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 markets

Drainage / Sewerage systems Industrial piping

GRP used in very different markets

Drainage / Sewerage systems Industrial piping

GRP used in very different markets

Drainage / Sewerage systems Industrial piping

Low pressure.

Medium High pressure.

Main focus: Need to withstand soil and traffic loads

Main focus: Need to pump from A to B and want to know under what (safety) conditions

Stability in hoop direction, pipe stiffness.

System integrity.

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: ASME B31.3 UKOOA ISO 14692

Example of standards: AWWA M45 / C950 EN 1796 EN 14364 ISO TR 10465

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: ASME B31.3 UKOOA ISO 14692

Example of standards: AWWA M45 / C950 EN 1796 EN 14364 ISO TR 10465

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 properties (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 properties (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.

GRP EN ISO 14692

pump from A to B and know under what (safety) conditions = Know the strength of installed pipeline

GRP EN ISO 14692

Know the strength of installed pipeline

I.

Strength of components ISO 14692 - part 2

:Qualification. Design Envelope

II.

Strength of pipe system ISO 14692 - part 3

:System Design. Site Quality PLan

III.

Installation of pipe system ISO 14692 - part 4

:Training & Qualification.

GRP EN ISO 14692

Design Envelope
1000,0

ASTM D 2992-96 FPI AD, Wavistrong serie EST, ID 150 mm pipe PL/PL, 65C, pressure, TUV

Mean

LCL

LPL

Data

pressure (barg)

Long-term envelope

100,0

2:1 load condition

1,00E+01 1,00E+02 1,00E+03 1,00E+04 1,00E+05 1,00E+06

10,0 1,00E+00

time (hrs)

Axial stress

2:

d a o 1l

ion t i nd o c

Hoop stress

GRP EN ISO 14692

Design Envelope
1000,0

ASTM D 2992-96 FPI AD, Wavistrong serie EST, ID 150 mm pipe PL/PL, 65C, pressure, TUV

Mean

LCL

LPL

Data

pressure (barg)

Long-term envelope Design envelope

100,0

2:1 load condition

1,00E+01 1,00E+02 1,00E+03 1,00E+04 1,00E+05 1,00E+06

10,0 1,00E+00

time (hrs)

Axial stress

2:

d a o 1l

ion t i nd o c

Hoop stress

f2

GRP EN ISO 14692

Design Envelope

Long-term envelope Design envelope

Axial stress

Axial stress Hoop stress

f2

GRP EN ISO 14692

Design Envelope

Long-term envelope Design envelope

Increase wall thickness!

Axial stress

Axial stress

Hoop stress

f2

Internal Pressure +

X Bending

GRP EN ISO 14692

Design Envelope

Long-term envelope Design envelope

Axial stress

Axial stress

Hoop stress

f2

f2= 0.67

X 9Bending

Internal Pressure +

GRP EN ISO 14692

Know the strength of installed pipeline

I.

Strength of components ISO 14692 - part 2

:Qualification. Design Envelope

II.

Strength of pipe system ISO 14692 - part 3

:System Design. Site Quality PLan

III.

Installation of pipe system ISO 14692 - part 4

:Training & Qualification.

GRP EN ISO 14692

Site Quality Plan

Site Quality Plan, describing: Installation instructions. Training + Qualification. Installation in accordance with system design (isometrics) QC.

GRP EN ISO 14692

Site Quality Plan

Site Quality Plan, describing: Installation instructions. Training + Qualification. Installation in accordance with system design (isometrics) QC.

GRP EN ISO 14692

Site Quality Plan

Site Quality Plan, describing: Installation instructions. Training + Qualification. Installation in accordance with system design (isometrics) QC.

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: ASME 31.3 UKOOA ISO 14692

Example of standards: AWWA M45 / C950 EN 1796 EN 14364 ISO TR 10465

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 integrity of pipe system.

Assessment of hoop stability (Soil & Traffic Loads)

AWWA M45

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

Product Ranges
Wavistrong Material Epoxy Size Range 25 to 1600mm Pressure range Up to 70 Bar Temperature -60C to +110C Red Box Yellow Box Material Epoxy Size Range 2 to 16 Pressure range Up to 3,500 psi Temperature -65C to +100C Fiberstrong Material Polyester Size Range 25 to 4000mm Pressure range Up to 20 Bar Temperature +65C Fiberstrong Material Vinylester Size Range 25 to 4000mm Pressure range Up to 20 Bar Temperature +85C

Materials & Methods of Construction

Considerations
Tensile Stress FRP Composite

Fibre

Properties of the fibre Properties of the resin Ratio of fibre to resin Geometry of fibres

Resin

Strain

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 Construction
Fibre orientation & fibre volume fraction

Chopped Strand

Woven Mat

Filament Wound

Materials of Construction
Resin Systems
Ult Tensile Strength

Considerations Good mechanical properties properties Good chemical properties (liner) Good resistance to environmental degradation

Plastic Deformation

Tensile Stress

Failure Elastic Deformation

Strain (%)

Strain to failure

Materials of Construction
Types of Resins
Polyester
-ABABABAS S S -ABABABA-

Epoxy
Epoxy Molecule

Vinylester
-ABAAAA-BAS S -ABAAAA-BA-

Catalyst Styrene Ester groups

Amine Molecule

Hardener No styrene No ester groups

Other resins: Phenolics, Cynate Esters, Silicones, Polurethanes, Bismaleimides, Polymides

Continuous wound - sizes 300 to 4000 mm diam.

Continuous Wound - FIBERSTRONG

Pure SilicaSan d Glass fibres Infrared curing

Chopped glass fibres

Chopped Strand

FIBERSTRONG - GRP / GRV Wall Structure

Exterior surface Structural wall (2) Pipe core E Underground applications Structural wall (1) Liner back-up Inner liner

FIBERSTRONG - Test Procedure

u o y If

e k a m

g i b ry e v a

? ? e pip

FIBERSTRONG - Scope of Supply

Pressure classes : PN 1, 3, 6, 10, 12, 16, 20 Stiffness classes : SN 2500, 5000, 10000 Size range : 350 mm to 4000 mm Temperature range: -40 C 85 C Installation type : Above ground / Underground Design type : 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

WAVISTRONG
GRE Wall Structure
0.3 mm epoxy coating ......... E-glass wall .................... 0.5 mm Resin Liner ....... Resin Glass 100% 30% 70% 0% 70% 30% E(CR)-glass C-glass

54 Test Pressure = 1.5 x design Safety Factor = 2 x design Weep 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

Standard Jointing Methods

Laminated Joint - 25mm to 4000mm

Flange Joints to DIN & ANSI - 25mm to 4000mm

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

Failure of pipe wall needs time Long term testing ASTM 2992 B Regression curve
Test Pressure Safety Factor Weep Pressure : 1.5 x design : 2 x design : 4 x design

Long term testing acc. ASTM 2992-B

System design
E-modulus
Support spans Expansion forces F = E x A x x T 10 times less than steel

Poisson Ratio
Expansion by pressure

Expansion coeficient Allowable stresses (Design Envelope)

Isotrope (steel) vs anisotrope (GRE) = P x D / 2t Safety factors (ASME B31.3, UKOOA, ISO 14692)