MERICAN SYSTEM Introduction-20170801
Transcript of MERICAN SYSTEM Introduction-20170801
MERICANMERICAN SystemSystem
TheThe fiberglassfiberglass reliningrelining systemsystem toto upgradeupgrade
inin--serviceservice steelsteel fuelfuel tanktank inin gasolinegasoline stationstation
SinoSino PolymerPolymer Co.,Co., Ltd.Ltd.
Part 1: Brief introduction
Part 2: Construction flow chart
Part 3: Construction specification
CodeCode forfor constructionconstruction andand acceptanceacceptance ofof
constructionconstruction qualityquality ofof MERICANMERICAN SystemSystem
Part 3: Construction specification
Part 4: Code for acceptance of construction quality
Part 5: MERICAN SYSTEM-Raw materials list
Part 6: MERICAN SYSTEM-Equipment list
Part 7: MERICAN SYSTEM-Construction workers
Part 1: Brief introduction – MERICAN system
-Developed according the actual requirement in Shanghai, MERICAN System is in line with the
Shanghai Environmental Protection Regulation No.182 (2017) and Sino Polymer owns IPRs
-MERICAN System is a fiberglass lining system which fabricating a double wall FRP tank in the
inside surface of single wall steel fuel tanks. It owns same composite specification as a double
wall FRP tank : two corrosion resistant laminates with the interstitial space in the middle, wall FRP tank : two corrosion resistant laminates with the interstitial space in the middle,
total thickness is between 11-15mm.
-After structural strength calculation and lamination structure design, the double wall FRP lining
replace all the functions of original steel tanks which includes load bearing, storage of oil,
corrosion resistance.
-The MERICAN 9505 series resin used in MERICAN System was certified by UL 1316 and
UL1746, it also conforms with the requirement in the standard of GB/T 30040.7 and SH/T 3177.
The innovation points in MERICAN System:
1- MERICAN 9505-50 UV curing resin is developed by Sino Polymer and in line with GB/T 30040
and SH/T 3177. It is also approved by UL.
2- When the wall thickness of original steel tank is less than 3.2mm, the lamination structure
design and lamination thickness of double wall FRP lining will be determined by the original
fuel tank’s allowable value of various loads and composites.
Part 1: Brief introduction – MERICAN system
3-The dry ice derusting method was used by MERICAN System which ensure there is no
secondary pollution and provide a more safety environment and no harm to health.
4- The pressure leak detection system was used is in line with the Shanghai Environmental
Protection Regulation No.182 (2017)
5- No need to dig a monitoring wells, no open hole in the top of the tank to reduce leakage points
and construction risk.
6, The interstitial space exists in the circumferential direction of the tank 360 °which ensure the
leakage detection has full coverage without dead ends.
Lining structure of
MERICAN System
Total
thickness:
11.5-15mm
Part 1: Brief introduction – MERICAN system
Primer
Outer FRP laminates: 4.0mm
Interstitial space layer: 3.5mm
Inner FRP laminates: 4.0mm
Original steel tank wall + dry ice rush removal
11.5-15mm
Part 1: Brief introduction – MERICAN system
Structure of
MERICAN System
MERICAN System is in line with the standard below
Nr. Standard No. Standard Name
1 GB 50156-2012
(2014 version)
Code for design and construction of automobile
gasoline and gas filling station
2 GB/T 30040-2013
( )
Lead detection systems
This standard is equals to BS EN 13160:2003
Part 1: Brief introduction – MERICAN system
(BS EN 13160:2003) This standard is equals to BS EN 13160:2003
3 SH/T3177-2015 Technical specification for buried glass fiber reinforced
plastic double skin oil tanks in fuel filling station
4 UL 1316 Glass-Fiber-Reinforced Plastic Underground Storage
Tanks for Petroleum Products, Alcohols, and
Alcohol-Gasoline Mixtures.
5 UL 1746 External Corrosion Protection Systems for
Steel Underground Storage Tanks.
