DESIGN OF SINGLE DECK FLOATING ROOF

75 1
Top pontoon = 8 THK 64
Rafter L 75x75x6
Outer Rim Inner Rim = 15 THK
975 Post
525
Bt Angle Deck plate = 8 THK
Bulkhead

198 2181 34248

38610
Shell ID 39006

TANK GEOMETRY DATA

Tank inside diameter (corroded) D 39006 mm
Tank height H 27000 mm

MOC of shell SA-516 Gr 65N

2
Specific minimum yield stress Sy 275 N/mm
2
Modulus of Elasticity E 209000 N/mm
3
Density of Material 7850 kg/m

Corrosion Allowance 3 mm
Min. specific gravity of product 0.7
Max. specific gravity of product 1
GEOMETRY DATA
Outer rim height Hor 975 mm
Inner rim height Hir 525 mm
Pontoon width w 2181 mm
Rim gap 198 mm
Outer rim Entended above pontoon Hext 75 mm
No of pontoons N 22

Outer Rim diameter = D - 2*Rim gap or 38610 mm

Inner Rim diameter = or - 2*w ir 34248 mm

Bulkhead Outer height = Hor-Hext-Ttp-Tbp Boh 884 mm

Bulkhead Inner height = Hir-Ttp-Tbp Bih 509 mm
Bulkhead width = wb-Tor-Tir wb 2157 mm
MEMBER SIZE & PROPERTIES
Outer rim thickness Tor 9 mm
Inner rim thickness Tir 15 mm
Top pontoon thickness Ttp 8 mm
Bottom pontoon thickness Tbp 8 mm
Bulkheads thickness Tb 8 mm
Deck plate thickness Td 8 mm
Circumferential truss plates 8 mm

Rafter 44 Nos. of L 75x75x6 @unit weight of 6.85 kg/m

Posts 44 Nos. of L 75x75x6 @unit weight of 6.85 kg/m
 ROOF SUPPORT LEG
a) Pontoon Leg:
No of Pontoon Leg, 22
Pontoon Leg Size 3" pipe x SCH 80 @unit weight 15.27 kg/m
Pontoon Leg Housing 4" pipe x SCH 80 @unit weight 22.32 kg/m
Pontoon Leg Length 2940 mm
Pontoon Leg Housing length 1084 mm

b) Deck leg
No of Deck Leg, Area od deck/30m2/leg 30
Deck Leg Size 3" pipe x SCH 80 @unit weight 15.27 kg/m
Deck Leg Housing 4" pipe x SCH 80 @unit weight 22.32 kg/m
Deck Leg Length 2927 mm
Deck Leg Housing length 823 mm
WEIGHT CALCULATION
Top Pontoon = /4 * (or -ir2) * Ttp
2
15675.2 kg
2 2
Bottom Pontoon = /4 * (or -ir ) * Tbp 15675.2 kg

Inner Rim = *in*Hir*Tir* 6651.3 kg

Outer Rim = *or*Hor*Tor* 8355.4 kg

Bulkheads =1/2*(Boh+Bih)*wb*Tb**N 2075.65 kg

Deck Plate =/4*ir*Td* 57852.21 kg

Pontoon Legs = no. of pontoon leg*sze*length 987.66 kg

Pontoon Legs housing = no. of pontoon leg*housing*length 532.29 kg
Deck Legs = no. of deck leg*sze*length 1340.86 kg
Deck Legs housing = no. of deck leg*housing*length 551.08 kg

Total Weight
Pontoon Components Wpontoon 55248.45 kg
Deck Components Wdeck 57852.21 kg
Total weight of floating roof Wroof 113100.7 kg

PONTOON VOLUME

38610 mm

37156 mm
34 3

509 2 34248 mm

341 1
2181

3
Volume 1 43.41 m
3
Volume 2 123.25 m
3
Volume 3 4.33 m
3
Toatal Pontoon Volume 170.98 m
 SETTING DECK LEVEL
OPERATING FLOATATION LEVEL - DECK

Deck Floating Depth Density of Deck

=
Deck Thk "Td" Density of Product

(deck) 89.71 mm
Deck Floating Depth D(deck) = x Td
(product)

OPERATING FLOATATION LEVEL - PONTOON

3 490 Freeboard above deck,

2 89.71 Product Level

142.3
1 Deck Level
52.59

Buoyant Force, FB = Fpontoon

x V displacement x g = W (pontoon) x g

Pontoon Weight, W(pontoon) 3

Product Discharge, V displacement = 78.93 m
(product)

To find the Floatation depth of Pontoon from inner corner of pontoon.

