FRP PIPING SYSTEM Introduction: Fiberglass reinforced plastic (FRP) piping made from epoxy vinyl ester resins provides excellent corrosion resistance in saturated inorganic brine service. However, the rapid rate of change and significant difference in temperatures mentioned previously would make FRP susceptible to thermal shock, which may lead to the cracking of the corrosion barrier and significant stress on the entire piping system. Carbon steel piping carrying a saturated inorganic brine solution was experiencing leaks within a year of installation. Even though brine temperatures were normally controlled to change gradually, the temperature of the brine could change rapidly from 20 C to 60 C ( 4 F to 140 F) in less than five seconds. The operating pressure was 345 kpa (50 psig). Other metallic piping substitutes were investigated with copper nickel piping being found to be the only metallic material suitable for resisting the corrosive nature of the saturated brine process stream. However, copper nickel piping is very expensive material. A lower cost alternative was needed and sought. Fiberglass reinforced plastic (FRP) piping made with epoxy vinyl ester resins and modified from standard manufacturing practices in order to handle rapid temperature changes was used for an immediate cost savings. The FRP piping has provided maintenance free service for three years. Custom fabricated FRP pipe, up to twelve inches in diameter, is approximately 1.5 to 2 times the cost of carbon steel pipe installed. As the pipe diameter increases the cost difference decreases. Knowledgeable FRP piping manufacturers can design piping systems to withstand thermal stresses put on them with the use of appropriate guides and anchors in high stress locations, as well as, fabricating the pipe for the required physical properties. However, a standard corrosion resistant barrier in FRP piping would probably not resist the effects of excessive thermal shocks experienced in the process. In order to meet the severe thermal requirements for the saturated inorganic brine, modifications to standard FRP corrosion resistant barrier were employed. Essentially all FRP equipment made with epoxy vinyl ester resins has a resin rich corrosion resistant barrier and structural wall. (The resin provides corrosion resistance and holds the shape of the fiberglass. While, the fiberglass is for strength). The standard FRP corrosion resistant barrier generally consists of a c glass or synthetic veil 0.3 mm (10 mils) thick and at least two layers of 450 g/m 2 (1.5 oz./sq, ft.) chopped strand glass mat for a total thickness of about 3 mm (100 mils). The corrosion resistant barrier being resin rich contains 70 80 wt% resin, while the structural portion of FRP equipment has s resin content close to 50 wt%. It is essential that the integrity of the corrosion resistant barrier be maintained in order to protect the structural wall of FRP equipment. There are several techniques that can be employed to greatly reduce Page 1 of 15
the effects of thermal shock and fatigue on the corrosion barrier of FRP equipment. Epoxy vinyl ester resin laminat. Glass Reinforced Plastics "GRP" or Reinforced Thermosetting Resin "RTR" Pipes exhibit, 1. Excellent adhesion. 2. Fatigue resistance. 3. Impact strength. 4. Chemical resistance. 5. Low shrinkage. 6. Long term performance. 7. Superior Mechanical & Chemical properties. 8. Excellent fatigue resistance under cyclic loading. Depends up on the type of Resin used, the Pipes & Fittings are categorized as GRP,GRV & GRE and are used for different industrial applications. Applications / Industries: 1. Sewerage Piping 2. Storm Water System 3. Water Desalination Plants. 4. Pumping Stations 5. Fire Main. 6. Power Plants. 7. Chemical & Petrochemical Plants. Stiffness Class of pipes: 1500 N/m2, 2500 N/m2, 5000 N/m2, 10000 N/m2 Pressure Class of Pipes: Gravity, 6 Bar, 12 Bar, 16 Bar, 25 Bar, 32 Bar Page 2 of 15
Installation: The requirements for proper installation of Fiberglass Piping System depends on the application Above Ground or Below Ground.It significantly vary from the procedures Of Metallic Piping System it needs review of design specifications, information on type and spacing of supports, anchors, guides etc. In general the deflections of unsupported span lengths are maintained within acceptable limits and also compensate for the effect of thermal expansion. Install carefully to keep stresses or strains in the system below acceptable limits. Types of Jointing and Preparation There are several methods available for the installation and adjusting of FRP pipe systems in the field. The following jointing methods are commonly used. 1. Adhesive bonded joint 2. Rubber seal joint 3. Flanged joint 4. Lamination joint 5. Mechanical coupler In case it is necessary to shorten the pipe length at a certain point in the line, re jointing can be performed by adhesive bonding or by laminating. The adhesive bonded joint is available up to and including a diameter of 400 mm. Cutting The pipe section to be cut should be marked using a marker pen and a pipe fitter's wrap a round guide. Ensure that the cut end is completely square as the reliability of the joint depends on it. The cutting of glass fiber reinforced epoxy pipes can be done by means of a hacksaw for diameters up to 100 mm. For diameters above 100 mm an abrasive cutting disc can be used. Do not cut close to the socket end of a rubber seal joint and/or adhesive bonded joint. The cutting distance away from the conical part of the bell end must be equal to, or longer than the length for laminated joints. Page 3 of 15
