FRPPIPINGSYSTEM

Introduction:
Fiberglassreinforcedplastic(FRP)pipingmadefromepoxyvinylesterresinsprovidesexcellentcorrosion
resistance in saturated inorganic brine service. However, the rapid rate of change and significant
differenceintemperaturesmentionedpreviouslywouldmakeFRPsusceptibletothermalshock,which
mayleadtothecrackingofthecorrosionbarrierandsignificantstressontheentirepipingsystem.

Carbonsteelpipingcarryingasaturatedinorganicbrinesolutionwasexperiencingleakswithinayearof
installation. Even though brine temperatures were normally controlled to change gradually, the
temperature of the brine could change rapidly from20C to 60C (4F to 140F) in less than five
seconds. The operating pressure was 345 kPa (50 psig). Other metallic piping substitutes were
investigatedwithcoppernickelpipingbeingfoundtobetheonlymetallicmaterialsuitableforresisting
the corrosive nature of the saturated brine process stream. However, coppernickel piping is very
expensivematerial.Alowercostalternativewasneededandsought.

Fiberglassreinforcedplastic(FRP)pipingmadewithepoxyvinylesterresinsandmodifiedfromstandard
manufacturingpracticesinordertohandlerapidtemperaturechangeswasusedforanimmediatecost
savings.TheFRPpipinghasprovidedmaintenancefreeserviceforthreeyears.CustomfabricatedFRP
pipe, up to twelve inches in diameter, is approximately 1.5 to 2 times the cost of carbon steel pipe
installed.Asthepipediameterincreasesthecostdifferencedecreases.

KnowledgeableFRPpipingmanufacturerscandesignpipingsystemstowithstandthermalstressesput
onthemwiththeuseofappropriateguidesandanchorsinhighstresslocations,aswellas,fabricating
the pipe for the required physical properties. However, a standard corrosionresistant barrier in FRP
pipingwouldprobablynotresisttheeffectsofexcessivethermalshocksexperiencedintheprocess.In
order to meet the severe thermal requirements for the saturated inorganic brine, modifications to
standardFRPcorrosionresistantbarrierwereemployed.

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
consistsofacglassorsyntheticveil0.3mm(10mils)thickandatleasttwolayersof450g/m2(1.5
oz./sq, ft.) chopped strand glass mat for a total thickness of about 3mm (100mils). The corrosion
resistant barrier being resin rich contains 7080wt% resin, while the structural portion of FRP
equipmenthassresincontentcloseto50wt%.

Itisessentialthattheintegrityofthecorrosionresistantbarrierbemaintainedinordertoprotectthe
structuralwallofFRPequipment.Thereareseveraltechniquesthatcanbeemployedtogreatlyreduce

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the effects of thermal shock and fatigue on the corrosion barrier of FRP equipment. Epoxy vinyl ester
resinlaminat.

GlassReinforcedPlastics"GRP"orReinforcedThermosettingResin"RTR"Pipesexhibit,

1. Excellentadhesion.
2. Fatigueresistance.
3. Impactstrength.
4. Chemicalresistance.
5. Lowshrinkage.
6. Longtermperformance.
7. SuperiorMechanical&Chemicalproperties.
8. Excellentfatigueresistanceundercyclicloading.

DependsuponthetypeofResinused,thePipes&FittingsarecategorizedasGRP,GRV&GREandare
usedfordifferentindustrialapplications.

Applications/Industries:
1. SeweragePiping
2. StormWaterSystem
3. WaterDesalinationPlants.
4. PumpingStations
5. FireMain.
6. PowerPlants.
7. Chemical&PetrochemicalPlants.

StiffnessClassofpipes:
1500N/m2,2500N/m2,5000N/m2,10000N/m2

PressureClassofPipes:
Gravity,6Bar,12Bar,16Bar,25Bar,32Bar

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Installation:
TherequirementsforproperinstallationofFiberglassPipingSystemdependsontheapplicationAbove
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
compensatefortheeffectofthermalexpansion.Installcarefullytokeepstressesorstrainsinthesystem
belowacceptablelimits.

TypesofJointingandPreparation
ThereareseveralmethodsavailablefortheinstallationandadjustingofFRPpipesystemsinthefield.
Thefollowingjointingmethodsarecommonlyused.

1. Adhesivebondedjoint
2. Rubbersealjoint
3. Flangedjoint
4. Laminationjoint
5. Mechanicalcoupler

In case it is necessary to shorten the pipe length at a certain point in the line, rejointing can be
performed by adhesive bonding or by laminating. The adhesive bonded joint is available up to and
includingadiameterof400mm.