D(pontoon) = Vol. displacement above Inner corner of pontoon

Pontoon cross area in volume 2

D(pontoon) = V displacement - Vbackslope (Volume-1) 142.30 mm

1/4 x x (or2-ir2)

The deck is set at the difference of flooting depth in pontoon & deck

Deck level height (h) = D(pontoon) - D(deck) 52.59 mm

 SETTING DECK LEVEL
NORMAL OPERATION FLOTATION LEVEL FOR ROOF - PONTOON & DECK

Actual product
3
Level 161.6 m
Deck
Level Deck

H- Floatating height above deck

Total Volume displaced by the roof

=
Volumn displaced by back slope, V1
+
Partial volumn displaced in poonton below the deck level, Va
+
Volumn displaced by the deck, Vb

Total volumn displaced by roof

Total roof weight W(roof) 3

V(displacement) = 161.572 m
(product)

3
1) Volume displaced by the backslope, Volumn 1 43.407 m

2) Partial Volumn displaced in pontoon below the deck level

Deck level height (h) x Volumn 2 12.733 m3
Bulk head inner height, Bih

3) Volumn Dispaced by the deck:

Area of deck plate x Floatation height above Deck

2
/4 * ir x H 921.21 H

Hence floating height above deck H 114.45 mm

FLOATATION LEVEL FOR ROOF - PONTOON & DECK FOR 10" (254mm) OF ACCUMULATED RAIN WATER
For deck to support 10" (254mm) of rain water:
Volumn of rain water collected at the deck, Vrain =
Vrain = Adeck x Hrain 233.99 m3
where
Adeck = Area of deck 921213536.6 mm2
Hrain = Rain accumulation of 10" 254.0 mm

Total volumn displaced by the roof with the 10" of rain water accumulation, Vdisplacement(rain)
W(roof)+Wt (rain) 3
Vdisplacement(rain) = 495.84 m
(product)
Floatation height above Deck,
Hrain = Vdisplacement(rain) - Volume.1 - Partial volume of Volume.2 375.55 mm
Area of roof
 CHECKING THE STRESSES AND DEFLECTION IN THE CENTRE DECK
CASE :1 NORMAL CASE - NO PONTOON PUNCTURED

4 3
q y y
4
= K 1 K 2 (11.11.1)
Et t t

2 2
y y
2
= K 3 K 4 (11.11.2)
Et t t
Where:
t= Plate thickness, Deck Td 8 mm
= Outer radius of the deck plate ir/2 17124 mm
q= Unit lateral pressure = Td x ( r(plate) - r(product) ) 0.000561 N/mm2

y= Maximum deflection
b = bending stress
d = diaphragm stress
= b + sd =
v= Poisson's ratio 0.3
E= Modulus of Elasticity 209000 N/mm2

The deck plate is fixed and held at its outer edge by the pontoon, hence condition is consider
as Fixed and Held. Uniform pressure q over entire plate (Case 3 in Roark's Formulas)

K 1= 5.33 5.86
2
1-

K 2= 2.6 2.86
2
1-

At the centre
K3= 2 2.86
1-

K4 = 0.976

At the edge
K3 = 4 4.40
2
1- n

K4 = 1.73

for q 4 56342.2
4
Et

Solving Equation 11.11.12

3 4
y y = q y= 216.0
K1 + K2 4
t t Et
Solving equation 11.11.2

2
y y = 788.90 at deck centre
= K3 + K4
E. t 2 t t = 1380.29 at deck edge

At Deck Center
total = [K3 * (y/t) + K4 * (y/t)2] * [E*t2/2] = 35.99 N/mm
2

bending = K3 * (y/t) * (E*t2) / 2 = 3.52 N/mm

2

diaphgram = K4 * (y/t)2 * (E*t2) / 2 = 32.47 N/mm

2

At Deck Edge,
2
total = 62.96 N/mm
2
bending = 5.41 N/mm
2
diaphgram = 57.55 N/mm