1. Adhesive bonded joints Before adhesive bonding, all safety precautions will need to be checked. Ensure that all necessary tools and materials are available. Adhesive bonded joints can only be made by fully trained and certified personnel. 1.1 Tools for adhesive bonded joints For assembly of adhesive bonded joints the following is needed: measuring tape + marker pen + pipe fitter's wrap a round + measuring gauge pipe clamp + bench + rubber strip (for use underneath the chain clamp) angle grinder with diagrit or carborundum cutting disc (grain 24) flapper sander and a sanding bobbin, a handsaw with a 24 teeth/inch blade, jig saw with a 14 teeth/inch blade shaver cleaning rag adhesive, spatula (=rubber scraper plate), emery cloth heating blanket, hot air gun (paint stripper gun), digital temperature gauge, variable energy control (rheostat), insulation blanket generator Cleaning fluid/gloves/dust mask/safety glasses. shelter (depending on the weather conditions) 1.2 Machining After the pipe has been cut to the exact length, the end will have be machined to the right diameter to ensure a proper joint. The surface has to be cleaned with a clean cloth. If the surface has been in contact with oil or grease, it should be cleaned with a clean cloth soaked in pure acetone, M.E.K. (methyl ethyl ketone) or M.I.B.K. (methyl isobutyl keton) (free of water). After drying, machining can start. There are 3 shavers available: one for diameters up to 50 mm, one for diameters from 80 mm to 250 mm and one for diameters from 200 mm to 400 mm. After the adhesive is applied a good bond is guaranteed. Any irregularity in thickness can be determined by measuring the spigot end in several places. On the machined spigot end the max. wall thickness difference allowed is 0.2% of the diameter of the pipe, with a minimum value of 0.3 mm. The spigot dimensions have to be in accordance with the values shown in the bonding instructions packed with the adhesive. Page 4 of 15
1.3 Bonding of the joint The bonding instructions are packed with every adhesive kit. Wastage of adhesive can be reduced by good planning and the best use of the adhesive kits. Too much adhesive applied to the socket will reduce the diameter and result in restricted flow. Remove excess adhesive with the aid of the spatula and finish the seam properly and smoothly. This can also be done inside the pipe, for example, by pulling a plug through the pipe. This will prevents problems using foam pigs later. The temperature of the heating blanket should be at least 90 C for applications of medium below 65 C and 125 C for medium temperatures between 65 C and 90 C. Curing time is nearly one hour and one hour warming up time. Curing time starts after the surface of the pipe has reached the required temperature underneath the heating blanket. During curing the joint should be insulated for example by using insulation blanket and seal off the pipe ends to prevent draughts through the pipe. Because of their configuration, flanged joints and laterals are difficult to cure from the outside by using a heating blanket. They can be cured with the following alternative procedure: A Roll up the heating blanket and place it on the inside of the pipe at the machined end. Fill the space inside the blanket with heat resistant material to ensure that the blanket is pressed against the pipe wall. The electrical cables must not be inside. B Heat the joint on the inside with a hot air gun / paint stripper or infra red device. Control the temperature with a digital temperature gauge. For laterals, the branch and the nearest joint must be cured first. The remaining parts can be cured with a heating blanket. Do not move the joint during setting of the adhesive! This can result in failure of the joint. After the cured joint has cooled down it may be loaded. Note In many cases the number of site joints can be reduced by prefabrication (spool building) in the factory. Integral Rubber seal joint (RSJ) and Rubber Seal Lock Joint (RSLJ) Before assembling the Rubber Seal Joints, all safety precautions will need to be checked. Ensure that all necessary tools and materials are available. Page 5 of 15
