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The UK's leading manufacturer of custom designed Plastic Tanks and chemical plant in plastics materials |
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Telephone: +44 (0) 1366 389600 or Use Main Contacts direct dial lines.
20/05/2013
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Main Section
- Latest News
Latest News
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FORBES INCREASE IN TANK & SCRUBBER EXPORTS HELPS THEM BEAT THE RECESSION
Having recently moved into their custom built factory on their Kelso site in the Borders of Scotland, Forbes has found increased manufacturing efficiencies within their new facilities which have enabled them to remain highly competitive. “We have risen to the challenge to ensure full production was maintained despite the demise of the chemical industries in the UK” states Melvyn Jupp, Managing Director. “Over the past few years the company has gradually increased our export business which accounts for twenty percent of our turnover in the past year”. Traditionally Forbes has maintained significant volumes of export work over the years. One of their largest export orders which included 46 large tanks all 3.5 metres diameter of various heights to allow shipment by Russian Railways, was shipped from the local docks at Berwick–upon -Tweed to St Petersburg & then by rail to Kazakhstan.
The demand Forbes has created for tanks, scrubbers & other chemical equipment manufactured in thermoplastic, GRP (glassfibre reinforced plastics) and dual laminate composites now spans the globe, even as far as China. With handling & manufacturing capacities in excessive of 10 tonnes, diameters over 5 metres with heights up to 18 metres, the company now offers a vast range of products from a few litres in capacity to in excess of 200,000 litres.
A major advantage Forbes has over many other manufacturers is the ability to manufacture in a large range of materials including polypropylene, HDPE, GRP including vinylesters, and GRP dual laminates incorporating thermoplastic inner shells of polypropylene, PVCu; PVDF and ECTFE Halar®. This ensures the correct material is selected to give long term chemical resistance with expected life spans in excess of 25 years.
The company’s expansion has led to significant export orders this past twelve months. Examples include 6 x 40m3 tanks to Portugal for petrochemicals, 5 x 40m3 large dual laminate tanks for a French power station handling sodium hypochlorite, caustic soda & iron salt solutions, other tanks going to India for ultra high purity water, 9 tanks of various sizes to Ireland for pharmaceuticals and also tanks for food productions to Greece.
The latest shipment leaving their Kelso works bound for Russia includes 6 x 20m3 capacity tank for Chlorine production plants for water treatment. This order is part of an ongoing development for similar tanks over the next few years. Currently in production is an export order for two massive scrubbing towers for China – 1 x 2.85 metres diameter x 22 metres high & 3.5 metres diameter x 14 metres high in dual laminate / ECTFE & vinylester fire resistant composites. These towers have sophisticated internals & PVDF packing media all manufactured in house. This order is due to he shipped during May.
Sales Contact - Melvyn Jupp - mjupp@forbesgroup.co.uk ; Tel: 01366 389640
Press relations contact – Lee Forbes – lforbes@forbesgroup.co.uk
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FORBES COMMISIONS FINAL PHASE OF LARGE NEW MANUFACTURING FACILITY
Forbes, UK’s leading manufacturers of tanks, vessels, scrubbing columns & chemical plant in plastic materials, has invested £1.56 million over the past two years on their custom designed manufacturing facilities in Kelso, on the Scottish Border
The UK’s largest manufacturer of custom tanks, scrubbers & other chemical equipment in thermoplastics & glassfibre composite materials. Used in the highly corrosive environments of a chemical manufacture to the ultra pure water & pharmaceutical applications & potable water built to meet Regulation 31, under the eye of the Drinking Water Inspectorate.
Forbes, a family company, established in 1960 which is still headed by, Lee Forbes who pioneered the development of tanks in plastics tanks in the early 60’s, and now, has never veered from its policy of continual inward investment to improve efficiency & maintain its market share by being highly competitive. Now UK’s largest manufacturer of custom designed and built tanks & other chemical equipment in plastics such as gas scrubbing and odour control towers, Forbes has just completed a brand new manufacturing facility on their Kelso site, on the Border of Scotland.
Managing Director, Melvyn Jupp states that this new facility will further increase efficiency of our already highly efficient operation. “The company’s setup is such that we can efficiently handle orders worth a few hundred Pounds to the large six figure contracts”. The company’s design, sales & head office is located at their new modern offices on a 2.5 acres site in Norfolk. Maintaining the “family” approach Forbes still prides it’s self on personal service which maintains customer support second to none.
Major investments over the past 3 years
This latest facility incorporates specialised buildings to handle tanks & vessels up to 17 metres in height with diameters up to 5 metres, depending on transportation restrictions, with capacities of up to 200 cubic metres. The main assembly buildings represents a major landmark in Kelso being 19 metres high incorporating 10 tonnes capacity overhead cranes
With new facilities in Norfolk, overall Forbes now occupies 6.2 acres (2.5 hectares) with a floor area 79,000 sq ft (7340 sq m).
The last expansion phase is made up of building in excess of 10 metres in height with numerous travelling cranes, they are ideal for the production of a variety of tanks & towers in GRP & thermoplastic / GRP composites.
