FRPPipingTechnicalAspects.

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FRPPIPINGSYSTEM
Introduction:
Fiberglassreinforcedplastic(FRP)pipingmadefromepoxyvinylesterresinsprovidesexcellentcorrosion
resistance in saturated inorganic brine service. However, the rapid rate of change and significant
difference in temperatures mentioned previously would make FRP susceptible to thermal shock, which
mayleadtothecrackingofthecorrosionbarrierandsignificantstressontheentirepipingsystem.
Carbonsteelpipingcarryingasaturatedinorganicbrinesolutionwasexperiencingleakswithinayearof
installation. Even though brine temperatures were normally controlled to change gradually, the
temperature of the brine could change rapidly from20C to 60C (4F to 140F) in less than five
seconds. The operating pressure was 345 kPa (50 psig). Other metallic piping substitutes were
investigatedwithcoppernickelpipingbeingfoundtobetheonlymetallicmaterialsuitableforresisting
the corrosive nature of the saturated brine process stream. However, coppernickel piping is very
expensivematerial.Alowercostalternativewasneededandsought.
Fiberglassreinforcedplastic(FRP)pipingmadewithepoxyvinylesterresinsandmodifiedfromstandard
manufacturingpracticesinordertohandlerapidtemperaturechangeswasusedforanimmediatecost
savings . The FRP piping has provided maintenance free service for three years. Custom fabricated FRP
pipe, up to twelve inches in diameter, is approximately 1.5 to 2 times the cost of carbon steel pipe
installed.Asthepipediameterincreasesthecostdifferencedecreases.
Knowledgeable FRP piping manufacturers can design piping systems to withstand thermal stresses put
onthemwiththeuseof appropriateguidesandanchorsinhighstresslocations,aswellas,fabricating
the pipe for the required physical properties. However, a standard corrosionresistant barrier in FRP
piping would probably not resist the effects of excessive thermal shocks experienced in the process. In
order to meet the severe thermal requirements for the saturated inorganic brine, modifications to
standardFRPcorrosionresistantbarrierwereemployed.
Essentially all FRP equipment made with epoxy vinyl ester resins has a resin rich corrosion resistant
barrier and structural wall. (The resin provides corrosion resistance and holds the shape of the
fiberglass. While, the fiberglass is for strength). The standard FRP corrosion resistant barrier generally
consists of a cglass or synthetic veil 0.3mm (10mils) thick and at least two layers of 450 g/m 2 (1.5
oz./sq, ft.) chopped strand glass mat for a total thickness of about 3mm (100mils). The corrosion
resistant barrier being resin rich contains 7080wt% resin, while the structural portion of FRP
equipmenthassresincontentcloseto50wt%.
It is essential that the integrity of the corrosion resistant barrier be maintained in order to protect the
structuralwallofFRPequipment.Thereareseveraltechniquesthatcanbeemployedtogreatlyreduce

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the effects of thermal shock and fatigue on the corrosion barrier of FRP equipment. Epoxy vinyl ester
resinlaminat.
GlassReinforcedPlastics"GRP"orReinforcedThermosettingResin"RTR"Pipesexhibit,
1. Excellentadhesion.
2. Fatigueresistance.
3. Impactstrength.
4. Chemicalresistance.
5. Lowshrinkage.
6. Longtermperformance.
7. SuperiorMechanical&Chemicalproperties.
8. Excellentfatigueresistanceundercyclicloading.
Dependsup onthe type ofResinused,thePipes&Fittingsare categorizedasGRP,GRV&GREandare
usedfordifferentindustrialapplications.
Applications/Industries:
1. SeweragePiping
2. StormWaterSystem
3. WaterDesalinationPlants.
4. PumpingStations
5. FireMain.
6. PowerPlants.
7. Chemical&PetrochemicalPlants.