It is the diaphragm stress at the edge which causes the tension at the outer edge of the deck
Hence, the radial force on the inner rim,
Rh = diaphgram x deck thickness = 460.39 N/mm
 PONTOON STRESS DESIGN CASE -1
PONTOON PROPERTIES

2 Nominal diameter of inner rim ir = 34248 mm

2157 525 Pontoon Inside Width = 2157 mm
4 1 Inner Rim Thickness, Tir = 15 mm
900 Outer Rim Thickness, Tor = 9 mm
a
Top Pontoon Thk, Ttp = 8 mm
2190 3 Btm Pontoon Thk, Tbp = 8 mm

Top pontoon slope angle @ 1 : 64 = 0.02 rad

Backslope angle, = 0.172 rad

2 3 2 4 3
A (mm ) Y (mm) AY (mm ) h (mm) Ah (mm ) I=(bd )/12
1 7875 7.5 59063 1096.00791 9459712532 147656.25
2 17258 1093.5 18871740 10.0079094 1728541.766 6692959948
3 17517 1109.8 19440532 6.30308154 695929.0769 6998680600
4 8100 2176.8 17631783 1073.25542 9330205345 54675
TOTAL 50750.1 56003117 18792342349 13691842880
Neutral Axis of combine section = 1104 mm
4
Moment of inertia of section Ix-x = 32484185228 mm
3
Section modulus available, Za = 29437202 mm

MATERIAL PROPERTIES
Material Properties SA-516 Gr 65N
Specified minimum yield stress, Sy 275 N/mm2
Yield strength reduction factor, k (Tabel M-1) 1
Allowable stress reduction factor (App. M.3.5), Ks(=k*Sy/206.7) 1
Allowable bending stress, Fb 183.33 N/mm2
Allowable compressive stress, Fc 165.00 N/mm2

PONTOON RING DESIGN

The uniform radial force acting on the Inner Rim is modelled as load point at each mm of circumference,
with a very small angle between load point approximated to uniform distributed load in the circular ring
design
Rh
Nlp = * ir = 107593.27 mm
Angle = 1/2 * 360 / Nlp = 0.0017
Mid Point Radialload on rim, Rh = 460.39 N/mm
(Note : Rh is negative for inward force)

(Reference to Roark's Formulas for stress and strain. 7th Edition. Table 9.2 case 7)
A mid-point,
Bending moment Cir. tensile force
Mm = Rh.Do 1 1 Tm = Rh
4 sin a a 2 * sin
At Reaction-point
Bending moment, Cir. tensile force
Mr = Rh.Do 1 1 Tr = Rh
4 a tan a 2 * tan
(Note Do = ir)
 PONTOON STRESS DESIGN CASE -1
RESULT
RING STABILITY CHECK MID-POINT LOAD-POINT
Bending Moment (Nmm) 19.18 -38.36558099
Circumferential force (N) 7883669.45 7883669.448
Bending stress (N/mm2) 0.0000007 -0.0000013
2
Circumferential stress (N/mm ) 155.3429879 155.3429878
2
Allow. Bending stress (N/mm ) 183.33 183.33
2
Allow axis stress (N/mm ) 165.00 165.00
Unity Check 0.94 0.94
Condition OK OK

CASE 2: INFLUENCE OF 10 INCH (254mm) OF RAIN ACCUMULATED ON CENTER DECK

10" rain

For deck to support 10" (254mm of rain water)

Volume of rain water collected at the deck,
3
Vrain = Adeck x Hrain 233.99 m
here
Adeck = Area of deck = /4 x ir2 921213536.6 mm
2

Hrain = Rain accumulation of 10" 254.0 mm

Weight of 10" accumulated rain water, Wrain = Vol. rain x rain 233988.24 kg

Upward Bouyant Load = Deck Area x Floatation Height x Product density 242173.32 kg
= /4 * (ir)2 * H(rain) *

Downward load due to deck steel and rain water Wdeck + Wrain 291840.45 kg

Net downward force acting on deck.