UL certificates for
MERICAN 9505
Part 1: Brief introduction – MERICAN system
The approval tests on MERICAN 9505 done by UL experts
Process Hand lay-up
Spray up
Vacuum Infusion/RTM
Pre-preg
Compatible fiberglass
OCV: M123 450, M123 600(Chopped Strand Mat)
Part 1: Brief introduction – MERICAN system
OCV: M123 450, M123 600(Chopped Strand Mat)
Jushi: EMC 450、EMC600( Chopped Strand Mat )
Jushi: ER13-2400-180(Spray roving)
OCV: OCV P209 2400TEX( Spray roving )
Taishan Fiberglass: ERS240-T132B( Spray roving )
Shangdong Fiberglass: ECR13-2400A-823P( Spray roving)
CPIC: ER 10-2400( Spray roving )
Compared with integral tank change, MERICAN System owns advantages below:
No dig at site, simple approval procedures, after the filing then it can be implemented.
In accordance with the requirements of the national standard:After upgrade, the steel
fuel tank will have a complete double FRP wall structure which meet the requirement of
GB/T30040-2013 Leak Detection System and GB 50156-2012 Code for design and
construction of automobile gasoline and gas filling station
Part 1: Advantage of MERICAN system
Stable & reliable leak detection system:Real time detection of tank system status
Short construction cycle:
For uninterrupted operation, it only takes 3 weeks to upgrading four 30m3 steel tank
Low overall cost:MERICAN system provide a much lower overall cost compared with
the overall tank change solution,
Very small tank capacity change:
After upgrading, the tank capacity is 97% of the original tank capacity.
Compared with the existed lining upgrade systems introduced from international market, the
MERICAN System is more suitable with Chinese national conditions with advantages below:
The main raw materials used in the system were approve by international authority third
party certification, the quality can be guaranteed. The resin was produced by Sino Polymer
which greatly reduce the cost of lining project.
The dry ice derusting process reduce the risk of explosion during construction and the risk of
Part 1: Advantage of MERICAN system
construction environmental pollution, reduce the health risks of construction workers.
The UV curing equipment owns characteristics of small size, light weight, long life, easy
moving which is in line with the single manhole of in-service steel fuel tank in Shanghai.
The operating voltage of UV curing equipment is low (12V) which is in line with limited space
voltage requirements, safe and efficient, ensure complete curing.
No need cut off the triangular steel support inside the in-service steel fuel tank to avoid
security risks
Compatible fiberglass is in full range
Site preparation,
Safety protection
Tank cleaning &
decontamination Dry ice derustingCut off the bottom
steel support
Inner wall repair,
apply the primer
Installation of Leak
Gas burst
testGas burst
test
Visual inspection,
Thickness
measurement
Part 2: MERICAN SYSTEM: Construction flow chart
Thickness
measurement
Out FRP
laminates
Interstitial
space layer
Installation of Leak
detection
prefabricated parts
Inner FRP
laminatesInstallation of Leak
detection system
Installation of
Electrostatic
discharge device
Interstitial
space test
Intermediate layer
pressure test
(Positive & Negative
pressure)
Thickness measurement,
appearance inspection,
barcol hardness test,
spark test
Thickness measurement,
appearance inspection,
barcol hardness test
Completion
acceptance
Grounding
resistance
1-Initial preparation work
1.1 Communicate with the owners,
investigate the working environment,
sign the security responsibility agreement,
confirm the construction considerations.
Part 3: MERICAN SYSTEM:
Construction Specification
confirm the construction considerations.
1.2 Equipment approach, commissioning:
Assembly and commissioning lighting, ventilation, spraying, light curing
equipment to ensure that the equipment is in good condition.
1.3 Personnel safety training.
1.4 Security protection settings.
1.5 Tank gas test.
2 Forced ventilation
The forced ventilation has to be done when the cleaning up of the oil in steel
tank was finished. The ventilation time should be at least 2 hours or more.
