See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/338084041

Glass-Reinforced Epoxy Pipes Subjected to Short-term High-Temperature

High-Pressure Loading Conditions

Article · January 2019

CITATIONS READS

0 1,596

4 authors, including:

Jamil Abdo Edris M. Hassan

Frostburg State University Dalhousie University
98 PUBLICATIONS   1,003 CITATIONS    28 PUBLICATIONS   219 CITATIONS   

SEE PROFILE SEE PROFILE

Nouby M Ghazaly
South Valley University
113 PUBLICATIONS   792 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

gtag2000@yahoo.com View project

Oman Cement Company View project

All content following this page was uploaded by Nouby M Ghazaly on 20 December 2019.

The user has requested enhancement of the downloaded file.

 International Journal of Advanced Science and Technology
Vol. 28, No. 16, (2019), pp. 1664 – 1670

Glass-Reinforced Epoxy Pipes Subjected to Short-term High-Temperature

High-Pressure Loading Conditions

Jamil Abdo1*, Matthew Beall1, Edris Hassan2, Nouby M.Ghazaly3

1
Department of Physics and Engineering, Mechanical Engineering Program, Frostburg,
MD, USA
2
Mechanical Engineering Department, Sultan Qaboos University, Muscat, Oman
3
Faculty of Engineering, South Valley University, Qena 83521, Egypt
*Corresponding author e-mail: jabdo@frostburg.edu

Abstract
Analysis of failure in oil and gas transmission pipes has been carried out in Oman oil and
gas industry for the last 10 years. It has been noticed carbon steel pipelines have shown a quite high
event of failure rate. A great fraction of failure incidents were classified as pipe corrosion failure
caused by adverse and corrosive environments (e.g., presence of Hydrogen Sulfide). Obstacles of
introducing composite pipes into oil and gas transmission line have been primarily related to
inadequate testing data to maintain materials' extended performance and integrity. Customized
testing facility has been designed and fabricated to substantiate design of GRE pipes under
controlled service conditions. Manufactured GRE pipes shall be qualified to be introduced and used
in oil and gas pipelines in Oman. The testing procedure was conducted based on reported ASTM and
ISO Standards. A pipe filled with crude oil was placed in thermal and pressure enclosure at a
temperature of 65oC and an internal pressure of 130 bars. Mechanical and material tests were
conducted to investigate performance and relevant pipes design specifications under such conditions.

Keywords: Composite; Pressure; Temperature; Testing; Performance; Pipe; Failure; Corrosion

1. Introduction
Growing trends to substitute conventional steel pipes used in oil and gas transmission lines have
led to the development of appropriate Glass-reinforced Epoxy (GRE) pipes. Attention has increased
towards fibrous reinforced composites (mainly due to their superior performance, ease of
manufacture and installation flexibility). Combining proper choices of reinforcements with
polymeric host matrix (in particular, thermosetting resin) and curing produce composite pipes with
considerable macroscopic properties. A fibrous composite consists of filamentary phase of
reinforcing fibers embedded in a continuous binder or matrix material phase results in high strength,
extended fatigue life, low density and application flexibility. Other properties of GRE pipes include
corrosion and wear resistances [1]. High level of interest in composite pipes has greatly enhanced
uses of composites in structural applications where properties such strength-to-weight and stiffness-
to-weight ratios are required as far as corrosion of metal pipes is considered such as in petrochemical
industry. Composites can be manufactured and optimized to attain certain balance of properties for
particular range of engineering applications [2]. Epoxy resins are most commonly used in advanced
composites where epoxy is combined with glass fibers or carbon fibers to provide required
serviceability and lifetime. Epoxy resins have remarkable adhesion to various substrates. Resins also
have good toughness and high corrosion and chemical resistance. This type of composite pipes is
called thermosetting composite. It is a blend of reinforcement and a thermoset resin matrix.
Reinforcement has a volume fraction ratio that allows load-carrying capacity while surrounding
matrix retains embedded reinforcements in preferred orientation. Matrix transfers loadings between
fibers and shields reinforcing members against environmental impacts of high temperature and
adverse moisture [3]. One must note that, acquisition cost of GRE pipes surpasses that of their
metallic counterpart’s pipes. However, due to the fact that corrosion of steel pipes is common in oil
and gas installation, the cost advantages of GRE pipes are greater when composites replace
corrosion susceptible metals. GRE pipes corrosion resistance improves overall usage reliability and
1664
ISSN: 2005-4238 IJAST
Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 28, No. 16, (2019), pp. 1664 – 1670

