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Doc. N°: MAN.2 ENG Rev.00
data: 29.06.2009
S.p.A.
TECHNICAL SPECIFICATION FRP TANKS - USE ABOVE GROUND
2. RANGE OF TANKS ............................................................................................................................................... 3 3. DESIGN ....................................................................................................................................................................... 3
3.1 DESIGN PARAMETERS ..................................................................................................................................... 3 3.2 STABILITY CALCULATION ............................................................................................................................. 4 3.3 FITTINGS.............................................................................................................................................................. 4 3.4 BOTTOMS ............................................................................................................................................................ 6 3.5 SYSTEM TO SUPPORT FRP TANKS ................................................................................................................ 7 3.6 PROPERTY OF LAMINATE ............................................................................................................................. 10
The oven must feature a regulatory system – temperature recorder.
5.9 GALVANIZING METAL PARTS Below We report the “Selip standard” as regards the procedures and cycles of “hot
galvanizing” applicable to metallic surfaces, with particular reference to: support rings and
frames for silos and tanks, ladders and walkways and all the fittings supplied to finish off the
tank.
DESCRIPTION OF THE PHASES
The work and testing phases comply with the EN ISO 1461 European norm:
1. DEGREASING in appropriate solutions at a temperature of 50/60°C
2. PICKLING in Hydrochloric Acid solution (HCl)
3. WASHING in running water
4. FLUXING in an aqueous solution of Ammonium Chloride (2NH4Cl) and Zinc Chloride
(ZnCl)
5. PREHEATING in a drying oven at a temperature of 100/120°C
6. GALVANIZING by immersion in a bath of melted zinc at a controlled temperature of
440/450°C
7. COOLING naturally in air.
Table of Coating Thicknesses (EN ISO 1461)
Articles and Thicknesses Minimum Average Thickness of
Coating
Steel ≥ 6.0mm 85µm
3.0mm ≤ Steel < 6.0mm 70µm
1.5mm ≤ Steel < 3.0mm 55µm
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5.10 PAINTING OF METAL PARTS Below we report the standard adopted by SELIP.
The work and testing phases conform to the main European norms:
1. PREPARATION
- SANDING at SA 2.5 grade according to the “standard” SIS 055900.
- CLEANING with a dry compressed air jet.
2. APPLICATION OF THE PRIMER
- No.1 coat of Inorganic Zinc, thickness = 70µm.
3. APPLICATION OF THE INTERMEDIATE LAYER and FINISHING
- No.2 coats of Polyurethane Varnish in powder, thickness = (50 + 50) µm.
N.B. : - Total thickness = 170µm
- RAL colour to be defined on request of customer
6. CHECKS AND TEST-RUNS
SELIP, a company certified in accordance with the ISO 9001 quality system, guarantees
respect for the following minimum requisites relating to:
• Visual inspections and acceptance criteria ;
• Dimensional inspections according to construction tolerances ;
• Various final test-runs and related certification ;
• Check on raw materials and related certification.
In the following table, the references to the norms applied:
ASTM D2563 Visual defects and acceptance criteria EN 10204 Raw material certification EN ISO 13920 : 2000 General tolerances
6.1 CLASSIFICATION OF VISIBLE DEFECTS AND ACCEPTANCE CRITERIA
Below are described and illustrated the most common visible defects met in articles made
from FRP. Every part of the article must be visually inspected to verify its suitability and
establish a conclusive acceptance. The visible defects are classified by type and level of
acceptability as shown in Table 1 below.
The level or levels of acceptability are indicated in the relevant test-run documents and, in
some cases may be indicated on the article’s drawing.
The levels of acceptability taken into consideration in the final test-run on the article are thr
Level 2 for liner and Level 3 for the mechanical reinforcement .