This development has also enhanced the facilities for the existing thermoplastic tank production shops. The specialised self-contained buildings, each dedicated to specific types of materials ensure there is no cross-contamination from other raw materials. Forbes manufactures thermoplastic tanks with capacities from 50 litres to in excess of 50,000 litres. Automation has played a large part in the success of the thermoplastic tank, Forbes now being one of the most competitive manufacturers in the UK. Being the pioneers of thermoplastic tanks with the first freestanding tank being produced in 1960, prior to the introduction of polypropylene, Forbes is very proud of their extremely safe, high quality tanks which continue to be used worldwide in large numbers.
Part of the new development will be linked to the already highly productive GRP winding shops. The production of GRP tanks & scrubber shells with or without a thermoplastic inner shell is fully automated in order to keep costs to a minimum and guarantee quality. The extended finishing facility will not only allow more efficient working but will also improve delivery times.
Automation
Automation of composite GRP tank production was introduced in the early 80’s with automatic hoop chop winding processes imported from the America. This process has been further developed by the company over the past twenty five years, this enabling Forbes to produce a number of large tank shells in a day. “The main limiting factor on output of large diameter tanks is the fitting out. This latest development will solve this problem” stated Kevin Johnston, Director in charge the Kelso factories. “This will allow our five winding mandrels to produce tanks simultaneously” Standard winding mandrels from 2 metres diameter to 4.1 metres in diameter, permits a large range of tank & tower shells to be produced within hours.
Managing Director, Melvyn Jupp, who is based at Head Office in Norfolk, stated “Over the past few years we have seen a huge growth in the demand for our quality products. Despite our highly competitive prices, where we were unable to win orders due to delivery times. Our sales team has been frustrated at times with our price being the most competitive but unable to meet the delivery requirements of the customer. This new facility has alleviated this delivery problem ”. There is a new metal fabrication shop, handling steel, stainless steel and aluminium. This “in house” facility has been a vital element within Forbes production since the 70’s. Forbes developed this ancillary facility to ensure only quality metal parts, such as access ladders, walkways, tank supporting structures and pipelines are fitted to their products when required.
Continued growth
Despite the current downturn in industry in UK & the rest of the World, Forbes is still extremely optimistic. Forbes’ continued success has been based on versatility and quality at the right price. Much of the business is repeat business from long established customers. Occasionally customers are attracted by other suppliers offering lower quality / cost products, however virtually all return to Forbes. As explained by Melvyn “Versatility is the trick! Being able to offer products made in a variety of plastics materials, to strict quality standards, has won us many orders. Unlike most manufacturers we are able to tailor the most suitable material to satisfy the application. This optimism is confirmed by our commitment to this major expansion at Kelso.
Forbes is continuing to grow”.
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BS 4994 - 1987 -v- EN 13121-3
Following the recent publication of BS EN 13121-3 "GRP tanks and vessels for above ground use", major errors and omissions have been found in this Code. British Standard 4994-1987, originally scheduled to be marked "obsolete", is to remain in place as a current design standard. Please find a statement from the British Plastics Federation outlining the current status. This has been confirmed by British Standards Institute.
If you have any queries please do not hesitate to contact me.
Lee Forbes
Chairman of BS4994 – 1987
UK committee member representative for EN13121
D D +44 (0) 1366 389625
Mobile 07775 816 166
lforbes@forbesgroup.co.uk
CURRENT SITUATION CONCERNING BS 4994-1987 &THE INTRODUCTION OF EN 13121
The British Plastics Federation
6 Bath Place
Rivington Street
London
EC2A 3JE
Tel: 0207 4575000
Fax: 0207 4575045
The UK Standard for GRP vessels and tank, British Standard 4994 – 1987 - “Design and Construction of Vessels and Tanks in Reinforced Plastics”, was based on experience since the early 1960’s with the publication of British Standard 4994-1973 which was later extended in1987 as British Standard 4994 -1987. This Standard has become recognised and specified in many parts of the world.
With harmonisation within the EU a Pan European Code, EN13121 - “GRP Tanks and vessels for use above ground”, has been published for the design, manufacture & application for reinforced tanks and vessels, this being primarily produced to meet The European Pressure Equipment Directive (PED) 97/23/EC for vessels operating above 0.5 bar pressure i.e. a pressure vessel code. EU Law dictates that BS 4994 – 1987 shall be withdrawn, as it is an internationally recognised code covering the same products.
Technically a vessel operating up to 0.5 bar pressure plus the hydrostatic head falls outside the PED. When this occurs, such products may be designed & constructed to proven good engineering practice.
With the requirement to meet the PED for vessels operating over 0.5bar pressure, the code had to satisfy all members of the EU, which after many years of discussions between the countries representatives, has generated EN13121-3-2008. This code was published during 2008 and has proved to be extremely complicated. Since publication a number of errors have been found in Part 3 – Design & Workmanship. The errors are considered so serious that a formal UAP (Unique Applications Procedure) has been issued & accepted by DIN / CEN. This has to be presented to all EU Countries to vote for acceptance or otherwise. Since the submission of the UAP, further errors have been identified which may have an impact on safety. These will also require amendment, which will almost certainly lead to further delays on the revised edition being published.
As EN 13121 is now under a UAP, BS 4994-1987 will remain the current design code until at least December 2010. However following the discovery of further errors which are not part of the current UAP, indications are that BS 4994 – 1987 will remain the current design standard well beyond 2010.