StiffnessClassofpipes:
1500N/m2,2500N/m2,5000N/m2,10000N/m2
PressureClassofPipes:
Gravity,6Bar,12Bar,16Bar,25Bar,32Bar

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Installation:
TherequirementsforproperinstallationofFiberglassPipingSystemdependsontheapplicationAbove
Ground or Below Ground .It significantly vary from the procedures Of Metallic Piping System it needs
review of design specifications, information on type and spacing of supports, anchors, guides etc. In
general the deflections of unsupported span lengths are maintained within acceptable limits and also
compensatefortheeffectofthermalexpansion.Installcarefullytokeepstressesorstrainsinthesystem
belowacceptablelimits.
TypesofJointingandPreparation
There are several methods available for the installation and adjusting of FRP pipe systems in the field.
Thefollowingjointingmethodsarecommonlyused.
1. Adhesivebondedjoint
2. Rubbersealjoint
3. Flangedjoint
4. Laminationjoint
5. Mechanicalcoupler
In case it is necessary to shorten the pipe length at a certain point in the line, rejointing can be
performed by adhesive bonding or by laminating. The adhesive bonded joint is available up to and
includingadiameterof400mm.
Cutting
Thepipesectiontobecutshouldbemarkedusingamarkerpenandapipefitter'swraparoundguide.
Ensure that the cut end is completely square as the reliability of the joint depends on it. The cutting of
glassfiberreinforcedepoxypipescanbedonebymeansofahacksawfordiametersupto100mm.For
diameters above 100 mm an abrasive cutting disc can be used. Do not cut close to the socket end of a
rubber seal joint and/or adhesive bonded joint. The cutting distance away from the conical part of the
bellendmustbeequalto,orlongerthanthelengthforlaminatedjoints.

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1. Adhesivebondedjoints
Before adhesive bonding, all safety precautions will need to be checked. Ensure that all necessary tools
and materials are available. Adhesive bonded joints can only be made by fully trained and certified
personnel.
1.1Toolsforadhesivebondedjoints
Forassemblyofadhesivebondedjointsthefollowingisneeded:
measuringtape+markerpen+pipefitter'swraparound+measuringgauge
pipeclamp+bench+rubberstrip(foruseunderneaththechainclamp)
anglegrinderwithdiagritorcarborundumcuttingdisc(grain24)flappersanderandasandingbobbin,a
handsawwitha24teeth/inchblade,jigsawwitha14teeth/inchblade
shaver
cleaningrag
adhesive,spatula(=rubberscraperplate),emerycloth
heating blanket, hot air gun (paint stripper gun), digital temperature gauge, variable energy control
(rheostat),insulationblanket
generator
Cleaningfluid/gloves/dustmask/safetyglasses.
shelter(dependingontheweatherconditions)
1.2Machining
Afterthepipehasbeen cutto theexactlength,theend willhavebe machinedtotherightdiameterto
ensureaproperjoint.Thesurfacehastobecleanedwithacleancloth.Ifthesurfacehasbeenincontact
with oil or grease, it should be cleaned with a clean cloth soaked in pure acetone, M.E.K. (methyl ethyl
ketone)orM.I.B.K.(methylisobutylketon)(freeofwater).Afterdrying,machiningcanstart.Thereare3
shaversavailable:onefordiametersupto50mm,onefordiametersfrom80mmto250mmandonefor
diametersfrom200mmto400mm.
Aftertheadhesiveisappliedagoodbondisguaranteed.Anyirregularityinthicknesscanbedetermined
by measuring the spigot end in several places. On the machined spigot end the max. wall thickness
difference allowed is 0.2% of the diameter of the pipe, with a minimum value of 0.3 mm. The spigot
dimensionshavetobeinaccordancewiththevaluesshowninthebondinginstructionspackedwiththe
adhesive.

