FRP/RTRP/GRP-Piping system for all Industrial Applications with in Middle East from 30 years

Sadath A Khan
Engineering Manager GRP/PE Division-Amiantit Dammam A Member of Standards Committee AWWA C-950 and M45-for GRP Pipes AWWA-D-120 for GRP Tanks

Presentation 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

Middle East
Arid (Dry) Region Little or No Rain Lack of Fresh Water Resources Surrounded by Red Sea, Arabian Gulf

Typical Characteristics are

( Varying Geomorphic Conditions

Changing Climates

Oscillating Water Tables

, High Salted Sabkha Soils Fluctuating Humidity's q Low Electrical Resistivity of Soils q Fast Track Construction

In Middle East Sea Water is Desalinated for Domestic Requirements Construction Requirements Industrial Demands etc. Desalination / Power / Chemical /Oil and Gas Plants are Being Built along the Coasts of Red Sea and Arabian Gulf.

Factors Affecting Traditional Materials

Seawater of Arabian Gulf and Red Sea TDS ranges from 40,000 to 65, 000 ppm It contains Dissolved Gases Decaying Organics, In-Organic and Other aggressive elements Acting alone or simultaneously produces various forms of Degradation

Factors Affecting Traditional Materials

Chemical Factors Oxygen, H2S, Chlorine Solubility, pH, Carbonate Solubility Physical Factors Velocity: Air Bubbles, Suspended Solids, Silt Temperature and Pressure

Factors Affecting Traditional Materials

Biological Factors Bio Fouling: Hard Shell, Semi Mobile and Mobile Types Plant Life and Animal Life: Oxygen Generation, Carbon Consumption

Common Degradation Process

Piping and other Equipments General Corrosion Attack of Material Impingement Attack Erosion By Suspended Solids Crevice Corrosions Stress Corrosions Cracking (SCC) HAZ(Weld and Heat Affected Zones)

Resulting

Resulting ..

Resulting .

Resulting

Selection of Materials.
Cost Plant Life Desired Feed Characteristics Material Compatibility Maintenance Capabilities Ease of Availability Overall Life Cycle Capital Cost Constraints Design and Operating Conditions

Material of Choice !!!

Material of Choice for All Applications

Fiberglass Reinforced Plastics FRP / GRP / GFRP RTRP / RPMP

FRP-Pipe Wall Construction

Glass Sand Resin Fiber Core

FRP-Pipe Wall Construction

Nomenclature

Fiber Reinforced Plastics (FRP) FRP

Fiberglass Reinforced Plastic (or Polyester) or Fiber Reinforced Plastic (or Polyester) (European Standards)

GRP

Glassfibre Reinforce Plastic (or Polyester) (BS Standards)

RTRP Reinforced Thermosetting Resin Pipe RPMP Reinforced Plastic (or Polymer) Mortar Pipe
(American Standards)

FRE GRE

F iberglass Reinforced Epoxy

Glassfibre Reinforced Epoxy

Classification

Classification based on Engineering Materials

Engineering Materials

Metals Basic Alloys

Non Metals

Polymers

Ceramics

Glasses

Others

Classification based on Engineering Materials

Polymers Elastomers Thermoplastics Thermosets EPDM Neoprene LDPE HDPE PVC PP Polyesters Epoxies Alkyds Pheonolics Acrylytes Silicones Nitrile F-carbons

FRP-Pipe Wall Construction-Chemistry

Thermoset Thermoplastic

Egg

Candle

How / Where FRP can be Used ?

Usage of FRP based on Resins

Properties
Resin Temperature Pressure Can Handle

FRP Polyester Piping

Polyester / Vinyester Up to65 C / 90 C Gravity to 40 Bar G / Full Vacuum All-Moderate Corrosive Fluids

GRE Epoxy Piping

Epoxy Up to150 C Gravity to 200 Bar G/ Full Vacuum All-High Corrosive Fluids

Applications

FRP can be used for all types of fluids

Industrial Waste Apps. Rehabilitation Applications Water Transmission Lines Above Ground Piping Pressure / Forced Mains Sewers Water Distribution Systems Suitable usage for more than 400 Chemicals Slurry Transportati on Piping Chemical Plants

Water Distribution Systems

Fire Fighting Networks Sea Water Intake & Outfall Piping Re-lining, Slip-Lining Applications

Storm Water Drainage Irrigation

Water & Sewage Treatment Plants Drinking / Potable Water

Desalination Plants Hydroelectric Plants Sewage Drainage

Distillate Water Piping

SubAqueous Piping Special Applications & Many Other Apps.

