Chemical Rraghavan
Chemical Rraghavan
Chemical Rraghavan
STORAGE TANKS
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FABRICATION OF GRP/FRP HUGE STORAGE TANKS
A new proven Technology
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•Max Fabricating Capacity: 500m3 up to 10000m3 volume
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In this paper, I am trying to introduce a new concept to
manufacture Large GRP tank fabrication developed by a
Taiwanese company M/s Kigent corp. Ltd.
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They are a professional FRP manufacturer of special
chemical tanks and equipments such as pressure vessels,
scrubbers, fume stacks. Their products have been widely
used in a variety of industries including petrochemical,
power generation, electronics, marine, and paper etc.
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During the last 5 years the constitution
material- viz metal material cost has group by
about 300-500% that had seriously affected the
budget of various projects. In order to reduce
down the investing cost, Kigent follow ASTM,
ASME, NBS, PS 15-69, BS 4994, CNS 11656-
K308 standards, and promote steps to
manufacture GRP products instead of ―costly
stainless steel and carbon steel equipments for
chemical-resistance market.
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Technical Data of on-site fabrication :
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LAMINATE
Characters of kigent on-site fabrication
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Supporting poles or frames: No-R.C. Foundation
required for mold or machinery supporting
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TANK FARM
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(TANKS, VESSELS, AND EXHAUST SYSTEMS WITH
DIMENSIONS BELOW 5 M DIA X 15 M LENGTH)
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VIEW OF THE KIGENT WORKS
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PRESSURE VESSEL – VAC TESTED
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VIEW OF TANK ERECTION
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FILAMENT WINDING PROCESS
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GRP TANK ERECTION
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Field-fabrication FRP tanks
6-30 M dia X 10-15 M Height
Consideration before fabrication
Resin selection
In order to select the suitable resin to resist the
chemical corrosion, we do concern about the
specimens dipping test especially in the industrial
waste water. It might contain some trifing chemicals
but damage FRP structure or affect the service life.
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Normally before fabrication, we shall test
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Put various resin casting as specimens and dip it on various
chemicals at elevated temperature to observe the colour
change, and determine suitable resin to be used to match
the chemical environment requirement.
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Normally the guarantee for the products is up to 5 years, and the
service life that definite by corrosion rate per corrosion barrier shall
be more than 50 years:
LENGTH WIDTH THICKNESS SURFACE ORIGINAL FINAL
AREA WEIGHT WEIGHT
W0 W1
(0C) (mm) (mm) (mm) (mm2) (g) (g)
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Fiberglass selection
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A VIEW OF RAW MATERIALS
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RAW MATERIALS-VEIL,WR
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Typical Properties of Post-cured(DM), 25mm(1”) Laminate
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STEPWISE PROCESS
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Advantages of Helical FW Process
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Laminate construction:
Fiberglass content and sequence
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Character of Kigent Helical FW Process
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The laminate contains woven roving, hoop winding & helical
winding on tank to provide high flexural & tensile strength for FRP
huge tanks to resist earthquake moment or vibration of liquid
vortex.
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Quality System:
WCS ISO-9001: 2008 Quality Certification
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Comparison of different materials used for 4600m3 waste water tank
When FRP or metal lined with others and panels to be considered
4600m3 FRP tank Carbon steel Carbon steel SS 316 Tank FRP Panel tank
waste Lined w/ rubber Lined w/FRP
water tank
Excellent Inside: Excellent Inside: Excellent Excellent FRP: Excellent
Corrosion Outside: Poor Outside: Poor Supports: Poor
resistance
Maintenance none Periodic Periodic none FRP panels: No
Supports: Poor
Gaskets: Poor
Aging by Good: Poor Poor 3% less No Aging FRP panels:
thermal 3% less aging. Non Rubber: Aging aging. 3% less aging.
stress peeling. Easy to peel off Easy to peel off Gaskets: Poor
Welding none Corroded Corroded Corroded Corroded
points on seams on seams on seams on Supports
Duration for 4-6months 8-10months 8-10months 4-6months 4-6months
Construction per one set
Service Life 50years more 20years less 20years less 50years more 20years less
Cost 100 %(approx) 150 %(approx) 150 %(approx) 300 %(approx) 100 %(approx)
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STEPS IN KIGENT TECHNOLOGY
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FILAMENT WINDING – IN ACTION
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Al Newberry— DESIGNED THE GRP TANK
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Wound On Knuckle
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ERECTION OF TANK IN PROGRESS
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Joining Shell With Bottom Knuckle
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•The FEA model was for a simplified dished head since the detailed
dished head design has been done with a separate FEA.
•Since seismic loading will allow only one plane of symmetry one
half of the vessel was modeled.
•The center section of the flat bottom needed not be modeled so
this area was not filled with element in order to reduce the size of
the model.
•The perimeter of this area was restrained in order to make the
model mathematically stable.
•The shell was designed for two load cases. The first load case
was hydrostatic head pressure
•The second load case was for hydrostatic head plus seismic
acceleration. The seismic zone used was zone 3
•. The analysis was performed using COSMOS M Version
•. Design Evaluated by Mr.Al Newberry
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TANK UNDER ERECTION
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Joining Shell To Shell
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GRP TANK UNDER ERECTION
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•The dished top cover was fabricated in 16 segments with a
crown radius of 20 m and a knuckle radius of 350 mm.
•The stiffener core size was 230 mm high, 125 mm for the
crown and 200 mm for the base.
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GRP TANK TOP DISHEND UNDER ERECTION
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JOINING THE COVER WITH THE SHELL
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GRP TANK TOP DISHEND UNDER ERECTION
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KIGENT VS OTHERS
Others Kigent Corp, Ltd.
Machine Steel mold bolted on center pole Steel mold stand on ground
design Mold rotated by driven vehicle None
No machine rotation Machine rotates along steel rail
FW angle 900 degree by hoop winding only 800 degree by helical winding
interactively
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Advantages of Kigent process
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Inspection methods
Solvent Test
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Hydrotest
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Torsion Test
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Pressure Test
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Thanking for the patience to know about a new
concept to fabricate successfully large GRP/FRP
tanks to save valuable land space/ time savings
/manual labour which save cost in the new
environment of Green energy era.
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