Fuel Oil Storage Vessel Design

Fuel oil Storage
Vessel Design
Plant & Equipment Design
Welahetti W.P.K
080533H
Level 04
4/5/2012

Fuel oil Storage Vessel Design 2012

Prasanna Welahetti Page 2

Contents
1 Data .................................................................................................................................... 4
2 Fuel oil Details .................................................................................................................... 4
3 Pressure vessel codes and standards ................................................................................ 5
4 Material Selection .............................................................................................................. 5
5 Design Pressure Calculation ............................................................................................... 6
6 Design Temperature Calculation ....................................................................................... 8
7 Design Stress Calculation ................................................................................................... 8
8 Wall thickness calculation .................................................................................................. 9
9 Selection of ends .............................................................................................................. 10
9.1 Head selection ........................................................................................................... 10
9.2 Bottom selection ....................................................................................................... 13
9.2.1 Bottom wall thickness calculation ..................................................................... 13
9.2.2 Checking for reinforcement ............................................................................... 14
10 Fabrication Procedure...................................................................................................... 16
10.1 Shell Fabrication .................................................................................................... 16
10.2 Head and cone fabrication .................................................................................... 19
10.3 Assembly of shell and head ................................................................................... 19
10.4 Assembly of shell and cone ................................................................................... 20
11 Technical Drawing ............................................................................................................ 21
11.1 Torispherical head heights calculation .................................................................. 21
11.2 Thickness reducing length calculation ................................................................... 21
11.3 Front Elevation ...................................................................................................... 22
11.4 Top elevation ......................................................................................................... 23
12 References ....................................................................................................................... 24



Table of figure
Figure 5.1 Vessel Pressures ........................................................................................................ 6
Figure 7.1 Typical design Stress for Plate .................................................................................. 8
Figure 8.1 Minimum Practical Wall thickness ............................................................................ 9
Figure 9.1 Torispherical Head .................................................................................................. 10
Figure 9.2 Stress concentration ............................................................................................... 12
Figure 9.3 Calculaded Stress concentration ............................................................................ 13
Figure 9.4 Reinforcement Checking Table ............................................................................... 14
Figure 9.5 Reinforcement for Conical Bottom ......................................................................... 15
Figure 10.1 Prepinging of Plates Edges .................................................................................... 17
Figure 10.2 Single V-joint ......................................................................................................... 18
Figure 10.3 Single V-groove welded Butt Joins ........................................................................ 18
Figure 11.1 Front Elevation ...................................................................................................... 22



1 Data
A vertical storage vessel is used to store fuel oil according to the class stipulated by the
appropriate codes and standards. The vessel is to be designed for the following conditions

2 Fuel oil Details

There are 6 types of fuel oil coming from petroleum refinery. Those are types are shown in
below,
- Number 1 fuel oil (also called the kerosene)
- Number 2 fuel oil
- Number 3 fuel oil
- Number 4 fuel oil
- Number 5 fuel oil
- Number 6 fuel oil
Fuel oil numbers 1 and 2 are referred to as distillate fuels oil, while fuel oil numbers 4, 5,
and 6 are labeled residual.
Number 5,6 fuel oil need to pre heat before feed to boiler or furnace. This is also call the
furnace oil. According to literature survey furnace oil should be store in 30-35C rage.
Therefore I have selected fuel oil as furnace oil.
Following priorities are important for selection of material for the vessel (According to
Ceypetco Product Specifications; Specification For Furnace Oil 800 Sec (P-026))
Absolute pressure - 1.1 atm

Operating temperature - 30-35C

Mean diameter -4.5 m

Length of cylindrical shell - 12 m



Density Max 970kg/m
3
Flash point Min 60C
Pour point Max 21C
Our operating temperature is 30-35 C. Pour point is less than operating temperature
therefore it cannot achieve semi solid conditions and flow property losses.
3 Pressure vessel codes and standards

Here I have followed the American Society
of Mechanical Engineers (ASME) Boiler
and Pressure Vessel Code. It is
internationally recognized code,
establishes rules of safety governing the
design, fabrication, testing and inspection
of boilers and pressure vessels.
Vessels, designed, fabricated and
inspected to meet ASME code division1
section VIII requirements are marked with
U. according to this vessel following
recommendations are suitable.
- U-70 for non toxic gases and liquids(Light duty vessels)
- temperature limit 250 F
- Pressure below 100 psi
4 Material Selection

There are several factors affecting to material selection. Those are Strength, Corrosion
Resistance, Resistance to Hydrogen Attack, Fracture Toughness, Fabricability.

