AGENDA ITEM: 650-608 Design Loads for Tank Roofs DATE: January 28, 2008 CONTACT: Randy Kissell, TGB Partnership PH: 919-644-8250 FX: 919-644-8252, email: randy.kissell@tgbpartnership.com PURPOSE: 1) To allow reduced live loads for tank roofs where allowed by load standards 2) To include unbalanced snow loads on tank roofs SOURCE: Committee members’ request REVISION: 3 IMPACT: 1) Reduce cost where reduced live loads are allowed by load standards; 2) Reduce the likelihood of failures when roofs are subjected to drifting snow loads. RATIONALE: General This version of the ballot addresses comments received in the ballot conducted before the Fall 2007 Refining meeting. Committee members requested an investigation into more precise loads for tank roofs. The first ballot addressed only aluminum dome roofs, but committee members requested that any changes to roof loads apply to all tank roofs. This ballot, therefore, uniformly addresses snow loads, wind loads, and minimum roof live loads for all tank roofs addressed by API 650. Loads on tanks were recently revised in agenda item 650-472, which provided more precise loads than previously required by API 650. For example, API 650 previously specified a 25 psf roof live load for all tanks in all locations. 650-472 (published in 650’s 10th edition, addendum 4) changed this, providing rules for determining the uniform snow load for the tank based on its location. Changes were also made to more accurately determine other loads such as minimum roof live load and wind load, and address load combinations. The 650-472 load changes were based on ASCE 7, Minimum Design Loads for Buildings and Other Structures, but the 650-472 snow load and minimum roof live load were simplified from the ASCE 7 approach. Now that the committee is requesting more precise loads, this ballot proposes to revise 650’s snow load and minimum roof live load requirements to more closely match ASCE 7. This will have the benefit of reducing costs in low snow load regions where ASCE 7 provides for lower minimum roof live loads, and making tank design more consistent with accepted practice for other structures. Another advantage will be to reduce roof failures due to drifting snow loads by addressing unbalanced snow loads for the first time in API 650. 650-608 Design Loads for Tank Roofs 1/28/08 1 Minimum Roof Live Load ASCE 7 section 4.9.1 prescribes minimum roof live loads as a function of the tributary area of a structural member and the rise-to-span ratio of dome roofs. The largest ASCE 7 minimum roof live load value of 20 psf is conservatively prescribed by API 650 5.2.1(e). ASCE 7 allows this value to be reduced to as little as 12 psf for structural components with large tributary areas in domes with large rise-to-span ratios. This ballot proposes to allow lower minimum roof live loads where allowed by ASCE 7, but no less than 15 psf. (AWWA D100 specifies 15 psf as a minimum.) This reduces the design load in regions where the ground snow load is small. Wind Loads This ballot would not change wind loads except that they would be applied to all roofs, including aluminum dome roofs, which currently have different wind loads based on outdated ASCE 7 arched roof wind loads. The discussion below provides the rationale for the roof wind load currently in API 650. ASCE 7-02 (Minimum Design Loads for Buildings and Other Structures) provides wind pressures for dome roofs in Figure 6-7. Dome pressures are a function of the tank-height-to-diameter ratio, distance from the windward edge, and roof profile. These were used in agenda item 650-472 to provide the wind pressure for doubly curved surfaces, and this ballot proposes to apply these to aluminum domes, since the ASCE 7 pressure is more accurate than the current API 650 G.4.2.2.1 provisions. The ASCE 7 dome wind pressure approach is briefly reviewed below. For typical profiles permitted by API 650 (for steel domes, see 5.10.6.1 and for aluminum domes, see G.6.2) on an 80’ diameter, 48’ tall tank, ASCE 7 Figure 6-7 gives an approximate average Cp = -0.97, so the design wind pressure is p = qh (GCp - GCpi) p = 36.4 (-0.97(0.85) – 0.18) = 36.4 (-0.94) = 36.6 psf (uplift) A computation of ASCE 7-02 wind pressure on domes is shown for 3 tanks below, using a dome radius equal to the tank diameter (D), a typical radius for API 650 tanks (see section 5.10.6 for steel domes and G.6.2 for aluminum domes), resulting in a dome-height-to-tank-diameter ratio of 0.13: Dome Roof Wind Pressure Coefficients Cp for 3 Tank Sizes 30’ x 40’h 80’ x 48’h 150’ x 48’h 5,000 bbl 43,000 bbl 151,000 bbl h/D 1.3 0.6 0.32 Pt. A (windward edge) -1.6 -1.4 -1.0 Pt. B (center) -1.0 -1.0 -0.8 Pt. C (leeward edge) -0.5 -0.5 -0.3 average coefficient -1.02 -0.97 -0.72 average uplift (psf) 38.1 36.6 28.8 In each case, the uplift on the windward side is about 3 times the uplift on the leeward side, producing a net horizontal force in a direction opposite to the wind direction. Therefore, the horizontal effect of the wind counteracts overturning and can be conservatively neglected. A 30 psf roof uplift pressure was selected as a reasonable average for all roofs based on the above, and matches that used for steel roofs in 650. 650-608 Design Loads for Tank Roofs 1/28/08 2 Snow Load The snow load currently given in API 650 5.2.1(g) is solely a balanced (uniform) load. ASCE 7-02 provides, in addition to balanced snow loads, unbalanced snow loads (ASCE 7 Figure 7-3). The ASCE 702 unbalanced snow load on dome roofs varies from 0.5 times the flat roof snow load pf at the roof’s crown to about 2 times the flat roof snow load at the 30o slope point (see the figure below). In plan, this load is distributed over a 90o sector and tapers to zero over the 22.5o sectors to either side of the 90o degree sector. The ASCE unbalanced distribution can be used to compute an average pressure in the loaded 90o sector of 1.58 times the flat roof snow load, when the area loaded is accounted for. (Arcs further from the roof center have more area). This ballot proposes for simplicity to use 1.5 times the flat roof snow load for the unbalanced load, and apply this over a 90o + 2(22.5 o) = 135 o sector (135/360 = 3/8 of the roof’s area). 2.0 pf Cs /Ce 0.5pf 30o slope Dome Elevation This ballot proposes that roof general buckling and tension ring checks for steel and aluminum domes be based on the unbalanced snow load since its intensity is greater than the balanced snow load, and the unbalanced load acts over a sufficiently large portion of the roof to cause general buckling and tension ring failure. ASCE 7 does not require unbalanced loads for dome roofs with a slope from the eave to the crown of 10o or less. If a cone roof is considered to be similar to a dome roof, then a cone roof with a slope of ¾ on 12 (3.57o) has a slope less than 10o, for which the only unbalanced load ASCE 7 requires is a partial loading (the balanced load acting over only part of the roof). Roof Design There are four types of fixed roofs addressed by API 650: Roof Type Supported Cone Roofs API 650 Reference 5.10.4 Self-Supporting Cone 5.10.5 650-608 Design Loads for Tank Roofs 1/28/08 Slope θ or Radius r 3.6 o (¾ on 12); may be greater 9.5 o < θ < 37o Safety Factor on Buckling 1.67 on column buckling variable from about 3 to 3 Roofs less than 2* Self-Supporting Dome 5.10.6 0.8D < r < 1.2D 4* and Umbrella Roofs Self-Supporting Appendix G 0.7D < r < 1.2D 1.65 on general buckling; Aluminum Dome Roofs 1.95 on member buckling *Safety factors for self-supporting cone and self-supporting dome roofs are given in Jawad and Farr, Structural Analysis and Design of Process Equipment. Fixed roofs will be more accurately designed as a result of this ballot by including unbalanced snow loads in their design. The table above shows that steel domes and self-supporting cone roofs have higher safety factors than the other roofs. This is partially due to the fact that API 650 places no tolerances on out-ofroundness for steel domes and self-supporting cones, so they can have geometric imperfections that reduce their buckling strength. However, since unbalanced loads will now be considered in their design, it is reasonable to reduce the steel dome safety factor for unbalanced loads to 3.5 as proposed in this ballot. The US unit equation