G Engelsman

Guidelines for GRP Vessels Under Pressure. Fibre-Wound Tel: (031) 705 1750 Fax: (031) 705 2399 [email protected]

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Composites Africa 2002 Conference and Exhibition Caesars Palace Johannesburg South Africa 21 August 2002

GUIDELINES FOR GRP VESSELS

By Gavin Engelsman ABSTRACT The use of GRP as a long-term, cost-effective, corrosion resistant product is now being used on a much greater scale than before. Many vessels that were previously made in steel are now being replaced with non-metallic / composite materials. In most cases this conversion process is being carried out without re-engineering the metallic construction concepts to suit those of GRP, unfortunately to the detriment of the end-user and the GRP Industry. Compliance with the relevant codes of practice and specifications are also overlooked. This paper shall highlight the pitfalls involved in this direct conversion process and provide guidelines for the design and construction of composite vessels. INTRODUCTION The following guidelines have been prepared to give the project engineer or end user a better understanding of the statutory requirements, design codes, and minimum required data when specifying or redesigning a non-metallic vessel. The advantages as well as disadvantages of non-metallic materials are stated to ensure that the engineer is au fait with the material limitations. Guidelines for the construction of composite vessels will be described, as well as a quick guide to the selection and determination of the various layers of construction and minimum wall thicknesses. STATUTORY REQUIREMENTS All pressure vessels shall meet the following requirements: SABS 0227:2000 The evaluation of the technical competence of inspection authorities for the certification, rectification, modification or repair of vessels under pressure : Which states that all vessels under pressure shall have the design verified by a Design Engineer Pr Eng, Pr Tech or Reg Cert Eng and certified by an Inspector of Pressurized Equipment. (IPE) accredited by SANAS. OHS Act 85 of 1993 Be designed and constructed to a code of practice which is recognized by the OHS Act. Have a nameplate that complies with the OHS act.

The responsibility has now been placed on the manufacture to comply with the above and to supply the following documentation with the vessel / tank: Certificate of Manufacture. Inspection release note. Pressure test certificate. Code data books. Certified design and plans. CODES FOR GRP VESSELS UNDER PRESSURE It is mandatory that these vessels are designed and manufactured to recognized codes/ standards and specifications. These specifications also indicate the correct non-metallic methods of construction, as well as prescribing the various tests that are to be undertaken on the raw materials and the finished product. It must be highlighted that unlike steel, where the manufacturer purchases a certified sheet of steel, with known properties, and forms it to construct the product. The GRP material and its properties are created at the same time as the composite product is fabricated. Although this is essentially an advantage, stringent quality control needs to be exercised to ensure that the required material properties are achieved. The following is a summary of some of the recognized codes of practice: for tanks, vessels and piping highlighting the key points. Design Codes: BS 4994-1987 Makes use of stated material properties. Excludes the chemical barrier in the strength calculation. Stipulates a minimum structural wall thickness of 5 mm for vessels under pressure. Penalizes filament winding between 15 and 75 AD Merkblatt N1 Relies on previously tested stress values for use in the strength calculation Excludes the chemical barrier in the strength calculation. Does not penalize filament winding RTP-1 Very detailed and complex specification Relies on previously tested stress values for use in the strength calculation Does not penalize filament winding Process piping specifications BS 6464-1984 Makes use of stated material properties.
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Excludes the chemical barrier in the strength calculation. Penalizes filament winding between 15 and 75.

BS 7159-1989 Makes use of stated material properties . Excludes the chemical barrier in the strength calculation. Does not penalizes filament winding ADVANTAGES AND DISADVANTAGES OF COMPOSITE FABRICATIONS RELATIVE TO OTHER CONVENTIONAL MATERIALS Users must understand both the advantages and disadvantages of composite constructed fabrications. ADVANTAGES Good corrosion resistance Thermoplastics as well as GRP are resistant to chemical attack for a wide range of chemicals of fluctuating concentration found in the Chlor-Alkali, Pulp and Paper and Petro-Chemical industry. Low maintenance costs Non-metallic equipment is resistant internally and externally to corrosion and does not require continual painting and preservation. Optimization of the material properties in the required directions. Unlike steel that is isotropic, having uniform strength in all directions. GRP material properties are created at the same time as the product is manufactured, thereby allowing the fibres to be orientated in such a way as to best suit the strength requirements. This anisotropy property can when correctly designed result in a saving in mass and cost. High tensile strength to weight ratio. Density of steel: 7850 kg/m Tensile strength of steel: 430 MPa Density of GRP : 1450 to 2000 kg/m Tensile strength of GRP 400 to 1000 MPa in direction of the fibre.

Table 1compares the properties of other metallic materials to GRP, by nature of their weights, to yield the same mechanical properties. Table 2 takes the properties of the materials, divides them by their relative densities and factors them to mild steel, being 1. Low transportation costs Due to the lightweight construction, large non-metallic items are less expensive to transport than steel items.

