Full liquid receiving floating disc and manufacturing method

Abstract

The application discloses a full-liquid floating disc and a manufacturing method thereof. The full-liquid floating disc comprises a floating disc body, wherein the floating disc body comprises a plurality of floating units which are connected into an integrated whole through splicing; the upper surface and the lower surface of the floating unit are provided with an electrostatic guide layer; and a carbon fiber surface felt is laid on the electrostatic guide layer and is cured to form the floating disc body. The application can avoid local insulation of the floating disc from being electrified and discharging to the grounding body, thereby avoiding the volatile oil gas in the storage tank from being ignited due to the electrostatic discharge, and effectively avoiding the fire accidents in the storage tank and the periphery.

Description

Technical Field

[0001] This invention relates to the field of oil and gas storage and transportation technology, specifically to a fully liquid-contact floating roof and its manufacturing method. Background Technology

[0002] Due to defects in structure, strength, operational stability, and sealing of floating roof equipment, the amount of oil volatilization is huge, which leads to excessively high oil and gas concentrations inside or around the storage tank, reaching the concentration of flammable volatile gases that can ignite and explode. Under the influence of lightning strikes or static sparks, fire accidents occur frequently inside and around the storage tank.

[0003] Chinese invention patent CN117585320A discloses a fiberglass floating roof structure and construction process. The fiberglass floating roof in this application adopts a hollow structure, significantly reducing its weight. Each annular buoyancy chamber is further divided into multiple compartments by a first, second, and third partition. This not only enhances the strength of the floating roof but also increases its anti-sinking performance due to the independence of each compartment. Even if individual compartments leak, it will not threaten the overall operational safety of the floating roof or the vertical storage tank. This increases the buoyancy of the floating roof while reducing its weight, increasing its buoyancy reserve, thereby improving its anti-sinking performance and practicality. However, this fiberglass floating roof structure and construction process still have issues regarding electrostatic charging and discharge protection of the insulating composite materials.

[0004] Existing floating roofs have failed to address the issue of electrostatic charging and discharge protection of insulating composite materials, resulting in localized electrical charging of the floating roof insulation and discharge to the grounding electrode, posing a risk of electrostatic discharge igniting volatile oil and gas inside the tank. Summary of the Invention

[0005] One objective of this invention is to provide a fully liquid-contaminated floating roof and its manufacturing method, so as to avoid the floating roof becoming partially insulated and discharging to the grounding body, thereby preventing the storage tank from igniting volatile oil and gas inside the tank due to electrostatic discharge, and avoiding fire accidents inside and around the storage tank.

[0006] According to the present invention, a fully liquid-contact floating disk includes: a floating disk body, the floating disk body including: a plurality of buoyancy units connected by splicing, the upper and lower surfaces of the buoyancy units are provided with an electrostatic conductive layer, and a carbon fiber surface felt is laid on the electrostatic conductive layer and cured to form the floating disk body.

[0007] In a preferred embodiment, the fully wetted floating roof further includes: a plurality of legs, the first end of the legs passing through the floating roof body and located on the upper surface of the floating roof body, the second end of the legs located below the floating roof body, and the outer surface of the legs being fitted with leg bushings for dissipating static electricity.

[0008] In a preferred embodiment, the fully wetted floating roof further includes an anti-rotation guide portion passing through the floating roof body near the edge of the floating roof body. The anti-rotation guide portion is disposed on the outside of the support leg, and the anti-rotation guide portion is provided with an antistatic sealing rubber on the outer periphery of the portion passing through the floating roof body.

[0009] In a preferred embodiment, the fully wetted floating roof further includes: a guide post passing through the floating roof body, the outer surface of the guide post being provided with a sealing sleeve, and the bottom end of the guide post and the bottom of the sealing sleeve being connected to the base.

[0010] In a preferred embodiment, the sealing sleeve is made of modified chlorosulfonated polyethylene rubber.

[0011] In a preferred embodiment, the fully liquid-contact floating roof further includes a vent valve, which includes a valve plug, a sleeve, a valve seat, and a grounding connection wire. The sleeve is disposed in the mounting hole of the floating roof body, the valve plug is disposed at the bottom of the sleeve, and the upper surface of the valve plug is provided with a gasket for dissipating static electricity. The valve plug and the sleeve can be sealed together by the gasket.

[0012] In a preferred embodiment, the sleeve has a valve seat inside and a grounding connection wire connected to its top. The valve seat is sealed to the float valve plug by the gasket.

[0013] In a preferred embodiment, the fully liquid-contact floating roof further includes a static electricity conductive mechanism, which includes a static electricity conductive wire, a lower plug-in, an upper plug-in, and a first plug-in cover plate and a second plug-in cover plate respectively disposed on the lower and upper surfaces of the floating roof body. The upper plug-in and the lower plug-in are respectively disposed on the upper surface of the second plug-in cover plate and the lower surface of the first plug-in cover plate. The upper surface of the lower plug-in is provided with a static electricity conductive wire, and the connecting end of the static electricity conductive wire passes through the first plug-in cover plate, the floating roof body, the second plug-in cover plate, and the upper plug-in in sequence.

[0014] In a preferred embodiment, the plurality of electrostatic conductive mechanisms are connected to each other via the connection end of the electrostatic conductive wire, and the connection end of the electrostatic conductive wire is connected to the floating disk body and its components.

[0015] This invention also provides a method for preparing a fully wetted floating roof, comprising the following steps:

[0016] S1. Build a horizontal plate inside the storage tank and lay the four prefabricated buoyancy units flat on the horizontal plate;

[0017] S2. Use a self-drilling screw to fix the joints of adjacent buoyancy units at the middle and cross joint positions to connect the adjacent buoyancy units into a whole, and fill the joints with filler and putty powder, wherein the composition of the putty powder is the same as the resin material used to make the buoyancy units.

[0018] S3. Using the same resin as the material used to make the buoyancy unit, through chopped strand mat, glass cloth and hand lay-up, the filler between the joints of adjacent buoyancy units is made into a rigid body around it, and forms an integral part with the buoyancy unit;

[0019] S4. Apply an electrostatic conductive layer to the upper and lower surfaces of the buoyancy unit, and lay carbon fiber surface felt on the surface of the electrostatic conductive layer. After curing, it becomes the floating table body.

