1 GENERAL DETAILS

a project = VOLTAS

b DOC. NAME - = DESIGN CALCULATION FOR 3 KL TANK

c DOC. NO. - = BPPL-140105

d UNIT - = -

e Name of the client = Unitop Acquacare

f Name of manufacturer = M/s BHAVI PLAST PVT LTD

g MOC - PPGL-FRP

h SERVICE- = LIQUOR STORAGE TANK

2 GEOMETRICAL DETAILS

a Shell Volume Desired V = 3.1 3.1 M^3

b L/D Ratio L/Di = 1.53 1.53 Ratio

c Diameter Di = >>>> 1370 1370.0 mm

d Total Height of the CYL. Shell (FRP) Hs = >>>> 2100 2100.0 mm

e Tank Shell FRP Wt. Hwt = kg

Top/Left Bottom/Left

f Cover Height or Length = 200 mm 0.0 mm

g Cover Volume = 0 m3 m3

h FRP Weight = 24.28 Kg 22.47 Kg

i Total FRP Weight = 167.85 Kg Kg

3 STORED LIQUID

GENERAL DESIGN DETAILS, SAFETY FACTOR AND ALLOWABLE LOADS

a Assumptions Regarding Stirring = Not Stirred

b Density of the liquid r = 1165 Kg/m3

1.165 g/cm3

c Design Fluid height (from base line) 2100 mm max

F-Ht = 2100 mm max

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

Consider? > no yes no

'Weight > 0 3606.9 0.0 3606.9

e Total Process Wt. = 3775 Kg

4 PRESSURE/VACUUM

a Fluid/Gas in equilibrium with stored Liquid =

b Pressure over and above fluid head Pi = 150.00

= 0.0014715 N/mm2

c Vacuum Pv = 75.00

= 0.0007358 N/mm2

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

6 TEMPERATURE

a Operating Temp Ot = 50 Deg Cel

Trace LIQUOR

mm W.C

mm W.C

b Design Temperature Dt = 70 Deg Cel

c HDT of resin used HDT = 100 Deg Cel

7 WHETHER IN-DOOR OR OUT-DOOR = Outdoor

a Wind Pressure*** Pw 156.60

= 0.001536216 N/mm2

8 Seismic Coefficient*** Ef = 0.14 No Unit

a *** Numerical value to be verified by approver

9 MATERIALS OF CONSTRUCTION

a 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

d Other Parameters = 2 0.0000046 / 0C

Kg/m^2

Isophthalic Resin

d Other Parameters = 2 0.0000046 / C

e UV protective top coat = [YES]

=

f thermoplastic lining = NO 3 mm of PPGL

= 12.05 33 Kg Approx

g Thermosetting lining = NO - mats of CSM/RESIN

10 FABRICATION

a Method of manufacturing =

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

Hand Lay-Up

Resin Rich Coat with UV

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 LININGK2 = 1.20 SINCE TP LINING

c Factor for Design Temperature

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

DT = #REF! Degree Cel.

K3 = 1.00

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

= 10.29

f Over all Safety Factor K-cal = 10.287 K

13 CALCULATIONS FOR ALLOWABLE DESIGN LOADS

CSM WRM

a LOAD LIMITED UNIT LOAD Ul = 19.44 24.30 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 = 0.139 0.152

[(Ul/X)*100]

b4 Design Strain (reinforcement limited) e-d,rein = 0.139 %

[minimum of e-l's of csm and wrm]

b5 Over all design strain e-d = 0.139 %

[min of all strains]

c STRAIN LIMITED LOADS

c1 CSM-Strain limited unit load Us = 19.44 22.22 N/mm per Kg/m2 Reinforcement

[=X*e-d/100]

d DESIGN UNIT LOADS

d1 Design Unit Load Ud = 19.44 22.22 N/mm per Kg/m2 Reinforcement

[Minimum among Ul and Us]

e Allowed Unit load per current mat Ud-1 = 8.749 13.554 N/mm (for mats specified at 9b)

