GENERAL DESIGN DETAILS, SAFETY FACTOR AND ALLOWABLE LOADS

1 GENERAL DETAILS
a project = DNL
b DOC. NAME - = DESIGN CALCULATION FOR (40 KL TANK)
c DOC. NO. - = -
d UNIT - = -
e Name of the client = DNL
f Name of manufacturer = M/s BHAVI PLAST PVT LTD
g MOC - PPHGL-FRP
h SERVICE- = ML STORAGE TANK
2 GEOMETRICAL DETAILS

a Shell Volume Desired V = 40.2 40.2 M^3

b L/D Ratio L/Di = 1.56 1.56 Ratio
c Diameter Di = > 3200 3200.0 mm
d Total Height of the CYL. Shell (FRP) Hs = > 5000 5000.0 mm
e Tank Shell FRP Wt. Hwt = kg

Top/Left Bottom/Left
f Cover Height or Length = 400 mm 0.0 mm
g Cover Volume = 0 m3 m3
h FRP Weight = 179.64 Kg 162.44 Kg
i Total FRP Weight = 1134.05 Kg Kg

3 STORED LIQUID

a Assumptions Regarding Stirring = Not Stirred

3
b Density of the liquid r = 1100 Kg/m
1.1 g/cm3

c Design Fluid height (from base line) 5000 mm max

F-Ht = 5000 mm max

d Fluid Weight L/B Covr Shell R/T Covr Total

Consider? > no yes no
'Weight > 0 44239.4 0.0 44239.4
e Total Process Wt. = 45373 Kg

4 PRESSURE/VACUUM

a Fluid/Gas in equilibrium with stored Liquid = Trace ML

b Pressure over and above fluid head Pi = 150.00 mm W.C

= 0.0014715 N/mm2

c Vacuum Pv = 150.00 mm W.C

= 0.0014715 N/mm2

5 CYCLIC LOAD: number of Cycles Ns = 3650 Nos/10 years

6 TEMPERATURE

a Operating Temp Ot = 90 Deg Cel

 b Design Temperature Dt = 100 Deg Cel 100
c HDT of resin used HDT = 100 Deg Cel

7 WHETHER IN-DOOR OR OUT-DOOR = Outdoor

a Wind Pressure*** Pw 156.60 Kg/m^2

2
= 0.001536216 N/mm

8 Seismic Coefficient*** Ef = 0.14 No Unit

a *** Numerical value to be verified by approver

9 MATERIALS OF CONSTRUCTION

a Resin = Isophthalic Resin

Heat Distortion Temperature HDT = 100 Degree Cel. resin density
e-r = 2 % 1.10
Furane? = N

CSM WRM SM glass density

b Glass Density = 0.45 0.61 0.04 Kg/m^2 2.54 g/cc
c Fibre Content = 33 45 10 %
Strain at break Coefficient of thermal exp
0
d Other Parameters = 2 0.0000046 / C

e UV protective top coat = [YES]

= Resin Rich Coat with UV

f thermoplastic lining = YES 3 mm of PPHGL

= 66.61 178 Kg Approx

g Thermosetting lining = NO - mats of CSM/RESIN

10 FABRICATION

a Method of manufacturing = Hand Lay-Up

b Construction TOP = CSM

SHELL = CSM/WRM
BOTTOM = CSM

c Post Curing = NO

d Post Curing Temperature = - Degree Cel.

11 DESIGN PROPERTIES CSM WRM Units

a Ultimate Tensile unit strength U 200.00 250.00 N/mm per Kg/m2 glass mat
(p 10, BS4994-87)

b Ultimate Tensile Strength S 89.29 200.00 N/mm2

S = U/Tg
 c Unit Modulus X 14000.00 16000.00 N/mm per Kg/m2 glass mat
(p 10, BS4994-87)

d Unit modulus of 1 mat X1 6300.00 9760.00 N/mm per Kg/m2 glass mat

e Modulus of Elasticity E 6250.00 12800.00 N/mm for (1 mat as specified at 9b)

E=X/Tg

f Fiber content {wt %} Fc 33.00 45.00 %

(ref p 20, Figure 5 BS4994-87)

g Resin to glass ratio r 2.03 1.22 No Unit

h Layer Thickness Constant TG 2.24 1.25 mm per Kg/m2 glass mat

i Inter Laminar Lap Shear Strength Tou 7.00 6.00 N/mm

j In Plane Poisson's Ratio IPPR 0.30 0.30

k Single mat thickness T-1 1.01 0.76 mm (for 1 mat as specified at 9b)

