Beruflich Dokumente
Kultur Dokumente
05.02.2014
Rev.
No.
Date
Description
M.C.
Z.K.
E.D.
Prepared
Checked
Contr. By
Onay
ORIGINATOR
EDOPEC
Published by
.
EDOPEC ENERJ PETROL MHENDSLK SANAY VE TCARET
LMTED RKET
Document Title
Document No.
EDO
190
CAL
COE
COR
INT
XXX
014
Co. Org.
Doc
Disc.
Unit
Prj.
Prj.
Prj.
Pro.Doc.
Cod
Type
Code
Code
type
NO
Year
Seq.No
218
Rev
DCC
Seq.
No
Page
Scale
17
Page
of
17
Table of Content
1.
DOCUMENTSCOPE .................................................................................................. 3
2.
REFERENCE ................................................................................................................ 3
2.1
ProjectSpecifications ............................................................................................................... 3
2.2
Codes ......................................................................................................................................... 4
2.3
ObjectDatasheets ..................................................................................................................... 4
2.4
VendorDocuments ................................................................................................................... 4
3.
SITECONDITIONS .................................................................................................... 5
4.
GENERALASSUMPTIONS ....................................................................................... 5
5.
CALCULATIONANDSIZINGMETHOD ................................................................ 6
5.1.
ProtectionCurrentDemand ..................................................................................................... 6
5.2.
SizingoftheAnodeGroundbed, ............................................................................................. 7
5.3.
VerificationofAdequacy .......................................................................................................... 9
5.4.
IRDrop&CircuitResistanceCalculation ............................................................................. 11
5.5.
SizingofthePowerSupply .................................................................................................... 17
Project:
Prj. Identification:
Document Title:
Document No.:
CALCULATION METHODOLOGY FOR AT-GRADE STORAGE TANK EXTERNALS
Revision:
Date: 05.02.2014
EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
1.
of
17
DOCUMENTSCOPE
The purpose of this document is to define the parameters and describe the engineering calculation
methods, to design effective and longtime Cathodic Protection (CP) system for external surfaces of
at-grade storage tanks (Hereafter called Tank) for; ONSHORE FACILITIES (Hereafter called The
Facility), by means of;
design assumptions,
verification of adequacy,
sizing of TR units
This document shall be considered as the main engineering calculation booklet for object-wise CP
calculation notes and detail drawings in order to design most effective way to protect the Tanks
bottom plates from the external electrochemical corrosion phenomenon.
2.
REFERENCE
2.1
ProjectSpecifications
The latest revision of Purchaser documents referred thereto has been considered as the main
reference for this document:DB-1718-999-P332-0204
RP-1718-999-6300-5002
RP-1718-999-1630-0007
RP-1718-999-2500-0001
The clarification sheets submitted along Purchaser documents are also considered as an integral
part of project specifications.
Project:
Prj. Identification:
Document Title:
Document No.:
CALCULATION METHODOLOGY FOR AT-GRADE STORAGE TANK EXTERNALS
Revision:
Date: 05.02.2014
EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
2.2
of
17
Codes
have been considered as the reference codes of this document. In case of conflict between
requirements specified in purchasers documents and the requirements of any other referenced
standard, the order of precedence shall be according to POR/MR document. Any conflict will be
brought to
Purchasers attention to receive a written clarification before proceeding with any
work.
4
2.3
ObjectDatasheets
The latest revisions of Mechanical datasheets of Tanks have been used to evaluate need of Cathodic
protection as the main reference for this document:-
2.4
DW-1718-101-2510-0101
SP-1718-121-2500-0101-3
SP-1718-125-2500-0101-6
SP-1718-128-0800-0101-3
SP-1718-129-2501-0101-4
SP-1718-130-2500-0101-8
SP-1718-144-2500-0101-3
SP-1718-146-2501-0102-5
SP-1718-146-2501-0104-5
SP-1718-146-2501-0105-6
VendorDocuments
VP- PO-1718-1186-101
are also pre-requisite and integral parts of this document that have been derived accordingly.
Project:
Prj. Identification:
Document Title:
Document No.:
CALCULATION METHODOLOGY FOR AT-GRADE STORAGE TANK EXTERNALS
Revision:
Date: 05.02.2014
EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
of
17
SITECONDITIONS
3.
4.
