MECHANICAL DESIGN CALCULATION

PROJECT : KHURJA SUPER THERMAL POWER PROJECT (2×660 MW)

THDC INDIA LIMITED

OWNER :
(A JV OF GOVT. OF INDIA & GOVT. OF U.P)
THDC INDIA LIMITED
OWNER’S CONSULTANT :
(A JV OF GOVT. OF INDIA & GOVT. OF U.P)

BOILER CONTRACTOR : L&T-MHI BOILERS PRIVATE LIMITED

FGD CONTRACTOR : ISGEC HEAVY ENGINEERING LIMITED

QFGDM : BABCOCK POWER ENVIRONMENTAL INC.

DOCUMENT NO : FS0004-66050100-CAL-1001 REV. NO. 0

TANK NAME : LIMESTONE SLURRY TANK-A&B DATE

TANK ID X HT. : 13.05M X 14.47M 19-Jan-21

TABLE OF CONTENT

1.0 DESIGN DATA

2.0 SHELL THICKNESS CALCULATION

3.0 BOTTOM THICKNESS CALCULATION

4.0 ROOF THICKNESS CALCULATION

5.0 SHELL TO ROOF JUNCTION CALCULATION

6.0 TANK COMPONENTS' WEIGHT CALCULATION (ESTIMATED)

7.0 WIND LOAD CALCULATION & ANALYSIS

8.0 CHECK FOR OVER-TURNING STABILITY OF TANK FOR WIND LOAD

9.0 INTERMEDIATE WIND GIRDER / STABILITY OF SHELL

10.0 CENTER OF GRAVITY CALCULATION FOR TANK SHELL

11.0 SEISMIC LOAD CALCULATION & ANALYSIS (OPERATING CASE)

12.0 STABILITY CHECK FOR SEISMIC LOAD

13.0 SEISMIC LOAD CALCULATION & SHELL COMPRESSION CHECK (EMPTY CASE)

14.0 UPLIFT LOAD CALCULATION & ANCHOR BOLT DESIGN

15.0 ANCHOR CHAIR DESIGN CALCULATION

16.0 MECHANICAL DATA SHEET

17.0 FOUNDATION LOAD DATA

1.0 DESIGN DATA

DESIGN CODE : IS-803:2013 & API-650-12th Ed:2016

TANK NAME : LIMESTONE SLURRY TANK-A&B

TANK ITEM CODE : 00HTK10-BB001 / 00HTK10-BB051

TANK QUANTITY : 1 NO. EACH

TANK CONFIGURATION : VERTICAL CYLINDRICAL FLAT ROOF

SERVICE : LIMESTONE SLURRY

TANK INSIDE DIAMETER ID = 13.050 M

TANK NOMINAL DIAMETER D = 13.062 M CL. 5.6.1.1 - API-650

TANK HEIGHT H = 14.470 M

LINING THICKNESS = 5.000 MM

TANK ID (AFTER LINING) = 13.040 M

OPERATING INTERNAL VAPOR PRESSURE Popi = 0.00 KPA

DESIGN INTERNAL VAPOR PRESSURE PI = 0.00 KPA

OPERATING INTERNAL VACUUM PRESSURE Pope = 0.00 KPA

DESIGN INTERNAL VACUUM PRESSURE PE = 0.50 KPA CL. 6.3.1.3 IS-875

HYDROTEST INTERNAL AIR PRESSURE PT = 0.00 KPA

DESIGN PRESSURE = ATM (+) FULL OF LIQUID

DESIGN TEMPERATURE DEG.C = 50 DEG.C

SPECIFIC GRAVITY (LIQUID) = 1.229

DESIGN SPECIFIC GRAVITY G = 1.280

HYDROTEST SPECIFIC GRAVITY Gt = 1.000

OVERFLOW LEVEL (DESIGN LIQUID LEVEL) DLL = 13.270 M

HIGH HIGH LIQUID LEVEL HHLL = 13.190 M

HIGH LIQUID LEVEL HLL = 13.040 M

LOW LIQUID LEVEL LLL = 5.260 M

LOW LOW LIQUID LEVEL LLLL = 4.500 M

LOW LOW LOW LIQUID LEVEL LLLLL = 4.350 M

CAPACITY GEOMETRIC/ NOMINAL = 1932.5 CUBIC M

CAPACITY OPERATING TOB- HHLL = 1761.5 CUBIC M

CAPACITY WORKING LLLL-HLL = 1140.5 CUBIC M

YIELD STRENGTH TENSILE STRENGTH
MATERIAL OF CONSTRUCTION MM
Fy (MPA) UTS (MPA)
SHELL PLATE IS 2062 E250 GR. BR CA = 1.50 250 410

BOTTOM PLATE IS 2062 E250 GR. BR CA = 1.50 250 410

ROOF PLATE IS 2062 E250 GR. BR CA = 1.50 250 410

STRUCTURAL IS 2062 E250 GR. A CA = 1.50 250 410

ANCHOR BOLT IS 2062 GR. BR CA = 1.50 250 410

LINING RUBBER LINING

WELD JOINT EFFICIENCY E = 0.85

EXTENT OF RADIOGRAPHY = SPOT RADIOGRAPHY

MODULUS OF ELASTICITY (@)DT = 200000 MPA

DENSITY OF MATERIAL DM = 7850 KG/M3

DENSITY OF LINING DL = 1400 KG/M3

PRODUCT DESIGN ALLOWABLE STRESS Sd = 164 MPa MIN [ (2/3) x Fy , (2/5) x UTS ]

HYDROSTATIC TEST ALLOWABLE STRESS St = 176 MPa MIN [ (3/4) x Fy , (3/7) x UTS ]

INTERNAL PRESSURE COMBINATION FACTOR Fp = 0.4 CL. 5.2.2: API-650

EXTERNAL PRESSURE COMBINATION FACTOR Fpe = 0.4 CL. 5.2.2: API-650

2.0 SHELL THICKNESS CALCULATION

SHELL LIQUID HEIGHT HL = 14.470 M

EQUIVALENT LIQUID HEIGHT FOR INTERNAL PRESSURE H(pi) = 0.000 M pi / (1000*G)

SHELL DESIGN LIQUID HEIGHT Hd = 14.470 M

EQUIVALENT TEST LIQUID HEIGHT FOR INTERNAL PRESSURE H(pt) = 0.000 M pt / (1000*G)

HYDROTEST LIQUID HEIGHT Ht = 14.470 M

MINIMUM NOMINAL THICKNESS Tmin = 5 MM CL. 5.6.1.1: API-650 & CL. 6.3.3.2 IS-803
 MINIMUM SHELL DESIGN THICKNESS TD = {4.9D ( Hd - 0.3 ) G } /( E.Sd )+ CA MM

CL. 5.6.3.2: API-650 & CL. 6.3.3.1 ; IS-803

MINIMUM HYDROTEST SHELL THICKNESS TT = {4.9D ( Ht - 0.3 ) Gt } / (E.St) MM

CL. 5.6.3.2: API-650

SHELL COURSES THICKNESS

Course Height Minimum As Built Corroded

No. SHELL COURSES Hd Td Ht Tt Adopted Thk.
W Thk. Weight Weight

M M MM M MM MM TA (MM) KG Kg

1 BOTTOM COURSE 2.000 14.470 9.83 14.470 6.07 9.83 12 7738 6771

2 1.250 12.470 8.65 12.470 5.22 8.65 10 4030 3425

3 1.250 11.220 7.92 11.220 4.68 7.92 10 4030 3425

4 1.250 9.970 7.18 9.970 4.14 7.18 8 3223 2619

5 1.250 8.720 6.45 8.720 3.61 6.45 8 3223 2619

6 1.250 7.470 5.71 7.470 3.07 5.71 8 3223 2619

7 1.250 6.220 4.98 6.220 2.54 5.00 6 2417 1813

8 1.250 4.970 4.24 4.970 2.00 5.00 6 2417 1813

9 1.250 3.720 3.51 3.720 1.47 5.00 6 2417 1813

10 1.250 2.470 2.78 2.470 0.93 5.00 6 2417 1813

11 TOP COURSE 1.220 1.220 2.04 1.220 0.39 5.00 6 2359 1769

12

13

14

15

SHELL COURSE HT. 14.470 37495 30499

TANK HT. 14.470 OK TS. WT. TSC.WT

TOP COURSE THICKNESS = 6 MM

TANK OUTSIDE DIAMETER (@ TOP) ODT = 13.062 M

TANK OUTSIDE DIAMETER (@ BOTTOM) OD = 13.074 M

3.0 BOTTOM THICKNESS CALCULATION

CL. 5.4.1 - API-650 & CL. 6.2.1 IS-803 All bottom plates shall have a corroded thickness of not less than 6 mm

BOTTOM THICKNESS REQUIRED = 6 MM (+) C.A.