for steel dome thickness given in 5.10.6.1 is modified as follows: Current equation: t = rr 200 T + C.A. > 3/16 in. 45 rr r T + C.A. and t = r 200 45 230 where T = balanced load and U = unbalanced load Ballot equations: Use the greater of t = U + C.A. > 3/16 in. 45 Designers may use the balloted equations given in 5.10.5 and 5.10.6 or they may perform more precise analyses if they wish. An example for a self-supporting steel dome is using 5.10.6 using the current 650 approach and this ballot’s approach is given below: Given: Balanced snow load = 20 psf Unbalanced snow load = 30 psf Tank diameter D = 80 ft Dome radius rr = tank diameter D External pressure = 1” w.c. = 5.2 lb/ft2 C.A. = 0 Assume a thickness of 0.375 in., which weighs 15.3 lb/ft2 Current method: T = balanced snow + 0.4(external pressure) + dead load = 20 psf + 0.4(5.2 psf) + 15.3 psf = 37.4 psf r T 80 37.4 t= r + C.A. = + 0 = 0.365 in. 200 45 200 45 Ballot method: U = unbalanced snow + 0.4(external pressure) + dead load = 30 psf + 0.4(5.2 psf) + 15.3 psf = 47.4 psf r T 80 47.4 t= r + C.A. = + 0 = 0.357 in. 230 45 230 45 650-608 Design Loads for Tank Roofs 1/28/08 4 T = balanced snow + 0.4(external pressure) + dead load = 20 psf + 0.4(5.2 psf) + 15.3 psf = 37.4 psf r T 80 37.4 t= r + C.A. = + 0 = 0.365 in. 200 45 200 45 For this example, the current method and the ballot method give the same result. Aluminum Dome Seismic Load The aluminum dome seismic load (G.4.2.3) needs to be updated since Appendix E has changed. This ballot corrects the dome seismic load to correspond with the new Appendix E seismic design requirements. Aluminum Dome General Buckling The aluminum dome general buckling equation is made dimensionless in this ballot to be consistent with the metric guidelines passed by the committee. The allowable buckling pressure is required to be compared to the revised loads in G.4.2.1 and G.4.2.2. Aluminum Dome Tension Ring The aluminum dome tension ring area equation given in G.4.1.4 has a typo. The US unit version should be 11D 2 180 tan sin( ) Ft Written in dimensionless form, making the applied load a variable, and using η sin(180o/η) ≈ π, this equation is An = An = D 2 ( LL DL) , which is used in this ballot. 8Ft tan BALLOT: Add unlined words 5.2.1 Loads Loads are defined as follows: (a) Dead Load (DL): The weight of the tank or tank component, including any corrosion allowance unless otherwise noted. (b) Design External Pressure (Pe): Shall not be less than 0.25 kPa (1 in. of water). This standard does not contain provisions for external pressures greater than 0.25 kPa. Design requirements for vacuum exceeding this value and design requirements to resist flotation and external fluid pressure shall be a matter of agreement between the Purchaser and the Manufacturer (see Appendix V). (c) Design Internal Pressure (Pi): Shall not exceed 18 kPa (2.5 lbf/in2). (d) Hydrostatic Test (Ht ): The load due to filling the tank with water to the design liquid level. (e) Minimum Roof Live Load (Lr): 1.0 kPa (20 lb/ft2) on the horizontal projected area of the roof. The minimum roof live load may alternatively be determined in accordance with ASCE 7, but shall not be less than 0.72 kPa (15 psf). The minimum roof live load shall be reported to the purchaser. (f) Seismic (E): Seismic loads determined in accordance with sections E.1 through E.6 (see Data 650-608 Design Loads for Tank Roofs 1/28/08 5 Sheet, Line 8). (g) Snow (S): The ground snow load shall be determined from ASCE 7 Figure 7-1 or Table 7-1 unless the ground snow load that equals or exceeds the value based on a 2% annual probability of being exceeded (50 yr mean recurrence interval) is specified by the purchaser. 1) The balanced design snow load (Sb) shall be 0.84 times the ground snow load. Alternately, the balanced design snow load shall be determined from the ground snow load in accordance with ASCE 7. 