Composites Fabricators Association Composites Fabricators Association COMPOSITES COMPOSITES P E E T T U R T O I T L E S UM EQUIPMENTI N P E E T T U R T O I T L E S UM EQUIPMENTI N FIBER REINFORCED PLASTIC PIPES FIBER REINFORCED PLASTIC PIPES ENGINEERED TO INTERNATIONAL INDUSTRIAL STANDARDS ENGINEERED TO INTERNATIONAL INDUSTRIAL STANDARDS POLYMER COMPOSITE ASIA SDN. BHD. POLYMER COMPOSITE ASIA SDN. BHD. A Member of Hexagon Holdings Berhad A Member of Hexagon Holdings Berhad 178134-P 178134-P
Transcript
CompositesFabricatorsAssociation
CompositesFabricatorsAssociation
COMPOSITESCOMPOSITES
P EE TT UR TO ITLE SUM EQUIPMENTI N
P EE TT UR TO ITLE SUM EQUIPMENTI N
FIBER REINFORCED PLASTIC PIPESFIBER REINFORCED PLASTIC PIPESENGINEERED TO INTERNATIONAL INDUSTRIAL STANDARDSENGINEERED TO INTERNATIONAL INDUSTRIAL STANDARDS
POLYMER COMPOSITE ASIA SDN. BHD.POLYMER COMPOSITE ASIA SDN. BHD.A Member of Hexagon Holdings BerhadA Member of Hexagon Holdings Berhad178134-P178134-P
FIBER REINFORCED PLASTIC PIPESTRUCOR®TRUCOR
Initial Concept DevelopmentComplete Engineering and DesignShop or On-Site Manufacturing
» Process and Effluent Piping» Storage and Process Vessels» Duct Systems and Valves» Large Field Manufactured Tanks» Washer and Ventilation Hoods» Stacks and Chimney Liners
Demolition and InstallationComplete Turn-key Capabilities
PCA has been providing industry with quality products and dependable service. Our dedication to quality and service has enabled us to forged ahead in the manufacturing of dependable Fiberglass Reinforced Plastic products. Our products are expertly designed by our own team of professional engineers and crafted to international industrial standards.Since 1988, PCA' s commitment to total solutions earned us reputation as a leader in the manufacture of FRP components in this part of the world.
Industries Served
Polymer Composite Asia Sdn Bhd
Products & Services Include:
Industrial
Marine
Mining
Chemical
Oil and Gas
Pollution Control
Power Plants
Pulp and Paper
Offshore
Radar Electrical
Plating
Transportation
Metal Finishing Water TreatmentEMI/RFI Testing
Building Construction
Recreation
POLYMER COMPOSITE ASIA SDN BHD
Office :A11-0-2, Megan Corporate Park, Jalan 2/125E, Taman Desa Petaling, 57100 Kuala Lumpur.Tel : 603-9051 5999 Fax : 603-9059 2733 E-mail : [email protected]
Factory :PT. Lot. 3266, Jalan AM 1, Arab-Malaysian Industrial Park, 71800 Nilai, Negeri Sembilan, Malaysia.Tel : 60-6-794 2000 Fax : 60-6-794 2333 Website : www.polymercompositeasia.com
178134-P A Member of Hexagon Holdings Berhad
CORROSION RATESMOOTH INTERIOR SURFACE
TRANSLUCENCY
DURABILITY
COLOUR
INSTALLATION TECHNIQUES
MODIFICATION & REPAIR
CORROSION RESISTANCE OF TRUCOR®
WEATHER RESISTANCE
EXTERIOR MAINTENANCE
HEAT RESISTANCE
LIGHT WEIGHT
Trucor® Pipe is made with a hard resin-rich inside surface that is extremely smooth, and highly resistant to buildup of scale and other similar surface deposits. This smooth surface offers minimal flow resistance, and consequently lower pressure drop due to friction.
The advantages of translucent Trucor® Pipe are as follows: PROCESS CONTROL- Operators are able to observe the liquid or detect
p r o d u c t s g o i n g i n t o t h e l i n e o r through a "closed" valve.
