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June 2011 TA N K S T O R A G E

FLOATING ROOF DESIGN

External floating roof or full contact internal floating roof? These tests compare emission levels, maintenance costs and the impact the
Issue 1 - May 2009

Decision time
Technical Articles
Floating Roof Design
Impact on Working Volume, Emissions and Operating Costs
been in existence for Floating design generally over roof half a century, varies with the material providing operators andused for construction. External floating regulatory bodies a reliable, roofs which are exposed to the time proven safety and elements use carbon steel emission control system. construction with pontoon or double deck generally designs. varies These The design designs the floating roof to with the allow material used for support potentially heavy loads of construction. External floating rain and snow and are also usually roofs which are exposed tofrom coated to prevent corrosion the elements use carbon steel weather exposure. Carbon steel floating roofs use heavy orleg construction with pontoon supports when landed as well as double deck designs. large air-filled 'compartments' These designs allow the known as pontoons for buoyancy. floating to steel support Externalroof carbon floating roofs potentially heavy some loads of rain also incorporate form of articulating pipe oralso flexible hose and snow and are usually deck drainage system to remove coated to prevent corrosion excess precipitation from their from weather exposure. surface. Carbon steel floating roofs use leg supports For heavy tanks that use fixed covered when as well as roofs large or roofs,landed like steel cone aluminum geodesic domes, the air-filled compartments internal floating roof for systems are known as pontoons typically constructed using lightbuoyancy. External carbon weight materials because they steel floating also don't have roofs to support the incorporate some form of on the environmental loads placed external floating roof systems. articulating pipe or flexible While materials vary, internal hose deck drainage system to floating roofs typically use remove excess precipitation The difference between a carbon aluminum as their structural from their surface. steel external floating and material, though roof some use a For tanks thin that gauge use fixed fiberglass, stainless internal floating roof volume loss steel or roofs, other composite panels. covered like steel cone height is anywhere from roughly Depending on design, internal roofs or aluminum geodesic floating Depending roof systems can usually 36 to 54. on tank domes, the internal floating be cable supported from the tank roof systems are typically diameter, that represents fixed roof structure, due to their a constructed usingof light-weight low mass. significant amount working materials because they do volume loss for identical sized One of the key differences not have to support the between tanks with carbon steel external or above ground storage tanks, environmental loads placed as aluminum internal floating roof is shown inon Image 2. the working external floating roof their volume. Each systems. While floating roof has materials a differentvary, cross internal floating roofs typically With all floating roof systems, the use aluminum as their floating roof has to remain floating structural material, though and not some landuse tofiberglass, work effectively. thin Floating r ostainless ofs ta n k or s other have gauge steel composite panels. restrictions on how highDepending you can fill design, internal floating the tankon with product. External roof systems can usually be floating cable roofsupported systems need to from the operate tank below the tank shell or fixed roof structure, foam ports. floating roof due toInternal their low mass. One of not the key differences systems must make contact between tanks with the underside ofwith the a tank fixed

decision has on working volumes

Floating roofs have been in existence for over half a century, providing operators and regulatory bodies a reliable, time proven safety and emission control system. Floating roofs function by reducing the formation and release of environmentally harmful and potentially explosive volatile organic chemicals in above ground storage tank loating roofs have systems. Typical floating roof designs

External Floating Roof


(Image Courtesy of Mesa Rubber)

Internal Floating Roof


(Image Courtesy of Sandborn Roofs)

- May 2009

Technical Articles

carbon steel external or only support environmental Image 1 - Typical Floating Roof but Designs aluminum internal floating live loads also their own roof is their working volume. mass, which varies from Each floating has a volume about 12 to 16psf. Pontoon sectional area roof displacing Internal floating roofs do not have that would otherwise be filled with a n y d i rvaries ect e xposu re to different cross sectional thickness based on stored product, translating into lost environmental loads like rain or area displacing volume that design and tank diameter but working volume due to the profile snow, and ranges are typically very light would otherwise be filled with generally from 32 to in depth of the floating roof system. mass, varying from about 1 to 2.5 stored product, translating 48 depth. The weight of use psf. in Internal floating roofs into lost working volume the floating roof will immerseor Carbon steel external floating roofs either air filled aluminum due theperimeter profile depth of to the pontoon anywhere use to large pontoons stainless steel pontoons, from air filled not floating only support environmental honeycomb panels or composite the roof system. 4-12. Also, external floating live loads but also their own mass, foam require filled panels for and buoyancy. Carbon steel external roofs primary which varies from about 12 to 16 Air filled pontoons vary in size but floating roofs use large secondary perimeter seals psf. Pontoon thickness varies are typically eight to ten inches in perimeter pontoons to diameter not to reduce emissions in the based on design and tank diameter and immerse in the

