Services

Service Application

Material Specification

Calculations

Case Study

Introduction

Internal Floating Roofs (IFR)

Types of Internal Floating Roofs (IFR)

Types of Seals

Parts of Accessories

Index

Internal Floating Roof floats directly on top

of the product, they are known to leave no

vapor space and eliminate the possibility of

flammable atmosphere. They are

manufactured through various industrial

codes and standards available.

Unfortunately, the designs get restricted to

only basic theory from reference book.

Some design engineers would rely on only

commercial software for basic design and

their limited knowledge on tank operation;

these have resulted in lots of Internal

Floating Roof failures in the industry. What

should have been easy to install, with good

handling and reliable in operations

becomes a challenge for many. We

through this technical document aim to

help procurement managers, purchase

engineers, traders etc make a well

informed decision with regards to

purchasing Internal Floating Roof.

Solar radiation is the main course of the

evaporative loses in the floating roof tanks.

The radiation striking the earth atmosphere

brings about 1.5 KW per square meter,

when measured normal to the sun rays. The

radiation is partly reflected, scattered and

partly absorbed by the atmosphere.

Variable vapor space tanks are equipped

with expandable Internal Floating Roofs to

accommodate vapor volume fluctuations

attributable to temperature and barometric

pressure changes.

The Current Scenario The Key Concern – Vapor Loss

Fig 0.1 depicts the difference between fixed roof and internal floating roof. Internal Floating Roof

controls vapor loss and ensures costly fuel is preserved and not let out into the atmosphere.

Designed to regulate gas venting, Internal Floating Roofs as compared to Fixed Roofs allow

explosive gases to vent into the atmosphere in a safe way. Installed inside the fixed roof storage

tanks, they are also an economically profitable option. Covering the major part of the liquid

surface and through an effective seal the emission reduction can be up to 98%. Emissions

generated by storage tanks are affected by two factors: how are the tanks used? (Content)

what is the tank type? These factors determine vapor pressure and it is vapor pressure that’s tied

to the main storage tanks emissions: standing losses and working losses. More specifically, a

tank’s individual characteristics can have a significant impact on generated emissions.

A lot of factors influence vapor pressure within the tank as shown in Fig.0.2. Average wind

speed, average temperature, vapor pressure etc. Even the less obvious characteristics, for

example, the color of the tank affects heat absorption, and increases or decreases vapor

pressure within the tank. Lighter colors absorb less heat than dark ones. One of the most vital

tank characteristics is the roof type. The most common types are floating-roofs and fixed-roofs.

Fixed roofs are permanently affixed to the top of the tank, which creates a great deal more

space for vapors to accumulate when the tank is less than full. The more vapors to build up for

rooms, the less material in the tank. Floating- roofs float on the top of the material, guided by

support legs and sealed with vapor seals around the rim. This means that there is little to no

vapor space between the liquid surface and the roof.

Standing losses – Floating Roof Tanks From rim seals, deck appurtenance and deck seams

Although, there are many types of storage tanks, Fixed – Roof Tanks, External Floating Tanks

and Internal Floating Roofs are the most in demand. The difference between the three can be

clearly seen pictorially above.

Internal Floating Roof vs External Floating Roof vs Fixed Roof Tank

Benefits of Internal Floating Roof are as follows: Lower Emission

ERGIL Internal Floating Roofs reduce emission from the storage tank. The Storage Tank remains

covered as the influence of wind, rain and lightning is eliminated. This further reduces product

emissions, product contamination by rain water and the risk of rim fires. This is possible as it is

designed under strictest of environment regulations.

Complies With International Regulations

ERGIL Internal Floating Roof complies with API 650 Code and Standard Design. This provides the

designer with selection of allowable stress to suit each design condition, which would be

specified by the storage tank owner.

Environment Friendly

Designed to regulate gas venting, Internal Floating Roofs protect the environment by not

releasing toxic gases into the atmosphere.

Safe

Internal Floating Roofs are shop tested to ensure they are leak proof. Quality of the products is

tested at the manufacturing facility before the product is ready for shipment.

The reduction in vapor lost makes Internal Floating Roof a very profitable option. Internal

Floating Roof is designed to exceed standard life expectancy due to study structure and

excellent quality control program. This makes it a very economical option.

