Their Properties, Specification, Codes, Joining, Supporting, and Applications (With PDF) &#; What Is Piping
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The full form of FRP is fiberglass-reinforced plastic which is a composite material consisting of a polymer matrix reinforced with fibers. So, an FRP pipe is a pipe manufactured of FRP material by contact molding or filament winding method. Various types of resins like thermosetting polyester, epoxy, phenolic resin, etc are used to get specific FRP pipe properties in the final product. The most widely used reinforcement is the glass fiber &#;E-glass&#;. As a corrosion-resistant alternative to metallic piping, the FRP piping system has found worldwide application. By selecting FRP as the pipe material, the need for internal lining, external coating, and cathodic protection can easily be eliminated. FRP piping system is available in a wide range of sizes starting from 1 inch to 144 inches.
Types of Pipes | Classification of ...
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Types of Pipes | Classification of Pipes (PDF)
Applications of FRP Pipes
Due to its high durability, corrosion resistance, and moderate strength, the use of FRP pipes is increasing day by day. FRP piping systems are used in various industries like:
Potable Water and desalination industries
Chemical, Petrochemical, Oil & Gas industries.
Ducting and Vent piping
Irrigation and Sanitary services
Water distribution and transmission
Slurry piping
Power plants, etc.
Properties of FRP Piping
The main properties that make FRP Pipes an ideal selection for various industries worldwide are
Excellent corrosion resistance
Excellent strength-to-weight ratio. Note that, the strength-to-weight ratio of FRP pipes is higher than steel or other metallic pipes.
Lightweight which makes it easy for handling and transport.
Dimensional stability
Non-toxicity
Low coefficient of friction (>25% better than steel) that ensures excellent flow characteristics.
Good abrasion resistance
Suitable for both aboveground and buried piping
Resistance to biological attacks like bacteria
Non-conductive to electricity and
Low maintenance cost
Typical mechanical properties of the FRP piping system are provided in the table below:
Mechanical Properties of FRP PipeTypical RangeTensile Strength14 to 550 MpaTensile Modulus3.5 to 34.5 GpaFlexural Strength28-480 MpaFlexural Modulus6.9 to 34.5 GpaPoisson&#;s Ratio0.3Thermal Co-efficient14 to 54 mm/mm/0CSpecific gravity1.2 to 2.3Compressive Strength69-275 MpaTable 1: Range of Mechanical Properties for FRP Pipe
Joining of FRP Pipes
As the FRP pipe lengths are limited by transportation and handling, they are required to be joined. Also, various FRP Pipe fittings need to be joined as per the requirement. The joining system of the FRP pipe should be such that it does not leak for the intended service condition at the operating pressure. Depending on the specific joint configuration and design conditions, the FRP pipe joints may be restrained or unrestrained.
Unrestrained FRP Pipe Joints
Joints that can withstand the internal pressure but can not withstand the longitudinal tensile loads are known as Unrestrained FRP Pipe joints. Examples of such joints are Coupling joints, bell and spigot joints, mechanical coupling joints with elastomeric seals, flanged joints, butt joints with laminated overlay, etc.
Restrained FRP Pipe joints
Such pipe joints are capable of withstanding both internal pressure and longitudinal tensile loads. For these joints, supplemental restraining elements are added to restrict the longitudinal loads. Threaded joints, bell, and spigot joints with laminated overlay or adhesive bonds are examples of Restrained FRP pipe joints.
Note that FRP pipe joint tightness must be ensured following ASTM D.
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FRP Pipe Fittings
Various FRP pipe fittings are available for proper piping layout needs. Common FRP pipe fittings are
Long radius and short radius FRP Pipe Elbows (22.5 Degrees, 30 Degrees, 45 Degrees, 60 Degrees, 90 Degrees, 180 Degrees)
Tee Connections (Equal Tee and Reducing Tee)
FRP Pipe flanges
Steel backing flanges
Flanged elbows
Smooth flow-reducing elbow
Special radius bend
Lateral connection
Cross connections
Wye Connections
Reducers (Eccentric and Concentric)
Flanged reducers
Codes and Standards for FRP Pipes
Frequently used Codes and Standards that govern the FRP piping details are
ISO
ANSI/AWWA C950
AWWA M45
ISO
AWWA C590
ISO
BS
ISO
ASTM D, ASTM D, ASTM D, ASTM D, ASTM D
Specification of FRP Pipes
While ordering FRP pipes the following data need to be provided to the vendor:
Pipe Diameter
Design and Operating temperature of the service fluid.