Due to the extremely complicated nature of EN 13121, which is primarily a pressure vessel code, there is a proposal through the British Plastics Federation that, if and when EN13121-3 is reissued with all errors corrected, the scope of BS 4994 – 1987 to be amended to incorporate tanks operating well below the 0.5 bar pressure requirement of PED. Alternatively to satisfy EU legal requirements the British Plastic Federation Technical Committee of the Chemical Plant Group has already prepared a UK National Standard CP-100-2008 “UK National Industry Standard for the Design & Construction of Non Pressure Tanks & Low Pressure Vessels in Reinforced Plastics”, this has been fully verified and is based on BS 4994 -1987. CP-100-2008 is ready for publication and will be available through the British Plastics Federation, London, early 2010.
British Standard 4994 – 1987 will be used for the design and construction of tanks & vessels in reinforced plastics until EN 13121-3 is reviewed, amended and reissued.
Lee Forbes
Chairman of BS4994 – 1987
UK committee member representative for EN13121
November 2009
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TROSSLEY TOWERS
LARGE DEGASSING TOWERS & FLOCULATION TANKS IMPROVE WATER QUALITY
As part of £7.0 million investment by South East Water to improve water quality from groundwater sources at Trosley and Borough Green in Kent, three large degassing / aeration towers and flocculation tanks were designed, built and installed by Forbes on behalf of the main contractors, Enpure. The treatment works is designed to handle up to 1533 cubic metres of water per hour.
Each tower is specifically designed by Forbes to remove dissolved carbon dioxide to increase the pH. The towers are 2.9 metres diameter with a height of 6.2 metres manufactured to meet the stringent requirements of the DWI Regulation 31 (Water Quality). Due to the towers being elevated to allow gravity discharge into the flocculation tanks. The overall height was restricted to 6.2 metres to ensure the existing pumps can handle the induced head and reducing the impact on the environment.
All the tower internals are in polypropylene including the Pall Ring Packing which was supplied by the Pall Ring Company. Included in the package are the aeration fans – complete with duty standby units; all the ducting from the fans into the towers, the large 700mm diameter outlet pipework in polypropylene reinforced with GRP, complete with manifolds from each tower to feed the degassed water into the flocculation tanks.
Enpure’s design which incorporated gravity feed to the flocculation process gives significant cost savings and this combined with the very low power requirement for the fans, helps to keep the overall running costs to a minimum.
Forbes installed the three towers complete with all tower internals; fans and ducting; the large diameter manifold from the tower outlets and the three flocculation tanks. Forbes, now in their 50th year, are the largest UK manufacturer of custom designed tanks and columns in the UK and is major supplier to the Water Utilities. They have the capability of both process and mechanical design in a large range of products in plastics materials and glassfibre reinforced composites. One piece structures in composite plastic materials up to 10 tonnes in weight can now be easily handled in their recently commissioned custom built manufacturing facilities in Kelso, in the Scottish Borders.
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WHICH TYPE OF PLASTIC TANK DO I SPECIFY?
Tanks for use in the Chemical Storage, Processing and the Water & Waste Treatment industries must not be handled as a commodity. Tanks must be safe, as the liability & risk to personnel & the environment is extremely high. To the engineer without experience in the selection of materials and design, tanks seem to be simple structures, almost bought from a product catalogue. This approach can easily lead to failures within the lifetime of the tank. It is essential the design, materials of construction and type of manufacture are carefully assessed to meet the application and design life required, at the same time producing the most economic solution. Often an inadequate tank is selected by the purchaser purely on economic grounds to meet a demanding budget.
Virtually all tanks are regarded as a long-term capital investment. In particular the Water Industries often demand at least 20 years design life. Therefore selection of the design Standards & materials of construction must follow suit.
No matter what the application is, it is essential the purchaser fully engages with the manufacturer to ensure a safe, correctly designed tank, is selected. Part of this initial selection process involves the critical factor relating to the materials of construction. Do not be misled by the manufacturer who can only offer very limited choice of materials. Look at the potential long-term effect of the contents on the materials of construction. This is particularly important when handling liquids in thermoplastic tank where the thermoplastic is not only the chemical resistor but also the load bearing structure. All plastics suffer from a small degree of permeation and many engineers discount this long-term effect on the polymeric structure, which can lead to environmental stress cracking or softening of the material. Always insist on certified design Standard with full design calculation thus ensuring the tank will meet requirements. Despite what some people think, materials can have a relatively short life due to degradation when the tank shell is under load. Long-term exposure to a number of chemicals when under stress can induce environmental stress cracking. .
Material selection is always a difficult area for the purchaser to consider, with various claims being made in relation to expected service life, by different manufacturers. The safest approach is to fully engage with an experienced manufacturer who can demonstrate successful long-term applications. The next safeguard is the requirement for detailed design. The product must be fully compliant to a recognised British or EU Standard without exceptions.
The suggested selection process includes:
MATERIAL SELECTION
a) Thermoplastic as the chemical resistor and load bearing structure
b) Glassfibre reinforced vinylester & polyester (GRP or FRP) laminate with a composite inner corrosion barrier
c) Thermoplastic inner shell corrosion barrier being the chemical resistor with the external GRP laminate being load bearing structure, this being fully protected from the effects of the contents. Examples of such tanks, in continual service for over 35 years, can be demonstrated by Forbes.
The area, which is not always addressed by the manufacturer, is proven expected long-term life. All materials have a degree of degradation over time, particularly in chemical environments. There are reduction factors published in EN 1771 for a number of chemicals in contact with thermoplastics, where permeation does have an affect on the physical properties of the material.
