STEEL TANKS WITH FLOATING ROOF

1. Introduction
The tanks with floating roof are most widespread method for decrease the loss when volatile oil products are
stored in them. They can be used when the tanks are open on top or they can be constructed inside in the
tanks with fixed roofs. They can be used also when the tanks are closed and it is not admissible any product
leak in the environment.

Floating roof

Floating roofs are strongly dependent on the good geometry of the shell, from vertical position of the
antirotation device and the roof itself must not have a slope. The cases of discrepancy from the project
condition of the tanks elements in the tanks lead to the key on the floating roof and to danger from fires. Big
part from tanks with floating roofs that are in exploitation in Bulgaria are constructed in the end of 70 years
and in the beginning of the 80 years. One of the most important problems is to find out whether these
facilities are good for further use. In Bulgaria serious research concerning the above mentioned tanks and
their behavior during the years and their status now have not been made.
The main advantages of the tanks with floating roofs are as follow:
1. Minimizing of the loss of the stored product due to its evaporations. The factors influencing the product
evaporation are:
a) temperature of the liquid;
b) the presence and the dimension of the vapor space above the liquid;
c) the possibility for ventilating of the vapor space;
d) the presence of the free surface of the product.

2. As a result of the decreased evaporating of the product the corrosion activity in the upper part shell courses
is decreased too.
3. The safety from fire is increased which is a result of the decreased evaporation of the volatile stuff hence
the lower risk from compound between the air and evaporating product which can be easily detonated.
4. Comparing with the tanks with fixed roofs there are smaller spaces inside the tanks with floating roofs
which must be used for foam extinguish and it allows fitting fire extinguished installations with smaller
power and their pipes to have smaller diameters.
5. The floating roof almost does not transmit the vertical longitudinal efforts to the shell. The risk from loss of
stability is decreased.
The floating roofs are implemented for the exploitation for the first time in 1923 by “Chicago Bridge & Iron”
Company and their construction is developed in the time. The correct choice of the type of floating roof can
decrease the risks during the exploitation. The factors which influence the tank construction and kind of the
floating roof are as follow:
- characteristic of the stored product;
- climate conditions and conditions on the site;
- volume of the stored product;
- the requirements toward of the tank as a facility as a whole.
The floating roofs may be separated in the different groups depending on the different criteria:
According to the presence of the fixed roof in the tank:

- external floating roofs.

The floating roofs projected and used for open on the top tanks.
They are made from steel and are welded. They must bear loadings from:
a) weather conditions (rain, snow, wind);
- 250 mm rain water for the period of 24 hours.
With tank owner agreement the real values for geographical area can be accepted for calculating the rain
loading;
- the normal snow loading for Bulgaria is st = 2,0 kN/m2. The coefficient for snow overloading is accepted to
be equal to γf =1,5. In this case the snow loading may be valid condition depend on area where the tank is
situated. Snow load can be irregularly distributed on the roof .

b) live loading on the roof;

- 2,2 kN movable concentrated loading of two persons upon 0,1 m2, who can stay on each one point on the
roof, which is floating or is in the lower position upon its supports;
c) loading from rolling ladder and supporting truss;
d) loading from additional manholes, nozzles, roof drain, and seal;
e) loading of the product upon the roof;
f) single deck roof – membrane and two neighboring compartments are punctured.
double deck roof - two neighboring compartments are punctured.

During this check, independently from the kind of the roof, there are not water and mobile load.

- internal floating roof

They appear because of the increased requirements of environment safety and to decrease the loss of oil
product. These floating roofs are fit inside under the fixed roof itself. They can be fit even in the tanks with
supported cone roof.
They can be made from steel, aluminum, or synthetic materials. They must bear the loading from:
a) 2,2 kN live concentrated load from two persons upon the 0,1m2, who can stay upon any point on the roof,
when it is floating or is in its lower position supported by its supports;
b) if there are not other conditions, all project calculation must be done when the product density is 0,7t/m3;

According to the kind of the construction, the floating roofs must be separated into the following groups:

- single deck, without pontoons, with and supporting truss upon the membrane
This is one from the first kind of the floating roofs. It was installed on the tank which diameter was up to 45
m. Due to its high boards the floating roof can continues to float even when there are water or snow upon it.