= 7.5 MM

ADOPTED BOTTOM PLATE THICKNESS tb = 8 MM OK

CORRODED BOTTOM PLATE THICKNESS tcb = 6.5 MM

PROJECTION OF BOTTOM O/S OF SHELL = 50 MM Cl 5.4.2- API 650

BOTTOM OUTSIDE DIAMETER = 13.174 M

BOTTOM PLATE OUTSIDE DIAMETER = 11.074 M

BOTTOM PLATE AS BUILT WEIGHT = 6049 Kg

BOTTOM PLATE CORRODED WEIGHT = 4915 Kg

ANNULAR PLATE REQUIREMENT

( API 650 Cl 5.5.1) Butt- Welded Bottom Annular plate shall be for material group IV to VI only,

As per the Design Code API 650, if the stress induced limit is as below:-

MINIMUM YIELD STRENGTH OF ANNULAR PLATE Fby = 250 MPA

EFFECTIVE PRODUCT HEIGHT = HXG

= 18.5216 M

<23, Hence Analysis as per API-650, Table-5.1a is acceptable

STRESSES IN BOTTOM COURSE

PRODUCT FILL CONDITION = ((Td-CA)/ corroded t) x Sd

PRODUCT FILL CONDITION = 130.07 MPA

<160MPa, Annular Plate Not Required

HYDROTEST CONDITION = ((Tt / nominal t) x St

= 88.92 MPA

<171MPa, Annular Plate Not Required

 As per CL. B.5 IS-803, Hydrostatic Stress St ≤ 3/7 Min. UTS UTS = 410.00 MPA

(3/7)* UTS = 175.71 MPA

St ≤ 3/7 Min. UTS, Hence Safe

ANNULAR PLATE PROVISION : YES

ANNULAR PLATE WIDTH CALCULATION

MINIMUM REQUIRED THICKNESS OF ANNULAR PLATE = 6.0 (+) CA

(Ref. API-650, Table-5.1a) = 7.50 MM

PROVIDED THICKNESS OF ANNULAR PLATE tab = 8.0 MM

CORRODED ANNULAR PLATE THICKNESS tcab = 6.50 MM

(I) MINIMUM INWARD RADIAL WIDTH ( API 650 Cl 5.5.2) W1 = 600 MM

(II) MINIMUM INWARD RADIAL WIDTH ( API 650 Cl 5.5.2) W2 = 2 x tab x SQRT [ Fby / (2 x Y x G x H)]

W2 = 475 MM

MINIMUM RADIAL WIDTH REQUIRED W = 662 MM MAX[W1, W2] + Outwards Proj.

PROVIDED WIDTH OF ANNULAR PLATE = 1050 MM OK

ANNULAR PLATE AS BUILT WEIGHT = 2512 Kg

ANNULAR PLATE CORRODED WEIGHT = 2041 Kg

4.0 ROOF THICKNESS CALCULATION

TYPE OF ROOF = FLAT ROOF

ROOF SLOPE = 0: 1

θ = 0.0000 DEGREE

ROOF TO CURB OVERLAP B = 70 MM

ROOF OUTSIDE RADIUS RR = 6.601 M

HEIGHT OF ROOF Hr = 0.000 M

SLANT LENGTH OF ROOF RL = 6.601 M

AREA OF ROOF Ar = 136.889 SQ. M. (π * RR* RL)

APPLICABLE LOADS

MINIMUM LIVE LOAD LrMIN = 1.225 KPA Cl 5.2.1 (f)- API 650 & Cl. 6.4.2.1 IS-803

ADOPTED LIVE LOAD (Including dust load) Lr = 1.500 KPA As per DBR

SNOW LOAD S = 0 KPA

EXTERNAL PRESSURE Pe = 0.50 KPA

DEAD LOAD ROOF PLATE = 10746 KG

NOZZLES & ACCESSORIES = 2,571 KG

INSULATION = 0 KG

LINER = 958 KG

MISC. LOADS = 7,712 KG (Piping Load-Approx.)

TOTAL DEAD LOAD DL = 21987 KG

DL = 1.576 KPA

LOAD COMBINATION : API-650 CL. 5.2.2

Load Combination, e(1) T = DL + ( Lr or S) + Fpe* Pe

= 3.276 KPA

Load Combination, e(2) U = DL + Pe + 0.4( Lr or S)

= 2.676 KPA

GREATER OF LOAD COMBINATION P = Greater of e(1) , e(2)

= 3.276 KPA

FLAT ROOF

MINIMUM THICKNESS OF ROOF PLATE tr5 = 5.0 MM

API-650 CL. 5.10.2.2 & IS-803 CL. 6.4.4 (a)

ADOPTED ROOF PLATE THICKNESS tr = 10.0 MM OK

CORRODED ROOF PLATE THICKNESS tcr = 8.5 MM

MAXIMUM ALLOWABLE ROOF PLATE SPAN b1 = 2000 MM As per IS-803 CL. 6.4.4 (e)

MAXIMUM ALLOWABLE ROOF PLATE SPAN b2 = tcr x SQRT (1.5Fy/P) ≤ 2100 MM As per API-650 CL. 5.10.4.4

b2 = 2100 MM
 RECTANGULAR PLATE, ALL EDGE FIXED : ROARK'S FORMULA. TABLE 11.4 CASE 8(a)

LOAD ON ROOF q = 0.00328 MPA LOAD COMBINATION(P)

MODULUS OF ELASTICITY E = 200000 MPA

σ (MPA) σmax (MPA) ymax(mm)

a (mm) b (mm) a/b β1 β2 α (β2)qb2/t2 (β1)qb2/t2 αqb4/Et3

3000 1500 2.00 0.50 0.25 0.028 25.21 50.74 3.74

b
4500 1500 3.00 0.50 0.25 0.028 25.50 51.00 3.83

3630 1500 2.42 0.50 0.25 0.028 25.50 51.00 3.83

a 5505 600 9.18 0.50 0.25 0.028 4.08 8.16 0.10

ALLOWABLE DEFLECTION ya = 4.25 MM (THICKNESS/2)

MAXIMUM DEFLECTION ymax = 3.83 MM ya>ymax, Hence Safe

ALLOWABLE STRESS Sd = 164 MPA

ACTUAL BENDING STRESS σmax = 51.00 MPA <S, Hence Safe

ROOF PLATE WEIGHT

ROOF PLATE THICKNESS tr = 10.0 MM

CORRODED ROOF PLATE THICKNESS tcr = 8.5 MM

ROOF PLATE AS BUILT WEIGHT = 10746 KG

ROOF PLATE CORRODED WEIGHT = 9134 KG

5.0 SHELL TO ROOF JUNCTION CALCULATION

MIN. TOP CURB MEMBER SIZE = L50 X 50 X 8

PROVIDED TOP CURB MEMBER = ISMC 250 Detail-b Figure F.2 - API-650

CURB MEMBER WEIGHT / SECTIONAL AREA = 30.6 KG/M 3900 SQ. MM

NO. OF GUSSET & SIZE = 0 NOS. 0 0 0

TOTAL WT. OF CURB MEMBER = 1381 KG H W t

6.0 TANK COMPONENTS' WEIGHT CALCULATION (ESTIMATED)
AS-BUILT WT. CORRODED WT.
W.1 BOTTOM
1 BOTTOM PLATES Y
THK. (MM) AREA (Sq.M)
8 96.32 6,049 4,915 KG
2 ANNULAR PLATES Y
THK. (MM) AREA (Sq.M)
8 39.99 2,512 2,041 KG
W.2 SHELL & ATTACHED ACCESSORIES
1 SHELL COURSES Y 37,495 30,499 KG
THK. (MM) WIDTH (M) DEV. LENGTH (M) NEW WT. (KG) COR. WT. (KG)
1 12 2.00 41.07 7,738 6,771
2 10 1.25 41.07 4,030 3,425
3 10 1.25 41.07 4,030 3,425
4 8 1.25 41.06 3,223 2,619
5 8 1.25 41.06 3,223 2,619
6 8 1.25 41.06 3,223 2,619
7 6 1.25 41.05 2,417 1,813
8 6 1.25 41.05 2,417 1,813
9 6 1.25 41.05 2,417 1,813
10 6 1.25 41.05 2,417 1,813
11 6 1.22 41.05 2,359 1,769
12 0 0.00 41.04 0 0
13 0 0.00 41.04 0 0
14 0 0.00 41.04 0 0
15 0 0.00 41.04 0 0

2 ANCHOR CHAIR Y
QTY
28 KG 1,482 1,482 1,334 KG
3 INTERMEDIATE WIND GIRDERS / STIFFENER Y
MEMBER SIZE UNIT WT. (KG/M) QTY UNIT LG. (M)
ISA 100 X 100 X 8 12.1 1 41.04 546 492 KG
4 TOP CURB ANGLE Y
MEMBER SIZE UNIT WT. (KG/M) QTY TOTAL LG. (M)
ISMC 250 30.6 1 41.04 1,381 1,243 KG
5 SHELL NOZZLES / MANHOLE KG 1950 Y 1,950 1,755 KG
6 INTERNAL / EXTERNAL ACCESSORIES (LIKE BAFFLES, DIP PIPE, GAUGE ETC.) KG 4982 Y 4,982 4,484 KG
7 INTERNAL SUPPORTS KG 0 Y 0 0 KG
8 PAD FOR INTERNAL / EXTERNAL ATTACHMENT KG 500 Y 500 450 KG
W.3 ROOF & ATTACHED ACCESSORIES
1 ROOF PLATES Y
THK. (MM) AREA (Sq.M)
10 136.89 10,746 9,134 KG
2 ROOF NOZZLES/MANHOLE KG 2070 Y 2,070 1,863 KG
3 OTHER ACCESSORIES MOUNTED ON ROOF (DIP PIPE, VENT ETC.) KG 0 Y 0 0 KG
4 PAD FOR INTERNAL / EXTERNAL ATTACHMENT KG 501 Y 501 451 KG