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TABLE 1
Type of Definition of Ref. LEVELS OF ACCEPTABILITY Defect Defect fig. n° Level 1 Level 2 Level 3
Open air bubbles in the Liner
Open air bubbles, present on the surface of the Liner that will come into contact with the product
1 None None None
Air bubbles in the Laminate
Areas with air bubbles enclosed by the Laminate, of a generally spherical shape and of varying dimensions
2 None N° 6 Bubbles maximum dimension 5 mm, on a surface examined of 0.5 m²
N° 12 Bubbles maximum dimension 10 mm, on a surface examined of 1 m²
Foreign body in the Laminate
Foreign bodies enclosed by the Laminate of the article
3 None Maximum n° 4 with maximum dimension of 3 mm
Maximum n° 6 with maximum dimension of 5 mm
Delamination of the Stratification
Separation of the layers of fibre-glass of the Laminate
4 None None None
Delamination due to mech. work
Circumscribed separation of the Laminate of the layers di fibre-glass due to mechanical operations
5 None Maximum dimension admissible = 15 mm
Maximum dimension admissible = 30 mm
Glass fibres protruding (exterior)
Areas where the fibres have not been impregnated, and are sticking out of the exterior surface
6 None Maximum n° 2 areas with maximum area of 0.04 m²
Maximum n° 4 areas with maximum area of 0.1 m²
Glass fibres protruding (interior)
Areas where the fibres have not been impregnated, and are sticking out of the interior surface
7 None None None
Scorching of the Lamination of Flanged Attachments
Obvious effect due to an exothermic reaction leading to changes in colour, deformation and decomposition of the Laminate
8 None None None
Inadequately impregnated areas
Areas of the Laminate where the fibre-glass is inadequately impregnated
9 None Maximum n° 4 areas with maximum dimension of 20 mm
Maximum n° 8 areas with maximum dimension of 50 mm
Transverse Fractures
Fracture in the stratification visible also from the other side that extends through the entire thickness of the Laminate
10 None None None
Surface cracks (spider’s web)
Superficial craquelure of the resin that does not involve the entire thickness of the Laminate
11 None None on cylinder and base; top Max w.=35 mm
On cylinder and base Max w.=10 mm ; top Max w.=70 mm
Unprotected cut surfaces (internal)
Cut surfaces inside the article of pure resin, which present unprotected fibre-glass
12 None None None
Surface irregularity
Presence on the surface of the article of craters, protuberances (lumps of resin) and knots of glass roving
13 None Maximum n° 5 areas with maximum dimension of 10 mm.
Maximum n° 10 areas with maximum dimension of 15 mm.
Internal runs Presence of obvious runs of resin on the surface inside the article
14 None None None
External runs Presence of obvious runs of resin and/or protective Gel-Coat
15 None Maximum n° 5 areas. Maximum n° 10 areas.
Transverse Cracks
Cracking that involves the entire thickness of the laminate, due to extraction from the mould when not perfectly polymerised.
16 None None None
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REPRESENTATION OF VISIBLE DEFECTS
Fig. 1 – Open air bubbles in the Liner Repair procedure
Grind the surface with the air bubbles including a surrounding area of about 50mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows: • apply to the ground area, using a brush, a layer of catalysed
resin followed by a layer of glass Mat type “E” of 300/450 g/m²;
• impregnate the layer of Mat with resin and roll to eliminate any air present;
• apply a layer of glass Surfacing type “C” of 30 g/m² impregnated with resin;
• with the resin still wet, apply to the repair a layer of detaching film (e.g. Mylar);
• allow to harden (about 2 hours) and remove the detaching film.
Fig. 2 – Air bubbles in the Laminate Repair procedure Grind the surface with the air bubbles including a surrounding area of about 30mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows: • apply to the ground area, using a brush, a layer of catalysed
resin followed by a layer of glass Mat type “E” of 300/450 g/m²;
• impregnate the layer of Mat with resin and roll to eliminate any air present;
• apply a layer of glass Surfacing type “C” of 30 g/m² impregnated with resin;
• with the resin still wet, apply to the repair a layer of detaching film (e.g. Mylar);
• allow to harden (about 2 hours) and remove the detaching film.