For GRP tanks & pressure vessels, long term experience to be demonstrated by the manufacturer or apply the guidance notes in BS 4994 - 1987 which will give the appropriate safety factor.
Typical examples of points to raise with the manufacturer
1. The long term chemical resistance is confirmed, with examples. Whilst the corrosion resistance charts indicate satisfactory resistance, if the thermoplastic is also acting as the load bearing structure, ensure the design gives a low level of strain as environmental stress cracking can occur long term. Many chemical resistance charts are based on short term testing only.
2. Ensure the grade of thermoplastic is correct for the application..
3. Confirm there is no risk of temperature excursions beyond the design temperature. The mechanical strength of thermoplastics rapidly reduces with relatively small increases in temperature of the contents.
4. Ensure the chemical resistance for GRP is compatible for the resin selected and a low level of strain is maintained, thus avoiding the risk of strain corrosion.
DESIGN SELECTION
To achieve long term safe working product, it is imperative the tank is designed to a recognised Standard. This will reduce the purchaser’s Healthy & Safety liability in the event of anything going wrong during the working life of the tank. It is important that all aspects of the chosen Standard are met, with statements such as “covered by the relevant parts of the Standard” to be treated with a high degree of suspicion.
Prior to specifying & manufacturing items to the relevant Standard the following information must be agreed & documented between the purchaser & manufacturer & confirmed by the manufacturer prior to design & manufacture:
1. Details of the liquids to be handled including any trace contaminants
2. Confirmation of chemical resistance of the thermoplastic & the agreed reduction factor for the long-term effect of the contents on the material of construction as detailed in EN 1771. For GRP structures where the inner corrosion barrier is a chemical resistant laminate such as vinylester, long-term test results for the particular application.
3. Maximum operating temperature
4. Design temperature
5. Safety factor –
For thermoplastics - BS EN 12573 - for guidance see EN 1771 (example below)
Type of loading & application Safety Factor
Static load at room temperature and constant conditions. No possible danger to persons, objects & the environment in the event of failure
1.3
Loading under alternating conditions (e.g. temperature, filling levels). Possible danger to persons, objects & environment in the event of a failure,
2.0
The factors of safety in above table are for two loading cases depending on the potential hazard posed by the tank. In each individual case, the designer / engineer shall decide which classification is appropriate for the tank being designed & what level of safety factor is to be used.
For GRP and GRP with inner corrosion barrier of thermoplastic, the safety factor is calculated within BS 4994 -1987 & EN 13121-2/3.
6. Configuration & detailed dimensions (i.e. flat base, conical or dished base, sloping base, conical. Dished or flat top. The less preferred configuration of a horizontal or rectangular tank).
7. Operating pressures
8. Design pressures
9. Site conditions – temperatures, wind & snow loadings.
10. Hazardous area requirements
11. Imposed loads – personnel, equipment, brackets holding external equipment, agitator supports and access ladders and platforms.
12. Operating conditions including filling & emptying velocities or agitation, which may cause vibrations and tank moment.
13. Method of support (i.e. flat full plinth or platform or skirt – specially designed cradles for horizontal configurations) & holding down design
14. Nozzle connections, size, standard & layout, including how safe access can be gained when is service.
15. Seismic loadings (if applicable)
16. Site access & layout
17. Transportation, installation & handling.
The operating requirements specified by the tank owner and the calculations by the supplier to determine the design life and critical features of the tank should form the basis of the documentation retained for the life of the tank.
For thermoplastics for demanding duties, use the extensive German Standard DVS 2205. A less demanding Standard EN12573 (which many engineers consider is lacking in a number of areas) will give you basic design parameters but does not address many areas covered in DVS2205.
For GRP /FRP and thermoplastic / GRP reinforced products apply the very comprehensive BS 4994:1987. The recent issue of EN 13121-3 has caused much consternation within the industry. This standard is primarily a pressure vessel code for GRP vessels up to 10-bar pressure rating to meet the European Pressure Equipment Directive (PED)
Due to the sheer complicated nature of EN 13121-3 code, coupled with an estimate of over forty errors within the document, there are suggestions from the industry that EN 13121-3 is withdrawn and the well proven BS 4994-1987 remains the mainstay for the design and manufacture of safe and reliable tanks and vessels which can exceed 200 cubic metres in capacity.
The most important message is to fully engage with the manufacturer to build a confident working relationship. Where the major problems have occurred in the past and are still being seen in the current financially restricted market - DO NOT BUY PURELY ON PRICE.
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Start of Phase 2
GRP Tanks outside the factory
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LEADING TANK MANUFACTURER COMPLETES PHASE 1 EXPANSION
Forbes, the UK’s leading manufacturers of custom designed and built tanks, vessels, scrubbing columns and chemical plant in thermoplastics and glass fibre composite materials, has just completed an investment of £500,000 in Phase 1 of a brand new manufacturing facility on their Kelso site in the Borders of Scotland. A further £500,000 expenditure for Phase 2 is scheduled to commence in March for completion in July 2009.
Forbes, a family company, established in 1960 which is still headed by, Lee Forbes who pioneered the development of tanks in plastics materials in the early 60’s, has never veered from its policy of continual inward investment to improve efficiency and maintain its market share by being highly competitive.