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1.3Bondingofthejoint
The bonding instructions are packed with every adhesive kit. Wastage of adhesive can be reduced by
goodplanningandthebestuseoftheadhesivekits.Toomuchadhesiveappliedtothesocketwillreduce
thediameterandresultinrestrictedflow.Removeexcessadhesivewiththeaidofthespatulaandfinish
the seam properly and smoothly. This can also be done inside the pipe, for example, by pulling a plug
throughthepipe.Thiswillpreventsproblemsusingfoampigslater.
The temperature of the heating blanket should be at least 90C for applications of medium below 65C
and125Cformediumtemperaturesbetween65Cand90C.
Curingtimeisnearlyonehourandonehourwarminguptime.Curingtimestartsafterthesurfaceofthe
pipe has reached the required temperature underneath the heating blanket. During curing the joint
should be insulated for example by using insulation blanket and seal off the pipe ends to prevent
draughtsthroughthepipe.
Becauseoftheirconfiguration,flangedjointsandlateralsaredifficulttocurefromtheoutsidebyusinga
heatingblanket.Theycanbecuredwiththefollowingalternativeprocedure:
A Roll up the heating blanket and place it on the inside of the pipe at the machined end. Fill the
space inside the blanket with heat resistant material to ensure that the blanket is pressed against the
pipewall.Theelectricalcablesmustnotbeinside.
B Heat the joint on the inside with a hot air gun / paint stripper or infra red device. Control the
temperature with a digital temperature gauge. For laterals, the branch and the nearest joint must be
curedfirst.Theremainingpartscanbecuredwithaheatingblanket.
Donotmovethejointduringsettingoftheadhesive!Thiscanresultinfailureofthejoint.Afterthecured
jointhascooleddownitmaybeloaded.
NoteInmanycasesthenumberofsitejointscanbereducedbyprefabrication(spoolbuilding)in
thefactory.
IntegralRubbersealjoint(RSJ)andRubberSealLockJoint(RSLJ)
BeforeassemblingtheRubberSealJoints,allsafetyprecautionswillneedtobe checked.Ensurethatall
necessarytoolsandmaterialsareavailable.

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Toolsforrubbersealjoints.
Forassemblyofrubbersealjointsthefollowingisneeded:
LubricantforOringandlockingstrip
Arodorstick
2pipeclamps
Chaintackles(2):uptoID500mmpullingforce750kg.
ID>500mmpullingforce1500kg.
Plasticorwoodenmallettodrivethelockingstripintotherubberseallockjoint
Nonfluffycleaningrags
Thefollowingactionsmustbetakeninordertoinstalltherubbersealjoint.

2.1.RubberSealJoint(RSJ)withpipestop
Clean the spigot and socket end thoroughly with a clean cloth before jointing. Do not use
materiallikedustersinordertoavoidfibersfromstickingtothesurfaceoftheseal.
Checkbothpipeendsfordamage.
Markthedepthofentryonthespigotend.
Themeasurementofthemarkonthespigotendisasfollows:depthofthesocketendminusend
play
Positiontherubberringintothegrooveofthespigotend.
Usearoundtoollikeascrewdriverunderneaththerubberringandworkitaroundafewtimesin
ordertodistributethetension.

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2.2.RubberSealJoint(RSJ)withoutpipestop
Toassemblearubberringjointusethismanual.Formarkingthedepthofentryonthespigotendusethe
instructionbelow.Markthedepthofentryonthespigotend.

Apply lubricant to the rubber ring and the entire inner surface of the socket end. Avoid any lubricant
under therubberringin ordertopreventitfromslippingoutofthe groove.Donottrytoassemblythe
joint without the use of any lubricant. Soft soap can be used as an alternative for the lubricant. Fit the
rubberlinedclampsonbothsidesofthejointensurethatthespigotendispositionedrightinfrontofthe
socketendandthatbothsectionsarefullyaligned.Attachthechaintacklestotheclampsonbothsides
ofthepartstobeconnectedandeasethespigotslowlyandgraduallyintothesocketuntilthemarkisin
linewiththefrontofthesocketend.
Ifindoubt,checkwithathinfeelergaugearoundthecircumference,toconfirmthattherubber
ringisintherightpositioninthegroove.
Diameters up to 300 mm can be installed without the use of tackles. The force necessary to make the
jointcanbedonebyusingawoodenbeamasaleverattheendofthepipe.Donottrytojointwopipes
at an angle, since it is probable that the rubber ring may slip out of the groove. However, if necessary,
only after assembly of the joint a permitted angle may be used. Do not use the maximum permitted
anglewhereyouanticipatesoilsettlement.

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2.3.RubberSealLockJoint(RSLJ)withpipestop
Position the hole so the locking strip can be inserted easily. Follow the assembly instructions for the
rubber seal joints (RSJ). Attach the chain tackles to the clamps on both sides of the pipe and ease the
spigotendslowlyandgraduallyintothesocketenduntiltherearstopofthespigotendispasttheholeof
thelockingstrip.Applysomelubricantonthefirstsectionofthelockingstrip.
Insertthelockingstripinsuchawaythatthebeveledendrestsagainsttheinsideofthesocket.