Advantages:
a) simplicity for execution, erecting and maintenance;

Disadvantages:
a) this kind of roof has not positive buoyancy and if its membrane be punctured it will sink;
b) the wind can push the accumulated water upon the roof toward one board and it will cause the bending and
probably sinking.
 Single deck floating roof without pontoons, with supporting trusses

- single deck, with outsider ring of pontoons on the periphery and a membrane in the middle.
Area of application
a) in the regions with small wind pressure where it is not possible to tear the membrane from the product;
b) in the regions with small sun shining where the lower temperature of the membrane helps the decrease of
evaporation of the product;
c) more often when tanks have diameter D ≤ 50 m.

Advantages:
a) they have simple construction which can be prefabricated and mounted easily;
b) they have little expenses for metal to unit of the covered surface;
c) they do not need additional special equipment for mounting.

Disadvantages:
a) increased possibility of membrane deformation;
b) there are peaks and dents on the central part which are obstacle on the way of the water to the roof drain;
c) difficulty to executing the membrane with slope toward roof drain without waves.

The partial solution of the problem with the deviation of membrane itself and its project is to put the
stiffening girders. They may be put in radial or circle direction.
When the stiffening girders are put in radial direction it is more convenient to put them above the membrane.
All erecting joints will be executed in bottom position.
When the stiffening rings have circle shape it is more convenient to put them under the membrane. They are
not an obstacle for movement of the water to the roof drain. But now all erecting joints must be made on the
ceiling which is inconvenient.
Another solution for improving the correct geometry of the membrane is to put the heavy objects (more often
sand) on the center of the roof. The additional tension of the central part is assured.
Both solutions require more steel and take higher manpower consumption.

Single deck roof with peripheral ring of pontoons

- single deck floating roof with peripheral ring of pontoons and one central pontoon
The design decision with central pontoon has two advantages:
a) the weight put upon in the center helps keeping of the membrane in its projected form;
b) the weight element is executed as a pontoon. This additional pontoon allows decreasing the dimensions of
the peripheral ring.

Area of application:
a) in the regions where the wind pressure is increased, where it is possible to tear the membrane from the
product and it must be avoid;
b) when the central part is executed by roll of sheets and it is required to stretch the membrane;
c) more often in the tanks with diameter D > 50 m.

Advantages:
a) improved geometrical form of the central part;
b) increased buoyancy of the roof in the case of punctured membrane;
c) simple construction for execution, erecting and maintaining;
d) relatively small metal expenses for unit covered surface.

Disadvantages:
a) complicated detail for roof drain.

Single deck floating roof with peripheral and central pontoons

- double deck floating roof, with two membranes covering all surface of the roof and structure between
them.
Area of application:
a) in regions with increased wind pressure, where it is possible to tear the membrane from the product and it
must be prevented;
b) in regions with increased sun shining when it is necessary to decrease temperature of the membrane which
contacts with the product;
c) more often when the tank has diameter D > 50 m.

Advantages:
a) the construction has enough stiffness and the geometrical form is well supported;
b) increased buoyancy of the roof comparing with the single deck roof;
c) decreased deformation when the snow load is irregular, when there is blast of wind;
d) when the blast of wind are strong it is possible the roof come off from the liquid.

Disadvantages:
a) increased metal and labor consumption;
b) many welding joints must be done in the closed space;
c) many erection devices are necessary.
 Double deck floating roof

- single deck floating roof with ring of pontoons in the periphery and many pontoons upon the
membrane
This kind of roof combines the strengths of the single deck and double deck floating roofs.
Area of application:
a) in region with increased wind pressure, where it is possible to tear the membrane from the product and it
must be prevented;
b) when the central part is executed by rolled sheets and it is required to stretch the membrane;
c) more often in the tanks which diameter D > 50 m.

Advantages:
a) they are simple enough as a construction which can be done easily;
b) they do not need the additional special erection devices;
c) increased buoyancy of the roof comparing with the single deck roof;
d) decreased deformation when the snow load is uneven and when there is blast of wind;
e) when the blast of wind are strong it is possible the roof come off from the liquid.

Disadvantages:
a) increased consumption of metal for one unit surface;
b) increased length of the welding joints.

