Storage Tanks

Selection and Sizing

CBE 497
1 Oct 02
richardhaw@sympatico.ca

Dow Chemical - LOPC

LOPC stands for Loss of Primary Containment.
Considerable effort goes into preventing loss of
product from storage tanks and vessels.
LOPC generally leads to fires and explosions with
loss of life and loss of investment.
LOC at Phillips in Houston in Oct 89 killed 23,
injured 130 and cost over $750 million.
LOC at Union Carbides plant in Bhopal, India killed
over 4000 people and cost UC well over $500 million.
This is why LOPC is so important.

Large Chemical Company Response To Bhopal Directive

Job 1
at Dow

Fire and
Expos ure
Calculations
F &E

HAZOP
and
P HA
Reviews

Phase
I to 4
Process
Engineering
R eviews

Safety &
Loss
Prevention
Reviews

Flow
Dispersion
Cons equence
QRA

Loss Of
Containment
Bhopal
Directive

MOE
Reviews

D.O.T
Emergency
Transport
Scenarios

PSV
Design Basis
And
Alternatives

Technical
Center
Reviews

Materials
Specialty
Reviews

Chemical
Exposure
Index
Calc'ns

P reStartup
Audit

Vessel
Inspection
Yearly
Reviews

Reactive
C hemical
R eviews

NIOSH Data
NIOSH stands for National Institute for
Occupational Safety and Health.
Lookup your chemical on the NIOSH
Pocket Guide to Chemical Hazards.
http://www.cdc.gov/niosh/npg/npg.html
As soon as you know you have a
certain chemical, extract the following
NIOSH data:

NIOSH Exposure Limits

Ca. Any substance that NIOSH considers to
be an occupational carcinogen is designated
by the notation Ca.
REL Recommended Exposure Limit based
on a 10 hour workday during a 40 hour work
week.
A ceiling REL is designated by a C
preceding the value. The ceiling value should
not be exceeded at any time.

NIOSH STEL
Short term exposure limit (STEL) is a
15 minute time weighted average (TWA)
exposure limit that should not be
exceeded at any time during a workday.

NIOSH Gives OSHA Limits

NIOSH also presents Occupational
Safety and Health Act data (OSHA).
OSHA uses PEL for permissible
exposure limits.

NIOSH Gives ACGIH Limits

The American Conference of Governmental
Industrial Hygiene (ACGIH).
ACGIH uses Threshold Limit Values (TLV)
which are 8 hour TWA concentrations
ACGIH A1 is a confirmed carcinogen.
ACGIH A2 is a suspected carcinogen.
ST is a 15 minute TWA value for a STEL.

NIOSH IDLH
IDLH stands for Immediately dangerous
to life and health.
IDLH represents the maximum
concentration from which, in the case
of respirator failure, one could escape
within 30 minutes without a respirator
and without experiencing any escapeimpairing or irreversible effects.

NIOSH Flammability
LEL = Lower Explosive Limit aka LFL
for Lower Flammable Limit in vol% in
air at room temperature.
UEL = Upper Explosive Limit aka UFL
for Upper flammable Limit in vol% in air
at room temperature.
Flash Point (Fl.P.) using either closed
cup (cc) or open cup (op) methods.

NIOSH Other Important Data

NIOSH gives the Auto Ignition
Temperature (AIT), if it is known.
Boiling Point (BP) at 1 atmosphere.
Freezing Point (FRZ) temperature.
Solubility in water (sol) as % by weight.
Specific gravity (Sp. Gr.).

NIOSH Incompatibilities
NIOSH give the important hazardous
incompatibilities or reactivities of each
substance.
This is where I would look for
polymerization potential and the need
to take special preventative action
should a polymerization reaction start
to generate high heat of reaction.

OSHA Classification of
Flammables
Class 1A flammable liquid. Fl.P. below
73F and BP below 100F.
Class 1B flammable liquid. Fl.P. below
73F and BP above 100F.
Class 1C flammable liquid. Fl.P. at or
above 73F and below 100F.