2.4.RubberSealLockJoint(RSLJ)withoutpipestop
Toassemblearubberringjointusethismanual.Formarkingthedepthofentryonthespigotendusethe
instructionbelow.

Usingaplastichammerorapieceofwood,tapthelockingstriphomeuntilitrestsagainstthefirstpart
of the strip. The end of the locking strips sticks out by approx. 100mm.This allows disassembly of the

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newlyassembledunit.Ensurethatthestopofboththesocketandendthespigotendareincontactwith
thelockingstripandthatthefullyextendedsystemiskeptinthisposition.
ForRSJsystemsanadditional'endplay'of30mmisallowedfordiametersupto300mmand50mmfor
diameters 350 mm up to 1200 mm. This 'end play' allows for contraction as a result of pressure,
temperaturechangesandsoilsettlementsandthereforeshouldnotbeusedintheinstallation.
2.5TypesoftheRubberringandthelockingstrip
ThecommonlyusedrubberringismadeofNBR(NitrilButadieneRubber).Othertypesofrubbercanbe
supplied depending on the medium and/or the temperature. The different types of rubber can be
recognizedbythefollowingcodes:
SStyreneButadieneRubber SBR colourcode redspot
NNitrileButadieneRubber NBR colourcode yellowspot
EEthanePropaneTerpolymer EPDM colourcode bluespot
FFluorElastomer FKM
HHydrogenatedNitrileButadieneRubber HNBR
2.6Disassemblyofrubbersealjoints
Inprincipalitispossibletotakerubbersealjointsapartwithinashortperiodafterinstallation.Inpractice
thejointwill becutoutduetothelackofspacetopullthespigotoutofthesocket,unlessitisthelast
installedjoint.
Thedismantlingprocedureforarubberseallockjointisasfollows:
Pushthepipebackintopositiontofreeupthelockingstripifpossible.Gripthelockingstripwithapair
of pliers or a plate clamp. Tap the pliers or use a crane to pull the plate clamp to remove the locking
strip.(Ifthelockingstripjams,turnthepipealittlewhilepullingthestrip).Pullthespigotendoutofthe
socket until the rubber ring is positioned at the insertion hole of the locking strip. Pull the rubber ring
through this hole, cut the rubber ring and remove the ring completely through the hole. Now the joint
canbereleasedcompletely.

3.Flangedjoints
Before assembling the Flanged Joints, all safety precautions will need to be checked. Ensure that all
necessarytoolsandmaterialsareavailable.

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3.1Toolsforflangedjoints
Toolsnecessaryforassemblyofflanges:
Ringspannerwithrequiredboltheadsize.
Torquewrenchwithrequiredsocketsize.
R.T.R.P. flanges are flat faced. These flanges must always be accurately aligned and not subject to any
stress.OntheR.T.R.P.sideoftheflangedjointtheboltsandnutsmusthavewasherstoavoidexceeding
thepermittedsurfacepressure.Asanalternative,asteelbackingringcanbeinstalled.Pipesmustnotbe
pulled together by tightening the bolts. If an R.T.R.P. pipeline is connected to a metal pipe, this metal
pipemustbeanchoredtopreventanymovementorloadsbeingtransmittedtotheR.T.R.P.line.
When assembling a wafertype butterfly valve, the bolts should be tightened first by hand. If leakage
occursduringpressuretests,theboltscanbetighteneduptothemax.
Topreventdamageoftheflangeswhentightening,spacersmaybeplacedbetweentheR.T.R.P.flanges.
Tightening of the bolts of flange connections must be done diagonally according to the sequence as
shown in figure . Bolts in flanges must be placed on either side of the centre line unless otherwise
specified.
Theflangemustbeconnectedperpendiculartotheaxisofthepipe.
In practice minor deviations might occur. If this happens, a gasket
with an Oring seal or a profiled gasket with vulcanized steel ring
(Kroll & Ziller) should be used. The flange must be installed free of
tension.
3.2Gasketsandtorques
ForR.T.R.P.flangesseveralgasketsmaybeused,dependingonthe
diameter, system pressure or specific requirements of the client. To prevent excessive bending on
R.T.R.P. flanges the max. bolt torques are specified. In order to determine the right torque value, it is
necessarytolubricatetheboltwith,forexample,molykote.
When assembling flanges, the bolt should be tightened by hand up to 30% of the max. Torque value. If
leakagesoccur,increasethetorquevalueupto60%ofthemaximumvalue.