Pipe Jacking & Tunneling Apps.

Peep in to FRP Stress Strains- Strength

FRP-Pipe Wall Enlarged Cross Section

Fibres Sand Filler

Resin

FRP-Pipe Stress- Strain

Isotropic materials: mechanical properties the same in all directions strength and stiffness not dependent on direction ex. thermoplastics, metals steel: E = 210000 MPa Orthotropic materials (GRP): mechanical properties direction dependent, strength and stiffness dependend on direction ex. reinforced concrete, fibre reinforced polyester polyester: E = 3000 4000 MPa continuous glass: E = 72000 76000 MPa

FRP-Pipe Stress- Strain

Flowtite vs Steel Stress-Strain Curves
800

700

High pressure pipe - hoop tensile

600

500

400

300

mild steel

200

100

0 0 0.5 1 1.5 2 2.5 3

Strain, %

FRP-Pipe Stress- Strain

200 180 160 140 120 100 E 80 1 60 40 20 0 0 0.5 1 1.5 2 2.5 3 3.5 4

High pressure pipe -hoop tensile

Low pressure pipe - hoop tensile

Above-ground - axial tensile

Standard pipe - axial tensile

Strain, %

FRP-Pipe Stress- Strain A 10 Bar G FRP pipe was allowed to BURST and guess expected failure pressure

Comparisons to Various Materials

Pipe Wall-Specific Gravity

8 6 4 2 0
FRP AL STEEL CONCRETE PVC

1.8

2.5 1.5 ~0.96

PE

Coefficient Of Thermal Expansion

30

30

15

~15

15 12 8 8
CONCRETE PVC PE

FRP

AL

STEEL

10-6 in/in/ F

Thermal Conductivity
1500 1500

1500
100

115

115 115
7.5 1.5

10

7.5
AL STEEL CONCRETE

1.1
1.1

2.4
PE

0
FRP

PV C

BTU - in / hr - ft2 - F

ASTM E84 Flame Spread for FRP

Asbestos/Cement

Halogenated-FRP Halogenated/ w/Antimony-FRP

Red Oak
Plywood Non-Halogenated

0 25 75 100

200

300

400

Consult data sheets for specific information.

Surge and Water Hammer-Surge wave celerity

1600 1400 1200 W ave C elerity-m 1000 800 600 400 200 0 C ON C D I C S FR P PV C PE 50

Usage of FRP World Wide- Literature Survey

Usage 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

Systems

In 1981, Ainsworth recommends GRP for Different

Applications

More Reported Literature available

FRP-Life Cycle Costs

Saving Time and Money-Life Cycle Costs

Material Installation Maintanance

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

Steel Plastics

Saving Time and Money-a Real Example

1400 Dia. 1400 Dia. 1300 Dia. 1200 Dia. Steel (C) GRP GRP GRP
Head, mtr Pump, KW Pipe Cost, $ Mil Pump Cost, $ Mil 105 3156 13.75 0.27 60 1803 15.68 0.15 82 2464 13.75 0.21 115 3456 12.10 0.29

Instal Cost, $ Mil Comparison

Power cost, $ Mil Annuity,Af=0.106 @ 10%, for 30yrs Project Cost, $ Mil

14.02 100%
2.03 19.17 33.19

15.83 113%
1.16 10.94 26.77

13.96 100%
1.59 14.95 28.91

12.39 88%
2.22 20.97 33.36

Comparison

100%

81%

87%

101%

Amiantit Initiative- GRP Plant in 1977 In Dammam Saudi Arabia

Amiantit Initiative-1977 Start of GRP Plant

Saudi Arabian Amiantit Company SAACStarted 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 Limited2001 DPFCL: Dubai P ipe Factory Company-2002 AQAP: Amiantit Qatar Pipes Company-2008 ABHL: Amiantit Bahrain Holding Limited2010

