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Dynaflow Lectures - March 26th 2009
Fiberglass Pipe Systems
Agenda
• Standards, very different markets.
• Why should we choose for Glassfibre Reinforced.
materials for piping systems.
• Product Ranges and Methods of Construction.
• Jointing Methods.
• Prefabrication.
• Design.
Examples of very different marketsIndustrial pipingDrainage / Sewerage systems
GRP used in very different marketsIndustrial pipingDrainage / Sewerage systems
GRP used in very different markets
Low pressure.
Main focus:
“Need to withstand soil and traffic loads”
Stability in hoop direction, pipe stiffness.
Medium – High pressure.
Main focus:
“Need to pump from A to B and want to know under what (safety) conditions”
System integrity.
Industrial pipingDrainage / Sewerage systems
GRP used in very different markets“Need to withstand soil and
traffic loads”“Need to pump from A to B
and want to know under what (safety) conditions”
Example of standards:AWWA M45 / C950
EN 1796EN 14364
ISO TR 10465
Example of standards:ASME B31.3
UKOOAISO 14692
GRP used in very different markets“Need to withstand soil and
traffic loads”“Need to pump from A to B
and want to know under what (safety) conditions”
Example of standards:AWWA M45 / C950
EN 1796EN 14364
ISO TR 10465
Example of standards:ASME B31.3
UKOOAISO 14692
GRP – EN 1796“Need to withstand soil and
traffic loads”
EN 1796
Title: Plastics piping systems for water supply with or without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin.
GRP – EN 1796“Need to withstand soil and
traffic loads”
GRP – EN 1796“Need to withstand soil and traffic
loads”
EN 1796, characteristics:
Pipe:Verification of long-term proper-ties (Stiffness, PN).
Joints:Verification of initial sealing.
Fittings:No verification on PN.
GRP – EN ISO 14692“Need to pump from A to B and
want to know under what (safety) conditions”
ISO 14692.
Title:Petroleum and natural gas industries – Glass-reinforced plastics (GRP) piping.
GRP – EN ISO 14692“pump from A to B and know
under what (safety) conditions”
GRP – EN ISO 14692“pump from A to B and know
under what (safety) conditions”
ISO 14692, characteristics:
Pipe:Verification of long-term proper-ties (PN, hoop & axial strength).
Joints & Fittings:Verification of long-term properties (as strong as pipe).
Pipe system:Assessment of integrity of pipe system based on known hoop and axial strength.
“pump from A to B and know under what (safety) conditions”
=
Know the strength of installed pipeline
GRP – EN ISO 14692
I. Strength of components :Qualification.
II. Strength of pipe system :System Design.
III. Installation of pipe system :Training & Qualification.
ISO 14692 - part 2
ISO 14692 - part 3
ISO 14692 - part 4
GRP – EN ISO 14692
Site Quality PLan
Design Envelope
Know the strength of installed pipeline
2:1 load condition
ASTM D 2992-96FPI AD, Wavistrong serie EST, ID 150 mm pipe PL/PL, 65°C, pressure, TUV
10,0
100,0
1000,0
1,00E+00 1,00E+01 1,00E+02 1,00E+03 1,00E+04 1,00E+05 1,00E+06
time (hrs)
pres
sure
(bar
g)
Mean LCL LPL Data
GRP – EN ISO 14692Design Envelope
2:1 load condition
Long-term envelope
Hoop stress
Axi
al s
tress
Long-term envelope
Hoop stress
Axi
al s
tress
f2
Design envelope
2:1 load condition
GRP – EN ISO 14692Design Envelope
2:1 load condition
ASTM D 2992-96FPI AD, Wavistrong serie EST, ID 150 mm pipe PL/PL, 65°C, pressure, TUV
10,0
100,0
1000,0
1,00E+00 1,00E+01 1,00E+02 1,00E+03 1,00E+04 1,00E+05 1,00E+06
time (hrs)
pres
sure
(bar
g)
Mean LCL LPL Data
Design envelope
Long-term envelope
f2
Axi
al s
tress
Axi
al s
tress
GRP – EN ISO 14692Design Envelope
Hoop stress
Axi
al s
tress
Axi
al s
tress
Hoop stress
Design envelope
Long-term envelope
f2
Axi
al s
tress
Axi
al s
tress
GRP – EN ISO 14692Design Envelope
Increase wall thickness!
