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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

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127, Tuas View Square, Westlink Techpark, Singapore 637 740
Tel : 68626278 / Fax : 68626279

DESIGN CALCULATION
FOR
NaOCl TANK
(1000 X 1100mm(T/T) BASED ON BS-4994-1987)

TFE Doc No:


Document Prepared By:
Document Approved By:

Main Contractor

TFE-CAL 001-2013
Name
Mr. Eleazar R. Mendoza

Signature

Rev 03
Date
21 March 2014

: ALTON International (S) PTE LTD

A) Design Data.
Tank Dimensions

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Inside Diameter
Str. Ht

: 1,000mm
: 1,100mm.

Fluid handle

: NaOCl, 15% (Hypochlorite)

Design Spec. gravity

: 1.025

Operating Pressure

: Atmospheric

Operating Temperature

: Ambient (200C / 320C)

Design pressure

: Full of Water

Design Temperature

: 200C / 650C

Design Wind Speed

: 45.4 m/s

Blast Resistance

: 300 mbar

Transportation acceleration

: 0.9g Longitudinal; 0.9g Transverse; 0.4g Vertical

Seismic aceleration

: 0.3g Longitudinal; 0.3g Transverse; 0.35g Vertical

Method of fabrication

: Hand lay

B) Design Codes and References


BS 4994 : 1987

: British Standard Specification for Design and


Construction of vessels and tanks in reinforced
plastics.
AISC-ASD Ninth Ed
: American Institute of Steel Construction
Allowable Stress Design Method, Ninth Edition
1989
MM-YAD-00-GU01-304001 Rev 2 : Equipment Design Conditions
MM-YAD-50-GU41-127001
: Piping and Instrumentation Diagram
MM-YAD-50-GU41-307001
: General Arrangement Drawing
MM-YAD-50-GU41-307002
: Tank Detail Drawing
MM-YAD-95-GU01-305001
: Data Sheet - Temporary Chlorination Injection
Package
MM-YAD-95-GU01-304001
: QP Reinstallation Specification for Temporary
Chlorination Injection Package
C) Materials and Design Strengths
I.

Material Properties:
Type of resin: VE (D-411) resin.

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Ultimate tensile unit Strength, UTUS = 200 N/mm (CSM)


= 250 N/mm (WR)
Unit modulus
= 14,000 N/mm (CSM)
= 16,000 N/mm (WR)
Maximum allowable strain,

= 0.2%. (Clause 9.2.4)

Note:
i.

Material strengths were based from minimum values provided in the BS4994:
1987 Table 5.
ii. CSM Chopped Strand Mat 450g/m2
iii. WR Woven Roving 800g/m2

II.
1.

Allowable and Design Unit Loadings


Design Factor, K
K= 3 x k1 x k2 x k3 x k4 x k5

(EQ 1)

where:
3: represents a constant which allows for the reduction of
material strength caused by long term loading.
k1: Handwork : 1.5
k2: Without thermoplastic lining: 1.2
k3: Heat distortion temperature of resin: 1.0
k4: Cyclic loading: 1.1
k5: Without post cure: 1.5
K=3 x 1.5 x 1.2 x 1.0 x 1.1 x 1.5 = 8.91

2.

Design unit loading, UZ

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

a) Determine the Load limited allowable unit loading, uL.


u
uL = K
(EQ 2)
where u is UTUS from Table 5.
200
uL,CSM = 8.91 = 22.45 N/mm per kg/m2 glass.
250
uL,WR = 8.91 = 28.06 N/mm per kg/m2 glass.
b) Allowable strain, = 0.2%
c) Strain limited allowable unit loading, uS.

uS = Xz

(EQ. 3)
where Xz is the unit modulus from Table 5.

uS,CSM = 14,000 x 0.2/100 = 28.0 N/mm per kg/m2 glass.


uS,WR = 16,000 x 0.2/100 = 32.0 N/mm per kg/m2 glass.
d) Design unit loading Uz.
Since UL < US, then the strain for each layer concerned shall be
determined. (clause 9.2.6 b)
uL
= X Z

(EQ. 4)

22.45
CSM = 14,000 x 100%

= 0.16%
28.06
WR = 16,000 x 100%
= 0.175%

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Therefore, the allowable strain, d = 0.16%. (Least of the two values)


The Design unit loading for each layer, uZ, shall be determined from the
formula below:

uZ = Xz d

(EQ. 5)

uZ,CSM = 14,000 x 0.16/100 = 22.40 N/mm per kg/m2 glass.


uZ,WR = 16,000 x 0.16/100 = 25.60 N/mm per kg/m2 glass.
Summary of Design unit loading:
For CSM, uZ,CSM = 22.40 N/mm per kg/m2 glass.
For WR, uZ,WR = 25.60 N/mm per kg/m2 glass.

