Dr Bugs Tan ADIPEC Conference Paper 2017

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Paper No. SPE-188686-MS

Creation of a

New Light Weight Grating

Bugs Tan PhD,

Malaysia University of Science and Technology

Mastek Oil Tools Sdn Bhd

MALAYSIA

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THE NEW LIGHT WEIGHT ANTI-SLIP GRATING

Creation of a light weight

anti-slip steel grating

Paper # SPE-188686-MS • Creation of a New Light Weight Grating • Bugs Tan PhD, Mastek Oil Tools MALAYSIA

LIGHT IN WEIGHT

BETTER INTEGRITY

COST BENEFIT

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TURNING IDEAS INTO INNOVATIONS

Common Steel Grating Innovative Litewalk steel grating

Paper # SPE-188686-MS • Creation of a New Light Weight Grating • Bugs Tan PhD, Mastek Oil Tools MALAYSIASlide 4 of 24


PROJECT FLOW CHART

Description of activities Purpose

1 Development of conceptual design Creation of the profile and new design of the components and grating panel

2 Finite Element Analysis (FEA) Optimization of the new design

3 Development of Prototype Load test to comply to industry standard

4 Corrosion Test Corrosion test to comply to industry standard

5 Filling of patent and trademark Protection of ideas

6 Commercialization Penetration into the marketplace

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CONCEPTUALIZATION

Profile of common grating Profile of the Load Bearing Bar for Litewalk


The Finite Element Analysis on the design of Litewalk grating


SIMULATION

No. Description of the Test Computer Software Test carried-out

1.

A workstation to simulate the

Finite Element Analysis of

the Litewalk grating designABAQCUS/CAE 6.6

Uniform distributed test

(UDL Test)

Concentrated Load Test

(CL Test)

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Purpose of the test is to:-

• Determine the deflection of the grating panel

• Deflection should not exceed 1/200 times (5mm) of the effective span or

10mm whichever is lesser

Standard complied to:-

• British Standard BS 4592 Part 1 : 1995

• Uniform distributed load (UDL) of 5kN/m²

• Concentrated load (CL) of 1 kN


OBJECTIVE OF THE SIMULATION TEST

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The performance of the simulation test on the load bearing bar


PARAMETER

Model 885-3515 920-3520

Width of grating panel (mm) 885 920

Height of load bearing bar 35

Width of load bearing bar 15 20

Thickness of load bearing bar 1.0, 1.2, 1.5, 1.8, and 2.0

Diameter of holes drilled at bar 6 mm NA

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DISPLACEMENT TEST RESULT OF FEA

FEA UDL t1.5 x w15 x h35mm load bearing FEA CL t1.5 x w15 x h35mm load bearing


DEVELOPMENT OF PROTOTYPE

Fabrication of the prototype Prototype model of the Litewalk grating panel


LOAD TEST CONDUCTED AT SIRIM

Concentrated load test of 1kN Uniform distributed load test of 5kN/m²


Results from 3 different exercise


SUMMARY OF THE LOAD TEST RESULTS

Load Manual

Calculation

FEA

Simulation

Test on

Prototype

Concentrated Load

(CL) 1kN

2.05mm 2.228mm 0.63mm

Uniform Distributed Load

(UDL) 5kN/m²

0.194mm 0.087mm 1.54mm

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SIGNIFICANT OF STUDY

• Although the result is within the deflection range allowable

• However, the result from the 3 exercises seems to be inconsistence.

• Recommendation

• More research work and load test

• Investigate and examine what could possible went wrong.

• It would bring benefit to the academia and the industry players,

• So people could fully understand the mechanical challenges for this type of project

Test procedure was carried-out in accordance to:-

• Alternative immersion ASTM G44-99 (2005)

Description of the corrosion test:-

• The purpose of the test to identify the form of corrosion

• Sample is dipped in 3.5% sodium chloride (NaCI) for 10 minutes

• then allowed it to dry for 50 minutes.

• Sample are visually examine at 200, 500 and 1,000 cycle interval

• Temperature at 27C ± 1 C and relative humidity of 45% ± 6%


CORROSION TEST

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The set-up of the corrosion test in a controlled environment


CORROSION TEST SET-UP

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BEFORE CORROSION TEST BEGINS

Data of the sample before the test commences

1 Temperature = room 27.3ºC and water was 26.5ºC

2 Humidity = 46.8%

3 pH value = 7.18 for both coated and uncoated

4 Weight of sample (dry) as follows:-

Sample before corrosion test commence


Specimens Coated /

Uncoated

Weight of sample

before test

Sample A Coated 2,758.88 gram

Sample B Coated 2,771.55 gram

Sample C Uncoated 2,794.79 gram

Sample D Uncoated 2,793.67 gram

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AFTER THE TEST COMPLETED

Results after 1,000 cycles

1 Temperature = room 27.8ºC and water was 26.2ºC

2 Humidity = 45.5%

3 pH value = Coated 7.39 and uncoated 9.62

4 Weight of sample (dry) as follows:-

Sample after corrosion test completed


Specimens Coated /

Uncoated

Weight of sample

after test

Sample A Coated 2,762.07 gram

Sample B Coated 2,774.71 gram

Sample C Uncoated 2,880.05 gram

Sample D Uncoated 2,883.18 gram

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Conclusion

• After 1,000 cycles (about 42 days) of alternative immersions , the coated

Litewalk grating sample are found to be resistant to corrosion.

• However, the uncoated Litewalk grating samples are physically corroded


CONCLUSION OF THE CORROSION TEST

Specimens Coated /

Uncoated

Weight before test Weight after test Weight different

Sample A Coated 2,758.88g 2,762.07g -3.19g

Sample B Coated 2,771.55g 2,774.71g -0.16g

Sample C Uncoated 2,794.79g 2,880.05g -85.26g

Sample D Uncoated 2,793.67g 2,883.18g -89.51g

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SUMMARY OF THE FINISHED PRODUCT

• This new product has significant advantages

over the traditional (common) steel grating.

• The 4 major advantages are:-

• A lot lighter in weight

• Grating panel is stronger

• Cost benefit

• It has a true anti-slip feature

Litewalk grating used on process facility



1) A grating panel that is light in weight

• The load bearing bar is hollow section

• It enables the overall grating panel to reduce in

weight significantly.

• Litewalk steel grating is lighter than common

steel grating of the same grade by up to 35%

• This lightness in weight will benefit the overall

structure

Litewalk being used on oil platforms



2) A grating panel that can take more load

• Design of the load bearing bar is hollow

• Yet, the integrity on the grating panel remained

intact.

• Litewalk grating can take 12% more load than

common steel grating of a same grade

Litewalk grating use at chemical plant



3) Cost benefit

• It consumes approximately 35% less raw

material to manufacture

• Cost of manufacturing is lower

• This cost saving is passed down to the

consumer…

• making Litewalk grating panel competitive in

price

Litewalk being used on walkways



4) A grating panel that is safer to walk-on

• The design of a hollow section bar allows the

creation of the embossed ring on the upper part

of the load bearing bar.

• These round rings provides a good anti-slip

traction on the foot wear.

• A person’s body mass weight is transferred to his

footwear

• thus naturally giving him a good grip when he

walks on the Litewalk grating panels.

Embossed rings that gives you a good grip


We would like to thank our research collaborator

UNIVERSITY of MALAYA, Kuala Lumpur

Thank You!

I’m pleased to take your questions

Bugs Tan PhD, Mastek Oil Tools MALAYSIA

[email protected]

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mailto:[email protected]

Engineering

Dr Bugs Tan ADIPEC Conference Paper 2017