12 CALCULATION OF SAFETY FACTOR

a Factor for Method of Manufacturing = Hand Lay-Up

K1 = 1.50

b Factor for Strength Loss = yes

Strength Loss = N/A
K2 = 1.20 SINCE TP LINING

c Factor for Design Temperature

[1.25-.0125(HDT-20-Dt)] HDT = 100 Degree Cel.
DT = 100 Degree Cel.
K3 = 1.10

d Factor For Cyclic Loading

Number Of Cycles in life time = 3650
[1.1+.9(log N-3)/3] K4 = 1.27

e Factor for Curing Temperature

Post Curing = not post cured
Post Cure TEMPERATURE = - [Degree Cel.]
K5 = 1.50
= 11.32

f Over all Safety Factor K-cal = 11.3157 K

13 CALCULATIONS FOR ALLOWABLE DESIGN LOADS

CSM WRM
a LOAD LIMITED UNIT LOAD Ul = 17.67 22.09 N/mm per Kg/m2 Reinforcement
[=U/K]

b DESIGN STRAIN
b1 Max allowable resin-strain e-res = 0.200 %
[min of 0.1*e-r and 0.2]
b2 Resin strain limited unit load Urs = 28.00 32.00 N/mm per Kg/m2 Reinforcement
b3 Allowable reinforcement strain e-rein = 0.126 0.138
[(Ul/X)*100]
b4 Design Strain (reinforcement limited) e-d,rein = 0.126 %
 [minimum of e-l's of csm and wrm]
b5 Over all design strain e-d = 0.126 %
[min of all strains]

c STRAIN LIMITED LOADS

c1 CSM-Strain limited unit load Us = 17.67 20.20 N/mm per Kg/m2 Reinforcement
[=X*e-d/100]

d DESIGN UNIT LOADS

d1 Design Unit Load Ud = 17.67 20.20 N/mm per Kg/m2 Reinforcement
[Minimum among Ul and Us]

e Allowed Unit load per current mat Ud-1 = 7.954 12.322 N/mm (for mats specified at 9b)
 CONICAL TOP

1 GEOMETRICAL DATA
a Angle w.r.t horizontal plane = 11.30 Degree
Angle of conical surface w r to vessel axis φ = 79 Degree

1649.2 400 This figure is only for design

Not to be consulted for fabrication

3200

b Diameter Di = 3200 mm
c Height Ht = 400 mm Considering radius which contribute to height
d Area of top cover Ac = 8.29 m^2
e Volume of the cone Vc = 1.07 m^3
f Slant Length Sl = 1649.2 mm

2 DESIGN FOR INTERNAL PRESSURE/VACCUM

a UPWARD STRESS Pi = 0.0014715 N/mm^2

b DOWNWARD STRESS Pv = 0.0014715 N/mm^2
IMPORANT : VENTED TO ATMOSPHERE
c UNIFORM LOAD CONSIDERED FOR ROOF AS A PRACTICE = 150.00 Kg/m^2 0.0014715 N/mm^2
d DESIGN STRESS Pd = 0.001472 N/mm^2

e MOMENT DUE TO UNIFORMLY DISTRIBUTED LOAD M = 128.08 Kg/m^2 for frp

(eq. 36 OF BS4994-87) β = 0.034
f PANEL DIMENSION rp = 1600.00 Kg/m^2 lining

g MASS OF CSM REINFORCEMENT REQUIRED(eq. 34 of BS4994) = 4.41 Kg/m2

h NO. OF CSM REQUIRED = 10
i MASS FOR ABOVE NO. OF CSM = 4.6 kg

3 THICKNESS TO LIMIT DEFLECTION

a α, CONSTANT α = 0.0031 from pg 36 of BS4994
b LAMINATE MODULUS Elam = 6250.00 N/mm^2
c MIN. THICKNESS PERMITTED Tm = 8.32
(rp(αp/Elam) eq.38 OF BS4994
d NO. OF CSM TO MEET THIS = 9

4 DESIGN NUMBER OF CSM = 10

a NO. OF CSM REQUIRED AS CHEMICAL LINING = 0

5 THICKNESS
a CONTRIBUTED BY MECHANICAL CSM tm-top = 10.3 mm
b CONTRIBUTED BY TP LINING tc-top = 3 mm
c TOTAL t-top = 13.27 mm
surface matt doesn’t contribute towards strength, is
d LAMINATE THICKNESS INCLUDING SURFACE MAT = 14.77 mm used only for getting finished surface