Cutting

Thepipesectiontobecutshouldbemarkedusingamarkerpenandapipefitter'swraparoundguide.
Ensurethatthecutendiscompletelysquareasthereliabilityofthejointdependsonit.Thecuttingof
glassfiberreinforcedepoxypipescanbedonebymeansofahacksawfordiametersupto100mm.For
diametersabove100mmanabrasivecuttingdisccanbeused.Donotcutclosetothesocketendofa
rubbersealjointand/oradhesivebondedjoint.Thecuttingdistanceawayfromtheconicalpartofthe
bellendmustbeequalto,orlongerthanthelengthforlaminatedjoints.

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1. Adhesivebondedjoints
Beforeadhesivebonding,allsafetyprecautionswillneedtobechecked.Ensurethatallnecessarytools
and materials are available. Adhesive bonded joints can only be made by fully trained and certified
personnel.

1.1Toolsforadhesivebondedjoints

Forassemblyofadhesivebondedjointsthefollowingisneeded:

measuringtape+markerpen+pipefitter'swraparound+measuringgauge
pipeclamp+bench+rubberstrip(foruseunderneaththechainclamp)
anglegrinderwithdiagritorcarborundumcuttingdisc(grain24)flappersanderandasandingbobbin,a
handsawwitha24teeth/inchblade,jigsawwitha14teeth/inchblade
shaver
cleaningrag
adhesive,spatula(=rubberscraperplate),emerycloth
heating blanket, hot air gun (paint stripper gun), digital temperature gauge, variable energy control
(rheostat),insulationblanket
generator
Cleaningfluid/gloves/dustmask/safetyglasses.
shelter(dependingontheweatherconditions)

1.2Machining

Afterthepipehasbeencuttotheexactlength,theendwillhavebemachinedtotherightdiameterto
ensureaproperjoint.Thesurfacehastobecleanedwithacleancloth.Ifthesurfacehasbeenincontact
withoilorgrease,itshouldbecleanedwithacleanclothsoakedinpureacetone,M.E.K.(methylethyl
ketone)orM.I.B.K.(methylisobutylketon)(freeofwater).Afterdrying,machiningcanstart.Thereare3
shaversavailable:onefordiametersupto50mm,onefordiametersfrom80mmto250mmandonefor
diametersfrom200mmto400mm.

Aftertheadhesiveisappliedagoodbondisguaranteed.Anyirregularityinthicknesscanbedetermined
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
dimensionshavetobeinaccordancewiththevaluesshowninthebondinginstructionspackedwiththe
adhesive.

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1.3Bondingofthejoint

The bonding instructions are packed with every adhesive kit. Wastage of adhesive can be reduced by
goodplanningandthebestuseoftheadhesivekits.Toomuchadhesiveappliedtothesocketwillreduce
thediameterandresultinrestrictedflow.Removeexcessadhesivewiththeaidofthespatulaandfinish
the seam properly and smoothly. This can also be done inside the pipe, for example, by pulling a plug
throughthepipe.Thiswillpreventsproblemsusingfoampigslater.

Thetemperatureoftheheatingblanketshouldbeatleast90Cforapplicationsofmediumbelow65C
and125Cformediumtemperaturesbetween65Cand90C.

Curingtimeisnearlyonehourandonehourwarminguptime.Curingtimestartsafterthesurfaceofthe
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
draughtsthroughthepipe.

Becauseoftheirconfiguration,flangedjointsandlateralsaredifficulttocurefromtheoutsidebyusinga
heatingblanket.Theycanbecuredwiththefollowingalternativeprocedure:

A Rollup the heating blanketandplaceitontheinsideofthepipeatthe machinedend. Fillthe

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
curedfirst.Theremainingpartscanbecuredwithaheatingblanket.

Donotmovethejointduringsettingoftheadhesive!Thiscanresultinfailureofthejoint.Afterthecured
jointhascooleddownitmaybeloaded.

NoteInmanycasesthenumberofsitejointscanbereducedbyprefabrication(spoolbuilding)in
thefactory.

IntegralRubbersealjoint(RSJ)andRubberSealLockJoint(RSLJ)

BeforeassemblingtheRubberSealJoints,allsafetyprecautionswillneedtobechecked.Ensurethatall
necessarytoolsandmaterialsareavailable.

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Toolsforrubbersealjoints.

Forassemblyofrubbersealjointsthefollowingisneeded:

LubricantforOringandlockingstrip
Arodorstick
2pipeclamps
Chaintackles(2):uptoID500mmpullingforce750kg.
ID>500mmpullingforce1500kg.
Plasticorwoodenmallettodrivethelockingstripintotherubberseallockjoint
Nonfluffycleaningrags

Thefollowingactionsmustbetakeninordertoinstalltherubbersealjoint.