2) The unbalanced design snow load (Su) for cone roofs with a slope of 10o or less shall be equal to the balanced snow load. The unbalanced design snow load (Su) for all other roofs shall be 1.5 times the balanced design snow load. Unbalanced design snow load shall be applied over a 135o sector of the roof plan with no snow on the remaining 225o sector. Alternately, the unbalanced snow load shall be determined from the ground snow load in accordance with ASCE 7. The balanced and unbalanced design snow loads shall be reported to the purchaser. (h) Stored Liquid (F): The load due to filling the tank to the design liquid level (see 5.6.3.2) with liquid with the design specific gravity specified by the purchaser. (i) Test Pressure (Pt): As required by F.4.4 or F.7.6. (j) Wind (W): The design wind speed (V) shall be 190 km/hr (120 mph), the 3 sec gust design wind speed determined from ASCE 7 Figure 6-1, or the 3 sec gust design wind speed specified by the purchaser (this specified wind speed shall be for a 3 sec gust based on a 2% annual probability of being exceeded (50 yr mean recurrence interval)). The design wind pressure shall be 0.86 kPa [V/190]2, [(18 lbf/ft2)(V/120)2] on vertical projected areas of cylindrical surfaces and 1.44 kPa(V/190)2, [(30 lbf/ft2)(V/120)2] uplift (2) on horizontal projected areas of conical or doubly curved surfaces, where V is the 3 sec gust wind speed. The 3 sec gust wind speed used shall be reported to the purchaser. 1. These design wind pressures are in accordance with ASCE 7 for wind exposure category C. As an alternative, pressures may be determined in accordance with ASCE 7 (exposure category and importance factor provided by purchaser) or a national standard for the specific conditions for the tank being designed. 2. The design uplift pressure on the roof (wind plus internal pressure) need not exceed 1.6 times the design pressure P determined in F.4.1. 3. Windward and leeward horizontal wind loads on the roof are conservatively equal and opposite and therefore they are not included in the above pressures. 4. Fastest mile wind speed times 1.2 is approximately equal to 3 sec gust wind speed. 5.10.5.1 Self-Supporting Cone Roofs For SI units, change: D T Minimum thickness = > 5 mm 4.8 sin 2.2 Maximum thickness = 12.5 mm, exclusive of corrosion allowance where D = nominal diameter of the tank shell (m) T = greater of load combinations (e)(1)and (e)(2) of Appendix R (kPa) θ = angle of cone elements to the horizontal (deg) 650-608 Design Loads for Tank Roofs 1/28/08 6 to: Minimum thickness = greatest of D T D U , , and 5 mm 4.8 sin 2.2 5.5 sin 2.2 where D = nominal diameter of the tank (m) T = greater of Appendix R load combinations (e)(1)and (e)(2) with balanced snow load Sb (kPa) U = greater of Appendix R load combinations (e)(1)and (e)(2) with unbalanced snow load Su (kPa) θ = angle of cone elements to the horizontal For US units, change: D T > 3/16 in. 400 sin 45 Maximum thickness = ½ in., exclusive of corrosion allowance Minimum thickness = where D = nominal diameter of the tank (ft) T = greater of load combinations (e)(1)and (e)(2) of Appendix R (lbf/ft2) θ = angle of cone elements to the horizontal (deg) to: Minimum thickness = greatest of D T D U , , and 3/16 in. 400 sin 45 460 sin 45 where D = nominal diameter of the tank shell (ft) T = greater of Appendix R load combinations (e)(1)and (e)(2) with balanced snow load Sb (lbf/ft2) U = greater of Appendix R load combinations (e)(1)and (e)(2) with unbalanced snow load Su (lbf/ft2) θ = angle of cone elements to the horizontal 5.10.6.1 Self-Supporting Dome and Umbrella Roofs For SI units, change: r T Minimum thickness = r + C.A. and > 5 mm 2.4 2.2 Maximum thickness = 12.5 mm, exclusive of corrosion allowance where D = nominal diameter of the tank shell (m) T = greater of load combinations (e)(1)and (e)(2) of Appendix R (kPa) r = roof radius (m) to: Minimum thickness = greatest of rr r T U + C.A., r + C.A., and 5 mm 2.4 2.2 2.7 2.2 where D = nominal diameter of the tank shell (m) 650-608 Design Loads for Tank Roofs 1/28/08 7 T = greater of Appendix R load combinations (e)(1)and (e)(2) with balanced snow load Sb (kPa) U = greater of Appendix R load combinations (e)(1)and (e)(2) with unbalanced snow load Su (kPa) r = roof radius (m) For US units, change: rr T + C.A. > 3/16 in. 200 45 Maximum thickness = ½ in., exclusive of corrosion allowance Minimum thickness = where D = nominal diameter of the tank shell (ft) T = greater of load combinations (e)(1)and (e)(2) of Appendix R (lbf/ft2) r = roof radius (ft) to: Minimum thickness = greatest of rr 200 r T + C.A., r 45 230 U + C.A., 3/16 in. 45 where D = nominal diameter of the tank shell (ft) T = greater of Appendix R load combinations (e)(1)and (e)(2) with balanced snow load Sb (lbf/ft2) U = greater of Appendix R load combinations (e)(1)and (e)(2) with unbalanced snow load Su (lbf/ft2) r = roof radius (ft) APPENDIX R – LOAD COMBINATIONS R.1 For the purposes of this standard, loads are combined in the following manner. Design rules account for these load combinations, including the absence of any load other than DL in the combinations: (a) Fluid and Internal Pressure: DL + F + Pi (b) Hydrostatic Test: DL + (Ht + Pt) (c) Wind and Internal Pressure: DL + W + 0.4Pi (d) Wind and External Pressure: DL + W + 0.4Pe (e) Gravity Loads: 1) DL + (Lr or Su or Sb) + 0.4Pe 2) DL + Pe + 0.4(Lr or Su or Sb) (f) Seismic: DL + F + E + 0.1Sb + 0.4Pi R.2 If the ratio of operating pressure to design pressure exceeds 0.4, the purchaser should consider specifying a higher factor on design pressure in (c), (d), (e)(1), and (f). Appendix G Current (10th edition, 4th addendum) 650-608 Design Loads for Tank Roofs 1/28/08 Replace with: 8 G.4.1.3 Local and general buckling of the dome roof must be considered with a minimum factor of safety of 1.65 applied to the buckling equation or method. General buckling of the dome roof shall be considered either by using non-linear finite element analysis or by the following equation: Wa = allowable total downward load in kPa G.4.1.3 General buckling The allowable general buckling pressure pa shall equal or exceed the maximum pressure given in R.1(e) where 1.6 E I x A pa = LR 2 ( SF ) E = modulus of elasticity of the dome frame members Ix = moment of inertia of the frame members for bending in a plane normal to the dome surface A = cross sectional area of the frame members R = spherical radius of the dome L = average length of the frame members SF = safety factor =1.65 Ix = moment of inertia of frame members against bending in a plane normal to the dome surface in cm4 Alternately, pa shall be determined by a non-linear finite element analysis with a safety factor of 1.65. In SI units: Wa = 108 .1 10 6 E I x Ag LR 2 ( SF ) where Ag = cross sectional area of beam in cm2 R = spherical radius of the dome in cm SF = safety factor = 1.65 In US units: 2258 10 6 E I x Ag Wa = LR 2 ( SF ) where Wa = allowable total downward load (lbf/ft2) Ix = moment of inertia of frame members against bending in a plane normal to the dome surface (in4) Ag = cross sectional area of beam (in2) R = spherical radius of the dome in (in.) SF = safety factor = 1.65 G.4.1.4 The minimum net tension ring area (exclusive of bolt holes and top flange protrusions) shall be determined per the following formula: In US units: An = 11D 2 180 tan ( ) Ft 650-608 Design Loads for Tank Roofs 1/28/08 G.4.1.4 Tension Ring The net tension ring area (exclusive of bolt holes and top flange protrusions) shall not be less than: An = D2 p 8 Ft tan where An = net area of tension ring 9 where An = net area of tension beam (in.2) D = nominal tank diameter (ft) η = number of dome supports θ = ½ the central angle of the dome or roof slope at the tank shell Ft = allowable stress of the tension ring (lbf/in2) In cases where the total dead load plus live load is greater than 1.34 kPa (28 lbf/ft2), the above formula shall be multiplied by W/1.34 (or 28), where W = the total dead load plus live load for the dome. Note: this formula does not include factors for bending stresses due to loads from the panel attached to the beam. These stresses must also be considered in the tension ring design, as per G.3.1. G.4.2 DESIGN LOADS Dome roofs shall be designed for the loads in 3.2.1, G.4.2, and G.4.3; and for the load combinations (a), (b), (c), (e), and (f) of Appendix Y. D = nominal tank diameter p = maximum pressure given in R.1(e) θ = ½ the central angle of the dome or roof slope at the tank shell Ft = tension ring allowable stress Note: this formula does not include