D) Design of Tank
1. Tank Shell Design

Provided Thickness:

5mm THK

Considering lower shell,


Maximum Pressure, = gh
where = specific density of NaOCl
= 1.025SG x 1000kg/m3
= 1,025 kg/m3

= 1,025 kg/m3 x 9.81m/s2 x 1.10 m


= 11,061 N/m2
= 0.011 N/mm2
Di
a) Circumferential unit load : Q = 2

(EQ 7)

= 0.011 x 1000/2
Q = 5.50 N/mm.

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Di
4M
W

2
Di
Di
b) Longitudinal unit load: Qx = 4

(EQ 9)

i. Determine Bending Moment due to Wind Pressure, M


Wind speed
Design wind speed, V b = 45.4 m/s
Dynamic pressure qs of standard method,
2

q s 0.613Vb ----- Eq (1)


2

q s = 0.613 x 45.4
2
= 1,263.49 N/m
2
= 0.0013 N/mm

Wind force acting on tank, Fw = C f

q wc

Take C f = 1, W c = width contact


Fw = 1x 0.0013 x 1000
= 1.30 N/mm
1.30 1,100 2
2
Max BM @ base =
M = 786,500Nmm

ii. Determine Operational Weight, W


A) Fluid = 0.5m3 x1025kg/m3 x 9.81m/s2
B) Tank & attachment = 65kg x 9.81m/s2

= 5,028 N
= 638 N

Total Weight, W = 5,666 N

External pressure, = 300mbar = 0.03N/mm2 (Blast Pressure)

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Case I. Empty Tank against Wind Pressure

Di
4M
W

2
Di
Di
Qx = 4
Qx 0

(EQ 9)

4 x786,500
638

2
x1000
x1000

Qx = 0.80 N/mm
Case II. Empty Tank against Blast Pressure

Di
4M
W

2
Di
Di
Qx = 4
Qx

(EQ 9)

0.03 x1000
4 x0
638

2
4
x1000
x1000

Qx = 7.30 N/mm
Case III. Empty Tank against Combination of Wind and Blast Pressure

Di
4M
W

2
Di
Di
Qx = 4
Qx

(EQ 9)

0.03 x1000 4 x 786,500


638

2
4
x1000
x1000

Qx = 8.30 N/mm
Case IV. Tank in Operation against Wind Pressure

Di
4M
W

2
Di
Di
Qx = 4
Qx 0

(EQ 9)

4 x786,500
5,666

2
x1000
x1000

Qx = -0.80 N/mm

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Case V. Tank in Operation against Blast Pressure

Di
4M
W

2
Di
Di
Qx = 4
Qx

(EQ 9)

0.03 x1000
4 x0
5,666

2
4
x1000
x1000

Qx = 5.70 N/mm
Case VI. Tank in Operation against Blast Pressure and Wind Pressure

Di
4M
W

2
Di
Di
Qx = 4
Qx

(EQ 9)

0.03 x1000 4 x 786,500


5,666

2
4
x1000
x1000

Qx = 6.70 N/mm
Check provided thickness against loadings:
Condition:
The Actual unit loads (Q) along circumferential and longitudinal direction
brought by liquid pressure, wind load and weight should not exceed the Design unit
loads (uZ) of the FRP Laminate, as described in the equation below:
u1m1n1 + u2m2n2 ++uZmZnZ Q

(EQ 6)

where:
m1,m2,,mZ = mass of reinforcement per unit area (in kg/m2
glass) in one layer of reinforcement type.
n1,n2,,nZ = number of layers of reinforcement type in
construction under consideration.
Using CSM with mCSM = 450g/m2 and Woven Roving with
mWR =800g/m2:
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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

A. Circumferential/Longitudinal uZLAM
N/mm per kg/m2 x 0.45kg/m2 x 4layers +
25.60 N/mm per kg/m2 x 0.80kg/m2 x 1layer
= 60.80 N/mm > Q = 5.50 N/mm, OK!
> Qx = 0.80 N/mm, OK!
> Qx = 7.30 N/mm, OK!
> Qx = 8.30 N/mm, OK!
> Qx = -0.80 N/mm, OK!
> Qx = 5.70 N/mm, OK!
> Qx = 6.70 N/mm, OK!
Since Qx in Case IV is negative and in compression, check on permissible maximum
compressive unit load shall be done.
0.6tX lam
Qp = FDo

(EQ 13)
where Xlam = X1m1n1 + X2m2n2 ++XZmZnZ
= 14,000x0.45x4 + 16,000x0.80x1
= 38,000
t = 5mm thk
F = 4 (safety factor, p. 25 BS 4994)
Do= 1,000mm + 2x5mm
= 1,010mm

0.6(5)(38,000)
Qp = ( 4)(1,010)

= 28.22 N/mm > Qx = -0.80N/mm, OK!

