Chapter wise assurance notes for ICAB KL Paper: Assurance.
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GENERAL DESIGN DETAILS, SAFETY FACTOR AND ALLOWABLE LOADS 1 a b c d e f g h
GENERAL DETAILS project DOC. NA ME ME DOC. NO. UNIT Nam e of the client Na Nam e of m anufacturer MOC SERVICEGEOMETRICAL DETAILS
a b c d e
Shell Volume Desired L/D Ratio Diam eter Total Height of of the CYL. Shell (FRP) Tank Shell FRP W t.
f g h i
Cover Height or Length Cover Volume FRP W eight Total FRP W eight
2
3
= = = = = =
VOLTAS DESIGN CALCULATION FOR 3 KL TANK BPPL-140105 - Unitop Acquacare M/s BHAVI PLAST PVT LTD PPGL-FRP = LIQUOR STORAGE TANK
V L/Di Di Hs Hwt
= = = = =
3.1 1.53 1370 2100
> >
3.1 1.53 1370.0 2100.0
Top/Left 200
= = = =
mm 0 m3 24.28 Kg 167.85 Kg
Bottom/Left 0.0
mm m3 22.47 Kg Kg
STORED LIQUID a
Assumptions Regarding Stirring
b
Density of the liquid
c
Design Fluid height (from base line)
= Not Stirred r
F-Ht d
Fluid W eight
e
To Total Process W t.
4
= 1165 1.165
Kg/m g/cm
2100
mm m ax
= 21 2100
mm m ax
L/B Covr Consider? > no no 'W eight > 0 = 3775
Shell yes 3606.9 Kg
R/T Covr no 0.0
PRESSURE/VACUUM a
Fluid/Gas in equilibrium with stored Liquid
b
Pressure over and above fluid head
Pi
= 150.00 = 0.00 0.0014 1471 715 5
mm W.C 2 N/mm
c
Vacuum
Pv
= 75.00 = 0.00 0.0007 0735 358 8
mm W.C 2 N/mm
5
CYCLIC LOAD: number of Cycles
Ns
= 36 3 650
Nos/10 years
6
TEMPERATURE Ot
= 50
Deg Cel
a Op O perating Temp
= Trace LIQUOR
M^3 Ratio mm mm kg
Total 3606.9
b c
7
Design Temperature HDT of resin used
Dt HDT
WHETHER IN-DOOR OR OUT-DOOR
a
8
a
9
= 70 = 100
Deg Cel Deg Cel
= Outdoor
Wind Pressure***
Pw
Kg/m^2 156.60 2 = 0.001536216 N/mm
Seismic Coefficient***
Ef
= 0.14
No Unit
*** Numerical value to be verified by approver
MATERIALS OF CONSTRUCTION a
Resin Heat Distortion Temperature
HDT e-r
= Isophthalic Resin = 100 Degree Cel. = 2 %
resin density 1.10
Furane? = N
CSM
WRM 0.61
b
Glass Density
= 0.45
c
Fibre Content
d
Other Parameters
= 33 45 Strain at break = 2
e
UV protective top coat
= [YES] = Resin Rich Coat with UV
f
thermoplastic lining
= NO = 12.05
g
10
Thermosetting lining
= NO
SM 0.04
glass density 2.54 g/cc
Kg/m^2
10 % Coefficient of thermal exp / 0C . 0.0000046
3 33 -
mm of Kg Approx
PPGL
mats of CSM/RESIN
FABRICATION a
Method of manufacturing
b Construction
= Hand Lay-Up TOP = CSM SHE LL = CS M/ WRM BOTTOM= CSM
c
Post Curing
= NO
d
Post Curing Temperature
= -
11
DESIGN PROPERTIES
Degree Cel.
CSM
WRM
Units 2
a
Ultimate Tensile unit strength (p 10, BS4994-87)
U
200.00
250.00
N/mm per Kg/m glass mat
b
Ultimate Tensile Strength S = U/Tg
S
89.29
200.00
N/mm
2
c
Unit Modulus (p 10, BS4994-87)
X
14000.00
16000.00
N/mm per Kg/m2 glass mat
d
Unit modulus of 1 mat
X1
6300.00
9760.00
N/mm per Kg/m glass mat
e
Modulus of Elasticity E=X/Tg
E
6250.00
12800.00
N/mm for (1 mat as specified at 9b)
f
Fiber content {wt %} (ref p 20, Figure 5 BS4994-87)
Fc
33.00
45.00
%
g
Resin to glass ratio
r
2.03
1.22
No Unit
h
Layer Thickness Constant
TG
2.24
1.25
mm per Kg/m 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
12
2
mm (for 1 mat as specified at 9b)
CALCULATION OF SAFETY FACTOR a
b
c
d
e
Factor for Method of Manufacturing K1
= Hand Lay-Up = 1.50
K2
= yes = N/A = 1.20
Factor for Strength Loss Strength Loss
Factor for Design Temperature [1.25-.0125(HDT-20-Dt)]
Factor For Cyclic Loading Number Of Cycles in life time [1.1+.9(log N-3)/3]
SINCE TP LINING
HDT DT K3
= 100 = #REF! = 1.00
K4
= 3650 = 1.27
K5
= not post cured = [Degree Cel.] = 1.50
Factor for Curing Temperature Post Curing Post Cure TEMPERATURE
Degree Cel. Degree Cel.
