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SPE-188686-MS
This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 13-16 November 2017.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or stora ge of any part of this paper without the
written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words;
illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.
Abstract
The invention of the light weight and anti-slip grating panel is an improved product that has
significant advantages over common steel grating. Beside the many features found on the new
grating, there are four major outstanding advantages over common steel grating. 1) The unique
design of the new grating that is lighter by approximately 35% in weight. This is made possible with
the creation of a hollow load bearing bar. The new grating being lighter in weight could also
potentially reduce the overall weight of the main building structure. 2) Even though the load bearing
bar is hollow but the overall integrity of the new grating panel is stronger. The new design can take
approximately 12% more loads. 3) It takes a lot lesser raw material to manufacture the new grating
panel. Thus, the finish product is priced competitively. This cost benefit will assist the consumer
greatly in the overall project cost management. 4) The embossed rings found on the new grating
provide a true anti-slip function. This safety feature aims to reduce the number of accident that occurs
at workplace especially on oily working surface and stair treads.
2 SPE-SPE-188686-MS-MS
1.0 INTRODUCTION
1.1 Field of the Invention
The present invention relates to an improved flooring system, inparticularly a grating panel
system that is a slip resistant grating and light in weight.
The development of the project from conceptual design stage to prototyping and to placing the
finish product into the market place went through six major stages. The detail of each stage is
provided in this paper. The summary of the process is shown in Table 1.
Steel grating systems are universally employed for a wide scope of industries; such uses may
include airplane unloading ramps, ramps, freight car flooring, ladder threads, material screens,
mezzanine floors, scaffolding, window guards, walkways, drainage pit covers and stage flooring.
There is a need to accomplish these characteristics of the grating technology presents continually
increasing advances endeavors for the respective manufacturers in order to provide a better result
in providing highly effective grating assembly, particularly for both retrofit and new construction
surfaces. This is particularly useful when the industry experience financial constrain when oil
price are low.
Another important aspect for consideration is the mechanism or technique for securing the
grating assembly that has anti-slip function and is costly. Hence, there is a need to create a better
surface that is inexpensive to manufacture.
The current ineffective slip-resistant technology may lead to instability which may result in
uneven pressure distribution and slippery surfaces, i.e. oily surfaces and, thus it could be
detrimental to the users, particularly in the heavy duty industry, or any other working area.
An example of the prior art is disclosed in CA 2469 345 A1, which relates to a method for
making an anti-slip grating system, wherein the said method includes applying a coating on the
top surface.
A problem that may incure in using of the above- mentioned grating system is in the coating that
may diminish over a period of time. While the conventional method provides a sufficient anti-
slip grating effect, however it requires tedious steps to manufacture. Thus a substantial amount of
labour supervision and time is required to ensure accuracy of suitable thickness of the anti-slip
coating thatis applied on the surface of the grating.
In additiona, in the conventional methods, appropriate spread or thickness of the coating may
requires the alignment or arrangement of the bars and plates. The imprecision arrangement of
these bars may result to inferior coating and consequently ineffective or poor anti-slip quality.
Furthermore some of the installation may require an extensive tool to fasten accessories so as to
fix the grating to the floor of the support structure or structural frame.
Moreover, the enhancements involving the grating and its installation method, although are
specifically engineered to withstand the harsh working environment, these grating assemblies
may be heavy and thus can be encumbrance to the users, in particular during installation and
maintenance work.
Hence, there is a need for an innovative floor grating and its installation method that is directed
to solving the above problems
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Thus, the primary object of the present invention was to improve to the grating and its
installation method that has a slip resistant feature, is of light weight, durable, hollow and is
substantially cost effective in term of assemblage and installation
The new design was first done on raw sketches. The approach was to collobrate with a local
university to seek technical assistance. The Center for Product Design and Manufacturing
(CPDM), a department within the Faculty of Engineering at the University of Malaya (UM) was
engaged to look into two main aspects; that is to find the optimum design for the new concept
and also to run a corrosion test on the material used.