Internal Pressure +
BendingX
Axi
al s
tress
Axi
al s
tress
GRP – EN ISO 14692Design Envelope
XInternal Pressure
+Bending
f2= 0.67
Axi
al s
tress
Hoop stress
Design envelope
Long-term envelope
f2
I. Strength of components :Qualification.
II. Strength of pipe system :System Design.
III. Installation of pipe system :Training & Qualification.
ISO 14692 - part 2
ISO 14692 - part 3
ISO 14692 - part 4
Know the strength of installed pipeline
GRP – EN ISO 14692
Site Quality PLan
Design Envelope
Site Quality Plan, describing:
• Installation instructions.
• Training + Qualification.
• Installation in accordance with system design (isometrics)
• QC.
GRP – EN ISO 14692Site Quality Plan
Site Quality Plan, describing:
• Installation instructions.
• Training + Qualification.
• Installation in accordance with system design (isometrics)
• QC.
GRP – EN ISO 14692Site Quality Plan
Site Quality Plan, describing:
• Installation instructions.
• Training + Qualification.
• Installation in accordance with system design (isometrics)
• QC.
GRP – EN ISO 14692Site Quality Plan
Conclusion“Need to withstand soil and
traffic loads”“Need to pump from A to B
and want to know under what (safety) conditions”
Example of standards:AWWA M45 / C950
EN 1796EN 14364
ISO TR 10465
Example of standards:ASME 31.3
UKOOAISO 14692
Conclusion“Need to withstand soil and
traffic loads”“Need to pump from A to B
and want to know under what (safety) conditions”
Assessment of hoop stability
(Soil & Traffic Loads)
AWWA M45
Assessment ofintegrity of pipe system.
ISO 14692
Revision of ISO 14692
Application of Glass Fibre Reinforced Pipes
Why?
Why not?• What do I buy?..... FRP, RTRP, GRE• Glass, brittle at low temps.• Standards?• Dimensions• Material Properties• Calculations• Joints, Glue??• Degeneration of properties in time
Why so?• No corrosion
– No corrosion allowance– No cathodic protection
• Long live (50 years design)• Light weight• Smooth walls, low friction• Mechanical properties,
– Flexible,– Safe failure behaviour
• Safe joints– Adhesive bonded– Mechanical, RSLJ, Key Lock.Tee-kay
• Standards, ISO 14692
Wavistrong
MaterialEpoxy
Size Range 25 to 1600mm
Pressure range Up to 70 Bar
Temperature -60°C to +110°C
Red BoxYellow Box
Material Epoxy
Size Range 2” to 16”
Pressure range Up to 3,500 psi
Temperature -65°C to +100°C
Fiberstrong
Material Polyester
Size Range 25 to 4000mm
Pressure range Up to 20 Bar
Temperature +65°C
Fiberstrong
Material Vinylester
Size Range 25 to 4000mm
Pressure range Up to 20 Bar
Temperature +85°C
Product Ranges
Materials & Methods of Construction
Considerations
• Properties of the fibre
• Properties of the resin
• Ratio of fibre to resin
• Geometry of fibres
Fibre
Resin
FRP Composite
Strain
Tens
ile S
tress
Materials of Construction
Glass Fibres
• C Glass / C Veil: Chemically resistant glass• E Glass: Structurally strong
Continuous roving for pipe construction
Rolled matting for field lamination
Materials of ConstructionFibre orientation & fibre volume fraction
Chopped Strand
Woven Mat
Filament Wound
Materials of ConstructionResin Systems
Considerations• Good mechanical properties
properties• Good chemical properties
(liner)• Good resistance to
environmental degradation
Plastic Deformation
Ela
stic
Def
orm
atio
n
Failure
Strain to failureStrain (%)Te
nsile
Str
ess
Ult TensileStrength
Materials of ConstructionTypes of Resins
Other resins:Phenolics, Cynate Esters, Silicones, Polurethanes, Bismaleimides, Polymides
Polyester- A – B – A – B – A – B – A -
- A – B – A – B – A – B – A -SS S
Vinylester- A – B – A – A – A – A - B – A -
- A – B – A – A – A – A - B – A -S S
CatalystStyreneEster groups
EpoxyEpoxy Molecule
Amine Molecule
HardenerNo styreneNo ester groups
Continuous wound - sizes 300 to 4000 mm diam.