According to ASME Section Viii, Division 1, and Subsection C; material selection was done.
Most of the pressure vessels are fabricating using low carbon steel. Carbon steel is not
resistance to corrode. Sometimes there can be mercaptance, acid, water droplets with the
fuel oil therefore it is better to go corrosion resistance material.
According to my trial calculation low alloy steel is give high tensile strength. It is more than
enough to operating vessel pressure and temperature. Therefore low alloy steel suitable for
this vessel.


According to above table; Low Alloy Steel SA-202 grade A is suitable.

5 Design Pressure Calculation

Assumptions
- Considered fuel oil as furnace oil

Figure 5.1 Vessel Pressures

= 1
Therefore;
>
To calculate the design pressure following equation can use;


Assume maximum furnace oil level is 12m.
Density of fuel oil (furnace oil) = 890/3
c hydrostati
P =

c hydrostati
P = 12 970 9.81

c hydrostati
P = 114188.4/2

=

= 1.1 1
= 0.1 = 10132.5 /2
= 10132.5 /2
5% 0f Pmax. Operating by gauge =506.625N/m2
506.625N/m2<114188.4/2
Therefore
gauge c hydrostati
P P
by ing max.operat
% 5 >
Therefore;
= 10132.5 /2 +114188.4/2
= 124320.9/2
=0.124MPa

c hydrostati gauge design
gauge c hydrostati
P P P
P P
+ =
>
by ing max.operat
by ing max.operat
% 5


6 Design Temperature Calculation

The strength of metals decreases with increasing temperature so the maximum allowable
design stress will depend on the material temperature. The design temperature at which the
design stress is evaluated should be taken as the maximum working temperature of the
material.
There is no any reaction inside the vessel; therefore body is non-directly heating. So we
have to go for following equation;
=
= 35
oC T T body of e temperatur highest
o
design
o
10 + =

= 35 +10
= 45
7 Design Stress Calculation
According to above material selection; fabrication material was low-alloy steel.

Figure 7.1 Typical design Stress for Plate

According to above table design stress is 240N/mm2.
= 240/2


8 Wall thickness calculation

=
124320.94.5
20.8524010
6

= 1.37
For the safety corrosion allowances need to include with the wall thickness.
= 3
Therefore;
= 1.37 +3
= 4.37
There will be a minimum wall thickness required to ensure that any vessel is sufficiently rigid
to withstand its own weight, and any incidental loads.
As a general guide the wall thickness of any vessel should not be less than the values
specified by standards including a corrosion allowance.

Figure 8.1 Minimum Practical Wall thickness

Diameter of vessel is 4.5m but wall thickness was 4.37mm with including corrosion
allowances. Therefore diameter needs to increase 14mm. (by referring chemical engineering
volume 6 and interpolating)
= 14


9 Selection of ends
9.1 Head selection
Plat heads are use for small vessel for low pressure and covers for man. Flanged only ends
are used for diameter less than 0.6m. This vessel diameter is 4.5m. Therefore flanged only
ends are not suitable for this vessel.
Flanged and dished elliptical ASME code type heads are used extensively in the construction
of tanks for liquefied petroleum gas, air receivers, and other unfired pressure vessels and
P
design
> 1.5 MPa . But fuel is in liquid phase and P
design
< 1.5 MPa. Therefore elliptical heads
are not suitable for this vessel.
Torispherical heads are suitable for inner pressure less than 13 bar. Therefore We have to
go to torispherical head because P internal is slightly grater than atmospheric pressure. It
minimizes the total cost of the plate material and its formation.

