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Two LPG bullet tanks on an industrial site

Structural FEA of LPG Bullet Tanks

ASME Section VIII, Division 2 Design by Analysis with SCL evaluation

FINITE ELEMENT ANALYSIS

Structural FEA of LPG Bullet Tanks

01 / VESSEL ARCHITECTURE

Understanding the complete tank assembly

Both models combine a long cylindrical shell with dish ends, internal ring stiffeners and top-mounted connections. The analysis follows how loads travel through this assembly and concentrates on the transitions around openings, reinforcement pads and attachments

  1. 01 Propane Vessel

    CAD view of the propane vessel with its internal rings

    Original CAD view from the consolidated propane report. The shell and repeated internal rings form the main vessel structure

  2. 02 Butane Vessel

    CAD view of the butane RevD vessel

    Original RevD CAD view. The domes, manholes and nozzle regions are retained for detailed assessment

  3. 03 Inside the Propane Vessel

    Cutaway of the propane vessel showing the internal stiffeners

    The cutaway exposes the internal stiffeners and the geometry behind the external shell

  4. 04 Inside the Butane Vessel

    End region of the butane vessel with its connections

    The end-region view shows the shell-to-head transition and local reinforcement around the connections

02 / MODEL DEVELOPMENT

Meshing the shell, openings and stiffeners

The CAD assemblies were prepared for finite element analysis. Full-vessel meshes capture the overall response, while the mesh around penetrations, lifting attachments and internal members resolves the local load paths

  • Finite element model of the propane vessel

    Propane finite element model

    The full model represents the shell courses, ends, top connections and attachment regions as one structural assembly

  • Finite element model of the butane RevD vessel

    Butane RevD finite element model

    The meshed assembly retains the detailed reinforcement and stiffener arrangement used in the pressure assessment

  • Mesh with three element layers through the shell thickness

    Through-thickness layers

    The Butane RevD report specifies three element layers through the shell and head thickness for stress linearization

  • Local mesh at the dome and nozzle interfaces

    Dome and nozzle interfaces

    Local mesh detail represents the changes in shape where openings interrupt the cylindrical shell

  • Mesh of an internal ring stiffener

    Internal ring stiffeners

    Separate ring views make it possible to follow the stress distribution in these internal members

03 / MATERIAL & LOADING BASIS

A programme of distinct loading conditions

The model material is SA 537 Class 1 steel. The reports assume homogeneous material and ideal welded connections. Each load case defines its own pressure, contents, inertia and restraint conditions

Model elastic modulus
203 GPa
Stated material yield strength
344.7 MPa
RevD design allowable stress
137.9 MPa
Load cases and source basis
STUDYWHAT THE MODEL EXAMINESSOURCE BASIS
Design pressureInternal / external pressure, fluid head and gravityPropane + Butane RevD
SeismicLongitudinal and lateral inertia with operating loadsPropane / Butane R2
HydrotestWater-filled vessel under the specified test loadingPropane / Butane R2
Support imbalanceAlternative distributions of bedding supportPropane / Butane R2
Section liftingSelf-weight of end and shell sections at lifting lugsPropane / Butane R2
Higher pressureSpecified pressure multiples in the archived studiesPropane / Butane R2
Gas-cloud loadingStatic representation of external overpressurePropane / Butane R2

Propane images use the consolidated Rev00 report for the RevD model. Butane R2 denotes earlier studies; these are not presented as a complete revalidation of the later RevD geometry

04 / DESIGN-PRESSURE ASSESSMENT

Applying pressure and tracing the response

  • Internal pressure applied to the propane vessel

    Propane: 1.85 MPa

    The case-specific loading definition applies internal pressure to the vessel, alongside the defined external pressure and operating loads

  • Design-pressure loading on the butane RevD vessel

    Butane: 0.883 MPa

    The RevD model has its own design-pressure basis. The two tanks are assessed against their respective loading definitions

  • Hydrostatic head and gravity loading

    Contents and gravity

    The operating setup represents hydrostatic head over 85% of the tank diameter, together with self-weight

  • Equivalent-stress contour of the propane vessel under design pressure

    Propane: 293.83 MPa

    The original equivalent-stress plot shows the highest local value near the end connections. The shell, rings and openings are then examined separately

  • Equivalent-stress contour of the butane RevD vessel under design pressure

    Butane RevD finite element model

    The original pressure-case contour identifies the higher-demand region in the revised vessel assembly. Detailed stress-category checks follow

These are local equivalent-stress maxima, not membrane-stress acceptance values. The tanks have different pressure bases, so this comparison does not rank their performance

05 / COMPONENT-LEVEL RESULTS

Looking closely at openings and reinforcement

  1. 01 Propane Dome

    Stress contour at the propane dome-to-shell connection

    The component view isolates the stress around the dome-to-shell connection under design pressure

  2. 02 Propane Manhole

    Stress contour around the propane manhole

    The manhole result shows how stress varies around the penetration and its connection to the vessel.