2.1.RubberSealJoint(RSJ)withpipestop

Clean the spigot and socket end thoroughly with a clean cloth before jointing. Do not use
materiallikedustersinordertoavoidfibersfromstickingtothesurfaceoftheseal.

Checkbothpipeendsfordamage.
Markthedepthofentryonthespigotend.
Themeasurementofthemarkonthespigotendisasfollows:depthofthesocketendminusend
play
Positiontherubberringintothegrooveofthespigotend.
Usearoundtoollikeascrewdriverunderneaththerubberringandworkitaroundafewtimesin
ordertodistributethetension.

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2.2.RubberSealJoint(RSJ)withoutpipestop

Toassemblearubberringjointusethismanual.Formarkingthedepthofentryonthespigotendusethe
instructionbelow.Markthedepthofentryonthespigotend.

Apply lubricant to the rubber ring and the entire inner surface of the socket end. Avoid any lubricant
undertherubberringinordertopreventitfromslippingoutofthegroove.Donottrytoassemblythe
jointwithouttheuseofanylubricant.Softsoapcanbeusedasanalternativeforthelubricant.Fitthe
rubberlinedclampsonbothsidesofthejointensurethatthespigotendispositionedrightinfrontofthe
socketendandthatbothsectionsarefullyaligned.Attachthechaintacklestotheclampsonbothsides
ofthepartstobeconnectedandeasethespigotslowlyandgraduallyintothesocketuntilthemarkisin
linewiththefrontofthesocketend.

Ifindoubt,checkwithathinfeelergaugearoundthecircumference,toconfirmthattherubber
ringisintherightpositioninthegroove.

Diameters up to 300 mm can be installed without the use of tackles. The force necessary to make the
jointcanbedonebyusingawoodenbeamasaleverattheendofthepipe.Donottrytojointwopipes
atanangle,sinceitisprobablethattherubberringmayslipoutofthegroove.However,ifnecessary,
only after assembly of the joint a permitted angle may be used. Do not use the maximum permitted
anglewhereyouanticipatesoilsettlement.

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2.3.RubberSealLockJoint(RSLJ)withpipestop

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
spigotendslowlyandgraduallyintothesocketenduntiltherearstopofthespigotendispasttheholeof
thelockingstrip.Applysomelubricantonthefirstsectionofthelockingstrip.

Insertthelockingstripinsuchawaythatthebeveledendrestsagainsttheinsideofthesocket.

2.4.RubberSealLockJoint(RSLJ)withoutpipestop

Toassemblearubberringjointusethismanual.Formarkingthedepthofentryonthespigotendusethe
instructionbelow.

Usingaplastichammerorapieceofwood,tapthelockingstriphomeuntilitrestsagainstthefirstpart
of the strip. The end of the locking strips sticks out by approx. 100mm.This allows disassembly of the

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newlyassembledunit.Ensurethatthestopofboththesocketandendthespigotendareincontactwith
thelockingstripandthatthefullyextendedsystemiskeptinthisposition.

ForRSJsystemsanadditional'endplay'of30mmisallowedfordiametersupto300mmand50mmfor
diameters 350 mm up to 1200 mm. This 'end play' allows for contraction as a result of pressure,
temperaturechangesandsoilsettlementsandthereforeshouldnotbeusedintheinstallation.

2.5TypesoftheRubberringandthelockingstrip

ThecommonlyusedrubberringismadeofNBR(NitrilButadieneRubber).Othertypesofrubbercanbe
supplied depending on the medium and/or the temperature. The different types of rubber can be
recognizedbythefollowingcodes:

SStyreneButadieneRubber SBR colourcode redspot

2.6Disassemblyofrubbersealjoints

Inprincipalitispossibletotakerubbersealjointsapartwithinashortperiodafterinstallation.Inpractice
thejointwillbecutoutduetothelackofspacetopullthespigotoutofthesocket,unlessitisthelast
installedjoint.

Thedismantlingprocedureforarubberseallockjointisasfollows:

Pushthepipebackintopositiontofreeupthelockingstripifpossible.Gripthelockingstripwithapair
of pliers or a plate clamp. Tap the pliers or use a crane to pull the plate clamp to remove the locking
strip.(Ifthelockingstripjams,turnthepipealittlewhilepullingthestrip).Pullthespigotendoutofthe
socketuntiltherubberringispositionedattheinsertionholeofthelockingstrip.Pulltherubberring
throughthishole,cuttherubberringandremovetheringcompletelythroughthehole.Nowthejoint
canbereleasedcompletely.