leads to reduce through-services expenses. Although, composite materials may by no means replace
conventional metal pipes such as steel. Composites, nonetheless, are expected to increasingly
respond to more structural problems in a sound and cost-effective way [4]. GRE pipes have been
considered in oil and gas installations and transmission lines owing to their outstanding performance
and stability. Chemical constituents, physical and mechanical properties of composites are outlined
in [5]. Failure incidents in oil and gas metal transmission pipelines during service can endanger
safety of people, cause serious environmental damages and lead to loss on income. Observations
have shown that aging (wear-out), corrosion, mechanical failures, i.e., valve/fitting failures, welding
defects and pressure surge problems are main causes of failures. The causes of failures, on the other
hand, appeared to be fairly random in nature, and that no tendency was apparent. Internal corrosion
in oil and gas metal transmission pipes is considered a major cause of failure. In Oman, majority of
metallic oil and gas transmission lines have attained service life span of 25 years. Replacement of
these pipes becomes indispensable to meet certain requirements such as corrosion resistance and
prevention of corrosion-related failure.

Mechanics of failure in filament-wound GRE pipes has been the subject of numerical and
experimental research studies. Response of laminated composite subjected to low rate impact was
examined in [6]. Experimental investigation of the influence of moisture absorption and exposure to
raised temperature on mechanical performance of fiber reinforced epoxy pipes has been presented in
[7]. Filament wound tube-shaped composite specimens were placed in distilled water at two ranges
of temperatures for roughly four months and effect of relative moisture absorption was reported. The
effect of pure hoop loading on the fatigue damage progression and fracture morphology of thin-
walled composite tubes fabricated by filament winding was monitored and investigated in [8].
Microscopical matrix damage, leakage (pin-hole formation) and final failure stages of GRP pipes
were observed and results were presented using S–N curves. Modes of failure in graphite-epoxy
tubes subjected to a set of static internal pressures at several surface crack locations and orientations
were examined in [9]. Failure examination of a filament-wound pipes made from glass reinforced
epoxy subjected open-ended state of internal pressure was conducted. A series of near surface
cracking and damage growth were observed [10]. The surge and repute strength of samples was
determined and its reliance on crack direction was considered. Luiz et al. [11] conducted
numerical/experimental study to inspect failure due to internal pressures in filament wound
composites. Thin-walled fiber reinforced epoxy tubes with end-caps were fabricated and assessed
using several winding angles. Progressive failure investigation allowed prediction of structural
pressure failure and offered information on how to estimate functional failure.

Moreover, a sequential failure modeling of glass reinforced polyester (GRP) pipe using stiffness
and strength degradation for laminated composites with quartz sand core layer was developed and
validated using a range of experiments in [12]. The effects of winding angles on the performance of
GRE pipes under multiaxial cyclic loading conditions were investigated in [13]. The performance of
such pipes studied using automated test procedure that is compatible with the internal qualification
requirements of the composite pipe manufacturers. Uyaner et al. [14] studied the failure behavior of
filament wound composites (GRP) pipes under impact loading. The test machine used in this study
recorded damage from initiation to failure for various impact energies. Progressive failure analysis
was used to study the consequence of varying some parameters on failure pressure of filament
wound composite tubes. Thereby improving design practices used in industry through parametric
studies of minimal thickness, length and optimal wind angles [15]. In other research study, laminated
multilayered composite structures with surface confined piezoelectric (PZT) patches have been
formulated and described to arrive at optimal design of smart laminated composite plates [16]. The
effects of hydrothermal ageing on the crushing behaviour of glass fibre-reinforced epoxy (GRE)
pipes with three different winding angles were discussed. Uniaxial compressive tests were
conducted on reference and aged samples. The compressive strength of the pipes was also predicted
using a Berbinau’s based model [17]. GRE pipes’ behavior under dynamic loading conditions was
resented in [18]. The authors quantified damage modes in GRE pipes caused by impact induced
loading using elastic-plastic finite element analysis.