1 GEOMETRICAL DATA

a Angle w.r.t horizontal plane = 16.27 Degree

Angle of conical surface w r to vessel axis φφφφ = 74 Degree

This figure is only for design

Not to be consulted for fabrication

b Diameter Di = 1370 mm

c Height Ht = 200 mm Considering radius which contribute to height

d Area of top cover Ac = 1.54 m^2

e Volume of the cone Vc = 0.10 m^3

f Slant Length Sl = 713.6 mm

2 DESIGN FOR INTERNAL PRESSURE/VACCUM

a UPWARD STRESS Pi = 0.0014715 N/mm^2

b DOWNWARD STRESS Pv = 0.0007358 N/mm^2

IMPORANT : VENTED TO ATMOSPHERE

c UNIFORM LOAD CONSIDERED FOR ROOF AS A PRACTICE = 200.00 Kg/m^2 0.001962 N/mm^2

d DESIGN STRESS Pd = 0.001962 N/mm^2

e MOMENT DUE TO UNIFORMLY DISTRIBUTED LOAD M = 31.30 Kg/m^2 for frp

(eq. 36 OF BS4994-87) β = 0.034

f PANEL DIMENSION rp = 685.00 Kg/m^2 lining

g MASS OF CSM REINFORCEMENT REQUIRED(eq. 34 of BS4994) = 2.08 Kg/m2

h NO. OF CSM REQUIRED = 5

CONICAL TOP

713.6

1370

200

h NO. OF CSM REQUIRED = 5

i MASS FOR ABOVE NO. OF CSM = 2.3 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 = 3.83

(rp(αp/Elam) eq.38 OF BS4994

d NO. OF CSM TO MEET THIS = 4

4 DESIGN NUMBER OF CSM = 5

a NO. OF CSM REQUIRED AS CHEMICAL LINING = 0

5 THICKNESS

a CONTRIBUTED BY MECHANICAL CSM tm-top = 5.1 mm

b CONTRIBUTED BY TP LINING tc-top = 3 mm

c TOTAL t-top = 8.05 mm

d LAMINATE THICKNESS INCLUDING SURFACE MAT = 9.55 mm

6 STIFFENER DESIGN

a STIFFENER ARRANGEMENT = 4.0

b DIMENSION OF BIGGEST PANEL = 538 by

Equation 47 of BS4994-87 685

c SECTOR AREA As = 383965.0 mm2

d LOAD W = 753.3392968

e UNIT LOAD w = 1.055688435

f PERMITTED DEFLECTION d = 7

g d=wl4/384EI EI = 104071880.4 mm

4

h MATERIAL USED FOR STIFFENER = unidirectional half round roving

i MODULUS FRP = 6250.0

j MOMENT OF AREA REQUIREMENT I = 16651.5 mm4

k BEAM DIMENSION W = 50 mm

D = 50 mm

t = 6 mm

l MOMENT OF INERTIA Is = 347072

m IS DESIGN SAFE ? = YES Is>I

7 DESIGN OF TOP COVER SHELL JOINT

a RADIUS OF SHELL TO COVER JOINT = 30 mm between 30 to 100mm

b ADDITIONAL OVERLAP DISTANCE BEYOND RADIUS(2*ROOT(Dit/2) = 118 mm

c LENGTH OF STIFFENER EXTENDING TO SHELL = 325 mm

d THICKNESS AT RADIUS EXTENDING TO SHELL AND TOP COVER = 10 mm

e NO. OF CSM REQUIRED TO MEET THIS = 10.0 Nos

8 WEIGHTS

A SURFACE MATa SURFACE MAT EXTERNAL = 1.5 m

2

b SURFACE MAT INTERNAL = 0.0 m2

c RESIN FOR SURFACE MAT = 0.061434397 kg RESIN WEIGHT = 0.124711827

surface matt doesn’t contribute towards strength, is

used only for getting finished surface

NOS. RADIAL

B CSM Total CSM RESIN

a WEIGHT OF CSM(MECHANICAL) LAYER IN KG = 10.50 3.47 7.04

b WEIGHT OF CSM(CHEMICAL) LAYER IN KG = 6.59

c TOTAL WEIGHT IN KG = 17.09 KG

C STIFFENER

a TOTAL LENGTH OF STIFFENER = 2854.40 MM

b STIFFENER WIDTH = 150 MM

c AREA = 0.43 M2

d NUMBER OF CSM = 6 NOS.