[0020] In a preferred embodiment, step S1 further includes: grinding the upper and lower surfaces of the buoyancy unit before splicing.

[0021] In a preferred embodiment, step S4 specifically includes: S41, during the curing period, the upper and lower surfaces of the buoyancy unit are laid up using alternating cloth and felt to achieve the designed layering, each layer is uniformly coated with resin, and air bubbles are removed with a pressure roller; S42, when the reinforcing layer is in a gelled state, a layer of carbon fiber surface felt is laid on it, and then a conductive resin is uniformly coated, air bubbles are removed and the layer is flattened using a pressure roller.

[0022] This invention has at least the following technical effects:

[0023] According to the present invention, the floating roof body comprises multiple buoyancy units connected by splicing, thereby enabling the floating roof body to be formed inside the tank without hot work or adhesive bonding. Furthermore, since both the upper and lower surfaces of the buoyancy units are provided with an electrostatic conductive layer, and a carbon fiber surface felt is laid on the conductive layer, the conductivity is further enhanced. This prevents the floating roof from becoming locally insulated and discharging to the grounding electrode, thus preventing the storage tank from igniting volatile oil and gas inside the tank due to electrostatic discharge, and avoiding fire accidents inside and around the storage tank.

[0024] According to the present invention, the fully liquid-contact floating roof includes multiple electrostatic discharge mechanisms, and the multiple electrostatic discharge mechanisms are connected by the connection end of the electrostatic discharge wire. The electrostatic discharge wire is connected to the floating roof body and its components, thereby realizing that the upper and lower surfaces, sealing layer and other parts of the fully liquid-contact floating roof are electrically connected, avoiding the risk of static electricity accumulation or even discharge during the movement of the fully liquid-contact floating roof. Attached Figure Description

[0025] Figure 1 A schematic diagram of the overall structure of a fully wetted floating roof according to an embodiment of the present invention is shown.

[0026] Figure 2A schematic diagram illustrating the assembly of a floating roof body according to an embodiment of the present invention is shown.

[0027] Figure 3 A schematic diagram illustrating the connection of the electrostatic discharge wires of a fully liquid-contacted floating roof according to an embodiment of the present invention is shown.

[0028] Figure 4 A schematic diagram of the electrostatic discharge mechanism of a fully liquid-contact floating roof according to an embodiment of the present invention is shown.

[0029] Figure 5 A schematic diagram of the structure of the vent valve of a fully liquid-contact floating roof according to an embodiment of the present invention is shown.

[0030] Figure 6 A schematic diagram of a fully wetted floating roof according to another embodiment of the present invention is shown.

[0031] As shown in the figure:

[0032] The fully liquid-contact floating roof-100 described in this invention;

[0033] Floating plate body-1;

[0034] Buoyancy Unit-11;

[0035] Electrostatic conductive layer -105;

[0036] Seal - 2;

[0037] Outriggers -3;

[0038] Guide column-4;

[0039] Anti-rotation rope-5;

[0040] Manhole-6;

[0041] Sampling hole -7;

[0042] Electrostatic discharge mechanism -8;

[0043] Second plug-in cover plate 82;

[0044] Add plugin 83;

[0045] 84-inch conductive wire;

[0046] First plug-in cover plate 85;

[0047] Download plugin 86;

[0048] Vent valve-9;

[0049] Floating valve plug-91;

[0050] Sleeve-92;

[0051] Valve seat-93

[0052] Grounding connection wire -94;

[0053] Another embodiment of the present invention: a fully liquid-contact floating roof-200;

[0054] In this application, all drawings are schematic and are used only to illustrate the principles of the invention, and are not drawn to scale. Detailed Implementation

[0055] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0056] In the description of this invention, it should be understood that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. In this invention, "a plurality of" refers to two or more.

[0057] It should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. "A plurality of" in this invention refers to two or more.

[0058] In this invention, unless otherwise explicitly specified and limited, the term "connection" should be interpreted broadly. For example, it can be a fixed connection, a detachable connection, an integral or interconnected connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0059] Example 1

[0060] like Figure 1 and Figure 2The diagram illustrates, schematically, the overall structure of a fully wetted floating roof according to an embodiment of the present invention. The fully wetted floating roof 100 of the present invention includes: a floating roof body 1, which comprises multiple buoyancy units 11 connected together in an integral manner. Optionally, the buoyancy units 11 are prefabricated in a factory using resin with both mechanical and corrosion-resistant properties, and matching glass fiber products. Optionally, all buoyancy units 11 are constructed as cuboids with a width of 200-240 mm, a thickness of 60-100 mm, and a length of 2000 mm. The buoyancy units 11 are joined together at adjacent seams to form a plate-like integral structure. A conductive layer 105 is provided on both the upper and lower surfaces of the buoyancy units 11, and a carbon fiber surface felt is laid on the conductive layer 105. After curing, the floating roof body 1 is formed. The resistivity of both the upper and lower surfaces of the floating roof body 1 is less than 10⁹ Ω. The tank wall is provided with a manhole 6 and a sampling hole 7. Multiple buoyancy units 11 can be transported into the tank through the manhole 6 on the inner wall of the tank.

[0061] According to the present invention, the floating roof body 1 includes a plurality of buoyancy units 11 connected together, thereby enabling the floating roof body 1 to be formed inside the tank without hot work or adhesive. Furthermore, since both the upper and lower surfaces of the buoyancy units 11 are provided with an electrostatic conductive layer 105, and a carbon fiber surface felt is laid on the electrostatic conductive layer 105, the electrostatic conductivity is further enhanced, preventing the floating roof from becoming locally insulated and discharging to the grounding body. This prevents the storage tank from igniting volatile oil and gas inside the tank due to electrostatic discharge, thus avoiding fire accidents inside and around the storage tank.

