Tanks, Vessels & Silos

GRP COMPOSITES

Tanks, Vessels & Silos

GRP COMPOSITES
In a GRP single laminate composite the glass/resin structure is protected from chemical attack by a contact surface with resin rich corrosion barrier. A wide choice of resin systems permits specification of the laminate to suit the required duty. Automated manufacture provides low cost products The design, manufacture, installation and operation of GRP tanks are covered by the comprehensive standard BS 4994:1987 Although light and easy to handle, the substantial strength achievable with GRP permits structures to be designed with integral steelwork such as ladders, handrailing, platforms and bridges. It is straightforward to include side access manways when building dual laminate GRP tanks.

BS4994:1987
THE DESIGN AND CONSTRUCTION OF VESSELS AND TANKS IN GLASS REINFORCED PLASTICS
High quality production has always been vital for Forbes as so many of the companys products are dedicated to specialised and hazardous duties. For many years we have been producing tanks and pressure vessels to this demanding standard which describes various categories of production in great detail even prescribing working conditions and the structure of fittings. Forbes is approved by leading inspection and insurance companies to manufacture to all categories of the standard. The broad compass and thoroughness of BS4994 make it an invaluable aid to those preparing risk assessments and safety plans.
BS4994 covers the design, manufacture, transport and installation of tanks and vessels in GRP (glassfibre reinforced plastic) materials. It is a very thorough and stringent standard. IT DOES NOT deal with any aspect of the manufacture of tanks in other materials such as metals or freestanding thermoplastics. For advice talk to Forbes on +44(0)1366 388941.

A QUALITY COMPANY
We are an independent privately owned business, soundly managed by a tightly knit team and with strong technical and financial bases. We are dedicated to supplying our customers with high quality products at competitive prices without jeopardising the well-being of our staff, the public at large, or the environment. Forbes stands by its products you will find our after sales service second to none. We strive towards continual company improvement and aspire to provide standards of excellence, efficiency and service that make Forbes a comfortable organisation to deal with.

DVS 2205 There is still no universal standard for the design of thermoplastics tanks although a European (CEN) standard is in preparation. In the meantime some manufacturers have been drawn to this German standard. Critics have pointed out that some aspects of DVS 2205 are basic and that in several crucial areas it refers inappropriately to metal design codes. To help specifiers evaluate DVS 2205 against BS 4994 we have prepared some guidance notes, please ask our sales department for a complimentary copy. Please also ask for a copy of our leaflet Thermoplastics Tanks.

CHOP-HOOP WINDING GRP

Glass fibres have excellent tensile strength, are non-combustible and chemically resistant, yet lack rigidity and form on their own. They are however an ideal reinforcing material when combined with thermosetting resins. Modern glassfibre technology dates from the 1930s but the material began to be properly exploited in the 1950s with the advent of synthetic resins which led to the development of modern polyester and vinylester resin systems. The intense research and development of GRP into a predictable engineering material was driven above all by the aerospace industry where its light weight was of course its main attraction. In the chemical and process industries, corrosion resistance has been the prime benefit and plastics materials are now the materials of choice for many applications, particularly storage and processing tanks, gas scrubbers and other chemical plant. BS4994, introduced in 1973, revised and expanded in 1987, covers the design and fabrication of GRP tanks and vessels in substantial detail (see P3) and has been the bedrock of Forbes progress as the leading UK manufacturer of custom-designed tanks and vessels. The corrosion barrier/contact surface of a GRP tank or other fabrication may be a resin rich layer or a thermoplastic inner shell, forming a dual laminate. The choice of manufacturing process depends very much on the duty for which the product is designed. GRP structures have excellent strength to weight performance and are very versatile, but the most economical configuration for dual laminate tanks is as self supporting vertical cylinders. Manual fabrication, including hand lay up of the GRP, allows substantial variation of the height and diameter of a tank a very useful consideration when a site has limited space. Traditional manual layup of GRP is labour intensive and effective quality management involves a great deal of detail. Cylindrical GRP tanks would seem to be a prime target for automated production and there have been various approaches, most based around the technique known as filament winding. Conscious that filament winding techniques do not produce ideal glass/resin ratios for process plant applications and determined that any automated production should match or improve on our existing standards, Forbes invested in a massive installation for the production of cylindrical GRP shells by chop-hoop winding. At the time of its installation it was thought to be the largest plant of its kind in the world and it has been much extended and improved since then. Automated controls constantly monitor the rate of deposition of both glass and resin and provide detailed quality records. The laminate is particularly strong and economical and combines the advantages of winding and spraying techniques, notably considerable multidirectional strength and enhanced interlaminar shear when compared to filament winding. Chop-hoop wound tanks with standard glass/resin combinations can economically handle many duties requiring chemical resistance. Water, corrosive liquids including sewage sludge, general effluent, liquid fertiliser, brine, and chemical storage are typical applications. Specialised resins such as the higher performance isophthalic polyesters and the sophisticated bisphenol and vinyl ester resins are suitable for very demanding applications. Some environments may require an enhanced performance glass reinforcement and in these circumstances special grades are used. Chop-hoop winding is also a most efficient process for the production of silos for the bulk storage of dry materials such as PDV salt, plastics granules and animal feed.