Part 3: MERICAN SYSTEM:
Construction Specification
3 Dry ice derusting
3.1 After the ventilation was qualified, cleaning the welding slag, burr, rust, oil, dust and
other floating objects in the steel tank and ensure the tank surface is flat.
3.2 Check the dry ice derusting equipment, inspect the compressed air flow and pressure of
the air compressor.
3.3 Dry ice derusting: -78 dry ice particles in the cleaning machine was driven by
compressed air impact on the tank surface with a high-speed to achieve the purpose of rust.
Part 3: Construction Specification
3.4 To ensure the safety, the whole dry ice derusting process should be monitored.
After dry ice derustingBefore dry ice
derusting
4 Correction on single steel wall tank
4.1 When the second tank cleaning and derusting was finished, and tank
flammable gas test was qualified, then cut off the bottom of the tank steel
support in about 500 ~ 600mm width.
Part 3: MERICAN SYSTEM:
Construction Specification
4.2 Cutting detection opening on reinforcement rib plate in the two sides tank
head, so that the tank head and the cylinder sandwich has good conduction
performance.
4.3 Using 9505TP resin putty in the tank flat head, inner wall reinforcement ribs,
welding seam to make transition section to ensure the smooth transition .
4.4 ESD device installation work.
Part 3: MERICAN SYSTEM:
Construction Specification
4.4 ESD device installation work.
5 Inspection and repair work on steel tank wall
5.1 Inspect the the steel single wall tank’s thickness, corrosion, crack
and deformation, etc.
5.2 Tank wall repair:
For the inner tank wall area where their is defects and the local wall thickness less
Part 3: MERICAN SYSTEM:
Construction Specification
For the inner tank wall area where their is defects and the local wall thickness less
than 3.2mm, the chopped strand mat and special resin should be used to repair to
to ensure the pressure capacity of the tank.
5.3 When the whole steel tank thickness is less than 3.2mm , then integrally
reinforcement is required. The design and thickness of the reinforced lamination
structure and thickness should follow mechanical strength calculation.
6 Apply the primer
6.1 Clean the dust and debris in the tank, then apply MERICAN 110 primer resin in
the steel tank inner surface within 4 hours after derusting. Surface inspection
should be done during coating. The surface should be smooth, smooth, uniform,
and no un-coating area, sticky, peeling, bubbles and spots and other defects exist,
if there is defect coating, it should be repaired at once.
6.2 After the completion of the construction, the pull test should be done. Bonding
Part 3: MERICAN SYSTEM:
Construction Specification
6.2 After the completion of the construction, the pull test should be done. Bonding
strength of 5.5MPa or more is qualified.
8 Outer wall glass fiber reinforced plastic (FRP) construction
8.1 Lay the trimmed fiberglass on the tank wall, soak with the UV curing resin, two
wove roving/mat’s overlap width should be at least 50mm on the same layer;
continue to lay the second piece of fiberglass mat, until reaching the design
thickness; roll out the bubble; resin brushing uniform, no missing part, resin dripping,
bubbles or burrs; resin content control at 70 ± 5%.
Part 3: MERICAN SYSTEM:
Construction Specification
bubbles or burrs; resin content control at 70 ± 5%.
8.2 After each unit is finished, cure them with a UV lamp. After curing, the outer wall
is subjected to the barcol hardness test, and the minimum barcol hardness value is
≥30.
8.3 After the outer glass fiber reinforced plastic is finished, the thickness detection,
visual inspection and EDM test are carried out with ultrasonic thickness detector.
If the thickness of a region does not meet the design requirements, or the
Part 3: MERICAN SYSTEM:
Construction Specification
If the thickness of a region does not meet the design requirements, or the
appearance inspection does not meet the requirements, you need to add resin
coating in the region, and re-testing it until achieve the thickness requirements.
9 Interstitial construction
Using MERICAN 9505-50 UV curing resin and 3D fabric to fabricate the middle gap
layer, cured with UV lamp. After the intermediate gap layer is finished, the visual
inspection and the curing degree test are carried out.