W.4 STRUCTURAL
1 ROOF PLATE SUPPORTING STRUCTURE / RAFTER Y
MEMBER SIZE UNIT WT. (KG/M) QTY LG. (M) WEIGHT (KG)
13000 13,000 11,700 KG

2 MONORAIL ARRANGEMENT Y
MEMBER SIZE UNIT WT. (KG/M) QTY LG. (M) WEIGHT (KG)
5000 5,000 4,500 KG
2 STAIRWAYS Y
WIDTH (M) UNIT WT.(KG/M2) QTY DEV. LG. (M)
1.2 130 1 22.11 3,449 3,104 KG
3 LADDER N
WIDTH (M) UNIT WT. (KG/M) QTY TOTAL LG. (M)
0.6 85 1 14.47 0 0 KG
4 ROOF PLATFORM Y
WIDTH (M) UNIT WT.(KG/M2) QTY TOTAL LG. (M)
3 50 1 6.5 980 882 KG
5 ROOF GRATING Y
WIDTH (M) UNIT WT.(KG/M2) QTY TOTAL LG. (M)
3 50 1 6.5 980 882 KG
6 ROOF HANDRAIL Y
HEIGHT (M) UNIT WT. (KG/M) QTY DEV. LG. (M)
1.1 20 1 41.35 910 819 KG
W.5 OTHER ACCESSORIES
1 AGITATOR & MOTOR MOUNTING Y 6,500 6,500 KG
Agitator Weight KG 5,500
Hoist Weight KG 500
Other accessories Weight KG 500
DENSITY
2 INSULATION AREA (Sq.M) THK. (MM) N
(KG/M3)
Shell Insulation 594 140 0 0 0 KG
Roof Insulation 137 140 0 0 0 KG
DENSITY
3 LINING AREA (Sq.M) THK. (MM) Y
(KG/M3)
Shell Lining 594 1400 5.0 4,156 4,156 KG
Roof Lining 137 1400 5.0 958 958 KG
Bottom Lining 134 1400 5.0 938 938 KG
4 MISCELLANEOUS Y
Assumption 10% 9,462 7,570

W.6 WEIGHT SUMMARY

1 ERECTION WEIGHT (Metal) 94,530 88,114 KG
(excluding wt. of external accessories, lining, insulation and misc. wt.)
2 EMPTY WEIGHT 1,16,545 1,08,236 KG
(including wt. of external accessories, lining, insulation and misc. wt.)
3 OPERATING LIQUID WEIGHT HHLL (M) SG
Operating liquid height 13.190 1.280 22,58,217 KG
(Process Liquid & HHLL)
4 DESIGN LIQUID WEIGHT DLL (M) SG
Design liquid height 13.270 1.280 22,71,914 KG
(Design Liquid & DLL)
5 HYDROSTATIC WATER WEIGHT TANK HT. (M) SG
Hydrostatic water height 14.470 1.000 19,35,439 KG
6 OPERATING WEIGHT (with Process Liquid) 23,74,762 KG
(Empty Wt. + Operating Liquid Wt.)
7 OPERATING WEIGHT (for Design) 23,88,459 KG
(Empty Wt. + Design Liquid Wt.)
8 HYDROSTATIC TEST WEIGHT 20,51,984 KG
(Empty Wt. + Test liquid Wt.)
9 DEAD WEIGHT LOAD COMBINATION
9.1 Dead Load In As-Built Condition Carried by Shell DLS = 73,941 7,25,363
Includes--> (Fixed Roof Structure) (As-Built) KG N
excludes--> (Bottom & Roof Plate, Bott. & Roof Insul / Liner &
accessories Attached to bottom & roof)
9.2 Dead Load In Corroded Condition Carried by Shell Ws = 63,716 6,25,055
Includes--> (Fixed Roof Structure) (Corroded) KG N
excludes--> (Bottom & Roof Plate, Insul / liner &
accessories Attached to bottom & roof)
9.3 As-Built Wt. of Roof Plate DLR = 23,644 2,31,944
Includes --> insulation/liner, platform, nozzles (As-Built) KG N
attached to the roof plate
9.4 Corroded Wt. of Roof Plate Wr = 9,134 89,604
excludes --> insulation/liner, platform, nozzles (Corroded) KG N

9.5 Dead Load In Corroded Condition Carried by Roof Wrs = 21,488 2,10,796
Includes--> ( Roof Plate, roof nozzle & (Corroded) KG N
accessories attached to roof)
Excludes--> (Bottom Plates, Shell Plate & fixed roof structure
accessories attached to bottom & shell, insul/ liner)
9.6 Corroded Wt. ( Roof Plate + Shell Plate & its attachment) W1 = Ws + Wr
excludes --> insulation/liner, roof attachment, bottom plates (Corroded) = 72,850 7,14,658
KG N
9.7 Corroded Wt. ( Shell Plate & its attachment + Roof Plate & its attachments) W2 = Ws + Wrs
excludes --> insulation/liner, bottom plates (Corroded) = 85,204 8,35,850
KG N
9.8 Total As-Built Wt. W3 = DLS + DLR
(excluding bottom plate & bottom liner) (As built) = 97,585 9,57,307
KG N
9.9 Total Bottom Wt. Wb = 9,498 93,178
(As built) = KG N

9.10 Total Wt. of Roof supporting structure/ rafter and monorail Wrf = 18,000 1,76,580
(As built) = KG N
7.0 WIND LOAD CALCULATION & ANALYSIS

(As per IS-875 Part-03: 2015 Edition)

TANK NOMINAL DIAMETER D = 13.062 M

TANK HEIGHT Ht = 14.470 M

BASIC WIND VELOCITY AT SITE Vb = 47 M/S (As per Project Specification)

DESIGN WIND VELOCITY AT HEIGHT Z Vz = k1.k2.k3.k4( Vb )

LOCATION TERRAIN CATEGORY = 2 (As per Project Specification)

RISK FACTOR / PROBABILITY FACTOR k1 = 1.070 (As per Project Specification)

based on terrain category and
FOR GIVEN TERRAIN CATEGORY & STR. CLASS k2 = 1.070
overall height
SITE TOPOGRAPHY FACTOR k3 = 1.000

IMPORTANCE FACTOR FOR CYCLONIC REGION k4 = 1.000

ADOPTED DESIGN WIND VELOCITY Vz = 53.81 M/S

WIND PRESSURE AT HEIGHT Z Pz = 0.6* Vz2 CL. 7.2 IS-875-03

= 1737.3 N/SQ.M

= 177.1 KGF/SQ.M

WIND DIRECTIONALITY FACTOR Kd = 1.000

AREA AVERAGING FACTOR Ka = 0.80

COMBINATION FACTOR Kc = 1.000

DESIGN WIND PRESSURE Pd = MAX [ Kd.Ka.Kc.Pz, 0.7Pz] CL. 7.2 IS-875-03

= 1389.9 N/SQ.M

= 141.7 KGF/SQ.M

EFFECTIVE WIND AREA ON SHELL Ac = OD * H * Fp

Ac = 227.02 SQ.M

CONTINGENCY FACTOR Fp = 1.2 Factor to account Piping, Stair, Platform

FORCE COEFFICIENT (SHAPE FACTOR) Cf = 0.70 Table 25 IS 875-03

DESIGN HORIZONTAL WIND SHEAR ON TANK SHELL PH = Cf * Ac * Pd Annex-D1 IS 875-03

= 22514 KGF Horz. 220.87 KN

HEIGHT OF ROOF Hr = 0.000 M

OVERALL HT OF TANK INCLD. ROOF H = 14.470 M

OVERALL TANK HT / DIAMETER RATIO H/D = 1.11

INTERNAL PRESSURE COEFFICIENT ON ROOF Cpi = 0.2 CL. 7.3.2.1 IS-875-03

EXTERNAL PRESSURE COEFFICIENT ON ROOF Cpe = -1.0 Table 20 IS 875-03

2
WIND FORCE ACTING ON TANK ROOF Pe = 0.785 * D * (Cpi - Cpe) * Pd Table 20 IS 875-03

= 22782 KGF Upward 223.49 KN

LOCATION OF Pe e = 0.1* D

= 1.306 M

UPLIFT DUE TO INT. DESIGN VAPOR PR. Wupi = 0.00 KN

= 0.00 KGF Upward

WIND MOMENT ABOUT B Mw]B = PH .Ht / 2 + Pe .e

(INCLUDING WIND ON ROOF) = 192649 KGF-M 1889.89 KN-M

WIND MOMENT ABOUT A Mw]A = PH .Ht / 2 + Pe . (e + Do/2)

