ratio (J) D2 (W (1 0.4AV ) Wwhere][ta 0.4Wint )WsWWt 𝜋D Wrs and roof loading acting on shell (Wrs 𝜋Dr ) and Wa 99 ta Fy Ge H , Wint 0.0 N/m.The maximum shell compression for mechanicallyanchored tank( () 1.273Mrw )1𝜎C Wt 1 0.4Av (5)21000tDsAnd the allowable shell compression (Fc) is calculatedusingGHD2t2(6)And the condition is maximum shell compressionshould be less than allowable shell compression (Tables 5,6).4.8 Anchor bolt designThe number of anchor bolt used N 20 and the materialfor the bolt considered is cast iron and the yield stress ofanchor bolt (Fy) is considered as 250 MPa. The failure pressure (Pf ) of(the bolt(is calculated))using the following equawhere DLR is the deadtion Pf 1.6P 0.000746 DLRDload of shell other than roof (corroded), dead load including roof (corroded) and dead load other than roof. Theis calculated using[d e s i g n p r e2 s s u r e] 785 W 0.8th) D[((P)] 1 and the test pressure2Pt 0.8th D[( 785 W1 and)the failure pressureis]2calculated using[ 1.5 Pf 0.08th D] 785 W3 and4Mthe wind load is PWR D2 785 DW W2 and the seis[( )()]4MS W1 0.4Amic load is calculated using. Also,2vDd e s i g n p re s s u re w i n d i s c a[l c u l]a t e d u s i n g[()]4M0.4P PWR 0.08th D2 785 DW W1 and thedesign pressure seismic[ is ] calculated using()][4M(0.4P 0.08th) D2 785 D S W2 1 0.4Av andis calculated using][the frangibility2 pressure(3PF 0.08th) D 785 W3.4.9 Design of annular bottom plateThe bearing pressure (Fbe) operating condition is calcu4Wlated using 𝜋D20 where Dbo is the annular bottom plateboTable 5 Dynamic hoop tensilestresses due to seismic motionof liquidFirewater tankY (m)Ni (N/mm)Nc (N/mm)Nh (N/mm)σt (MPa)Allowable σt (MPa)ResultShell course 1Shell course 2Shell course 3Shell course 4Shell course ble 6 Dynamic hoop stressfor D/H 1.33Firewater tankY (m)Ni (N/mm)Nc (N/mm)Nh (N/mm)σt (MPa)Allowable σt (MPa)ResultShell course 1Shell course 2Shell course 3Shell course 4Shell course 1234567890)
SN Applied Sciences (2019) 1:81 https://doi.org/10.1007/s42452-018-0071-2Research ArticleFig. 2 Main steps for CFD analysisouter diameter and Wo is the operating weight. Therequiredplate thickness (tbr) is calculated bottom[ annular]fbeusing Np where t b is the annular bottom platetthickness.bTable 7 Mesh descriptionArea firewater tankMesh typeScale factorNodesElementsTetrahedron mesh117,40815,075Fig. 4 Graph of iteration/time step4.10 Design of vertical gussetcross section of the gusset is calculated using[The( effecti
This research article focuses on the design, fabrication and analysis of rewater storage tank in order to assess tank integrity and maintaining compliance with industry and regulatory standards. The storage tank is considered of xed
in the Gap project as the design and fabrication requirements are closely linked. Furthermore ISO 19902 is covering both design and fabrication aspects and making reference to this code will imply that requirements both to design and to fabrication need to be adhered to. 2.2 Basis of comparison of fabrication requirements
SHEET METAL FABRICATION SL1180 Sheet Metal Fundamentals . SL1152 Drafting, Pattern Development and Layout SL1131 Fabrication Fundamentals . SL1245 Layout and Fabrication - Parallel Lines SL1255 Layout and Fabrication - Radial Lines SL1261 Layout and Fabrication - Triangulation SL1743 Air Quality Management . SL1153
Blowdown Separator Skid Fabrication. Instantaneous Heat Exchanger (Steam to Water & Glycol) Skid Fabrication. Simplex and Duplex construction Mechanical Pressure Power Pump Skid Fabrication. Clean Steam Generator (Steam to Steam) Skid Fabrication. Pressurized Hybrid Deaerator Tank Skid Fabrication. Process & Steam Specialties Fabricated Skid .
Module #3 CMOS Fabrication Agenda 1. CMOS Fabrication - Yield - Process Steps for MOS transistors - Inverter Example - Design Rules - Passive Components - Packaging Announcements 1. Read Chapter 2 Module #3 ECOM 5335 VLSI Design Page 2 CMOS Fabrication CMOS Fabrication - We have talked about
Autoconnect: Computational design of 3D-printable connectors [2015] Fabrication in Graphics High-level design Computational Design of Mechanical Characters [2013] Fabrication in Graphics Process optimization Clever support: Efficient support structure generation for digital fabrication [2014]
Design, Fabrication, and Analysis of MEMS Three-Direction Capacitive Accelerometer Kevin Petscha and Dr. Tolga Kayaa aCentral Michigan University, Mount Pleasant, MI 48859 Email: {petsc1k, kaya2t}@cmich.edu Abstract In this project we present the design and fabrication of a MEMS three-direction capacitive accelerometer.
zBifbitiBasic fabrication process zCMOS fabrication zLayout design rules zProcess variation and yield zManufacturing cost zSummary CMOS F b i tiCMOS Fabrication zCMOS: “Complementary” means using both n-type and p-type de ices on the same chipdevices on the same chip zTwo main technologies: zP-Well zSubstrateisNSubstrate is N-TypeNType. N .
provided a unique challenge for our pipe fabrication facility. Initial fabrication was done overseas before being shipped to Canada, and our team was responsible for unloading the subassembly pipe spools and turning them into the larger, full-sized spools to be sent to the refinery site. Thanks to our large fabrication facility and