47C
2C
2-48C
Max 40 C
91% January
80 to 100%
up to 80%
varies between 24 to 64 meters above sea level
over the site locations
GENERALASSUMPTIONS
With regard to the project specifications and Cathodic Protection System Design Philosophy and
Considerations document No. VP- PO-1718-1186-101, the following assumptions shall be
considered to formulate all the relevant details of calculation.
a) Cathodic protection system for tanks is assumed to be in full integration within the
further installation of CP system for future buried piping system on said facility.
b) External Cathodic protection for all applicable Tanks assumed to be the type
Impressed Current system (ICCP)
c) The soil under the tank base assumed NOT containing of asphalt, oily sand or
bitumen.
d) The connecting pipes including inlet/outlet, fire fighting, cooling, and close drainage
system along earthing system do not require galvanic isolation from Tanks due to the
usage of HDPE geo-membrane acting as a dielectric shield underneath the tank.
e) Tanks which of those operating temperature are below 120C shall be externally
subjected of cathodic protection. However, the temperature effect on increasing the
protective current demand over 80C is assumed to be negligible.
f) Tanks which of those operating temperature are minimum of 120C does not require
external cathodic protection. Thus, those current demands assumed being nil in such a
way.
g) Where the tank base shall be constructed on full concrete pad foundations the tank
bottom plate is not required to be protected by external cathodic protection system.
The current demand assumed null and void. Provision of chloride extraction for such a
concrete pad shall be considered while calculating polarization current demand for
rebar in concrete.
h) All the tanks which the need of cathodic protection is considered to null and void shall
be bonded via Cathode Bonding boxes to the relevant Piping system.
Project:
Prj. Identification:
Document Title:
Document No.:
CALCULATION METHODOLOGY FOR AT-GRADE STORAGE TANK EXTERNALS
Revision:
Date: 05.02.2014
EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
5.
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17
CALCULATIONANDSIZINGMETHOD
Individual Impressed Current Cathodic Protection System (ICCP) shall be sized for various Tanks
within the boundary of Facility. The sizing of individual ICCPs shall be addressed on object-wise
Calculation Notes and Installation Details.
The Calculation Note for each of subjected Tanks shall show the following details as minimum;
Hence the formulations as described below have been derived from the project reference documents.
5.1. ProtectionCurrentDemand
The protection current demand is the current required to maintain an efficient protection level during
the design life, and is calculated by the following Equation;
I P FT CT (I B IT ) FD
(Eq.1.1)
where:
IP
FT
CT
IB
IT
FD
5.1.a)BasicCurrentDemand
In order to calculate the tank basic current demand ( I B ), the coated and bare surfaces of tank base
plate extracted for coating efficiency, in conduction to relevant current density is used as per
equation1.2;
I B B (1 CE)SP C (CE)SP
(Eq.1.2)
where:
SP
B
C
CE
Project:
Prj. Identification:
Document Title:
Document No.:
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Revision:
Date: 05.02.2014
EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
of
17
5.1.b)TemperatureRiseCurrentDemand
Protection current demand of tanks has a nature of inflation, affected from the temperature rise on
surfaces subjected to be protected in direct conduction of Tank operating temperature. Hence IT
shall be calculated and added to the basic current demand, which is calculated from;
I T I F 1.25
where:
T
SP
10
IF
(Eq.1.3)
:temperature rise over 30C up-to 80C in accordance to the tank operating temperature
: tank bottom plate surface area in contact with infill material (m2)
5.1.c)ProtectionSurfaceArea
The Tank base plate planned to be erected on foundation infill material with specific diameter is the
certain area of the object to be protected. However the base plat is lap welded within a proper slope
in order to drain fluid impurities and debris through internal sump pit.
Regardless of either inward or outward slope of the tank base plate the exact slant surface area
subjected to be protected is calculated as follows;
d h 2 d 2
1
S P dl
2
2
(Eq.1.4)
In which;
h
d
:height of cone
:base diameter of cone
5.2.
SizingoftheAnodeGroundbed,
MMO Titanium anodes with excellent current output and long lifetime are proven to have the
following advantages:
Project:
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EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
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17
5.2.a)AnodeShape
MMO Titanium anodes to be installed underneath the tank shall be in the shape of ribbon with
standard dimensions available in market. A MMO Ribbon anode with 6.35 mm width and 0.635 mm
thickness has been considered for use on this project.