(INCLUDING WIND ON ROOF) = 341439 KGF-M 3349.52 KN-M

MWS]A (WIND LOAD ON SHELL ONLY ABOUT A) MWS]A = PH .Ht / 2

= 162891 KGF-M 1597.96 KN-M

 8.0 CHECK FOR OVER-TURNING STABILITY OF TANK FOR WIND LOAD

API-650 CL 5.11 based on wind load calculation as per IS:875-2015

DEAD LOAD IN CORRODED CONDITION CARRIED BY SHELL Ws = 63,716 KG = 625055 N

DEAD LOAD IN CORRODED CONDITION CARRIED BY ROOF Wrs = 21,488 KG = 210796 N

Qualified corroded bott thk. to calculate wL tb = 6.50 ( API 650,CL-5.11.2.3(1) )

YIELD STRESS OF THE BOTTOM PLATE Fby = 250 MPa

NORMAL LIQUID HEIGHT HOL = 5.260 M LLL is considered for conservatism

TANK DIAMETER D = 13.062 M

MIN [ SPECIFIC GRAVITY OF PRODUCT, 0.7] G = 0.7

wL = Min.of [70tb*sqrt{Fby.G.H }, 70.4*H.D]

= 13805 4837

= 4837 N/m

TOTAL LIQUID RESISTING UPLIFT WL = wL * π * D

= 198485 N

= 20233 KGF

Mpi = Wupi* D / 2 = 0.00 KGF-M

INTERNAL PRESSURE COMBINATION FACTOR Fp = 0.4

2
Fp*Mpi = (π * D^ /4) * Int. Pr. = 0.00 KGF-M

MDL = Ws * D / 2 = 416130 KGF-M

MDLR = Wrs* D / 2 = 140337 KGF-M

MF = WL * D / 2 = 132141 KGF-M

Check For Overturning Stability

Case-1 0.6 Mw]A + Mpi < MDL / 1.5 + MDLR

0.6 Mw]A + Mpi = 204863 KGF-M 2010 KN-M

MDL / 1.5 + MDLR = 417757 KGF-M 4098 KN-M

Anchorage Not Required

Case-2 Mw]A + Fp(MPi) < (MDL + MF)/2 + MDLR

Mw]A + FP.Mpi = 341439 KGF-M 3350 KN-M

(MDL + MF)/2 + MDLR = 414472 KGF-M 4066 KN-M

Anchorage Not Required

Case-3 Mws]A + FP.Mpi < MDL / 1.5 + MDLR

Mws]A + FP.Mpi = 162891 KGF-M 1598 KN-M

MDL / 1.5 + MDLR = 417757 KGF-M 4098 KN-M

Anchorage Not Required

Hence, Anchorage NOT required for stability against overturning due to wind
 WIND LOADING ON FOUNDATION (ADOPTED VALUES) Point B Point A Unit

WIND SHEAR Fwind = 243 243 KN

WIND MOMENT Mwind = 2079 3684 KN-M

SLIDING FRICTION API 650 CL. 5.11.4

MAXIMUM SHEAR DUE TO WIND LOAD PH = 22514 KGF

CORRODED WEIGHT OF TANK Wc = Ws + Wrs + Wbottom (corroded)

= 90118 KGF

MAXIMUM ALLOWABLE SLIDING FRICTION μ = 0.4

NET RESISTANCE TO SHEAR R = Wc * μ

= 36047 KGF

NET SHEAR TO BE RESISTED BY ANCHORAGE Fn = PH - R

= -13533 KGF

No sliding of tank

SLIDING FORCE ON INCLINED SUPPORT = (Fwind*cos Ѳ + WE* sin Ѳ) - μ * WE*cos Ѳ

= -34901.48455 kgf

No sliding of tank

SLOPE OF BOTTOM PLATE = 1 : 100

INCLINATION OF BOTTOM WRT HORIZONTAL PLANE Ѳ = 0.01 RAD

FRICTION COEFFICIENT μ = 0.4

CORRODED WEIGHT OF TANK WE = 90118 KGF

9.0 INTERMEDIATE WIND GIRDER / STABILITY OF SHELL

(As per Cl. 5.9.7 of API-650 & CL.6.3.3.6 IS-803)

BUCKLING CHECK = Corroded condition

ASSUMED UNIFORM THK OF SHELL tuniform = 4.50 MM TOP SHELL COURSE THK.

DESIGN INTERNAL VACUUM Po = 0.50 KPA

WIND PRESSURE ON SHELL Pd = 1.390 KPA

TOTAL EQUIVALENT EXTERNAL PRESSURE Pw = Po + Pd

= 1.890 KPA

No Increase in Unstiffened Ht, But Decrease if Total Ext.Pr is more than design base wind pressure

AS PER API-650
Refer Note 2(d) Under API 650 CL-5.9.7.1, Pbase = 1.720 KPA

WIND VELOCITY FORCE FACTOR WF = 1.10 MAX OF [ 1 , Pw / Pbase]

MAXIMUM HEIGHT OF UNSTIFFENED SHELL H1 = 9.47 * t * ( t / D)^1.5 * (1/ WF) M

= 7.84 M

AS PER IS-803

Pbase = 1.470 KPA

WIND VELOCITY FORCE FACTOR WF = 1.29 MAX OF [ 1 , Pw / Pbase]

MAXIMUM HEIGHT OF UNSTIFFENED SHELL H1 = 14700 t x ( t / D)^1.5 x (1 / P)* (1/ WF) M

= 5.51 M

TRANSPOSED HEIGHT OF TANK SHELL

Transposed height of shell courses below curb angle of shell

Wtr = W * { tuniform / tactual }2.5

Course
Shell Course No. tuniform tactual Trans. Height
Height

W (m) (mm) (mm) Wtr (m)

1 2.000 4.50 10.50 0.240

2 1.250 4.50 8.50 0.255

3 1.250 4.50 8.50 0.255

4 1.250 4.50 6.50 0.498

5 1.250 4.50 6.5 0.498

6 1.250 4.50 6.5 0.498

7 1.250 4.50 4.5 1.250

8 1.250 4.50 4.5 1.250

9 1.250 4.50 4.5 1.250

10 1.250 4.50 4.5 1.250

11 1.220 4.50 4.5 1.220

12 0.000 0 0 0

13 0.000 0 0 0

14 0.000 0 0 0

15 0.000 0 0 0

∑ 14.470 8.466

CHECK FOR STIFFENER REQUIREMENT

TOTAL TRANSPOSED HEIGHT OF SHELL TRH = ∑ Wtr

= 8.466 M

TRH / H1 = 1.54

Intermediate Wind Girder Required

Minimum intermediate wind girder required = 1 No.

Provided intermediate wind girder = 1 No.

Equal distance of Int. Wind girder / Vacuum Stiffeners d = TRH / (no of stiffeners + 1)

= 4.23 m on transposed height

LOCATIONS OF STIFFENERS & THEIR SECTIONAL PROPERTIES

Spacing

FIRST STIFFENER ELEVATION ELT1= 10.170 m HT1= 4.30 M

SECOND STIFFENER ELEVATION ELT2= 0m HT2= M

API:650 Cl. 5.9.7.5: Minimum 150 mm distance required from wind girders to horizontal joint of the shell.
REQD. MINIMUM SECTIONAL Z1 = (1/17) *D2 * HT1 * (WF)

MODULUS OF STIFFENER NO. 1 = 55.48 cm3

REQD. MINIMUM SECTIONAL Z2 = (1/17) *D2 * HT1 * (WF)

MODULUS OF STIFFENER NO. 2 = 0.00 cm3

Detail-C Fig. 5.24 of API-650 SIZE WT. (KG/M)

PROVIDED STIFFENER NO. 1 = ISA 100 X 100 X 8 12.1

PROVIDED STIFFENER NO. 2 =

RING-01 RING-02

b1 = 144.0 mm

h1 = 4.5 mm

y1 = 2.3 mm

b2 = 8 mm

h2 = 92 mm

y2 = 50.5 mm

b3 = 100 mm

h3 = 8 mm

y3 = 100.5 mm

A1 = 648.0 mm2

A2 = 736.0 mm2

A3 = 800.0 mm2

Ay1 = 1458.0 mm3

Ay2 = 37168.0 mm3

Ay3 = 80400.0 mm3

CHECK FOR BRACKET REQUIREMENT c1 = 54.5 mm

Cl. 6.3.8.10 IS:803 c2 = 50.0 mm

Horiz. Leg length / web (h2)= 92.0 mm X1 = 52.2 mm

16 x Leg / web thk. (b2)= 128 mm X2 = 4.0 mm

Bracket is not required X3 = 46.0 mm

Ʃ A X2 = 3473656 mm4

ƩI = 524486 mm4

Iyy = 3998142 mm4

Zmin = 73.36 cm3

Safe
10.0 CENTER OF GRAVITY CALCULATION FOR TANK SHELL

COURSE AS BUILT CORRODED

COURSE HT. COM. HT. (Ln) AS BUILT CORR. THK.
COURSE NO. HT./2 WEIGHT Wn Ln X Wn WEIGHT Wnc Ln X Wnc
(M) (M) THK. (MM) (MM)
(M) (KG) (KG)

