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n the hydrocarbon industry, especially refineries, many storage
tanks exist. A storage tank is a container or vessel generally used
to store raw crude, intermediate and final-product liquids from
refineries or other process industries. The roots of these tanks can
be fixed, cone, domed or floating. Tanks vary in diameter and can
measure up to 102 m. Large-diameter tanks, larger than 90 m
with heights up to 20 m are not uncommon in refineries. These
tanks act as feed sources to feed pumps and as reservoir to store
discharge from pumps.
With regards to differential settlement between the tank and
connected piping (generally large pipes), there are two pipe-
supporting approaches:
Spring supportfirst support away from the tank nozzle
that supports the connected pipe
Support directly from the tank foundation or extended tank
foundation.
The effectiveness of both approaches will be discussed in rela-
tion to the effect of hydrobulging on large-diameter liquid-filled
tanks and the interrelated effects on nozzle-load analysis.
Background. Tank settlement occurs in large diameter tanks
holding heavy products, so stress analysis needs to be performed
on piping that is connected to tank nozzles. To take care of heavy
loads on the nozzle due to tank settlement, spring support is an
acceptable approach. However, another school of thought advo-
cates first support from the tank foundationthis avoids using a
spring support, saving cost. This support is taken directly from the
tank foundation or by extending the tank foundation.
Before proceeding, the following terms need to be understood:
Tank settlementgradual settling of the tank foundation dur-
ing an extended period of time which creates a relative difference
in elevation between the piping and the tank nozzle. Most settle-
ment occurs during hydrotesting of the tank but it can continue
for years since its a slow process and it may take more years to
reach full settlement. The tank settlement amount depends on soil
characteristicsprimarily, consolidation and compressibility.
Spring supportsflexible supports used when excessive
loads are encountered on the nozzle due to vertical displace-
ments of line and equipment. These supports are used to absorb/
accommodate the vertical displacement and to support the line
in these conditions.
First support from tank foundationrefers to normal rest
supports that are taken from the tank foundation or by extending
the tank foundation to support the line connecting to the tank
nozzle. This serves the same purpose as using a spring support.
This type of support will also settle by the same amount as the
tank foundation.
Tank bulgingradial growth occurs on the shell due to
product static head for large-diameter tanks. Bulge formations
appear because a static head may cause circumferential and
longitudinal strains.
Methodology. For large-diameter storage tanks with heavy liq-
uid, tank bulging occurs since there is a slight growth of the tank
shell in radial direction. When this radial-shell growth occurs at
the nozzle location, the nozzle is rotated slightly. Even the smallest
nozzle rotation will cause the associated piping to either lift-off
from the first support from the tank foundation or excessively
compress the pipe at the first support from the tank foundation.
This happens even if the vertical displacement of the tank nozzle
is in a downward direction. This assumes that the first support is
a rigid support from the tank foundation extension.
A case study was done on the piping connected to a 36-in.
nozzle on a 76-m-diameter tank that was used for crude stor-
age in a refinery tank farm. Various interrelated aspects of tank
bulging on the first support from the tank foundation and nozzle
loads were studied. Radial-shell growth and nozzle vertical dis-
placement at varying heights and shell thickness were tabulated.
A vertical displacement effect on the nozzle occurred due to it
rotating from tank bulging. This caused the support of the asso-
ciated piping to lift off or come down. Nozzle-load analysis for
both systemsfirst support from the tank foundation and spring
supportswere developed.
A similar stress-run was made where all design parameters
were kept similar except that the first support from the tank foun-
dation was replaced by a spring support. Nozzle loads for both
the stress-runs and the behavior of first support from the tank
foundation and spring support were compared and studied.
Case study with the following tank design
parameters:
Tank diameter: 76,000 mm
Tank product design height (H): 18,500 mm
Specific gravity of liquid (G): 1.0
Vertical distance (L) between nozzle (N1) and tank bottom:
875 mm
Shell thickness at shell-nozzle junction(t) : 38 mm
Nozzle (N1) standout from outer shell (S): 340 mm
Nozzle (N1) and connecting pipe size: 36 in.