2
= Downward load - Upward bouyant load 53.91 kg/m
Deck Area

4 3
q y y Eq 11.11.1
4
= K 1 K 2
Et t t

2 2
y y
2
= K 3 K 4 Eq 11.11.2
Et t t
Here,
t = Plate thickness, deck = Td 8 mm
= Outer radius of the deck plate = ir /2 17124 mm
2
q = Unit lateral pressure 0.0005287 N/mm
y = Maximum deflection
b = bending stress
d = diaphragm stress
= b + d = Maximum stress due to flexure and diaphragm tension combined
2
v = Poisson's ratio = 0.3 E = Modulus of Elasticity = 200000 N/mm
 The deck plate is fixed and held at its outer edge by the pontoon, hence condition is consider
as Fixed and Held. Uniform pressure q over entire plate (Case 3 in Roark's Formulas)

K 1= 5.33 5.86
2
1-

K 2= 2.6 2.86
2
1-

At the centre
K3= 2 2.86
1-

K4 = 0.976

At the edge
K3 = 4 4.40
2
1- n

K4 = 1.73

for q 4 55496.2
4
Et

Solving Equation 11.11.1

3 4
y y = q y= 214.95
K1 + K2 4
t t Et

Solving Equation 11.11.2

2
y y = 781.36 (at Deck Centre)
= K3 + K4
E. t 2 t t = 1367.02 (at Deck Edge)

At Deck Center
2 2 2 2
total = [K3 * (y/t) + K4 * (y/t) ] * [E*t / ] = 34.11 N/mm
2 2 2
bending = K3 * (y/t) * (E*t ) / = 3.35 N/mm
diaphgram = K4 * (y/t)2 * (E*t2) / 2 = 30.76 N/mm
2

At Deck Edge,
total = [K3 * (y/t) + K4 * (y/t)2] * [E*t2/2] = 59.67 N/mm
2

bending = K3 * (y/t) * (E*t2) / 2 = 5.16 N/mm

2

diaphgram = K4 * (y/t)2 * (E*t2) / 2 = 54.52 N/mm

2

It is the diaphragm stress at the edge which causes the tension at the outer edge of the deck
Hence, the radial force on the inner rim,
Rh = diaphgram x deck thickness = 436.14 N/mm
 PONTOON STRESS DESIGN - CASE 2
Pontoon Properties :
Nominal diameter of Inner Rim, ir 34248 mm
Section modulus available, Za2 29437202 mm3
Cross sectional area, Aa 50750.0825 mm2

Material Properties :
Material Properties SA-516 Gr 65N
Specified minimum yield stress, Sy 275 N/mm2
Yield strength reduction factor, k (Table M-1) 1
Allowable stress reduction factor (App. M.3.5), Ks (= k.Sy/206.7) 1.00
Allowable bending stress, Fb = 2/3*Sy 183.33 N/mm2
Allowable compressive stress, Fc = 0.6*Sy 165.00 N/mm2

Pontoon Ring Design :

The uniform raidal force acting on the inner rim is modelled as load point at each mm of circumference,
with a very small angle between load point approximated to unifrom distributed load in the circular
ring design.
Rh Number of load point @ each mm,
Nlp = * ir = 107593.265
Angle = 1/2 x 360/Nlp = 0.00167
Radial load on rim, Rh = 436.14 N/load pt
Mid Point (Note : Rh is negative for inward force)