The inventor has the responsibility to made sure that the researchers developed the new grating
that conforms to the industrial standard for steel grating. The development of the new grating is
based on the industry standard using the British Standard BS 4592: Part 1: 1995 Industrial type
flooring walkways and stair tread Part 1 - Specification for aluminium and steel open bar
gratings.
At the time of writing this paper, the latest revision of this standard is BS 4592: Part 1: 2006
Industrial type of flooring and stair treads Part 1 Metal open bar gratings Specification
Before commencing with the R&D work the definition of the various type of grating that is
found in the market was taken into consideration. Figure 1 gives a description of the various type
of grating which is used in the industry.
Upon completition of the R&D the name Litewalk was registered as a trademark. Figure 2 is the
trademark registered with the Malaysia Intellectual Property Office (MyIPO)
SPE-SPE-188686-MS-MS 5
Computer
No. Description of the Test Test carried-out
Software
3. The development for the profile of the load bearing bar was also carried-out. A typical
design of the profile can be seen on Figure 3
4. The performance of the test for the load bearing bar is based on five different types of the
thickness. Figures 4 and 5 shows the typical results of the FEA simulation test on the load
bearing bar
2. The formulation of the deflections for each loading conditions is shown as:
5qL4
For Uniformly Distributed Load (UDL):
384 EI z
SPE-SPE-188686-MS-MS 7
7 PL3
For Concentrated Load:
768EI z
Each profile for the load bearing bar is then taken through a simulation test using Finite Element
Analysis (FEA). This test is to examine its strength for each and every model to see if they could
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Each model runs through the FEA test for two type of test. One, for general duty of 5.0kN/m
uniformly distributed load test and two, 1.0 kN for concentrated load as per described in item 2.4
above - Description of the Simulation Test
The FEA simulation was conducted successfully for each and every model. Results of the FEA
were obtained for every model and the results were satisfactory. This exercise has validated the
conceptual design of the new profile of the load bearing bar. Figure 4 and 5 illustrates the results
of the FEA test for two models.
The protoype grating panels were fabricated manually. Figure 7 and 8 shows the work of the
fabrication being carried out in a workshop.
With the completion of fabrication, the prototype grating panels were sent to the Scientific and
Industrial Research Institute of Malaysia (SIRIM), to carry-out the load test. The objective is to
make comparision and examine the results of the load test conducted on an actual piece of
grating panel against the results obtained from the FEA simulation.
Table 5- Results of the load test on the prototype carried out at SIRIM
SPE-SPE-188686-MS-MS 9
1) Mathematical manual calculation. This has been discussed in item 3.2 above
2) FEA simulation test. This has been discussed in item 2.2 to 2.4 above
3) Actual load test on the prototype. This has been discussed in item 4.1 to 4.3 above
The three results from the three different tests at three different stages have been tabulated in
Table 6 below. For simplicity, the tabulation is done just for one (single) model. The results
shows in this table is for model with the profile of thickness 1.5mm x width 15mm x height
35mm
Concentrated Load
(CL) 2.05mm 2.228mm 0.63mm
Uniform Distributed
Load (UDL) 0.194mm 0.087mm 1.54mm
Reference:
American Society for Testing and Materials, ASTM G 44 9: Standard Practice for Exposure of
Metals and Alloys by Alternate Immersion in Neutral 3.5% Sodium Solution. 1991 Annual Book
of ASTM Standard, Vol 03: Wear and Erosion: Metal Corrosion.
1 ASTM G44 (Clause 3: "The alternative immersion test utilises a 1-h cycle that includes a
10 minutes period in an aqueous solution of 3.5% sodium chloride (NaCI) followed by a
50 minutes period out of the solution, during which the specimens are allowed to dry"
2 The samples are visually examined at 200, 500 and 1,000 cycles. The temperature,
humidity, and pH data were also recorded on each determined cycle.
