A new proven Technology….. - FRP Institute

1 SATYENPOLYMERSPVTLTDP resentation by R. Raghavan1 FABRICATION OF GRP/FRP HUGE STORAGE TANKSA new proven , OFGRP/FRP HUGE STORAGE TANKSA new proven Technology3 MaxFabricatingCapacity:500m3upto10000m3v olume MaxFabricatingDiameter:6meterupto30meter SuggestFabricatingHeight:10meterupto15me ter4 Inthispaper, , , ,steel, ,bestcorrosionresistance,goodperformance composite-productsforcustomerisKigent ,scrubbers, ,powergeneration,electronics,marine, ,thiscompanyhasproduced500m3 FRPstoragetanks,6setsof8mdiax10mH,for32- 37%HydrochloricacidforFormosaandwithstoo dshake-testfromthefamous921( ) ,Kigenthasdevelopedtheon-siteHelicalFila mentWindingtechnologytoproducethehuge& sHelicalFWmachine,wecouldfabricatethetan kwhendiameterisupto30mand15mforheight, ,KigentfollowASTM,ASME,NBS,PS15-69,BS499 4,CNS11656-K308standards,andpromotesteps tomanufactureGRPproductsinsteadof Data of on-site fabrication : WorkingCapacity:Diameterfrom5 Mto30M,Heightupto20M Max-Application.

2 2000m3,16 Mdiax10 MHeight ManufactureCode:ASMERTP-1,ASTMD-3299,NBS PS15-69,BS4994,CNS11656-K308 Resintobeused:NovolacVinylester,EpoxyVin ylester,HalogenatedResin,Hetacidresin Fiberglasstobeused:NexusPolyesterTissue, C-veil,Choppedstrandmat,Wovenroving,Fila menthooproving Helicalwindingangle:10-15degreerelativet ocircumference Physicalproperties:ASTM requirementtobematched9 LAMINATEC haracters of kigent on-site fabrication No-limitsoftank No-vibrationofrotationcausedbydrivenmoto rtoaffectmoldstability10 Supporting poles or frames: Foundation required for mold or machinery supporting Fast fabrication: 4-8 days supposed only to produce one segment for 100 m3 FRP tank Fast erection & lifting : 4-8 working days only for 1000 m3 FRP tank Working labors required.

3 5-10 persons for one 1000 m3 FRP Tank 1112 TANK FARM(TANKS, VESSELS, AND EXHAUST SYSTEMS WITH DIMENSIONS BELOW 5 M DIA X 15 M LENGTH)1314 VIEW OF THE KIGENT WORKS15 PRESSURE VESSEL VAC TESTED16 VIEW OF TANK ERECTION17 FILAMENT WINDING PROCESS18 GRP TANK ERECTIONF ield-fabrication FRP tanks 6-30 MdiaX10-15 MHeightConsiderationbeforefabrication ResinselectionInordertoselectthesuitable resintoresistthechemicalcorrosion, before fabrication, we shall test20 Putvariousresincastingasspecimensanddipi tonvariouschemicalsatelevatedtemperature toobservethecolourchange, ,percentageofhardeners, , 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.

4 22 LENGTHWIDTHTHICKNESSSURFACEAREAORIGINAL WEIGHTW0 FINAL WEIGHT W1(0C)(mm)(mm)(mm)(mm2)(g)(g)Test 1-173%H2S04(aq) (aq) WEIGHTW0 FINAL WEIGHT W1 WEIGHT LOST(W0-W1)(W0-W1*1000/DENSITY (G/CM3)Corrosion RateCorrosion Rate(g)(g)(g)(mm3)mm/ ,causticalkalinity,orsolventchemicals,no rmallydoublesyntheticveilshouldbeusedint hecorrosionbarriertopreventattackcausedb ythetriflingcaustic, VIEW OF RAW MATERIALS-VEIL,WR26 PropertySIUS StandardTest MethodTensile Strength 130 Mpa19,000 D-3039/ISO 527 Tensil Modulus 12 x 1000000 psiASTM D-3039/ISO 527 Flexural Strength 210 MPa30,000 D-790/ISO 178 Flexural Modulus D-790/ISO 178 Glass Content40%40%ASTM D-2584/ISO 117225 mm(1 ) construction 3t CR + Reinforced layers.)