5.2.b)AnodeQuantities
Anode quantities shall be subject of calculation by the following means;
Required quantities of anode to provide essential current of designated anodes design life,
Adequacy of current distribution underneath the tanks by means of earth potential shift
criteria. (See clause no. 5.3)
The required length of anode for each tank shall be calculated by dividing total protection current
demand by maximum current output of the ribbon in fine sand; i.e.,
I
LM P
A
(Eq.2.1)
where:
IP
A
LM
However the actual anode length shall be subject of verification of adequacy factor ( FA ) on
distribution of current by means of Anodic Voltage Cone, underneath of entire bottom plate of tank
meeting the following criterion;
V V (P P ) (PL PS )
FA Max Min U S
(PU PS )
VMax
(Eq.2.2)
where:
VMax
:the maximum level of Anodic Voltage Cone calculated at a certain point underneath the tank
VMin
PU
PL
PS
: the minimum level of Anodic Voltage Cone calculated at a certain point underneath the tank
:upper limit of protective potential allowed as per project specifications (-1200mV wrt Cu/CuSo4)
: lower limit of protective potential allowed as per project specifications (-850mV wrtCu/CuSo4)
:natural potential of Steel bottom plate (considered to be -550mV wrt Cu/CuSo4)
Hence the actual length, the quantities of segments and spacing between parallel ribbon anodes shall
be determined in a way to ensure the even current distribution underneath the tank have enough
adequate for protection of tank bottom plate under within project protective potential rages.
Project:
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Revision:
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EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
5.3.
of
17
VerificationofAdequacy
In order to evaluate the adequacy of current distribution underneath the tank (item b in sec.6.3.), the
voltage cone and superposition concepts shall be taken into account.
When the protection current is transmitted to the soil via the anode bed, a voltage gradient is
produced in the soil which exponentially decreases with increasing distance from anode bed, being
the greatest at the vicinity of the anode.
At a distance from the anode bed where no
appreciable field strength due to the protection
current is detectable, the soil potential approaches
zero. This potential is termed that of the remote
ground.
The voltage between the remote ground and the
anode bed is the anode voltage. Because of the
cone-shaped curve of the voltage distribution on the
soil surface (Figure 2), this is called the Voltage
Cone of the anode bed. The height of the voltage
cone depends on the anode voltage and its shape
depends on the arrangement of the anodes.
CurrentDrainPoint
(SingleVerticalAnode,
DeepWell,etc.)
RibbonAnode
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EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
10
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17
This will be calculated by using the following formula from Handbook of Cathodic Corrosion
Protection by W. von Baeckmann.
2
l
l
r t
2
2
2
Vr
I
ln
2 l
l
l
r2 t2
2
2
(Eq.3.1)
where:
Vr
I
l
t
r
At the stage of calculating the potential shift of the soil underneath the tank bottom plate by use of
the above formula, the superposition effect of all segments of MMO ribbon anodes shall be
considered. For instance, for calculating the potential shift at the point of the tank bottom
immediately above segment 1 in Figure 4, the superposition effects of segments 2, 3, 4, , N shall
be obtained and added to the potential shift emanates from segment 1 itself.
Similarly, for segment 2, the effects of segments 1, 3, 4, , N shall be calculated as per segment 1
that shall be individually calculated for all of the segment of anodes up to the segment N.
VS( j )
n
j 1
Vr ( i ) ( i , j )
i 1
(Eq.3.2)
where:
: earth potential shift with superposition effects of all anode segments (repeated for individual
locations at the point of the tank bottom plate immediately above each segment of anode)
Vr (i, j ) : function of Earth potential shift effect arisen from individual segments of anode to a certain
location of tank bottom plate
VS
In which with respect to the Eq.3.1, the function of earth potential shift arisen from individual
segments of anode is defined as below;
I i
V r (i , j)
ln
2 l i
i j rs
i j rs 2
l
l
t2 i i
2
2
Project:
(Eq.3.3)
Prj. Identification:
Document Title:
Document No.:
CALCULATION METHODOLOGY FOR AT-GRADE STORAGE TANK EXTERNALS
Revision:
l
l
t i i
2
2
Date: 05.02.2014
EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
11
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17
where:
j
Ii
: the variable number of a certain location affected by earth potential shift of individual anode
segments
: the variable number of anode segment that its effect at a certain (J) location is under study
: current flow from the segment of anode that its effect at a certain (J) location is under study
li
: length of the segment of anode that its effect at a certain (J) location is under study
t
rs
: vertical distance between tank bottom and anode( Typically 0.4 meters)
: horizontal distance between segments of anode (shall be adjusted during verification for
optimum usage of anode and protection adequacy)
Hence the maximum and minimum value of earth potential shift with superposition effects of all
anode segments beneath the tank bottom plate can be addressed as follows;
(Eq.3.4)
(Eq.3.5)
That shall be used in order to verify the of adequacy factor ( FA ) indicated on pervious section as per
Eq.2.2. Hence the distance between the segment of anodes from each ( rs ) shall be adjusted for
optimum installation by both means of efficient usage of anode and protection adequacy.