CLEANING - Operators can "see" when the lines need cleaning.
LOCATION OF PLUGGED SECTIONS- Operators can "see" when and where the trouble
occurs.
PCA's laminate construction provides the proper balance of chemical-resisting resins to reinforcing material to provide maximum impact and tensile strength when subjected to the specified corrosive conditions, operating temperatures, and pressures.
Unless otherwise specified, Trucor® Pipe is fabricated with clear, unpigmented resin to provide the advantages of translucency, to permit visual inspection during and after production, and to provide maximum corrosion resistance. When the customer desires color-coded pipe, the outer layer of resin-saturated mat is pigmented.
Trucor® Pipe can be installed quickly and easily because of its light weight, workability and simplicity of joining.BUTT JOINTS - This is the simplest and most economical method of field joining Trucor® Pipe. The technique can be mastered by plant personnel with minimum instruction and training.FLANGES - This method is required when Trucor® Pipe is combined with existing flanged systems, valves or other equipment. Flanges are also recommended for systems subject to frequent or regular dismantling. PCA offers a complete line of press-moulded or contact-moulded flanges with compatible strength and resistance characteristics.
Trucor® Pipe is easily repaired or modified for new system layouts. Pipe can be cut to any desired shape with a hack saw, power saw, or saber saw. Field Joining Kits (containing all necessary materials and complete instructions) are available from PCA for use by plant personnel.
Unlike the electrochemical corrosion of most metals, plastic materials are affected by chemical reaction, or by solvation - the penetration of the plastic by a corrosive element that causes softening, swelling, and ultimate failure. Because of the basic differences between the electrochemical and solvation reactions, it is not easy to evaluate or measure the resistance of Trucor®Fiber Reinforced Plastic Pipe.
Chemical resistance for Trucor® Fiber Reinforced Plastic Pipe is determined by immersing the laminates in corrosive media, and by testing under simulated operating conditions. Other qualitative data is obtained by tests of strength retention, surface hardness, and visual inspection for chemical attack.
Trucor® Pipe and other PCA process equipment have been performing successfully in a wide range of field installation during the past 10 years. In addition, PCA conducts a continuing program of laboratory research and design studies to provide our customers with the ultimate in pipe performance. PCA corrosion engineers also evaluate the operating conditions specified in every request for a quotation to assure that correct resins and reinforcing materials are selected.
Trucor® Pipe is ideal for outdoor installations because it is practically impervious to the effects of sunlight, heat, cold, and other weather conditions. Ultraviolet absorbers are added to the basic resin. Where wet chlorine gas contaminated with hydrogen is being, handled, Trucor® Pipe can be supplied partially pigmented to eliminate danger of explosion caused by ultraviolet light.
Trucor® Pipe is resistant to industrial fumes, gasses or spillage because it is corrosion-resistant throughout. This means that no external protection, such as paints of coatings is required.
Trucor® Pipe fabricated with polyester and vinylester resins can handle operating temperatures as high as 320°.F. Maximum service temperatures will vary with the chemical condition and maximum service pressure.
The light weight of Trucor® Pipe makes it easy to install and often requires both lighter and fewer hangers that most metal pipe. The following chart shows the comparison with specific gravity of other materials.
STEEL ALUMINIUM7.85 2.55 - 2.75
TRUCOR®1.5 - 1.9
INTRODUCTION
WHY USE FIBER REINFORCED PLASTIC PIPES ?
Trucor® Fiber Reinforced Plastic Pipe is, chemically and structurally engineered with the proper balance of resin and glass to resist a wide range of acids and alkalis.... as well as weathering, spillage and corrosive fumes. This excellent combination of corrosion and strength characteristics is achieved through PCA's special "Laminate Construction". Starting with a resin-rich reinforced interior surface, successive layers of glass mat or cloth are expertly mandrel-wound over the smooth interior shell to provide a uniform dependable pipe ideally suited for severe corrosion applications. Designed and built to handle operating temperatures to 320°F, at pressure to 150 psi, Trucor® Fiber Reinforced Plastic Pipe is available in lengths up to 20 feet, and diameters from 2 to 72 inches. PCA also offers a complete line of standard and custom fittings fabricated from identical resins and reinforcement.
