Index

Introduction

Internal Floating Roofs (IFR)

Types of Internal Floating Roofs (IFR)

Types of Seals

Parts of Accessories

Services

Service Application

Material Specification

Calculations

Case Study
The Current Scenario The Key Concern Vapor Loss

Internal Floating Roof floats directly on top Solar radiation is the main course of the
of the product, they are known to leave no evaporative loses in the floating roof tanks.
vapor space and eliminate the possibility of The radiation striking the earth atmosphere
flammable atmosphere. They are brings about 1.5 KW per square meter,
manufactured through various industrial when measured normal to the sun rays. The
codes and standards available. radiation is partly reflected, scattered and
Unfortunately, the designs get restricted to partly absorbed by the atmosphere.
only basic theory from reference book. Variable vapor space tanks are equipped
Some design engineers would rely on only with expandable Internal Floating Roofs to
commercial software for basic design and accommodate vapor volume fluctuations
their limited knowledge on tank operation; attributable to temperature and barometric
these have resulted in lots of Internal pressure changes.
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.
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 thats tied
to the main storage tanks emissions: standing losses and working losses. More specifically, a
tanks individual characteristics can have a significant impact on generated emissions.

Standing losses Floating Roof Tanks

From rim seals, deck appurtenance and deck seams

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.
 Internal Floating Roof vs External Floating Roof vs Fixed Roof Tank

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.

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.

Economic
al
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.
Some other advantages of International Floating
RoofLong 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.

Advantages

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
Full Contact Type

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.
Advantages

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.

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
A New Type of Internal Floating Roof - Megafloat
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, its 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.
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 Support Sealing Systems

Legs are used to keep the Internal Floating Depending on the design of the tank, ERGIL Internal Floating
Roof at a certain height when there is no Roofs comes with the support hole sealing. Teflon seal
liquid inside the storage tank. Generally, withstand majority of the stored liquids and minimizes the
there are two types of settings: Level 1: This vapor loss.
level is used for setting the tank level for
discharge, Level 2 is for cleaning operations
inside the tank.

Tank Manhole

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.
Internal Floating Roof has the following standard components.

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 Funnelss Film

Foot Plates-Support Foam Barrier The Grounding ables and

Connection Plates Rape connector

The Sample Funnels The Sample Funnels Film Sheet

The anti-rotation The Grounding Cables and Rape

Funnels connector

NA NA NA

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 Customers 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 Dual Seal Mechanical Seal

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.
1leg pipe (T=2MM), L=1400 MM 6060 T66/ 6XXX SERIES
1pipe for vacuum (T=2MM), L= 1899 6060 T66 / 6XXX SERIES
breaker MM
Throttle leg 11/4PIPE, THK. = EN-AW-6060 /6XXX
2MM SERIES
Npu 300 joining plate 280X120X2MM 1050 H14/5XXX SERIES
Npu 80 joining plate 200X70X2MM 1050 H14/5XXX SERIES
Pontoon = npu 300 joining 200X70X2MM 1050 H14/5XXX SERIES
plate
Polyamide lef plug (Q35X40MM) POLYAMIDE/KESTAMIDE
Equal angle-npu 80 40X40 MM L 40 MM 1050 H14/5XXX SERIES
joining plate
Npu 80-npu 80 joining 40X40 MM L 40 MM 1050 H14/5XXX SERIES
plate
Manhole 4MM PLATE 1050 H14/5XXX SERIES
Manhole bottom plate 4MM PLATE 1050 H14/5XXX SERIES
Vacuum breaker and 4MM PLATE 1050 H14/5XXX SERIES
bottom plate
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 (T=2MM PLATE) 1050 H14/5XXX SERIES
plate
Anti-rotation
Anti-rotation system 8MM ROPE ASI 304
Rope 4 ASI 304
Rope 8 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.)

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 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

2. Rafter Sizing

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,

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

x-axis y-axis Rafter Length (mm) Total Rafter Lengtht Weight (kg)
(mm)
1 730 4754 9509 9508.56 8,16
2 2190 4283 8565 17130,09 14,70

3 3650 6265 12530.67

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);
6. Seal Sizing

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.

7. Pontoon 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)

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

Evaporation Loss Calculation with

Design and Engineering of Internal API Standards
Floating Roof

Our company, provides internal flationg Calculations and previous applications

roofs 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.
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

Floating roof designed according to every Cleaning methods of fuel and chemical
storage tanks properties such as level and tanks can be done using without any
economically. All of the 20 inch and 24 inch change in internal floating roofs.
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

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 tanks erection works at job site.
Storage Tank Equipment

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. StorageTechs 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

Tank Equipment Product List

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

Fire Fighting Equipment Product List

Bladder Tank
Foam Monitor
Foam Mixer
Foam Maker
Foam Top Pourer
Foam Sprinklers
Deluge Valves
Hydrants
Detection Systems
Headquarters
ECC Business Park B2 Kat: 11 No: 348
34149 Bakirkoy / ISTANBUL / TURKEY
Phone: +90 212 485 40 07 (pbx)
Fax: +90 212 485 40 42
Website: www.ergil.com
Website:
www.ergil.storagetech.com
Email: sales@ergil.com
Middle East & North Africa Region
Jumeirah Lake Towers, X2 Tower 1906
P.O. Box: 123661
Dubai, UAE
Phone: +971 4 450 8051
Fax: +971 4 450 80 41
CIS Region
B. Salaroglu 1331 8 th rl: No: 2
Baku, Azerbaijan, AZ1000
Phone: +994 507364339
Far East Asia Region
Level 21, Centennial Tower
Singapore 039190
Phone: +65 6549 7515 (DID)
Fax: +65 6549 7001