3.Flangedjoints
Before assembling the Flanged Joints, all safety precautions will need to be checked. Ensure that all
necessarytoolsandmaterialsareavailable.

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3.1Toolsforflangedjoints

Toolsnecessaryforassemblyofflanges:

Ringspannerwithrequiredboltheadsize.
Torquewrenchwithrequiredsocketsize.

R.T.R.P. flanges are flat faced. These flanges must always be accurately aligned and not subject to any
stress.OntheR.T.R.P.sideoftheflangedjointtheboltsandnutsmusthavewasherstoavoidexceeding
thepermittedsurfacepressure.Asanalternative,asteelbackingringcanbeinstalled.Pipesmustnotbe
pulled together by tightening the bolts. If an R.T.R.P. pipeline is connected to a metal pipe, this metal
pipemustbeanchoredtopreventanymovementorloadsbeingtransmittedtotheR.T.R.P.line.

When assembling a wafertype butterfly valve, the bolts should be tightened first by hand. If leakage
occursduringpressuretests,theboltscanbetighteneduptothemax.

Topreventdamageoftheflangeswhentightening,spacersmaybeplacedbetweentheR.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.

Theflangemustbeconnectedperpendiculartotheaxisofthepipe.
In practice minor deviations might occur. If this happens, a gasket
with an Oring seal or a profiled gasket with vulcanized steel ring
(Kroll&Ziller)shouldbeused.Theflangemustbeinstalledfreeof
tension.

3.2Gasketsandtorques

ForR.T.R.P.flangesseveralgasketsmaybeused,dependingonthe
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
necessarytolubricatetheboltwith,forexample,molykote.

Whenassemblingflanges,theboltshouldbetightenedbyhandupto30%ofthemax.Torquevalue.If
leakagesoccur,increasethetorquevalueupto60%ofthemaximumvalue.

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3.3RecommendedBoltTorques

MaxTorque MaxTorque
BoltTorque MaxTorque(Nm)
(Nm) (Nm) Torque
ID BS4504 DIN1882
DIN2502 DIN2501 Increment
(mm) Table10 DIN2501
ND16 ND25 (Nm)
(PN10) ND10
ASA150 ASA300
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

BoltTorque Toque
MaxTorque
ID(mm) BS4504Table10 Increment
(Nm)
(PN10) (Nm)
350450 95115 400 14

500600 115170 500 27

7001400 170230 700 34

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3.4Assemblyanddisassemblyofflangedequipment

Ensurethatthejointisfullyextendedandthestopofboth,thesocketandthespigotendareincontact
withthelockingstrip.Assemblingflangedparts(equipment,valves,adjustingpieces,orificeflangesetc.)
onemustbearinmindthatthesepartscouldalsobedismantled.Toprovidespacefordisassemblyinany
installation there must be a rubber seal joint at one side. This allows some displacement in the axial
directionusingtheclearanceinthesocket.

4. Buttandwrapjoints
Beforestartingabuttandwrap(lamination)joint,allsafetyprecautionswillneedtobechecked.Ensure
that all necessary tools and materials are available. A reliable laminated joint can only be made by
personnelauthorizedandtrainedtodoso.

4.1Toolsbuttandwrapjoints

LaminationjointForbuttandwrapjointsthefollowingisneeded:

1. Measuringtape+pipefitter'swraparound+markerpen
2. Cleaningrags
3. Anglegrinderwithdiagritorcarborundumcuttingdisc(grain24),ahandsaw24teeth/inch,
4. jigsawwitha14teeth/inchblade
5. Anglegrinder+sandingdisc+flexiblesupportdisc
6. Resin,hardenerandglassreinforcement+apairofscissors
7. Gloves,brushes,rollers,dustmasksinquantities asmentionedinthefitandlaminatingsets,a
pairofsafetyglasses
8. Shelter(dependingontheweathercircumstances)
9. Insulationblanket, hotair gun (paintstrippergun), digital temperaturegauge,gasburner, field
oven, Heating blanket, variable energy control (rheostat) [These items are especially for GRE
Lamination]
10. Pipeclamp,benchandrubberstrips(underchainclamp)
11. Generator

For the butt and wrap joint procedures see instructions enclosed with the lamination sets. These
instructionsinclude;cuttingandsanding,mixing,thefitprocedure,laminationandcuring.