[0062] In one or more embodiments, the buoyancy unit 11 can be a standard plate with regular dimensions (for example, in this embodiment, the width of the standard plate is 500-550mm, which enters the storage tank directly through the manhole in the tank wall, and the length can be designed according to the inner diameter of the tank; optionally, the length of the standard plate is 2000mm-3000mm), an irregularly shaped plate, or an edge plate. The main structural function of the irregularly shaped plate and the edge plate is the same as that of the standard plate, and the thickness is also 600-1000mm. The specific shape and size are measured according to the on-site installation parameters of the buoyancy unit. The edge plate in the buoyancy unit is installed on the edge of the floating roof after the buoyancy unit 11 is assembled, so that the floating roof forms a circle for installing the seal 2.

[0063] In one or more embodiments, since the surface of the buoyancy unit 11 is an insulating surface, the upper and lower surfaces of the buoyancy unit 11 are polished before being assembled into the tank. Optionally, a grinding wheel or sandpaper is used to polish the upper and lower surfaces of the buoyancy unit 11.

[0064] like Figure 2As shown, a horizontal platform is constructed inside the storage tank, and four prefabricated buoyancy units 11 are laid flat on the platform. Self-drilling screws are used to fix the adjacent buoyancy units 11 at the midpoint and cross-joint positions of their seams, connecting them into a single unit. The seams are filled with filler (e.g., flame-retardant porous polypropylene (PP), polyurethane, polyvinyl chloride foam modules, etc.) and putty powder, the composition of which is the same as the resin material used to manufacture the buoyancy units 11. Using the same resin material as the buoyancy units 11, chopped strand mat, glass cloth, and hand lay-up methods are used to form a rigid body around the filler between the seams of adjacent buoyancy units 11, creating a unified structure with the buoyancy units 11. This achieves the buoyancy units 11 through thermosetting bonding at the bottom and top.

[0065] After all the buoyancy units 11 are assembled into one unit, an electrostatic conductive layer 105 is applied to the upper and lower surfaces of the buoyancy units 11, and a carbon fiber surface felt is laid on the surface of the electrostatic conductive layer 105. After curing, it becomes the floating disk body 1. The specific steps are as follows: In the fully cured modules, the upper and lower parts of the buoyancy units 11 are laid in an alternating manner using cloth felt to achieve the designed layering, and the seams between the layers are staggered, with a fiber overlap width of not less than 50mm. Resin is evenly applied to each layer to ensure the resin content, and air bubbles are removed with a pressure roller; when the electrostatic conductive resin is mixed according to the ratio and the reinforcing layer (i.e., the layer formed by the electrostatic conductive resin) on the upper and lower parts of the floating disk is in a gelled state, a layer of surface felt is laid on it. The surface felt should be continuous, and the overlap width should not be less than 10mm. Then, the mixed electrostatic conductive resin is evenly applied to ensure the resin content, and air bubbles are removed and the surface is flattened using a pressure roller to allow it to fully cure.

[0066] In one or more embodiments, the fully wetted floating roof 100 of the present invention further includes: a plurality of legs 3, the first end of the legs 3 passing through the floating roof body 1 and located on the upper surface of the floating roof body 1, the second end of the legs 3 located below the floating roof body 1, and a leg bushing fitted on the outer surface of the legs 3 for discharging static electricity. Optionally, the legs 3 are perpendicular to the floating roof body 1. Optionally, the legs 3 are constructed as hollow cylinders and made of glass. After the floating roof body 1 is assembled, the legs 3 can be installed. During installation, holes are made in the floating roof body 1, and the edges of the holes are cured with resin of the same material as the floating roof body 1; the leg bushing passes through the bottom of the floating roof body 1, and the bushing disc is coated with fiberglass putty to fully adhere to the bottom surface of the floating roof body 1; after the leg bushing is fixed, the legs 3 are passed through the leg bushing and bonded to the leg bushing. The first end of the support leg 3, which extends from the upper surface of the floating body 1, is wrapped with the same layer to achieve anti-static properties.

[0067] After the outriggers 3 are installed, mounting holes are made on the upper surface of the floating platform body 1. The edges of these mounting holes are cured with resin of the same material as the floating platform body 1 to facilitate the installation of corresponding floating platform accessories. These accessories include one or more of the following: anti-rotation rope 5, manhole 6, sampling port 7, and vent valve 9. During the splicing process between the floating platform accessories and the floating platform body 1, putty powder is filled at the joints. The putty powder composition is the same as the resin material of the buoyancy unit 11. Using chopped strand mat, glass cloth, and hand lay-up, the filler between the joints of the buoyancy unit 11 forms a rigid body with the surrounding area, becoming an integral part of the buoyancy unit 11. After the floating platform accessories and the floating platform body 1 are spliced ​​together, an electrostatic conductive layer is applied to the connection between the upper and lower surfaces of the floating platform accessories and the floating platform body 1. Then, carbon fiber surface felt is laid, and after curing, it becomes the floating platform body 1, achieving electrical connection between the electrostatic conductive layers on the surfaces of the floating platform accessories and the floating platform body 1.

[0068] like Figure 3 and Figure 4 As shown, in one or more embodiments, a static discharge mechanism 8 is further included. The static discharge mechanism 8 includes: a static discharge wire 84, a lower plug-in 86, a first plug-in cover plate 85, a second plug-in cover plate 82, and an upper plug-in 83. The first plug-in cover plate 85 and the second plug-in cover plate 82 are respectively disposed on the lower surface and the upper surface of the floating disk body 1. The upper plug-in 83 and the lower plug-in 86 are respectively disposed on the upper surface and the lower surface of the second plug-in cover plate 82 and the first plug-in cover plate 85. A static discharge wire is disposed on the upper surface of the lower plug-in 86. The connection end of the static discharge wire 84 passes sequentially through the first plug-in cover plate 85, the floating disk body 1, the second plug-in cover plate 82, and the upper plug-in 83.

[0069] In one or more embodiments, the fully liquid-contact floating roof 100 includes a plurality of electrostatic discharge mechanisms 8, which are connected to each other by the connection ends of electrostatic discharge wires 84. The connection ends of the electrostatic discharge wires 84 are connected to the floating roof body 1 and its components, including but not limited to seals 2, legs 3, guide posts 4, anti-rotation ropes 5, manholes 6, sampling holes 7, and vent valves 9.