SPE-SPE-188686-MS-MS 11
1 The coated and uncoated sample is taken for a visual examination before running the test.
Please to refer to figure 11
Table 10 below shows the difference in weight after the test. The greater the lost in weight is
interpreted as weak to corrosion. While marginal lost in weight is interpreted as resistance to
corrosion.
Table 10- Shows the weight difference after the corrosion test
The Litewalk grating has been commercialized in Malaysia and it has been used in a serveral
places. Figures 13, 14, 15, 16 and 17 shows some of the application where this new product has
being used
6.5 Conclusion
This paper discusses the creation of a new light weight steel grating panel. Steel grating is the
most preferred type of grating material used on oil platforms and refineries. In the market today,
grating panels can also be found made from other types of material such as aluminium and fiber
reinforced plastic (FRP). But galvanized steel grating still remains the most popular type of
grating used in the industry. The total weight of the grating constitutes approximately 5% to 15%
of the total weight of a typical oil production and refinery, and a higher percentage for a gas
production facility. The existing design for steel grating has not changed since its inception about
a hundred years ago. The design remains the same with very little improvements.
This has brought about the challenge for improvement. A new hollow section load bearing bar
was created. By having the load bearing bar made in a hollow shape instead of the conventional
solid flat bar stripes, this creative new design has enabled the grating panel to be made much
lighter in weight. This concept initially went through simulation test by using ABAQCUS/CAE
engineering software. The type of steel material, the thickness of the steel plate, width of the
hollow section bar and more importantly the height of the hollow section bar were tested by
running a finite element analysis. This test was also to find its optimum strength from the various
models with different dimensional parameter. The findings of the analysis were taken into
account and further design was incorporated into the hollow section bar to create the anti-slip
function. This anti-slip function works very well by having the embossed rings placed on the
upper part of the load bearing bars. It gives a good traction when one walks on it
A few pieces of the prototype grating panels were constructed and sent for load test in an
authorized institution. Two types of load tests were conducted using procedures as stated in the
British Standard BS 4592. This compliance is compulsory for grating and stair treads. The new
design passed both tests. An intensive corrosion test was also carried out to make sure the
galvanized coating on the new grating was able to withstand the harsh condition of the sea by
using procedure ASTM G44-99. Again, the result from the test was positive.
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6.6 Disclaimer
The views and opinions expressed in this article are those of the authors and do not necessarily
reflect the official opinion or position of any agency in the industry. Any forward looking
statements are entirely of the authors personal view and he does not speak on behalf of any
society. Without prejudice to the generality of this paper, the author does not represent, warrant,
undertake or guarantee that the use of guidance in the report will lead to any particular outcome
or result.
6.7 Acknowledgment
The author wish to record a sincere thanks the Faculty of Engineering at the University of
Malaya, in-particularly the team of engineers and researchers from the Center of Product Design
and Manufacturing (CPDM). The team has shown full dedication and committment towards this
project. Thank you for your co-opration which has resulted in making this project a success.
7.0 REFRENCES
1 British Standard BS 4592-1: 1995 Industrial type flooring, walkways, and stair treads. Specification for open bar gratings
2 British Standard BS 4592-1: 2006 Industrial type flooring and stair treads Part 1: Metal open bar gratings Specification
3 ASTM G44 - 99(2005) Standard Practice for Exposure of Metals and Alloys by Alternate Immersion in Neutral 3.5% Sodium Chloride
Solution
4 ASTM A415 Specification for Hot-Rolled Carbon Steel Sheets, Commercial Quality (Withdrawn 1970)
SPE-SPE-188686-MS-MS 15
Figure 4- FEA displacement results of UDL for the 885-3515 of 1.5mm thickness
SPE-SPE-188686-MS-MS 17
Figure 5- FEA displacement results for CL for the 885-3515 of 1.5mm thickness