bending stresses due to loads from the panel attached to the beam. These stresses must also be considered in the tension ring design per G.3.1. G.4.2 DESIGN LOADS Dome roofs shall be designed for: a) the loads in 5.2.1. b) the load combinations in Appendix R.1(a), (b), (c), (e), and (f). G.4.2.1 Unbalanced Load The design shall consider one-half of the uniform downward load required applied to one-half of the dome with only the dead load on the other half. G.4.2.2 Wind Load G.4.2.2.1 For dome structural design, the minimum wind load shall be the load resulting from a design wind speed of 190 km/h (120 mph) which imposes a velocity pressure of 1.48 kPa (31 lbf/ft2)). The following pressure coefficients shall be used: G.4.2.1 Unbalanced Load The design shall consider one-half of the uniform downward load required applied to one-half of the dome with only the dead load on the other half. G.4.2.2 Wind Load G.4.2.2.1 For dome structural design, the minimum wind load shall be the load resulting from a design wind speed of 190 km/h (120 mph) which imposes a velocity pressure of 1.48 kPa (31 lbf/ft2)). The following pressure coefficients shall be used: Windward quarter = -0.9 Center half = -0.7 Leeward quarter = -0.5 Windward quarter = -0.9 Center half = -0.7 Leeward quarter = -0.5 For domes designed for 3 sec gust wind speeds other than 190 km/h (120 mph), the wind load shall be multiplied by the following: For domes designed for 3 sec gust wind speeds other than 190 km/h (120 mph), the wind load shall be multiplied by the following: In SI units: (V/190)2 In SI units: (V/190)2 In US Customary units: (V/120)2 In US Customary units: (V/120)2 650-608 Design Loads for Tank Roofs 1/28/08 10 Where V = wind speed (3 sec gust) in km/h (mph). Where V = wind speed (3 sec gust) in km/h (mph). Note: The velocity pressure of 1.48 kPa (31 lbf/ft2) is based on ASCE 7-98, Category II, Exposure C, with an Importance Factor of 1.0. G.4.2.2.2 See 3.11 for tank overturning stability. Note: The velocity pressure of 1.48 kPa (31 lbf/ft2) is based on ASCE 7-98, Category II, Exposure C, with an Importance Factor of 1.0. G.4.2.2.2 See 3.11 for tank overturning stability. G.4.2.3 Seismic Load If the tank is designed for seismic loads, the roof shall be designed for a horizontal seismic force determined as follows: F = 0.6 ZIWr where F = horizontal seismic force. Z, I, and Wr are as defined in Appendix E. The force shall be uniformly applied over the surface of the roof. G.4.2.1 Seismic Load If the tank is designed for seismic loads, the roof shall be designed for G.4.2.4 Panel Loads G.4.2.2 Panel Loads G.4.2.4.1 Roof panels shall be of one-piece aluminum sheet (except for skylights as allowed by G.8.4) and shall be designed to support a uniform load of 3 kPa (60 lbf/ft2) over the full area of the panel without sustaining permanent distortion. G.4.2.2.1 Uniform Load Roof panels shall be one piece aluminum sheet (except for skylights as per G.8.4). The roof shall be designed to support a uniform load of 3 kPa (60 lbf/ft2) over the full area of a panel. G.4.2.4.2 The roof shall be designed to support two concentrated loads 1100 N (250 lbf), each distributed over two separate 0.1 m2 (1 ft2) areas of any panel. G.4.2.2.2 Concentrated Load The roof shall be designed to support two concentrated loads 1100 N (250 lbf), each distributed over two separate 0.1 m2 (1 ft2) areas of any panel. G.4.2.4.3 The loads specified in G.4.2.4.1 and G.4.2.4.2 shall not be considered to act simultaneously or in combination with any other loads. a) a horizontal seismic force Fh = AiWr b) a vertical seismic force Fv = ±AvWr where Ai, Av, and Wr are as defined in Appendix E. Forces shall be uniformly applied over the surface of the roof. Horizontal and vertical forces need not be applied simultaneously. G.4.2.2.3 Application The loads specified in G.4.2.2.1 and G.4.2.2.2 shall not be applied simultaneously or in combination with any other loads. Appendix L Change “11. Thickness * _______ In. Snow Load* to Minimum Roof Live Load _______ psf Balanced Snow Load _________ psf Unbalanced Snow Load _______ psf 650-608 Design Loads for Tank Roofs 1/28/08 11