= f
13
Over all Safety Factor
K-cal
= 10.287
10.29
K
CALCULATIONS FOR ALLOWABLE DESIGN LOADS a
LOAD LIMITED UNIT LOAD [=U/K]
b DESIGN STRAIN b1 Max allowable resin-strain [min of 0.1*e-r and 0.2] b2 Resin strain limited unit load b3 Allowable reinforcement strain [(Ul/X)*100] b4 Design Strain (reinforcement limited)
Ul
CSM = 19.44
e-res
= 0.200
Urs e-rein
= 28.00 = 0.139
e-d,rein = 0.139
WRM 24.30
N/mm per Kg/m Reinforcement
% 32.00 0.152
N/mm per Kg/m Reinforcement
%
[minimum of e-l's of csm and wrm] b5 Over all design strain [min of all strains]
e-d
= 0.139
c STRAIN LIMITED LOADS c1 CSM-Strain limited unit load [=X*e-d/100]
Us
= 19.44
d DESIGN UNIT LOADS d1 Design Unit Load [Minimum among Ul and Us]
Ud
=
e
Allowed Unit load per current mat
Ud-1
19.44
= 8.749
%
2
22.22
N/mm per Kg/m Reinforcement
22.22
N/mm per Kg/m Reinforcement
13.554
N/mm (for mats specified at 9b)
2
CONICAL TOP
1 a
GEOMETRICAL DATA
Angle w.r.t horizontal plane Angle of conical surface w r to vessel axis
= =
φ
16.27 74
Degree Degree
200
713.6
This figure is only for design Not to be consulted for fabrication
1370
b c d e f
Diameter Height Area of top cover Volume of the cone Slant Length
2
DESIGN FOR INTERNAL PRESSURE/VACCUM
a b
UPWARD STRESS DOWNWARD STRESS
c d
UNIFORM LOAD CONSIDERED FOR ROOF AS A PRACTICE DESIGN STRESS
e f
MOMENT DUE TO UNIFORMLY DISTRIBUTED LOAD (eq. 36 OF BS4994-87) PANEL DIMENSION
g h i
MASS OF CSM REINFORCEMENT REQUIRED(eq. 34 of BS4994) NO. OF CSM REQUIRED MASS FOR ABOVE NO. OF CSM
3 a b c d
Di Ht Ac Vc Sl
= = = = =
1370 200 1.54 0.10 713.6
mm mm m^2 m^3 mm
Considering radius which contribute to height
Pi = 0.0014715 N/mm^2 Pv = 0.0007358 N/mm^2 IMPORANT : VENTED TO ATMOSPHERE = 200.00 Kg/m^2 Pd = 0.001962 N/mm^2 M= β = rp = = = =
31.30 0.034 685.00
0.001962
N/mm^2
Kg/m^2 for frp Kg/m^2 lining
2.08 5 2.3
Kg/m2
0.0031 6250.00 3.83
from pg 36 of BS4994 N/mm^2
kg
THICKNESS TO LIMIT DEFLECTION
α, CONSTANT
α = Elam = Tm =
LAMINATE MODULUS MIN. THICKNESS PERMITTED (rp(αp/Elam) eq.38 OF BS4994 NO. OF CSM TO MEET THIS
4 a
DESIGN NUMBER OF CSM
5 a b c
THICKNESS
d
LAMINATE THICKNESS INCLUDING SURFACE MAT
6
STIFFENER DESIGN
a b c d e f g h i j k
STIFFENER ARRANGEMENT DIMENSION OF BIGGEST PANEL Equation 47 of BS4994-87 SECTOR AREA LOAD UNIT LOAD PERMITTED DEFLECTION d=wl /384EI MATERIAL USED FOR STIFFENER MODULUS FRP MOMENT OF AREA REQUIREMENT BEAM DIMENSION
l m
MOMENT OF INERTIA IS DESIGN SAFE ?