No anchor chair on tank base.
Hydrobulging of storage tanks and
its effect on first support selection
Case studies prove that installing variable spring supports is a viable option
M. G. CHOUDHURY, S. JOHRI and R. TRIPATHI, BecRel Engineering Pvt. Ltd., Mumbai, India
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SEPTEMBER 2010 HYDROCARBON PROCESSING
Notes:
1. The case study was done for a hydrostatic condition; how-
ever, the temperature effect on tank bulging was not considered.
2. Radial deflection due to tank bulging is calculated based
on Appendix P clause P.2.5.1 of API-650, using the understated
formula:
W =
9.8 10
6
GHR
2
Et
1 e
L
cos(L)
L
H

1
]
1
+ oRAT (1)
Temperature effect, i.e., R T; in Eq. 1 is considered 0. Thus,
Eq. 1 is rewritten as:
W =
9.8 10
6
GHR
2
Et
1 e
L
cos(L)
L
H

1
]
1
where:
W = the shells unrestrained radial growth (mm)
G = design specific gravity of the liquid
H = maximum allowable tank filling height (mm)
R = nominal tank radius (mm)
= characteristic parameter, 1.285/ (Rt)
0.5
(1/mm)
L = vertical distance from the opening centerline
to the tank bottom (mm)
E = modulus of elasticity (MPa)
t = shell thickness at the opening connection (mm)
= thermal expansion coefficient of the shell material
(mm/mm, C)
T = normal operating temperature minus installation
temperature (C)
= unrestrained shell rotation resulting from product
head (radians)
S = Nozzle standout from outer shell
X = Vertical displacement of nozzle due to rotation,
i.e., lifting-off support (mm)= S x tan
Calculating radial growth in relation to height:
= characteristic parameter = 0.001068815 (1/mm)
L = 0.935213 (radians)
W = 24.4738 mm
= 0.01811 radians; 1.0376 degrees
tan = 0.01811
X = 6.1583 mm
A negative sign indicates lifting-off support since the nozzle
rotates in a clockwise direction. Table 1 shows W calculated at
different thicknesses and varying heights from the tank base.
Based on Table 1, an L vs. W chart is plotted to observe the
trend of changing radial-shell growth at different heights from
the tank base (Fig. 1).
Vertical displacement effect on nozzle due to tank
bulging on nozzle loads
Case 1Nozzle load with first support from the tank foundation
and vertical displacement due to nozzle rotation because of a bulge.
For the piping arrangement illustrated in Fig. 2, nozzle loads are
listed in Table 2. The loads and displacements for first support from
the tank foundation are listed in Table 3.
TABLE 1. Calculation scenarios when using different
shell thicknesses
t (mm) W (mm) L (mm)
38 31.5062825 2,500
34 27.62671196 5,000
33 27.34424293 7,250
26 22.8354091 10,000
22 19.04995468 12,500
16 15.27965145 15,000
11 6.349985021 17,500
10 3.492491761 18,000
0
5
10
15
20
25
30
35
2,500 5,000 7,250 10,000 12,500 15,000 17,500 18,000
L
W
Series 1
Radial-shell growth (W) vs. heights from tank base (L). FIG. 1
220
230
240
250
260
270
280
290
320
Y
First support (rigid) from tank foundation
with settlement same as using anchor
C node and displacement concept
Tank modeled
as rigid element
Tank modeled
as rigid element
Vertical displacement from
nozzle rotation due to bulge
input at nozzle node using
displacement
X Z
Piping arrangement of line connected to tank nozzle using
first support from tank foundation.
FIG. 2
Y
X Z
220
230
240
250
260
270
280
290
320
First support (rigid) from tank foundation
with settlement same as using an anchor
C node and displacement concept
Tank modeled
as rigid element
Tank foundation as
anchor with settlement
Piping arrangement of line connected to tank nozzle with
first support from tank foundation.