30 Years of Journey of GRP

8 - Machines at AFIL - Dammam 6- Machines at AFIL-Jeddah 2 machines at FPCL- Dammam 2500 Machine at DPFC- Dubai 4000 mm machine at Qatar-2008 4000 mm machine at Bahrain-2010 is coming up

Product Range
o Diameter o Pressure o Stiffness
: 80 mm to 4000 mm : Gravity to 40 Bars (464 psi) : 1250, 2500, 5000, 10,000 12,500 Pa o Joint System : Couplings, Butt-strap, Flngs o Installation : Underground, Aboveground Under Sea Applications o Resin : Polyester, Vinylester & Epoxy o Tanks : U/G Up to 48,000 USG A/G H Up to 35,000 USG A/G V Up to 30,000 USG o Structural MH & Liner:1000 & 1200 mm Dia

FRP-Pipe Production - Range

Diameters 80 mm 4000 mm Pressure Gravity 40 Bars G Application UG AG Under Sea Relining
300 mm to 2400 mm ...> up to 4000 mm

FRP-Pipe Stiffness - Range

Load = P 2xP 4xP

2500 Pa

5000 Pa

10000 Pa

30 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 Lining

ALL Types of Fittings Were Fabricated

Elbows,Tees, Reducers, Flanges, Blind Fl

All Types of Fittings are Possible

 Under Ground
Above Ground

 Under-Sea / Off-Shore
 On Ground  Slip Lining
Applications

Under-Sea Continued. Around 50 Projects were already under operation Diameters Up to 3700 mm Supported in Design/ Installation in Various Projects

Performance of FRP in P and D Plants

 Under Ground  Above Ground  Under-Sea / Off-Shore  On Ground  Slip Lining

On 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

 Under Ground  Above Ground  Under-Sea / Off-Shore  On Ground  Slip Lining

Typical Oldest Case Histories >25Years

Results of GRP pipe Installed in 1980

Traceablity and Pipe Identification
z z z z z z z

Pipe Nominal Diameter Pipe Identification number Pipe production date Nominal Pipe wall thickness Pipe nominal Pressure rating Pipe Nominal Stiffness Pipe Actual Stiffness

1800 mm 2B-1910-X 09th July 1980 22.71 mm H-010 K Pa 1388 Pa STIS 1432 Pa STIS
Stiffness Comparison Chart at appro 25 Years of Ope ration Based on Ac tual Stiffness

Hoop Tensile Strength 45 MPa Axial Tensile Strength 25 MPa

12.46%

Based on Design Stiffness

8.86%
0% 2% 4% 6% 8% 10% 12% 14% Percentage

Results of GRP pipe Installed in 1980

To Conclude and Summarize.

Summary of 30 Years GRP Supplies

Diameters 80 mm 4000 mm Pressure Gravity 40 Bars G Application UG AG Under Sea Relining

300 mm to 2400 mm ...> up to 4000 mm

Summary of 30 Years GRP Supplies...

Type of Production Aboveground Horizontal Tanks Aboveground Vertical tanks Underground storage tanks Large diameters for Sewer Large diameters for water Small Diameters Pipes for Sewer Small Diameters Pipes for Water Aboveground Pipes Perforated Pipes Quantity 1,648 1,243 5,111 4,321,795 1,983,848 3,814,540 504,350 285,420 101,176 Unit pcs pcs pcs Meters Meters Meters Meters Meters Meters

Summary of 30 Years GRP Supplies

Below Ground
24 meters

Pipe Lining/Rehabilitation

Above/ Industrial Piping

A Total of 11, 559 Km - GRP supplied

Sub-aqueous

Finally Some Interesting Applications

Conclusions and Recommendations

GRP Pipes are suitable for All Applications better than that of Traditional Materials No Maintenance, INSTALL it FORGET it Not in Theory but Exists over 30 Years Commercially Viable Greater Flexibilities Need to Adopt Now in All Applications

QUESTIONS & ANSWERS

YOU CAN CONTACT me

sadathcn@[Link] sadathcn@[Link]

Middle East Region

Middle East Region