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Engineering design of vertical steel tanks

Design-construction department “RussianTankWorks” provides tank engineering design services subject to

  • Safety Guidelines 03-69
  • National State Standard 31385-2008
  • API STD 650

According to these documents requirements, vertical steel tanks should be designed as custom-specific items, manufactured for a particular enterprise and for maintenance in certain conditions. Thus, the notion of “a typical tank project” has lost its sense in tank industry. Therefore, in order to avoid maintenance problems in the future, it is crucial to order all the needed tank projects from a competent company.

Our Design-construction department services in tank design

1. Technical design assignment approval coordination

The first stage of steel tanks designing is preparation and approval coordination of Technical design assignment (aka “Data sheet”). The best way is when both the Customer and the Design Engineer work on this stage. We suggest that you involve us in this process at the starting point. This will help reduce metal consumption of the future enterprise and avoid a lot of mistakes, because we have a rich practical experience of both designing and manufacturing and assembling tanks. We always keep in mind the Customer’s requests as to maintenance of the would-be tank.

TDA for tank engineering design contains design premises that serve as the basis for tank calculation and preparing design projects of metal framework and detailed metal framework drafts.

2. Tank location on the Master layout.

  • We provide the Customer with a rough draft of the designed tank location.
  • We consider all rules and regulations for tank disposition on the territory of the enterprise.
  • We help optimize maintenance processes.

Our master designers will allocate the designed tanks on the master layout in the best way, taking in consideration technological and logistical objectives of the Customer. Our guiding principles are safety, space saving, reducing future maintenance expenses and easy future expansibility of TB.

The importance of this designing stage is in correlating the designed structure with other facilities on the site. It is necessary to plan the places of connection to pipelines to be able to determine the location of respective pipe junctions on the tank.

3. Calculation of vertical tanks

  • We produce calculations in 1-2 days.
  • We reduce metal consumption, thus saving the Customer’s money.
  • We are accurate in calculating weights.
  • We provide durability, rigidity and reliability of tanks.
  • We choose the steel type competently.
  • We provide maximum life cycle.

Competent tank construction calculations helps to provide its durability, rigidity, reliability and required operational properties. Ordering such calculations, our Customer will receive accurate data on:

  • Weight of structural components: walls, bottom, roof, hatches and pipe junctions, stairs, platforms and fences, anchorages, lightning protection and packaging.
  • Corrosion margin necessity.
  • Sufficient thickness of tank walls and steel grades zonally, according to durability, stability and earthquake resistance.

If there are tanks of several types at one enterprise, our Design-construction department designs tank batteries.

Tank calculation methods

4. Design projects of metal framework tanks and detailed metal framework tanks drafts

  • Design projects of metal framework, made by our Design-construction department, provide comprehensive data for drawing detailed metal framework drafts, erection schemes and foundation design.
  • Our designers have over 15-years experience of tank design.
  • We develop project design of off-standard size tanks in the light of specific features of the installation site.
  • We can make design projects according to European or American standards.

The next stage of vertical tanks engineering design is developing technical design project of metal framework, in compliance with National State Standard 31385-2008 and working detailed metal framework drafts.

Design projects of metal framework tanks are developed by specialized design-construction departments and contain general tank layout, outline plans and layers, along with units and constructive elements with indication of materials, thickness, profiles, and requirements to welding joints.

Design projects of metal framework contain instructions for methods of manufacturing, grades of steel, assembly techniques and tanks testing. They also include detailed specification of metal, sufficient for its purchase.

Results of calculation of vertical steel tank construction and its foundation pressures are also included in the project.

Detailed metal framework tanks drafts are normally developed by designers of the manufacturing plant, where the tank metal framework will be manufactured. These are detailed drafts of all elements, made with consideration for factory equipment to optimize their manufacturing process.

Design-construction department assumes all responsibility for high-quality design project and drafts compilation, because the Customer doesn’t directly approve them, but only signs the Technical design assignment for tank engineering design.

5. Tank foundation engineering design

  • We offer the most money-saving foundation type.
  • We compile the engineering survey task.
  • We develop detailed projects of reinforced-concrete structures with detailed drawings of foundation structural elements.
  • We take into consideration individual features of the construction site important for foundation works.
  • We guarantee construction reliability.