[0070] According to the present invention, the fully liquid-contact floating disk 100 includes a plurality of electrostatic discharge mechanisms 8, which are connected to each other by electrostatic discharge wires 84. The electrostatic discharge wires 84 are connected to the floating disk body 1, the seal 2, the support leg 3, the guide column 4, the anti-rotation rope 5, the manhole 6, the sampling hole 7, and the vent valve 9, so as to realize the electrical connection of the entire fully liquid-contact floating disk 100 and avoid the risk of static electricity accumulation or even discharge during the movement of the fully liquid-contact floating disk 100.

[0071] Specifically, fiberglass putty is applied to the surfaces of both the second plug-in cover plate 82 and the first plug-in cover plate 85, and then pressed around the through hole of the buoyancy unit 11. The electrostatic conductive wire 84, located on the upper surface of the lower plug-in 86, is inserted through the bottom of the first plug-in cover plate 85 and passes through the through hole of the buoyancy unit 11, and is fixed by the upper plug-in 83. The electrostatic conductive wire 84 is bonded and fixed above the buoyancy unit 11 using electrostatic conductive resin and surface carbon fiber. By setting the electrostatic conductive wire 84, electrical communication between the upper and lower surfaces of the floating roof is ensured, and the resistance of the upper and lower surfaces of the fully liquid-contact floating roof 100 and the tank wall of the storage tank is not greater than 0.5 × 10⁶ Ω.

[0072] In one or more embodiments, the fully wetted floating roof 100 further includes a sealing element 2 disposed between the floating roof body 1 and the tank body of the storage tank. The sealing element 2 employs an elastic seal and a secondary tongue-shaped scraper seal to compensate for circumferential gap dimensional deviations, while ensuring sufficient flexibility and tight fit with the tank wall, thereby achieving good sealing performance. It should be noted that, to control static electricity in the seal, the connection ends of the conductive wire 84 can be connected to the static grounding plate terminal block at 0°, 90°, 180°, and 270° on the inner wall of the storage tank, using the tank's axis as a reference, to achieve anti-static properties.

[0073] In one or more embodiments, the fully wetted floating roof 100 further includes an anti-rotation guide 5 passing through the floating roof body 1 near the edge of the floating roof body 1. The anti-rotation guide 5 is disposed on the outside of the support leg 3 to prevent the floating roof body 1 from rotating. Optionally, the anti-rotation guide 5 is made of stainless steel anti-rotation rope. The anti-rotation guide 5 is provided with an anti-static sealing rubber on the outer periphery of the part passing through the floating roof body 1 to seal the opening of the floating roof body 1, while ensuring that the anti-rotation guide 5 and the floating roof body 1 do not generate static electricity through friction when the floating roof body 1 moves up and down.

[0074] In one or more embodiments, the fully wetted floating roof 100 further includes: a guide post 4 passing through the floating roof body 1, the guide post 4 being disposed inside the anti-rotation guide portion 5, and having a sealing sleeve on its outer surface; the bottom end of the guide post 4 being connected to the base; the sealing sleeve enclosing the guide post 4 and its bottom being connected to the base; optionally, the sealing sleeve and the base are connected by bolts. The top of the sealing sleeve is sealed with a sealing rubber sheet in conjunction with three layers of annular pressure plates. The sealing rubber sheet and the annular pressure plates are fixed in a cross-shaped manner. After the sealing rubber sheet is connected to the sealing sleeve, a seal is formed and it fits against the guide post 4 to achieve an overall seal.

[0075] Since the sealing bladder can move up and down with the floating roof body 1, to prevent fire and explosion accidents caused by electrostatic discharge, the sealing bladder is made of a telescopic bladder with excellent conductivity, corrosion resistance, and flame retardant properties. Optionally, in this embodiment, the sealing bladder is made of modified chlorosulfonated polyethylene rubber. On the one hand, modified chlorosulfonated polyethylene rubber has strong weather resistance and strong resistance to media, resulting in a long service life; on the other hand, modified chlorosulfonated polyethylene rubber has conductive properties, which can quickly discharge generated static electricity to achieve antistatic properties and prevent the accumulation of static sparks that could cause safety accidents. In addition, modified chlorosulfonated polyethylene rubber is a flame-retardant material with an oxygen index of over 30.

[0076] All independent components of the fully wetted floating roof 100 of this invention are connected to the static discharge grounding plate via the connection end of the static discharge wire 84, which can be made of stainless steel wire rope. The length margin of the static discharge wire 84 is not less than 1000 mm. All metal parts of the fully wetted floating roof 100 of this invention are electrically connected to each other and connected to the external grounding device of the tank through the tank wall.

[0077] In one or more embodiments, such as Figure 5 As shown, the fully wetted floating roof 100 of the present invention further includes a vent valve 9 designed with a fully wetted structure, used to expel gas from the lower space of the fully wetted floating roof 100 when the storage tank is initially filled with liquid. The vent valve 9 includes a float valve plug 91, a sleeve 92, a valve seat 93, and a grounding connection wire 94. The sleeve 92 is disposed in the mounting hole of the floating roof body 1 and is constructed in an inverted conical shape. The float valve plug 91 is disposed at the bottom of the sleeve 92, and a gasket for dissipating static electricity is disposed on the upper surface of the float valve plug 91. The gasket is fully bonded to the upper surface and side of the float valve plug 91. When the vent valve 9 moves upward due to the liquid entering the storage tank, the float valve plug 91 and the sleeve 92 are sealed together by the gasket to achieve anti-static effect.

[0078] The sleeve 92 contains a valve seat 93, which is optionally conical. Two grounding wires 94 are connected to the top of the sleeve 92. Optionally, the grounding wires 94, sleeve 92, and valve seat 93 are all fastened with threaded fittings. Optionally, the two grounding wires 94 are positioned opposite each other at the top of the sleeve 92 to suspend the float valve plug 91, preventing it from falling when the liquid level inside the tank is lower than the support leg 3. A gasket is used in the middle of the valve seat 93 to achieve a secondary seal with the float valve plug 91. Optionally, the gasket is made of PTFE. The float valve plug 91 is connected to the static electricity dissipation mechanism 8 via the connection end of the static electricity dissipation wire 84, thereby preventing the float valve plug 91 from sloshing and accumulating static electricity at the liquid interface.