Design, operating, Surge, vacuum, and test pressures.
Live loads in case of buried piping.
Maximum/minimum buried depth and trench Widths.
Details of Soil properties and trench preparation.
Supporting of FRP Piping System
FRP piping systems must be supported properly to avoid excessive sagging. Maximum acceptable sagging is the lower of 12.5 mm or 0.5% of span length. The manufacturer&#;s guidelines with respect to the supporting shall be followed. Usually, clamped supports with an elastomeric pad are used for support.
Fig. 1: FRP Pipe Supporting
Drawbacks of FRP Piping
The main drawbacks of FRP piping systems are
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FRP pipe is not recommended for carrying fluid with temperatures more than C
Slight degradation from UV rays is found to occur which can be reduced by using pigments, dyes, UV stabilizers, fillers, etc in the resin system.
FRP vs GRP: Difference between FRP and GRP
FRP stands for fiber-reinforced plastic while GRP stands for Glass reinforced plastic. So, from the name, it is clear that there is a change in the reinforcing fiber. But, both FRP and GRP are normally used to indicate the same plastic piping products.
FRP vs Steel: Differences between FRP and Steel
As FRP Pipes have superior corrosion resistance capabilities and over the long term it is economic, Steel pipes are replaced by FRP pipes. So, in this section, it will be great to find the differences between FRP and Steel.
Steel pipes are isotropic while FRP pipes are anisotropic and the properties change with respect to direction.
FRP pipes are more flexible than Steel pipes due to the lower modulus of elasticity.
FRP piping systems are designed considering a higher factor of safety than steel piping. The usual factor of safety in the design of FRP pipes varies in the range of 5 to 10.
Other major differences between FRP and Steel pipes are provided in Table 2 below:
PropertyFRPCSRemarksDensity kg/cu.m kg/cu.mLoads on support are less in the case of FRP pipe as compared to Steel. Handling and transportation of FRP are easier than Steel pipes.Co-efficient of thermal expansion27 X 10-6 mm/mm 0C11 X 10-6 mm/mm 0CExpansion is almost 2.5 times of Carbon Steel Pipe. So more thermal growth in the case of the FRP Piping system.* This value may change from vendor to vendorModulusAxial= N/sq.mmElastic= N/sq.mmConsiderable difference in the strength of FRP & CS. Anchor loads are less in FRP Pipes as compared to steel pipes.Shear= N/sq.mmTensile Strength80-135 MPa456 MPaMechanical Strength is higher for Steel material as compared to FRP.Yield Strength70-135 MPa227 MPaThe yield strength of FRP is lesser than that of Steel.Allowable Stress4,000 PSI to 20,000 PSI20,000 PSIThe strength of the GRE varies drastically and hence proper vendor data is a must.Corrosion resistanceSuperiorInferiorThe corrosion resistance of carbon steel is much lower than that of FRP pipes.JointsThreaded or gluedWeldedFRP joints are to be checked for higher axial loads and pressureTable 2: FRP vs Steel
FRP vs HDPE: Differences between FRP and HDPE Pipes
The main differences between FRP and HDPE pipes are listed in Table 3 below:
FRP PipeHDPE PipeFRP is Orthotropic composite materialHDPE is isotropic material.The cost of FRP pipe is very highThe cost of HDPE pipes is considerably lower than FRP Pipes.Lower thermal expansion coefficientThe thermal expansion coefficients of HDPE pipes are extensively higher as compared to FRP pipes.FRP pipes have a comparatively higher temperature range than HDPE PipesLowe temperature rangeFabrication time is comparatively longerQuicker fabrication.The strength and Elastic modulus for FRP pipes are higher than HDPELower strength and elastic modulus.Easy installation at the siteCostly complex equipment is required for installation.Highly skilled professionals are required for site work of FRP piping systemsHDPE pipe works can be done by semi-skilled operators.Much lighter in weight due to lower all thickness even though the density of FRP is normally higher than HDPEHeavier due to higher wall thickness.A fire-retardant version of FRP pipes can be made.HDPE pipes are highly flammableTable 3: FRP vs HDPE
The initial cost of FRP pipes is normally higher than the metallic piping systems. But when comparing the total cost over the complete service life FRP Pipes come as a winner due to their long service life.