Figure 9.1 Torispherical Head
The ratio of the knuckle to crown radii should not be less than 0.06, to avoid buckling; and
the crown radius should not be greater than the diameter of the cylindrical section.
= 4.5 +0.028 = 4.528
= 124320.9/2
= 240 /2
Assume;
R crown = D outer
r
knuckle
= 6% D outer


Therefore;
= 4.528
= 0.272
Calculate the effective external head height he;

Substituting to above equation;
= 0.767

= 1.132

= 2.89
From above three values of he; need to select minimum value for calculate the head
thickness. Therefore
= 0.767



Stress concentration factor for formed heads:
t/D
o

h
E
/ D
o
0.00075 0.0005 0.001 0.002 0.005 0.01 0.02 0.04
0.15 5.34 5.50 5.18 4.55 2.66 2.15 1.95 1.75
0.20 2.55 2.60 2.5 2.3 1.7 1.45 1.37 1.32
0.25 1.48 1.50 1.46 1.38 1.14 1 1 1
0.30 0.98 1.00 0.97 0.92 0.77 0.77 0.77 0.77
0.40 0.59 0.59 0.59 0.59 0.59 0.59 0.59 0.59
0.50 0.55 0.55 0.55 0.55 0.55 0.55 0.55 0.55
Figure 9.2 Stress concentration
0
=
0.767
4.528

0
= 0.17
Calculation of shape factor C; by interpolating from above table
C
P D
t
design
design outer
l theorotica
*
2
*
o
=
Assume =1; therefore substituting to above equation;
=
124320.9
20.8524010
6

=3.0510
4

And also;
=



C value can determine using above intersection point;
4.21
5.81 4.528
=
3.65
9.056 5.04

= 4.07
=3.0510
4
4.07
= 5.62
There should be corrosion allowances for;
Thickness of the head =5.62+3
=8.62mm
Therefore thickness of head is 8.62mm. But there is no low-alloy steel plate for this
thickness in market. Therefore for head fabrication 10mm thickness low-alloy steel sheet is
needed.
9.2 Bottom selection
Furnace oil has high viscosity at 35 (10,000SSU). Therefore it is more suitable for conical
bottom for vessel. Then furnace oil is easy flow.
9.2.1 Bottom wall thickness calculation
Assume this vessel; = 30

t/ D
outer

0.0005 0.00075 0.001 0.002 0.005 0.01 0.02 0.04
h
E/
D
outer
=0.17 4.34 4.22 4.21 3.65 2.276 1.87 1.718 1.578
t(mm) 5.99 5.82 5.81 5.04 3.14 2.58 2.37 2.18
t(mm) 2.264 3.396 4.528 9.056 22.64 45.28 90.56 181.12
Figure 9.3 Calculaded Stress concentration
( )
c
D
design
+
=
. P 6 . 0 cos 2
P
t
design
design
actual
o o


=
0.1243 4.528
2 cos30 240 0.85 0.6 0.124

= 1.59+3
= 4.59
But there is plates available in market 4.59mm thickness. Therefore 6mm thickness plate
needs to fabricate conical bottom.
9.2.2 Checking for reinforcement

Figure 9.4 Reinforcement Checking Table

.
=
0.124
0.85 240

=6 10
4

By extrapolating
=
6 10
4
1 10
3
1 10
3
2 10
3
13 18 +13
= 11
11 < 30
Therefore;
< .
Therefore conical bottom required reinforcement.