rim area (area between the pontoon and tank shell wall). The primary seal is typically contained within the pontoon rim area while the secondary seal extends anywhere from 18-24 above the pontoon level. For external floating roof pontoon designs, that total volume loss profile equates to about 42-72 or more above product level. Internal floating roofs do not have any direct exposure to environmental loads like rain or snow and are typically very light in mass, varying from about 1 to 2.5psf. Internal floating roofs use either air filled aluminum or stainless steel pontoons, air filled honeycomb panels or composite foam filled panels for buoyancy. Air filled pontoons vary in size but are typically 8-10 in diameter and immerse in the stored product approximately 4-5

but generally ranges from 32 to product approximately 4 to Tank stored working volume floating roof design 48 in depth. The weight of the 5 inches. Honeycomb Panels or floating roof will immerse the composite foam filled panels float pontoon anywhere from 4 to 12. in full contact with the liquid Elevated Liquid Surface Temperature Fixed Roofs Shelters product Directrequire Sunlight Also, external floating in roofs surface and only immerse into the from Direct Sunlight primary and secondary perimeter product by about to 1. and wind effects. Elevated Seal Losses caused by wind and vacuum seals to reduce emissions in effect. the Internal floating roof systems only Sealed Cables rim area (area between the require a single liquid mounted No Emission Paths seal, which typically extends above pontoon and tank shell wall). The the liquid level by 8 to 12. For primary seal is typically contained Emission Paths Max Fill Height internal floating roof a design and within the pontoon rim area while at Leg Locations depending on the perimeter seal the secondary seal extends system used the total volume loss anywhere from 18 to 24 above profile will vary from about 9 to the pontoon level. For external 18 above product floating roof pontoon designs, that 36 ~ 54level. Loss total volume loss profile equates to about 42 to 72 or more above product level.

www.sandbornroofs.com

Low Fill Height

Steel Pontoon External Floating Roof

Full Contact Internal Floating Roof


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roof or support rafters. As a result, the net capacity of tanks is restricted to a certain minimum

Image 2 - Tank Working Volume by Floating Roof Design

drainage systems. seals EFR systems onPerimeter the same sized onFLOATING both designs, tank and operatingexternal low/high or level ROOF DESIGN internal floating roofs may require conditions. Chart A: the difference in in netapproximately operating volume between a 10 replacement pontoon EFR system and full Chart contact IFRsystem A perimeter to 20 year cycles. EFR 150' dia. x 48' Shell Barrels % Volume seal systems are larger151,092 than IFR 100% Total Ta nk Capacity seal systems and are significantly 113,319 75% Steel Pontoon EFR 124,336 82% Full Contact IFR more expensive to replace on an Difference 11,017 7% on-going basis. Some IFR storage Based on 3-6 Operating, 4-0 Head Loss 54 EFR vs 12 IFR Based Low on 3'-6 Low Operating, 4'-0 Head Loss 54 EFR vsseveral 12 columns IFR tanks use several steel to inches. Honeycomb Panels conditions including or composite foam filled tank turnovers (shell losses), support the fixed steel cone roof panels float in full contact vapour pressure, atmospheric with the liquid conditions (heat/wind) and system, sosurface each column will have a and only immerse into the floating roof design. The product by about 0.5-1. penetration floating roof components corresponding seal Internal floating roof systems affecting emission loss that replaced at the only are require typically a single liquid include the perimeter seal mounted seal, which typically design (single/double), same time as the seal extends above the liquid level perimeter support type (legs/cables/ by 8-12. For an internal grid), penetration seals system. floating roof, depending on for columns and ladders, as External floating roof system tanks require a drain system, consisting of either an articulated pipe or flexible hose to drain the rainwater and melted snow off the surface of
the perimeter seal system used, the total volume loss profile will vary from about 9-18 above product level. The difference between a carbon steel external floating roof and an internal floating roof volume loss height is anywhere from roughly 36-54. Depending on tank diameter, that represents a significant amount of working volume loss for identical sized aboveground storage tanks. With all floating roof systems, the floating roof has to remain floating and not land to work effectively. Floating roof tanks have restrictions on how high the tank can be filled with product. External floating roof systems need to operate below the tank shell or foam ports. Internal floating roof systems must not make contact with the underside of the tank fixed roof or support rafters. As a result, the net capacity of tanks is restricted to a certain minimum (low) and maximum (high) operating levels. Chart A shows the difference in net operating volume between a pontoon External Floating Roof (EFR) system and full contact Internal Floating Roof (IFR) system. In this example, the IFR systems adds 7% more net tank operating volume compared to the EFR systems on the same sized tank and operating low/high level conditions. Floating roof design also has a significant impact on the total amount of volatile organic chemicals (VOCs) product emission losses. VOC emissions vary based on
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ro o f systems compon en s a f215' f e c tx ing and drain on atlarge emission losstank include perimeter 60' diameter inthe 20 year TA N K S T O R A G E June 2011 seal design (single/double), service intervals. (legs/cables/grid), Chart support C: The approximate type maintenance costs of replacing the perimeter seal, penetration seal and drain systems on a large 215 x penetration seals for columns and 60 diameter tank in 20 year Chart service intervals C ladders, as well asMaintenance the floating Costsroof Materials d e c k c o n sYears t r u c t 20 i o n ( 40 if its Steel Pontoon EFR Perimeter bolted/welded/sealed together). $144,700 $289,400
Seals & Hose Drain Full Contact IFR Perimeter $54,700 $109,400 Carbon steel Seals & Columns Seals EFR systems require steel legs for supports when landed Difference $90,000 $180,000

