Dynaflow Lectures - March 26 th Fiberglass Pipe Systems

Transcription

1 Dynaflow Lectures - March 26 th 2009 Fiberglass Pipe Systems

2 Agenda Standards, very different markets. Why should we choose for Glassfibre Reinforced. materials for piping systems. Product Ranges and Methods of Construction. Jointing Methods. Prefabrication. Design.

3 Examples of very different markets Drainage / Sewerage systems Industrial piping

4 GRP used in very different markets Drainage / Sewerage systems Industrial piping

5 GRP used in very different markets Drainage / Sewerage systems Industrial piping Low pressure. Medium High pressure. Main focus: Need to withstand soil and traffic loads Main focus: Need to pump from A to B and want to know under what (safety) conditions Stability in hoop direction, pipe stiffness. System integrity.

6 GRP used in very different markets Need to withstand soil and traffic loads Need to pump from A to B and want to know under what (safety) conditions Example of standards: AWWA M45 / C950 EN 1796 EN ISO TR Example of standards: ASME B31.3 UKOOA ISO 14692

7 GRP used in very different markets Need to withstand soil and traffic loads Need to pump from A to B and want to know under what (safety) conditions Example of standards: AWWA M45 / C950 EN 1796 EN ISO TR Example of standards: ASME B31.3 UKOOA ISO 14692

8 GRP EN 1796 Need to withstand soil and traffic loads EN 1796 Title: Plastics piping systems for water supply with or without pressure Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin.

9 GRP EN 1796 Need to withstand soil and traffic loads

10 GRP EN 1796 Need to withstand soil and traffic loads EN 1796, characteristics: Pipe: Verification of long-term properties (Stiffness, PN). Joints: Verification of initial sealing. Fittings: No verification on PN.

11 GRP EN ISO Need to pump from A to B and want to know under what (safety) conditions ISO Title: Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping.

12 GRP EN ISO pump from A to B and know under what (safety) conditions

13 GRP EN ISO pump from A to B and know under what (safety) conditions ISO 14692, characteristics: Pipe: Verification of long-term properties (PN, hoop & axial strength). Joints & Fittings: Verification of long-term properties (as strong as pipe). Pipe system: Assessment of integrity of pipe system based on known hoop and axial strength.

14 GRP EN ISO pump from A to B and know under what (safety) conditions = Know the strength of installed pipeline

15 GRP EN ISO Know the strength of installed pipeline I. Strength of components :Qualification. ISO part 2 Design Envelope II. Strength of pipe system :System Design. ISO part 3 Site Quality PLan III. Installation of pipe system :Training & Qualification. ISO part 4

16 GRP EN ISO Design Envelope ASTM D FPI AD, Wavistrong serie EST, ID 150 mm pipe PL/PL, 65 C, pressure, TUV 1000,0 Mean LCL LPL Data Long-term envelope pressure (barg) 100,0 2:1 load condition 10,0 1,00E+00 1,00E+01 1,00E+02 1,00E+03 1,00E+04 1,00E+05 1,00E+06 time (hrs) Axial stress 2:1 load condition Hoop stress

17 GRP EN ISO Design Envelope ASTM D FPI AD, Wavistrong serie EST, ID 150 mm pipe PL/PL, 65 C, pressure, TUV 1000,0 Mean LCL LPL Data Long-term envelope pressure (barg) 100,0 2:1 load condition Design envelope 10,0 1,00E+00 1,00E+01 1,00E+02 1,00E+03 1,00E+04 1,00E+05 1,00E+06 Axial stress time (hrs) 2:1 load condition Hoop stress f 2

18 GRP EN ISO Design Envelope Long-term envelope Design envelope Axial stress Axial stress Hoop stress f 2

19 GRP EN ISO Design Envelope Long-term envelope Design envelope Increase wall thickness! Axial stress Axial stress Hoop stress f 2 Internal Pressure + X Bending

20 GRP EN ISO Design Envelope Long-term envelope Design envelope Axial stress Axial stress Hoop stress f 2 Internal Pressure + Bending X f 2 = 0.67

21 GRP EN ISO Know the strength of installed pipeline I. Strength of components :Qualification. ISO part 2 Design Envelope II. Strength of pipe system :System Design. ISO part 3 Site Quality PLan III. Installation of pipe system :Training & Qualification. ISO part 4

22 GRP EN ISO Site Quality Plan Site Quality Plan, describing: Installation instructions. Training + Qualification. Installation in accordance with system design (isometrics) QC.

23 GRP EN ISO Site Quality Plan Site Quality Plan, describing: Installation instructions. Training + Qualification. Installation in accordance with system design (isometrics) QC.

24 GRP EN ISO Site Quality Plan Site Quality Plan, describing: Installation instructions. Training + Qualification. Installation in accordance with system design (isometrics) QC.