MSDS Information
MSDS stands for Material Safety Data Sheets.
A repeat of NIOSH data.
Most large companies publish their MSDS on
the internet.
Often six different MSDS sets of one
chemical are compared and a consensus is
taken to resolve differences in toxic and
flammability data particularly auto ignition.
(NH3 as an example).

Vapor Pressure Data

Generate your own Antoine Constants over
your temperature range including summer to
winter ambient temperatures.
The typical Antoine equation is:
Log10(P) = A + B/(t+C)
where P is
in psia, t is in deg C and A,B,C are the
Antoine Constants.
3 sets of (P,t) data required to solve for A,B,C
in 3 equations.

Antoine Constants for EO

Solve for Antoine Constants For

Log10(P) =A +B/(t+C)
Basis
P1 =
P2 =
P3 =
C=
B=
B=
Diff =

Ethylene Oxide

EO
C2H4O

MW =

44

P in psia and t in C

Dow Phys Prop File & Perry 6, p3-56

11.497
32.335
75.009

psia
psia
psia

t1 =
t2 =
t3 =

4.44
32.22
60.00

C
C
C

238.2665 Perturb Till Diff =near Zero

-1061.38464 From P1 and P2
-1061.38467 From P1 and P3
3.6287E-05
A = 5.43362455
B = -1061.38467
C=
238.2665

LEL =
Atm Press =

14.696
psia

F
40
90
140

Vapor Pressure Plot for EO

Vapor pressure, PSIA

Vapor Pressure of EO
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
0.00

20.00

40.00
Temperature, C

60.00

80.00

Vapor Pressure Info

Look to see where VP is at lowest ambient
temperature.
If the VP is below atmospheric pressure of
14.7 psia, and if the chemical is a flammable
chemical, air will leak into the vessel creating
an extremely hazardous situation.
Static electricity created by falling liquid into
the vessel can set off an explosion.

Pad Depad with an Inert gas

To prevent air from leaking into a flammable
vessel under sub atmospheric pressure, add
nitrogen as a pad gas to maintain the
pressure above 14.7 psia.
As the vessel requires venting during filling,
de-pad the inert gas & hydrocarbon to a flare
or to a recovery system.
As an alternative, heat the tank to bring the
vapor pressure above 14.7 psia.

Pad Depad Sketch

The Enthalpy Chart

The Enthalpy Chart Contd

It provides a roadmap for your process.
Try to find an enthalpy chart for your
single component chemicals.
If one is not available, you can
construct your own from HYSIS.
The enthalpy chart tells you about the
need for pre-heaters, vaporizers, superheaters, knock-out pots, pumps,
compressors.

MIACC or RMP?
Check to see if your chemical is listed
on the Major Industrial Accident
Coordinating Committee List.
Check to see if your chemical is listed
on the U.S. Risk Management Plan List.
These lists tell you whether or not you
need to take toxic or flammable
preventative measures in your design.

U.S. RMP
The U.S. RMP method is now favored in
Canada over the CDN MIACC method.
If your chemical is on the list and if your
quantity exceeds the specified threshold
quantity, you must run the RMP program to
determine the environmental impact on the
public and file the results with the EPA.
The EPA will approve your plant design if you
have developed a suitable emergency
response plan with the public.

RMP Computer Program

RMP Worst Case Scenario tells you the impact
distance from your storage tank to the public for
either a toxic or flammable chemical.
Free download at
http://www.epa.gov/ceppo/tools/rmp-comp/rmp-comp
.html
Download it on to your hard disc.
Its very simple to use.
If you dont know your storage quantity yet, run the
threshold quantity to see how big a problem you
may have. You may decide to store less.

Design Tools Needed

The Ideal Gas Law, P1V1/T1 = P2V2/T2

Daltons law of Additive Pressure.
Dew Point calculation.
Bubble Point calculation.
Flash % calculation.
Equation of state PV = (Z)(n)(R)(T)
The Antoine Vapor Pressure equation.

API Storage Tanks

API Low pressure storage, DP < 15 psig

Pressure Vessels, DP>15 psig

High pressure where DP > 15 psig.