Tools for rubber seal joints. For assembly of rubber seal joints the following is needed: Lubricant for O ring and locking strip A rod or stick 2 pipe clamps Chain tackles (2): up to ID 500 mm pulling force 750 kg. ID > 500 mm pulling force 1500 kg. Plastic or wooden mallet to drive the locking strip into the rubber seal lock joint Non fluffy cleaning rags The following actions must be taken in order to install the rubber seal joint. 2.1. Rubber Seal Joint (RSJ) with pipe stop Clean the spigot and socket end thoroughly with a clean cloth before jointing. Do not use material like dusters in order to avoid fibers from sticking to the surface of the seal. Check both pipe ends for damage. Mark the depth of entry on the spigot end. The measurement of the mark on the spigot end is as follows: depth of the socket end minus end play Position the rubber ring into the groove of the spigot end. Use a round tool like a screwdriver underneath the rubber ring and work it around a few times in order to distribute the tension. Page 6 of 15
2.2. Rubber Seal Joint (RSJ) without pipe stop To assemble a rubber ring joint use this manual. For marking the depth of entry on the spigot end use the instruction below. Mark the depth of entry on the spigot end. Apply lubricant to the rubber ring and the entire inner surface of the socket end. Avoid any lubricant under the rubber ring in order to prevent it from slipping out of the groove. Do not try to assembly the joint without the use of any lubricant. Soft soap can be used as an alternative for the lubricant. Fit the rubber lined clamps on both sides of the joint ensure that the spigot end is positioned right in front of the socket end and that both sections are fully aligned. Attach the chain tackles to the clamps on both sides of the parts to be connected and ease the spigot slowly and gradually into the socket until the mark is in line with the front of the socket end. If in doubt, check with a thin feeler gauge around the circumference, to confirm that the rubber ring is in the right position in the groove. Diameters up to 300 mm can be installed without the use of tackles. The force necessary to make the joint can be done by using a wooden beam as a lever at the end of the pipe. Do not try to join two pipes at an angle, since it is probable that the rubber ring may slip out of the groove. However, if necessary, only after assembly of the joint a permitted angle may be used. Do not use the maximum permitted angle where you anticipate soil settlement. Page 7 of 15
2.3. Rubber Seal Lock Joint (RSLJ) with pipe stop Position the hole so the locking strip can be inserted easily. Follow the assembly instructions for the rubber seal joints (RSJ). Attach the chain tackles to the clamps on both sides of the pipe and ease the spigot end slowly and gradually into the socket end until the rear stop of the spigot end is past the hole of the locking strip. Apply some lubricant on the first section of the locking strip. Insert the locking strip in such a way that the beveled end rests against the inside of the socket. 2.4. Rubber Seal Lock Joint (RSLJ) without pipe stop To assemble a rubber ring joint use this manual. For marking the depth of entry on the spigot end use the instruction below. Using a plastic hammer or a piece of wood, tap the locking strip home until it rests against the first part of the strip. The end of the locking strips sticks out by approx. 100mm.This allows disassembly of the Page 8 of 15
newly assembled unit. Ensure that the stop of both the socket and end the spigot end are in contact with the locking strip and that the fully extended system is kept in this position. For RSJ systems an additional 'end play' of 30 mm is allowed for diameters up to 300 mm and 50 mm for diameters 350 mm up to 1200 mm. This 'end play' allows for contraction as a result of pressure, temperature changes and soil settlements and therefore should not be used in the installation. 2.5 Types of the Rubber ring and the locking strip The commonly used rubber ring is made of NBR (Nitril Butadiene Rubber). Other types of rubber can be supplied depending on the medium and/or the temperature. The different types of rubber can be recognized by the following codes: S Styrene Butadiene Rubber SBR colour code red spot N Nitrile Butadiene Rubber NBR colour code yellow spot E Ethane Propane Terpolymer EPDM colour code blue spot F Fluor Elastomer FKM H Hydrogenated Nitrile Butadiene Rubber H NBR 2.6 Disassembly of rubber seal joints In principal it is possible to take rubber seal joints apart within a short period after installation. In practice the joint will be cut out due to the lack of space to pull the spigot out of the socket, unless it is the last installed joint. The dismantling procedure for a rubber seal lock joint is as follows: Push the pipe back into position to free up the locking strip if possible. Grip the locking strip with a pair of pliers or a plate clamp. Tap the pliers or use a crane to pull the plate clamp to remove the locking strip. (If the locking strip jams, turn the pipe a little while pulling the strip). Pull the spigot end out of the socket until the rubber ring is positioned at the insertion hole of the locking strip. Pull the rubber ring through this hole, cut the rubber ring and remove the ring completely through the hole. Now the joint can be released completely. 3. Flanged joints Before assembling the Flanged Joints, all safety precautions will need to be checked. Ensure that all necessary tools and materials are available. Page 9 of 15