(Reference to Roark's formula for stress and strain. 7th edition. Table 9.2 case 7)
At mid-point,
Bending moment, Circ. Tensile force,
Mm = Rh * Do 1 - 1 Tm = Rh
4 sin 2. sin
At Reaction-point,
Bending moment, Circ. Tensile force,
Mr = Rh * Do 1 - 1 Tr = Rh
4 tan 2. tan
RESULT
Ring Stability check Mid-point Load-Point
Bending Moment (Nmm) 18.172 36.345
Circumferential force (N) 7468397.78 7468397.78
Bending Stress (N/mm2) 0.00000062 0.00000123
Circumferential Stress (N/mm 2) 147.1603082 147.1603081
2
Allow. Bending stress (N/mm ) 183.33 183.33
2
Allow. Axial stress (N/mm ) 165.00 165.00
Unity Check 0.89 0.89
Condition OK OK

LOAD CASE -1 LOAD CASE -2

STRESSES SUMMARY
Deck center Deck edge Deck center Deck edge
total (N/mm2) 35.99 62.96 34.11 59.67
bending (N/mm2) 3.52 5.41 3.35 5.16
2
diaphgram (N/mm ) 32.47 57.55 30.76 54.52
 ROOF SUPPORT LEG DESIGN

22 No. at R4 18541
15 No. at R3 13716
10 No. at R2 8839
5 No. at R1 4267

GEOMETRIC DATA
Support leg size 3" SCH 80
Pipe outside diameter 88.90 mm
Pipe Thickness 7.62 mm
Pipe Area, Aleg 1945.76 mm2
Radius of gyration r= I = Do2-Di2 24.89 mm
Aleg 4

MATERIAL PROPERTIES
Material of construction for roof support leg SA 333 GR 6
Specific Minimum Yield stress, Sy 241 N/mm2
Modulus of elasticity 209000 N/mm2
Density of material, (plate) 7850 kg/m3
Leg Material

LOADING DATA
Support leg length at
i) R1 : Lsp1 2927 mm
ii) R2 : Lsp2 2927 mm
iii) R3 : Lsp3 2927 mm
iv) R4 : Lsp4 2940 mm

Deck O.D 34231 mm

Deck Thickness, td 8 mm
Deck Area, Adeck 920299221 mm2
Center deck weight, Wdeck 57794.791 kg

Design Live Load, L live 1.2 KN/m2

Effective radius for area of deck support by leg:
R3eff = 1/2 (ir/2 +R3) 15415.75
R2eff = 1/2 (R3+R2) 11277.5
R1eff = 1/2 (R2+R1) 6553

Area of deck suppported by legs at

2
i) R1 = *(R1eff) 134905671.69 mm2
2 2
ii) R2 = *[(R2eff) -(R1eff) ] 264648384.82 mm2
2 2
iii) R3 = *[(R3eff) -(R2eff) ] 347030823.13 mm2
iv) R4 = *[(deck/2)2-(R3eff)2] 173714341.24 mm2
SUPPORT LEG AT INNER DECK R1
No. of leg at R1 5
Area of deck support by legs at R1, A1 134905671.7 mm2
Deck load on each leg A1' 26981134.3 mm2
Deck load on one leg Wdeck x A1' 1694.415 kg
Adeck 16.62 kN
Live load on one leg = Llive x A1' 32.38 kN
Total load on one leg = Deck load + Live Load 48.99 kN

Stress on support leg at inner deck R1, P1 = Total Load/A leg 25.180 N/mm2

ALLOWABLE STRESS
As per AISC code,
Slenderness Ratio,
= = K Lsp1 / Rxx 117.61
where,
K 1
Column Slenderness ratio dividing elastic & inelastic buckling

Cc = 2 2 E 130.84
Sy
When < Cc

Sc. All. = [1-2 /2Cc2]*Sy (i) 75.08 N/mm2

5/3+3\8Cc -3/8Cc3

When Cc < < 120

Sc. All. 12 E (ii) 77.80 N/mm2

23

When 120 <= <=200

Sc. All. Smaller of (i) or (ii) 74.20 N/mm2

1.6 - /200

In this case the allowable stress Sc. All is 75.08 N/mm2

Since P1 < Sc.all, the support leg at inner deck R1 is Ok

SUPPORT LEG AT INNER DECK R2

No of leg at R2 10
Area of deck supported by leg ar R2, A2 264648384.8 mm2
2
Deck area on each leg A2' 26464838.5 mm
Deck load on one leg = Wdeck x A2' 1661.99 kg
Adeck 16.30 KN
Live load on one leg = Llive x A2' 31.76 KN
Total load on one leg = Deck load + Live load 48.06 KN
2
Stresses on support leg at inner deck R2,P2 = Total load/ A leg 24.70 N/mm
ALLOWABLE STRESS
As per AISC code,
Slenderness Ratio,
= = K Lsp2 / Rxx 117.61
where,
K 1
Column Slenderness ratio dividing elastic & inelastic buckling