Fig. 3 – Foreign bodies in the Laminate Repair procedure
Grind the area with the “foreign bodies”, including a surrounding area of about 30mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows:
• apply to the ground area, using a brush, a layer of catalysed resin followed by a layer of glass Mat type “E” of 300/450 g/m² impregnated with resin. Roll to eliminate any air present;
• with the resin still wet, apply to the repair a layer of detaching film (e.g. Mylar);
• allow to harden (about 2 hours) and remove the detaching film.
In the event of heavy grinding (4-5 mm) the repair must be done in two phases.
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Fig. 4 – Delamination of the Stratification Repair procedure A repair of delamination of the stratification of limited dimensions (about 250mm in diameter) is carried out by injecting some catalysed resin under vacuum between the delaminated layers. Proceed as follows: • make 2 holes opposite each other of Ø 6-8 mm, as near as
possible to the perimeter of the delamination; • insert a vacuum tube into one hole and start to suck out the air• inject catalysed resin into the other hole using a syringe until
the delamination is completely filled; • allow the resin to harden for about 2 hours.
Fig. 5 – Delamination due to mechanical work
Repair procedure
Remove the delaminated areas including a surrounding area of about 10mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows:
• apply to the ground area, using a brush, a layer of catalysed resin followed by one or more layers of glass Mat type “E” of 300/450 g/m²;
• impregnate the layer of Mat with resin and roll to eliminate any air present;
• apply a layer of glass Surfacing type “C” of 30 g/m² impregnated with resin;
• with the resin still wet, apply to the repair a layer of detaching film (e.g. Mylar);
• allow to harden (about 2 hours) and remove the detaching film.
Fig. 6 – Glass fibres protruding (exterior) Repair procedure Remove the fibres protruding from the stratification, using abrasive tools. Carefully clean the ground area and where necessary apply a layer of gel-coat or paraffined resin (for exterior finishing).
Fig. 7 – Glass fibres protruding (interior) Repair procedure Remove the fibres protruding from the stratification, including a surrounding area of about 20mm using abrasive tools. Carefully clean the ground area and use a brush to apply a layer of paraffined resin (for internal finishing).
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Fig. 8 – Scorching (delamination) of the lamination of Flanged Attachments
Repair procedure
Remove the delaminated areas including a surrounding area of about 20mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows: • apply to the ground area, using a brush, a layer of catalysed
resin followed by one or more layers of glass Mat type “E” of 300/450 g/m²;
• impregnate the layer of Mat with resin and roll to eliminate any air present;
• allow to harden for about two hours. In the event of deep delamination (4-5mm) the repair must be done in two phases
Fig. 9 – Inadequately impregnated areas
Repair procedure
Grind the inadequately impregnated surface, including a surrounding area of about 50mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows: • apply to the ground area, using a brush, a layer of catalysed
resin followed by one or more layers of glass Mat type “E” of 300/450 g/m²;
• impregnate the layer of Mat with resin and roll to eliminate any air present;
• allow to harden for about two hours. In the event of deep delamination (4-5mm) the repair must be done in two phases.
Fig. 10 – Transverse Fractures Repair procedure
The repair of transverse fractures is carried out in two distinct phases, i.e.: a repair of the Liner followed by the exterior.
Grind the fractures in the Liner including a surrounding area of about 50mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows: • apply to the ground area, using a brush, a layer of catalysed resin
followed by one or more layers of glass Mat type “E” of 300/450 g/m²; • impregnate the layer of Mat with resin and roll to eliminate any air
present; • apply a layer of glass Surfacing type “C” of 30 g/m² impregnated with
resin; • with the resin still wet, apply to the repair a layer of detaching film (e.g.