e WEIGHT = 1.2 KG RESIN WEIGHT = 2.346745052

D ADDITIONAL THICKNESS AT JOINT

a Area of additional thickness = 0.51 M2

b weight of additional thickness = 1.16 KG RESIN WEIGHT = 2.34781532

10 WEIGHT OF TOP COVER = 24.28 KG

Thickness Build up

CSM-WRM balanceCSM - 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= 1.00b Segments starts (from base-line) from = 0.00 from= 1100.00c Support Centre Line (from base-line) To = 1100.00 To= 2100.00d Segment Length Sl-A = 1100.00 Sl-B= 1000.00e slope θ = 5.00 %

f additional shell length due to slope hθ = 68.50

11.28 11.28 11.28

SHELL DESIGN 1.00 2.00

1 SEGMENT DETAILS

a Segment, from (mm from base line) = 2100.00 1100.00

to to

b Segment, to (mm from base line) = 1100.00 0.00

c Segment length (mm) Hs = 1000.00 1100.00

d Stiffner Gap in the segment (mm) L = 1000.00 1100.00

Maximum allowed =

Volume Of Shell m3 Vs = 1.47 1.62

MASS Ms = 1717.57 1889.32

e Max Fluid Head at lawest point. (mm) Hs-f = 1000.00 2100.00

Consider 150 mm extra fluid pressure for safety = 1150.00 2250.00

f Progressive Volume Of Fluid ( M3) = 1.47 3.10

Progessive Mass Of Fluid (Kg) = 1717.57 3606.89

2 DESIGN FOR CIRCUMFERENCIAL UNIT LOAD

a Unit load d.t. fluid pressure (N/mm) Qcf = 9.00 17.61

[sp gravity*height*dia*9.81/2000000]

b Unit load d. t. internal pressure, Qcp = 1.01 1.01

[Qcp=Pi*Di/2]

c Max Circumferential Unit Load Qcm = 10.01 18.62

[Qcm = Qcf+Qcp]

d Circumferencial Unit Load

due to vaccum, Qcv = 0.50 0.50

[Qcv=Pv*Di/2]

e Design Circumfer. Unit load Q-fi = 10.01 18.62

[MAXIMUM of Qcv or Qcm]

[Eq 7 of BS 4994-87]

2 2

f Mat requirement for this (Nos) CSM = 2 3

CSM ROUNDUP= 3 3

WRM = 1 1

3 DESIGN OF SHELL OF AXIAL LOAD, 14.3, BS 4994-87

Chemical Resistant

CYLINDRICAL SHELL

a Weight Transmitted from.....

Top Cover or Bottom Cover (Kg) W1 = 24.28

b total weight load acting compressive(Kg) 24.28 59.42

c max compressive unit load Qax-c 0.01 0.01

(W/3.142Di)

d axial tensile load due to internal pressure Qax-t 0.50 0.50

(Pidi/4)

e axial compressive load due to vacuum Qax-c 0.25 0.25

(Pvdi/4)