This current paper proposes design and fabrication of customized in-house testing setup. The
1665
ISSN: 2005-4238 IJAST
Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 28, No. 16, (2019), pp. 1664 – 1670

custom-made setup is capable of reproducing working environment essential to complete design

proof and qualification of GRE pipes according to ASTM and ISO testing standards.

2. Materials and Methods

GRE pipes were manufactured by Composite Pipes Industry of Oman (CPI) using numerically
controlled filament winding machine. Pipe's dimensions are 250-mm diameter, 2.5-meter length with
a thickness of 12-mm. Each pipe consists of 12 layers with (±55°) 6 winding angles. Specimens used
for testing were split-disk type of specimens. Dimensional characteristic and reinforcement
orientation were recognized to satisfy proposed design requirements, i.e., pressure rating,
temperature range, leak and functioning at intense levels of temperature and pressure as well as
chemicals concentrations. Testing procedure is illustrated in subsequent sections followed by
discussion of results and conclusion.

3. Experimental Setup
The current work proposes GRE pipe a substitute to conventional steel pipes. Nevertheless, using
GRE pipelines comes with some obstacles that are largely related to lack of experimental testing
results to maintain materials' long-run behavior and service life. Performance and durability of GRE
pipes have been evaluated by means of investigating its mechanical properties, patterns of micro-
macro cracks on tested specimens. Reference specimens were taken from unloaded pipe subjected to
tensile testing and split-disk testing. Results were compared with testing results of specimens taken
from a pipe loaded with crude oil under high pressure and high temperature conditions. Results were
collected, interpreted and presented into a form of design indicators.
Figure 1 shows a dedicated in-house test assembly that has been designed and constructed with
enhanced capacity of handling prescribed high temperature and high pressure loading conditions.
Custom-designed thermal enclosure unit was built to ensure steady-state temperature of 65oC with a
maximum variation of 3°C in the testing temperature for the duration of 1000 hours. The unit
provides up to a maximum temperature of 90°C. The unit is equipped with heater, blower and access
holes for pressure tubing, temperature gauging and instrumentation wiring.

Figure 1: GRE pipes in (a) and thermal enclosure in (b).

The recent appropriate practice of qualifying glass reinforced epoxy pipes in petroleum industry
has been based on linear curve fitting. This procedure provides reliable long term prediction of the
behavior of the GRE pipes through extrapolating lower confidence bound to design and rate for a
stable service span of 25 years. Proposed in-house built experimental setup implements 1000 hours
Short term Endurance Test [19]. The test generates long-run mechanical behavior of such pipes
under intricate performance conditions. Notably, multiaxial state of hoop and axial stresses as a
consequence of high internal high pressure and high temperature is present. We can estimate long-
term hydrostatic strength or pressure-strength for glass reinforced epoxy pipes, by assessing
1666
ISSN: 2005-4238 IJAST
Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 28, No. 16, (2019), pp. 1664 – 1670

strength-regression records derived from the testing pipes. One may collect data from the current
experimental setup, interpret it and, eventually, manipulate it into a form of design and
manufacturing figures of merit.

4. Testing
4.1 Mechanical Testing
A reference pipe that was not filled with crude oil and not subjected to any type of loading
conditions has been used to collect benchmarking results on the pipe’s mechanical properties such as
limits of applied load and stresses in axial and hoop directions. A second GRE pipe filled with crude
oil was subjected a pressure as high as 130 bar and temperature range of 650C. This condition has
been continued for 1000 hours. Consequences of high temperature and pressure (HTHP) conditions
on structural integrity and long term stability of GRE pipes were undertaken and observed.
The practice for arriving at structural design and manufacturing of GRE pipes under such
loadings is based on the ASTM Standard D-2992. Frequent sets of split-disk tensile experiment have
been carried out on specimens sliced from the reference pipe and the pipe loaded with crude oil and
subjected to HTHP for 1000 hours. Figure 2 shows four strain gauges attached to the split-disk
specimen in axial and hoop directions. The mechanical testing was conducted using a 250 kN Dartec
universal hydraulic test machine as shown in Figure 3.

Figure 2: Split-disk samples with strain gages attached in circumferential direction (a) on the
external surface (b) on the internal surface.