FIG. 3
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Behavior of first support from tank foundationit is evi-
dent from Table 3 that the line doesnt rest on the support taken
from the tank foundation at node 290. The support doesnt take
any load in both operating and sustained conditions.
Case 2nozzle load with first support from the tank founda-
tion, without vertical displacement.
The piping arrangement shown in Fig. 3 is similar to Fig. 2,
except that the vertical displacement due to nozzle rotation from
tank bulging is not considered at nozzle node 340. For the piping
arrangement shown in Fig. 3, nozzle loads are listed in Table 4.
The loads and displacements for the first support from the tank
foundation are listed in Table 5.
Table 4 indicates that, if there is no hydrostatic bulge and no
nozzle rotation, the rigid support from the extended foundation
is reliable.
Behavior of first support from tank foundationTable 5
indicates that the rest support from the tank foundation serves its
purpose of supporting the line when vertical displacement due to
nozzle rotation is taken out of the picture. This support settles at the
same rate as that of the tank, thereby reducing the loads coming on
nozzle. This is similar to the function served by the spring support at
the same location as that of the rest support (refer to Cases 3 and 4).
TABLE 2. Calculated nozzle loads and moments
using first support from tank foundation and vertical
displacement
Node 340 F
X
F
Y
F
Z
M
X
M
Y
M
Z
Operating case 7,764 61,076 9,422 79,100 12,966 8,965
Sustained case 310 61,043 596 79,119 435 8,937
MAX 7,764 61,076 9,422 79,119 12,966 8,965
TABLE 3. Calculated loads and displacements on first
support from tank foundation with vertical displacement
from nozzle rotation because of bulge
Node 290 F
X
F
Y
F
Z
D
X
D
Y
D
Z
Operating case 0 0 0 1.145 0.460 9.050
Sustained case 0 0 0 0.038 0.448 0.411
MAX 0 0 0 1.145 0.460 9.050
TABLE 4. Calculated nozzle loads and moments using
first support from tank foundation, without vertical
displacement from nozzle rotation because of bulge
Node 340 F
X
F
Y
F
Z
M
X
M
Y
M
Z
Operating case 7,924 33,689 9,942 2,626 12,918 37,469
Sustained case 144 32,476 55 501 469 37,053
MAX 7,924 33,689 9,942 2,626 12,918 37,469
TABLE 5. Calculated loads and displacements
using first support from tank foundation, no vertical
displacement from nozzle
Node 290 F
X
F
Y
F
Z
D
X
D
Y
D
Z
Operating case 0 16,362 0 1.140 13.0 9.459
Sustained case 0 17,751 0 0.042 13.0 0.002
MAX 0 17,751 0 1.140 13.0 9.459
TABLE 6. Calculated nozzle loads and moments
considering spring support, without vertical
displacement
Node 340 F
X
F
Y
F
Z
M
X
M
Y
M
Z
Operating Case 7,987 8,231 9,956 34,760 13,173 16,950
Sustained Case 87 8,044 45 35,504 235 17,292
MAX 7,987 8,321 9,956 35,504 12,918 37,469
TABLE 7. Spring details for spring support at node 290
Type Variable spring support
Load variation 13%
Quantity 1
Model DV35
Size 17
Horizontal movement 9.529 mm
Vertical movement 9.279 mm
Hot load 51,349 N
Installed load 44,850 N
Spring rate 700 N/mm
Y
X Z
240
250
260
270
280
290
320
Tank modeled
as rigid element
First support spring
Tank foundation as
anchor with settlement
Piping arrangement of line connected to tank nozzle using
spring support as first support.
FIG. 4
240
250
260
270
280
290
320
Y
X Z
First support spring
Tank modeled
as rigid element
Tank foundation as
anchor with settlement
Vertical displacement due
to nozzle rotation from bulge
input at nozzle node using
displacement
Piping arrangement of line connected to tank nozzle with
first support as spring support.