Since from the checking, strength of FRP laminate reinforced with 4 layers of CSM
and 1 layer of Woven Roving with the described mass is greater than the required unit loading
along circumferential and longitudinal direction, therefore the provided thickness of 5mm
thick (4CSM +1WR) is SAFE!
2. Tank Bottom design
I.

Provided Thickness: 5mm THK

Slanted Circular base will be supported by FRP Webs


(see Figure 1)
a = 300mm; b = 300mm;

a/b= 1;

1 = 0.014
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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

p = 0.011 N/mm2
X LAM
4 x14000 x0.45 1x16000 x0.80
5
ELAM = t =
=7,600

60

50

300
300
300 300

a. Check provided thickness against pressure load:


1 b 4

E
LAM

0.25

0.014 x 0.011x300 4

7,600

Ts.base =
=
= 3.58mm < 5mm, OK!

0.25

b. Check FRP plate supports against pressure load.


Plate thickness: 7mm

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

CSM Lap shear strength = 7 N/mm2


Check against shear:
p = 0.011 N/mm2
0.011N / mm 2 x300mm
7 N / mm 2
tmin =

= 0.47 mm < 7mm, OK!


c. Check provided thickness against Blast pressure:
1 b 4

E
LAM

0.25

0.014 x 0.03 x300 4

7,600

Ts.base =
=
= 4.60mm < 5mm, OK!

0.25

d. Check FRP plate supports against pressure load.


Plate thickness: 7mm
CSM Lap shear strength = 7 N/mm2
Check against shear:
p = 0.03 N/mm2
0.03 N / mm 2 x300mm
7 N / mm 2
tmin =

= 1.29mm < 7mm, OK!

3. Tank Cover Design


I.

Provided Thickness: 6mm THK

Check Cover Thickness Design Against Maintenance Load:


Maintenance load = 50kg x9.81m/s2 / (500mm)2
= 0.002 N/mm2

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Consider cover to be a rectangular flat panel 1000mm long with


supports at 270 mm o.c.

tmin =

1 pb 4

E
LAM

0.25

where: 1 = 0.028 (see table 8 of BS4994:1987)


b = 270 mm
X
14,000 x0.45 x 4layers 16,000 x0.80 x1layer
E LAM LAM
t =
5
= 7,600
0.028 x 0.002 x 270 4

7,600

0.25

Therefore, tmin =
= 2.50 mm < 6mm, OK!

Calculate stiffener support:


Tributary width, W = (227mm + 270mm)/2 = 248.50mm
w = p x b = 0.002 N/mm2 x 248.50mm = 0.497 N/mm
L = 963 mm
M = wL2 / 8 (considering simply supported stiffener)
= 0.497 N/mm x 9632 / 8
= 57,613 N-mm
M
57,613
SxREQD = 0.66 Fy = 0.66 x 248

= 352 mm3 = 0.35 cm3


Use SHS 25x25x2.3mmT M/S (Sx= 1.27cm3 > SxREQD) OK!

II.

Check Cover Thickness Design Against Blast Load:


P = 0.03 N/mm2

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Consider cover to be a rectangular flat panel 1000mm long with


supports at 270 mm o.c.

tmin =

1 pb 4

E
LAM

0.25

where: 1 = 0.028 (see table 8 of BS4994:1987)


b = 270 mm
X
14,000 x0.45 x 4layers 16,000 x0.80 x1layer
E LAM LAM
t =
5
= 7,600
0.028 x 0.03x 270 4

7,600

0.25

Therefore, tmin =
= 4.92 mm < 6mm, OK!

Calculate stiffener support:


Tributary width, W = (227mm + 270mm)/2 = 248.50mm
w = p x b = 0.03 N/mm2 x 248.50mm = 7.455 N/mm
L = 963 mm
M = wL2 / 8 (considering simply supported stiffener)
= 7.455 N/mm x 9632 / 8
= 864,192 N-mm
M
864,192
SxREQD = 0.66 Fy = 0.66 x 248

= 5,280 mm3 = 5.28 cm3


Use SHS 50x25x3.0mmT M/S (Sx= 6.30cm3 > SxREQD) OK!
4. Checks for Lifting Lugs
Qty: 2 pcs.
Using M/S grade plate.