9.2.2.1 Calculation of reinforcement

Figure 9.5 Reinforcement for Conical Bottom

=
0.1243
240 0.85

4.528
2
30
8
1
11
30

= 5.71 10
4

=
Pdesign Di
2 P design

=
0.1243 4.5
2 240 0.85 0.1243
= 1.37mm
Lets assume reinforcement thickness is t ;
= 8
2 +(8 2)
5.71 10
4
= 8 0.00459 2
+8 0.00137 2
= 5.99
|
.
|
\
| A
=
o
o
o
1
8
tan
2
i
D p
A


10 Fabrication Procedure
10.1 Shell Fabrication
1. Cutting
The most commonly used process for the cutting and edge preparations of carbon
steel plates is oxyacetylene cutting, and that for stainless steel plates in plasma-arc
cutting. The cut edges will have excessive oxide deposition that is black in color. This
is to remove by grinding, and the acceptable level is at least 1.0mm deep into the
presence of oxides shall be completely removed. Here the maximum and minimum
low alloy steel plates thicknesses are 14mm and 6mm.
Here we can use laser cutting also for this. Compare to Oxy-acetylene flame; quality
of the edge can be mirror smooth, and a precision of around 0.1mm, Cutting speeds
on thin (1.2mm) sheet can be as high as 25m a minute form laser cutting.
2. Crimping
Plate rolling roundness and efficiency is enhanced by the use of the crimping process
prior to rolling. Crimping sets the correct radius on the ends of the plate and
eliminates the waste of excess material. Following tools can use for the fabrication
Hand Crimping Tools, Crimping Pliers, Hydraulic Hand Pumps crimpers, Separable
Hydraulic crimper.

3. Heating

To increase the bending ability of plate, it is important to heating. Inside the furnace
heating is normally doing.

4. Rolling

Using rolling machines, ends of
plates are connecting properly
according to required diameter is
the challenge of rolling. The shell
plate will have more strength in
the direction of rolling compared
to its transverse direction. Hence,
as far as possible, the direction of
the bending of the plate shall be
same as that of the original
direction of rolling, which is the
direction of rolling, which is the
direction of the length of the plate
as shown in below.


5. Prepinging
Once the shell plate is fed into the bending machine, first both the ends are pressed
to the required shape, as below.

Figure 10.1 Prepinging of Plates Edges
6. Welding

Longitudinal seam is fitted for welding. When the thickness of the plate is less than
16mm single-V welded joints are recommended. This wall thickness is 14mm.
Therefore single V-groove welded butt joints are suitable this welding.


Figure 10.2 Single V-joint

Figure 10.3 Single V-groove welded Butt Joins

7. Heat Treating

It is important that your fabrications are properly heat treated. Thermal heat
treatments are specified to steel materials that have been cold-formed, flame cut, or
fabricated, and prior to final machining to reduce residual stresses for dimensional
stability and to improve service life. Temperature is increased up to 1750.

8. Testing
There are several types of testing methods to test the fabrication. When vessel
carried out with lethal substances and thickness is greater than 38.1mm; fully
radiography is more suitable. But here thickness is less than 38.1mm. Therefore fully
Radiography is unwanted (more economical). Spot Radigraghy also use to measure
the efficiency of weld joints.



10.2 Head and cone fabrication

Usually head manufactures are following above three steps. Nowadays automatic head
design machines can use for the head design.
10.3 Assembly of shell and head



10.4 Assembly of shell and cone



11 Technical Drawing
11.1 Torispherical head heights calculation
=

2

R=4.5m
r=0.272m
by substituting;
= 27.89
= = 240.3
= = 522.6
for calculate h flanged;
= + +
and
=
2
3

by solving above eq;
= 1525.8

11.2 Thickness reducing length calculation

According to the ASME code; thickness different into three times those values were
calculated.



11.3 Front Elevation

Figure 11.1 Front Elevation



11.4 Top elevation

4.772
4.5

Top elevation


12 References
- http://www.simetric.co.uk/si_liquids.htm
- http://www.nature.nps.gov/hazardssafety/toxic/fueloil.pdf
- http://www.ceypetco.gov.lk/Ceypetco_Products.htm#CP17
- http://www.rodewelding.com/plate-rolling/
- http://www.rodewelding.com/heat-treating/
- Chemical engineering Volume 6; Richardson& Clusion
- ASME Section VIII

Fuel Oil Storage Vessel Design

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