5 M= Chopped strand mat, Fw= Glass roving; 3200 g/m2 by Hoop winding and Helical winding. Wr= Woven roving, 800 g/m2 Typical Propertiesof Post-cured(DM), 25mm(1 ) Laminate27 STEPWISE PROCESS28 Advantages of Helical FW Processa. Good strength in axial and longitudinal directions; excellent vacuum resistance; not easy to rupture; no safety worry, and specified in ASTM D-3299b. Good seismic resistance; suitable for fabricating extra-large FRP storage tanksc. Keep high flexural ability, when the height & diameter ratio is greater than 229 Laminate construction: fiberglass content and sequence 3031 Character of Kigent Helical FW Process3233 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 System:WCS ISO-9001.

6 2008 Quality Certification Process quality control Delivery quality control Process capability statistics and analysis Internal quality auditing Customer complaints handling Failure and quality variation handling procedure Management auditing procedure Feeding stock quality control35364600m3 wastewater tankFRP tankCarbon steelLined w/ rubberCarbon steelLined w/FRPSS 316 TankFRP Panel tankCorrosion resistance Excellent Inside: Excellent Outside: Poor Inside: Excellent Outside: Poor Excellent FRP: Excellent Supports: Poor Maintenance none Periodic Periodic none FRP panels: NoSupports: Poor Gaskets: Poor Aging by thermal stress Good: 3% less aging. Non peeling. Poor Rubber: Aging Easy to peel off Poor 3% less aging.

7 Easy to peel off No Aging FRP panels: 3% less aging. Gaskets: Poor Welding points none Corroded on seams Corroded on seams Corroded on seams Corroded on Supports Duration for Construction 4-6months per one set 8-10months 8-10months 4-6months 4-6months Service Life 50years more 20years less 20years less 50years more 20years less Cost 100 % approx 150 % approx 150 % approx 300 % approx 100 %(approx Comparison of different materials used for 4600m3waste water tankWhen FRP or metal lined with others and panels to be considered37 STEPS IN KIGENT TECHNOLOGY38 FILAMENT WINDING IN ACTION39Al Newberry DESIGNED THE GRP TANK40 Wound On Knuckle41 ERECTION OF TANK IN PROGRESS42 Joining Shell With Bottom Knuckle43 TheFEAmodelwasforasimplifieddishedheadsi ncethedetaileddishedheaddesignhasbeendon ewithaseparateFEA.)

8 Sinceseismicloadingwillallowonlyoneplane ofsymmetryonehalfofthevesselwasmodeled. Thecentersectionoftheflatbottomneedednot bemodeledsothisareawasnotfilledwitheleme ntinordertoreducethesizeofthemodel. Theperimeterofthisareawasrestrainedinord ertomakethemodelmathematicallystable..Th eanalysiswasperformedusingCOSMOSMV ersion . 44 TANK UNDER ERECTION45 Joining Shell To Shell46 GRP TANK UNDER ERECTION47 Thedishedtopcoverwasfabricatedin16segmen tswithacrownradiusof20mandaknuckleradius of350mm. Theinsideheightofthedishwas2883mm. Eachsegmentwasstiffenedwithatrapezoidals tiffener. Thestiffenercoresizewas230mmhigh,125mmfo rthecrownand200mmforthebase. DISH END -DETAILS48 GRP TANK TOP DISHEND UNDER ERECTION4950 JOINING THE COVER WITH THE SHELL 51 GRP TANK TOP DISHEND UNDER ERECTION52 OthersKigent Corp, mold bolted on center poleSteel mold stand on groundMold rotated by driven vehicleNoneNo machine rotationMachine rotates along steel railLimitationA huge RC foundation required to buried to keep the balance of the center poleNo RC foundation requiredTank s diameter is limited by the weight of mold and FRP tank.

9 The heavy weight Only loaded on the center poleNo limits to tanks diameter due to weight of Mold & FRP tank stands on ground Vibration caused by driven motor to affect mold stability and balanceNo vibration (because the steel mold stand on ground)Laminate forming to be affected by unstable mold, when mold easily collapsed or demolded to destroy the strength before curingNoneFW angle 900 degree by hoop winding only800 degree by helical winding interactivelyKIGENT VS OTHERS53 Advantages of Kigent process No-limitstotank No-vibrationorrotation:Bydrivensubjectto affectmoldstability54 Inspection methods Solvent Test55 Hydrotest56 Torsion Test57 Pressure Test585960 Thankingforthepatiencetoknowaboutanewcon cepttofabricatesuccessfullylargeGRP/FRPt ankstosavevaluablelandspace/timesavings/ manuallabourwhichsavecostinthenewenviron mentofGreenenergyera.

10 (EveryPennysavedinconstructionmaterial,l andareagivessatisfactionasthenewgenerati onwillenjoythefruitofsavings)