Stress Analysis of FRP Piping System
In piping stress analysis guides or flexibility specifications, FRP lines are considered critical irrespective of their sizes. So, a proper stress analysis must be performed to investigate the stresses, loads, displacements, supports, etc to decide if the FRP piping system will work smoothly throughout its design life. I have developed an online course explaining step-by-step procedures for FRP piping stress analysis. You can check it out here.
Fiberglass Reinforced Plastic
Fiberglass Reinforced Plastics (FRP)
FRP vs GRP: Difference Between FRP and GRP
FRP stands for Fiber Reinforced Plastic while GRP stands for Glass Reinforced Plastic. The name makes it clear that there is a change in the reinforcing fiber. But both FRP and GRP are normally used to denote the same plastic products.
Introduction:
In recent years, FRP has been widely used in process, water and chemical industries due to their high resistance to corrosion.
FRP pipes are also increasingly used for the transport of Water, Oil, Fuel, Glycol, Wastewater, Sewer, etc. As a result, the demand for FRP pipes is continuously increasing.
The service life is usually very high, in the range of 50 years. Thus, the total cost of FRP pipes for life becomes cheaper as compared to metal pipes.
What is FRP..
The full form of FRP is a composite material consisting of a polymer matrix reinforced with fibers. So, an FRP pipe is a pipe manufactured of FRP material by contact molding or filament winding method. Various types of resins like thermosetting polyester, epoxy, phenolic resin, etc are used to get specific FRP pipe properties in the final product.
The most widely used reinforcement is the fiberglass. As a corrosion-resistant alternative to metallic piping, the FRP piping system has found worldwide application.
Filament Wound Laminate
1 C-Glass surface veil
2 Chopped Strand Mat
3 Woven Roving
4 Filament Wound Strand
5 Outer surface layer with U.V. inhibitor
a Corrosion Barrier (Abrasion Barrier) (Thickness .100in nominal)
b Structural Wall (Thickness in accordance with pressure rating)
Common Fibers include:
Glass is a very good insulating material and, when blended with the matrix, forms fiberglass or glass reinforced plastic. Compared to carbon fiber, it is both less strong and rigid and less brittle and expensive.
Carbon based fiber reinforced plastics offer high tensile strength, chemical resistance, stiffness, and temperature tolerance along with low thermal expansion and weight. The carbon atoms form crystals which lie mostly along the fiber&#;s long axis. This alignment makes the material strong by making the ratio of strength to volume high.
Aramid is a fiber component that results in robust and heat-resistant synthetic fibers. It finds wide applications in many industries.
FRP Pipes
FRP Flanged Fittings
By selecting FRP as the pipe and fittings materials, include flanges, elbows, tee's, crosses, reducers etc., the need for internal lining, external coating, and cathodic protection can easily be eliminated. FRP piping system is available in a wide range of sizes starting from 1 inch to above 100 inches.
More than just FRP pipe systems
Besides pipelines, storage tanks, towers, grids on walkways, profiles (like steel profiles) etc. are also manufactured from FRP. Below a description of a storage tank
Introduction:
FRP storage tanks are divided into vertical storage tanks and horizontal storage tanks. The winding material selection of storage tanks must be appropriate, quality priority, and price consideration.
In the actual production, the tank wall structure of the FRP-wound storage tank is generally an inner liner layer, a strength layer and an outer surface layer.
Material and resin selection:
Due to the different functions of the layers, the materials are selected differently, and the inner liner is directly in contact with the medium, and the material selection is correct or not, which plays a key role in controlling the leakage of the wound storage tank.
To use vinyl resin if store acidic medium, to use bisphenol A resin if store alkali medium, to use alkali-free glass fiber if need to be water and alkali resistant, to use medium-alkali glass fiber if need to be acid-resistant , and the inner liner is made of surface felt and chopped together to reinforce to increase the amount of glue and enhance the impermeability.
The strength layer mainly meets the strength and stiffness requirements of the storage tank. Material selection should fully consider that the selected resin matrix must have good penetrability with the glass fiber for winding to form a dense structural layer; the outer surface is in direct contact with the external environment, and the material is selected according to the aging resistance requirement.