1 2.00 1.00 1.00 7738 7738 6771 6771 12.0 10.5

2 1.25 0.63 2.63 4030 10578 3425 8991 10.0 8.5

3 1.25 0.63 3.88 4030 15615 3425 13273 10.0 8.5

4 1.25 0.63 5.13 3223 16519 2619 13422 8.0 6.5

5 1.25 0.63 6.38 3223 20548 2619 16695 8.0 6.5

6 1.25 0.63 7.63 3223 24577 2619 19969 8.0 6.5

7 1.25 0.63 8.88 2417 21452 1813 16089 6.0 4.5

8 1.25 0.63 10.13 2417 24473 1813 18355 6.0 4.5

9 1.25 0.63 11.38 2417 27494 1813 20621 6.0 4.5

10 1.25 0.63 12.63 2417 30516 1813 22887 6.0 4.5

11 1.22 0.61 13.86 2359 32697 1769 24522 6.0 4.5

12 0.00 0.00 0 0 0 0 0 0.0 0

13 0.00 0.00 0 0 0 0 0 0.0 0

14 0.00 0.00 0 0 0 0 0 0.0 0

15 0.00 0.00 0 0 0 0 0 0.0 0

TOTAL ∑ 14.47 37495 232207 30499 181594

C.G. OF SHELL FROM BOTTOM OF SHELL (AS-BUILT) = 6.193 M ∑Ln x Wn / ∑Wn

C.G. OF SHELL FROM BOTTOM OF SHELL (CORRODED) = 5.954 M ∑Ln x Wnc / ∑Wnc

AVERAGE THICKNESS OF TANK WALL (AS-BUILT) = sum ( course width x course thk.) / Total course height

= 8.0 MM

AVERAGE THICKNESS OF TANK WALL (CORRODED) = sum ( course width x course thk.) / Total course height

= 6.5 MM
11.0 SEISMIC LOAD CALCULATION & ANALYSIS (OPERATING CASE)

AS PER IS:1893 PART-02:2014 & SITE SPECIFIC SPECTRA

NOMINAL DIAMETER OF TANK D = 13.062 m

TOTAL HEIGHT OF TANK SHELL Ht = 14.470 m

MAXIMUM OPERATING LIQUID LEVEL h = 13.190 m High High Liquid Level

DENSITY OF LIQUID G = 1280.0 kg/m3

ROOF HEIGHT Hr = 0.000 m

CENTER OF GRAVITY OF SHELL FROM BASE hw = 6.193 m

CENTER OF GRAVITY OF ROOF FROM BASE ht = 14.475 m

THICKNESS OF BOTTOM PLATE tb = 0.008 m

THICKNESS OF ROOF PLATE tr = 0.010 m

HORIZONTAL DIST. ON BASE OF TANK FROM CENTRE OF TANK R = 6.531 m (D/2)

FRICTION CO-EFFICIENT µ = 0.400

REFER WEIGHT CALCULATION SHEET

TOTAL WEIGHT OF TANK SHELL mw = DLS - Wrf

mw = 55941 Kg

TOTAL WEIGHT OF TANK ROOF mt = DLR + Wrf

= 41644 Kg

TOTAL WEIGHT OF TANK BOTTOM mb = 9498 Kg

TOTAL WEIGHT OF TANK CONTENTS m = 2258217 Kg High High Liquid Level

TIME PERIOD (T)

AVERAGE THICKNESS OF TANK WALL t = 0.0080 m

MODULUS OF ELASTICITY OF TANK WALL E = 2.00E+11 N /m2

h/ D RATIO h/D = 1.01

ACCELERATION DUE TO GRAVITY g = 9.810 m/s2

CO-EFFICIENT FOR TIME PERIOD FOR IMPULSIVE MODE Ci = 4.42 Fig. 5 IS-1893 Part-2

CO-EFFICIENT FOR TIME PERIOD FOR CONVECTIVE MODE Cc = 3.28 Fig. 5 IS-1893 Part-2

TIME PERIOD OF IMPULSIVE MODE OF VIBRATION Ti = Ci x h x sqrt ( G*D / t*E)

Ti = 0.188 sec

TIME PERIOD OF CONVECTIVE MODE OF VIBRATION Tc = Cc x sqrt (D / g)

Tc = 3.782 sec

DESIGN HORIZONTAL SEISMIC COEFFICIENT (Ah)

MULTIPLYING FACTOR FOR LIQUID RETAINING TANKS Im = 0.096 As per Site Specific Spectra

AVE. RESPONSE ACC. CO-EFF. @ Ti FOR 2% DAMPING (Sa/g)i = 3.500 As per Site Specific Spectra

AVE. RESPONSE ACC. CO-EFF. @ Tc FOR 5% DAMPING = 0.360 As per Site Specific Spectra

AVE. RESPONSE ACC. CO-EFF. @ Tc FOR 0.5% DAMPING (Sa/g)c = 1.75 x (Sa/g) value at Tc for 5% damping

= 0.630

DESIGN HORZ. SEISMIC COEFF. (IMPULSIVE MODE) Ahi = Im x (Sa/g)i g

Ahi = 0.3360 g

DESIGN HORZ. SEISMIC COEFF. (CONVECTIVE MODE) Ahc = Im x (Sa/g)c g

Ahc = 0.0605 g

VERTICAL SEISMICITY Av = 2/3 [Ahi] g As per Site Specific Spectra

Av = 0.2240 g
 PARAMETERS OF SPRING MASS MODEL

h/ D ratio h/D = 1.010 h = 13.190 m

mi: Impulsive mass of liquid mi/m = 0.810 mi = 1830115 kg

mc: Convective mass of liquid mc/m = 0.227 mc = 513741 kg

hi: Height of impulsive mass above bottom of tank wall hi/h = 0.407 hi = 5.370 m

(without considering base pressure)

hc: Height of convective mass above bottom of tank wall hc/h = 0.744 hc = 9.809 m

(without considering base pressure)

hi*: Height of impulsive mass above bottom of tank wall hi*/h = 0.492 hi* = 6.489 m

(considering base pressure)

hc*: Height of convective mass above bottom of tank wall hc*/h = 0.757 hc* = 9.984 m

(considering base pressure)

BASE SHEAR : SEISMIC

Base shear at the bottom of tank in impulsive mode Vi = (Ahi) x (mi + mw + mt) kgf

= 647707 kgf

= 6354.01 KN

Base shear at the bottom of tank in convective mode Vc = (Ahc) x mc kgf

= 31071 kgf

= 304.81 KN

TOTAL BASE SHEAR AT THE BOTTOM OF TANK V = sqrt (Vi^2 + Vc^2)

= 6361.31 KN

BASE MOMENT : SEISMIC

Bending moment at the bottom of tank in impulsive mode Mi = (Ahi) x [ mi hi + mw hw + mt ht ] kgf-m

= 3621326 kgf-m

= 35525.21 KN-m

Bending moment at the bottom of tank in convective mode Mc = (Ahc) mc hc kgf-m

= 304781 kgf-m

= 2989.90 KN-m

TOTAL MOMENT AT BOTTOM OF TANK M = sqrt (Mi^2 + Mc^2)

= 35650.81 KN-m

OVERTURNING MOMENT

Overturning moment at the bottom of base plate

in impulsive mode Mi* = (Ahi) (mi (hi*+tb) + mw (hw+tb) + mt (ht+tb) + mbtb/2 )

= 4314320 kgf-m

= 42323.48 KN-m

Overturning moment at the bottom of base plate

in convective mode Mc* = (Ahc) mc ( hc*+ tb)

= 310453 kgf-m

= 3045.54 KN-m

TOTAL OVERTURNING MOMENT @ BOTTOM OF BASE PL. M* = sqrt (Mi^2 + Mc^2)

= 42432.91 KN-m

HYDRODYNAMIC PRESSURE

Impulsive Hydrodynamic Pressure

Impulsive hydrodynamic pressure on wall Piw(y) = Qiw(y) (Ah)i ρ g h cos ф

Qiw(y) = 0.866 [1 -(y / h) 2 ] tanh(0.866 D / h)

Maximum pressure will occur at ф = 0

At base of wall y = 0

Qiw(y = 0) = 0.602

Piw(y) = 33.495 KN/m2

Convective Hydrodynamic Pressure

Convective hydrodynamic pressure on wall Pcw = Qcw(y) (Ah)c ρ g D [1- 1/3 cos2 ф] cosф

Qcw(y) = 0.5625 cosh(3.674y/D)/ cosh(3.674h /D)

Maximum pressure will occur at ф = 0

At base of wall y = 0

Qcw(y = 0) = 0.028

[1- 1/3 cos2 ф] cosф = 0.667

Pcw(y=0) = 0.182 KN/m2

At y=h y = 13.190

Qcw(y = h) = 0.5625

[1- 1/3 cos2 ф] cosф = 0.667

Pcw(y=h) = 3.720 KN/m2

Impulsive hydrodynamic pressure on the base slab (y=0)

Pib = 0.866 (Ahi) ρ g h sinh(0.866 x /L) / cosh(0.866 l'/ h)

= 19.485 KN/m2

Where,

D = 13.062 m

h = 13.190 m

x = 6.531 D/2 m

L = 13.190 h m

l' = 6.531 D/2 m

Convective hydrodynamic pressure on the base slab (y=0)

Pcb = Qcb(x) (Ah)c ρ g D

Qcb(x) = 1.125[x/D – 4/3 (x/D) 3] sech (3.674 h/D)

