Design Specifications for Storage Tanks
The University of Melbourne
School of engineering
Process Equipment Design – CHEN90012
Major Assignment – Part 1
Wei Leng
Student number:818219
Executive summary
This report writes about the design process of storage tank(T2) in pressure vessel. Based on
the factorial separation process, A waste stream contains 4mole% methane,70 mole% 1-
pentanol and 26mole% benzene and expends isothermally in the flash drum. In the different
part of mixture, CH4 is taken from the top of the flash drum as gas phase which is separated
from liquids of 1-pentanol and benzene. Through the transfer by compressor and precooling
by heat exchanger, eventually CH4 goes to storage tanks(T2) which are required 1.65MPa
maximum gauge pressure.
According to the Australian Standards documentation, this design of storage tanks of
pressure vessel follow the official requirements. This design report mainly relates to AS1210
and AS4332.
According to the beginning of separation process, the volumetric flow rate of Methane is
248.4 kg/hr. The expected time of storage Methane is 24 hours and after that these
Methane will be transported by train. Because the operating gauge pressure of storage tanks
is 1.65 MPa, therefore these tanks are constituted of cylindrical section with ellipsoidal end
caps. The inlet, outlet nozzles and pipes are also designed to working under high pressure. In
aspect of safety and work well in extreme conditions, the design temperature and pressure
are 10% more than the maximum limit of gauge temperature and pressure, which is
1.815MPa and 50°C. From the details calculation of tank, this report shows that the vessel
should use Class 2A construction of AS 1548-7-430R,N,T carbon steel. The vessel’s size is
3.048m diameter and 10.15m long which’s space is 68.8 m 3. There are 9 tanks used to meet
24 hours production of Methane. The farm layout is two rows of tanks and each row has four
tanks paralleled. Specific standards of the other fittings and supports can be found in the
equipment specification sheet of pressure vessel.
Equipment name Storage tank
Equipment code T2
Operating pressure (kPa(g)) 1650.0 Design pressure (kPa(g)) 1815.0
Operating temperature (°C) 35 Design temperature (°C) 50
Service fluid Methane(CH4)
Material of construction, grade Carbon Steel
Applicable code AS1548,7-430R, N, T
Vessel class Class 2A
Vessel Diameter (m) 3.048 Shell thickness (mm) 32
Vessel Length (m) (T-T) 10.15 Corrosion allowance (mm) 1.57
Vessel volume (m3) 68.8
End Diameter (m) (ID) 32 End Type Semi-
ellipsoidal
End height (m) 0.762 End thickness (mm) 32
End volume (m3) 3.7 Corrosion allowance (mm) 1.57
Supports 2 saddles, the lowest height is 0.5m
Orientation Horizontal
Inlet Nozzle DN 32, Schedule 80 flanges DN 65, PN 20, Class 150, socket
weld
Outlet Nozzle DN125, Schedule 80 flanges DN 65, PN 20, Class 150, socket
weld
Drain Nozzle DN 32, Schedule 80 flanges DN 65, PN 20, Class 150, socket
weld
Accessories and Other Pressure relief valve
Demister
Temperature indicator
Pressure indicator
Inspections Visual check
Hydrostatic pressure test
Manhole
Material Balance Calculation
(1)Around Flash Drum (T1)
Inlet -32,000 kg/hr which include:
- 4 mole% CH4
- 70 mole% C5H11OH
- 26 mole% C6H6
If the mixture contains 100kmol gas, their mass percentages is individually:
Component kmol m=n*M (kg) Mass %
CH4 4 4*16.04 64.16 100*(64.16/8265.52) 0.776
C5H11OH 70 70*88.15 6170.5 100*(6170.5/8265.52) 74.65
4
C6H6 26 26*78.11 2030.86 100*(2030.86/8265.52 24.57
)
total 8265.52 100
In order to simplify calculation and make the distillation column design practical, assume
that benzene and 1-pentanol cannot volatilise in air and CH4 is not soluble in liquid. (from
the pre-requirement in design assignment)
Outlet =Mass% x Inlet
Methane : 0.776% x 32,000= 248.4 kg/hr, which is transferred from T1 to C1
1-Petanol : 74.654% x 32,000= 23889.3 kg/hr, which is transferred from T1 to P1
Benzene : 24.57% x 32,000= 7862.4 kg/hr, which is transferred from T1 to P1
Because Methane is transported by train from the facility once a day, so the demand of
Methane one day is :
mtotal =248.4 × 24=5961.5 kg/day
ntotal =m/M = 371.66 kmol/day
(2)Methane storage tank design
[Link] calculation
required operating temperature=35°C
required maximum gauge pressure= 1.65MPa,
required maximum absolute pressure=1650kPa+101.3kPa=1751.3kPa=17.51bar
because the surge pressure should not exceed 10% extra of limit. Therefore,
design pressure=maximum gauge pressure x (1+10%)=1.815MPa
And considering work temperature is hard to control. In case of Methane doesn’t cool
enough before going to tanks, therefore design temperature ups to 50°C.
Checking with Fig.1.3.1, AS1210, maximum gauge pressure 1.65MPa should be concluded
into high pressure work condition. So it should be designed as pressure vessel.
