Energy Efficient Advanced Interlock Panel System for Tank Insulation - An Innovation In Tank Insulation Applications SHIVDAS MANIKKAN

Agenda • Introduction • Advanced Double Interlock Pre-Fabricated

Insulation Panel System • Advantages of Double Interlock Pre-Fabricated

Insulation Panel System • Conventional Insulation System & Concerns • Insulation and Metal Jacketing Options • Fabrication & Erection of Pre-Fabricated Insulation

Panel System.

Insulation In the petroleum and chemical industries it is customary to store

liquids and the like within large tank structures which are usually installed out in the open where they are exposed to the elements, both heat and/or cold. These storage facilities usually comprise circular steel or other metallic tank structures which by reason of being installed out in the open, must be provided with a suitable insulating material so that the products in storage within the storage tanks may be kept at the desired temperatures. In storage tank insulation systems, it has thus been customary to apply some type of an insulating material exteriorly of the metallic tank structure and to securely bind the same thereto by the use of an adhesive or by circumferential bands extending completely around the outside diameter of the tank and secured in a fixed position. Various arrangements or systems have been provided in the past for securing insulation and metal cladding to storage tanks.

Heat Loss Without Insulation

Why Insulation?

Heat Loss With 50 mm Insulation

Maintenance Temperature : 60 °C

Min. Ambient Temperature : 5 °C

Max. Ambient temperature : 45 °C

Insulation Type : Mineral Wool

Tank Dimensions : 30 m dia x 12 m height

3,624 KW

153 KW

Introduction • The Vertical Seamlock Panel concept was developed in the

US to answer challenges resulting from specific meteorological constraints generated by tornados, high winds and heavy rains.

Introduction • Initial objectives were

– Having a very robust system able to withstand local weather conditions

– Reducing time spent for construction – Avoiding use of scaffolding

Introduction • Further objectives developed through the years

– Long lifetime (over twenty five years, double compared to traditional)

– None fibrous materials (closed cell structure, no water absorption, better K-Value)

– High energy savings resulting in a low Total Cost of Ownership – Under insulation corrosion minimized – Maintenance free

Advanced Interlock Panel System for Tank Insulation This is the latest state of the art technology where the panels are pre-fabricated by laminating insulation material with pre-formed metal jacket. The wire ropes installed circumferentially on the tanks at predetermined interval to support the pre-fabricated panels. These panels fabricated to the height of the storage tanks include mating seam that are mechanically folded to make system as double-locking standing seam panel system.

Technical Concept • The technical concept is based

on vertical insulating panels prefabricated in workshop which are assembled on Site by a seam system

Technical Concept • A cable is fixed around the tank.

Stainless steel clips fixed on this cable are captured within the seam made between two panels.

Close-up view of standing Seam

Advantages • Advantage on Schedule

• Advantage on Safety • Advantage on Under Insulation Corrosion • Advantage on energy usage

Advantage on Schedule • Time usually spent on site and related to construction is transferred

to manufacturing activities in workshop controlled environment

Tank erection

Insulation Site

Time Conventional insulation

Time

Tank erection

Insulation Site

Insulation Workshop

Vertical seamlock Panel insulation

GAIN ON SCHEDULE

Advantage on Safety Use of hanging basket instead of scaffolding

Advantage on under Insulation Corrosion • Fully locked double seam system eliminates water

penetration resulting in a reduction of under insulation corrosion

• Next to the support ring, no rims or other welding required

on side walls resulting in a minimization of locations where under insulation corrosion could develop itself

Advantage on Life time • Use of PUR / PIC insulation materials guarantees a longer life time

and a more efficient system

The graph shows 5% increase in water contents results in 200% increase in thermal conductivity of mineral wool

Advantage on energy usage High thermal insulation resistance of PIC material resulting in: • Less energy needed to maintain the

content of the tank at the required temperature

• Long cool down cycle

Vertical seam lock panel insulated

tank cools down from 80ºC to 60ºC at an average ambient temperature of

12ºC takes 1664 hours or almost 10 weeks

Conventional insulated tank cool under same conditions takes 1332 hours or 7.8

weeks

Conventional Insulation System

•Most commonly used system •Steel structure and pins are welded on the tanks shell and roof •Insulation is secured with SS Bands •Metal cladding is fastened with the rivets and self tapping screws