PCA manufactures pipe and fitting laminates with a variety of liner and structural wall constructions. In order to achieve optimum chemical resistance, all laminates are composed of an Inner Surface, an Interior Layer, a Structural Layer and an Exterior Surface Layer. The combination of Inner Surface and Interior Layer is often referred to as the Liner or Corrosion Barrier and is generally considered to contribute structural strength as well as corrosive resistance to the laminate.
Laminate Construction
LAMINATES
An essential part of FRP pipe is the proper selection of resin to suit the type of service desired. Selection criteria is often based on the type of chemical environment and the operating temperature Resin Selection Guide
Resin Type Chemical Environment Max Operating Temp.° F ° Celsius
Isophthalic Mild Chemical 180 82Bispherol Strong Acid, Chemical 250 121Vinylester Strong Acid, Solvents, 250 121
.010 - .020" smooth resin-rich interior surface reinforced with surfacing veil (C-Grade). This layer is 90% resin with 10% glass reinforcement. This resin-to-glass ratio ensures optimum corrosion-resistance when combined with the best resin for the specific chemical conditions.
Pipe in all diameters is built with an additional chemical-resistant liner at least 90 mils in thickness, and containing 70 to 75% of resin by weight.
Subsequent reinforcing layers containing a slightly higher percentage of glass-reinforcement are applied to build the pipe to the desired strength and wall thickness. Contact Moulded structural layers will have typical glass content by weight of around 30 t0 45% and Filament Wound structural layers will have 55 to 70% glass content by weight.
The outer surface is applied with a resin coating formulated to inhibit air for full cure. The coating conatins UV inhibitors and pigments to minimize UV degradation. If the outer surface is exposed to a corrosive environment, then a "C" veil shall be added on for chemical protection.
®TRUCOR CONTACT - MOULDED AND FILAMENT WOUND PIPELAMINATE CONSTRUCTION FOR CORROSION RESISTANCE AND STRENGTH
MATERIAL & CONSTRUCTION
PCA offers two standard types of FRP laminate construction for piping and duct systems: Filament Wound, and Contact Molded.
This is a process where a continuous glass strand roving pre-saturated in a resin bath is helically wound around a rotating mandrel at a specified winding angle. The winding process is repeatedly done in bi-directional layers until the desired wall thickness is achieved. Trucor pressure piping is made with a 54¾° winding angle, which provides the theoretical optimum 2 : 1 hoop to axial strength ratio required for pressure piping. Vacuum piping, duct and O-ring gasketed joint piping which require increased hoop strength, will normally be wound at greater winding angles, such as 65°.
This method of laminate construction uses multiple layers of fiberglass chopped strand, woven roving and non-woven glass fabrics saturated with resin and laid onto a prefabricated mould. It is then hand-rolled to release air bubbles trapped beneath the layers.
This is a variant of the contact molding described above in which a spray gun equipped with a chopper cuts glass strand into short lengths and ejects the chopped glass into the resin spray. The resin and glass are deposited onto the mould and hand rolled as described above. This chopped glass is used in lieu of chopped strand
Filament Wound Construction
Contact Moulded Construction
Spray-up
MANUFACTURING METHODS
MATERIAL & CONSTRUCTION
Laminate properties will vary with the type and orientation of reinforcement and resin content. The data listed below is based on industry standards as well as research and testing conducted by PCA. This information may be used as a general guide for system design.
