Global AST Solutions Provider Since 1978
www.hmttank.com
The GRP floating roof
Netwerkdag Brandweer & BRZO
Global AST Solutions Provider Since 1978
www.hmttank.com
History of the DeckMaster GRP IFR
Dow Chemicals Terneuzen - 24m (80ft) Tank
First GRP full contact panel roof installed in 1988 - 25 years
service in BTX (Benzene/Toluene/Xylene mix)
1988
Shell Gent - 24m (80ft) Tank
Introduction of first full contact
seamless self supporting GRP
IFR installed in 1994 -19 years
service in Gasoline
Vopak Botlek Rotterdam - 17.5m (57ft) Tank
Introduction of anti- static layer to the composite
structure. Installed in 1995 - 18 years service in EDC
1994
1995
Global AST Solutions Provider Since 1978
www.hmttank.com
History of the DeckMaster GRP IFR
Shell KPRL Kenya - 60m (180ft) Tank
First Combi Tank – GRP DeckMaster + Dome
1998
Statoil - 39m (40ft) Tank
First Large diameter GRP External roof installed in 2012
2002
2012
Total number of
installations
to date 195
Shunitsu - 12m (40ft) Tank
First GRP External roof installed in 1999 - 14 years
service - Waste Water Tank
Global AST Solutions Provider Since 1978
www.hmttank.com
So, what’s holding composites back?
• Despite three decades of GRP availability, there is lack of awareness.
Key Advantages of GRP
1.
Non-corrosive - Capable of withstanding the full range of caustic chemicals.
2.
Lightweight - GRP is approximately 60-75% lighter than steel, yet it is pound-for-pound
stronger.
3.
No Maintenance - UV stabilization means no painting or lacquering is required after installation
4.
Impact Resistance - Tests have shown GRP stands up to large impacts, without permanent
deformation, saving costly repairs
5.
Easy to work with - GRP does not require specialist cutting or welding equipment and can
usually be installed with simple hand tools.
6.
Anti Static and Anti Spark - GRP is perfectly suited to sensitive environments, thanks to its
ability to dissipate static electricity
7.
No pre-fabrication required - Short lead time, Size independent. Standard material suitable
to nearly all products.
Global AST Solutions Provider Since 1978
www.hmttank.com
Key benefits of the DeckMaster GRP IFR
Key user benefits:
• Maintenance-free – corrosion resistant, requires no painting, coating or spare parts
• Minimal construction time – all materials fit through one 24” manway no cranes required
• Unsinkable – due to its multi-cell honeycomb core structure
• Fully Engineered and field-proven – 25 years experience in multiple chemicals
• Maximizes tank capacity – Low profile cross-section increases working capacity
• Short lead time – all material readily availible , no pre-fabrication required
• Short engineering lead time - Requires minimal detailing
• Product compatability – Chemical compatabil to all stored products except strong solvents like acetone
Global AST Solutions Provider Since 1978
www.hmttank.com
Economic Considerations
 Emissions Performance
• Best available IFR control technology
 Working Capacity
• ~2 feet of gained capacity vs. traditional steel pontoon EFR
 Inventory Utilization (reduced heel)
• Equivalent capabilities to best in class
 Maintenance & Durability
• Lowest maintenance, longest lasting technology available
 Ease and Speed of Installation
• Reduces costs and minimizes out-of-service time
Global AST Solutions Provider Since 1978
www.hmttank.com
IFR Technology Comparison
Best < < <
Steel
Pontoon
Aluminum
Skin &
Pontoon
> > > Worst
GRP /
Fiberglass
Steel
Pontoon
Corrosion resistance/
chemical compatibility
Initial Material Cost
Ability to handle flow rates,
turbulence, gas upsets
Installation Cost
Ability to handle high cycle
frequency, repetitive stress
Material Lead Time
(engineering & fabrication)
Ability to handle drag
forces & rim torque
Installation Time
Buoyancy ratio
Material entry factors (door
sheet vs. manway/window)
Buoyancy redundancy
Float test required vs. at
purchaser’s option
Fire protection
Depth of System
(impact on capacity)
Ability to be suspended
(no confined space entry)
Heel reduction/
minimization capability
Assuredness of
gas-free certification
Walkability
Potential to trap
hydrocarbons
Ease of access under roof
during maintenance
Emissions performance
Ease of tank bottom
inspection
Aluminum
Skin &
Pontoon
GRP /
Fiberglass
Global AST Solutions Provider Since 1978
Construction of a GRP Internal Floating Roof
78m DeckMaster IFR Completed in 6 weeks
Shell / CNOOC - Nanhai 2004
www.hmttank.com
Global AST Solutions Provider Since 1978
www.hmttank.com
Construction of a GRP Internal Floating Roof
Stage 1 - The Mould
•
The mould structure is a simple platform structure made from laminated chipboard fixed on
construction beams with adjustable supports.
•
Laminated chipboard does not stick to the coating layer of the GRP roof which makes it a
perfect moulding material.