Part 3: MERICAN SYSTEM:
Construction Specification
10 Leak detection system install
Install the leak detection system in accordance with the construction plan.
11 Inner wall glass fiber reinforced plastic (FRP) construction
11.1 Lay the trimmed fiberglass on the outer FRP wall, soak with the UV curing resin,
two wove roving/mat’s overlap width should be at least 50mm on the same layer;
continue to lay the second piece of fiberglass mat, until reaching the design thickness;
roll out the bubble; resin brushing uniform, no missing part, resin dripping, bubbles or
burrs; resin content control at 70 ± 5%.
Part 3: MERICAN SYSTEM:
Construction Specification
burrs; resin content control at 70 ± 5%.
11.2 After each unit is finished, cure them with a UV lamp. After curing, the outer wall
is subjected to the barcol hardness test, the minimum barcol hardness value is ≥40.
11.3 After the inner glass fiber reinforced plastic is finished, carry out the thickness
detection and visual inspection. If the thickness of a region does not meet the design
requirements, or the appearance inspection does not meet the requirements, you
need to add resin coating in the region, and re-testing it until achieve the thickness
requirements.
11.4 Polish and repair the burrs, bulge and blistering part on the inner surface.
Part 3: MERICAN SYSTEM:
Construction Specification
11.4 Polish and repair the burrs, bulge and blistering part on the inner surface.
12 Stiffeners wrapping (2nd time)
After the completion of the construction of the inner wall, use 9505-50 and 4 layers of
CSM to wrap the stiffeners again. Polish and repair the uneven part, to achieve flat,
burr-free surface, no missing coating area.
13 Gap connect test
Inject the identifying liquid into the middle gap layer, using the specialized lamp to
.
Part 3: MERICAN SYSTEM:
Construction Specification
check inside the tank for its connection situation.
14 Interstitial pressure test
14.1 To test middle gap layer for gas pressure, test pressure=35KPa, pressure
rate=5KPa/min, holding pressure for 30min. No pressure drop, no leakage can be
considered as qualified.
14.2 To test middle gap layer for liquid pressure, test pressure=18KPa, holding
pressure for 30 min. No pressure drop, no leakage can be considered as qualified.
Part 3: MERICAN SYSTEM:
Construction Specification
pressure for 30 min. No pressure drop, no leakage can be considered as qualified.
15 Leak detection system install
Connect the embedded part of inspection hole with one end of metallic bend pipe,
and connect the other end with metallic connecting pipe, connect it with manhole
outlet pipe and attach to the pressure gauge outside the tank.
The highest
monitoring point
Transmissible
pressure gauge
Stainless steel flexible pipe
Hand rolling
pressure testing
pump Stainless steel vessel
Part 3: MERICAN SYSTEM:
Construction Specification
Middle gap layer volume & pressure test
The lowest
monitoring point
Copper tube
16 Electrostatic installation
A stainless steel plate with a total surface area of not less than 0.04 * V m2 (V: total
tank volume) is attached to the bottom of the tank, and the stainless steel plate is
connected to the pre-embedded conductive screw with a copper mesh braided
strap. Lightning anti-static grounding should meet GB50156 requirements.
压力值导出管 人孔盖板Pressure value export tube Manhole cover
Part 3: MERICAN SYSTEM:
Construction Specification
Electrostatic Export Illustration
油罐筒体钢板
转换接头
外层玻璃钢
压力值导出管
内层玻璃钢
2#压力值检测点
静电导出板
间隔层
1#压力值检测点
压力值导出管
静电跨接线
δ≥3.2mm
δ=4mm
δ=4mm
Pressure value export tube
1# Pressure value test point
Interstitial layer
Convert joint
Tank steel wall
Outer FRP wall
Pressure value export tube
Inner FRP wall
Electrostatic export board
2# Pressure value test point
17 Inner wall FRP surface treatment
17.1 After passing the inspection, polish and seal the inner FRP surface.
17.2 Brush coating the inner FRP surface with UV curing conductive resin,
rich resin layer ≥ 0.2mm, requiring flat and smooth surface, no tacky.