Forbes products are used in a wide variety of applications from highly corrosive environments such as chemical manufacture and storage through to ultra pure water and pharmaceutical applications and potable water including products built to meet Regulation 31, of the Drinking Water Inspectorate reguirements.
Director, Melvyn Jupp states that this new facility will further increase the efficiency of our already highly efficient operation. “The company’s setup is such that we can effectively handle orders worth from just a few hundred Pounds up to large six figure contracts”. The company’s design, sales and head office is located at their new modern offices on a 2.5 acres site in Norfolk. Maintaining the “family” approach Forbes still pride themselves on a personal service that maintains customer support second to none.
A MAJOR INVESTMENT
This latest facility incorporates specialised buildings to handle tanks and vessels up to 14 metres in height with diameters up to 5 metres, depending on transportation restrictions, with capacities of up to 200 cubic metres. One of the main assembly buildings represents a major landmark in Kelso being 18 metres high incorporating 10 tonnes capacity overhead cranes. The overall investment, which is being met by existing company funds, will exceed £1 million.
The overall site in Kelso is 4 acres with a factory floor area of 18,000 sq metres and substantial access and external storage areas. With the majority of these building being in excess of 8 metres high with numerous travelling cranes, they are ideal for the production of a variety of tanks and towers in GRP and thermoplastic / GRP composites.
This development will also enhance the facilities for the existing thermoplastic tank production shops. The specialised self-contained buildings ensure there is no cross-contamination from other raw materials. Forbes manufacture thermoplastic tanks with capacities from 50 litres to in excess of 50,000 litres. Automation has played a large part in the success of the thermoplastic tank, Forbes are one of the most competitive manufacturers in the UK. Being the pioneers of thermoplastic tanks with the first freestanding tank being produced 1960, prior to the introduction of polypropylene, Forbes are very proud of their extremely safe, high quality tanks which continue to be used worldwide.
Part of the new development will link the already highly productive GRP winding shops to the new shops. The production of GRP tanks and scrubber shells with or without a thermoplastic inner shell is fully automated in order to keep costs to a minimum and guarantee quality. The extended finishing facility will not only allow more efficient working but will also improve delivery times.
Automation of composite tank production was introduced in the early 80’s with automatic hoop chop winding processes imported from the America. This process has been further developed by the company over the past twenty five years, which enables Forbes to produce a number of large tank shells in a day. “The main limiting factor on output of large diameter tanks is the fitting out. This latest development will solve this problem,” stated Kevin Johnston, Director in charge of the Kelso factories. “This will allow our five winding mandrels to produce tanks simultaneously”. Standard winding mandrels from 2 metres diameter to 4.1 metres in diameter permit a large range of tank and tower shells to be produced within hours.
Melvyn, who is based at the Head Office in Norfolk, stated “Over the past few years we have seen a huge growth in the demand for our quality products. Our sales team has been frustrated at times with our prices being the most competitive but we have been unable to meet the delivery requirements of the customer - meaning lost orders despite our highly competitive prices. This new facility will alleviate this delivery problem”. The second phase, which is due to commence in March, will incorporate separate fabrication shops, general assembly and stores areas. There will also be a new metal fabrication shop, handling steel, stainless steel and aluminium. This “in house” facility has been a vital element within Forbes production since the 70’s. Forbes developed this ancillary facility to ensure only quality metal parts, such as access ladders, walkways, tank supporting structures and pipelines are fitted to their products where required.
CONTINUED GROWTH
Despite the current downturn in industry in the UK and the rest of the World, Forbes are still extremely optimistic. Forbes’ continued success has been based on versatility and quality - at the right price. Much of the business is repeat business from long established customers. Occasionally customers are attracted by other suppliers offering lower quality / cost products, however virtually all return to Forbes. As explained by Melvyn “Versatility is the key! Being able to offer products made in a variety of plastics materials, to strict quality standards, has won us many orders. Unlike most manufacturers we are able to tailor the most suitable material to satisfy the application. This optimism is confirmed by our commitment to this major expansion at Kelso. Forbes will continue to grow”.
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NO ISSUES ON PRODUCT STORAGE FOR NEW PLANT
Kemira Water, the largest suppliers of water treatment coagulants in the world, commissioned Forbes Technologies Ltd to design, build & install 16 large capacity storage and processing tanks for their new PAX (polyaluminium chloride) plant near Chester. The process involves the production and storage of concentrated corrosive solutions.
A series of vertical cylindrical tanks holding 100 cubic metres each, are used for product storage. Each tank has an integral access ladder and top mounted handrails to allow access to the roof. .A further group of vertical cylindrical processing tanks complete with dished bases mounted on steel legs for load cells, form the main part of the production area. These production tanks have integral steel bridges to support large agitators. Included in the chemical storage are two tanks for concentrated hydrochloric acid. To contain hydrogen chloride fumes from these large storage tanks and to ensure compliance with the environmental permit, Forbes has designed & manufactured a fume scrubber with sump tank, which stands 9m high, this also being in vinylester E-CR glassfibre composite materials
Kemira and Forbes together with the main contractor Stopford Projects selected “Hoop Chopped Wound” GRP tanks incorporating sophisticated vinylester resins reinforced with
E-CR glassfibre specially imported from Canada. The process tanks are manufactured in high heat, high chemical resistant novolac epoxy based vinylester resin to withstand, not only the potential corrosion problem, but also the heat produced during processing. The vinylester resin composite is very robust which is a requirement for this type of agitated tank.