[0079] Based on the above-mentioned fully liquid-contact floating roof 100, the present invention also provides a method for preparing a fully liquid-contact floating roof, comprising the following steps:

[0080] S1. Build a horizontal plate inside the storage tank and lay the four prefabricated buoyancy units 11 on the horizontal plate.

[0081] S2. Use a self-drilling screw to fix the joints of adjacent buoyancy units 11 at the middle position and the cross joint position to connect the adjacent buoyancy units 11 into a whole, and fill the joint with filler (e.g., flame-retardant porous polypropylene PP, polyurethane, polyvinyl chloride foam module, etc.) and putty powder, wherein the composition of the putty powder is the same as the resin material used to make the buoyancy unit 11.

[0082] S3. Using the same resin as the material used to make the buoyancy unit 11, through chopped strand mat, glass cloth and hand lay-up, a rigid body is formed around the filler between the joints of adjacent buoyancy units 11, and it is integrated with the buoyancy unit 11, so that the buoyancy unit 11 is formed by thermosetting connection at the bottom and top.

[0083] S4. After all the buoyancy units 11 are assembled into one unit, an electrostatic conductive layer 105 is applied to the upper and lower surfaces of the buoyancy units 11, and a carbon fiber surface felt is laid on the surface of the electrostatic conductive layer 105. After curing, it becomes the floating disk body 1.

[0084] In one or more embodiments, step S4 specifically includes: S41, during the curing period, the upper and lower parts of the buoyancy unit 11 are laid up in an alternating manner with cloth and felt to achieve the designed layering, and the seams between the layers are staggered, the fiber overlap width is not less than 50mm, each layer is uniformly coated with resin to ensure the resin content, and air bubbles are removed with a pressure roller; S42, when the conductive resin is mixed in proportion and the reinforcing layer on the upper and lower surfaces of the floating plate body 1 is in a gelled state, a layer of carbon fiber surface felt is laid on it. The carbon fiber surface felt should be continuous and the overlap width should not be less than 10mm. Then, the mixed conductive resin is uniformly coated to ensure the resin content, and air bubbles are removed and the surface is flattened with a pressure roller to allow it to fully cure.

[0085] In one or more embodiments, the preparation method of the fully liquid-contact floating roof further includes: S5, applying fiberglass putty to the surfaces of the second plug-in cover plate 82 and the first plug-in cover plate 85, and pressing it around the through hole of the buoyancy unit 11; S6, inserting the electrostatic conductive wire 84 provided on the upper surface of the lower plug-in 86 through the bottom of the first plug-in cover plate 85 and through the through hole of the buoyancy unit 11, and fixing it through the upper plug-in 83; S7, bonding and fixing the electrostatic conductive wire 84 to the upper part of the buoyancy unit 11 with electrostatic conductive resin and surface carbon fiber.

[0086] Example 2

[0087] Figure 6A schematic diagram of a fully wetted floating roof according to another embodiment of the present invention is shown. Because conventional metal floating roofs, such as carbon steel or stainless steel floating roofs, suffer from corrosion problems at the media contact points, this embodiment employs a composite of a fiberglass floating roof and a metal floating roof to create a composite metal floating roof. Figure 6 As shown, the fully wetted floating roof 200 of the present invention includes: a floating roof body 1 and a metal disc 10 located on the upper surface of the floating roof body 1. The floating roof body 1 is directly cured and molded under the metal floating roof 10 using composite resin, thereby achieving curing and bonding between the composite material floating roof body 1 and the metal floating roof 10. The floating roof body 1 contacts the liquid surface through a corrosion-resistant composite material, thus avoiding direct contact between the metal floating roof 10 and the stored liquid, and completely avoiding the disadvantages of metal disc corrosion. The floating roof body 1 includes multiple buoyancy units 11 connected together. Optionally, the buoyancy units 11 are prefabricated in a factory using resin with both mechanical and corrosion-resistant properties and matching glass fiber products. Optionally, each buoyancy unit 11 is constructed as a cuboid with a width of 200-240 mm, a thickness of 60-100 mm, and a length of 2000 mm. Each buoyancy unit 11 is spliced ​​into a plate shape at adjacent seams. Both the upper and lower surfaces of the buoyancy unit 11 are provided with an electrostatic conductive layer 105, upon which a carbon fiber surface felt is laid. After curing, the floating disk body 1 is formed. The resistivity of both the upper and lower surfaces of the floating disk body 1 is less than 10⁹ Ω. The tank wall is provided with a manhole 6 and a sampling port 7. Multiple buoyancy units 11 can be transported into the tank through the manhole 6 on the inner wall of the tank.

[0088] According to the present invention, the fully wetted floating roof 200 includes: a floating roof body 1 and a metal disc 10 disposed on the upper surface of the floating roof body 1, which can completely avoid the drawbacks of metal disc corrosion. Furthermore, since the floating roof body 1 includes multiple buoyancy units 11 connected together, the floating roof body 1 can be formed inside the tank without hot work or adhesive bonding. Moreover, since both the upper and lower surfaces of the buoyancy units 11 are provided with an electrostatic conductive layer 105, and a carbon fiber surface felt is laid on the electrostatic conductive layer 105, the electrostatic conductivity is further enhanced, preventing the floating roof from becoming locally insulated and discharging to the grounding body, thereby preventing the storage tank from igniting volatile oil and gas inside the tank due to electrostatic discharge, effectively preventing fire accidents inside and around the storage tank.

[0089] In one or more embodiments, the buoyancy unit 11 can be a standard plate with regular dimensions (for example, in this embodiment, the width of the standard plate is 500-550mm, which enters the storage tank directly through the manhole in the tank wall, and the length can be designed according to the inner diameter of the tank; optionally, the length of the standard plate is 2000mm-3000mm), an irregularly shaped plate, or an edge plate. The main structural function of the irregularly shaped plate and the edge plate is the same as that of the standard plate, and the thickness is also 600-1000mm. The specific shape and size are measured according to the on-site installation parameters of the buoyancy unit. The edge plate in the buoyancy unit is installed on the edge of the floating roof after the buoyancy unit 11 is assembled, so that the floating roof forms a circle for installing the seal 2.