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3.3RecommendedBoltTorques
ID
(mm)
BoltTorque
BS4504
Table10
(PN10)
MaxTorque(Nm)
DIN1882
DIN2501
ND10
MaxTorque
(Nm)
DIN2502
ND16
ASA150
MaxTorque
(Nm)
DIN2501
ND25
ASA300
Torque
Increment
(Nm)
25 25 70 70 100 7
40 25 100 100 150 7
50 25 100 100 150 7
80 25 100 100 150 7
100 20 100 100 250 7
150 35 150 150 250 14
200 45 150 150 300 14
250 55 150 300 500 14
300 75 150 300 550 14

ID(mm)
BoltTorque
BS4504Table10
(PN10)
MaxTorque
(Nm)
Toque
Increment
(Nm)
350450 95115 400 14
500600 115170 500 27
7001400 170230 700 34

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3.4Assemblyanddisassemblyofflangedequipment
Ensurethatthejointisfullyextendedandthestopofboth,thesocketandthespigotendareincontact
withthelockingstrip.Assemblingflangedparts(equipment,valves,adjustingpieces,orificeflangesetc.)
onemustbearinmindthatthesepartscouldalsobedismantled.Toprovidespacefordisassemblyinany
installation there must be a rubber seal joint at one side. This allows some displacement in the axial
directionusingtheclearanceinthesocket.
4. Buttandwrapjoints
Beforestartingabuttandwrap(lamination)joint,allsafetyprecautionswillneedtobechecked.Ensure
that all necessary tools and materials are available. A reliable laminated joint can only be made by
personnelauthorizedandtrainedtodoso.
4.1Toolsbuttandwrapjoints
LaminationjointForbuttandwrapjointsthefollowingisneeded:
1. Measuringtape+pipefitter'swraparound+markerpen
2. Cleaningrags
3. Anglegrinderwithdiagritorcarborundumcuttingdisc(grain24),ahandsaw24teeth/inch,
4. jigsawwitha14teeth/inchblade
5. Anglegrinder+sandingdisc+flexiblesupportdisc
6. Resin,hardenerandglassreinforcement+apairofscissors
7. Gloves, brushes, rollers, dust masks in quantities as mentioned in the fit and laminating sets, a
pairofsafetyglasses
8. Shelter(dependingontheweathercircumstances)
9. Insulation blanket, hot air gun (paint stripper gun), digital temperature gauge, gas burner, field
oven, Heating blanket, variable energy control (rheostat) [These items are especially for GRE
Lamination]
10. Pipeclamp,benchandrubberstrips(underchainclamp)
11. Generator
For the butt and wrap joint procedures see instructions enclosed with the lamination sets. These
instructionsinclude;cuttingandsanding,mixing,thefitprocedure,laminationandcuring.

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4.2Cuttingandsanding
Markoffthepipestobejoinedusingapipefitterssleeveandfelttippedpen.Sawthepipe(sections)to
the right length, with a straight cut perpendicular to the pipe axis. The pipe can be shortened using a
diagrit,carborundumslittingdiscorwithadiamondedgeddisc.Useasander(Anglegrinder)toremove
the top coat of the pipes when cut to the right length, in order to give a clean and rough surface for
adhesion. Clean the sanded part with a clean, non fluffy cloth or brush. The pipe sections must now be
cleanandfreeofdust.
4.3Mixing
Thefullcontentsofthehardenermustbeaddedtothecontainerwiththeresinandcarefullymixed.The
resinandhardenercontaintherightmixingratio.
4.4Fitlayer
Thefunctionsofthefitlayerare,firstly,toensureproperpositioningand,secondly,tocreateaseal.The
fitlayer,withitslowerviscosity,willnotdrainfromtheVshapedseam.