The Fiberex “E-CR” glassfibre continuous rovings used in the tank production, produce a very strong continuous “belt of glassfibre” in the “hoop” direction of the cylinder. This specific grade of glassfibre was selected for its exception strength, being at least 15% stronger than the conventional type “E” glassfibre. This coupled with the enhanced chemical resistance has produced extremely “safe” storage for these aggressive applications. Designed to British Standard 4994 -1987 category 1 and with ‘K’ factors (safety factor) exceeding 10 for some of the processing tanks, Kemira are expecting a life in excess of 25 years of continual use.
“Hoop Chopped” winding is an automated process for the deposition of composite materials producing consistent quality laminates for tank production. The combined strength of the unidirectional continuous fibres directly in line with the hoop loading mixed with chopped multidirectional fibres in a 50% ratio laminated with 50% by weight of resin give an ideal composite material for chemical plant manufacture.
“Following a lengthy selection & evaluation process plus Forbes’s technical advice, we were able to specify the ideal composite materials for this very demanding application” stated Pete Aspden of Kemira. “With Forbes’ 45 years experience and proven track record for quality tanks, they were the first choice of manufacturer.”
Forbes Technologies Ltd is the largest manufacturer of custom designed tanks and columns in plastics materials in the UK. With their four specialised plants located in Kelso in the Scottish Borders, tanks in excess of 10 tonnes in weight can be easily handled. With over 45 years of fabrication experience, modern custom built manufacturing facilities equipped with automated production plant, the company is able to produce high quality low cost products. This is achieved with the high labour content normally associated with GRP lamination being drastically reduced by automation.
Forbes has recently moved to new custom built head office in Norfolk. The company has dedicated facilities in Kelso for the manufacture of products in:
a) GRP incorporating a variety of resins & glassfibre systems
b) GRP/ thermoplastic dual laminates incorporating polypropylene; UPVC; and the highly chemical resistant fluoroplastics, PVDF & Halar ECTFE as the chemical resistant inner shell.
c) Free standing tanks up to 50 cubic metres and scrubbers in polypropylene and HDPE
Unlike many suppliers, Forbes can select the ideal materials and design to specific requirements which are ideal for the application. The company having this wide spectrum of materials and process available has no particular “axe to grind” in terms of offering only one material or one method of manufacture. Truly engineered products specific to your application.
Sales contact - Colin Wills – 01366 389625 cwills@forbesgroup.co.uk
PR enquires to Director - Melvyn Jupp – 01366 389640 mjupp@forbesgroup.co.uk
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LATEST NEWS
FORBES CHARTERS A SHIP TO EXPORT 42 LARGE GRP PROCESSING VESSELS TO KAZAKHSTAN
Having successfully won a US$ 950,000 contract for 42 large GRP processing vessels for Kazakhstan, Forbes Technologies Ltd was faced with the problem of transporting these light weight structures to this virtually land locked country adjacent to the Chinese Border. Having investigated the possibility of shipping via the Baltic and through canals to the River Volga, which flows into the Caspian Sea, it was concluded that rail shipment through Russia was the most economic route. Despite the high cost of shipping, the contract was won against stiff competition from the Chinese, who are near neighbours to Kazakhstan.
A 4000 ton ship was chartered being loaded at Berwick upon Tweed docks local to Forbes’ extensive manufacturing facilities in Kelso in the Scottish Borders. The contract for a series of processing & waste treatment vessels 3.5 metres diameter by 9 metres tall, were thought to be too large to ship by rail, once in Russia. However it was found the Russian rail system could handle loads as wide as 3.7metres, therefore allowing safe transport south to Kazakhstan.
BIG SHIP
The 100 metres long vessel sailed from Berwick upon Tweed to St Petersburg with all 42 tanks; some as deck cargo. These were then trans-shipped to specialized rail trucks in St Petersburg port area for the journey south.
All 42 processing tanks were manufactured in a high chemically resistant NPG based polyester resin / acid resistant E-CR glassfibre composite, these very robust, highly chemical resistant tanks are designed with earthquake loadings. Manufactured by automated hoop chopped winding process producing exceptionally strong tanks. The majority had large agitators with integral baffles built into the shells. The major reagents being used are highly aggressive ferrous & ferric salts in acidic solutions. With a design life of 20 years the tanks were specified to withstand acid & alkaline chemical solutions used in the mineral extraction process.
EXPERIENCE
Forbes has over 46 years of experience in building tanks from a few litres capacity to in excess of 200 tonnes capacity, in a variety of plastics. These include polypropylene, HD polyethylene, UPVC, PVDF and sophisticated vinylester & polyester resin glassfibre laminates. They also design & construct gas & odour control scrubbers & other chemical and water treatment equipment in plastics materials.
Melvyn Jupp, Director, states “That with the lack of expansion of manufacturing industries in the UK, Forbes is successfully developing a healthy export business to countries within the EU and Turkey, Romania, China and the Middle East. With our specialist knowledge built up over the past 46 years in chemical plant design & manufacture in plastics materials, we have a great deal to offer to the export market”
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URGENT PRESS RELEASE
FORBES WINS $950,000 EXPORT CONTRACT FOR LARGE GRP PROCESSING VESSELS FOR A MINERAL EXTRACTION PLANT IN KAZAKHSTAN
Forbes Technologies Ltd, based in Downham Market, Norfolk with extensive manufacturing facilities in Kelso, Scottish Borders, have been successful in winning a 950,000 US Dollar contract for a series of processing & waste treatment vessels 3.5 metres diameter by 9 metres tall to be installed in mineral extraction & mining operation in Kazakhstan.