The choice of foundation type and its engineering design are carried out on the basis of the results of geotechnical research and design projects of metal framework that contains calculations of foundation pressures.

Development of reinforced-concrete structures project is as an important stage of tank design as any other. Earth- and reinforced-concrete works are an essential part of tank construction estimate value; so the choice of the foundation type directly influences the construction budget. At the same time, the foundation must be reliable, providing stability of the whole construction.

The design engineer must have experience in reinforced-concrete structures engineering design for tanks, because tank foundations have different construction from building bases, for instance.

6. Preparing managerial and technical documents for tank erection.

  • We promptly develop appropriate and well-calculated Projects for implementation of construction operations, Method Statements for crane operations and other Method Statements.
  • We reduce heavy construction vehicles expenses.
  • We plan installation in tight working space.
  • We provide compliance with all rules and regulations.
  • We guarantee high speed and safety of construction and installation works.
  • We prevent installation errors.
  • Your managerial and technical documents preparation expenditures will repay at all stages of construction and installation works.

Engineering design works are also important to quickly, properly, safely and cost effectively install the manufactured tank. The following documents are needed at the installation site:

  • Projects for implementation of construction operations.
  • Method Statements for crane operations.
  • Method Statements for welding and installation.

These documents are drafted in compliance with manufacturing rules, industrial, environmental and occupational safety standards.

In practice at small and medium size construction sites these documents are often prepared perfunctorily, for supervision agencies, or not at all.

However, properly made Projects for implementation of construction operations and Method Statements for crane operations, that take into account installation site peculiarities, heavy vehicles resources and other important input data, can provide up to 50% economy of installation expenses.

Accurate managerial and technical documents can help avoid costly errors and even tragic accidents on the site. Method Statements for welding provide following a production process and, as a result, quality of welded joints. They also help prevent problems with regulatory authorities.

Tank installation is a very peculiar operation, so it should be designed by professionals with experience in such construction type.

7. Preparation of Method Statements for tank rust-proof protection

  • We choose the best method of rust-proof protection.
  • We develop Method Statements for rust-proof protection.
  • We design necessary tooling and equipment.
  • We prevent material overrun.

If the tank rust-proof protection is planned, a Design project for these works will be required.

When choosing rust-proof coating type, a number of different factors should be considered: operating conditions, stored product specific features, its supply, discharge and storage techniques, climate factors, etc. After analyzing these factors, the coating is chosen with the Customer’s participation.

Then, as part of Method Statement, the order of coating deposition is spelled out on the tank layout, along with surface preparation method, requirements to layer thickness, etc.

Rust-proof coating project specifies consumables expenditure norms (for example, sand for sandblast finish, earth and enamel). This allows to purchase the needed quantity of materials, avoid material overrun and work stoppage due to lack of materials.

8. Tank heat insulation design project

  • We promptly develop detailed heat insulation projects based on heat loss and material pressures calculations.
  • We choose the best effective insulating material.
  • We make detailed drafts of installation hardware and all units.
  • We provide accurate consumables data sheets.

Design-construction department “RussianTankWorks” carries out engineering design works for tank heat insulation, choosing the insulation material and describing bonding and protection techniques.

It is vital to choose insulation material with due regard to facility specifics, in order to ensure product storage temperature control, and, at the same time, avoid unnecessary expenditures.

We do not recommend to carry out heat insulation works without a project, because a competently designed project guarantees, firstly, reliability of the insulation construction (wind and weather impact is taken into account, along with hydrostatic pressure on the tank walls, etc.)

Secondly, tank heat insulation design starts with heat loss calculation which guarantees keeping the preset thermal mode.

After all calculations with the Customer’s active participation the heat insulation method is chosen. There is a great variety of these materials available on the market today, and their cost, operational properties and, importantly, bonding techniques are very different. Thus, to make the best choice, practical experience of the Designer is irreplaceable. That is why our Design-construction department collects feedback from heat insulation specialists of our Building and Construction Department, along with customers, who had working experience with certain materials.

Accurate heat insulation design project also describes material bonding methods and contains detailed specification and drafts of all units. This provides accurate installation works and materials saving thanks to correct cutting and bonding order.

Reference data for the design of industrial plants for your region