7 a b c d e
DESIGN OF TOP COVER SHELL JOINT
8 A a b c
WEIGHTS
NO. OF CSM REQUIRED AS CHEMICAL LINING
CONTRIBUTED BY MECHANICAL CSM CONTRIBUTED BY TP LINING TOTAL
=
4
= =
5 0
tm-top = tc-top = t-top =
5.1 3 8.05
mm mm mm
=
9.55
mm
RADIUS OF SHELL TO COVER JOINT ADDITIONAL OVERLAP DISTANCE BEYOND RADIUS(2*ROOT(Dit/2) LENGTH OF STIFFENER EXTENDING TO SHELL THICKNESS AT RADIUS EXTENDING TO SHELL AND TOP COVER NO. OF CSM REQUIRED TO MEET THIS
surface matt doesn’t contribute towards strength, is used only for getting finished surface
= =
4.0 NOS. RADIAL 538 by 685 mm As = 383965.0 W = 7 53 .3 39 29 68 w = 1 .0 55 68 84 35 d = 7 mm EI = 1 04 07 18 80 .4 = unidirectional half round roving = 6250.0 I = 16651.5 mm W = 50 mm D = 50 mm t = 6 mm Is = =
347072 YES
Is>I
= = = = =
30 118 325 10 10.0
mm mm mm mm Nos
= = =
1.5 0.0 0.061434397
m m kg
between 30 to 100mm
SURFACE MAT SURFACE MAT EXTERNAL
SURFACE MAT INTERNAL RESIN FOR SURFACE MAT
RESIN WEIGHT
0.124711827
= = =
Total 10.50 6.59 17.09
CSM 3.47
= = = = =
2854.40 150 0.43 6 1.2
MM MM M2 NOS. KG
RESIN WEIGHT
2.346745052
Area of additional thickness weight of additional thickness
= =
0.51 1.16
M2 KG
RESIN WEIGHT
2.34781532
WEIGHT OF TOP COVER
=
24.28
KG
B a b c
CSM
C a b c d e
STIFFENER
D a b
ADDITIONAL THICKNESS AT JOINT
10
WEIGHT OF CSM(MECHANICAL) LAYER IN KG WEIGHT OF CSM(CHEMICAL) LAYER IN KG TOTAL WEIGHT IN KG
TOTAL LENGTH OF STIFFENER STIFFENER WIDTH AREA NUMBER OF CSM WEIGHT
RESIN 7.04
KG
CYLINDRICAL SHELL Chemical Resistant
Thickness Build up
CSM-WRM balance CSM - WRM=
a b c d e f
1
SHELL Number of segments Segments starts (from base-line) Support Centre Line (from base-line) Segment Length slope additional shell length due to slope
1.00 SM Same Segment
8.00 0.00 1100.00 1100.00 5.00 68.50
Ns-A from To Sl-A
= = = = θ = hθ =
SHELL DESIGN 1
SEGMENT DETAILS Segment, from (mm from base line) a
2
3
11.28
1.00
2.00
Hs
=
1000.00
1100.00
L
= =
1000.00
1100.00
Volume Of Shell m3 MASS
Vs Ms
= =
1.47 1717.57
1.62 1889.32
Max Fluid Head at lawest point. (mm) Consider 150 mm extra fluid pressure for safety Progressive Volume Of Fluid ( M3) Progessive Mass Of Fluid (Kg)
Hs-f
= = = =
1000.00 1150.00 1.47 1717.57
2100.00 2250.00 3.10 3606.89
Segment length (mm)
d
Stiffner Gap in the segment (mm) Maximum allowed
f
11.28
=
c
DESIGN FOR CIRCUMFERENCIAL UNIT LOAD a
Unit load d.t. fluid pressure (N/mm) [sp gravity*height*dia*9.81/2000000]
Qcf
=
9.00
17.61
b
Unit load d. t. internal pressure, [Qcp=Pi*Di/2]
Qcp
=
1.01
1.01
c
Max Circumferential Unit Load [Qcm = Qcf+Qcp]
Qcm
=
10.01
18.62
d
Circumferencial Unit Load due to vaccum, [Qcv=Pv*Di/2]
Qcv
=
0.50
0.50
Q-fi
=
10.01
18.62
2 2 3 1
2 3 3 1
e
Design Circumfer. Unit load [MAXIMUM of Qcv or Qcm] [Eq 7 of BS 4994-87]
f
Mat requirement for this (Nos)
DESIGN OF SHELL OF AXIAL LOAD, 14.3, BS 4994-87
CSM = CSM ROUNDUP= WRM =
1.00 CSM Another Segment
1.00 1100.00 2100.00 1000.00
%
1100.00 to 0.00
Segment, to (mm from base line)
e