RESIN SYSTEMS
There are many resins available for GRP fabrication, by no means all of them suitable for high specification applications. Orthophthalic polyester resins are perhaps most widely used. NPG isophthalic polyesters offer increased chemical resistance and higher temperature performance. Bisphenols and vinyl esters are generally employed for particularly demanding tasks. While specifying the resin for an application the design engineer also determines the suitable grade of glass reinforcement.

IMPARTIALITY
We are equipped to manufacture in a wide range of materials and will always endeavour to offer objective solutions to your requirements.

ECONOMICAL STANDARD DESIGNS FOR CHOP-HOOP GRP TANKS SERIES 2

POST CURING
The principle of post-curing GRP tanks and vessels to achieve maximum performance from the laminate is well known and is referred to in BS4994. Curing, by linking free styrene monomers and other organic residuals within the laminate ensures optimum physical and chemical properties and reduces the possibility of taint in higher temperature, taste-sensitive, applications. Resin manufacturers specifications outline the time and temperature requirements for post-curing their products. Without post-curing, laminates can in some demanding applications suffer from chemical degradation or the risk of taint. Also because of the lower ultimate tensile strength of the laminate increased safety factors in the design of the tank would result in greater wall thickness to achieve the required strength. Our massive post-curing oven, fitted with a calibrated chart recorder, is over 5 metres in diameter and 13 metres long. It is capable of o sustaining temperatures in excess of 100 C over long periods. Customers can benefit when post-curing is specified by improved chemical resistance, increased strength, and avoidance of taint.

MODEL
PVT 5/2 PVT 7.5/2 PVT 10/2 PVT 12.5/2 PVT 15/2 PVT 20/2

Capacity (litres)
5000 7500 10,000 12,500 15,000 20,000 10,000 15,000 20,000 25,000 30,000 20,000 30,000 40,000 50,000 60,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 50,000 60,000 70,000 80,000 90,000 100,000 110,000 120,000 130,000 140,000 150,000 160,000

Diameter (mm)
2000 2000 2000 2000 2000 2000 2400 2400 2400 2400 2400 3050 3050 3050 3050 3050 3500 3500 3500 3500 3500 3500 3500 3500 4111 4111 4111 4111 4111 4111 4111 4111 4111 4111 4111 4111

Nominal Wall Height (mm)*

2180 2980 3775 4570 5365 6960 3000 4100 5200 6300 7400 3540 4910 6280 7650 9020 4000 5040 6080 7120 8160 9200 10,240 11,280 4770 5530 6290 7050 7810 8570 9330 10,090 10,850 11,610 12,370 13,130

Approximate Weight (kg)

250 300
* Includes 390mm dish height

SILOS
One piece body with smooth interior assures complete emptying Smooth knuckle with no internal crevices Translucent shell permits visual contents check against integral calibration

350 420 480 600 330 400 570 680 800 620 820 1000 1200 1400 850 1050 1200 1400

SERIES 2.4

PVT 10/2 PVT 15/2 PVT 20/2 PVT 25/2 PVT 30/2

* Includes 600mm dish height

INDUSTRIAL AND AGRICULTURAL SILOS

MODEL

CAPACITY CUBIC M.

CAPACITY, TONNES BULK DENSITY 600 KG/M3 1200 KG/M3

HEIGHT, METRES

SERIES 3

PVT 20/3 PVT 30/3 PVT 40/3 PVT 50/3 PVT 60/3

PCS 24.06
* Includes 600mm dish height

6 10 12 15 20 25 30 34 38 20 25 30 35 50

3.6 6 7.2 9 12 15 18 20.4 22.8 12 15 18 21 30

7.2 12 14.4 18 24 30 36 40.8 45.6 24 30 36 42 60

4.51 5.48 5.97 6.70 7.91 9.13 10.34 11.32 12.29 6.55 7.30 8.05 8.80 11.05

6.16 7.13 7.62 8.35 8.56 10.78 11.99 12.97 13.94

PCS 24.10 PCS 24.12 PCS 24.15 PCS 24.20 PCS 24.25

SERIES 3.5

RANGE OF MANUFACTURE
We manufacture storage tanks in various materials from 200 to 200,000 litres capacity. All our products are custom designed and manufactured but where appropriate we will suggest an adaption of a standard design to minimise costs and lead times.