Manufactured in a high chemically resistant NPG based polyester resin / E-CR glassfibre composite, these very robust, highly chemical resistant tanks are designed with earthquake loadings with the majority having large agitators with integral baffles built into the shells. The major reagents being used are highly aggressive ferrous & ferric salts solutions as used in many sewage treatment plants.
The contract was won against stiff competition from the Chinese who are near neighbours to Kazakhstan. The consignment is being shipped via Berwick-on-Tweed docks to St Petersburg and then overland south to the site. The tanks will be used for chemical extraction & precipitation of various minerals.
Melvyn Jupp, Director, stated “This large export order demonstrates that UK manufacturers can still compete against the Far Eastern competition. Our custom designed & built tanks were chosen because of our recognized quality coupled with our capability in manufacturing such a large volume of high capacity tanks. Fortunately our Kelso facilities are designed for high volume production, a necessity in this instance for quick delivery & keeping costs to a minimum”. “This is a case where the company has invested in automation and specialize buildings to remain in the forefront of our market”.
A number of tanks are already in manufacture with some completed product being prepared for shipment. With a design life of 20 years the tanks were specified to withstand acid & alkaline chemical solutions used in the extraction process.
This is the following a recent export contract where Forbes beat Far Eastern competitors. Six months ago they installed a large gas scrubbing tower 1.7m diameter x 20 metres high for a chemical plant in China. Forbes personnel assisted in the installation. The tower was constructed in very sophisticated fluoroplastics reinforced with vinylester resin glassfibre laminate.
Despite this large volume order, Forbes has the facilities to maintain existing customers needs and it has not been necessary to extend delivery times to customers.
Forbes has over 45 years of experience of building tanks from a few litres capacity to in excess of 200 tonnes capacity, in a variety of plastics. These include polypropylene, HD polyethylene, UPVC, PVDF and sophisticated vinylester & polyester resin glassfibre laminates. They also design & construct gas & odour control scrubbers & other chemical and water treatment equipment in plastics materials.
Contacts:
Sales: Colin Wills
tel: +44 (0) 1366 389625
email: cwills@forbesgroup.co.uk
PR information: Melvyn Jupp
tel: +44 (0) 1366 389640
email: mjupp@forbesgroup.co.uk
Website – www.forbesgroup.co.uk
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PURCHASING A TANK? - BE AWARE OF THE PITFALLS
With the ever increasing Health & Safety & Environmental liabilities being placed on specifiers, purchasers, end-users & manufacturers of tanks containing both hazardous & non hazardous liquids, great care must be taken not only with the design of the basic tank & safety bund, but also with ancillary safety items. It is not uncommon for the safety protection equipment to induce alternative risks.
To ensure the end-user has a totally safe system of chemical storage, even with a simple bunded tank, the designer / manufacturer must make a full HAZOP (hazard assessments) in various “what if” scenarios. Before we discuss the possible problems which can be unwitting induced by the end user or by lack of full “what if” assessments by the supplier, let us examine the tank. options. The majority of ‘one piece’ tanks up to capacities of 200 cubic metres, whether for hazardous, corrosive or non hazardous duty, construction in plastic materials is now very much norm.
Get your materials & design standard correct
There are two common types of plastics materials used for the construction of tanks for chemical storage. For the smaller capacities unreinforced thermoplastic such as polypropylene and HDPE designed to DVS 2205 - Merkblatt (German Standard). This Standard looks at all parameters and is specific in dictating safety factors based on risk. The recently issued EN 12573 is a very poor substitute for the well proven DVS 2205. The EN 12573 does not address essential items such as wind loadings, personnel loadings, plus other areas which DVS 2205 includes. For large volumes of liquid &/or any hazardous applications the advice is to insist on calculations conforming EN12573 followed by detailed design parameters not covered in the EN by applying the extensive DVS Merkblatt code. A further major weakness of EN 12573 is the allowable range of safety factors from 1.3 to 2.0. Unlike DVS 2205 Merkblatt, there is no guidance or comment as to which safety factor to select . As the EN is based on parts of the well proven DVS 2205 Merkplatt, the inference must be drawn that any engineer looking at EN must refer to DVS 2205 for guidance in areas omitted by the EN standard. The engineer cannot ignore parameters such as wind loadings, roof loading and more importantly correct choice of safety factors. There is no other verified authority to reference. Therefore the engineer must choose a safety factor of 2.0. for any large capacity tank holding hazardous material in a critical situation which could cause harm to personnel or the environment To cut costs suppliers of tanks reduce safety factors and amazingly stay within the EN standard.
DVS requires the designer to look at the long term strain curves and incorporate an ageing factor. The all thermoplastic tank being strain limited in design rather than stress limited, the chemical resistance of the thermoplastic can substantially be degraded in many aggressive environments as the strain level increases with time. Depending on the type of thermoplastic, this ageing factor together with chemical resistance is a major consideration. Particularly with low & medium density linear polyethylene’s the resistance compared to say the chemical grade P100 HD polyethylene; a reduction of over 50:1 to environmental stress cracking has been seen in the laboratory in certain environments.