3.1 Tools for flanged joints Tools necessary for assembly of flanges: Ring spanner with required bolt head size. Torque wrench with required socket size. R.T.R.P. flanges are flat faced. These flanges must always be accurately aligned and not subject to any stress. On the R.T.R.P. side of the flanged joint the bolts and nuts must have washers to avoid exceeding the permitted surface pressure. As an alternative, a steel backing ring can be installed. Pipes must not be pulled together by tightening the bolts. If an R.T.R.P. pipeline is connected to a metal pipe, this metal pipe must be anchored to prevent any movement or loads being transmitted to the R.T.R.P. line. When assembling a wafer type butterfly valve, the bolts should be tightened first by hand. If leakage occurs during pressure tests, the bolts can be tightened up to the max. To prevent damage of the flanges when tightening, spacers may be placed between the R.T.R.P. flanges. Tightening of the bolts of flange connections must be done diagonally according to the sequence as shown in figure. Bolts in flanges must be placed on either side of the centre line unless otherwise specified. The flange must be connected perpendicular to the axis of the pipe. In practice minor deviations might occur. If this happens, a gasket with an O ring seal or a profiled gasket with vulcanized steel ring (Kroll & Ziller) should be used. The flange must be installed free of tension. 3.2 Gaskets and torques For R.T.R.P. flanges several gaskets may be used, depending on the diameter, system pressure or specific requirements of the client. To prevent excessive bending on R.T.R.P. flanges the max. bolt torques are specified. In order to determine the right torque value, it is necessary to lubricate the bolt with, for example, molykote. When assembling flanges, the bolt should be tightened by hand up to 30% of the max. Torque value. If leakages occur, increase the torque value up to 60% of the maximum value. Page 10 of 15
3.3 Recommended Bolt Torques ID (mm) Bolt Torque BS 4504 Table 10 (PN 10) Max Torque (Nm) DIN 1882 DIN 2501 ND 10 Max Torque (Nm) DIN 2502 ND 16 ASA 150 Max Torque (Nm) DIN 2501 ND 25 ASA 300 Torque Increment (Nm) 25 25 70 70 100 7 40 25 100 100 150 7 50 25 100 100 150 7 80 25 100 100 150 7 100 20 100 100 250 7 150 35 150 150 250 14 200 45 150 150 300 14 250 55 150 300 500 14 300 75 150 300 550 14 ID (mm) Bolt Torque BS 4504 Table 10 (PN 10) Max Torque (Nm) Toque Increment (Nm) 350 450 95 115 400 14 500 600 115 170 500 27 700 1400 170 230 700 34 Page 11 of 15
3.4 Assembly and disassembly of flanged equipment Ensure that the joint is fully extended and the stop of both, the socket and the spigot end are in contact with the locking strip. Assembling flanged parts (equipment, valves, adjusting pieces, orifice flanges etc.) one must bear in mind that these parts could also be dismantled. To provide space for disassembly in any installation there must be a rubber seal joint at one side. This allows some displacement in the axial direction using the clearance in the socket. 4. Butt and wrap joints Before starting a butt and wrap (lamination) joint, all safety precautions will need to be checked. Ensure that all necessary tools and materials are available. A reliable laminated joint can only be made by personnel authorized and trained to do so. 4.1 Tools butt and wrap joints Lamination joint For butt and wrap joints the following is needed: 1. Measuring tape + pipe fitter's wrap a round + marker pen 2. Cleaning rags 3. Angle grinder with diagrit or carborundum cutting disc (grain 24), a handsaw 24 teeth/inch, 4. jig saw with a 14 teeth/inch blade 5. Angle grinder + sanding disc + flexible support disc 6. Resin, hardener and glass reinforcement + a pair of scissors 7. Gloves, brushes, rollers, dust masks in quantities as mentioned in the fit and laminating sets, a pair of safety glasses 8. Shelter (depending on the weather circumstances) 9. Insulation blanket, hot air gun (paint stripper gun), digital temperature gauge, gas burner, field oven, Heating blanket, variable energy control (rheostat) [These items are especially for GRE Lamination] 10. Pipe clamp, bench and rubber strips (under chain clamp) 11. Generator For the butt and wrap joint procedures see instructions enclosed with the lamination sets. These instructions include; cutting and sanding, mixing, the fit procedure, lamination and curing. Page 12 of 15
