FRP/RTRP/GRP-Piping system for all Industrial Applications ...

1 FRP/RTRP/GRP-Piping system for all Industrial Applications with in middle East from 30 yearsSadath A KhanEngineering ManagerGRP/PE Division-Amiantit DammamA Member of Standards CommitteeAWWA C-950 and M45-for GRP PipesAWWA-D-120 for GRP TanksPresentation Topic Introduction Characteristics of middle East Region Reported Failures of Various Materials Optimal Choice of Materials Literature Survey Regarding FRP Usage FRP or GRP or RPMP or RTRP Initiative By Amiantit to Supply FRP in 1977 30 Years Journey of GRP 30 Years of Supplies to KSA and GCC-ME Conclusions and Recommendations Arid (Dry) Region Little or No Rain Lack of Fresh Water Resources Surrounded by Red Sea, Arabian Gulf middle East(Varying Geomorphic Conditions Changing Climates Oscillating Water Tables,High Salted Sabkha Soils Fluctuating Humidity'sqLow Electrical Resistivity of SoilsqFast Track ConstructionTypical Characteristics areIn middle EastSea Water is Desalinated for Domestic RequirementsConstruction RequirementsIndustrial Demands / Power / Chemical /Oil and Gas Plants are Being Builtalong the Coasts of Red Sea and Arabian Gulf.)

2 Factors Affecting Traditional MaterialsSeawater of Arabian Gulf and Red SeaTDS ranges from 40,000 to 65, 000 ppmIt contains Dissolved GasesDecaying Organics, In-Organic and Other aggressive elementsActing alone or simultaneously produces various forms of DegradationChemical FactorsOxygen, H2S, ChlorineSolubility, pH, Carbonate SolubilityPhysical FactorsVelocity:Air Bubbles, Suspended Solids, SiltTemperature and PressureFactors Affecting Traditional FactorsBio Fouling: Hard Shell, Semi Mobile and Mobile TypesPlant Life and Animal Life: Oxygen Generation, Carbon ConsumptionFactors Affecting Traditional and other EquipmentsGeneral Corrosion Attack of Material Impingement AttackErosion By Suspended SolidsCrevice CorrosionsStress Corrosions Cracking (SCC)HAZ(Weld and Heat Affected Zones)Common Degradation ProcessResulting Resulting Resulting Resulting.

3 Resulting Resulting .. Resulting Resulting ..Selection of Cost Plant Life DesiredFeed CharacteristicsMaterial CompatibilityMaintenance CapabilitiesEase of AvailabilityOverall Life Cycle Capital Cost ConstraintsDesign and Operating ConditionsMaterial of Choice !!!Fiberglass Reinforced PlasticsFRP / GRP / GFRPRTRP / RPMPM aterial of Choice for All ApplicationsFRP-Pipe Wall Construction ResinGlassFiberSandCoreFRP-Pipe Wall Construction Nomenclature FRPF iberglass Reinforced Plastic (or Polyester)or Fiber Reinforced Plastic (or Polyester)(European Standards)GRP Glassfibre Reinforce Plastic (or Polyester)(BS Standards)RTRPR einforced Thermosetting Resin PipeRPMP Reinforced Plastic (or Polymer) Mortar Pipe(American Standards)FREF iberglassReinforced EpoxyGREG lassfibre Reinforced EpoxyFiber Reinforced Plastics (FRP)

4 ClassificationClassification based on Engineering MaterialsEngineering MaterialsMetals Non MetalsBasicAlloysPolymersCeramicsGlasses OthersClassification based on Engineering MaterialsPolymers ThermoplasticsThermosetsHDPELDPEP olyestersEpoxiesAlkydsPhe ono licsElastomersPPPVCNe opre neNit rileEPDMA crylyte sF-carbonsSiliconesThermoplasticCandleTh ermosetEggFRP-Pipe Wall Construction-Chemistry How / Where FRP can be Used ? Usage of FRP based on ResinsGravity to200 Bar G/ Full VacuumGravity to 40 Bar G / Full VacuumPressureAll-High Corrosive FluidsAll-Moderate Corrosive FluidsCan HandleUp to150 CUp to65 C / 90 CTemperatureEpoxy Polyester / VinyesterResinGREE poxy PipingFRP Polyester PipingPropertiesApplications Water Distribution SystemsIn du st r ial W aste ApplicationsPr essu r e / Forced Mains SewersWater T r an smission LinesIrrigationWater Distribution SystemsAbove Ground PipingWater & Sewage Treatment PlantsStorm Water DrainageFire Fighting Ne t w or k sSuitable usage for more

5 Than 400 ChemicalsSewage DrainageDesalination PlantsDrinking / Potable WaterSlurry Transportation PipingPipe Jacking & Tunneling , Slip-Lining ApplicationsSub-Aqueous PipingHydro-electric PlantsDistillate Water PipingSea Water Intake & Outfall PipingChemical PlantsSpecial Applications & Many Other can be used for all types of fluidsPeep in to FRP Stress Strains- Strength FRP-Pipe Wall Enlarged Cross SectionFibresResinSand FillerIsotropic materials: mechanical properties the same in all directions strength and stiffness not dependent on direction ex. thermoplastics, metalssteel: E = 210000 MPaOrthotropic materials (GRP): mechanical properties direction dependent, strength and stiffness dependend on direction ex.