NS-B= from= To= Sl-B=
2100.00 to 1100.00
b
=
3.00 CSM
11.28
a b c d e
4
Weight Transmitted from..... Top Cover or Bottom Cover (Kg) total weight load acting compressive(Kg) max compressive unit load (W/3.142Di) axial tensile load due to internal pressure (Pidi/4) axial compressive load due to vacuum (Pvdi/4)
AXIAL UNIT LOAD DUE TO WIND/SEISMIC LOADS a WIND LOAD (N) b (Sf. Pw.Di.Hs)
W1 Qax-c
24.28 24.28 0.01
59.42 0.01
Qax-t
0.50
0.50
Qax-c
0.25
0.25
= =
0.70 1473.23
0.70 1620.55
ON
1 segment 736615.57
2 segment 2592886.81 3248474.67
736615.57 2404.59
5841361.49 5049.64
1202295.69 1202295.69
5302123.98 5841361.49
Sf = Ww
=
c
Bending Moment Bending moment contribute by 1 segment Bending moment contribute by 2 segment Bending moment contribute by 3 segment Bending moment contribute by 4 segment
d e f
SEISMIC LOAD (N) Ef x Wp BENDING MOMENT DUE TO THIS LOAD DESIGN BENDING MOMENT
Mw Md
g
AXIAL UNIT TENSION/COMP DUE TO WIND LOAD
Qm-tc 0.82
N/MM
h i
MAX AXIAL UNIT LOAD DUE TO COMPRESSIVE LOAD DUE TO TENSILE LOAD
j
DESIGN AXIAL UNIT LOAD
k
MAT REQUIREMENT
3.96
1.07 1.32
4.23 4.47
1.32
4.47
CSM
2
2
WRM
0
0
3 1
3 1
l
CURRENT MAT REQUIREMENT
CSM WRM
m
THICKNESS
CSM 3.0 WRM 1 TOTAL 3.79
3.0 0.8 3.79
5
6
7
8
DESIGN AGAINST BUCKLING DUE TO COMPRESSIVE LOAD ASSUMED MAT FOR COMPRESSIVE LOAD a
CSM 3.00 WRM 1.00 THICK 3.76 SHELL 1377.52
3.00 1.00 3.76 1377.52
b
X-lam
CSM 18900.00 WRM 9760.00 TOTAL 28660.00
18900.00 9760.00 28660.00
c d
TOTAL COMPRESSIVE LOAD THICNESS NECESSARY TO ACHIEVE PERMISIBLE LOAD tc=FDo/0.6Xlam
Qax-C 1.07 tmin 0.34
4.23 1.35
e
MATS REQUIREMENT TO MEET THIS
CSM WRM
3 1.00
3 1.00
L P L t-lam X-LAM S tm Elam CSM WRM
2100.00 0.00154 2100.00 4 28660 0.73 4 7622 4 2
2100.00 0.00154 2100.00 4 28660 0.73 4 7622 5 3
CSM WRM tm tc t-tot t
4 2 5.6 3 8.6 10.1
5 3 7.3 3 10.3 11.8
CSM RESIN WRM RESIN
7.75 15.73 5.25 6.41
9.69 19.66 7.88 9.61
= = = = =
35.14 81.97 38.78 0.17 0.35
46.83
121.10
KG
DESIGN FOR EXT ERNAL PRESSURE STIFFENER GAP IN MM a TOTAL EFFECTIVE PRESSURE b EFFECTIVE LENGTH OF SHELL c THICKNESS OF SHELL d YOUNGS MODULUS e FACTOR L/Do f MINIMUM SHELL THK TO AVOID BUCKLING g h
MAT REQUIREMENT TO MEET THIS
i
DESIGN NUMBER OF MATS
j k l m
THICKNESS OF MECHANICAL LAYER THICKNESS OF CHEMICAL LAYER TOTAL THICKNESS INCLUDING SURFACE MAT
FRP WEIGHT CALCULATION W-lam (kg/m2) a
b
WT OF M ECHANICAL LAYER
c d
WT OF CHEMICAL LAYER ( TOTAL) WT OF SURFACE MAT
TOTAL SHELL WT
Wtm TOTAL Wtc Wsm TOTAL
0.17
FLAT BOTTO 1 2
TP LINING AREA OF BOTTOM
3
DESIGN FOR VACUUM ( Not applicable to storage tank vented to atmosphere pressure)
a b c
Upward Stress Downward Stress Moment Due to Uniformaly Distributed Load
Ab
Pv
= =
YES 1.5
M2
Md
= = =
0.000736 NA 10.79
N/mm2 (SINCE CONTINUOUSLY SUPPORTED BOTTOM) Nmm
β1 rp Mcsm
= = =
0.03125 685.00 1.22
mm kG/M2
Ncsm
=
3
α Elam tmin
= = =
0.010660 6250.00 4.08
=
4
SHELL BOTTOM thickness of bottom shell No. of csm required
= =
4 4
BOTTOM FRP THICKNESS contributed by Mech CSM contributed by chemical total