Mylar); • allow to harden (about 2 hours) and remove the detaching film. Grind the fractures in the exterior layer as above, carefully clean the ground area and carry out the repair as above by applying layers of 450 g/m² Mat to reach the thickness removed. Allow to harden for about 2 hours and clean the laminated areas with abrasive tools.
Grind the area with the “surface cracks”, including a surrounding area of about 30mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows:
• apply to the ground area, using a brush, a layer of catalysed resin followed by one or more layers of glass Mat type “E” of 300/450 g/m². Impregnate the layer of Mat with resin and roll to eliminate any air present;
• apply a layer of glass Surfacing type “C” of 30 g/m² impregnated with resin;
• with the resin still wet, apply to the repair a layer of detaching film (e.g. Mylar);
Allow to harden (about 2 hours) and remove the detaching film.
In the event of deep delamination (4-5mm) the repair must be done in two phases.
Fig. 12 – Unprotected cut surfaces Repair procedure Sand down the cut and/or ground surfaces using abrasive paper. Carefully clean the sanded areas and use a brush to apply a layer of paraffined resin.
Fig. 13 – Surface irregularity Repair procedure Remove the surface irregularity - usually to be found on the outside of stratification - including a surrounding area of about 50mm using abrasive tools. Carefully clean the ground area and where necessary use a brush to apply a layer of paraffined resin (for external finishing).
Fig. 14 – Internal runs Repair procedure Remove the runs of resin from the inside of the stratification, including a surrounding area of about 20mm using abrasive tools. Carefully clean the ground area and use a brush to apply a layer of paraffined resin (for internal finishing).
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Fig. 15 – External runs Repair procedure Remove the runs of gel-coat from the outside of the stratification, including a surrounding area of about 20mm using abrasive tools. Carefully clean the ground area and use a brush (or a spray) to apply a layer of gel-coat (for external finishing).
Fig. 16 – Transverse Cracks Repair procedure
The repair of transverse cracks is carried out in two distinct phases, i.e.: a repair of the Liner followed by the exterior.
Grind the cracks in the Liner including a surrounding area of about 50mm using abrasive tools. Carefully clean the ground area and carry out the repair as follows: • apply to the ground area, using a brush, a layer of catalysed
resin followed by one or more layers of glass Mat type “E” of 300/450 g/m²;
• impregnate the layer of Mat with resin and roll to eliminate any air present;
• apply a layer of glass Surfacing type “C” of 30 g/m² impregnated with resin;
• with the resin still wet, apply to the repair a layer of detaching film (e.g. Mylar);
• allow to harden (about 2 hours) and remove the detaching film.
Grind the cracks in the exterior layer as above, carefully clean the ground area and carry out the repair as above by applying layers of 450 g/m² Mat to reach the thickness removed. Allow to harden for about 2 hours and clean the laminated areas with abrasive tools.
6.2 TOLERANCE Selip products conform to that indicated in the EN 13920 norms as regards construction
tolerance.
In particular:
• Linear Tolerance – according to classes D and B of EN 13920
• Angular Tolerance – according to class D of EN 13920
See the following schematizations:
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6.3 TEST EQUIPMENT AND INSTRUMENTS
Instruments for testing must be tared and SIT certified
Checks on the thickness of the tank must be carried out with ultrasound instruments
tared immediately before the test on a representative sample of the type of laminate
7. PREPARATION FOR SHIPPPING Fittings must be protected by flanged covers which avoid damaging the external face
The tank must be fixed to the trailer by using cloth bands and blocked by wooden wedges to stop
it from rolling or shifting
THE USE OF STEEL CABLES AND CHAINS IS FORBIDDEN
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8. TECHNICAL AND TEST- RUN DOCUMENTATION Technical and test-run documentation can be supplied in Italian, English or German and
at the times and in the ways foreseen by the contract.
