GRP Pipes & FittingsGRP Pipes & Fittings

1 GRP Pipes & Fittings Product Manual pipe Manufacturing Processes Available Filament Winding (Continuous Advancing Mandrel). Filament Winding (Fixed Mandrel). Page 2. Company Profile Al-Watani Factory For Fiberglass Company was established over 20 years ago in Kuwait and serves the Composite industry locally and its neighboring GCC States. During its early years, it produces GRP. moulded products, and a range of fiberglass water storage tanks for household use. Later, it embarked on larger products such as shelters, domes, and other customized items. Today, it manufactures Odour Control Vessels, Water Treatment Equipments and other made-to-order GRP. vessels and storage tanks. In 1998 its Plastic division was started and production of polyethylene tanks were initiated.

2 Capacities of PE water storage tanks ranging from 1000 liters to 10,000. liters became the standard sizes for villas & the industrial sector. Yet another ambitious endeavour was established in 1999 when the Polymer Concrete Division started operation. It produces a complete range of polymer concrete Pipes , Fittings , and manholes for the sewer system. Currently, the company is supplying simultaneously a number of projects for the country's sewerage requirements. The manufacturing facility now covers 100,000 square meters and is fully equipped with state of the art technologies and machineries. The GRP Division is equipped with filament-winding (helical & cross- helical winding patterns-PLC controlled), spray-up, RTM, and hand laminating machines, and is capable of producing large cylinders up to 4250mm diameter with lengths of up to 12 meters.

3 It also manufactures UL-listed GRP underground fuel storage tanks from 4,000 liters to 120,000 liters. Its new GRP pipe manufacturing plant is about 5,000 square meters and produces Pipes of diameters ranging from 300mm to 2600mm at production rate of about 26 meters per hour of high-quality gravity sewer GRP Pipes and pressure lines, qualified and tested to international standards. The company now employs over 800 personnel and is growing to cope up with market demands. Page 3. Watani's design philosophy is to pro- Well casings and well pump risers vide products with suitable properties Penstocks and the required margin of safety that will enable the pipe to perform satis- Gasoline handling and distribution network factorily after extended period of op- eration (more than 50 years) under Flue gas stack typical service conditions.

4 With the GRP Piping Technology from VEM, Watani is looking forward to Advantages of Watani providing GRP Piping solutions to the GRP pipe System various fields: Water distribution both civil and Light Weight industrial Sewer Systems both urban and Their lightweight, high-strength ratios industrial require lighter support structures than Irrigation networks the heavy metallic systems which en- ables additional cost savings. Water intakes for cooling water systems No need for expensive heavy-duty Waste water outfalls to sea machineries during installation. Sealines and rivers crossings Process lines for industrial plants Corrosion-Resistant Fire fighting networks Corrosive fluids and vent gas No need for linings or cathodic pro- Reference Standards stacks tection.

5 AWWA Manual 45 Thermosetting-Resin) pipe Joints using Flexible Elastomeric A Fiberglass pipe Design Manual for Underground and Seals. Aboveground Installation AWWA C 950. Fiberglass Pressure pipe ASTM D 638. Standard Test Method for Tensile Properties of Plastics ASTM D 2310. Standard Classification for Machine-Made ASTM D 1599. Fiberglass (Glass-Fiber Reinforced Thermosetting-Resin) Standard Test Method for Short-Term Hydraulic Failure pipe . Pressure pipe , Tubing and Fittings . ASTM D 2996 ASTM D 2105. Standard Specification for Filament-Wound Standard Test Method for Longitudinal Tensile Properties Fiberglass (Glass-Fiber Reinforced Thermosetting-Resin) of Fiberglass (Glass-Fiber Reinforced Thermosetting- pipe . Applicable to Epoxy, Polyester, and furan resins, in Resin) pipe and Tube.