25 Conclusion Need to withstand soil and traffic loads Need to pump from A to B and want to know under what (safety) conditions Example of standards: AWWA M45 / C950 EN 1796 EN ISO TR Example of standards: ASME 31.3 UKOOA ISO 14692

26 Conclusion Need to withstand soil and traffic loads Need to pump from A to B and want to know under what (safety) conditions Assessment of hoop stability (Soil & Traffic Loads) Assessment of integrity of pipe system. AWWA M45 ISO Revision of ISO 14692

27 Application of Glass Fibre Reinforced Pipes Why?

28 Why not? What do I buy?... FRP, RTRP, GRE Glass, brittle at low temps. Standards? Dimensions Material Properties Calculations Joints, Glue?? Degeneration of properties in time

29 Why so? No corrosion No corrosion allowance No cathodic protection Long live (50 years design) Light weight Smooth walls, low friction Mechanical properties, Flexible, Safe failure behaviour Safe joints Adhesive bonded Mechanical, RSLJ, Key Lock.Tee-kay Standards, ISO 14692

30 Product Ranges Wavistrong Material Epoxy Size Range 25 to 1600mm Pressure range Up to 70 Bar Temperature -60 C to +110 C Red Box Yellow Box Material Epoxy Size Range 2 to 16 Pressure range Up to 3,500 psi Temperature -65 C to +100 C Fiberstrong Material Polyester Size Range 25 to 4000mm Pressure range Up to 20 Bar Temperature +65 C Fiberstrong Material Vinylester Size Range 25 to 4000mm Pressure range Up to 20 Bar Temperature +85 C

31 Materials & Methods of Construction Tensile Stress Fibre FRP Composite Resin Considerations Properties of the fibre Properties of the resin Ratio of fibre to resin Geometry of fibres Strain

32 Materials of Construction Glass Fibres C Glass / C Veil: Chemically resistant glass E Glass: Structurally strong Continuous roving for pipe construction Rolled matting for field lamination

33 Materials of Construction Fibre orientation & fibre volume fraction Chopped Strand Woven Mat Filament Wound

34 Materials of Construction Resin Systems Ult Tensile Strength Considerations Plastic Deformation Good mechanical properties properties Good chemical properties (liner) Good resistance to environmental degradation Tensile Stress Elastic Deformation Failure Strain (%) Strain to failure

35 Materials of Construction Types of Resins Polyester -A B A B A B A - Epoxy S S S Epoxy Molecule -A B A B A B A - Vinylester -A B A A A A -B A - Catalyst Styrene Ester groups Amine Molecule Hardener No styrene No ester groups S S -A B A A A A -B A - Other resins: Phenolics, Cynate Esters, Silicones, Polurethanes, Bismaleimides, Polymides

36 Continuous wound - sizes 300 to 4000 mm diam.

37 Continuous Wound - FIBERSTRONG Chopped glass fibres Pure SilicaSan d Glass fibres Chopped Strand Infrared curing

38 FIBERSTRONG - GRP / GRV Wall Structure Exterior surface Structural wall (2) Pipe core E Underground applications Structural wall (1) Liner back-up Inner liner

39 FIBERSTRONG - Test Procedure If you make a very big pipe??

40 FIBERSTRONG - Scope of Supply Pressure classes Stiffness classes Size range Temperature range Installation type Design type : PN 1, 3, 6, 10, 12, 16, 20 : SN 2500, 5000, : 350 mm to 4000 mm : -40 C 85 C : Above ground / Underground : Restrained / Unrestrained

41 FIBERSTRONG Jointing types Laminated Joint 25mm to 4000mm Double Bell Coupler 50mm to 4000mm

42 FIBERSTRONG Applications River & seawater intakes & outfalls Gravity sewer lines Jacking & microtunneling WWT plant underground piping Irrigation main lines

43 Helical Wound - WAVISTRONG

44 Helical Wound diameters mm Filament Wound

45 WAVISTRONG Production Process

46

47 WAVISTRONG GRE Wall Structure Resin Glass 0.3 mm epoxy coating... E-glass wall mm Resin Liner % 30% 70% 0% 70% 30% E(CR)-glass C-glass 54 ¾ Test Pressure = 1.5 x design Safety Factor = 2 x design Weep Pressure = 4 x design

48 Standard Jointing Methods LB/LS (rubber seal joint) / FB/LS (rubber seal lock joint) 50mm to 1400mm CB/CS (taper/straight) / TB/TS (taper/taper) 25mm to 600mm

49 Standard Jointing Methods Laminated Joint - 25mm to 4000mm Flange Joints to DIN & ANSI - 25mm to 4000mm

50 WAVISTRONG - Scope of Supply Pressure classes Size range Temperature range Installation type Design type : PN 8, 10, 12.5, 16, 20, 25, 32, 40, 50 : 25mm to 1600mm : From -40 C to 110 C : Above ground / Underground : Restrained / Unrestrained

51 WAVISTRONG - Applications Crude oil Cooling water Fire fighting CO 2 lines Water injection lines Well head tubing Potable water Sewer lines

52 WAVISTRONG Fittings

53 Laminated elbow

54 Prefabrication (Spools)

55 Utilisation of Prefabricated Spools Effluent lines BP U.K.

56 Utilisation of Prefabricated Spools Cooling water ID 800 mm Degussa Antwerp

57 Design of pipe systems: Testing

58 Design of pipe systems Failure of pipe wall needs time Long term testing ASTM 2992 B Regression curve Test Pressure Safety Factor Weep Pressure : 1.5 x design : 2 x design : 4 x design

59 Long term testing acc. ASTM 2992-B

60 System design E-modulus Support spans Expansion forces F = E x A x α x T 10 times less than steel Poisson Ratio Expansion by pressure Expansion coeficient Allowable stresses (Design Envelope) Isotrope (steel) vs anisotrope (GRE) σ = P x D / 2t Safety factors (ASME B31.3, UKOOA, ISO 14692)