[0090] In one or more embodiments, since the surface of the buoyancy unit 11 is an insulating surface, the upper and lower surfaces of the buoyancy unit 11 are polished before being assembled into the tank. Optionally, a grinding wheel or sandpaper is used to polish the upper and lower surfaces of the buoyancy unit 11.

[0091] like Figure 2 As shown, a horizontal platform is constructed inside the storage tank, and four prefabricated buoyancy units 11 are laid flat on the platform. Self-drilling screws are used to fix the adjacent buoyancy units 11 at the midpoint and cross-joint positions of their seams, connecting them into a single unit. The seams are filled with filler (e.g., flame-retardant porous polypropylene (PP), polyurethane, polyvinyl chloride foam modules, etc.) and putty powder, the composition of which is the same as the resin material used to manufacture the buoyancy units 11. Using the same resin material as the buoyancy units 11, chopped strand mat, glass cloth, and hand lay-up methods are used to form a rigid body around the filler between the seams of adjacent buoyancy units 11, creating a unified structure with the buoyancy units 11. This achieves the buoyancy units 11 through thermosetting bonding at the bottom and top.

[0092] After all the buoyancy units 11 are assembled into one unit, an electrostatic conductive layer 105 is applied to the upper and lower surfaces of the buoyancy units 11, and a carbon fiber surface felt is laid on the surface of the electrostatic conductive layer 105. After curing, it becomes the floating disk body 1. The specific steps are as follows: In the fully cured modules, the upper and lower parts of the buoyancy units 11 are laid in an alternating cloth felt manner to achieve the designed layering, and the seams between the layers are staggered, with a fiber overlap width of not less than 50mm. Resin is evenly applied to each layer to ensure the resin content, and air bubbles are removed with a pressure roller; the electrostatic conductive resin is mixed according to the ratio, and when the upper and lower reinforcing layers of the floating disk are in a gelled state, a layer of surface felt is laid on top of them. The surface felt should be continuous, and the overlap width should not be less than 10mm. Then, the mixed electrostatic conductive resin is evenly applied to ensure the resin content, and air bubbles are removed and the surface is flattened using a pressure roller to allow it to fully cure.

[0093] In one or more embodiments, the fully wetted floating roof 100 of the present invention further includes: a plurality of legs 3, the first end of the legs 3 passing through the floating roof body 1 and located on the upper surface of the floating roof body 1, the second end of the legs 3 located below the floating roof body 1, and a leg bushing fitted on the outer surface of the legs 3 for discharging static electricity. Optionally, the legs 3 are perpendicular to the floating roof body 1. Optionally, the legs 3 are constructed as hollow cylinders and made of glass. After the floating roof body 1 is assembled, the legs 3 can be installed. During installation, holes are made in the floating roof body 1, and the edges of the holes are cured with resin of the same material as the floating roof body 1; the leg bushing passes through the bottom of the floating roof body 1, and the bushing disc is coated with fiberglass putty to fully adhere to the bottom surface of the floating roof body 1; after the leg bushing is fixed, the legs 3 are passed through the leg bushing and bonded to the leg bushing. The first end of the support leg 3, which extends from the upper surface of the floating body 1, is wrapped with the same layer to achieve anti-static properties.

[0094] After the outriggers 3 are installed, mounting holes are made on the upper surface of the floating platform body 1. The edges of these mounting holes are cured with resin of the same material as the floating platform body 1 to facilitate the installation of corresponding floating platform accessories. These accessories include one or more of the following: anti-rotation rope 5, manhole 6, sampling port 7, and vent valve 9. During the splicing process between the floating platform accessories and the floating platform body 1, putty powder is filled at the joints. The putty powder composition is the same as the resin material of the buoyancy unit 11. Using chopped strand mat, glass cloth, and hand lay-up, the filler between the joints of the buoyancy unit 11 forms a rigid body with the surrounding area, becoming an integral part of the buoyancy unit 11. After the floating platform accessories and the floating platform body 1 are spliced ​​together, an electrostatic conductive layer is applied to the connection between the upper and lower surfaces of the floating platform accessories and the floating platform body 1. Then, carbon fiber surface felt is laid, and after curing, it becomes the floating platform body 1, achieving electrical connection between the electrostatic conductive layers on the surfaces of the floating platform accessories and the floating platform body 1.

[0095] like Figure 3 and Figure 4 As shown, in one or more embodiments, a static discharge mechanism 8 is further included. The static discharge mechanism 8 includes: a static discharge wire 84, a lower plug-in 86, a first plug-in cover plate 85, a second plug-in cover plate 82, and an upper plug-in 83. The first plug-in cover plate 85 and the second plug-in cover plate 82 are respectively disposed on the lower surface and the upper surface of the floating disk body 1. The upper plug-in 83 and the lower plug-in 86 are respectively disposed on the upper surface and the lower surface of the second plug-in cover plate 82 and the first plug-in cover plate 85. A static discharge wire is disposed on the upper surface of the lower plug-in 86. The connection end of the static discharge wire 84 passes sequentially through the first plug-in cover plate 85, the floating disk body 1, the second plug-in cover plate 82, and the upper plug-in 83.

[0096] In one or more embodiments, the fully liquid-contact floating roof 100 includes a plurality of electrostatic discharge mechanisms 8, which are connected to each other by the connection ends of electrostatic discharge wires 84. The connection ends of the electrostatic discharge wires 84 are connected to the floating roof body 1 and its components, including but not limited to seals 2, legs 3, guide posts 4, anti-rotation ropes 5, manholes 6, sampling holes 7, and vent valves 9.

[0097] According to the present invention, the fully liquid-contact floating disk 100 includes a plurality of electrostatic discharge mechanisms 8, which are connected to each other by electrostatic discharge wires 84. The electrostatic discharge wires 84 are connected to the floating disk body 1, the seal 2, the support leg 3, the guide column 4, the anti-rotation rope 5, the manhole 6, the sampling hole 7, and the vent valve 9, so as to realize the electrical connection of the entire fully liquid-contact floating disk 100 and avoid the risk of static electricity accumulation or even discharge during the movement of the fully liquid-contact floating disk 100.