4.2 Cutting and sanding Mark off the pipes to be joined using a pipe fitter s sleeve and felt tipped pen. Saw the pipe (sections) to the right length, with a straight cut perpendicular to the pipe axis. The pipe can be shortened using a diagrit, carborundum slitting disc or with a diamond edged disc. Use a sander (Angle grinder) to remove the top coat of the pipes when cut to the right length, in order to give a clean and rough surface for adhesion. Clean the sanded part with a clean, non fluffy cloth or brush. The pipe sections must now be clean and free of dust. 4.3 Mixing The full contents of the hardener must be added to the container with the resin and carefully mixed. The resin and hardener contain the right mixing ratio. 4.4 Fit layer The functions of the fit layer are, firstly, to ensure proper positioning and, secondly, to create a seal. The fit layer, with its lower viscosity, will not drain from the V shaped seam. 4.5 Laminating Grind the surface (ensure the top coating is removed) and remove the dust using a clean dry cloth or brush to ensure a good adhesion between fit layer and laminate. The work must continue within the hour, otherwise the grinding and cleaning operation will have to be repeated. Ensure that tolerances are not exceeded! The laminate should be built up following the procedure already mentioned. The woven rovings, the application of resin/hardener mix and the correct sequence of building up the woven rovings must be done according to the instructions on the lamination kit. Remove excess resin using a rubber spatula. Page 13 of 15
4.6 Curing The lamination will harden at ambient temperatures. This can be speeded up by applying heat using for example, an infra red device or hot air gun. The hardening process needs to be done gradually. After the lamination is no longer sticky, curing can be continued with the aid of heating blankets, hot air guns or ovens. Heating up to the curing temperature should also be performed gradually. The curing time only starts when the laminate has reached the correct curing temperature. The joint is ready and can be tested when the laminate is fully cured and has cooled down. 5. Mechanical couplers 5.1 Tools for mechanical couplers For Straub and Taylor Kerr: Allen key and torque wrench. For Dresser, Viking Johnson and Inland couplers: ring spanner. FRP pipes have lower torques than steel pipes, depending on the wall thickness Mechanical couplers, normally used for steel pipes, can also be used: e.g. Straub, Viking Johnson, Dresser, Taylor Kerr. However, restraining couplers should not be used as these may damage the FRP pipes. With these couplers connections between R.T.R.P. and other materials can be made. Reducing couplers are available for pipes with different outside diameters. When using these type of couplers, the cut R.T.R.P. pipe ends must be sealed with a resin coating. See lamination instructions. These couplers may also be used for quick repairs of underground pressure systems. As these couplers do not provide axial restraint, they must not be used within a specific distance of a change of direction as this can cause separation of the joint. One of the factors determining this length is the friction value of the surrounding soil. Adequate fixing of above ground pipe systems is required. The torques given on the joints do not apply to FRP Pipes. After installation of Dresser couplers the stopper bolt must be removed and replaced by a plug in order to prevent damage of the pipe wall. Page 14 of 15
Applicable Codes / Standards: ASTM D 2996 : Standards Specification for Filament Wound Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Pipe. ASTM D 3517 : Standards Specification for Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Pressure Pipe. ASTM D 3262 : ASTM D 3754 : Standards Specification for Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Sewer Pipe Standards Specification for Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Sewer and Industrial Pressure Pipe. ASTM D 4024 : Standards Specification for Machine Made Fiberglass (Glass Fiber Applicable from ½ in. through 24 in. (13 mm through 600 mm) ANSI B 16.5 # 150 bolt circle flanges. ASTM D 4161 : Standard Specification for Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Pipe Joints Using Flexible Elastomeric Seals. API 15 LR : Specification for Low Pressure Fiberglass Line Pipe. Applicable to 2 in. through 12 in (50 mm through 300 mm) diameter pipe of Epoxy or polyester resin for use at cyclic pressure (6,895 k pa). AWWA C 950 : AWWA M 45 : ASME B 31.3 : AWWA Standard for Fiberglass Pressure pipe. Fiberglass Pipe Design Manual Process Piping BS 5480 : British Standard Specification for Fiberglass (GRP) pipes, joints and Fittings for use for water supply or sewerage. BS 7159 : British Standard Code of practice for Design and construction of Fiberglass (GRP) piping systems for individual plants or sites. Page 15 of 15