Preliminary design of tank
--Cylindrical
--Diameter≈3m,
because it is a part of pressure vessel, depended on Australian Pressure Vessel Heads Pty
Ltd, 3048 ID semi ellipsoidal ends are chosen as the end caps of Methane storage tanks. End
Diam=3048mm, ITH=762mm, SF=76mm, Cap litres=3.7m 3. In order to match perfectly,
therefore:
cylindrical part diameter = end diameter = 3048 mm
--L/D=3M
Check capacity
D=3.048m
L=9.144m
For ellipsoidal ends
Volume of vessel = Vtank+2* Vends
=π*1.5242*9.144+2*3.7
=74.12 m3
∙ cm3
∵PV=nRT, R=83.14 ¯
moleK
6
18.15 ×74.12 ×10
∴n= =50.08 kmole
83.14 ×323.15
Mass=n × M=50.08 × 16.04=803.28kg
mtotal/Mass=5961.5/803.28=7.42,
So design 8 tanks for storage and 1 more tank which support extra space to storage excess
methane. Additionally, one empty tank can let the other tanks work in turn. It is convenient
for inspection and maintenance in regular.
mtotal
Average m= =745.19 kg/tank ; n = m/M= 46.46 kmol
8
nRT 46460 ×83.14 × 323.15
PV=nRT, Vtotal= = =68.8m3
P 18.15
∵Vtotal=πr2L+2Vends
∴L= (Vtotal-Vends) ⁄(πr2)=8.41m
Ltotal =L+2*( ITH+ SF+ tends)
=8.41+2*(0.762+0.076+0.032)=10.15m
Ltotal/D=10.15/3.048=3.33,
Close to 3 so the tanks are well proportioned
[Link] selection
In accordance with methane’s chemical and physical property, Methane is not toxic and also
stable in room temperature. But it is easy oxidized and has asphyxiant dangerous if it has a
high density in air. Depends on the Table 3.3.1 in AS 1210, AS1548, 7-430R,N,T carbon steel
is chosen as suitable material for tanks construction.
[Link] thickness
Calculate wall thickness of ellipsoidal ends and cylindrical section
PdK Pd
tends = ; tshell=
2 fη− p 2 fη− p
ITH=762mm, SF= 76mm, f=108MPa, P=1.815MPa, η=0.85
K is related to D/2H, when D/2H= 3048/(2*762)=2, K equal to 1 from Table [Link] in
AS1210.
1.815 ×3048 ×1 1.815 ×3048
tends = =30.43mm ; t shell= =30.43mm
2 ×108 × 0.85−1.815 2 ×108 × 0.85−1.815
Using standard plate thickness of carbon steel is 32mm and 1.57 mm extra thickness as
corrosion allowance. It is class 2A vessel.
The end caps will be connected with double welded double V butt joints.
fittings
[Link] nozzle
Mass flow rate= 248.4 kg/hr
Molar flow rate=248.4/16.04=15.49 kmol /hr=4.3 mol/s
Assume pipeline pressure= 1.9MPa, which is close to design pressure and assume it can
support enough driving force to transfer methane to tanks.
4.3 ×8.314 × 323.15
Volumetric flow rate= V =nRT/P= =0.00608 m3/s
1.9 ×10 6
Because Vapor in high pressure’s velocity is 5-10m/s, say, the velocity of methane is in the
middle of range: 7.5m/s
Therefore, the Area of pipeline, A=Vflow rate/Vvapor=0.00608/7.5=8.11 × 10-4 m2
∵πR2=A
∴R=
√ A
π
=
√ 8.11 × 10−4
π
=0.0161m
D=2R= 0.0322m =32.2mm
From Bluescope pipeline supplies, the nearest standard pipe size is DN32, try Schedule 80
and in order to match perfectly on the size of pipeline, the inlet nozzle will be designed as
the same standard as pipeline. From Table D2 in AS 4041, selecting ASME-A 106-Grade C
seamless carbon steel as inlet nozzle’s constructed materials.
o.d=42.2mm; tn=4.85mm; i.d= 32.5mm
double check actual velocity
A=πR2=π(0.0325m)2/4=8.2968 × 10-4 m2
Vvapor= Vflow rate/A=0.00608/(8.2968 × 10-4)=7.33 m/s , which is still in the range of high
pressure vapor, OK.
Calculate the minimum wall thickness
Pd
tf =
2 feM− p
f=184Mpa, P=1.815MPa, e=1.0, M=0.7, d=32.5mm
1.815 × 32.5
tf = = 0.2325mm,
2 ×184 × 1× 0.7−1.815
which is much thinner than twall. Eventually, using tn=4.85mm as wall thickness which also
contains corrosion allowance=2 mm inside.
Equal area compensation for opening
Area removed:
od
2
Ar=π ¿ & π(ra)2=2Ar
¿
׿
∴ra=
√2 od= √2 × 0.0422=0.02983m
2 2
a area of radius 0.02983m and thickness of 32mm plate should be used on compensation of
opening area.
e. Outlet nozzle
Used the same materials as pipeline which is ASME-A106-Grade C, seamless carbon steel .