Continuous Wound - FIBERSTRONG
Infrared curing
Pure SilicaSandChopped
glass fibres Glass fibres
Chopped Strand
FIBERSTRONG - GRP / GRV Wall Structure
E Underground applications
Exterior surface
Structural wall (2)
Pipe core
Structural wall (1)
Liner back-upInner liner
FIBERSTRONG - Test Procedure
If you make a very big pipe ??
FIBERSTRONG - Scope of Supply
• Pressure classes • Stiffness classes• Size range• Temperature range• Installation type• Design type
: PN 1, 3, 6, 10, 12, 16, 20: SN 2500, 5000, 10000: 350 mm to 4000 mm: -40 °C – 85 °C: Above ground / Underground: Restrained / Unrestrained
FIBERSTRONG – Jointing types
Laminated Joint 25mm to 4000mm
Double Bell Coupler 50mm to 4000mm
FIBERSTRONG
Applications
• River & seawater intakes & outfalls
• Gravity sewer lines • Jacking & microtunneling• WWT plant underground piping • Irrigation main lines
Helical Wound - WAVISTRONG
Helical Wound diameters 25 – 1600 mm
Filament Wound
WAVISTRONG Production Process
WAVISTRONGGRE Wall Structure
0.3 mm epoxy coating .........0.3 mm epoxy coating .........EE--glass wall ....................glass wall ....................……
0.5 mm Resin Liner .......0.5 mm Resin Liner .......
100%100%30%30%70%70%
ResinResin
0%0%70%70%30%30%
E(CR)E(CR)--glassglassCC--glassglass
GlassGlass
54 ¾°
Test Pressure = 1.5 x designSafety Factor = 2 x designWeep Pressure = 4 x design
Standard Jointing Methods
LB/LS (rubber seal joint) / FB/LS (rubber seal lock joint)50mm to 1400mm
CB/CS (taper/straight) / TB/TS (taper/taper)25mm to 600mm
Laminated Joint - 25mm to 4000mm
Flange Joints to DIN & ANSI - 25mm to 4000mm
Standard Jointing Methods
WAVISTRONG - Scope of Supply
• Pressure classes• Size range• Temperature range• Installation type• Design type
: PN 8, 10, 12.5, 16, 20, 25, 32, 40, 50: 25mm to 1600mm: From -40 °C to 110 °C: Above ground / Underground: Restrained / Unrestrained
WAVISTRONG - Applications
• Crude oil• Cooling water• Fire fighting• CO2 lines• Water injection lines• Well head tubing• Potable water• Sewer lines
WAVISTRONG Fittings
Laminated elbow
Prefabrication (Spools)
Utilisation of Prefabricated Spools
Effluent lines – BP U.K.
Utilisation of Prefabricated Spools
Cooling water ID 800 mm – Degussa Antwerp
Design of pipe systems: Testing
Design of pipe systems
Test Pressure : 1.5 x designSafety Factor : 2 x designWeep Pressure : 4 x design
• Failure of pipe wall needs time
• Long term testing
• ASTM 2992 – B
• Regression curve
Long term testing acc. ASTM 2992-B
System design
• E-modulus– Support spans– Expansion forces F = E x A x α x ∆T– 10 times less than steel
• Poisson Ratio– Expansion by pressure
• Expansion coeficient
• Allowable stresses (Design Envelope)– Isotrope (steel) vs anisotrope (GRE) σ = P x D / 2t
– Safety factors (ASME B31.3, UKOOA, ISO 14692)
Recommended