Part 3: MERICAN SYSTEM:
Construction Specification
Operation room (2nd meter)Transmissible pressure gauge (1st meter)
4-20 mA direct current signal
Part 3: MERICAN SYSTEM:
Construction Specification
Double wall tank pass-through layer leakage detection principle
The highest monitoring point
The lowest
monitoring point
No. Acceptance check items Test standards and methods Acceptance standard Using table type Remarks
1 Dry ice derustingUltrasonic thickness gauge Wall thickness ≥3.2mm Attached table 2 accuracy
Pulling force tester ≥5.5MPa Attached table 1Electric spark leak detector 2KV leak detection qualified Attached table 3
2 Outer FRP wall
Fixed size template checking Surface bubble less then 2 /Each bubble’s
maximumthickness≤
Ultrasonic thickness gauge FRP≥4mm Attached table 2 accuracy0.01mm
Electric spark leak detector 15KV leak detection qualified Attached table 3 Tank wall temperature
minusEnvironmental
dew point >GB/T 3854-2005 >30 Attached table 4
Part 4: Code for acceptance of construction quality
Environmental dew point >
3 Inner FRP wall
Fixed size template checking Surface bubble less then 2 /Each bubble’s
maximumthickness≤
Ultrasonic thickness gauge FRP≥4mm Attached table 2 accuracy0.01mm
GB/T 3854-2005 >40 Attached table 4
4 Middle interstitial layer
35Kpa gas pressure test No pressure drop, no leakage Attached table 6
Connectivity performance testing V=(0.002~0.02)Vt Attached table 5
18Kpa liquid pressure test No pressure drop, no leakage Attached table 6
5 Electrostatic Export device megohmmeter measuring R≤10Ω Attached table 7
6Middle interstitial layer
leakage detection system
Visual inspection 1st and 2nd meter confirm and normal /
1. Visual inspection
1.1 After outer/inner FRP construction finished, visual inspect the appearance
with specialized lamp; the surface should be flat and smooth, no
impurities/exposed fiber/cracking/scratching/ flaw/whitening or severe inequality
of the color;
1.2 In any 300mm×300mm size, bubble number should no more than 2 (each
Part 4: Code for acceptance of construction quality
1.2 In any 300mm×300mm size, bubble number should no more than 2 (each
bubble’s maximum diameter=3mm) , the maximum dept of the bubble should not
exceed 1/5 of outer(inner) wall thickness and less than 1mm.
1.3 After the middle interstitial layer construction finished, visual inspect the
appearance with specialized lamp; 3D fabric should be evenly soaked with resin,
no bubble, no whitening on inner side.
2. Thickness inspection2.1 After outer/inner FRP construction finished, the thickness should be
inspected, actual measured thickness should no less than design thickness.
2.2 Use Ultrasonic thickness gauge (accuracy = 0.01mm)
2.3 Each tank should test 32 spots evenly distributed, if the test failed, the outer
wall should be thickened.
2.4 If the failed area exceed than 5%, then the relevant area should be double
checked; If it still exceed than 5%, then the outer wall should be constructed one
more layer and test the thickness until reach the requirement.
Part 4: Code for acceptance of construction quality
more layer and test the thickness until reach the requirement.
3. Barcol hardness test3.1 After outer/inner FRP construction finished, test the barcol hardness
according to GB/T 3854-2005; outer wall min. hardness=30, inner wall min.
hardness=40
3.2 Testing spot should be distributed evenly
on the external surface of the inspected part.
Testing spots should be no less than 10 in
shell cover&tank body, and should be no less
than 5 in reinforced parts.