5.4.
IRDrop&CircuitResistanceCalculation
The size and current capacity of the ICCP system shall be designed within calculation of IR and drop
equivalent circuit resistance of the system.
The following parameters are affecting the total circuit resistance and resulting IR drop on various
system components subsequently;
The transition resistance between the surface of the anode and the electrolyte, i.e., the
resistance of the interface of anode and its surrounding soil (see clause no. 5.4.a)
The resistance of soil resulting IR drop to anode to a certain point of earth (tank bottom
plate), as an interfering function of close distribution of anode instead of remote earth
criterion. (effects of Vx described in clause no. 5.4.b)
The internal resistance of the anode groundbed (i.e., Tint described in clause no.5.4.e),
Project:
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EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
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12
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17
An equivalent electrical circuit may be outlined and the overall resistance of the circuit shall be
considered as follows.
Hence, the output driven voltage of ICCP system shall be calculated from equivalent circuit
resistance through the following equation.
E Rc RAint RA RE RSt Rc I P Vx Vs
(Eq.4.1)
5.4.a)TransitionResistanceofAnodeGroundbed
In order to include the effects of IR drop of anode groundbed to earth, the transient resistance
between anode grids to the soil shall be calculated, as the equivalent resistance ( R A )shown in
equation no. 4.2.
RA
1
SUM
(Eq.4.2)
which is the reverse of the total conductance of parallel running of the segments of ribbon anodes in
soil as follows;
n
SUM ( )
i 1
1
1
1
1
Ri R1 R2
Rn
(Eq.4.3)
Hence the resistance of individual segment of ribbon anodes (from one to n) shall be calculated
individually using equation no. 4.4
Ri
2 li
li2
ln
td
(Eq.4.4)
in which,
li
d
Project:
Prj. Identification:
Document Title:
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CALCULATION METHODOLOGY FOR AT-GRADE STORAGE TANK EXTERNALS
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Date: 05.02.2014
EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
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13
of
17
5.4.b)IRDroptoEarth
Due to the close installation of anode grid to the structure, current density (current per unit of crosssectional area of the earth) flowing away from the anode ground bed is high at close area and
exponentially decreases with increase of distance. Where the current density is highest, the greatest
point-to-point potential shift can be observed in the earth. The net result of this effect is that most of
the IR drop in the earth for a single anode normally is encountered within the first few centimeters.
In order to calculate the maximum IR drop of the groundbed to earth, arisen from interfering anode
current flowing to the cathode (Bottom Plate) from electrolyte (tank infill material), the resistance
between anode grid to the soil immediately beneath the steel bottom plate shall be considered as a
deteriorative effect on reducing driven voltage of ICCP system.
Hence the IR drop to earth shall be calculated for unit length of ribbon anode (Say one meter length)
to the closest distance to the tank bottom plate (Say horizontal zero distance from anode, but at a
vertical distance between anode and tank bottom plate), under maximum applicable current density
per unit length of anode, by using the following formula from Handbook of Cathodic Corrosion
Protection by W. von Baeckmann).
2
l
l
r t
2
2
2
Vx
where:
I
l
t
r
I
ln
2 l
l
l
r2 t2
2
2
(Eq.4.5)
5.4.c)Structuretosoilresistance
The structure resistance to soil shall be calculated considering the based on both of the bare and
coated resistance of structure to soil. Structure specific polarization resistance for defected and bare
area and structure specific coating resistance represented per meter square in Ohm ( .m 2 ) shall be
divided to the appropriate surface area with reference to the coating efficiency of the structure. The
bare steel to soil have a specific polarization resistance value of 10 .m 2 , while the specific coating
resistance is varies between 2000 to 5000 .m 2 .
The quality of the coating changes the specific coating resistance has a direct effect to the protective
current density of the structure as well. The increase of the specific coating resistance will extremely
decrease the protective current density of structure. However in order to calculate the highest value as
the extreme edge for protective current demand, the coating efficiency has been considered to be 50%
only resulting 50% of the tank bottom plate to be considered bare and in direct contact to the soil.