Codes for API Tanks

API-12B bolted tanks

API-12D field welded tanks
API-12F shop welded tanks
API-620 large welded, low pressure
tanks
API-650 welded steel tanks for oil
storage.

Codes for Pressure Vessels

ASME VIII - Pressure Vessel Code
B51-M1981 Canadian Standards
Association Code for the
Construction and Inspection of Boilers
and Pressure Vessels.

Codes for Piping

American National Standards Institute
(ANSI)
B31.1 Power Piping
B31.2 - Fuel Gas Piping
B31.3 - Chem Plant & pet Plant Piping.
B31.4 Liquid petroleum Transportation
Piping
B31.4 1974 Refrigeration Piping
B31.8 gas Transmission Piping

Fire Protection
National Fire protection Association (NFPA)
No. 30 Flammable & Combustible Liquids
Code
No. 58 Liquified Petroleum Gases, Stg &
Hdlg.
No. 59 Liquified Petroleum Gases at Utility
Gas Plants.
PSV Design NFPA 30
PSV Design API-520 & API-521

Drainage
NFPA 30 - 2-3.3 Control Of Spillage From
Aboveground Tanks (see PSV Size & Cost
V3.7)

Dyking
Dyke Dimensions on CD-ROM
Dyke L =

S
18.87

61.38
58.73
2.65
Dia
S
21
18.87
Ht = 21

2.11

above grade, h

H Ab Hole = 9.89
Hole Ht, h = 9.00
18.89

18.89

slope

S = 18.87

EO Storage

UC MIC Storage Area

Sizing API Tanks

Need Liquid Density, lb/cf

Need a Soil Bearing reading in lb/sf.
Maximum allowable Ht of liquid = HL
Max HL = lb/sf / lb/cf = ft. of liquid
Need storage time in hours, days or weeks.
Need average flow rate, cu. Ft / hr
Volume = (cu. Ft. / hr )(hours).
Never fill more than 90%.
Diameter, D = [ cu. Ft. / .785 / HL ]^0.5

Selection of API Tanks

API 650 Tanks on CD-ROM.
Select tanks from large data base that
meet volume and maximum height limits.
Select options

Length of pipe rack

Painting
Insulation thickness
Dyke type concrete or earthen
Year for escalation of cost in database.

Calculate Heat Loss

Heat Loss From Vessels on CD-ROM
May have to add re-circulating pumps
and heat exchangers.
Basic goal is to save energy at
DCFRRAT of 20% or better.

Determine Breathing Losses

Storage Tank Venting folder on CD-ROM
Read Design Methods for Storage Tank
Venting.
BLOSS program on CR-ROM for breathing
losses due to ambient temperature
changes and pump in / pump out changes.
Make changes in process to lower losses.

Sizing Pressure Vessels

Pressure Vessels V1.5 on CD-ROM

Need volume, cf, by (lb/hr)(hrs) / (lb/cf)
Use a safety factor of 40%.
Select diameter, D, and length, L, so
that L/D = 4 to 5 or thereabouts.
Select Design Pressure, DP, and Design
Temperature, DT, to safely cover all
upset conditions.

Sizing PV Contd
Select Corrosion Allowance ca,
usually 1/16 inch for inside.
May have to allow 1/16 inch for outside
corrosive atmospheres near Cl2
plant.
Select materials from data base.
Select Joint Efficiency, E, = 0.85 or 1.0
Select flange rating = 150 lb, 300 lb or ?