6 Reinforced concrete, fibre reinforced polyesterpolyester: E = 3000 4000 MPacontinuous glass: E = 72000 76000 MPaFRP-Pipe Stress- StrainFRP-Pipe Stress- StrainFlowtite vs SteelStress-Strain rain, %mild steelHigh pressure pipe - hoop , %1 EStandard pipe - axial tensileAbove-ground - axial tensileLow pressure pipe - hoop tensileHigh pressure pipe -hoop tensileFRP-Pipe Stress- StrainFRP-Pipe Stress- StrainA 10 Bar G FRP pipe was allowed to BURST and guess expected failure pressureComparisons to Various Wall-Specific Gravity ~ Of Thermal Expansion10-6in/in/ F~1515883001530 FRPALSTEELCONCRETEPVC12 PEThermal Conductivity0101001500 BTU - in / hr - ft2- EELCONCRET EPV E84 Flame Spread for FRPC onsult data sheets for specific OakNon-Halogenated0100200300400 XXPlywood25 75 Surge and Water

7 Hammer-Surge wave celerity02004006008001000120014001600 CONCDICSFRPPVCPE5 0 Wave Cel eri t y-mUsage of FRP World Wide- Literature SurveyUsage of FRP World Wide- Literature Survey In 1970, 1350 mm - Canada In 1974, 1200 mm - Peru In 1975, Office of Saline Water - USA, recommends GRP in Desal Plants In 1980, Reynolds recommends GRP in Distribution and Other Sy stems In 1981, Ainsworth recommends GRP for Different Applications More Reported Literature .. availableFRP-Life Cycle CostsSaving Time and Money-Life Cycle Costs 0% 10%20% 30% 40% 50% 60% 70% 80% 90% 100% Material Installation Maintanance Steel PlasticsSteel PlasticsSaving Time and Money-a Real Example 1400 Dia.

8 Steel (C) 1400 Dia. GRP 1300 Dia. GRP 1200 Dia. GRP Head, mtr 105 60 82 115 Pump, KW 3156 1803 2464 3456 Pipe Cost, $ Mil Pump Cost, $ Mil Instal Cost, $ Mil Comparison 100% 113% 100% 88% Power cost, $ Mil Annuity,Af= @ 10%, for 30yrs Project Cost, $ Mil Comparison 100% 81% 87% 101% Amiantit Initiative- GRP Plant in 1977In Dammam Saudi ArabiaAmiantit Initiative-1977 Start of GRP Plant Saudi Arabian Amiantit Company SAAC-Started GRP Plant in 1977 JV with Owens Corning (OC)/Flowtite/SAAC SAAC-overtake OC in 2000 Globalization Commences in 2000 One of the worlds biggest capacities More than 15 Machines Continuous production-365/7/24 30 Years of Journey of GRP AFIL-Dammam-1977 AFIL-Jeddah-2000 FPCL: Fiberglass Pipe Company Limited-2001 DPFCL: Dubai Pipe Factory Company-2002 AQAP: Amiantit Qatar Pipes Company-2008 ABHL.

9 Amiantit Bahrain Holding Limited-201030 Years of Journey of Machines at AFIL - Dammam6- Machines at AFIL-Jeddah2machines at FPCL- Dammam2500 Machine at DPFC- Dubai4000 mm machine at Qatar-20084000 mm machine at Bahrain-2010 is coming up Product RangeoDiameter: 80 mm to 4000 mmo Pressure: Gravity to 40 Bars (464 psi)o Stiffness: 1250, 2500, 5000, 10,00012,500 PaoJoint system : Couplings, Butt-strap, FlngsoInstallation: Underground, AbovegroundUnder Sea ApplicationsoResin : Polyester, Vinylester & EpoxyoTanks : U/G Up to 48,000 USGA/G H Up to 35,000 USGA/G V Up to 30,000 USG oStructural MH & Liner:1000 & 1200 mm Dia300 mm to 2400 mm.

10 > up to 4000 mmFRP-Pipe Production - RangeDiameters 80 mm 4000 mmPressureGravity40 Bars GApplication UGAG Under SeaRelining2500 Pa5000 Pa10000 PaLoad = P2 x P4 x PFRP-Pipe Stiffness - Range30 Years Supplies and Applications Under Ground Above Ground Under-Sea / Off-Shore On Ground Slip Lining Under Ground Above Ground Under-Sea / Off-Shore On Ground Slip LiningALL Types of Fittings Were FabricatedElbows,Tees, Reducers, Flanges, Blind FlAll Types of Fittings are PossibleApplications Under Ground Above Ground Under-Sea / Off-Shore On Ground Slip LiningUnder-Sea Cont i nue 50 Projects were already under operationDiameters Up to 3700 mmSupported in Design/ Installation in Various ProjectsPerformance of FRP in P and D Plants Under Ground Above Ground Under-Sea / Off-Shore On Ground Slip LiningOn Ground Applications For Sewage and Water Line with Flexible Couplings and Special Supports Useful for Rugged Terrain Can be Used for Slopes Similar Lines Under Operation