Figure 3: Split-disk specimen with fixtures (ASTM D-2290)

4.2 Microscopic Testing
Morphology of fractured surfaces of tested specimens was carried out using Scanning Electronic
1667
ISSN: 2005-4238 IJAST
Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 28, No. 16, (2019), pp. 1664 – 1670

Microscopy. SEM Model of JEOL (JSM-7600F) was used. Micrographic images were considered to
investigate fractured surfaces of the GRE pipes at micro levels. Failed specimens from tensile split-
disk test were inspected to set apart changes in failure manners of each sample. SEM samples were
carefully cut through its fractured cross-sectional areas using abrasive cutter. GRE is a
nonconductive material. Nonconductive specimen causes image distortion and faulty scanning.
Hence, the specimen's surface must be electrically conductive [20, 21].

5. Results and Discussion

5.1 Mechanical Behavior
Results obtained from the series of tensile test and split-disk test appear to offer resourceful
technique to evaluate performance of GRE pipes subjected to controlled adverse environment.
Failure in the GRE pipes is typically governed by rupture of the pipe in the hoop direction. Such
arrangement of strain gauges would measure considerable variation in hoop stresses in relation to the
thickness of the pipe and provide better estimate of GRE pipes different thicknesses. Figure 4
represents split-disk tensile test specimen. It shows that the specimen has sustained higher tensile
loading with additional level of displacement. Elastic portion of the split-disk specimen indicates
that the elastic behavior of such specimen is further governed by crystallographic directions of the
reinforcement. It means that elastically anisotropic behavior of GRE pipe is distinct in split-disk
specimen. Figure 5 shows hoop and axial strains in split-disk specimens as a result of applied load.
Plots of the reference specimens and specimens under HTHP loading conditions are very closely
overlapped. This illustrates good conformity in mechanical behavior of GRE pipes under such
conditions.

Figure 4: Split-disk specimen (Load vs. Displacement)

Figure 5: Reference specimen and split-disk specimen (Load vs. Strains)

5.2 Fractographic Observations
It is worth pointing out that elastic-plastic transition behavior in glass-reinforced polymeric
(GRE) is cumbersome to examine under prescribed HTHP loading conditions. Therefore,
1668
ISSN: 2005-4238 IJAST
Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 28, No. 16, (2019), pp. 1664 – 1670

micrographic images were used to study fractured surfaces of the GRE pipes at micro-levels. SME
images are given in Figures 6 and 7. The micrographic images show fractured surfaces of the split-
disk specimens. Uneven swelling of matrix and hence matrix cracking as well as interfacial
debonding of reinforcements are visible. SEM images demonstrates that, interfacial features, internal
surface of the fractured specimens are due to the application of tensile load as high as 130 KN.
Delamination during split-disk test is attributed to differences of stiffness of the filament. It is also
noted that fractures on the reinforcement surfaces are steadily brittle. This is due to prolong exposure
to high temperature of about 65oC and pressure of around 130bar.

Figure 6: Debonding in a helically wound filament of 55o during split-disk test of GRE under
HPHT condition.

Figure 7: Breakage in a helically wound filament of 55o during split-disk test of GRE under
HPHT condition.

6. Conclusion
This research study presents design and fabrication of customized in-house testing setup. The
custom-made setup is capable of reproducing working environment essential to complete design
proof, qualification and manufacturing of GRE pipes to be used in oil transmission pipelines
according to ASTM and ISO testing standards. Throughout this work, a pipe filled with crude oil
was positioned in the thermal enclosure compartment at a temperature range of 65oC and subjected
to an inside pressure of around 130 bars. The pipe was kept in testing enclosure unit for a period of
1000 hours. Specimens were then subjected to mechanical and material testing. The tests assured
that mechanical performance and relevant design specifications and fabrication technique were
established. A second reference pipe was used to gather a number of functional benchmarking
records of GRE pipes performance include load carrying capacity, longitudinal and circumferential
stresses. A series of tensile split disk testing were conducted on specimens cut from the reference
pipe and the pipe under HTHP conditions. Spilt-disk tests have revealed that tested specimens can
sustain up to a maximum strength of 250 MPa in the hoop direction. In composite pipes industry the
reinforcements are helically wound over a mandrel to form a pipe. Therefore, split-disk specimens
give more realistic results. Comparison has shown a great agreement between two pipes mechanical
behavior under such loading and environmental conditions.
1669
ISSN: 2005-4238 IJAST
Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 28, No. 16, (2019), pp. 1664 – 1670