= 0.0183

Pcb = 0.182 KN/m2

Pressure Due to Wall Inertia

Pww = (Ah)i t ρm g

= 0.272 KN/m2

Where,

Thickness of 1st shell course t = 10.5 mm

Density of shell material ρm = 7850 kg/m3

Pressure Due to Vertical Excitation

Hydrodynamic pressure on tank wall due to vertical ground acceleration

Pv = (Av) [ρ g h ( 1- y / h )]

At the base of wall, i.e. y = 0

Pv = 37.100 KN/m2

MAXIMUM HYDRODYNAMIC PRESSURE

Phd = Sqrt ( (Piw + Pww)^2 + Pcw^2 + Pv^2)

= 50.166 KN/m2

HYDROSTATIC PRESSURE Phs = G*g*h

= 165.624 KN/m2

Maximum hydrodynamic pressure = 30.3 % of Hydrostatic Pressure

TOTAL HOOP STRESS IN 1st SHELL COURSE St = [(Phd+Phs)*D] / (2t)

= 134.2 MPA

ALLOWABLE SEISMIC HOOP STRESS Sa = 218.1 MPA . = 1.33 X Sd

St < Sa, Hence, Safe

SLOSHING WAVE HEIGHT / FREEBOARD HEIGHT REQUIREMENT

Maximum sloshing wave height dmax = (Ah)c R D / 2

 = 987 mm (self Anchored Tank)

= 1185 mm (Mechanically Anchored Tank)

Where, Table-3: IS:1893-Part-02

R = 2.500 (self Anchored Tank)

R = 3.000 (Mechanically Anchored Tank)

Available Freeboard = Tank Height - High High Liquid Level (HHLL)

= 1280 mm

Hence, Safe in Self Anchored Case

Hence, Safe in Mechanical Anchored Case

SLIDING RESISTANCE

CL. E.7.6 API-650

Base shear due to seismic V = 6361.31 KN

Friction force between tank bottom & foundation Vs = μ(Ws + Wr + Wf + Wp)(1.0 – 0.4Av)

= μ(Wop)(1.0 – 0.4Av)

= 8067.28 KN

Where,

μ = 0.4

Upto HLL Wop = 2258217 Kg (Ws + Wr + Wf + Wp)

= 22153 KN

V < Vs

No Sliding of Tank

SEISMIC SHEAR TO SHELL FROM ROOF

Vmax = 2V / (ПD)

= 2 Ahi Wr / (ПD)

= 0.682 Kg/mm

Shear Stress in top Shell Course Stop = Vmax / top shell course corroded thk.

= 0.152 Kg/mm2

= 1.487 MPa

Allowable Shear Stress 0.8 YP = 200 MPa

Hence, Acceptable

12.0 STABILITY CHECK FOR SEISMIC LOAD

CL. E.6.2 - API 650

Seismic Coefficients

Impulsive Horizontal Seismic Coefficient Ahi = 0.3360 g

Convective Horizontal Seismic Coefficient Ahc = 0.0605 g

Vertical Seismicity Av = 0.2240 g

CHECK FOR SELF-ANCHORAGE OF TANK

CL. E.6.2.1.1 API-650 (Resistance to Overturning )

Maximum wt of liquid content to resist overturning wa = Minimum [ 99 ta.(Fby.Ge.H )0.5 & 201.1*Ge*H*D ]

= Minimum [ 39890 40375 ]

= 39890 N/m

Where,

ta = Minimum [ bottom shell thk. , bottom pl. thk.] in corroded

= Minimum [ 10.5 6.5 ]

= 6.5 mm

Yield point of bottom plate under shell Fby = 250 MPa

Yield point of bottom shell course Fty = 250 MPa

Design Specific Gravity of liquid G = 1.280

Effective Specific gravity of liquid incl. vertical seismic effect Ge = 1.165 G (1 – 0.4Av)
Max. Liquid Height During Earthquake HL = 13.190 m HHLL is considered

Nominal Tank Diameter D = 13.062 m

Seismic Moment (at bottom of shell) Mrw = 35650.81 KN-m

= 35650805 N-m
Corroded Wt. ( Shell Plate & its attachment + Roof Plate & its
= Ws + Wrs
attachments)

= 85,204 kg

= 835850 N

Weight of tank shell and fixed roof wt = (Ws + Wrs) / (ПD)

= 20369 N/m

0.4 wint = max( Poper, 0.4*Pi ) * D/4

0.4 wint = 0.00 N/m

Thickness of bottom shell course t = 12.00 mm

wt (1-0.4*Av) = 18544 N/m

ANCHORAGE RATIO J = Mrw / [D2 {(wt (1 -0.4* Av) + wa - 0.4wint}]

= 3.576

J ≤ 0.785 Not Applicable Case

0.785 < J ≤1.54 Not Applicable Case

J > 1.54 Tank is not stable and cannot be self-anchored for the design load.

MAXIMUM LONGITUDINAL SHELL-MEMBRANE COMPRESSION STRESS

Corroded Thickness of bottom shell course ts = 10.500 mm

1/1000ts = 0.00009524 mm

wt( 1+ 0.4*Av) = 22194 N/m

(1.273 Mrw / D2 ) = 265998 N/m

2.3
0.607-0.18667 [J] = -2.8914

SHELL COMPRESSION IN SELF-ANCHORED TANKS

J ≤ 0.785 Not Applicable Case

Compressive Stress in shell bottom course Sc = [wt( 1+ 0.4*Av) + 1.273 Mrw / D^2] * (1/1000ts) MPa

= 27.447 MPa

0.785 < J ≤1.54 Not Applicable Case

Compressive Stress in shell bottom course Sc = [ { wt(1 + 0.4Av) + wa) / (0.607 – 0.18667[J] 2.3 } - wa ] * ( 1/1000ts)

= -5.844 MPa

SHELL COMPRESSION IN MECHANICALLY-ANCHORED TANKS

J > 1.54 Tank is not stable and cannot be self-anchored for the design load.

Compressive Stress in shell bottom course Sc = [wt( 1+ 0.4*Av) + 1.273 Mrw / D^2] * (1/1000ts) MPa

= 27.447 MPa

ALLOWABLE LONGITUDINAL SHELL-MEMBRANE COMPRESSION STRESS IN TANK SHELL

ts = 10.500 mm (corroded case)

G = 1.280

GHD2/ t2 = 26.127

GHD2/ t2 is ≥ 44 Not Applicable Case

Fc = 83ts / D

= 66.720 MPa

GHD2/ t2 < 44 Applicable Case

Fc = [ { 83ts ⁄ (2.5D) } + 7.5 sqrt(GH) ] < 0.5Fty MPa

= 57.598 125 MPa

= 57.598 MPa

Fc > Sc Acceptable
 13.0 SEISMIC LOAD CALCULATION & SHELL COMPRESSION CHECK (EMPTY CASE)

NOMINAL DIAMETER OF TANK D = 13.062 m

TOTAL HEIGHT OF TANK SHELL Ht = 14.470 m

HORIZONTAL SEISMIC COEFFICIENT Ah = 0.336 g

VERTICAL SEISMIC COEFFICIENT Av = 0.224 g

TOTAL WEIGHT OF TANK SHELL mw = 55941 kg

TOTAL WEIGHT OF TANK ROOF mt = 41644 kg

CENTER OF GRAVITY OF SHELL FROM BASE hw = 6.193 m

CENTER OF GRAVITY OF ROOF FROM BASE ht = 14.475 m

APPROX SHELL WEIGHT PER UNIT LENGTH mu = 3866 kg/m

BASE SHEAR (SEISMIC EMPTY CASE) Ve = 32788.5 kgf

= 321.7 KN

BASE MOMENT (SEISMIC EMPTY CASE) Me = 318944.2 kgf-m

3128.8 KN-m

SEISMIC MOMENT
SHELL ANALYSIS POINT SHELL WT. SHELL C.G. ROOF WT. ROOF C.G. SEISMIC FORCE(kgf)
(kgf-m)
Ms= Ah x (mwx(hw-hx)
COURSE hx (mm) mw (kg) hw (m) mt (kg) ht (m) Fs= Ah x (mw+mt)
+mtx(ht-hx))

1 0.000 55941 6.193 41644 14.475 32788.5 318944.2

2 2.000 55941 6.193 41644 14.475 32788.5 253367.2

3 3.250 55941 6.193 41644 14.475 32788.5 212381.6

4 4.500 55941 6.193 41644 14.475 32788.5 171396.0

5 5.750 55941 6.193 41644 14.475 32788.5 130410.4

6 7.000 27971 10.332 41644 14.475 23390.4 135902.3

7 8.250 27971 10.332 41644 14.475 23390.4 106664.3

8 9.500 27971 10.332 41644 14.475 23390.4 77426.3

9 10.750 13985 12.401 41644 14.475 18691.3 59878.2

10 12.000 13985 12.401 41644 14.475 18691.3 36514.1

11 13.250 6993 13.435 41644 14.475 16341.8 17576.1

12

13

14

15

SECTION SECTION ALLOWABLE

SHELL SHELL THICKNESS AXIAL FORCE MOMENT ACTUAL COMPRESSION CHECK
AREA MODULUS COMPRESSION
P (kgf) =
Z (m3)=
((mw+ms)- A (m2) = Sa (Mpa) = (83xts)/(2.5xD)
COURSE ts (mm) Ms (kgf-m) pix(D/2)^2xt Sa (Mpa) = (P/A)+ (Mz/Z)
(muxhx))x(1+ pixDxts < 0.5*Fy
s
Av)
1 10.5 119444 0.431 318944.2 1.407 4.9 MPa 26.7 MPa OK