Issue 1 - May 2009

Technical Articles
Type Years Steel Pontoon EFR Full Contact IFR Difference 1 7,480 5,490 1,990

well as the floating roof deck construction (if its bolted/ welded/sealed together). Carbon steel EFR systems require steel legs for supports when landed due to their significant mass. Most EFR systems use an adjustable leg with support collar penetration sleeves to allow the operators to increase or decrease the landed height from low operating to a higher maintenance position allowing clearance for workers underneath. Adjustable leg supports provide an emission path for VOC vapours to escape into the atmosphere. Aluminum internal floating roofs can use thinner legs supports or suspended cable supports from the tank fixed roof. Suspended cable supports are adjusted from the top of the tank fixed roof and have no emission paths from the sealed deck connections. External floating roofs are also subject to higher overall emission losses due to the heating effects of solar radiation and vacuum effects of wind travelling across the top of the tank. internal floating roofs (IFR) are sheltered from the direct wind and sunshine and as a result environmental

due to their significant mass. of seal & drain materials. 215' dia. x 60' Tank Size. Most EFR systems use an factors have a much smaller not leak and result in 2008 Pricing. US Dollars impact on the VOC emission rainwater contamination leg with support lossadjustable on IFR tanks. of the stored product or collar In this the on-going seal Chart B is example, a sample VOC possible contamination penetration sleeves to allow the emission calculation for a steel of groundwater (and the maintenance costs of the IFR leg aupported pontoon EFR corresponding disposal costs). operators to increase or decrease versus a cable supported full Chart C shows the the system is approximately 37% contact aluminum IFR system height approximate maintenance the landed from low on the same size tank. In this of costs of replacing the seal equivalent costs the EFR sample, the EFR equipped perimeter seal, penetration maintenance. Depending on the tank system shows 27% seal and drain systems higher emission rates than the on a large 215ft by 60ft design and construction quality of IFR equipped tank system. diameter tank in 20 year Another impact of floating IFR service intervals. the aluminum system, their roof design is the ongoing In this example, the onmaintenance costs for the going seal maintenance expected life-span can be as long floating roof seals and costs of the IFR system is as their steel EFR counterparts. drainage systems. approximately 37% the
Perimeter seals on both designs, external or internal floating roofs, may require replacement in approximately 10 to 20 year cycles. EFR perimeter seal systems are larger than IFR seal systems and are significantly more expensive to replace on an on-going basis. Some IFR storage tanks use several steel columns to support the fixed steel cone roof system, so each column will have a corresponding penetration seal that is typically replaced at the same time as the perimeter seal system. External floating roof system tanks require a drain system, consisting of either an articulated pipe or flexible hose to drain the rainwater and melted snow off the surface of the floating roof. These drainage systems need to be replaced after a few maintenance cycles to ensure they do equivalent costs of the EFR seal maintenance. Depending on the design and construction quality of the aluminum IFR system, their expected life-span can be as long as their steel EFR counterparts. While these comparisons concern floating roof design, tank operators will have to weigh the operational and lifetime benefits versus the difference in capital costs of tank construction between the two systems. Both systems offer industryproven solutions to safe storage of VOCs, however the floating roof design and its ongoing maintenance costs, emissions and operational limits all play an influential part of the process of deciding which system provides the best solution. n For more information:
www.sandborn.ca

*Materials Only, Averaged based on 20 year lifespan of seal & drain *Materials Only, Averaged based on 20 year lifespan materials. 215 dia. x 60 Tank Size. 2008 Pricing. US Dollars

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Chart B: a sample VOC emission calculation for a steel leg supported pontoon EFR versus a cable Chart B supported full contact aluminum IFR system

Based on Crude OilBased (RVP on 5),Crude Results generated from EPA Tanks Software 215 dia. x 60 Tank Size Oil (RVP 5), Results generated from 4.0.9d EPA Tanks 4.0.9d Software 215 dia. x 60 Tank Size

Emission Losses (lbs per Year) 5 10 15 20 25 37,400 74,800 112,200 149,600 187,000 27,450 54,900 82,350 109,800 137,250 9,950 19,900 29,850 39,800 49,750

While floati will h and differ const syste

Chart B is a sample VOC emission

the floating roof.

These drainage

Both prove

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