6 STIFFENER DESIGN

a STIFFENER ARRANGEMENT = 6.0 NOS. RADIAL 4 OF THEM AS BRANCHING

b DIMENSION OF BIGGEST PANEL = 1256 by
Equation 47 of BS4994-87 1600
c SECTOR AREA As = 1381845.1 mm2
d LOAD W = 2033.385075
e UNIT LOAD w = 1.2329208
f PERMITTED DEFLECTION d = 16
g d=wl4/384EI EI = 1484642130.0 mm4
h MATERIAL USED FOR STIFFENER = unidirectional half round roving
i MODULUS FRP = 6250.0
j MOMENT OF AREA REQUIREMENT I = 237542.7 mm4
k BEAM DIMENSION W = 50 mm
D = 50 mm
t = 5 mm

l MOMENT OF INERTIA Is = 307500

m IS DESIGN SAFE ? = YES Is>I

7 DESIGN OF TOP COVER SHELL JOINT

a RADIUS OF SHELL TO COVER JOINT = 100 mm between 30 to 100mm
b ADDITIONAL OVERLAP DISTANCE BEYOND RADIUS(2*ROOT(Dit/2) = 256 mm
c LENGTH OF STIFFENER EXTENDING TO SHELL = 325 mm
d THICKNESS AT RADIUS EXTENDING TO SHELL AND TOP COVER = 15 mm
e NO. OF CSM REQUIRED TO MEET THIS = 15.2 Nos

8 WEIGHTS
A SURFACE MAT
a SURFACE MAT EXTERNAL = 8.3 m2
b SURFACE MAT INTERNAL = 0.0 m2
c RESIN FOR SURFACE MAT = 0.331642826 kg RESIN WEIGHT = 0.673234936
B CSM Total CSM RESIN
a WEIGHT OF CSM(MECHANICAL) LAYER IN KG = 115.20 38.02 77.18
b WEIGHT OF CSM(CHEMICAL) LAYER IN KG = 35.57
c TOTAL WEIGHT IN KG = 150.77 KG

C STIFFENER
a TOTAL LENGTH OF STIFFENER = 9895.45 MM
b STIFFENER WIDTH = 150 MM
c AREA = 1.48 M2
d NUMBER OF CSM = 5 NOS.
e WEIGHT = 3.3 KG RESIN WEIGHT = 6.77962258

D ADDITIONAL THICKNESS AT JOINT

a Area of additional thickness = 2.60 M2
b weight of additional thickness = 5.86 KG RESIN WEIGHT = 11.88716168

10 WEIGHT OF TOP COVER = 179.64 KG

 CYLINDRICAL SHELL
Chemical Resistant Thickness Build up
CSM-WRM balance
CSM - WRM= 1 1.00 3.00 1.00
SM CSM CSM
SHELL Same Segment Another Segment
a Number of segments Ns-A = 8.00 NS-B= 1.00
b Segments starts (from base-line) from = 0.00 from= 4000.00
c Support Centre Line (from base-line) To = 4000.00 To= 5000.00
d Segment Length Sl-A = 1000.00 Sl-B= 1000.00
11.28 11.28 11.28
SHELL DESIGN 1.00 2.00 3.00 4.00 5.00
1 SEGMENT DETAILS
a Segment, from (mm from base line) = 5000.00 4000.00 3000.00 2000.00 1000.00
to to to to to
b Segment, to (mm from base line) = 4000.00 3000.00 2000.00 1000.00 0.00

c Segment length (mm) Hs = 1000.00 1000.00 1000.00 1000.00 1000.00

d Stiffner Gap in the segment (mm) L = 1000.00 1000.00 1000.00 1000.00 1000.00
Maximum allowed =

Volume Of Shell m3 Vs = 8.04 8.04 8.04 8.04 8.04

MASS Ms = 8847.87 8847.87 8847.87 8847.87 8847.87

e Max Fluid Head at lawest point. (mm) Hs-f = 1000.00 2000.00 3000.00 4000.00 5000.00
Consider 150 mm extra fluid pressure for safety = 1150.00 2150.00 3150.00 4150.00 5150.00
f Progressive Volume Of Fluid ( M3) = 8.04 16.09 24.13 32.17 40.22
Progessive Mass Of Fluid (Kg) = 8847.87 17695.74 26543.62 35391.49 44239.36