For GRP composite reinforced laminates BS 4994 – 1987 covers very detailed design of all the required parameters for safe storage of chemicals. Using BS 4994 the design engineer has the total confidence in safety of final design of GRP structures. Great care must be taken in selecting the correct materials. For example weak acidic solutions can cause acid strain corrosion in Type E glassfibre laminates. E-CR glassfibre should be selected this giving protection against such attack even if problems of damage occur to the corrosion barriers. For highly corrosive conditions sophisticated vinylester resins are the norm.
Omitting a side manway can be an initial saving but very costly for the future
One major consideration for any tank above 2 metres in height is the necessity to include a side mounted manway for safe access during inspections. For hazardous / corrosive liquid storage it is now often a scheduled mandatory requirement that tanks are inspected internally irrespective as to the type of tank or material of construction. Risk assessment into confined space dictates gas levels must be checked & the safe removal of a collapsed person.
GRP reinforced tanks offer side mounted manways as a standard within the BS4994 design code. One major disadvantage of the “all” thermoplastic tank is the stipulation in EN 12573 & DVS 2205 Standards that no connection above 300 mm diameter is permitted in the vertical wall below liquid level.. If a failure is due to ‘stepping’ out side the EN Standard, in law, the entire liability will fall on that engineer. If any fabricator presents design calculations for larger nozzle connections, including side manways, it is essential the design is verified by an experienced organisation such as TUV who verifies the German DVS & other Merkblatt safe design Standards. This high risk area is sometimes addressed by a fabricator’s own design methods. The advice is to ensure any such calculations are verified by an experienced authority such as TUV of Germany.
The alternative to side access is to enter the tank via the top manway by calling in a specialist company, with breathing apparatus.; winches; internal scaffolding, full PPE and gas monitors which far out weighs the initial cost of fitting a side access during construction if permitted.
When is a “bunded” tank not a bunded tank?
Virtually all tanks now have to have a separate bund tank or catchment area to contain 110% of the volume of the tank. The so called ‘double wall’ tank is not a fully bunded system and leaves the end user somewhat exposed should a problem occur. In the true sense a bund is a separate item which should contain the outlet valves, overflows and immediate pipework from the tank. The only exception to this is when there is no side mounted fittings or connections and the contents are pumped out from the top of the tank. If a double wall tank is used in this fashion the outer skin must be designed to contain the entire contents safely for a suitable period..
Common problems associated with incorrectly specified, operated or maintained chemical storage systems
• Floatation – One of the most common problems is the tank floating within the bund area due to either rainwater accumulating &/or overfilling of the tank. Unless specifically designed most tanks in plastics materials will not withstand the up thrust created by floatation. Reported instances over the years show damaged tanks & pipework connections broken due to floatation, allowing the contents to escape into the bund.
Optional solutions offered on: Forbes MINIBULK® range of tanks:
1) Fit a rain protection shroud together with a TC® (Total Containment) shield.
2) Install a bund alarm to give warning of any liquid on the floor of the bund
3) Fit a separate containment / catchment area under the overflow, thus preventing any risk of liquid building up in the bunded area, if small overfills occur. This area can have warning alarms when liquid enters this separate small bunded area.
4) To prevent overfilling of the tank install a high level alarm switch in the storage tank.
5) Design the base of the tank to withstand the upthrust generated by floatation & ensure holding down detail is adequate.
6) Mount the tank on an elevated platform or plinth within the bund.
• Joints or valves leaking due to corrosion or damage – particularly with highly corrosive contents which fume, such as hydrochloric acid. A shallow dilute solution of corrosive liquor if allowed to build up in the bund can quickly destroy the valve bolting which will lead to the contents escaping into the bund.
Optional solutions offered on: Forbes MINIBULK® range of tanks:
1) Fit bolting which is resistant to the contents – for instance for hydrochloric acid fit a special grade Titanium bolting.
2) Only use plastic valves & union connections in the bund area.
3) Protect the bund area by fitting an overflow bund area within the major bund.
• Leakage occurring caused by a damaged tank “jetting” over the top edge of the bund wall – this scenario is rare but must be risk assessed.
Optional solutions offered on: Forbes MINIBULK® range of tanks
1) Fit a TC® (Total Containment) shield which will prevent “jetting” of liquid over the bund wall should the tank shell be damaged.
2) Increase the height of the bund.
• Tank & bund misalignment due to incorrect assembly causing pipework to be stressed with the potential of pipework failure – this is caused by the installer (often the contractor or end user) not taking care in aligning the pipework & valves between the tank and the bund wall.
Optional solutions offered on: Forbes MINIBULK® range of tanks:
Complete installation service offered by the manufacturer. This places the onus a single source.
Conclusion
It is evident from the above discussion that serious risks of leakage of toxic products into the environment or injury to personnel are a real possibility if the incorrect design, wrong materials of construction are selected, plus failing to carry out an accurate risk assessments in terms of installation, operation and maintenance. To obtain the most cost effective system coupled with safest system of storage, it is extremely important the purchaser & end user selects an experienced tank manufacturer who can fabricate in a number of materials and who can produce verified design calculations. They must be able to offer a full HAZOP assessment applicable to the specific application. Often making savings on the initial capital costs can come back and “bite you” at a later date.
Lee Forbes is the managing Director of the Forbes Group of companies & has been designing & building tanks & chemical plant in both thermoplastics plastics & GRP composites since the early 60’s
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