[0098] Specifically, fiberglass putty is applied to the surfaces of both the second plug-in cover plate 82 and the first plug-in cover plate 85, and then pressed around the through hole of the buoyancy unit 11. The electrostatic conductive wire 84, located on the upper surface of the lower plug-in 86, is inserted through the bottom of the first plug-in cover plate 85 and passes through the through hole of the buoyancy unit 11, and is fixed by the upper plug-in 83. The electrostatic conductive wire 84 is bonded and fixed above the buoyancy unit 11 using electrostatic conductive resin and surface carbon fiber. By setting the electrostatic conductive wire 84, electrical communication between the upper and lower surfaces of the floating roof is ensured, and the resistance of the upper and lower surfaces of the fully liquid-contact floating roof 100 and the tank wall of the storage tank is not greater than 0.5 × 10⁶ Ω.

[0099] In one or more embodiments, the fully wetted floating roof 100 further includes a sealing element 2 disposed between the floating roof body 1 and the tank body of the storage tank. The sealing element 2 employs an elastic seal and a secondary tongue-shaped scraper seal to compensate for circumferential gap dimensional deviations, while ensuring sufficient flexibility and tight fit with the tank wall, thereby achieving good sealing performance. It should be noted that, to control static electricity in the seal, the connection ends of the conductive wire 84 can be connected to the static grounding plate terminal block at 0°, 90°, 180°, and 270° on the inner wall of the storage tank, using the tank's axis as a reference, to achieve anti-static properties.

[0100] In one or more embodiments, the fully wetted floating roof 100 further includes an anti-rotation guide 5 passing through the floating roof body 1 near the edge of the floating roof body 1. The anti-rotation guide 5 is disposed on the outside of the support leg 3 to prevent the floating roof body 1 from rotating. Optionally, the anti-rotation guide 5 is made of stainless steel anti-rotation rope. The anti-rotation guide 5 is provided with an anti-static sealing rubber on the outer periphery of the part passing through the floating roof body 1 to seal the opening of the floating roof body 1, while ensuring that the anti-rotation guide 5 and the floating roof body 1 do not generate static electricity through friction when the floating roof body 1 moves up and down.

[0101] In one or more embodiments, the fully wetted floating roof 100 further includes: a guide post 4 passing through the floating roof body 1, the guide post 4 being disposed inside the anti-rotation guide portion 5, and having a sealing sleeve on its outer surface; the bottom end of the guide post 4 being connected to the base; the sealing sleeve enclosing the guide post 4 and its bottom being connected to the base; optionally, the sealing sleeve and the base are connected by bolts. The top of the sealing sleeve is sealed with a sealing rubber sheet in conjunction with three layers of annular pressure plates. The sealing rubber sheet and the annular pressure plates are fixed in a cross-shaped manner. After the sealing rubber sheet is connected to the sealing sleeve, a seal is formed and it fits against the guide post 4 to achieve an overall seal.

[0102] Since the sealing bladder can move up and down with the floating roof body 1, to prevent fire and explosion accidents caused by electrostatic discharge, the sealing bladder is made of a telescopic bladder with excellent conductivity, corrosion resistance, and flame retardant properties. Optionally, in this embodiment, the sealing bladder is made of modified chlorosulfonated polyethylene rubber. On the one hand, modified chlorosulfonated polyethylene rubber has strong weather resistance and strong resistance to media, resulting in a long service life; on the other hand, modified chlorosulfonated polyethylene rubber has conductive properties, which can quickly discharge generated static electricity to achieve antistatic properties and prevent the accumulation of static sparks that could cause safety accidents. In addition, modified chlorosulfonated polyethylene rubber is a flame-retardant material with an oxygen index of over 30.

[0103] All independent components of the fully wetted floating roof 100 of this invention are connected to the static discharge grounding plate via the connection end of the static discharge wire 84, which can be made of stainless steel wire rope. The length margin of the static discharge wire 84 is not less than 1000 mm. All metal parts of the fully wetted floating roof 100 of this invention are electrically connected to each other and connected to the external grounding device of the tank through the tank wall.

[0104] In one or more embodiments, such as Figure 5 As shown, the fully wetted floating roof 100 of the present invention further includes a vent valve 9 designed with a fully wetted structure, used to expel gas from the lower space of the fully wetted floating roof 100 when the storage tank is initially filled with liquid. The vent valve 9 includes a float valve plug 91, a sleeve 92, a valve seat 93, and a grounding connection wire 94. The sleeve 92 is disposed in the mounting hole of the floating roof body 1 and is constructed in an inverted conical shape. The float valve plug 91 is disposed at the bottom of the sleeve 92, and a gasket for dissipating static electricity is disposed on the upper surface of the float valve plug 91. The gasket is fully bonded to the upper surface of the float valve plug 91. When the vent valve 9 moves upward due to the liquid entering the storage tank, the float valve plug 91 and the sleeve 92 are sealed together by the gasket to achieve anti-static effect.

[0105] The sleeve 92 contains a valve seat 93, which is optionally conical. Two grounding wires 94 are connected to the top of the sleeve 92. Optionally, the grounding wires 94, sleeve 92, and valve seat 93 are all fastened with threaded fittings. Optionally, the two grounding wires 94 are positioned opposite each other at the top of the sleeve 92 to suspend the float valve plug 91, preventing it from falling when the liquid level inside the tank is lower than the support leg 3. A gasket is used in the middle of the valve seat 93 to achieve a secondary seal with the float valve plug 91. Optionally, the gasket is made of PTFE. The float valve plug 91 is connected to the static electricity dissipation mechanism 8 via the connection end of the static electricity dissipation wire 84, thereby preventing the float valve plug 91 from sloshing and accumulating static electricity at the liquid interface.