2 8.5 109980 0.349 253367.2 1.138 5.3 MPa 21.6 MPa OK

3 8.5 104065 0.349 212381.6 1.138 4.8 MPa 21.6 MPa OK

4 6.5 98150 0.267 171396.0 0.870 5.5 MPa 16.5 MPa OK

5 6.5 92235 0.267 130410.4 0.870 4.9 MPa 16.5 MPa OK

6 6.5 86320 0.267 135902.3 0.870 4.7 MPa 16.5 MPa OK

7 4.5 80405 0.185 106664.3 0.602 6.0 MPa 11.4 MPa OK

8 4.5 74490 0.185 77426.3 0.602 5.2 MPa 11.4 MPa OK

9 4.5 68575 0.185 59878.2 0.602 4.6 MPa 11.4 MPa OK

10 4.5 62660 0.185 36514.1 0.602 3.9 MPa 11.4 MPa OK

11 4.5 56745 0.185 17576.1 0.602 3.3 MPa 11.4 MPa OK

12

13

14

15

SEISMIC LOADING ON FOUNDATION

Operating Empty
Adopted Values Unit
Case Case
Base Shear Vs = 6997 354 KN

Ringwall Moment Mrw = 39216 3442 KN-m

Slab Moment Ms = 46676 3442 KN-m

14.0 UPLIFT LOAD CALCULATION & ANCHOR BOLT DESIGN

As per Table 5.21a API:650

Input Data

Av VERTICAL EARTHQUAKE ACCELERATION = 0.224 %g

D TANK DIAMETER = 13.062 M

H TANK HEIGHT = 14.470 M

Fp PRESSURE COMBINATION FACTOR = 0.4

Fty YIELD STRENGTH OF BOTTOM SHELL COURSE = 250 MPA

FyAB YIELD STRENGTH OF ANCHOR BOLT = 250 MPA

Mws (=) PWS X D X H2 / 2 = 1900592 N-M

Mrw SEISMIC MOMENT = 35650805 N-M

Pi INTERNAL DESIGN PRESSURE = 0.000 KPA

Pf FAILURE PRESSURE = 0.000 KPa

Pt TEST PRESSURE = 0.000 KPa

Pwr WIND UPLIFT FORCE ON ROOF = [(Cpi-Cpe)*Pd] = 1.668 KPa

Pws WIND PRESSURE ON SHELL = [Pd] = 1389.9 N/SQ.M

W1 CORRODED WEIGHT ( ROOF + SHELL + FIXED ATTACHMENT ON SHELL) = 714658 N

W2 CORRODED WEIGHT (SHELL + FIXED ATTACHMENT ON SHELL + = 835850 N

PORTION OF ROOF PLATES AND FRAMING)

W3 NOMINAL WEIGHT ( ROOF + SHELL + FIXED ATTACHMENT ON SHELL) = 957307 N

ANCHOR BOLT GEOMETRIC DATA

TANK OUTSIDE DIAMETER @ BOTTOM OD = 13074 MM

BOLT ECCENTRICITY e = 110.5 MM OK

BOLTS CIRCLE DIAMETER B.C.D. = 13295 MM

MIN. NUMBER OF BOLTS (API CL 5.12.3 MAX. SPACING AT PERIMETER: 3 METER) N = 13.9

PROVIDED NUMBER OF BOLTS N = 28 @ 12.86 Degree

SPACING BETWEEN ANCHOR BOLTS Sp 1,492 MM <3000mm, OK

DIA. OF ANCHOR BOLT d = 56 MM

AREA OF EACH BOLT (AS-BUILT) Ab = 2,463 mm²

ROOT DIA. OF ANCHOR BOLT (CORRODED) = 53 mm CA= 1.50

ROOT AREA OF EACH BOLT (CORRODED) = 2,206 mm²

Net Uplift Load per Bolt
Uplift Load Case Net Uplift Formula, U (N) Design Load for anchor chair per Bolt
U = U/N
(N) (N) (N) (N)

Design Pressure [Pi X D2 X 785] - W1 -714658 -25524 -38285 1.5*U/N

2
Test Pressure [Pt X D X 785] - W3 -957307 -34190 -51284 1.5*U/N
2
Wind Load [PWR X D X 785] + [4 X MWS/D] - W2 -30450 -1087 -1631 1.5*U/N

Seismic Load [4 X MRW/D] - W2 X (1 - 0.4 x Av) 10156453 362730 1088191 3*U/N

Design Pressure + Wind [Fp (Pi + PWR) X D2 X 785] + [4 X MWS/D] - W1 -43285 -1546 -2319 1.5*U/N

Design Pressure + Seismic [Fp X Pi X D2 X 785] + [4 X MRW/D] - W1 X (1 -0.4 Av) 10266786 366671 1100013 3*U/N
2
Frangibility Pressure [3 X Pf X D X 785] - W3 Not Applicable

Actual Stress in
Uplift Load Case Allowable Stress in Bolts Allowable Stress in Bolts
Bolts
(MPa) (MPa) (MPa)

Design Pressure (5/12) x Fy 104 -11.6 SAFE

Test Pressure (5/9) x Fy 139 -15.5 SAFE

Wind Load 0.8 x Fy 200 -0.5 SAFE

Seismic Load 0.8 x Fy 200 164.4 SAFE

Design Pressure + Wind (5/9) x Fy 139 -0.7 SAFE

Design Pressure + Seismic 0.8 x Fy 200 166.2 SAFE

Frangibility Pressure Fy Not Applicable

 Allowable Stress in Shell at
Uplift Load Case Allowable Stress in Shell at anchor attachment
anchor attachment
(MPa) (MPa)

Design Pressure (2/3) x Fty 167

Test Pressure (5/6) x Fty 208

Wind Load (5/6) x Fty 208

Seismic Load (5/6) x Fty 208

Design Pressure + Wind (5/6) x Fty 208

Design Pressure + Seismic (5/6) x Fty 208

Frangibility Pressure Fty Not Applicable

Allowable Actual Allowable

Design Load
Max. Uplift (U) Max. Load per Bolt Stress in Stress in Stress in
Governing Case for chair
Bolts Bolts Shell

(N) (N) (MPa) (MPa) (MPa) (N)

Design Pressure + Seismic 10266786 366671 200 166.2 208 1100013

15.0 ANCHOR CHAIR DESIGN CALCULATION

As per AISI Steel Plate EngineeringData, Volume 2, Part 5, “Anchor Bolt Chairs.”

PARAMETER MIN. REQ.

a= TOP PLATE WIDTH ALONG THE SHELL 200 MM 7.874 INCH

b= TOP PLATE LENGTH 280 MM 11.024 INCH

c= TOP PLATE THICKNESS 32 MM 1.260 INCH

d= ANCHOR BOLT DIAMETER 56 MM 2.205 INCH

e= ANCHOR BOLT ECCENTRICITY 110.5 MM 4.350 INCH 2.525 OK

f= DISTANCE FROM OUTSIDE OF TOP PLATE TO EDGE OF HOLE 129.5 MM 5.098 INCH 3.205 OK

g= DISTANCE BETWEEN VERTICAL PLATES 120 MM 4.724 INCH 3.205 OK

h= ANCHOR CHAIR HEIGHT 500 MM 19.685 INCH 12"<h<3a OK

j= VERTICAL PLATE THICKNESS 20 MM 0.787 INCH

k= VERTICAL PLATE WIDTH (AVERAGE) 165 MM 6.496 INCH

m= CORRODED BOTTOM PLATE THICK 6.5 MM 0.256 INCH

R= RADIUS OF SHELL TO THE CENTRE LINE OF THE SHELL PLATE 6531 MM 257.126 INCH

ts= BOTTOM SHELL COURSE THICKNESS (CORRODED) 10.5 MM 0.413 INCH

tr= R-PAD THICKNESS FOR ANCHOR CHAIR 12 MM 0.472 INCH

t= BOTTOM SHELL COURSE THICKNESS (UNDER CONSIDERATION) 22.5 MM 0.886 INCH

q= BASE PLATE PROJECTION 50 MM 1.969 INCH

X= R-PAD WIDTH 250 MM 9.843 INCH

Y= R-PAD HEIGHT 550 MM 21.654 INCH

STRESS CALCULATION

Pa= MAXIMUM ALLOWABLE ANCHOR BOLT LOAD 615752 N 138.43 KIPS Ab x FyAB

Pb= APPLICABLE BOLT LOAD 1100013 N 247.29 KIPS FROM UPLIFT CALC

IMPACT FACTOR 3.0 3.0

P= DESIGN LOAD FOR ANCHOR CHAIR: MIN (Pa, Pb) 615752 N 138.43 KIPS

BEND STRESS IN TOP PLATE

S= CRITICAL STRESS IN TOP PLATE P (0.375g - 0.22d)/ (f * c2)

152 MPA 22.01 KSI

Allowable Stress in Shell at anchor attachment 208 MPA 30.22 KSI

Stress are within allowable limit, Hence safe

STRESS IN SHELL DUE TO ANCHOR REACTION

REDUCTION FACTOR (Z) 1.0 / [ {0.177a.m / (R.t) 0.5} *(m/t) 2 + 1.0]