Application:
FRP tanks can be used to store tanks of various media. They are resistant to pressure, corrosion, ageing, long service life, light weight, high strength, impermeability, heat insulation, insulation, non-toxicity and smooth surface. It is widely used in coatings, pharmaceuticals, building materials, chemicals, pigments, resins, food, scientific research and other industries.
Drawbacks of FRP
FRP is not recommended for carrying fluid with temperature more than 100 degrees celsius
Slight degradation from UV rays is found to occur which can be reduced by using pigments, dyes, UV stabilizers, fillers, etc in the resin system
FRP Storage Tank
FRP Columns
FRP Grids on walkways
Sources:
www.frpwt.com
HeBei WeiTong FiberGlass Co., Ltd.
www.versteden.com
Versteden fiberglass piping systems
www.fibrex.com
FIBREX FRP piping systems
Some Codes and Standards for FRP
ASTM D, Standard Specification for Contact-Molded &#;Fiberglass&#; (Glass Fiber-Reinforced Thermosetting Resin) Corrosion Resistant Pipe and Fittings, ASTM. West Conshohocken, PA
ASTM D, Obtaining Hydrostatic or Pressure Design Basis for Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Fittings. ASTM, West Conshohocken, PA
ASME B31.3 Process Piping. ASME, New York, NY
ASTM D, Specification for Contact Molded Fiberglass (Glass-Fiber Reinforced Thermosetting Resin) Flanges. ASTM, West Conshohocken, PA
ISO , Glass fibre reinforced thermosetting plastics (GRP) pipes and fittings - Nominal diameters, specified diameters and standard lengths
ANSI AWWA C950-, This standard describes the fabrication and the testing of nominal 1-in through 156-in (25-mm through 4,000-mm) fiberglass pipe and joining systems for use in both aboveground and belowground water systems. Service and distribution piping systems and transmission piping systems are included
AWWA M45, Selection, installation, and maintenance of fiberglass pipe in potable water systems
ISO -1, Petroleum and natural gas industries - Glass-reinforced plastics (GRP) piping
What Is The Difference Between FRP And GRP?
A: FRP stands for fiber-reinforced plastics, it&#;s a term typically used stateside here in North America. GRP is a term that means the same thing. But it&#;s generally used over in Europe and Asia and stands for glass-reinforced plastic.
The backbone of the industrial revolution has always been thought to be led by the steel industry. While steel still plays an especially important role in structural building it has drawbacks. In fact, all metals do because even the strongest metal will eventually succumb to rust. Whether aluminum or steel&#;there is no metal impervious to the elements.
Wood is even more fragile as even though it does not rust, it can be weakened by moisture. It can also be broken by force, ravaged by termites, or succumb to mold.
Some might suggest simple plastic as an alternative and while they&#;re on the right path&#;it&#;s not quite right. Plastic alone can warp and will crack or melt when exposed to high temperatures, and it lacks strength. However, the solution isn&#;t too far from it.
FRP IS THE ANSWER
In all honesty, there is not a substance on earth that can hold its shape, strength, and structural integrity forever&#;but FRP comes awfully close.
Now, here in North America, we refer to this superior substance as FRP which as mentioned stands for fiber-reinforced plastic. It is a term that encompasses a wide array of products and applications. In Europe and Asia, they have the same product, but it&#;s called GRP&#;glass reinforced plastics. It is the same exact thing, simply different terminology like how a trunk here is a boot in England.
FRP is a composite material comprised of a matrix of a thermoset resin, and is reinforced using fibers. There are many different types of resins used in making FRP depending on the application. These plastic resins can include:
Polyurethane
Polyester
Vinyl ester
Epoxy
Phenol formaldehyde (occasionally)
The fibers used for reinforcement in DEFI products are typically glass. However, in the industry there are FRP products made with fibers that can include:
Basalt
Carbon
Kevlar
Nomex
In the early years of FRP, there were even some reinforcements made from paper, asbestos, or wood. That is obsolete these days due to their inferior durability compared to carbon and glass.
It Solves Problems On Many Levels
Like all composites, FRP has advantageous characteristics that best the singular components they&#;re made of. For example, the fiber reinforcements add elasticity as well as strength to the matrix which is tough but still relatively weak. This combination creates an even tougher material that is also long-lasting. This allows it to be turned into a variety of complex structural shapes and platforms or sheets for all applications.