For more specific design information, contact PCA Engineering Department.
t = Thickness of pipe wall in mm inclusive 100ml corrosion barrierv = Vacuum rating in psig (gauge pressure)
l All internal pressure rating on a factor of safety 10 to 1l All vacuum rating on a factor of 5 to 1l Rating above suitable for operating Temperature of 180 °F (82 °C)l Rating above computed on a standard strain limit of 0.0014l Pipe of other ratings is available upon request
To establish product weight, w (in kg/m), use formula:w = 0.150 D x twhere D = diameter in inch
t = wall thickness in mms.g. assumed at 1.90
Note: Use this table as a guide only. The pipe final design thickness shall be decided upon knowing all design parameters.
Nom Nom Dia Internal Pressure Rating of PipesDia in. Mm 25 psig 50 psig 75 psig 100 psig 125 psig 150 psig(D) (d) t v t v t v t v t v t v
t = Thickness of pipe wall in mm inclusive 100ml corrosion barrierv = Vacuum rating in psig (gauge pressure)
All internal pressure rating on a factor of safety 10 to 1All vacuum rating on a factor of 5 to 1Rating above suitable for operating Temperature of 180 °F (82 °C)Pipe of other ratings is available upon request
To establish product weight, w (in kg/m), use formula:w = 0.1372 D x twhere D = diameter in inch
t = wall thickness in mms.g. assumed at 1.72
Note: Use this table as a guide only. The pipe final design thickness shall be decided upon knowing all design parameters.
CONTACT MOULDED PIPE DATA CHART
MATERIAL & CONSTRUCTION
D D O.D. L B.C. No of Ø Bolt Nom Dia Nom Dia Holes Hole Size
(In) (mm) (in) (in) (in) (in) (in)
3 1 51 25 4 /8 6 3 /8 4 /8 ½7 51 ½ 38 5 ½ 6 3 /8 4 /8 ½
52 50 6 ½ 6 4 ¾ 4 ¾ /852 ½ 63 7 ½ 6 5 ½ 4 ¾ /853 75 8 6 6 4 ¾ /854 100 9 ½ 6 7 ½ 8 ¾ /8
76 150 11 ¼ 8 9 ½ 8 /8 ¾78 200 14 8 11 ¾ 8 /8 ¾
710 250 16 ½ 10 14 ½ 12 1 /8712 300 19 ½ 10 17 12 1 /8
54 1350 66 ¾ 15 62 ¾ 44 2 1 ¾60 1500 73 ½ 15 69 ¼ 52 2 1 ¾66 1650 80 ½ 15 76 52 2 1 ¾72 1800 87 18 82 ½ 60 2 1 ¾84 2100 100 ¼ 18 95 ½ 64 2 ¼ 296 2400 113 ¾ 18 108 ½ 68 2 ½ 2 ¼
Dimensions are in inches. Pressure is in inches water gauge.
1 Bolt diameter is hole size minus /8 inch.
Trucor flat face flange are manufactured by contact moulding. Laminates are manufactured in accordance with ASTM C-582. . Bolt Circle Diameter as per ANSI B16.5 for 150 lb Steel Flanges for 1" ~ 24" and ANSI B16.1 for 125 Lb Cast Iron Flange for 30" ~ 96” L is a standard dimension. Special lengths are available 26 in. and 28 in. are not covered by ANSI Stds.
Larger sizes are designed to suit specific applications. Flange thickness, T, are minimums at design pressures Flanges thickness for other pressure rating are available upon request.
• Fabricated tees and laterals are available in all diameters.
• These fittings must be heavily reinforced when used in pressure service.
• Dimensions shown are suitable for flanging.• Fabricated reducing tees and laterals are available in
all diameters.• Tee and lateral intersections can be fabricated into
piping runs, thereby eliminating extra end joints.
TEES, CROSSES AND LATERALS
TEE
D
C-E
C-EC-E
45° LATERAL
D
C-E
X
L
CROSSES
D
C-E
C-E
C-EC-E
D x D L a1 2
3 x 2 2 ½ 63 x 1.5 3 ¾ 64 x 3 2 ½ 64 x 2 5 66 x 4 5 66 x 3 7 ½ 66 x 2 10 68 x 6 5 88 x 4 10 68 x 3 12 ½ 610x8 5 810 x 6 10 810 x 4 15 6
12 x 10 5 1012 x 8 10 812 x 6 15 8
14 x 12 5 1014 x 10 10 1014 x 8 15 8
16 x 14 5 1216 x 12 10 1016 X 10 15 1018 X 16 5 1218 X 14 10 1218 X 12 15 1018 X 10 20 10
Dimensions are in inches.