Cc = 2 2 E 130.84
Sy
When < Cc

Sc. All. = [1-2 /2Cc2]*Sy (i) 75.08 N/mm2

3 3
5/3+3\8Cc - /8Cc

When Cc < < 120

Sc. All. 12 E (ii) 77.80 N/mm2

23

When 120 <= <=200

Sc. All. Smaller of (i) or (ii) 74.20 N/mm2

1.6 - /200

In this case the allowable stress Sc. All is 75.08

Since P2 < Sc.all, the support leg at inner deck R2 is Ok

SUPPORT LEG AT INNER DECK R3

No of leg at R3 15
Area of deck supported by leg ar R3, A3 347030823.1 mm2
2
Deck area on each leg A3' 23135388.2 mm
Deck load on one leg = Wdeck x A3' 1452.90 kg
Adeck 14.25 KN
Live load on one leg = Llive x A3' 27.76 KN
Total load on one leg = Deck load + Live load 42.01 KN
2
Stresses on support leg at inner deck R3,P3 = Total load/ A leg 21.59 N/mm

ALLOWABLE STRESS
As per AISC code,
Slenderness Ratio,
= = K Lsp3 / Rxx 117.61
where,
K 1
Column Slenderness ratio dividing elastic & inelastic buckling

Cc = 2 2 E 130.84
Sy
When < Cc

Sc. All. = [1-2 /2Cc2]*Sy (i) 75.08 N/mm2

5/3+3\8Cc -3/8Cc3

When Cc < < 120

Sc. All. 12 E (ii) 77.80 N/mm2

23

When 120 <= <=200

Sc. All. Smaller of (i) or (ii) 74.20 N/mm2

1.6 - /200

In this case the allowable stress Sc. All is 75.08 N/mm2

Since P3 < Sc.all, the support leg at inner deck R3 is Ok

SUPPORT LEG AT INNER DECK R4

No of leg at R4 27
Area of deck supported by leg ar R4, A4 173714341.2 mm2
2
Deck area on each leg A4' 6433864.5 mm
Deck load on one leg = Wdeck x A4' 404.05 kg
Adeck 3.96 KN
Pontoon Weight, Wpontoon 55248.45 kg
5022.59 kg
49.26 KN
Live load on one leg = Llive x A4' 7.72 KN
Total load on one leg = Deck load + Live load 60.94 KN
2
Stresses on support leg at inner deck R4,P4 = Total load/ A leg 31.32 N/mm

ALLOWABLE STRESS
As per AISC code,
Slenderness Ratio,
= = K Lsp4 / Rxx 117.61
where,
K 1
Column Slenderness ratio dividing elastic & inelastic buckling

2
Cc = 2 E 130.84
Sy
When < Cc

Sc. All. = [1-2 /2Cc2]*Sy (i) 75.08 N/mm2

5/3+3\8Cc -3/8Cc3

When Cc < < 120

Sc. All. 12 E (ii) 77.80 N/mm2

23
When 120 <= <=200

Sc. All. Smaller of (i) or (ii) 74.20 N/mm2

1.6 - /200

In this case the allowable stress Sc. All is 75.08 N/mm2

Since P4 < Sc.all, the support leg at inner deck R4 is Ok

STRESSES SUMMARY
Leg at radius No of leg Actual stress,(N/mm2) Allowable stress,(N/mm2) RESULT
4267 5 25.18 75.08 OK
8839 10 24.70 75.08 OK
13716 15 21.59 75.08 OK
18541 22 31.32 75.08 OK