Good thermal insulation properties GRP and plastic are good insulators thereby reducing the heat loss through the vessel wall, and reduces the degree of lagging/insulation required. Coefficients of thermal conductivity: Steel: 46 W/m C GRP: 0.2 W/m C Easy to repair and refurbish. Once a steel vessel becomes badly corroded, welding of patches no longer becomes a viable option. GRP on the other hand can have the corroded surface sandblasted and a new corrosion barrier applied throughout the entire vessel, thereby extending the life span of the vessel . Dual laminate construction - best of both worlds Vessels can be constructed using thermoplastic/ fluoroplastic liners, offering superior chemical resistance, and reinforced with GRP, which has good mechanical properties, giving the best of both worlds.

LIMITATIONS/ DISADVANTAGES The end user needs to be aware of the limitations of non-metallic equipment: High temperature The major limitation for non-metallic materials is their inability to handle high temperatures. Table 3 gives an indication of the maximum temperatures of the various non-metallic materials. Thermoplastic and fluoroplastic lined items are difficult to replace Plastic liners are not easy to replace and in the case of the more exotic liner materials such as: ECTFE, PFA, MFA and FEP, specialized welding equipment is required. Low tensile modulus relative to steel. GRP has a low tensile modulus when compared to steel which results in the vessel being very sensitive to small amounts of vacuum and if not designed accordingly can have disastrous effects.

REDESIGNING OF METALLIC CONCEPTS, HIGHLIGHTING GOOD NON-METALLIC CONSTRUCTION TECHNIQUES. Taking an existing steel design, changing the material to a composite material is seldom the most cost-effective solution. A fresh look at what the vessel was intended for should be undertaken considering the following factors:

Configuration / shape of the vessel GRP has a high tensile strength as well as a high elongation, giving it a low tensile modulus when compared to steel. This causes GRP to have a low resistance against bending, making the construction of flat panels very thick and costly. Where possible: Rectangular shaped vessels should be redesigned as cylindrical vessels. Flat panels should be avoided and redesigned using semi-ellipsoidal and hemispherical shapes. Radiusing of all sharp corners Sharp corners and sharp intersections should be redesigned with flowing radiuses as: The glass mat is applied by hand and rolled into place using pig hair rollers, which can not get into the sharp corners. The strength of the mat is in the direction of the fibre and it is essential that the fibre can flow from one plain to another without a break in the fibre. Sharp corners cause high stress concentrations. Sharp corners cause resin rich zones, which are prone to exothermic reactions and cracking. All edges should have a minimum fillet radius of 5 mm. The design specifications stipulate minimum radii for changes in direction. The following figures are extracts from BS 4994 1987. Figure 1 details the recommended radii for the intersection of a flat bottom to a cylinder. Figure 2 details the recommended radii for the intersection of a cone to a cylinder. Where laminates terminate they shall not end abruptly but taper into the parent material. Figure 3 details a minimum taper of 1 in 6 for the termination of all laminates. Nozzle attachments Minimum flange thickness Nozzles should be designed to accommodate not only the pressure requirement but also induced forces caused by piping, over tightening of the bolts, man loads and other in service operating conditions. For nozzle sizes up to 300 NB a minimum flange thickness equivalent to 600 kPa or 20 mm will accommodate any of these stray forces. Flange design (1, , 4, Rule) For example, If the flange face is 30 mm thick, The hub behind the flange should be the thickness of the flange. i.e. 15 mm, And the length of the hub should be 4 times the thickness of the flange. i.e. 120 mm Refer figure 4.
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Fibre direction in the flange / hub. Ensure that there is continuity of the fibres from the hub into the face of the flange. Incorrect lay-up is the cause of many nozzle failures. Refer figure 5. Minimum nozzle stand offs. A nozzle stand-off of 150 mm provides sufficient bonding length up the nozzle shank for the attachment laminate and still allows adequate clearance for the bolts and backing ring. A minimum bond length of 75 mm is required by BS 4994-1987. Compensating pads Load compensating pads of between 2 and 3 times the diameter of the opening should be applied around all cut outs in the vessel shell. Refer figure 6. Gussets Some specifications recommend the use of gussets on smaller nozzles, in these cases conical gussets should be used, as triangular plate gussets generally offer little support as the attachment gusset laminate can not be adequately radiused in these confined areas. A correctly constructed nozzle, with a stand off of 150 mm, should not require gussets. Connecting pipe work All connecting pipe work and fittings should be independently supported so as to induce no load on the vessel.

Designing for vacuum Do not ignore the effects of small amounts of vacuum (1 kPa(g) ) induced in the vessel. As discussed, due to GRPs low tensile modulus, relatively low vacuum conditions need to be considered in detail and the vessel suitably reinforced, ribbed or a vacuum breaker fitted. MINIMUM DESIGN PARAMETERS The following minimum design parameters need to be specified by the end user and taken into account in the structural design and material of selection. Design temperature Design pressure. Design vacuum. Product. Product concentration. Product density. Cyclic loading.