2 DESIGN FOR CIRCUMFERENCIAL UNIT LOAD

a Unit load d.t. fluid pressure (N/mm) Qcf = 19.86 37.12 54.39 71.65 88.92
[sp gravity*height*dia*9.81/2000000]

b Unit load d. t. internal pressure, Qcp = 2.35 2.35 2.35 2.35 2.35
[Qcp=Pi*Di/2]

c Max Circumferential Unit Load Qcm = 22.21 39.48 56.74 74.01 91.27
[Qcm = Qcf+Qcp]

d Circumferencial Unit Load

due to vaccum, Qcv = 2.35 2.35 2.35 2.35 2.35
[Qcv=Pv*Di/2]

e Design Circumfer. Unit load Q-fi = 19.86 37.12 54.39 71.65 88.92
[MAXIMUM of Qcv or Qcm]
[Eq 7 of BS 4994-87]
2 3 4 5 6
f Mat requirement for this (Nos) CSM = 2 4 4 5 6
CSM ROUNDUP= 4 4 5 5 6
WRM = 2 2 3 3 4
3 DESIGN OF SHELL OF AXIAL LOAD, 14.3, BS 4994-87

a Weight Transmitted from.....

Top Cover or Bottom Cover (Kg) W1 = 179.64
b total weight load acting compressive(Kg) 179.64 289.03 398.42 507.82 617.21
c max compressive unit load Qax-c 0.02 0.03 0.04 0.05 0.06
(W/3.142Di)
d axial tensile load due to internal pressure Qax-t 1.18 1.18 1.18 1.18 1.18
(Pidi/4)
e axial compressive load due to vacuum Qax-c 1.18 1.18 1.18 1.18 1.18
(Pvdi/4)

4 AXIAL UNIT LOAD DUE TO WIND/SEISMIC LOADS

a WIND LOAD (N) Sf = = 0.70 0.70 0.70 0.70 0.70
 b (Sf. Pw.Di.Hs) Ww = 3441.12 3441.12 3441.12 3441.12 3441.12

c Bending Moment ON 1 segment 2 segment 3 segment 4 segment 5 segment

Bending moment contribute by 1 segment 1720561.92 5161685.76 8602810 12043933 15485057
Bending moment contribute by 2 segment 6882247.68 13764495 20646743 27528991
Bending moment contribute by 3 segment 15485057 25808429 36131800
Bending moment contribute by 4 segment 0 27528991 41293486
Bending moment contribute by 5 segment 43014048

d SEISMIC LOAD (N) 1720561.92 12043933.44 37852362.24 86028096.00 163453382.40

Ef x Wp 12387.02 24774.04 37161 49548 61935
e BENDING MOMENT DUE TO THIS LOAD Mw 6193510.40 24774041.60 55741594 99096166 154837760
f DESIGN BENDING MOMENT Md 6193510.40 24774041.60 55741593.60 99096166.40 163453382.40

g AXIAL UNIT TENSION/COMP DUE TO WIND LOAD Qm-tc 0.77 3.08 6.93 12.32 20.32

MAX AXIAL UNIT LOAD N/MM

h DUE TO COMPRESSIVE LOAD 1.97 4.29 8.15 13.55 21.56
i DUE TO TENSILE LOAD 1.95 4.26 8.11 13.50 21.50

j DESIGN AXIAL UNIT LOAD 1.97 4.29 8.15 13.55 21.56

k MAT REQUIREMENT CSM 2 2 2 2 3

WRM 0 0 0 0 1

l CURRENT MAT REQUIREMENT CSM 4 4 5 5 6

WRM 2 2 3 3 4

m THICKNESS CSM 4.0 4.0 5.0 5.0 6.0

WRM 2 1.5 2.3 2.3 3.1
TOTAL 5.56 5.56 7.33 7.33 9.10

5 DESIGN AGAINST BUCKLING DUE TO COMPRESSIVE LOAD

a ASSUMED MAT FOR COMPRESSIVE LOAD CSM 4.00 4.00 5.00 5.00 6.00
WRM 2.00 2.00 3.00 3.00 4.00
THICKNESS
6.00 6.00 8.00 8.00 10.00
SHELL 3212.00
OD 3212.00 3216.00 3216.00 3220.00