FIG. 5
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Case 3Nozzle load, using first support with a spring and
no vertical displacement.
The piping arrangement illustrated in Fig. 4 is analyzed with
a variable spring support in lieu of rest support from the tank
foundation at node 290. Vertical displacement from nozzle rota-
tion because of a bulge is not considered at nozzle node 340. For
this case, nozzle loads are listed in Table 6. The details for spring
support at node 290 are listed in Table 7.
Case 4Nozzle load with first support as spring, with vertical
displacement.
The piping arrangement shown in Fig. 5 is analyzed with a
variable spring support in lieu of rest support from the tank foun-
dation at node 290, with consideration of vertical displacement
from nozzle rotation because of bulge considered at nozzle node
340. For this case, nozzle loads are listed in Table 8. Details for
spring support at node 290 are listed in Table 9.
For all cases, all forces (F
X
, F
Y
and F
Z
) at nozzle node 340 are
in Newtons. Moments (M
X
, M
Y
and M
Z
) are in Newtons-meter.
All displacements (D
X
, D
Y
and D
Z
) at node 290 are in mm. Pip-
ing analysis is done using stress analysis software.
Inferences. As seen from the calculations, using the first sup-
port from the tank foundation in lieu of a spring support is not
the best approach. Although this support settles with the same
value as that of the tank foundation, this support is not active
since nozzle rotation occurs from tank bulging, resulting in
nozzle loads that are higher than should be allowed.
First support for lines connected to nozzles on large-diam-
eter tanks with significant settlement values is better served to
use a spring support. Keep in mind, the spring support should
be designed to take in settlement effects. Also, the spring sup-
port, if possible, should be designed for vertical displacement
of the nozzle due to nozzle rotation from tank bulging. This
is evident from the spring behavior as seen in calculation. The
spring may show opposite displacement behavior during settle-
ment and the nozzles vertical displacement from rotating due
to tank bulging.
Conclusion. For large-diameter tanks, tank bulging plays a
role in nozzle loads and support selection. The nozzle rotation
effect when considered in stress analysis, gives an indication of
adverse effects from first support from the tank foundation on
nozzle loads. Therefore, it is advisable to install variable spring
supports for such cases. HP
M. G. Choudhury is senior vice president and head of piping
engineering at BecRel Engineering Pvt. Ltd. He has over 38 years of
experience in piping design and engineering, including pipe stress
analysis. Mr. Choudhury has also worked at EIL, TOYO, CHEMTEX
and SABIC.
Saurabh Johri has been working extensively in the field of
pipe stress analysis for the past four years at BecRel Engineering Pvt.
Ltd., Mumbai, India. Mr. Johri is a production engineering gradu-
ate and also has a mechanical engineering diploma from Aligarh
Muslim University, India. He was involved with pipe stress analysis
for Reliance SEZ Refinery in Jamnagar, Gujrat, India (JERP).
Radharaman Tripathi is a mechanical engineering graduate
and has been associated with pipe stress analysis at BecRel Engi-
neering Pvt. Ltd., Mumbai, India. He has a mechanical engineering
diploma. Recently, Mr. Tripathi has been involved with the pipe stress
analysis for Reliance SEZ Refinery in Jamnagar, Gujrat, India (JERP).
TABLE 8. Calculated nozzle load moments using a
spring support, with vertical displacement from nozzle
rotation because of bulge
Node 340 F
X
F
Y
F
Z
M
X
M
Y
M
Z
Operating case 7,857 23,871 9,445 24,238 13,340 21,081
Sustained case 223 23,844 580 24,265 78 21,104
MAX 7,857 23,871 9,445 24,265 13,340 21,104
TABLE 9. Spring details for spring support at node 290
Type Variable spring support
Load variation 7%
Quantity 1
Model DV35
Size 17
Horizontal movement 9.126 mm
Vertical movement 4.982 mm
Hot load 51,291 N
Installed load 54,780 N
Spring rate 700 N/mm
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