Flange Data
PRESSURE - TEMPERATURE RATINGS FOR STEEL PIPE FLANGES AND FLANGED FITTINGS
American National Standard ANSI B16.5 - 1977
Class
Hydro TP, psig
Temp, Deg F
-20 TO 100
200
300
400
500
600
650
700
750
800
850
900
950
1000

150 lb
300 lb
400 lb
600 lb
900 lb
1500 lb
450
1125
1500
2225
3350
5575
MAXIMUM ALLAOWABLE NON-SHOCK PRESSURE, PSIG
285
740
990
1480
2220
3705
260
675
900
1350
2025
3375
230
655
875
1315
1970
3280
200
635
845
1270
1900
3170
170
600
800
1200
1795
2995
140
550
730
1095
1640
2735
125
535
715
1075
1610
2685
110
535
710
1065
1600
2665
95
505
670
1010
1510
2520
80
410
550
825
1235
2060
65
270
355
535
805
1340
50
170
230
345
515
860
35
105
140
205
310
515
20
50
70
105
155
260

2500 lb
9275
6170
5625
5470
5280
4990
4560
4475
4440
4200
3430
2230
1430
860
430

Sizing Contd
Cylindrical Shell thickness = t where
t = (P)(R) / [(S)(E) - (0.6)(P)]
P = Design Pressure, psig, aka MAWP for
Maximum allowable Working pressure.
R = Vessel radius, inches
S = Stress value of material, lb/sq. inch
E = Joint Efficiency = 0.85 or 1.0
P = (S)(E)(t) / [R + (0.6)(t)]

Sizing Cond
2:1 Ellipsoidal head
t = (P)(D) / [(2)(S)(E) - (0.2)(P)]
Final tf = [t + ca] rounded to next
thickness
P = (2)(S)(E)(tf) / [(D) + (0.2)(tf)] where P
is now the back-calculated Design
Pressure
Units same as above.

Final Design Conditions

Design thickness is selected on the
basis of the maximum of:
Longitudinal seam of cylindrical shell
Head type ellipsoidal or ASME
Flange rating

Mechanical Results & Cost

Tag No.
Case No.
Type
Time Period
Fab Eqt Index, FEI
CND$/US$
Duty US>CAN
Vessel ID, ft
Tan-Tan, L, ft
Operating Temp =
Operating Pressure =
Design PSIG
Design Temp, F
Back Calc DP, psig
2:1 SE Head bc DP =
Corr Allow, in
Efficiency
Radiographing
Mat'l Option
Mat'l factor =
Allow Stress, psi=
Density, lb/ci =

PRESSURE VESSEL COST ESTIMATE

Example - Richardson's
Case 2
VKO w Demister
4th Qrt 94
1988
Year =
75 - 04
361.31
1.00
1.00
4.50
54.00
inches
11.00
132.00
inches
130.00
F
95.00
psig
130.00
Flange Rating =
150
lb
200.00
Flange Press =
258
psig
143.87
Flange Mess = 150 lb Flgs O.K.
144.53
0
-19.83
Good for full vacuum
1.00
psig at thk =
0.2500
inches
100% X-ray
304 SS
Cyl Sur Area =
187.32
sf
2.50
Cyl Vol =
174.95
cf
15,624
Cyl Vol =
4,954
Litres
0.28702
BLEVE Time =
7.24
minutes

Results Contd
Tp rounded, in. =
Twind, in. =
Tgirth, in. =
Tb =Tw+Tg =
Tb rounded, in. =
Tb final, in. =
Top Thk+CA, in.
Btm Thk+CA, in.
Avg thk top to btm
Wt Shell, lb =
Cs Max, FOB Vendor
Cs, Avg, FOB Vendor=
Cs Min., FOB Vendor
Internals Cost
Total Est'd Cost
Act Cost FOB Vendor
Actual Freight
Actual Cost =

0.25000
0.00584
0.11214
0.11798
0.18750
0.25000
0.25000
0.25000
0.25000
2,140
$34,550
$31,444
$28,337
$1,044
$32,487
$0
$0
$0

Min. Thk =

0.18750

Special Cost
Est'd Cost
Factor
Range
1.00
$34,550
1.00
$31,444
1.00
$28,337
Shop Installed Demister
1.0000

Other Storage Tank Issues

Cold Insulation to prevent dew point
forming on external surfaces.
Complete Hazard Analysis.
Mini- Quantitative Risk Analysis (QRA).
Spheres
Floating Roof API tanks.
Pressure Safety Valve (PSV) design.

End of Presentation
Good luck with your storage tank
designs.
Any questions?
If you have questions later, email me at
richardhaw@sympatico.ca