Economic

al

Some other advantages of International Floating

Roof Long life time Durability Static electric protection

Perfect evaporation Strong and Rigid Minimum evaporation

Prevention Construction area

Maximum fuel and chemi – High corrosion resistance Minimum maintenance

Cal item impermeability

Supplier of Internal Floating Roofs, ERGIL

designs, manufactures and supplies Internal

Floating Roofs to customers around the world.

It provides Full Contact and Pontoon Type

Floating Roofs, manufactured at it is 35,000sqm

manufacturing facility at Mersin. Our Mersin,

Turkey manufacturing facility is equipped with

the latest technology, including fully

automated welding, rolling. Including fully

automated welding, rolling. CNC plasma

cutting, shot blasting, heating, painting system

and lifting machines. This capability enables

ERGIL to bear and meet complex projects and

deliver great quality of service.

More tank storage / Additional

Benefits / Trustworthy Leadership

Internal Floating Roof Types

Pontoon Type: Pontoon type floating roofs

are the most economical type of floating

roofs in the market. Besides having

economic benefits, they also protect the

environment by not releasing toxic gasses

to the atmosphere. ERGIL comes with in-

house manufactured floating roof seals.

Fig 0.4 and Fig 0.5 are Technical depictions of Pontoon Type Internal Floating Roof. View

from the top and view from the bottom.

All the assembly parts of Pontoon Type can be Most Effective Prevents

passed Through standard manhole Internal Floating Vapor Loss

Roof

The complete IFR can be manufactured from ERGIL offers Adjustable

Material, usually an aluminum alloy that is ‘’hybrid’’ designs Aluminum Leg or

Compatible, with the stored product. with the pontoon Stainless Steel

and other ‘wetted’ Adjustable

parts manufactured Cable Supports

from material com-

partible with the

stored product

and the other parts

manufactured in

aluminum

Advantages

ERGIL manufactures and supplies Full Contact Type of Internal Floating Roofs, which comply

with API 650 standards. Most effective floating roofs in the market. ERGIL Internal Floating Roofs

minimize evaporation loss of stored products such as jet fuels, gasoline, diesel and crude oil that

can be supplied as aluminum or stainless steel. Fig 0.6 and Fig

0.7 are the technical depictions of Full Contact Type Internal Floating Roof top and side view.

Full Contact Type

Designed not to sink as it is No vapor cavity Easy installation

Constructed in foam below deck

Robust Design Leak Proof Full Contact types of IFR

have an advantage on

smaller diameter tanks

when sometimes it is not

possible to configure

enough pontoons to

obtain the necessary

buoyancy.

The low profile design means Ease of tank Narrow profile

That this type of IFR takes up maintenance

less space in the tank so

potentially the tank can

store more product. However

the type of rim gap seal

selected should be considered

as its dimensions may limit the

travel of the IFR.

Advantages

Internal Floating Roof Comparison Chart

FULL CONTACT TYPE PONTOON TYPE Adjustable Cable Support - Yes

No Deck Walkways Required - Yes

No Vapor Cavities Below Yes No

Deck

Sealed Deck Seams Yes No

Anti Spark Material Yes No

Installed Through Standard Yes No

API

MegaFloat is designed to meet all standards and specific requirements of the industry,

demanding safer and efficient ways to operate the tanks. Manufactured to be installed inside

fixed roof storage tanks, it’s a Full Contact Roof with absolutely no gap, thereby reducing

emission and restricting vapor build up. The differentiating factor between the roof and the

product allows dangerous fumes to collect. MegaFloat is designed to be much more reliable

than other available Internal Floating Roofs, the technical drawing of Float (Fig 0.5) can be

seen below.

A New Type of Internal Floating Roof - Megafloat

Advantages

No gap

Minimum vapor loss

No leakage

Prefabricated, installation takes very short time

Honeycomb Type

ERGIL manufactures Honeycomb Type Internal Floating Roof which floats in full surface contact

with the liquid, eliminating a free liquid surface and formation of hazardous trapped vapors.

Panels are buoyant, weighing less than one pound square foot and can float large loads.

Advantages

Wont burn

Minimizes evaporation losses

Can be easily installed

Reduces air pollution

Economical

Parts of Internal Floating Roof and its benefits

Seal Material Specifiacations Vacuum Hatch

The seals (impermeability equipment) are

comprised of polythene plates due to their

irresponsiveness to petroleum products.