6 Sizes from 1 in. to 16 in. (25mm to 400mm). ASTM D 695. ASTM D 3262 Standard Test Method for Compressive Properties of Rigid Standard Specification for Fiberglass (Glass-Fiber Rein- Plastics. forced Thermosetting-Resin) Sewer pipe . Applicable for Pipes 8 in. through 144 in. (200mm through 3,60mm) di- ASTM D 790. ameter with or without siliceous sand, and polyester or Standard Test Methods for Flexural Properties of Unrein- epoxy resin. forced Plastics and Electrical Insulating Materials. ASTM D 3517 ASTM D 1598. Standard Specification for Fiberglass (Glass-Fiber Rein- Standard Test Method for Time-To-Failure of Plastic pipe forced Thermosetting-Resin) Pressure pipe . Applicable for Under Constant Internal Pressure. Pipes 8 in. through 144 in. (200mm through 3,600 mm).

7 Diameter, with or without siliceous sand, and polyester or ASTM D 2143. epoxy resin. Standard Test Method for Cyclic Pressure Strength of Rein- forced Thermosetting Plastic pipe . ASTM D 3754. Standard Specification for Fiberglass (Glass-Fiber ASTM D 2992. Reinforced Thermosetting-Resin) Sewer and Indus- Standard Practice for Obtaining Hydrostatic or Pressure trial Pressure pipe . Applicable for 8 in. through 144 Design Basis for Fiberglass (Glass-Fiber Reinforced Ther- in. (200 mm through 3,600 mm) diameter, with or mosetting-Resin) pipe and fitting . without siliceous sand, and polyester or epoxy resin. ASTM D2142. ASTM D 4161 Standard Test Method for Determination of External Load- Standard Specification for Fiberglass (Glass-Reinforced ing Characteristic of Plastic pipe by Parallel-Plate Loading.)

8 Page 4. Qualification and Quality Control Tests Strain-Corrosion The purpose of this test is to simulate the worst service condition of a gravity sewer pipe . The test is conducted by subject- ing 18 ring samples of the pipe , then deflected to various levels and held constant. The ends of the ring specimen is sealed such that the test solution of sulfuric acid is contained in the deflected specimen. The time-to-failure is measuered for each sample which is evident when the test solution passes through the pipe wall (leakage). The test data is tabulated and a graph is plotted and extrapolated to 50 years using least square regression analysis technique. This is done by exposing 18 pieces pipe specimens to constant internal hydrostatic pressures at differing pres- sure levels and measuring the time to failure for each test.

9 To duplicate service conditions, the joints is sealed by an elastomeric seals with GRP coupling. The longitu- dinal (axial) load is resisted by the test fixtures in a way, that only the circumferential loads are induced into the pipe wall. In actual condition, the longitudinal forces is resisted by a thrust block and the joint is fixed using a coupling with rubber o rings. The time-to-failure is de- termined when the test fluid passes through the pipe Hydrostatic Design Basis HDB (1) (2) (3). The test procedure of ASTM 2992-96 Obtaining Hydrostatic pipe Outer Wall Test Time to Hoop or Pressure Design Basis for Fiber Glass (Glass-Fiber- Number Diameter Tickness Pressure Failure Stress Reinforced Thermosetting-Resin) pipe and Fittings mm mm bar h MPa Procedure B is used as guidelines.

10 The test was com- - . misioned by ANYANG FLYING EAGLE GROUP COMPANY 1 5 LTD. To Horizon Engineering Group Co. LTD. In year 1997. 2 8 pipe samples were taken from GRP Pipes produced by CON- 3 12 TINUOUS FILAMENT-WINDING process thru VEM technol- ogy. Test result is tabulated in Table 1. 4 4 5 90 6 201 Table 1 pipe Dimensions and Test Results 7 150 Nominal Average 8 120 Nominal Diameter 500 - 9 312 Outer Diameter (AWWA) 514 10 345 Nom. Wall Thickness 11 404 Resistant Wall Thickness 12 307 Internal Liner Thickness - 13 908 5600 Outer Liner Thickness - 14 1580 Mean Resistant Diameter 15 12000 *. 16 9890 Hoop Tensile Modulus 18,000 MPa 17 12000 *. 18 12000 *. 19 2680 (*) Discontinued 20 3250 (1) Measured according to ASTM D 3567. 21 5840 average of 5 readings 22 3500 (2) Measured according to ASTM D 3567 23 7220 average of 4+ readings at each end of the pipe 24 8200 (3) Calculated on mechanical thickness 25 Page 5.