Z= 0.99 1.00

Q= [1.43 ah2/ (R.t)] + (4ah2)0.333

Q= 1067.7 42.1

S= STRESS IN SHELL DUE TO ANCHOR REACTION ( P x e/t2 ) x { (1.32 x Z /Q) + (0.031 / (Rt)0.5) }

S = 176 MPA 25.59 KSI

Allowable Stress in Shell at anchor attachment 208 MPA 30.21 KSI

Stress are within allowable limit, Hence safe

SIDE PLATES THICKNESS

MIN. THK. OF VERTICAL PLATES Max. [0.5 INCH. 04(h-c), (P/25k)]

19 MM 0.74 INCH

ADOPTED THK. OF VERTICAL PLATE 20 MM 0.79 INCH OK

STRESS IN SIDE PLATE (Sv) = P / (2*J*K)

93 MPA 13.53 KSI

Allowable Stress in side plate 208 MPA 30.22 KSI

Stress are within allowable limit, Hence safe

WELD SIZE CHECK

FILLET WELD SIZE w= 10 MM 0.394 INCH

VERTICAL LOAD IN WELD Wv = P / (a+2h) 2.93 KSI /INCH

HORZ. LOAD IN WELD Wh = P / (ah + 0.667*h2) 0.33 KSI /INCH

RESULTANT LOAD W = SQRT ( Wv^2 + Wh^2) 2.95 KSI /INCH

ALLOWABLE WELD DESIGN STRESS (Sw) 13.6 KSI /INCH

ALLOWABLE LOAD FOR GIVEN WELD SIZE (Wa) = 0.707 x Sw x w 3.79 KSI /INCH

Wa > W, Hence safe

WEIGHT CALCULATION

TOP PLATE = 14 KG

GUSSET = 26 KG

R-PAD = 13 KG

TOTAL NO. OF ANCHOR CHAIR = 28 NOS.

TOTAL WEIGHT (NO. OF ANCHOR CHAIR X UNIT WEIGHT) = 1482 KG

16.0 MECHANICAL DATA SHEET

DESIGN PARAMETER DESIGN DATA

IS-803:2013 & API-650-12th

DESIGN CODE TANK SIZE (ID X HT) 13.05M X 14.47M
Ed:2016
WIND CODE IS-875 Part-03: 2015 DESIGN LIQUID LEVEL mm 13270

AS PER IS:1893 PART-02:2014 &

SEISMIC CODE DESIGN PRESSURE ATM (+) FULL OF LIQUID
SITE SPECIFIC SPECTRA
TANK NAME LIMESTONE SLURRY TANK-A&B OPERATING PRESSURE ATM (+) OPERATING LIQUID

TAG NO. 00HTK10-BB001 00HTK10-BB051 HYDROTEST PRESSURE FULL OF WATER

O
QUANTITY 1 NO. EACH DESIGN TEMPERATURE C 50

O
TANK TYPE VERTICAL CYLINDRICAL FLAT ROOF OPERATING TEMPERATURE C 37

ROOF TYPE FLAT ROOF SERVICE FLUID LIMESTONE SLURRY

DESIGN FLUID DENSITY kg/m3 1280

ACCESSORIES CORROSION ALLOWANCE mm 1.50

SPIRAL STAIRCASE YES (LST-A) / NO (LST-B) JOINT EFFICIENCY 0.85

ROOF HANDRAIL YES RADIOGRAPHY SPOT RADIOGRAPHY

EARTHING LUG YES INSULATION TYPE/THK. Not Applicable

GOOSE NECK WITH BIRD SCREEN YES BASEIC WIND SPEED m/s 47

NAME PLATE YES SEISMIC DESIGN As per Site Spectra

FLUSH CLEAN-OUT DOOR YES GEOMETRIC/NOMINAL CAPCITY m3 1932.5

AGITATOR YES OPERATING CAPACITY (TOB-HHLL) m3 1761.5

BAFFLE & ITS SUPPORT YES WORKING CAPACITY LLLL-HLL m3 1140.5

MONORAIL ARRANGEMENT YES ERECTION WEIGHT (APPROX) KG 94,530

EMPTY WEIGHT (APPROX) KG 1,16,545

OPERATING WEIGHT (APPROX) KG 23,88,459

HYDROTEST WEIGHT (APPROX) KG 20,51,984

TANK DETAILS

BOTTOM PLATE DETAIL SHELL PLATE DETAIL

ANNULAR PLATE PROVISION YES COURSE NO. COURSE HT. COURSE THK.

BOTTOM PLATE THICKNESS mm 8 NOTE-01 mm mm

BOTTOM PLATE OUTSIDE DIAMETER mm 11074 1 2000 12 NOTES

1. COURSE NOS. ARE FROM BOTTOM TO
SLOPE OF BOTTOM PLATE 1/ 100 2 1250 10
TOP.
ANNULAR PLATE THICKNESS 8 3 1250 10 COURSE NO(1) IS BOTTOM MOST.
mm

ANNULAR PLATE OD mm 13174 4 1250 8

2. 10 MM GAP SHALL BE PROVIDED B/W
ANNULAR PLATE WIDTH mm 1050 5 1250 8
TOP OF CURB TO SHELL TOP.
6 1250 8 ACOORDINGLY HEIGHT OF NON-
UNIFORM COURSE WIDTH SHALL BE
ROOF PLATE DETAIL 7 1250 6 REDUCED.

TYPE OF ROOF FLAT ROOF 8 1250 6

3. MAXIMUM SPACING B/W STIFFNER FOR
ROOF SLOPE 0/ 1 9 1250 6
FLAT ROOF TANK IS ALONG THE WIDTH
ROOF TO CURB OVERLAP 70 10 1250 6 OF PLATE.
mm

ROOF OUTSIDE DIAMETER mm 13202 11 1220 6

ROOF PLATE THICKNESS mm 10 12 0 0

NO. OF RAFTER No. Not Applicable 13 0 0

MAX. SPACING B/W STIFFENER mm 1500 14 0 0

15 0 0

14.47 OK
 ACCESSORIES DETAILS

TOP CURB MEMBER INTERMEDIATE WIND GIRDEER

TOP CURB MEMBER ISMC 250 NO. 1

TYPE Detail-b Figure F.2 - API-650 FIRST STIFFENER ELEVATION mm 10170

NO. OF GUSSET 0 FIRST STIFFENER SIZE ISA 100 X 100 X 8

GUSSET SIZE Not Applicable SECOND STIFFENER ELEVATION mm 0

SECOND STIFFENER SIZE 0

TYPE Detail-C Fig. 5.24 of API-650

SHELL MANHOLE DETAIL 1 NO. ROOF MANHOLE DETAIL 1 NO.

MANHOLE SIZE OD 600 MANHOLE SIZE OD 616

NECK THICKNESS mm 14 NECK THICKNESS mm 8

COVER FLANGE THICKNESS mm 20 COVER FLANGE THICKNESS mm 8

BOLTING FLANGE THICKNESS mm 20 BOLTING FLANGE THICKNESS mm 8

REINFORCING PAD SIZE mm 12 X 1255 REINFORCING PAD SIZE mm 8 X 1150

Figure 5.7a-Shell Manhole : Figure 5.16-Roof Manholes :

DETAIL DETAIL
API-650 API-650

CLEAN-OUT DOOR DETAIL YES ROOF LOADS

DOOR SIZE mm 610 X 610 LIVE LOAD 1.500 KPA

NECK THICKNESS mm 14 DEAD LOAD (ROOF PLATE+ NOZZLES) 1.576 KPA

COVER & BOLTING FLANGE THICKNESS mm 20 OTHER LOADS AS PER DBR "FS0004-66990100-DBR-1001"

BOTTOM REINFORCEING PLATE THK mm 20 ROOF STRUCTURE WEIGHT (KG) 18,000

REINFORCING PAD THICKNESS mm 12

Figure 5.12-Flush-Type Cleanout

DETAIL
Fittings:API-650
17.0 FOUNDATION LOAD DATA

LIMESTONE SLURRY TANK-A&B

M 56 BOLT B.C.D. = 13295 MM

28 NOS. 200

292
162 MM 20 120 20
MM MM MM
TANK ID = 13050 MM

32 MM SHELL THK. = 12 MM

468 MM WELD SIZE = 10 MM

20 R-PAD THK. = 12 MM
2170
THK

MM 8 MM

BASE OD = 13174 MM

1500 MM

FOUNDATION LOAD DATA

WEIGHT DATA

ERECTION WEIGHT KG 94,530

EMPTY WEIGHT KG 1,16,545

OPERATING WEIGHT KG 23,88,459

HYDROTEST WEIGHT KG 20,51,984

WIND

SHEAR FORCE KN 243

MOMENT KN-M 3684

SEISMIC (OPERATING CASE)

SHEAR FORCE KN 6997

MOMENT KN-M 46676

SEISMIC (EMPTY CASE)

SHEAR FORCE KN 354

MOMENT KN-M 3442

BOLT DATA

BOLT SIZE M 56

BOLT LENGTH MM 2170

B.C.D. MM 13295