4.5Laminating
Grind the surface (ensure the top coating is removed) and remove the dust using a clean dry cloth or
brush to ensure a good adhesion between fit layer and laminate. The work must continue within the
hour,otherwisethegrindingandcleaningoperationwillhavetoberepeated.Ensurethattolerancesare
not exceeded! The laminate should be built up following the procedure already mentioned. The woven
rovings,theapplicationofresin/hardenermixandthecorrectsequenceofbuildingupthewovenrovings
must be done according to the instructions on the lamination kit. Remove excess resin using a rubber
spatula.

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4.6Curing
Thelaminationwillhardenatambienttemperatures.Thiscanbespeededupbyapplyingheatusingfor
example,aninfrareddeviceorhotairgun.Thehardeningprocessneedstobedonegradually.Afterthe
lamination is no longer sticky, curing can be continued with the aid of heating blankets, hot air guns or
ovens. Heating up to the curing temperature should also be performed gradually. The curing time only
starts when the laminate has reached the correct curing temperature. The joint is ready and can be
testedwhenthelaminateisfullycuredandhascooleddown.
5. Mechanicalcouplers

5.1Toolsformechanicalcouplers
ForStraubandTaylorKerr:Allenkeyandtorquewrench.
ForDresser,VikingJohnsonandInlandcouplers:ringspanner.
FRPpipeshavelowertorquesthansteelpipes,dependingonthewallthickness
Mechanical couplers, normally used for steel pipes, can also be used: e.g. Straub, Viking Johnson,
Dresser, Taylor Kerr. However, restraining couplers should not be used as these may damage the FRP
pipes.
WiththesecouplersconnectionsbetweenR.T.R.P.andothermaterialscanbemade.Reducingcouplers
are available for pipes with different outside diameters. When using these type of couplers, the cut
R.T.R.P.pipeendsmustbesealedwitharesincoating.Seelaminationinstructions.Thesecouplersmay
alsobeusedforquickrepairsofundergroundpressuresystems.Asthesecouplersdonotprovideaxial
restraint, they must not be used within a specific distance of a change of direction as this can cause
separationofthejoint.Oneofthefactorsdeterminingthislengthisthefrictionvalueofthesurrounding
soil. Adequate fixing of above ground pipe systems is required. The torques given on the joints do not
applytoFRPPipes.AfterinstallationofDressercouplersthestopperboltmustberemovedandreplaced
byapluginordertopreventdamageofthepipewall.

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ApplicableCodes/Standards:
ASTMD2996: Standards Specification for Filament Wound Fiberglass (Glass Fiber
ReinforcedThermosettingResin)Pipe.
ASTMD3517: Standards Specification for Fiberglass (Glass Fiber Reinforced
ThermosettingResin)PressurePipe.
ASTMD3262:StandardsSpecificationforFiberglass(GlassFiberReinforcedThermosetting
Resin)SewerPipe
ASTMD3754:StandardsSpecificationforFiberglass(GlassFiberReinforcedThermosetting
Resin)SewerandIndustrialPressurePipe.
ASTMD4024: StandardsSpecificationforMachineMadeFiberglass(GlassFiber
Applicablefromin.through24in.(13mmthrough600mm)
ANSIB16.5#150boltcircleflanges.
ASTMD4161:StandardSpecificationforFiberglass(GlassFiberReinforced
ThermosettingResin)PipeJointsUsingFlexibleElastomericSeals.
API15LR:SpecificationforLowPressureFiberglassLinePipe.Applicableto2in.through
12in(50mmthrough300mm)diameterpipeofEpoxyorpolyesterresinfor
useatcyclicpressure(6,895kpa).
AWWAC950:AWWAStandardforFiberglassPressurepipe.
AWWAM45:FiberglassPipeDesignManual
ASMEB31.3:ProcessPiping
BS5480:BritishStandardSpecificationforFiberglass(GRP)pipes,jointsandFittingsfor
useforwatersupplyorsewerage.
BS7159:BritishStandardCodeofpracticeforDesignandconstructionofFiberglass(GRP)
pipingsystemsforindividualplantsorsites.