  3. 03 Propane Reinforcement Pad

    Stress contour on the propane reinforcement pad

    The pad contour identifies local demand around the reinforced opening

  4. 04 Butane RevD Dome

    Stress contour at the butane RevD dome

    The revised connection is checked as a separate component in addition to the full-tank result

  5. 05 Butane RevD Manhole

    Stress contour around the butane RevD manhole

    The extracted contour focuses attention on the manhole transition and the local stress pattern

  6. 06 Butane RevD Reinforcement Pad

    Stress contour on the butane RevD reinforcement pads

    The revised pads are reviewed alongside the adjoining shell and connection geometry

  7. 07 Propane Internal Ring

    Stress contour on a propane internal ring

    The ring is isolated to show the stress gradient through its section and around its circumference

  8. 08 Butane RevD Internal Ring

    Stress contour on a butane RevD internal ring

    Reviewing the stiffener separately reveals demand that can be difficult to distinguish in a complete-vessel contour

06 / ASME SECTION VIII, DIVISION 2

Design by Analysis using SCL methodology

The assessment uses Stress Classification Lines (SCLs) through the wall thickness at selected shell, dish-end and connection locations. Stress linearization separates membrane and bending response for evaluation against the ASME Section VIII, Division 2 criteria cited in the reports

  • SCL path through the propane dish-end wall

    Propane dish-end path

    The SCL crosses the wall at a selected high-stress location. The thickness-average membrane response and linear bending component support the stress-category assessment

  • SCL paths in the butane RevD dish end

    Butane RevD dish-end path

    The revised geometry has corresponding SCL checks. Membrane and membrane-plus-bending results are compared with the limits for the assigned stress category and loading condition

SCL results on the design-pressure paths
DESIGN PRESSURE PATHMEMBRANE / MPaMEMBRANE + BENDING / MPa
Propane dish end128.97133.09
Propane mid-shell126.86132.43
Butane RevD dish end123.66151.74
Butane RevD mid-shell105.60119.36
Butane RevD dome121.96167.60

Selected equivalent-stress values from the detailed tables; membrane + bending uses the larger reported surface value. The reports record satisfaction of the applicable checks for these paths. Their stated general membrane limit is 137.9 MPa; the corresponding combined limit is 206.85 MPa.

07 / DOCUMENTED DESIGN DEVELOPMENT

Refining the butane connection geometry

The Butane RevD report records changes to the reinforcement pads, dome thickness and shell-to-dish-end stiffeners. These details show how the structural assessment was carried into a revised geometry for evaluation

  • Butane RevD reinforcement pads

    Reinforcement pads

    Recorded pad diameters: dome 2,950 mm, manhole 2,300 mm and N2 nozzle 1,280 mm. A 1:3 chamfer provides the specified transition

  • Butane RevD dome wall thickness

    Dome wall thickness

    The documented dome arrangement uses a 38 mm lower ring and a 20 mm upper ring

  • Butane RevD shell-to-head stiffeners

    Shell-to-head stiffeners

    The revision adds the detailed stiffener arrangement at the shell-to-dish-end junction, including 20 mm-thick plates

08 / SEISMIC STUDIES

Examining response in two directions

The archived seismic cases apply 0.15 g acceleration longitudinally and laterally. Changing direction changes the way inertia is carried by the shell, internal stiffeners and connection regions

  • Propane longitudinal seismic stress contour

    Propane: longitudinal stress

    The longitudinal seismic case reports a local equivalent-stress maximum of about 299.4 MPa in the consolidated study

  • Butane R2 longitudinal seismic stress contour

    Butane R2: longitudinal stress

    The earlier butane model shows a 369.26 MPa local maximum. This result belongs to the R2 study and is not a RevD acceptance result

  • Butane R2 longitudinal seismic deformation

    Butane R2: longitudinal movement

    The original plot shows 10.265 mm maximum total deformation, with movement distributed along the shell and between the internal rings

  • Butane R2 lateral seismic stress contour

    Butane R2: lateral stress

    The lateral contour shows 255.84 MPa maximum equivalent stress. The change in direction alters both the stress distribution and the locations carrying higher demand

09 / HYDROTEST ASSESSMENT

Checking the water-filled test condition

The hydrotest models represent a fully water-filled vessel and the specified test loading. The change in contents and pressure produces a different stress distribution, which is examined through complete-vessel contours and detailed component checks

  • Propane hydrotest equivalent-stress contour

    Propane hydrotest study

    The original equivalent-stress contour reaches 485.35 MPa locally. The report also examines selected stress-linearization paths under its test-condition criteria

  • Butane R2 hydrotest equivalent-stress contour

    Butane R2 hydrotest study

    The earlier butane contour reaches 401.45 MPa locally. The separate study traces the demand through the shell, ends, stiffeners and openings

These plots are analysis outputs, not physical hydrotest records. Local peaks exceed the stated material yield strength and require the report’s stress-category and modelling context; they do not establish an unrestricted pass