D x D L a1 2
20 x 18 5 1220 x 16 10 1220 x 14 15 1224 x 20 10 1224 x 18 15 1224 x 16 20 1226 x 24 5 1226 x 20 15 1226 x 18 20 1228 x 26 5 1228 x 26 10 1228 x 20 20 1230 x 24 15 1230 x 20 25 1230 x 18 30 1230 x 16 35 1236 x 30 15 1536 x 24 30 1542 x 36 15 1542 x 30 30 1548 x 42 15 1548 x 36 30 1554 x 48 15 1554 x 42 30 1560 x 54 15 1560 x 48 30 15
Dimensions are in inches.
Tapered reducers are contact molded with a standard Stub end flanges, duct flanges and full face drilled slope in concentric or eccentric configurations. flanges can be provided on the large end of all reducers.
Length is calculated as follows : an additional flange fitting is required on the small end.L = 2 ½(D - D )1 2
Flanged reducers can be provided in configurations Centerline offset of eccentric reducers is calculated as shown below, with any flange type. follows :
E = ½ (D - D )1 2
Special dimensions are available.
FITTING
REDUCERS FLANGED REDUCERS
CONCENTRIC REDUCER ECCENTRIC REDUCER
La a La a
D1 D1D2 D2E
FLANGED JOINTS
Flanged joints are used in piping systems for ease of installation and connection to equipment. All flanges are desgined to accommodate operating pressures specified by the user.
FRP flat face drilled flanges are provided with standard bolting patterns conforming to ANSI B16. 1 class 125 (identical to ANSI B16.5 class 150 through 24’ size.)
These flat face drilled flanges MUST be bolted to flat face companion flanges with full gaskets. PCA flangeshave moulded finish faces for proper sealing and machined or spot faced back faces for proper washer seating. Flange face ‘O’ ring gaskets grooves can be provided upon request.
PCA also provide FRP stub ends with steel backing flanges. They are an economical alternative to drilled flanges in sizes from 1 ½ “through 48” diameter. These flanges conform to ANSI standard bolting patterns, are easy to install, provide rotational flexibility and can be mated to raised face flanges.
FRP drilled duct flanges conforming to ASTM D-3982 are provided for ventilation and gas or vapour service where standard ANSI drilling is not required.
BUTT JOINTS
BUTT JOINTS
The Butt joint system provides a strong, leakproof joint, making it the most common way of assembling custom made FRP piping in the shop or in the field. These are designed for system operating pressures and contact moulded to the same thickness as the equiplent contact moulded pipe fittings. Joint reinforcing is supplied in varying widths and is pre-cut for each particular pressure and diameter. The maximum joint thickness occurs at the center and tapers down in thickness towards each side.
PCA strongly recommends that all FRP joints be carried out by trained personnel with experience in this field.Final fit-up and assembly joints should not be made until the system hangers, supports and anchors have been properly located and installed and equipment connections finalized. Because of the high rate of thermalexpansion in FRP piping, it is necessary to perform all measuring, cutting, fitting and joining, procedures at the same ambient temperature.
Standard field joint kits include pre-cut glass reinforcing materials, resin putty, laminating resin, surfacing resin and catalyst.
It is important that all personel making FRP joints read and understand the Material Safety Data Sheets priorto working with these materials.
The design of Fiberglass Reinforced Plastic piping • Contact molded pipe and fitting laminates are systems should be performed by persons designed in accordance with ASTM C-582.experienced in the fundamentals of piping stress
• In contact moulded pipe design, the standard analysis as well as composite materials. PCA 100 mil inner surface and interior layer is maintains a complete staff of professional considered a structural element of the laminate engineers and designers to assist in the design and is included in wall thickness calculations.process.