Project:
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Document Title:
Document No.:
CALCULATION METHODOLOGY FOR AT-GRADE STORAGE TANK EXTERNALS
Revision:
Date: 05.02.2014
EDO-CAL-COE-COR-INT-XXX-014-190-218-REV-A- CP
CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
14
of
17
Hence the resistance of structure to soil shall be calculated individually for bare and coated tank
bottom plate surface area s follows;
RE
1
1
RREC
(Eq.4.6)
REB
where:
RE
REC
R EB
rU
SP (CE)
(Eq.4.6)
R EC
rP
S P (1 CE )
(Eq.4.7)
where:
rU
rP
SP
CE
5.4.d)Linear/internalresistanceofstructure
And because of huge surface area of the metal structure the linear resistance of the tank bottom
plate, RS , is negligible.
5.4.e)InternalResistanceofAnodeGroundbed
Typically the internal anode groundbed resistance of the tanks ICCP system is consisting of Anode
Grid network and Anode feeder cable. Thereby the internal resistance of Anode grounded shall be
calculated within the consideration of internal
resistance of both of above items in series.
Either the internal resistance of anode feeder(s) or
the internal resistance for anode grid itself will result
IR Drop that shall be taken on account when
calculating and sizing ICCP system of each tank.
Prj. Identification:
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CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
15
of
17
Increasing the quantities of anode feeder cable with an average of resistance on each (RFC) to be
connected to the anode grid via several feeding points (F) will divide the current flow into the
groundbed, resulting the portions of the anode grid to act as parallel circuits and facing lower internal
resistance (Rint) as desired.
Hence, the total resistance anode groundbed (i.e. the resistance between anode junction box and the
chosen point "C" underneath the tank within worst case condition) shall be calculated to be adjusted
to reach to the proper internal resistance as below;
R Aint
RFC Rint
NF
(Eq.4.8)
where:
R A int : total internal resistance of anode groundbed
R FC :average internal resistance of each anode feeder cable
R int
NF
that shall be calculated as an average of for all segment of feeder from feeder 1 to N as follows;
R FC
where:
l
Avg c i
a c
li
ac
i 1
(Eq.4.9)
RAn t
lr
ar
(Eq.4.10)
RTi t
lt
at
(Eq.4.11)
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CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
Page
where:
t
ar
at
lr
lt
16
of
17
In order to distribute the protective current within an equi-potentially designed anode grid consist of
the cells from segments of Ribbon anodes and Ti conductor bars the linear internal resistance of both
shall be equalized to each at a value of Ri.
There by the distance of conductor bar to each shall be adjusted in order to meet the following
criteria;
Ri RTi R An
(Eq.4.12)
Hence, the distance of conductor bar (lt) is used to address the total length of Ti Conductor bar
required to be used on anode grid.
Additionally if an arbitrary point of C is chosen under the tank bottom plate, the current flowing
from to the anode grid and through the soil to the structure, will pass a path like what is depicted in
figure 7.
Then, the internal resistance of point Fi to C will be calculated using Delta-Star Conversion
Law of the circuits resulting to the value of Rint on an extreme edge:
Rint 3 Ri
5.4.e)InternalResistanceofMainCables
As indicated above various parameters are involved to calculate different resistance in equivalent
circuit of ICCP system such as;
NF
lt
Hence the adjustments of those values are resulting to minimize the IR drop to its optimum value that
shall be in-line to the driven voltage of ICCP system.
Additionally the internal resistances of main positive Rc and main negative Rc cables have the
same roll that the sizing of the cable shall be calculate in a way that the calculated equivalent circuit
resistance Req to meet below criteria;
Req
In which;
E Vx Vs
IP
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CALCULATION_METHODOLOGY FOR TANK BOTTOM
EXTERNALS
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17
of
17
Hence the value of Rc and Rc is calculated as properly sized as per below equation;
Rc
c lc
(Eq.4.13)
ac
where:
Rc
c
li
ac
5.5.
SizingofthePowerSupply
Considering the calculated maximum current demand for the protection of the tank to be I P and an
additional 50% margin to shall be added in order to address the output current capacity of power
supply unit.
The output voltage of the power supply unit shall be in rating to meet all the requirements describe
on section 5.4 of this document but limited to the maximum value of the 50 Volts.
Within the consideration that AC power will be easily provided in facility, Transformer-Rectifier
units (TRU) or individual channel Transformer-Rectifier units (TRC) shall be used to generate
required DC current as the power supply unit. TRU/TRC shall be installed outside of classified area
preferably insides of substations.
Where the installation within the substations is not feasible, the TRU may be subject of outdoor
installation under company approval.
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CALCULATION_METHODOLOGY FOR TANK BOTTOM
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