PVT 30/3.5 PVT 40/3.5 PVT 50/3.5 PVT 60/3.5 PVT 70/3.5 PVT 80/3.5

Silo diameter 2.4m Dome height 0.6m Cone depth 1.95m o Cone angle 60
* Includes 680mm dish height

PCS 24.30 PCS 24.34 PCS 24.38 PCS 30.20 PCS 30.25 PCS 30.30 PCS 30.35 PCS 30.50

1600 1800 2000 2250 1400 1600 1800 2000 2150 2350 2600 2900 3100 3350 3650 3950

Silo diameter 3.05m Dome height 0.6m Cone depth 2.64m o Cone angle 60 Leg length (L) 3.1m (H) 4.75m Outlet height above ground (L) 1.15m (H) 2.8m

NON TANK PRODUCTS

The technologies we use to build tanks are directly transferable to many other items of process plant and we design and manufacture a wide range of custom and standard products such as Salt Saturators, Silos, Scrubbing and Stripping Towers (see page 8) in a variety of materials. We also apply our substantial experience in process plant in the manufacture of complex one-off fabrications, in skid and container mounted modules and by offering a full turnkey supply, installation and commissioning service.

PVT 90/3.5 PVT 100/3.5

SERIES 4

PVT 50/4 PVT 60/4 PVT 70/4 PVT 80/4 PVT 90/4 PVT 100/4 PVT 110/4 PVT 120/4 PVT 130/4 PVT 140/4 PVT 150/4 PVT 160/4

If you require a larger silo we can also offer 3.50m and 4.14m diameters. Please ask us to quote.

* Includes 770mm dish height

/H HIGH LEG

/L LOW LEG

SAFETY MATTERS
Health and safety issues are high on the agenda in all enterprises, especially as legislation has continued to focus the attention of safety officers on avoidable problem areas. During installation the Construction (Design and Management) Regulations detail the responsibilities of the client to appoint a supervisor to manage safety. Once commissioned the plant safety officer must have risk assessments and method statements in place for day-to-day operations. Tanks have to be entered to satisfy planned maintenance schedules. Awareness of the hazards involved in confined space working has grown, especially in the light of several well-publicised tragedies. It has become more common for safety procedures to demand breathing apparatus, winches and back-up staff but even 600mm diameter topmounted manways are too small to winch an inert colleague through.

PRODUCT RANGE
Thermoplastics Tanks Tanks, Vessels & Fabrications
GRP/THERMOPLASTICS DUAL LAMINATES

Tanks, Vessels & Silos

GRP COMPOSITES

MINIBULK Chemical Storage Systems Sectional Tanks Silos

FOR SOLIDS & LIQUIDS

Salt Saturators Pressure and Vacuum Vessels Fume and Odour Scrubbing Systems Vent Scrubbers CO2 Degassers Stripping Towers Carbon Adsorption Units Bio Treatment Systems Ancillary Steelwork Skid Mounted Modules Turnkey Projects

SIDE ACCESS MANWAYS

The safest and most practical aid to entering tanks, and providing emergency backup, is the provision of side access manways. The small initial cost is quickly recovered by operational savings, let alone the substantial contribution to safer working practices. The Health & Safety Commission document L101(section 95) states top openings to vessels, tanks etc. should be avoided due to difficulty of access and rescue. Bottom or low manholes are preferable. The document also states that the minimum size of opening should be 575mm. The implementation of the Confined Space Regulation (CSR) which is now mandatory further emphasises this requirement. It is further suggested that all vertical tanks and vessels with a wall height in excess of 2.4 metres should be fitted with a side mounted access manway no more than 1.3 metres above the base. It is straightforward to build side manways in GRP tanks during manufacture design and construction are thoroughly covered by BS 4994.

For further information visit our website at: www.forbesgroup.co.uk

FORBES
Denver Downham Market Norfolk PE38 0DR UK Tel +44 (0)1366 388 941 Fax +44 (0)1366 385 274
Email sales@forbesgroup.co.uk Website: www.forbesgroup.co.uk

BS EN ISO 9001 FM 24188

ANGLIA DESIGN AND MARKETING 01 366 384 942 010104