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Fiber Glass Piping System

Providing the developer with a detail that meets local planning requirements regarding Fiberglass from floor to roof level. We are catering to the need of Automotive, Military, Chemical Processing, Oil & Gas, Construction, Petrochemical, Electrical / Utility, Pulp & Paper, Food & Beverage, Transportation,
Infrastructure etc.

TYPICAL APPLICATIONS INCLUDES:
Potable Water Suppler
Sewage
Acoustics, Modular and Kiosks
Chemical Storage & Transportation
Wastewater Treatment Applications
Fiberglass Piping Systems

1.General
Thermoset piping systems are composed of plastic materials and are identified by being permanently set cured or hardened into shape during the manufacturing process. Thermoset piping system are combination of resins and reinforcing materials. These piping systems are generally not manufactured to dimensional or pressure standards. Therefore, considerable variation between manufacturers exist in regard to available size, maximum pressure rating and maximum temperature rating. Performance requirements, including manufacturing, conforms to ASTM Standards in order to not sole-source the piping system.

The Three primary thermoset resins are as follows (Other resins are also available.):

Reinforced Polyesters
Reinforced polyester thermoset piping systems are the most widely used due to affordability and versatility. The maximum continuous operating temperature for optimum chemical resistance is 71C (160F).

Reinforced Vinyl Esters
The vinyl ester generally used for chemical process piping systems is bisphenol-A fumarate due to good corrosion resistance.

Reinforced Epoxies
Although epoxies cure without the need for additional heat, almost all pipes are manufactured with heat-cure.

a. Thermoset Piping Characteristics

Typical advantages of thermoset piping systems can be summarized as follows:

- High strength-to-weight ratio.
- Low installation costs.
- Ease of repair and maintenance.
- Smoothness of the internal wall that minimizes the head losses and avoids the deposits.
- Flexibility, low axial modulus of elasticity allows lightweight restraints and reduces expansion loops.
- Low thermal and electrical conductivity.
- High Mechanical resistance due to the glass reinforcement.
- Absolute impermeability of pipes and joints both from external to internal and vice-versa.
- Very long life of the material, virtually infinite, dose not need maintenance.

b. Corrosion Resistance
Like other plastic materials, thermoset piping systems provide both internal and external corrosion resistance. For compatibility of thermoset plastic material with various chemicals, due to the different formulations of the resin groups, manufacturers are contacted to confirm material compatibility.

c. Materials of Construction
Fiberglass is the most common reinforcing material used in thermoset piping systems because of its low cost, high tensile strength, lightweight and good corrosion resistance. Other types of commercially available reinforcement include graphite fibers for use with fluorinated chemicals such as hydrofluoric acid; aramid; polyester; and polyethylene. The types of fiberglass used are E-glass; S-glass for higher temperature and tensile strength requirements; and C-glass for extremely corrosive applications.
Most thermoset piping systems are manufactured using a filament winding process for adding reinforcement. This process accurately orients and uniformly places tension on the reinforcing fibers for use in pressure applications. It also provides the best strength-to-weight ratio as compared to other production methods. The other main method of manufacturing is centrifugal casting, particularly using the more reactive resins. Thermoset piping can be provided with a resin-rich layer (liner) to protect the reinforcing fibers. The use of liners is recommended for chemical and corrosive applications. Liners for filament wound pipe generally range in thickness from 0.25 to 1.25 mm (0.01 to 0.05 in), but can be custom fabricated as thick as 2.8 mm (0.110 in) and are often reinforced. Liner thickness for centrifugally cast thermoset piping generally ranges from 1.25 to 2.0 mm (0.05 to 0.08 in); these liners are not reinforced. If not reinforced, liners may become brittle when exposed to low temperatures. Impacts or harsh abrasion may cause failure under these conditions.

d. Operating Temperatures
Following table lists recommended temperature limits for reinforced thermosetting resin pipe:
Recommended Temperature Limits for Reinforced Thermosetting Resin Pipe


Materials

Recommended Temperature Limits

Resin

Reinforcing

Minimum

Maximum

 

 

oF

oC

oF

oC

Epoxy

Glass Fiber

-20

-29

300

149

Furan

Carbon

-20

-29

200

93

Furan

Glass Fiber

-20

-29

200

93

Phenolic

Glass Fiber

-20

-29

300

149

Polyester

Glass Fiber

-20

-29

200

93

Vinyl Ester

Glass Fiber

-20

-29

200

93

 

Pipe and Fittings Dimensions
Applicable Standards Main applications:

For Filament Wound Fiberglass pipe
For gravity sewers
For water pipe

ASTM D-2996
ASTM D-3262
AWWA C-950

Stiffness
The stiffness of MZ RP (Reinforced Polymer) pipe is selected from one of the three stiffness classes listed below. The stiffness class represents the pipe's minimum initial specific stiffness (EI/D3) in N/m2.