Insulation

Pop rivets / Self Tapping Screws every 150 mm for cladding securement

Corrugated metal Cladding

Bolts every 300 mm

SS Straps

Tank Shell

SS Bands

Corrugated metal Cladding

Mineral wool

Concerns with Conventional Insulation System

MS Angle Structure

• A need for repair and replacement of bands due to expansion and contraction as a result of temperature gradient • A need for welding of anchoring studs to the outside wall and roof of the tank. • Fastening the insulation and the metal jackets to the studs. • Reduction in thermal efficiency • Penetration of moisture through the joints and metal jackets. • Due to Welding of Structures Insulation of existing Live Tanks not possible.

Why Interlock Panel System for Tank Insulation? •Cost Effective Eliminating Scaffolding & heavy structure work for insulation and cladding support which results in lower cost and schedule Compression. •Superior Structure Continuous 360 degree interlocking seams provide rigidity that reduces moisture ingress and offer superior wind resistance, thermal efficient and aesthetically superior •Maintenance Free Interlocking Panels eliminate the use of external horizontal bands that require maintenance over time. Screws are not required, so jacket penetrations are eliminated. •Repairable Single panels may be replaced if damaged.

Eliminates Scaffolding

Scaffolding is required for conventional insulation tanks, depending on the size of the tanks, it takes approximately 30 days to make around the tank of 60 to 80 m dia. and 20 m height. This affects the project schedule, lots of man-hours are put into which increase the project cost. Some times the safety is compromised which is the top most priority of any project.

Installation of Vertical Double Locking Standing Seam pre-fabricated insulation panel Eliminates Scaffolding

Eliminate Costly & Time Consuming Welding Work For Insulation Pins & Cladding Support

Insulation Pins & Cladding Support are welded to the Conventional Insulation Tanks to hold the Insulation & Cladding

The metal ropes around the tank holds the pre-fabricated insulation panel. This eliminates costly & time consuming process of welding.

Applications for Pre-fabricated Double Locking Standing Seam insulation panel

Tank Roof

Tank Shell

INSULATION TYPE K-FACTOR BTU*IN/HR*FT*°F

MAX EXP. TEMP MAX PANEL LENGTH

% MOISTURE ABSORBENCY

POLYISOCYANURATE .19 250°F (121°C) 75’ – 0” 2%

FIBERGLASS .24 850°F (454°C) 30’ – 0” >20%

MINERAL WOOL .26 1200°F (649°C) 30’ – 0” >20%

CELLULAR GLASS .30 900°F (482°C) 30’- 0” 0%

MATERIAL SELECTION

VERTICAL SEAMLOCK PANEL TANK INSULATION SYSTEM

METAL JACKETING

JACKETING TYPE GAUGE TYPE PAINT OPTION

MOISTURE BARRIER

ALUMINUM (STUCCO EMBOSSED) 0.024”, 0.032” 3105 H154 √ √

STAINLESS STEEL (STUCCO EMBOSSED) 0.016”, 0.020” 304 2b √ √

GALVALUME (SMOOTH) 0.022”, 0.024” AZ55 GRADE 80 √ √

THERMAL INSULATION

Conventional Insulation System for Tank Roof

Heavy Steel Structure along with the Insulation SS Bands & Cladding Support are required to support the conventional Insulation on the Tank Roof. The risk of moisture penetration with this design is high, due to uneven tank roof surface and removal of rivets with high wind velocity are the common concerns.

Self Tapping Screws @300mm

Metal jacket

Insulation Securing Band

Sealing Cap

Floating Ring

50 x 50 x 6 mm Angle support for Insulation

Pre-fabricated double-locking seam panel for Cone Roof & Dome Roof Tanks eliminate heavy Steel Structure

The Double Locking Standing Seam pre-fabricated insulation panel can provide Radial and Parallel design on the tank roof and prevents and moisture intrusion and gives Aesthetically superior look. Insulation Pins & Supports are not required.