10 / BEDDING & SUPPORT IMBALANCE

Testing alternative support distributions

  • Diagram of two subgrade support assumptions

    Two support assumptions

    The archived diagrams vary support along the vessel length to represent alternative subgrade distributions

  • Elastic support applied along the lower shell of the FE model

    Applying the support to the FE model

    The model assigns different support values along the lower shell. This tests the sensitivity of the vessel to the assumed bedding response

  • Butane R2 deformation for the first support arrangement

    Butane R2: first arrangement

    The first displayed support arrangement gives about 23.08 mm maximum total deformation. The local movement follows the changed support distribution

  • Butane R2 deformation for the second support arrangement

    Butane R2: second arrangement

    The second arrangement gives about 19.4 mm maximum total deformation. Both the displacement pattern and component stresses were reviewed

The propane study also includes two support-imbalance conditions. These are prescribed support scenarios; they are not site settlement measurements or a geotechnical verification

11 / SECTION-LIFTING ASSESSMENT

Following the handling loads through the lugs

Separate models assess an end section with its dome and a cylindrical shell section under self-weight. Restraints at the lifting attachments change the load path, placing particular emphasis on the lug, pad and adjacent shell

  • Propane end-section model with its dome

    End section with dome

    The original propane model includes the dish end, a length of shell, internal rings and top connections

  • Cylindrical shell section model

    Cylindrical shell section

    The shell-only model has its own attachment positions and local response. These are partial-section studies

  • Propane end-section deformation under lifting

    Propane end-section movement

    The source plot reports about 1.5 mm maximum total deformation for the modelled lifting condition

  • Butane R2 end-section deformation under lifting

    Butane R2 end-section movement

    The original contour reports 3.18 mm maximum total deformation. The open shell edge and attachment regions show distinct movement

  • Stress contour on the propane lifting lug

    Propane lifting lug

    The isolated attachment plot shows approximately 200 MPa local equivalent stress for the end-section lifting case

  • Stress contour on the butane R2 lifting lug

    Butane R2 lifting lug

    The earlier butane attachment result shows 301.29 MPa locally. The report also reviews the adjoining shell and internal rings

These results apply to the modelled sections, self-weight and restraint assumptions. They do not describe a complete-vessel lift or an approved site rigging procedure

12 / HIGHER-PRESSURE STUDIES

Exploring the specified pressure scenarios

The archive includes studies labelled burst-pressure analysis. The propane report examines a 2.5-times-MAWP case; the earlier butane study includes 2.5-times and 4-times cases. MAWP is maximum allowable working pressure

  • Propane equivalent-stress contour at 2.5 times MAWP

    Propane: 2.5-times case

    The original contour reports 732.65 MPa local equivalent stress under the prescribed higher-pressure loading

  • Butane R2 equivalent-stress contour at 2.5 times MAWP

    Butane R2: 2.5-times case

    The selected contour reports 574.24 MPa. The archive also contains a separate 4-times pressure scenario

These are applied-load studies, not measured burst pressures. The reported peaks exceed the material yield strength; the plots alone cannot establish actual failure pressure or a usable capacity margin

13 / EXTERNAL OVERPRESSURE

Assessing a gas-cloud loading scenario

The project extends the assessment to a gas-cloud loading case represented as static external overpressure, with the defined mound and gravity loads. The component results show where that assumed loading is carried within each vessel

  • Propane static-overpressure stress contour

    Propane static-overpressure study

    The displayed contour reports approximately 288 MPa local equivalent stress. The report reviews the shell, rings and top connections separately

  • Butane R2 static-overpressure stress contour

    Butane R2 static-overpressure study

    The earlier model shows 367.64 MPa locally, with the ring-stiffener response examined in separate component plots

The archived setup is a static structural representation. These results do not represent a time-resolved blast simulation or an experimentally demonstrated explosion rating

14 / ENGINEERING FINDINGS

Connecting the analysis to design decisions

Engineering questions and what the work established
ENGINEERING QUESTIONWHAT THE WORK ESTABLISHED
Pressure responseFull-vessel and component stress patterns for both design-pressure bases.
Local connection demandSeparate assessment of domes, manholes, pads and internal rings.
Stress classificationASME VIII-2 SCL evaluations, with selected through-thickness checks recorded as satisfied in the reports
Geometry developmentDocumented Butane RevD pad, dome and end-stiffener changes
Other loading conditionsResponse under seismic, hydrotest, support variation, section lifting and prescribed overpressure scenarios

The study records an engineering assessment across multiple revisions. Earlier R2 findings remain identified by their source; no claim of physical testing, commissioning or complete-vessel certification is made

Outcome

A detailed basis for vessel design review

The ASME Section VIII, Division 2 assessment connected full-vessel response with the behaviour of individual pressure-boundary components. SCL evaluations resolved membrane and bending stresses at critical regions and supported the documented design development The delivered analysis package gave the engineering team a traceable basis for reviewing the propane and butane vessels across the defined operating, test and handling scenarios

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