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4.2Cuttingandsanding

Markoffthepipestobejoinedusingapipefitterssleeveandfelttippedpen.Sawthepipe(sections)to
the right length, with a straight cut perpendicular to the pipe axis. The pipe can be shortened using a
diagrit,carborundumslittingdiscorwithadiamondedgeddisc.Useasander(Anglegrinder)toremove
the top coat of the pipes when cut to the right length, in order to give a clean and rough surface for
adhesion.Cleanthesandedpartwithaclean,nonfluffyclothorbrush.Thepipesectionsmustnowbe
cleanandfreeofdust.

4.3Mixing

Thefullcontentsofthehardenermustbeaddedtothecontainerwiththeresinandcarefullymixed.The
resinandhardenercontaintherightmixingratio.

4.4Fitlayer

Thefunctionsofthefitlayerare,firstly,toensureproperpositioningand,secondly,tocreateaseal.The
fitlayer,withitslowerviscosity,willnotdrainfromtheVshapedseam.

4.5Laminating

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,otherwisethegrindingandcleaningoperationwillhavetoberepeated.Ensurethattolerancesare
notexceeded!Thelaminateshouldbebuiltupfollowingtheprocedurealreadymentioned.Thewoven
rovings,theapplicationofresin/hardenermixandthecorrectsequenceofbuildingupthewovenrovings
must be done according to the instructions on the lamination kit. Remove excess resin using a rubber
spatula.

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4.6Curing

Thelaminationwillhardenatambienttemperatures.Thiscanbespeededupbyapplyingheatusingfor
example,aninfrareddeviceorhotairgun.Thehardeningprocessneedstobedonegradually.Afterthe
laminationisnolongersticky,curingcanbecontinuedwiththeaidofheatingblankets,hotairgunsor
ovens.Heatinguptothe curingtemperatureshouldalsobeperformedgradually.Thecuringtimeonly
starts when the laminate has reached the correct curing temperature. The joint is ready and can be
testedwhenthelaminateisfullycuredandhascooleddown.

5. Mechanicalcouplers

5.1Toolsformechanicalcouplers

ForStraubandTaylorKerr:Allenkeyandtorquewrench.
ForDresser,VikingJohnsonandInlandcouplers:ringspanner.

FRPpipeshavelowertorquesthansteelpipes,dependingonthewallthickness

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.

WiththesecouplersconnectionsbetweenR.T.R.P.andothermaterialscanbemade.Reducingcouplers
are available for pipes with different outside diameters. When using these type of couplers, the cut
R.T.R.P.pipeendsmustbesealedwitharesincoating.Seelaminationinstructions.Thesecouplersmay
alsobeusedforquickrepairsofundergroundpressuresystems.Asthesecouplersdonotprovideaxial
restraint, they must not be used within a specific distance of a change of direction as this can cause
separationofthejoint.Oneofthefactorsdeterminingthislengthisthefrictionvalueofthesurrounding
soil.Adequatefixingofabovegroundpipesystemsisrequired.Thetorquesgivenonthejointsdonot
applytoFRPPipes.AfterinstallationofDressercouplersthestopperboltmustberemovedandreplaced
byapluginordertopreventdamageofthepipewall.

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ApplicableCodes/Standards:
ASTMD2996: Standards Specification for Filament Wound Fiberglass (Glass Fiber
ReinforcedThermosettingResin)Pipe.

ASTMD3517: Standards Specification for Fiberglass (Glass Fiber Reinforced

ASTMD3262:StandardsSpecificationforFiberglass(GlassFiberReinforcedThermosetting
Resin)SewerPipe

ASTMD3754:StandardsSpecificationforFiberglass(GlassFiberReinforcedThermosetting
Resin)SewerandIndustrialPressurePipe.

ASTMD4024: StandardsSpecificationforMachineMadeFiberglass(GlassFiber

Applicablefromin.through24in.(13mmthrough600mm)

ANSIB16.5#150boltcircleflanges.

ASTMD4161:StandardSpecificationforFiberglass(GlassFiberReinforced
ThermosettingResin)PipeJointsUsingFlexibleElastomericSeals.

API15LR:SpecificationforLowPressureFiberglassLinePipe.Applicableto2in.through
12in(50mmthrough300mm)diameterpipeofEpoxyorpolyesterresinfor
useatcyclicpressure(6,895kpa).

AWWAC950:AWWAStandardforFiberglassPressurepipe.

AWWAM45:FiberglassPipeDesignManual

ASMEB31.3:ProcessPiping

BS5480:BritishStandardSpecificationforFiberglass(GRP)pipes,jointsandFittingsfor
useforwatersupplyorsewerage.

BS7159:BritishStandardCodeofpracticeforDesignandconstructionofFiberglass(GRP)
pipingsystemsforindividualplantsorsites.

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