Parallel design for Cone & Flat Roof Tanks

Radial design for Dome Roof Tanks

Aluminum Flashing

Aluminum Rim Angle

Sealant

Aluminum Standing Seam Panel

Sealant

Vertical Panels on Tank Roof

Crown

Existing & In-Service Tanks – No Welding Permitted

Shell

Vertical Seamlock Panel Tank Insulation System

Conventional Tank Insulation System

SAFETY Smaller crew size, fewer installation steps, fewer field construction hours

vs. Larger crew size, more installation steps, more field construction hours

COST No scaffolding No tank appurtenances required No painting required on low temp tanks

vs. Scaffolding required Insulation support pins and rings required

PERFORMANCE Fewer field construction work hours vs. Takes 2-3 times more field construction work hours required

SCHEDULE Compresses field schedule due to fewer field work hours vs. Takes 2-3 times longer to install.

MAINTENANCE Minor caulking maintenance around penetrations vs. Regular, involving band tightening and replacing weathered insulation, screws, etc.

AESTHETICS Superior vs. Inferior

DESIGN LIFE 20+ Years vs. <15 years

SECUREMENT All internal protected from the elements by the insulation system vs. All external subject to the elements

QUALITY 100% hermetically protected from the elements with minimal rivets vs.

Exposed to elements with multiple laps and screws, requires regular maintenance

WIND >120 m/hr ( 193 km/hr) vs. <70 m/hr (115 km/hr)

The Vertical Seamlock Panel advantages over Conventional Tank Insulation system are: Vertical Seamlock Panel System has high thermal efficiency and has high resistance against moisture intrusion as compared to Conventional System. Maintenance free system Eliminates expensive scaffolding Eliminates the need of SS Horizontal bands which are mandatory for the conventional system, thus decreasing the cost of the system. Eliminates the need of Steel Structures required for supporting the insulation material. Eliminates the need of MS Angle support rings, normally installed at a distance of 2m for conventional system, for fastening the Aluminium Jacketing. Continuous 360 degree seams provides rigidity Structurally superior compared to conventional application Single panels can be replaced if damaged Needs lesser time for installation Zero maintenance insulation system with a life of 20+ years. This system reduces a customer’s TIC (Total Installed Cost) by compressing schedules and eliminating the use of scaffolding and TOC (Total Operating Cost) by providing a thermally superior insulation system.

Technical Comparison – Conventional Vs Vertical Seamlock Panel

Vertical double locking standing seam insulation panel

Pre-fabricated one piece construction

Eliminates costly scaffolding

Compresses field construction schedule

Reduces field construction work hours

Maintenance free

High wind resistance

Thermal efficiency

Aesthetically superior

Vertical Seamlock Panel Insulation- BENEFITS

Vertical Seam-lock Panel vs. Conventional

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CONVENTIONAL

VERTICAL

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T O T A L I N S T A L L E D CO S T

TANK SIZE

Alternatives • Conventional Applications • Other Panel Systems

Conventional Banded in Place Applications

• High Maintenance Installation

• Labor Intensive Application

Conventional Application

Aesthetics Conventional v/s Vertical Seam-Lock

Conventional Applications • Expensive Scaffold Cost • Periodical Maintenance

Horizontal Panel System • Multiple Components per

Ring • Excessive External

Accessories • Higher Cost per Sq Ft

Installation

Conventional Installations-High Maintenance

• Requires Periodical Maintenance

• Labor Intensive Application

Conventional Banded In Place Application

Conventional v/s Vertical Seam-Lock

• Conventional Installation

COST EVALUATION Tank Dimension of 100’od x 40’ High

Vertical Seam Interlock panel Installation

Shell Sq.Ft

Structural Steel & Welding

Scaffold Cost Material Cost Labor Cost Total

12560 $ 1.75 $ 2.94 $ 2.08 $ 2.53 $ 9.35

Installed Cost $ 117,436.00

Shell Sq.Ft

Structural Steel & Welding

Tank Access Material Cost Labor Cost Total Cost

12560 & 0.50 $ 0.09 $ 2.60 $ 2.53 $ 5.72

Installed Cost $ 71,843.00