Stiffness Class

SN
2500
5000
10000

N/m2
2500
5000
10000

Stiffness is selected according to two parameters. These are:

(1) Burial conditions, which include native soil, type of backfill and cover depth and
(2) Negative pressure, if it exists.

Wall Thickness
The wall thickness of the pipe depends on the pressure requirements.
Fittings

MZ has created a standardized line of RP fittings that are fabricated using the same materials that are used to produce MZ RP pipe. One of the benefits of MZ RP pipe is the ability to fabricate a wide assortment of fittings, standard as well as non-standard.

Fabrication Methods
Fittings are manufactured by the hand lay-up, contact molding and spray-up process. In hand lay-up and contact molding processes veil and alternate layers of mat and woven roving saturated with resin are applied on the mold. The operation is repeated until the required thickness is achieved. In spray up process continuous strand roving is fed through a chopper gun, combined with catalyzed resin, and sprayed onto the mould surface. The operation is repeated to reach the required thickness.

Wall Structure
Fiberglass fitting wall such as the pipe wall consists of three layers perfectly adherent one to the other in order to have a monolithic structure, each having different characteristics and properties in relation to their function. Liner and topcoat are the same as the pipe. The difference consists in the mechanical resistant layer due to the type of reinforcement used.

Jointing

We recommend following types of jointing systems for Fibreglass pipes.

a) Mechanical coupling Joint
b) Butt and Strap
· Mechanical Coupling Joint
Mechanically coupled joints typically seal on the OD of plain end pipes through the use of gaskets that are compressed to affect the seal. Most of the commonly available mechanical couplers can be used to join pipes.

Application field

Diameters : 75 mm to 1600 mm
Pressures : up to 16 bar

The Butt and Strap
The butt and strap joining method (also known as the butt and wrap, the butt weld, and the reinforced overlay joint; and sometimes referred to as an adhesive) is the oldest and most reliable joining method in the industry today. The butt and strap is made as it is described - two pieces of pipe are butted together and layers of chopped strand mat and woven roving are wrapped around the pipe in a resin matrix. The weld is applied to the exterior of the pipe and, if accessible, the interior as well (usually on pipe larger than 18" nominal I.D.). Refer to Figure for a typical butt weld joint. By using the same materials as the pipe, the butt weld joint can be designed with axial and bending strength properties equal to or superior than the pipe. Sometimes the butt and strap joint is referred to as an adhesive, as it is a mechanical, not a chemical, bond.

Thermoset Piping Burial
Reinforced polyester, vinyl ester, and epoxy pipe may be buried. The same basic principles, which apply to burying plastic pipe, also apply for thermoset pipe regarding frost line, trench excavation, pipe installation, and backfill. For operating pressures greater than 689 kPa (100 psi), the internal pressure determines the required wall thickness. For operating pressures less than 689 kPa (100 psi), the vertical pressure on the pipe from ground cover and wheel load dictates the required wall thickness of the pipe...

Finished Pipe

All pipes are subjected to the following control checks:
- Visual inspection
- Wall thickness
- Section Length
- Diameter
- Hydrostatic leak tightness test to twice rated pressure (only Pn6 and above)

On a sampling basis, the following control checks are performed :
- Pipe stiffness
- Deflection without damage or structural failure
- Axial and circumferential tensile load strength
- Drop Test

A common element shared by all standard is the need for a pipe manufacturer to demonstrate compliance with the standards minimum performance requirements. In the case of GRP pipe, these minimum performance requirements fall into both short-term and long-term requirements. The most important of these, and generally specified at the same level of performance in all the previously defined standards is joint, initial ring deflection, long-term ring bending, long-term pressure and strain corrosion capability.

Comparison of GRP pipeline system
Versus Conventional Pipelines such as Ductile, Concrete, CLAY etc.

 

Conventional

GRP

Joint traceability ?

No

Yes

Low maintenance costs ?

No

Yes

Corrosion resistant ?

No

Yes

Flexible pipe, less liable to stress fractures ?

No

Yes

Operational system during additional branch ?

No

Yes

Reduced labour requirement in pipe lifting
and installation due to weight differential

No

Yes

Reduced labour skill in Jointing operations

No

Yes

Reduced joint stress due to pipe flexibility ?

No

Yes

Lower energy requirement to overcome pipe friction ?

No

Yes

Extra Protection required

Yes

No

Liable to layer separation ?

Yes

No

Potential joint leakage ?

Yes

No