These seals prevent vapored liquid from

escaping over the floating roof.

Vacuum Hatch are located on the longest leg

of the roof and opens when the leg support

touches the bottom of the tank. When it

opens, it protects tank from the vacuuming.

Legs are used to keep the Internal Floating

Roof at a certain height when there is no

liquid inside the storage tank. Generally,

there are two types of settings: Level 1: This

level is used for setting the tank level for

discharge, Level 2 is for cleaning operations

inside the tank.

Legs Support Sealing Systems

Depending on the design of the tank, ERGIL Internal Floating Roofs comes with the support hole sealing. Teflon seal withstand majority of the stored liquids and minimizes the vapor loss.

When installing Internal Floating Roof to Fixed Roof

having systems, Internal Floating Roof equipments are

designed to inserting the tank from 20 inch or 24 inch

manhole hatch. Internal Floating equipments are

inserted from the manhole hatch and assembly to tank

inside.

Tank Manhole

Panels Manhole Cover Liquid Gasket H Profiles Vacuum Cover Seal F profiles Tensioning Hitches and Connecting bolt Angler Profiles Turnbuckle Bearings Foam Barrier Foot Pipe-Support Turnbuckle spring assembly The Sample Funnels’s Film Foot Plates-Support Foam Barrier The Grounding ables and Connection Plates Rape connector The Sample Funnels The Sample Funnel’s Film Sheet The anti-rotation The Grounding Cables and Rape Funnels connector NA NA NA

Internal Floating Roof has the following standard components.

Fluids Handled

TYPE OF IFR COMPATIBILITY YES/NO Aviation gasoline Full Contact Type Yes Gasoline Full Contact / Pontoon Type Yes Naphtalene Full Contact / Pontoon Type Yes Naptha Full Contact / Pontoon Type Yes Toluene Full Contact / Pontoon Type Yes Xylene Full Contact / Pontoon Type Yes

Internal Floating Roof (IFR) Installation work at Customer’s Job Site

Full Contact Type Internal Floating Roof Installation in

Calabar, Nigeria

Internal Floating Roof Installation in Part Harcourt, Nigeria

MOL IFR Installation in Romania

Shell IFR Installation in Turkey

Azmeco IFR Installation in Azerbaijan

Ergil Seal Types

Designed for cutting contact between stored product, tank inside surface and floating roof,

Seals are designed and manufactured as per user requirement.

ERGIL offers various tank seal designs for any specific service requirement including single &

double wiper seal, foam log seal and mechanical seal. Besides this, many different seal

materials are also available for most petroleum and chemical applications.

Mechanical seals are fully stainless steel, whereas the other are manufactured from Nitril,

Polyurethane and Teflon material.

Advantages

Minimized vapor losses

Protects the environment

Designed to remain in full contact with the tank shell reducing emmisions and possible rim

fires

Single Seal is designed to

prevent vapor leakage and

to protect from possible

VOC and vapor loss. This

standard seal design called

Single Seal is made from

elastic synthetic rubber and

special polyethylene

materials.

Dual Seal is designed to

provide a double sealing

system technology using

elastic synthetic rubber

products. This standard seal

design called Double Seal is

made from high quality

elastic synthetic rubber and

polyethylene material.

Mechanical Seal This seal is

designed especially for long

service life under no repair

and maintenance works in oil

companies as well as many

oil tank terminals. Light weight

construction.