Single deck roof with pontoons on the periphery and many pontoons in the middle

2. Criteria for determining the type of the floating roof

The purpose of the tank, kind and the characteristics of the stored product, the conditions of the site must
be taken into account when the type of floating roof is being chosen. The correct determination of its kind
and the facilities connected with it can assures easer maintenance and quick return of the investments.

a) stability of the floating roof:

It is one of the most important conditions for the correct work. Moving loads which are not balanced upon
the roof can cause inclination of the roof and floating with slope. There is the higher risk for the roof to
sink there. It is necessary to assure the work of the roof in the projected position by means of correct
constructing;
b) product
- aggressiveness of the stored product. It is necessary to take care of chemical characteristic of the liquid
and the possibility to damage the roof equipment which is not metal. Some chemical products can destroy
the seals of the roof in several weeks of exploitation;
- density of the product. According to the API Std. 650 volume weight of the product which are used
when the calculations for the buoyancy are made is ρf = 0,7 t/m3. It is not likely to store product with
smaller density but it is possible to happen. The information for the minimal values of the ρf allows the
designer to determine the sinking of the roof;
- steam pressure of the product. It is one of the most important characteristic of the roof when the kind of
the roof is being determined. According to the NFPA the use of the floating roofs in the tanks for storage
of oil and oil products is recommended when the steam pressure of the liquid bigger or equal to 1,5 psia
(78 mm Hg), but not bigger than 11,1 psia (570 mm Hg). If the steam pressure exceeds 11-12 psia the
heating during the day will causes the considerable increase of the steams under the floating roof. The
inflation of the central part as balloon is possible. The cooling of the product during the night will
decrease the pressure and will allow to the roof to restore its previous form with slope toward the center.
It is possible when there is the combination of the considerably inflated membrane by insider pressure,
which slope is from the center toward the periphery and the water upon the roof, the correct drain of the
water to be difficult.
When the steam pressure of the liquid is high, approaching 11,1 psia or higher then it is better to use
double deck floating roof. Its rigid construction keeps it in the projected form, even when there are the
steam under it and it assure uninterrupted drain. On the other side the double deck roofs protect the roof
from excessive heating.

c) technological process
It is necessary to measure the speed of filling/emptying. When we do not consider this speed and it do not
correspond to the erected technological facilities it is possible damage and even destroying of the roof.
In order to fix the floating roof according to its designed position (for avoiding its rotation), the
antirotation devices must be put inside in the tank, parallel to the shell.
In the past the number of antirotation devices usually was two per tank. Now during the repairing works
one of the antirotation devices can be removed and only one antirotation device can left. It must be done
in order to neutralize of the inclinations of the autorotation devices from their designed position during
the erections and during the exploitation. When the antirotation devices are not vertical it is possible to
key of the floating roof with all consequences connected with it. It is necessary that the antirotation device
supports all horizontal efforts which were supported before by two devices.

3. Constructive requirements
a) approximately 200 mm free space must have between external floating roofs and the shell, where the
seal will be mounted. The modern seals assure good jam and normal work when the distance between
shell and roof is from 100 to 300 mm;
b) minimal thickness of the steels in the pontoons in the membrane is 5mm (tr ≥ 5 mm);
c) the maximal distance between the roof supports of the floating roof must not be bigger than 1000 x tr
(thickness of the membrane);
d) distance from roof supports to welding joint in the membrane is not smaller than 300 mm;
e) when there are the girders stiffening the membrane, roof supports must be put in the area in this
stiffening.
f) the length of the supports is deferent depending on its status:
- during the exploitation – minimal height must grant the tank filling without the liquid jet to touch the
vertical board. It is unacceptable that the floating roof in its lowest position to lie upon the technological
facilities;
- during the repairing works on the tank - the minimal distance depends on considerations for easy doing
of the repairing works. It is assumed to be 1800 mm in the lowest point of the roof.
g) the floating roof , stepped through its supporting constructions on the bottom or when floats on the
liquid must have the slope toward the roof drain not less than 1:100. For insider roofs this slope have not
be considered;
h) upon the floating roofs must be constructed foam dam which height must not be less than 300 mm at 1
m from shell of the tank;
i) for fixing the roof according to the design conditions the antirotation devices must be considered. They
do not allow the rotation of the roof. They must bear the horizontal forces, caused by the rolling ladder,
by the uneven load from snow, by wind and by rotation of the stored product when it is mixed or the tank
fills;
j) the drain pipe must have the diameter not smaller than 3” for the tank which have the diameter D ≤ 36
m. The drain pipe must have the diameter not smaller than 4” for the tanks which have the diameter D >
36 m;
k) the pontoons situated on the periphery must be separated by waterproofed barriers and every pontoon
must have manhole for inspection;
l) in the central part of the roof must have one manhole for inspection, through which people can go to the
roof when the roof is in its lower position and the tank is empty.