Minimise Product Dead S<strong>to</strong>ck in S<strong>to</strong>rage Tankby Engr. Ng Kim Chu, MIEM, P. EngfeatureWith the price increase of crude oiland palm oil, the value of dead s<strong>to</strong>ck ins<strong>to</strong>rage tanks of the related products hasalso greatly increased. This should havecaused concern <strong>for</strong> product owners.There are many product s<strong>to</strong>ragetanks in petro and petro-chemicalplants and also in the palm oil industry.Depending on the tank suction nozzleelevation (height), pump location, pipingarrangement (refer <strong>to</strong> Figure 1) andpump characteristic, all tanks will havevarying dead s<strong>to</strong>cks. The <strong>to</strong>tal value ofdead s<strong>to</strong>ck in these tanks can vary from10 <strong>to</strong> hundreds of millions of ringgit.For one 30m in diameter diesels<strong>to</strong>rage tank, based on standard tankdesign with the tank suction nozzle at0.6m above tank bot<strong>to</strong>m, at the currentprice of RM2,000 per m 3 , the amount ofdead s<strong>to</strong>ck is estimated at 706m 3 whilethe value is approximately RM1.41million. (Refer <strong>to</strong> Table 1 <strong>for</strong> deads<strong>to</strong>ck value calculation of various tankdiameters.)Technical ConsiderationTo assess whether the amount of deads<strong>to</strong>ck of any tank can be lowered, weneed <strong>to</strong> calculate if the NPSHA (NetPo<strong>sit</strong>ive Suction Head Available) of therelevant product pump/s <strong>for</strong> the tankis higher than the NPSHR (Net Po<strong>sit</strong>iveSuction Head Required). Once this isdetermined, we can further calculatehow much dead s<strong>to</strong>ck can be loweredand the cost savings.Calculation of NPSHATo calculate NPSHA, we have <strong>to</strong> collectthe following info/data:1. Current minimum tank operatinglevel2. Elevation or height of existing tanksuction nozzle3. Size of tank suction nozzle4. Piping arrangement between tanksuction nozzle <strong>to</strong> pump suctionnozzle5. Pump suction nozzle elevation6. Product properties7. NPSHR of the relevant pump/sFrom the above info/data, we thencalculate the friction loss from the tank<strong>to</strong> the pump and work out the NPSHA.(Refer <strong>to</strong> Table 2.) From the differencebetween NPSHA and NPSHR, we shallbe able <strong>to</strong> decide how far the minimumtank operating level can be lowered andthe amount of dead s<strong>to</strong>ck reduced.Take, <strong>for</strong> example, an installationwhich has a diesel s<strong>to</strong>rage tank of 30min diameter. The original minimum tankoperating level was set at 1.0m abovethe bot<strong>to</strong>m datum plate. After the reviewexercise, the set minimum levelwas lowered <strong>to</strong> 0.6m. The dead s<strong>to</strong>ck hasbeen reduced by 282m 3 and s<strong>to</strong>ck valuereduced by RM565,000. At 4% interestper annum, the cost savings is estimatedat RM22,600 per annum. The cos<strong>to</strong>f modification was around RM25,000,there<strong>for</strong>e, the payback in less than two<strong>year</strong>s.An example <strong>for</strong> NPSHA calculation isas follows:Tank Suction NozzleModificationIn most cases, <strong>for</strong> existing tanks <strong>to</strong> lowerthe dead s<strong>to</strong>ck, suction nozzle modificationwill be necessary. Generally, thisTable 1: Dead s<strong>to</strong>ck value calculationDiamAream 2Suct NozSize-mSuct NozHt.-mMin. LevelmDead S<strong>to</strong>ck Prod Price-m 3 RM/m 3ReducedD/S-m 3D/S ValueSaving-RMInt. SavingRM p.a.- - - - - - - - - 0.043 7.069 0.20 0.40 0.70 4.95 2000 3.53 2827.43 113.105 19.635 0.20 0.40 0.70 13.74 2000 9.82 7853.98 314.166 28.274 0.20 0.40 0.70 19.79 2000 14.14 11309.73 452.398 50.265 0.25 0.50 0.83 41.47 2000 25.13 32672.56 1306.9010 78.540 0.25 0.50 0.83 64.80 2000 39.27 51050.88 2042.0412 113.097 0.25 0.50 0.83 93.31 2000 56.55 73513.27 2940.5315 176.715 0.30 0.60 0.95 167.88 2000 106.03 123700.21 4948.0118 254.469 0.30 0.60 0.95 241.75 2000 152.68 178128.30 7125.1320 314.159 0.30 0.60 0.95 298.45 2000 188.50 219911.49 8796.4625 490.874 0.40 0.60 1.00 490.87 2000 294.52 392699.08 15707.9630 706.858 0.40 0.60 1.00 706.86 2000 424.12 565486.68 22619.4735 962.113 0.50 0.60 1.05 1010.22 2000 577.27 865901.48 34636.0640 1256.637 0.50 0.60 1.05 1319.47 2000 753.98 1130973.36 45238.9310 May <strong>2009</strong> Jurutera
NPSH available calcTable 2: NPSHA calculationDen<strong>sit</strong>y kg/m 3 input 820Total Delta head friction m input 3.09Height liquid in tankabove pumpm input 2Vapour pressure mbar input 0featureHead vapour pressure m calc 0Atm pressure m calc 12.43NPSH available m calc 11.34modification can be carried out easily.There are two types of suction nozzlein a normal tank design. One type is thedouble ends design with flange at eachend. The other type only comes with anexternal nozzle. Refer <strong>to</strong> Figures 2a and2b <strong>for</strong> the proposed modification of thetank nozzle <strong>for</strong> the above mentioned typeof nozzles. nFigure 1: Isometric piping from tank <strong>to</strong> productpumpFigures 2a and 2b: Tank nozzle modificationA Predictive Method in Analysing Past Data –A Real Case on Production Line Setup Timeby Ir. Gan Chun ChetThere are many data collected that need <strong>to</strong>be analysed <strong>to</strong> determine whether a predictionis possible. Many methods can be applied <strong>to</strong>predict one data ahead of the previous data.The purpose of knowing one step ahead is <strong>to</strong>determine if the prediction of the next numberis a true number so that people can rely on it.Some judgments are blurred by the fact thatit is only a guess. The accuracy of the nextnumber is not known until it occurs.There are several methods that canbe applied <strong>to</strong> determine if a prediction isaccurate. Keep in mind that prediction error isanother fac<strong>to</strong>r that has <strong>to</strong> be considered be<strong>for</strong>ea decision is made. Otherwise, a predictionvalue is simply accepted in blind faith. Twosimple methods are listed here which could beused in a real application.• Moving Average• Exponential Smoothing Graph 1: Machine set-up time trendJurutera May <strong>2009</strong>11