[0106] Based on the above-mentioned fully liquid-contact floating roof 200, the present invention also provides a method for manufacturing a fully liquid-contact floating roof, comprising the following steps:

[0107] S1. The bottom of the metal floating roof 10 is rinsed and polished smooth. A small modular assembly method for the floating roof buoyancy unit is used, and the conductive resin is prepared according to the specified ratio. A layer of surface felt is laid on the bottom of the metal floating roof, with the surface felt continuous and the overlap width not less than 10mm. Then, the prepared conductive resin is evenly applied, ensuring the resin content is correct. Air bubbles are removed using a pressure roller, and the surface is flattened.

[0108] S2. At the bottom of the metal floating roof 10, an alternating layering method of fabric and felt is adopted, with staggered seams between layers and a fiber overlap width of not less than 50mm. Resin is evenly applied to each layer to ensure the resin content, and air bubbles are removed with a pressure roller to prepare a composite material reinforcement layer. Optionally, to increase the buoyancy of the floating roof, prefabricated standard units of composite material floating roofs are laid on the fabric and felt layer.

[0109] S3. The prefabricated buoyancy unit is designed with alternating cloth and felt layers, with staggered seams between layers and fiber overlap width not less than 50mm. Resin is evenly applied to each layer to ensure resin content. Air bubbles are removed with a pressure roller to prepare the composite material reinforcement layer.

[0110] S4. When the composite material reinforcement layer is in a gelled state, lay a layer of surface felt on top. The surface felt should be continuous, and the overlap width should not be less than 10mm. Then, evenly apply the prepared conductive resin, ensuring the resin content is correct. Use a roller to remove air bubbles and flatten the surface to allow it to fully cure.

[0111] Although the invention has been described with reference to preferred embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, the technical features mentioned in the various embodiments can be combined in any manner as long as there is no structural conflict. The invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A fully liquid-contact floating roof, comprising: The floating table body includes multiple buoyancy units connected by splicing. The upper and lower surfaces of the buoyancy units are provided with an electrostatic conductive layer, and a carbon fiber surface felt is laid on the electrostatic conductive layer and cured to form the floating table body.

2. The fully liquid-contact floating roof according to claim 1, characterized in that, Also includes: Multiple outriggers, with the first end of each outrigger passing through the floating disk body and located on the upper surface of the floating disk body, and the second end of each outrigger located below the floating disk body. Outrigger bushings are fitted onto the outer surface of each outrigger for discharging static electricity.

3. The fully wetted floating roof according to claim 2, characterized in that, It also includes an anti-rotation guide portion that passes through the floating table body near the edge of the floating table body. The anti-rotation guide portion is located on the outside of the support leg, and the anti-rotation guide portion is provided with an anti-static sealing rubber on the outer periphery of the part of the anti-rotation guide portion that passes through the floating table body.

4. The fully liquid-contact floating roof according to claim 1, characterized in that, Also includes: A guide post passes through the floating roof body, and a sealing sleeve is provided on the outer surface of the guide post. The bottom end of the guide post and the bottom of the sealing sleeve are both connected to the base.

5. The fully wetted floating roof according to claim 4, characterized in that, The sealing sleeve is made of modified chlorosulfonated polyethylene rubber.

6. The fully wetted floating roof according to claim 1, characterized in that, Also includes: A vent valve includes a float valve plug, a sleeve, a valve seat, and a grounding connection wire. The sleeve is disposed in the mounting hole of the float body, the float valve plug is disposed at the bottom of the sleeve, and the upper surface of the float valve plug is provided with a gasket for dissipating static electricity. The float valve plug and the sleeve can be sealed together by the gasket.

7. The fully wetted floating roof according to claim 6, characterized in that, The sleeve has a valve seat inside and a grounding connection wire connected to the top. The valve seat is sealed to the float valve plug by the gasket.

8. The fully wetted floating roof according to claim 1, characterized in that, It also includes a static discharge mechanism, which includes: a static discharge wire, a lower plug-in, an upper plug-in, and a first plug-in cover plate and a second plug-in cover plate respectively disposed on the lower and upper surfaces of the floating disk body. The upper plug-in and the lower plug-in are respectively disposed on the upper surface of the second plug-in cover plate and the lower surface of the first plug-in cover plate. A static discharge wire is disposed on the upper surface of the lower plug-in. The connecting end of the static discharge wire passes through the first plug-in cover plate, the floating disk body, the second plug-in cover plate, and the upper plug-in in sequence.

9. The fully wetted floating roof according to claim 8, characterized in that, Multiple electrostatic conductive mechanisms are connected to each other via the connection ends of the electrostatic conductive wires, and the connection ends of the electrostatic conductive wires are connected to the floating disk body and its components.

10. A method for preparing a fully liquid-contact floating roof, comprising the following steps: S1. Build a horizontal plate inside the storage tank and lay the four prefabricated buoyancy units flat on the horizontal plate; S2. Use a self-drilling screw to fix the joints of adjacent buoyancy units at the middle and cross joint positions to connect the adjacent buoyancy units into a whole, and fill the joints with filler and putty powder, wherein the composition of the putty powder is the same as the resin material used to make the buoyancy units. S3. Using the same resin as the material used to make the buoyancy unit, through chopped strand mat, glass cloth and hand lay-up, the filler between the joints of adjacent buoyancy units is made into a rigid body around it, and forms an integral part with the buoyancy unit; S4. Apply an electrostatic conductive layer to the upper and lower surfaces of the buoyancy unit, and lay carbon fiber surface felt on the surface of the electrostatic conductive layer. After curing, it becomes the floating table body.

11. The method for preparing a fully liquid-contact floating roof according to claim 9, characterized in that, Step S1 also includes: grinding the upper and lower surfaces of the buoyancy unit before splicing.

12. The method for preparing a fully liquid-contact floating roof according to claim 9, characterized in that, Step S4 specifically includes: S41. During the curing period, the upper and lower surfaces of the buoyancy unit are laid up using alternating cloth and felt to achieve the designed layering. Each layer is evenly coated with resin and air bubbles are removed with a pressure roller. S42. When the reinforcing layer is in a gelled state, lay a layer of carbon fiber surface felt on it, then evenly brush on the conductive resin, and use a pressure roller to remove air bubbles and flatten it.

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