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Throat thickness = cos 450 x weld thickness


= 0.707 x 3m thk = 2.12mm

(Effective fillet throat; AISC)

Allow shear stress = 0.4 x 248N/mm2 = 99.20 N/mm2


Total weight of tank (empty): Approx. 65kg x 9.81m/s2 x SF 2.43
= 1,549.50 N
1,549.50 / 2
t
0.35mm
(
40

17
.
5
)

99
.
20
a) Thickness req.
Use 6mm thick flat bar is safe Ok

b) Welding length:

1,549.50 / 2
3.68mm
2.12 99.20

Actual welding length 150 > 3.68mm Ok


FRP compensation
Using CSM lap shear strength = 7 N/mm

Minimum shear area reqd: for lifting lug,


1,549.50
110.70mm 2
A= 27
FRP overlay 350 x 350 mm
Bonding area= (350 x 350) (50 x 200 x2) (75 x150)
2
2
= 91,250 mm > 110.70 mm ---- Ok
Check Unit Load reqd from FRP layer,

1,549.50
2.38 N / mm
2
(
200

125
)
Unit load reqd: =
2

Use 3 plies x 0.45 kg/m x 22.40N/mm CSM = 30.24 N/mm > 2.38 N/mm -- Ok
Check Anchor Support and Bolting
Number of support considered = 4

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

I) Load force generated by Transportation acceleration motion


Weight of empty weight of tank

65.0 kg

Longitudinal Direction:
Longitudinal acceleration (gx) = 0.9g
Load generated due to acceleration (Fgx)

=
=
=
=

8.829 m/s2
W x gx
65 x 8.829
573.885 N

=
=
=
=

8.829 m/s2
W x gy
65 x 8.829
573.885 N

Transverse Direction:
Transverse acceleration (gz) = 0.9g
Load generated due to acceleration (Fgz)
Vertical Direction:
= 3.924m/s2
= W x gy
= 65 x 3.924
=
255.06 N
Therefore, consider Fgx/ Fgz

Vertical acceleration (gy)


= 0.4g
Load generated due to acceleration (Fgy)

Force acting on the per support = 573.885 N / 4 = 143.47 N


II) Load force generated by Seismic acceleration motion
Operating Weight of tank:
A) Fluid = 0.5m3 x1025kg/m3
B) Empty Tank

= 513 kg
= 65 kg

Total Operating Weight, W

= 578 kg

Longitudinal Direction:
Longitudinal acceleration (gx) = 0.3g
Load generated due to acceleration (Fgx)

=
=
=
=

2.943 m/s2
W x gx
578 x 2.943
1,701 N

Transverse Direction:

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Design Calculation for Temporary Chlorination Storage Tank
0mm x 1100mmSt Ht

Transverse acceleration (gz) = 0.9g


Load generated due to acceleration (Fgz)

=
=
=
=

2.943 m/s2
W x gx
578 x 2.943
1,701 N

=
=
=
=

3.435 m/s2
W x gy
578 x 3.435
1,985 N

Vertical Direction:
Vertical acceleration (gy)
= 0.35g
Load generated due to acceleration (Fgy)

Therefore, consider Fgy


Force acting on the per support = 1,985 N / 4 = 496.25 N
III) Load force generated by Combined Windload and Blast load:
Fw = 1.30 N/mm (see page 6, Wind Load Calculations)
Blast Force, FB = 0.03 N/mm2 x 1000mm = 30 N/mm
Combined Wind and Blast, FC = 1.30N/mm + 30 N/mm = 31.30N/mm
Calculate Lateral force due to combined Wind and Blast loads:
P = 31.30N/mm x 1100mm (Ht of Tank) = 34,430 N
Force acting per support = 34,430N / 4 = 8,607.50 N
Since the combination of Wind Load and Blast is greater than the load generated by
transportation and seismic acceleration, Hold down lugs to be design with the greater value.
Check of Hold down lugs against tearing.

8,607.50
P
Require unit load = bnet = (100 18) = 104.97 N/mm
Assume 12 layer FRP bracket base.

Design unit load = ucsmmcsmncsm


= 22.40 N/mm per kg/m2x0.45 kg/m2x12layers
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Design Calculation for Temporary Chlorination Storage Tank
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= 120.96 N/mm > 104.97 N/mm, OK!


Since the bearing capacity of FRP bracket base is greater than the required
unit load, therefore use of 12mm thk FRP bracket base is SAFE.
Check using M16 anchor bolt:
1) Check for Shear Capacity.
Anchor bolt (single shear) G 4.6 bolts
From BS 5950, table 51
Shear capacity, P s = p s x A s
P s = 160N/mm2 x 157
= 25,120N per bolt
= 25,120N > 8,607.50 N ---- OK!
Check Overturning Moment
Check for against lift off
Tensile strength of anchor bolts
P t = A t Pt
= 157 x 192 = 30,144 N
Tensile force acting on per anchor bolts

F=

4M
pDi 2

W
4
Dpc

Nb

4 18.94 x 10 6
1

638 N 0
1,130
4
F=

31.30 1,100 2
2
M=
= 18.94x106N-mm

; Dpc = c-to-c distance of opposite HD Lugs

= 16,602N < Pt = 30144N-- OK

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