Fiber-reinforced plastics are incredibly strong, exceptionally durable, and super resistant to impact and denting. They can also handle climates and environments of the harshest nature, especially corrosive ones such as oil rigs. In fact, when compared to metals like steel or aluminum, FRP has a much higher strength to weight ratio. This means that it can be as strong as steel while also weighing a fraction of what steel weighs. It is for that reason that many FRP products from DEFI are used in aerospace, marine, ballistic armor, and automotive industries.
Today, FRP can be purchased in a variety of different makeups with different resins and fibers. The greater the fiber volume the stronger the FRP. These days, fiber volume comes between 20% to 70% for most FRP products. There are also different processes by which the fiber-reinforced plastics can be made as we covered last month. At DEFI we can manufacture our FRP according to your exact needs and specifications.
Using The Right Reinforcement Fiber In FRP
In addition to using the right preform manufacturing method and molding process for your parts, the right fiber is also key. Different types of reinforcement fibers will offer different advantages that will speak to your application needs.
Naturally, glass is by far the most often used material for fiber reinforcement. It&#;s usually combined with polyester or polyurethane resin&#;this is referred to as fiberglass. It&#;s a combination that is so common and well known that the name fiberglass was coined just for that composite.
The reason glass is so common is because it is so easy to work with for a wide variety of applications. It allows for extremely specific alignment of the fibers to suit unique part designs. This results in a product with the best strength, elasticity, and resistance to deformation of any fiber. Additionally, it is highly resistant to extreme heat or cold. You will most often find fiberglass in car parts such as gas and brake pedals, insulation for windows, and elevator cables. Yes, it is that strong.
Now, carbon and Kevlar fibers enhance the elasticity of the FRP product as well as help boost compression and electrical strength. Products made from these fibers are lightweight and corrosion-resistant. It is heavily used in the medical equipment industry and carbon has recently been used in the aerospace sector. In fact, a plane you may have flown on, the Airbus 310 uses carbon FRP in the production of the aircraft&#;s rudders.
Basalt is extremely resistant to a myriad of environmental and inorganic conditions. It boasts the highest chemical and heat resistance of all fibers&#;especially salt. Therefore, it makes sense that basalt is commonly used in boat design as well as bridges and piers along coastlines.
STRUCTURAL ADVANTAGES OF FIBER REINFORCED PLASTICS
Fiber-reinforced plastics are quite an advantageous building material with benefits that are both physical and cosmetic. So many industries are turning to FRP products once they realize the long-term fiscal savings.
Fiber-reinforced plastics first gained exposure as a material for the manufacturing world because of strength versus other materials. Materials such as regular polymers, thermoplastics, and even metals like aluminum and steel simply couldn&#;t compare. FRP products offer the same strength but also boost elasticity, durability, and flexibility. It also does this while weighing only a fraction of their traditional counterparts. In addition to those benefits, the amount of elasticity and the strength can even be adjusted as needed. This makes FRP a very adaptable material that can be used across many industries for many different applications with ease.
In terms of shape and complexity, FRP can be manufactured into huge complex designs using several geometric shape combinations. The material thickness can be adjusted from as little as 1/16 of an inch up to ½ inch if needed. Shapes can be both contoured or rounded and can offer tight tolerances with a uniform thickness.
As touched on before, FRP also boasts exceptional resistance to several factors including impact, extreme temperatures, corrosion, and more. Its non-magnetic properties are also the reason for the dominance of fiber-reinforced plastics in aerospace and medical imaging equipment.
Aesthetic Benefits of Fiber Reinforced Plastics
In addition to the durability and exceptional lifespan of FRP materials, they also can be made to be aesthetically appealing. Since FRP experience virtually no shrinkage during the molding process it makes for consistent results during a production run.
FRP can be painted while in the mold using a gel coat that gives a Class A glossy finish right out of the mold. Since the material bonds to the gel coat so well, paint chipping, cracking, or flaking is a non-issue. The paint will stay shiny and retain color vibrance over an exceedingly long period, unlike traditional painted materials.
CHOOSE DEFI FOR THE BEST IN FRP
When it comes to FRP, the only way you could be disappointed in the material is if it&#;s not manufactured properly. DEFI has several decades of experience in creating some of the best FRP products in the United States. Our products and installation services are second to none and used in a multitude of industries. Contact us today and see what DEFI can do for your project and your bottom line.
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