References
1. Daniel, M.; Ishai, O. Engineering mechanics of composite materials; 2nd edition, Oxford
Press, 2006.
2. Donaldson, S. L.; Miracle, D. B. ASM handbook on composites; ASM International, 2001.
3. Reddy, J. N. Mechanics of laminated composite plates: theory and analysis; 2nd edition,
CRC Press: Taylor and Francis Group, 2004.
4. Mableson, A. R. Refurbishment of steel tubular pipes using composite materials. Plastics,
Rubber, and Composites 2000, 29 (10), 558–565.
5. Hossain, M. The current and future trends of composite materials: an experimental study.
Journal of Composite Materials 2011, 45 (20), 2133–2144.
6. Belingardi, G.; Vadori, R. Low velocity impact tests of laminate glass-fiber–epoxy matrix
composite material plates. International Journal of Impact Engineering 2002, 27 (2), 213–
229.
7. Ellyin, F.; Maser, R. Environmental effects on the mechanical properties of glass fiber–
epoxy composite tubular specimens. Composites Science and Technology 2004, 64 (12),
1863–1874.
8. Martins, L. A.; Bastian, L. F.; Netto, T. A. The effect of stress ratio on the fracture
morphology of filament wound composite tubes. Materials and Design 2013, 49, 471–484.
9. Chang, D. J. Burst tests of filament-wound graphite–epoxy tubes. Journal of Composite
Martials 2003, 37 (9), 811–829.
10. Arikan, H. Failure analysis of (±55°)3 filament wound composite pipes with an inclined
surface crack under static internal pressure. Composite Structures 2010, 92 (1), 182–187.
11. Luiz, A. L.; Fernando, L.; Netto, A. Structural and functional failure pressure of filament
wound composite tubes. Materials and Design 2012, 36, 779–787.
12. Roham, R. Experimental and theoretical investigations on the failure of filament wound
GRP pipes. Composites: Part B: Engineering 2013, 45 (1), 257–267.
13. Krishnan, P.; Abdul-Majid, M. S.; Afendi, M.; Gibson, A. G.; Marzuki, A. Effects of
winding angle on the behaviour of glass/epoxy pipes under multiaxial cyclic loading.
Materials and Design 2015, 88 (25), 196–206.
14. Uyaner, M.; Kara, M.; Sahin, A. Fatigue behavior of filament wound E-glass/epoxy
composite tubes damaged by low velocity impact. Composites Part B: Engineering 2014, 61,
358–364.
15. Martins, L.; Bastian, F.; Netto, T. Reviewing some design issues for filament wound
composite tubes. Materials And Design 2014, 55, 242–249.
16. Muc, A.; Kedziora, P. Optimal design of smart laminated composite structures. Materials
and Manufacturing Processes 2010, 25 (4), 272–280.
17. Fitriah, S.; Abdul Majid, M.; Ridzuan, M.; Daud, R.; Gibson, A.; Assaleh, T. Influence of
hydrothermal ageing on the compressive behaviour of glass fibre/epoxy composite pipes.
Composite Structures 2017, 159, 350–360.
18. Alshahrani, R.; Merah, F.; Shafique, M. A.; Al-Nassar, Y. On the impact-induced damage in
glass fiber reinforced epoxy pipes. International Journal of Impact Engineering 2016, 97,
57–65.
19. ASTM D-2992. Standard practice for obtaining hydrostatic or pressure design basis for
“fibreglass” (glass-fiber-reinforced thermosetting-resin) pipe and fittings; American Society
for Testing and Materials, 2012.
20. Suzuki, E. High-Resolution scanning electron microscopy of Immunogold-Labelled cells by
the use of thin plasma coating of osmium. Journal of Microscopy 2002, 208 (3), 153–157.
21. Abdo, J, Tahat M, Abouelsoud A, The effect of frequency of vibration and humidity on the
stick–slip amplitude. International Journal of Mechanics and materials in Design 6 (1), 45-
51.

1670
ISSN: 2005-4238 IJAST
Copyright ⓒ 2019 SERSC

View publication stats