4. Middle interstitial layer pressure test4.1 To test middle gap layer for gas pressure, test pressure=35KPa, pressure rate=5KPa/min, holding pressure for 30min. No pressure drop, no leakage can be considered as qualified.4.2 To test middle gap layer for liquid pressure, test pressure=18KPa, holding pressure for 30 min. No pressure drop, no leakage can be considered as qualified.4.3 Overpressure is strictly prohibited, observe the pressure value at any moment during the test.5. Spark test :Conduct the spark test according to HG/T 4090 standard. If the spark test failed, the
Part 4: Code for acceptance of construction quality
Conduct the spark test according to HG/T 4090 standard. If the spark test failed, the area should be marked, cutoff the FRP layer, clean the primer, polish the tank wall and scrubbing with acetone, then coat the primer, fabricate FRP outer wall, re-construction area should be twice of themarked area.
For a 120m3 petrol station (with four 30m3 oil storage tanks) :
Item Material Name Quantity Unit Application
1 MERICAN9505-50 Light Cured Resin 2500 kg Inner and outer FRP
2 MERICAN 9505TP Matrix Repair Resin 600 Kg
3 MERICAN 110 Prime Coat Resin 40 Kg Primer resin
4 EMC450-127 Chopped Strand Mat (alkali free) 1200 kg Inner and outer FRP
5 3D Fabric 260 m2 Middle gap layer
Part 5-MERICAN SYSTEM: Raw materials list
5 3D Fabric 260
6 Styrene 40 Kg Add curing agent to the resin
7 Photoinitiator 20 kg Resin curing
8 Acetone 80 kg
9 MEKP-9 20 kg
10 Talcum Powder 200 kg
11 Steel Plate 2 Piece
12 Stainless Steel Bolt 40 Set
Item Equipment Name Qty. Unit Application Remarks
1 UV light curing lamp 1 Set Resin curing
2 Adhesion tester 1 Piece Adhesion test for the primer layer
3 Gas tester 2 Piece Gas detection during tank operation5-in-1, with explosive
determination of organic matter
4 Thickness gauge 1 Piece Measure the thickness of FRP Range 20mm
5 Resin spray pump 1 Piece Spray resin A lot of types for choice
6 Resin gun 2 Set Spray resinOne set for use, the other
standby
7 Precision digital pressure gauge 1 Piece Middle layer test pressure Test pressure for middle layer
8 Dry ice derusting machine 1 Set De-rust the inner surface of steel tank Pipeline more than 15m
9 Manual hoist 2 Piece Lifting material, emergency equipment 1.5t electric hoist is usable
10 Explosion-proof axial flow fan 2 PieceForced ventilation for in-tank construction
work
Explosion-proof type,
3KW 64m3/h
Part 6: MERICAN SYSTEM - Equipment list
10 Explosion-proof axial flow fan 2 Piecework 3KW,64m3/h
11 Explosion-proof electrical box 2 Piece Power distribution facilitiesOne for sandblasting, the other
for spray resin
12 Explosion-proof lamp 4 Set In-tank lightingOne set for sandblasting, two
sets for lining
13 Gas welding machine 1 Set Repair tanks, weld conducting bolts Repair tank wall
14 Gas welding equipment 1 Set Cut stiffeners, open detection holesCut stiffeners, open detection
holes
15 Barcol Impressor 1 Piece Resin hardness test after curing
16 Labor protection products 1 Set Whole construction process
17 Supervisory equipment 1 Set Whole construction process
18 Communication equipment Several Set Whole construction process
Item Job title Number of People Remarks
1 Project Leader 1 Certified
2 Technician (part-time) 0 Technical information
3 Safety officer (part-time) 0 Certified
4 Electrician (part-time) 0 Certified
Part 7: MERICAN SYSTEM-Construction workers
4 Electrician (part-time) 0 Certified
5 Foreman 1 Be certified for anti-corrosion
6 Welder (part-time) 0Be certified for special construction
work permit
8 Anticorrosion worker 6Work in two shifts,
day shift and night shift, certified
Total 8 People
Thank you!Add:No. 130 Muhua Road, Shanghai
Zip code:201507
TEL:+86-21-64252619
FAX :+86-21-64250084
E-mail: [email protected]
Website: www.sinopolymer.cn
www.hchp.com.cn