RULE OF THUMB GUIDELINES. A composite laminate is made up of various stages. The inner liner being the layer in direct contact with the product. Then followed by the backing layer and structural layer and finally the exterior chemical barrier (C.B.). The following is a guide to the selection and construction of these layers. Inner liner Minimum of 1 surface tissue/ veil, preferably 2. C glass tissue is normally used and is preferable for chemicals such as Chlorine. Synthetic veils are preferred for sodium based chemicals such as Sodium Hydroxide and Soda Hypo. ECTFE (Halar) melt blow fibre is excellent for most corrosive media, except Chlorine. Alternatively a liner may be used. Minimum 3 mm thick thermoplastic liner of: HDPE, PPL, uPVC, and cPVC. or Minimum 2.3 mm thick fluoroplastic liner of: ECTFE, PTFE, ETFE, FEP and PFA.

Backing layer 1.2 kg/m Chop Strand Mat (CSM) for aggressive media 2.5 mm thick 2.4 kg/m Chop Strand Mat (CSM) very aggressive media (Chlorine) 5.0 mm thick ECR GLAS is recommended for acid applications for long-term corrosion resistance. Structural layer Hand lay up (HLU) Filament wound (FW) Exterior CB 1 layer C glass tissue, pigmented. Resin rich waxed topcoat layer, pigmented. Thickness comparisons The following can be used as a quick reference table. Laminate Chopped strand mat. Woven roving Filament wound helical Filament winding chop/ hoop mass/m 1 kg 1 kg 1 kg 1 kg Thickness 2.1 mm 1.1 mm 0.8 mm 1.0 mm Glass % 25-35 50 50-65 60-65
Hoop Design Burst Strength (HDBS)

6-7 MPa 10-14 MPa 27-36 MPa 27 MPa

Quick thickness calculation: T = pD/ 2 in mm. Where, P = pressure in MPa D = Diameter in millimeters = Strength 27 MPa FW 9 MPa HLU Minimum thickness. The following are some recommended minimum total thickness for: Piping = 4.5 mm Fittings = 6.0 mm Flanges = 20 mm Tanks/vessels = 6.0 mm CONCLUSION There are distinct advantages in industry using non-metallic vessels, providing the vessel: Meets the statutory requirements Is designed to a recognized specification/ design code. Has been correctly re-engineered using non-metallic construction principals. Is manufactured by a reputable non-metallic manufacturer with an approved quality system. i.e.: SABS ISO 9001. Complies with the OHS Act. Is designed, manufactured and tested under the surveillance of a government approved AIA. Is fitted with a OHS Act compliant nameplate. Is supplied with a manufactures certificate of compliance. Is supplied with pressure test certificate. ACKNOWLEDGEMENTS The author thanks Fibre-Wound SA and its staff for the experience gained from working with them and to industry for their co-operation in promoting non-metallic products in the market place. REFERENCES Pilkington Reinforcements Limited Booklet BS 4994-1987 BS 6464-1984

BS 7159-1989 AD-Merkblatt N1 RTP-1 SABS 0227-2000 OHS Act 85 of 1993 Fibre-Wound Works Instruction Manual sections 3,4 and 9.

AUTHOR Gavin Engelsman has been involved in the non-metallic industry for the past 12 years. He has designed over 300 items of composite equipment and is a member of the Polymeric Composite Institute of South Africa. He is involved with industry in assisting them with the rewriting and formulation of non-metallic specifications. He is also dedicated to the guidance and training of Mechanical Engineering students in the non-metallic field.

Attachments.
Table 1 Reference FIG 49 PILKINTON MATERIAL COMPARABLE WEIGHT TO GIVE SAME RESISTANCE TO ELONGATION Steel Aluminum alloy Uni-directional rod (70%) Fabric laminate (60%) Mat laminate (30%) 1.0 0.8 1.2 2.5 5.7 SAME RESISTANCE TO BENDING SAME LOAD CARRYING CAPACITY

1.0 0.4 0.4 0.5 0.6

1.0 0.7 0.2 0.5 0.9

Table 2 Takes the properties of the materials, divides them by their relative densities and factors them to mild steel, being 1.

FACTORED SPECIFIC PROPERTIES (PROPERTIES DENSITY & FACTORED TO MS) MATERIAL Mild Steel Aluminum, L73 E-glass / epoxy HM carbon / epoxy Aramid / epoxy HS carbon / epoxy TENSILE 1.0 2.8 10.4 12.3 19.6 19.6 COMPRESSIVE 1.0 2.4 5.6 10.2 3.8 12.5 MODULUS 1.0 1.0 0.7 5.0 2.1 3.2

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Table 3 Maximum recommended temperatures of some of the more common thermoplastics and fluoroplastics. ABBREVIATION MATERIAL IN SERVICE TEMPERATURE FOR CONTINUOUS OPERATION (C) 130 150 140 100 100 60 60

GRP ECTFE PVDF PP CPVC UPVC HDPE

Glass Fibre Reinforced Products Ethylene Chlorotrifluoroethylene Polyvinylidene fluoride Polypropylene Chlorinated polyvinyl chloride Unplasticized polyvinyl chloride High density polyethylene

Figure 1: Flat bottom / cylinder intersection

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Figure 2: Cylinder / cone intersection

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Figure 3: Minimum taper of 1 in 6 for the termination of all laminates.

Figure 4: Flange design

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Figure 5: Fibre direction in the flange / hub.

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Figure 6: Compensation pad

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