The reasonable time of transferring all methane in 8 storage tanks to transported facilities
on train is 1 hour, 2 tanks will go empty at the same time and the time of transferring is 15
minutes per tank. Assuming methane can be full of tank space and all of them can be
transferred into train. This ideal condition can simplify calculation. The ideal result of
evacuation will be a little faster than reality. If the design outlet nozzle can be used in ideal
condition that means it will also be safe in reality.
Volumetric flow rate, Vflow rate = 68.8/15= 0.0764 m/s
Assume gas velocity of methane in high pressure is v=7.5m/s
A= Vflow rate/v=0.0102 m2
r=
√ 0.0102
π
= 0.057m
d=2r=0.114m
From Australian Standards of carbon steel linepipe·dimensions, the nearest pipe size is
DN125, chosing 80 Schedule for extra strength.
o.d=0.1413m ; i.d=0.1318m ; tn =0.00953m
double check actual velocity
A=πR2=π(0.1318m)2/4=0.01364 m2
∴v= Vflow rate/A
=0.0764/0.01364=5.60m/s, which is in the velocity range of vapor in high pressure
calculate the minimum wall thickness:
Pd
tf =
2 feM− p
f=184Mpa, P=1.815MPa, e=1.0, M=0.7, d=131.8mm
1.815 × 131.8
tf = =0.9352mm, which is much thinner than tn. Eventually,
2 ×184 × 1× 0.7−1.815
using twall=9.53mm as wall thickness which also contains corrosion allowance=2 mm inside.
Equal area compensation for opening
Area removed:
od
2
Ar=π ¿ & π(ra)2=2Ar
¿
׿
∴ra=
√ 2 od= √2 × 0.1413=0.1m
2 2
a area of radius 0.1m and thickness of 32mm plate should be used on compensation of
opening area.
f. flange
According to the pipe size, in order to match perfectly between different components, DN 32
socket weled carbon steel flange is chosen as suitable size. In accordance with Temperature
Pressure Ratings in AS 1210, at the range of -29°C- 38°C，PN20, Class 150 carbon steel
flange is chosen and its maximum working pressure is 1.96MPa, which is close to design
pressure.
[Link] relief valve
On the purpose of controlling pressure inside storage tanks and release the excess pressure,
a pressure relief valve should be installed. The requirement of it is the same as inlet nozzle,
using a carbon steel ASME-A106-C Grade pipelines of DN 32, Schedule 80 construction. If the
actual working pressure is higher than design pressure 1.815MPa, pressure relief valve
should stop it climbing and drops down to a normal level.
[Link] and pressure indicator
In order to control and regulate the reaction condition, a temperature and pressure indicator
should be installed on pressure vessels. If there are some conditions strange which are
detected by indicators, they can transmit information to central control system and then
self- control. Or transmit to alarm system which can decrease the chance of accident
happened.
i. Demister
The purpose of a mist extractor is to prevent droplets in air go out with methane. It provides
a surface area that small droplets of liquid may attach to form larger droplets that will fall
against the upward flow of gas. The demister is bolted to a support ring welded to the inside
of the vessel, and is designed to be removed through the manway during inspection and
maintenance.
inspection holes
For the convenience of inspection and maintenance for people, a manhole should be
designed in project of pressure vessel. The size of it is recommended to 450mm diameter
which is easy for a person go inside. It is usually located at the lower part of one end cap. In
order to compensate the opening area of manhole and reinforce the strength on cylindrical
section, an equal area should be added.
Area removed
od
2
Ar=π ¿ & π(ra)2=2Ar
¿
׿
∴ra=
√ 2 od= √2 × 450=0.318m
2 2
a radius of 0.318m and thickness of 32mm carbon steel plate should be placed around the
area of manhole.
Supports
The tank is designed 3.048 diameter and 10.15 long. Therefore, it should be put horizontal
and support by two saddles which can to support the weight and accommodate expansion
of the vessel. Discarding the Ring supports for horizontal vessels is because it’s hard to
fabricate and more expensive than saddles support. Saddles should be fabricated under
vessel and covering the angle of 120°. In addition, saddles should be located at about 20% L
of the shell. ds= 8.41*20%=1.68m
farm layout
The location of the nearest tank cannot be settled in 250m from T1. Follow the requirement
in AS 4332, the layout of methane tanks should be divided in two rows, each row has 4
tanks. In order to control individually and avoid of impacting each other, valves must be set
on inlet and outlet on every tank. Moreover, valves must also be set on two side of each row.
Every tank should arrange 3 meters away to each other for security consideration.
Managerial aspects
Before operation, the pressure vessel should pass the hydrostatic test,
fh
Ph=1.5P × = 2.73MPa. Moreover, welded joint should be examined by visual test
f
whether there is anywhere broken or not. There are 9 tanks designed to storage methane. 8
tanks for storage and 1 more tank which support extra space to storage excess methane.
One empty tank can let the other tanks work in turn. It is convenient for inspection and
maintenance in regular. In addition, there is a tolerance of time if train cannot arrive in time
and facility can keep on operating. Most importantly, excess methane storage in extra space
avoid too high pressure in other tanks which increase security during work.