LIST OF DOCUMENTS L E V 1
L E V 2
L E V 3
STANDARD
CONSTRUCTION DRAWING PRODUCED BY AUTOCAD, FEATURING : • CONSTRUCTION DETAILS • TABLE OF FITTINGS • LIST OF MATERIALS • DESIGN AND WORKING CONDITION • INSTRUCTIONS FOR CONCRETE BASE
X
X
X
ON PAYMENT
REPORT ON TANK CALCULATIONS WITH : • INSPECTION OF THEORETICAL THICKNESSES • CALCULATION OF TANK STABILITY UNDER CONDITIONS OF
PRESSURE, UNDER-PRESSURE, EXTERNAL LOADS • INSPECTION OF THE ANCHORAGE
X
ON REQUEST
LOADS ON THE BASE IN THE FOLLOWING CONDITIONS : • TANK IN USE • WIND • EARTHQUAKE
X
X
ON REQUEST DECLARATION OF CONFORMITY X X
ON REQUEST INSPECTION AND FINAL TEST-RUN PLAN / QIP SELIP X X
ON REQUEST VISUAL / DIMENSIONAL TEST CERTIFICATE
• WORK CHECKS – VISUAL INSPECTION • DIMENSIONAL CHECK
X
X
ON PAYMENT CERTIFICATE OF POLYMERIZATION / BARCOL TEST X
ON REQUEST MATERIAL CERTIFICATES X X
ON PAYMENT HYDRAULIC TEST CERTIFICATES X
ON PAYMENT CALCINATION TEST CERTIFICATE (GLASS / RESIN RELATIONSHIP) X
ON PAYMENT GASCHROMATOGRAPHY TEST CERTIFICATE (STYROL RESIDUE) X
ON REQUEST RESULTS OF MECHANICAL TESTS ON SELIP LAMINATES X X
ON REQUEST LAMINATOR / WELDER CERTIFICATES (TÜV OF MUNICH) X X
ON REQUEST CERTIFICATION OF THE FACTORY (TÜV OF MUNICH) X X
STANDARD
USER’S AND MAINTENANCE MANUAL,WITH THE FOLLOWING SUBJECTS : • IDENTIFICATION DATA • GENERAL INFORMATION • TECHNICAL CHARACTERISTICS, TANK DENOMINATION,
PRODUCTS CONTAINED • TRANSPORT, UNLOADING, STORAGE, INSPECTION, MOVING • INSTALLATION, CHECK ON BASE, CONNECTION TO EXTERNAL
PIPES • USE OF TANK, OPERATOR POSITION, GUARANTEES • CLEANING AND MAINTENANCE, INTERNAL CHECKS, CLEANING
OF WORK AREAS • PERIODIC CHECKSI, GENERAL WARNINGS, ORDINARY
MAINTENANCE, EXTRAORDINARY MAINTENANCE • DISMANTLING AND DEMOLITION • SPARES
X X X
ON PAYMENT OTHER TESTS / TEST-RUNS X
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9. GARANTEES The manufacturer must guarantee that he has the necessary skills and give the
commercial guarantees to supply the goods ordered, at least :
9.1 TECHNICAL GUARANTEES (SKILLS) • Quality system certificate for at least 10 years ;
• TÜV-certified production facilities ;
• TÜV-certified staff for the lamination of fittings ;
• The presence of an internal technical office. The Technical Director shall be a registered
engineer ;
• The presence of an internal office for quality assurance and control ;
• An adequate department for customer assistance and service management ;
• The possibility of handling orders and correspondence in Italian, English, German, and
French ;
• Plants which conform to the safety norms in force
9.2 COMMERCIAL GUARANTEES
• The supplier must be classified with rating “A” according to the Basilea 2 regulations ;
• The minimum turnover of the supplier must be 7 million Euros ;
• The minimum net assets of the supplier must be equal to 1.5 million Euros ;
• The supplier must produce insurance policies with maximum coverage :
Product Policy minimum € 2,500,000 per mishap
Civil Responsibility Policy minimum € 3,000,000 per mishap
Transport Policy minimum equal to the goods transported
• The Product Policies must guarantee the product for a minimum of 24 months from the