Single Seal Dual Seal Mechanical Seal

1’’leg pipe (T=2MM), L=1400 MM 6060 T66/ 6XXX SERIES

1’’pipe for vacuum

breaker

(T=2MM), L= 1899

MM

6060 T66 / 6XXX SERIES

Throttle leg 11/4’PIPE, THK. =

2MM

EN-AW-6060 /6XXX

SERIES

Npu 300 joining plate 280X120X2MM 1050 H14/5XXX SERIES

Npu 80 joining plate 200X70X2MM 1050 H14/5XXX SERIES

Pontoon = npu 300 joining

plate

200X70X2MM 1050 H14/5XXX SERIES

Polyamide lef plug (Q35X40MM) POLYAMIDE/KESTAMIDE

Equal angle-npu 80

joining plate

40X40 MM L 40 MM 1050 H14/5XXX SERIES

Npu 80-npu 80 joining

plate

40X40 MM L 40 MM 1050 H14/5XXX SERIES

Manhole 4MM PLATE 1050 H14/5XXX SERIES

Manhole bottom plate 4MM PLATE 1050 H14/5XXX SERIES

Vacuum breaker and

bottom plate

4MM PLATE 1050 H14/5XXX SERIES

Foam dam 0.5X1.5X310 METER 1050 H14/5XXX SERIES

Eyebolt 1050 H14/5XXX SERIES

Gauge funnel (T=2MM PLATE) 1050 H14/5XXX SERIES

Gauge funnel-bottom

plate

(T=2MM PLATE) 1050 H14/5XXX SERIES

Anti-rotation

Anti-rotation system Ø8MM ROPE ASI 304

Rope Ø4 ASI 304

Rope Ø8 ASI 304

Skaflex - SKAFLEX

Stud M6X60MM 6063/6XXXX SERIES

Stud M6X50MM 6063/6XXXX SERIES

Stud M6X40MM 6063/6XXXX SERIES

Stud M8X40MM 6063/6XXXX SERIES

Stud M10X40MM 6063/6XXXX SERIES

Nut M6 6063/6XXXX SERIES

Nut M8 6063/6XXXX SERIES

NUT M10 6063/6XXXX SERIES

U-BOLT - 6063/6XXXX SERIES

Seal 330mm Polythylene

Sample Design Calculation of an Internal Floating Roof – How it

works?

This is a sample design and calculation where 10 meters diameter is taken for a Pontoon Type

Internal Floating Roof. API-650 standard has been used for calculation design.

Pontoon Type Internal Floating Roof Members;

Rim plate

Rafters

Box Profile

Girders

Cover Sheet

Seal

Pontoon

Leg

Foam Dam (Optional)

Accessories (Anti-Rotation, Vacuum Breaker, Manhole, Roof Drain and etc.)

2. Rafter Sizing

A. Calculation & Sizing Members

1 Rim Plate Sizing

Rim Plate Length (mm) = 2 x 3/4 x (R-190)………. Formula (1)

Rim Plate Length (mm) = 2 x ¾ x (5000-190)= 30222 mm

Rim Plate Profile: 40 x 300 x 40 x 2 Thk, 3000 mm length

Quantity of Rim Plate = Rim Plate Length / 3000 = 30222 / 3000 11 Qty

For rafter sizin, we use circle formula as shown as below;

X2 + y2=r2……….Formula (2)

X: ‘’x’’ axis coordinate

Y: ‘’y’’ axis coordinate

r: Radius of tank

Rafter Profile: 40 x 80 x 40 x2 Thk., 3000 mm length,

x-axis y-axis Rafter Length (mm) Total Rafter Lengtht (mm)

Weight (kg)

1 730 4754 9509 9508.56 8,16

2 2190 4283 8565 17130,09 14,70

3 3650 6265 12530.67

Total rafter length calculated in excel basis formula sheet as seen below;

Total rafter length (mm): 39168

Total Quantity of rather plates: 39168/3 ### 14 Qty.

3. Box Profile Sizing

Box profile quantity is as similar as rafter profiles. Because box profiles comes over rafter to hold cover

sheet stable above the rafters. So needed box profile quantity: 14Qty.

4. Girder Sizing

For girder sizing, we use circle formula also shown as below; X2 + y2 = r2……..Formula (2)

x - axis y - axis Girder Length Total Girder Length (mm) Weight (kg)

0 4810 9620 9620,00 4,13

2000 4374 8749 17497,93 7,51

4000 2671 5343 10685,39 4,58

5. Cover Sheet Sizing

We use cover sheet to block evaporation of fuel gas. This cover sheet is made of aluminum plate has 0.5 mm thickness. They have 1500 mm width sheets (Figure 3). For calculation of cover sheet also based on excel sheet and formulated as below, circle formula (Formula 2);

We use PE seal system for evaporation of fuel gas. (Figure. 4) While roof system travelling inside

of the tank, it wipes along the tank side. For calculation we use the formula below,

Seal Length (mm): 2 x 3/2 x (R-190)……… Formula (3)

Seal Length (mm): 2 x 3/2 x (5000 – 190) 30222 mm

This length is for single wiper seal.