4 AXIAL UNIT LOAD DUE TO WIND/SEISMIC LOADS

a WIND LOAD (N) Sf = = 0.70 0.70

b (Sf. Pw.Di.Hs) Ww = 1473.23 1620.55

c Bending Moment ON 1 segment 2 segment

Bending moment contribute by 1 segment 736615.57 2592886.81

Bending moment contribute by 2 segment 3248474.67

Bending moment contribute by 3 segment

Bending moment contribute by 4 segment

736615.57 5841361.49

d SEISMIC LOAD (N) 2404.59 5049.64

Ef x Wp

e BENDING MOMENT DUE TO THIS LOAD Mw 1202295.69 5302123.98

f DESIGN BENDING MOMENT Md 1202295.69 5841361.49

g AXIAL UNIT TENSION/COMP DUE TO WIND LOAD Qm-tc 0.82 3.96

MAX AXIAL UNIT LOAD N/MM

h DUE TO COMPRESSIVE LOAD 1.07 4.23

i DUE TO TENSILE LOAD 1.32 4.47

j DESIGN AXIAL UNIT LOAD 1.32 4.47

k MAT REQUIREMENT CSM 2 2

WRM 0 0

l CURRENT MAT REQUIREMENT CSM 3 3

WRM 1 1

m THICKNESS CSM 3.0 3.0

WRM 1 0.8

TOTAL 3.79 3.79

5 DESIGN AGAINST BUCKLING DUE TO COMPRESSIVE LOAD

a ASSUMED MAT FOR COMPRESSIVE LOAD CSM 3.00 3.00

WRM 1.00 1.00

THICKNESS3.76 3.76

SHELL OD1377.52 1377.52

b X-lam CSM 18900.00 18900.00

WRM 9760.00 9760.00

TOTAL 28660.00 28660.00

c TOTAL COMPRESSIVE LOAD Qax-C 1.07 4.23

d THICNESS NECESSARY TO ACHIEVE PERMISIBLE LOAD tmin 0.34 1.35

tc=FDo/0.6Xlam

e MATS REQUIREMENT TO MEET THIS CSM 3 3

WRM 1.00 1.00

6 DESIGN FOR EXTERNAL PRESSURE

a STIFFENER GAP IN MM L 2100.00 2100.00

b TOTAL EFFECTIVE PRESSURE P 0.00154 0.00154

c EFFECTIVE LENGTH OF SHELL L 2100.00 2100.00

d THICKNESS OF SHELL t-lam 4 4

e YOUNGS MODULUS X-LAM 28660 28660

f FACTOR L/Do S 0.73 0.73

g MINIMUM SHELL THK TO AVOID BUCKLING tm 4 4

Elam 7622 7622

h MAT REQUIREMENT TO MEET THIS CSM 4 5

WRM 2 3

i DESIGN NUMBER OF MATS CSM 4 5

WRM 2 3

j THICKNESS OF MECHANICAL LAYER tm 5.6 7.3

k THICKNESS OF CHEMICAL LAYER tc 3 3

l TOTAL t-tot 8.6 10.3

m THICKNESS INCLUDING SURFACE MAT t 10.1 11.8

7 FRP WEIGHT CALCULATION

a W-lam (kg/m2) CSM 7.75 9.69

RESIN 15.73 19.66

WRM 5.25 7.88

RESIN 6.41 9.61

b WT OF MECHANICAL LAYER Wtm = 35.14 46.83

TOTAL = 81.97

c WT OF CHEMICAL LAYER ( TOTAL) Wtc = 38.78

d WT OF SURFACE MAT Wsm = 0.17 0.17

TOTAL = 0.35

8 TOTAL SHELL WT 121.10 KG

1 TP LINING = YES

2 AREA OF BOTTOM Ab = 1.5 M2

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

a Upward Stress Pv = 0.000736 N/mm2

b Downward Stress = NA (SINCE CONTINUOUSLY SUPPORTED BOTTOM)

c Moment Due to Uniformaly Distributed Load Md = 10.79 Nmm

β1*p*D2 Equation 30 of BS 4994

β1 from P32 for fixed edge condition (Type1) β1 = 0.03125

d Panel Dimension rp = 685.00 mm

e Mass of CSM Required Mcsm = 1.22 kG/M2

Eq 34 of BS4994-87

f No. of csm requiredto meet this Ncsm = 3

4 THICKNESS TO LIMIT DEFLECTION

α a constant α = 0.010660

laminate modulus Elam = 6250.00 N/mm2

Min. thickness permitted tmin = 4.08

αp.rp4/Elam)^0.25

No. of csm to meet this = 4

5 SHELL BOTTOM

thickness of bottom shell = 4

No. of csm required = 4

6 BOTTOM FRP THICKNESS

contributed by Mech CSM = 8 mm

contributed by chemical = 3.00 mm

total = 11 mm

7 SHELL BOTTOM JOINT

a overlap radius either side = 148 mm

Radius of joint = 50 mm

Fig 16, pg 50, BS 4994

Corner Thickness = 15 mm

8 MATERIAL REQUIREMENT

SM

Surface Mat External = 1.5 m2

Surface Mat Internal = 0 m2

weight of sm = 0.1 kg

CSM csm Resin

Weight of CSM (Mech) Wtm (Kg) = 16.08 5.31 10.77

Weight of CSM (Chem) Wtc (Kg) = 6.32

total weight of bottom panel Wt = 22.47 Kg

FLAT BOTTOM