•
Adjustable supports makes it possible to build on a perfectly flat surface
Global AST Solutions Provider Since 1978
www.hmttank.com
Construction of a GRP Internal Floating Roof
Stage 2 - The Bottom Laminate
•
First Layer is the anti-static layer – Utilizing vinyl ester resin mixed with graphite
•
Second Layer is the chemical barrier layer – Resin rich layer with a C glass Veil.
•
Third Layer is the structural layer – This layer is a Multi-axial stitched glass mat ideally suited
for sandwich construction, achieving further weight reductions compared with previous
lamination schedules
Global AST Solutions Provider Since 1978
www.hmttank.com
Construction of a GRP Internal Floating Roof
Stage 3 - Core Material
• The main function of the core
material is to distribute local loads
and stresses over large areas.
• Local stresses applied to one side of
the sandwich have only a reduced
local effect because the exposed
skin and the core will distribute the
loads to a larger area of sandwich
• Polypropylene honeycomb can
stretch and carry loads without
failure after the yield point, so
that the value at ultimate shear is
still higher than at yield.
• Polypropylene Honeycomb core
must be the individually extruded
type.
Description
The polypropylene honeycomb is bonded to the bottom
laminate with the same resin used in the lamination process.
Sand Buckets are used to weigh down the core to achieve
Value
60
Unit
Density:
Compressive
Strength:
kg/m3
0.81
N/mm2
Shear Strength
0.31
N/mm2
Shear Modulus
7.2
N/mm2
Global AST Solutions Provider Since 1978
www.hmttank.com
Construction of a GRP Internal Floating Roof
Stage 4 – Top Laminate
•
Multi-axial stitched
reinforcements are ideally
suited for sandwich
construction, achieving further
weight reductions compared
with previous lamination
schedules
•
When used with sandwich
construction to provide the
required cross section for
flexural stiffness ideally suited
for sandwich construction
Global AST Solutions Provider Since 1978
www.hmttank.com
Construction of a GRP Internal Floating Roof
Stage 5 – Top coating
•
The final layer consists
of a fire retardant resin
layer mixed with graphite
to create an Anti-Static
conductive coating.
Global AST Solutions Provider Since 1978
www.hmttank.com
Construction of a GRP Internal Floating Roof
Day 1
Day 2
Day 3
Day 4
Day 5
Day 6
Day 7
Day 8
30m DeckMaster IFR Completed in 12 days
Tupras - Turkish Petroleum Refinarys
2012
Day 12
Global AST Solutions Provider Since 1978
www.hmttank.com
Construction of a GRP Internal Floating Roof
Quality Assurance
All lamination is performed according to the ASTM C-582.
This specification covers composition, thickness, fabricating procedures, and physical property requirements for
glass fiber reinforced thermoset polyester, vinyl ester, or other qualified thermosetting resin laminates
comprising the materials of construction for RTP corrosion-resistant tanks.
82 m Ø DeckMaster constructed in 7 weeks!!
Global AST Solutions Provider Since 1978
www.hmttank.com
Fire Testing & the NFPA 11
NFPA 11 Rim-fire senario proposal for the
GRP Deckmaster Floating Roof
Global AST Solutions Provider Since 1978
www.hmttank.com
Fire Testing with the LAST Fire group
Spain 28-31 July 2008 Test 1A
Full contact GRP FR with spill fire
Structural inspection after fire test
Global AST Solutions Provider Since 1978
www.hmttank.com
Spain 28-31 July 2008 Test 1B & C
Pre-ignition for test with fixed roof
And Full contact GRP IFR
The result after 30minutes of burning
No damage visible to GRP IFR Just
some melted aluminum from the roof
Global AST Solutions Provider Since 1978
www.hmttank.com
Spain 28-31 July 2008 Test
Hole Burn Test for NFPA approval
Test Criteria:
1.
Make one 100mm
hole in External GRP
roof
2. GRP roof must float
on 400 L Heptane
Fig. A1 (EFR floating in Heptane)
Fig. A3 (Burning for 75min.)
Fig. A2 (100mm hole in IFR)
3.
Set Heptane in the
hole on fire and let
burn for 1 hour.
4.
The GRP Floating roof
must keep it’s
structural integrity
and remain afloat
after a 60min. Burn
Global AST Solutions Provider Since 1978
www.hmttank.com
Conclusions on the LAST Fire tests
• The HMT Full Contact GRP Floating Roof maintains its structural
integrity and buoyancy.
• The HMT mechanical rim seal remains intact, with only minor damage
to the PTFE seal skirt.
• Full Surface pool fires can not be considered as a credible fire scenario
for a full contact GRP external and internal floating roof.
Witnessed and approved by:
SHELL GLOBAL SOLUTIONS
STATOIL
LAST FIRE GROUP – Sub committee RPI Resource Protection International
(Chairman for the setup of the fire test scenario, Dr. Niall Ramsden)
Global AST Solutions Provider Since 1978
www.hmttank.com
Friendly football match played on a 78m diameter
DeckMaster IFR during a water test.