6. Seal Sizing

Pontoons provide float specialty to the roofs. They lift all weight inside of the liquid. To calculate

this, we are using excel based formula chart and software we programmed.

Qp = Tifr / Fbp x K………… Formula (4)

7. Pontoon Sizing

We calculate hardware quantities as per formulas. Every piece of the roof has a special formula for

calculating quantities. Apart from this ERGIL also uses software for calculation.

The Case Study

ERGIL Supplies Customized Internal Floating Roofs to Gulf Petrochemical

Gulf Petrochemical choose ERGIL to provide a substantial number of Internal Floating Roofs for

their projects in India, Tanzania and United Arab Emirates.

Services Offered By ERGIL

Design and Engineering of Internal

Floating Roof

Our company, provides internal flationg

roof’s design, and after sales support for all

types of chemical and petroleum tanks with

property of standards. The internal roofs

have configurable feet when setting in tank

inside projects using of tank height settings.

With exit hatch you can exit top of the roof.

After production progress of floating roof

impermeability equipments with API 650

standard are installing.

Calculations and previous applications

shows that kind of applications are very

profitable for business managers.

Evaporations, calculations, calculated in

tank production process. There is no rough

about calculations after the installation.

Data is picked before application and

checked by our experts and calculation

based on API 2519 standard TNO formula

Assembly of Internal Floating Roof Cleaning of Storage Tank

Evaporation Loss Calculation with

API Standards

Floating roof designed according to every

storage tank’s properties such as level and

economically. All of the 20 inch and 24 inch

parts of floating roof designed for pass from

manhole hatches. Out of usage time is very

short because installation takes very easy

and quick. Assembly of internal floating

roofs, installed by our high quality and

experienced team

Cleaning methods of fuel and chemical

tanks can be done using without any

change in internal floating roofs.

Inspection of Storage Tank

Our special QC inspectors are knowledgeable on all of the most recent national regulations and

international design requirement. Normally we are kindly recommended to invite our

experienced supervisor during your first tank’s erection works at job site.

An ERGIL brand, StorageTech, promises to provide complete solutions for storage tank terminals for

oil, gas, power, construction, and chemical industries. StorageTech™ mainly focuses on

manufacturing of various kinds of strorage tank equipment. StorageTech™ mainly focuses on

manufacturing of various kinds of storage tank equipments. StorageTech™’s product line includes

but not limited to breather valves, flame arresters, firefighting systems, floating pipes, external and

internal floating roofs. StorageTech always aims to provide best quality and reasonable prices for

our clients

Pressure Vacuum Vents

Flame Arresters (Detonation, Deflagration)

High Velocity Vent for Cargo Tanks

Breather Vent (Free Vents)

Emergency Relief Vents

Manhole Cover

Standard & Locking type gauge hatches

Non Atmospheric gauge hatch

Fuel Filters

Sight Glass

Mechanical Level Indicator

Oil Skimmers

Drain Systems

Drain Systems

Floating Suction Pipes

Internal Aluminum Floating Roof

Mechanical, Foam and Wiper Seals

Tank Equipment Product List

Storage Tank Equipment

Fire Fighting Equipment Product List

Bladder Tank Foam Monitor Foam Mixer Foam Maker Foam Top Pourer Foam Sprinklers Deluge Valves Hydrants Detection Systems

Headquarters Middle East & North Africa Region CIS Region Far East Asia Region

ECC Business Park B2 Kat: 11 No: 348 Jumeirah Lake Towers, X2 Tower 1906 B. Salaroglu 1331 8th rl: No: 2 Level 21, Centennial Tower 34149 – Bakirkoy / ISTANBUL / TURKEY P.O. Box: 123661 Baku, Azerbaijan, AZ1000 Singapore 039190 Phone: +90 212 485 40 07 (pbx) Dubai, UAE Phone: +994 507364339 Phone: +65 6549 7515 (DID) Fax: +90 212 485 40 42 Phone: +971 4 450 8051 Fax: +65 6549 7001 Fax: +971 4 450 80 41

Website: www.ergil.com Website: www.ergil.storagetech.com

Email: sales@ergil.com