b X-lam CSM 25200.00 25200.00 31500.00 31500.00 37800.00

WRM 19520.00 19520.00 29280.00 29280.00 39040.00
TOTAL 44720.00 44720.00 60780.00 60780.00 76840.00

c TOTAL COMPRESSIVE LOAD Qax-C 1.97 4.29 8.15 13.55 21.56

d THICNESS NECESSARY TO ACHIEVE PERMISIBLE LOAD tmin 0.94 2.05 2.87 4.78 6.02
tc=FDo/0.6Xlam

e MATS REQUIREMENT TO MEET THIS CSM 5 4 4 4 5

WRM 3.00 2.00 2.00 2.00 3.00

6 DESIGN FOR EXTERNAL PRESSURE

a STIFFENER GAP IN MM L 2000.00 2000.00 3500.00 3500.00 3500.00
b TOTAL EFFECTIVE PRESSURE P 0.00154 0.00154 0.00154 0.00154 0.00154
 c EFFECTIVE LENGTH OF SHELL L 2000.00 2000.00 3500.00 3500.00 3500.00
d THICKNESS OF SHELL t-lam 6 6 8 8 10
e YOUNGS MODULUS X-LAM 44720 44720 60780 60780 76840
f FACTOR L/Do S 0.31 0.31 0.31 0.31 0.31
g MINIMUM SHELL THK TO AVOID BUCKLING tm 7 7 8 8 8
Elam 7453 7453 7598 7598 7684
h MAT REQUIREMENT TO MEET THIS CSM 5 5 5 5 5
WRM 3 3 3 3 3

i DESIGN NUMBER OF MATS CSM 5 5 5 5 6

WRM 3 3 3 3 4
j THICKNESS OF MECHANICAL LAYER tm 7.3 7.3 7.3 7.3 9.1
k THICKNESS OF CHEMICAL LAYER tc 3 3 3 3 3
l TOTAL t-tot 10.3 10.3 10.3 10.3 12.1
m THICKNESS INCLUDING SURFACE MAT t 11.8 11.8 11.8 11.8 13.6

7 FRP WEIGHT CALCULATION

a W-lam (kg/m2) CSM 22.62 22.62 22.62 22.62 27.15
RESIN 45.92 45.92 45.92 45.92 55.11
WRM 18.40 18.40 18.40 18.40 24.53
RESIN 22.45 22.45 22.45 22.45 29.93

b WT OF MECHANICAL LAYER Wtm = 109.39 109.39 109.39 109.39 136.72

TOTAL = 574.29
c WT OF CHEMICAL LAYER ( TOTAL) Wtc = 215.67
d WT OF SURFACE MAT Wsm = 0.40 0.40 0.40 0.40 0.40
TOTAL = 2.02

8 TOTAL SHELL WT 791.98 KG

 FLAT BOTTOM
1 TP LINING = YES
2 AREA OF BOTTOM Ab = 8.0 M2

3 DESIGN FOR VACUUM ( Not applicable to storage tank vented to atmosphere pressure)

a Upward Stress Pv = 0.001472 N/mm2

b Downward Stress = NA (SINCE CONTINUOUSLY SUPPORTED BOTTOM)
c Moment Due to Uniformaly Distributed Load Md = 117.72 Nmm
β1*p*D2 Equation 30 of BS 4994
β1 from P32 for fixed edge condition (Type1) β1 = 0.03125
d Panel Dimension rp = 1600.00 mm
e Mass of CSM Required Mcsm = 4.22 kG/M2
Eq 34 of BS4994-87
f No. of csm requiredto meet this Ncsm = 9

4 THICKNESS TO LIMIT DEFLECTION

α a constant α = 0.010660
laminate modulus Elam = 6250.00 N/mm2
Min. thickness permitted tmin = 11.32
αp.rp4/Elam)^0.25
No. of csm to meet this = 11

5 SHELL BOTTOM
thickness of bottom shell = 11
No. of csm required = 11

6 BOTTOM FRP THICKNESS

contributed by Mech CSM = 11 mm
contributed by chemical = 3.00 mm
total = 14 mm

7 SHELL BOTTOM JOINT

a overlap radius either side = 268 mm

Radius of joint = 50 mm
Fig 16, pg 50, BS 4994
Corner Thickness = 28 mm

8 MATERIAL REQUIREMENT
SM
Surface Mat External = 8.0 m2
Surface Mat Internal = 0 m2
weight of sm = 0.3 kg

CSM csm Resin

Weight of CSM (Mech) Wtm (Kg) = 123.22 40.67 82.55
Weight of CSM (Chem) Wtc (Kg) = 34.51
total weight of bottom panel Wt = 158.05 Kg