• In certain chemical environments such as hot wet chlorine and chlorine dioxide, additional material is added to the interior layer as a
Yield - FRP composites do not yield. corrosion allowance and is not included in Consequently, plastic deformation structural calculations.cannot be relied upon to distribute
• Filament wound pressure pipe laminates are loads and relieve stress.manufactured with a helical winding angle of 54 ¾°.Modulus - FRP structures are much more
flexible than steel due to the lower • Wall thickness are considered suitable for modulus of elasticity. Tensile
operating temperatures to 180°F with premium modulus of FRP ranges from
grade polyester and vinyl ester resins.approximately 1 to 4 million psi compared to about 30 million psi
Contact moulded pipe and fitting designs are for steel.
design with safety factor of 10. The formula for wall thickness is :
Temperature - Mechanical properties of FRP d r o p r a p i d l y a t e l e v a t e d
t = Prtemperatures. Most resins used
S/SFby PCA are suitable for use up to 212°F. Special resins and designs
P = pressure, psigallow FRP to be used up to 320°F.
r = pipe radius, in.in certain environments. There is
s = ultimate tensile strengthlittle strength reduction, or
SF = safety factor of 10brittleness at low temperatures.
Trucor FRP pipe and fittings are designed and custom manufactured for specific applications. The following design criteria are followed :
Differences Between FRP and Steel Pipe Design
Product Design
PIPE SYSTEMS DESIGN
PIPE SYSTEMS DESIGN
Vacuum conditions must be considered for all FRPpipe installations. Because of the relatively low modulus FRP materials which makes it more susceptible to collapse, the possibility of vacuum due to planned, as well as unplanned, operating conditions must be analyzed. Since a vertical drop of 34 feet of water (at sea level) will produce a full vacuum within a pipe, care must always be taken to properly drain, vent and valve pipingsystems.
A safety factor is normally applied to collapse or bucklingconditions. The winding angle of filament would piping will affect hoop and axial properties. If a system will operate only under vacuum conditions, either without possibilityof internal pressure or with a low internal pressure, the winding angle may be increased to improve hoop propertiesfor buckling resistance. External stiffeners may be manufactured on pipe 18 in. Diameter and larger to providebuckling resistance.
Collapse Pressure, Pc, for unstiffened pipe may be calculated by the following formula:
3P = 2.2 ER’ (t/d)c
Collapse Pressure, Pc for stiffened pipe may be calculatedby the following formula:
2 5P = 0.92 Et R’c1.5 Lr
Design Pressure, External = P k/Fc
P = Collapse Pressure, psic
E = hoop flexural modulus, psiR’ = strength retention at temperature
F = Safety factorr = pipe radius, in.d = pipe diameter, in.t = wall thickness, in.L = length between stiffeners, in.K = 0.9 for unstiffened pipe 0.8 for stiffened pipe
The required moment of inertia for pipe stiffenersmay be calculated by the following formula:
3I = SFLd Pc
24E
ExpansionThe coefficient of thermal expansion for FRPis between two and three times the rate of steel, depending on glass content and orientation. A design coefficient for contactmoulded pipe, having a low glass content, is
-618 x 10 , while high glass content filamentwound pressure pipe has a design coefficient
-6 of 16 x 10 for axial expansion:
Internal pressure will also cause FRP pipe toexpand as the pipe is strained.
Expansion and contraction of FRP pipingmust be recognized and taken into accountduring the design of supports and anchors However, relatively low modulus of the material makes FRP quite forgiving when good, basic design practice is followed.When piping is completely restrained byanchors or in underground installations, nomovement takes place and the expansion stresses are absorbed in the pipe wall laminate. Stress can be calculated as follows:
S = E x DL = E bDTa a
L
b
Ea = Modulus of elasticityL = Length = Thermal coefficient of expansion
Example above illustrates that anchoring pipeto restrain thermal expansion develops stresses less than 10% of the ultimate compressive stress of the FRP laminate. However, thethrust force may be significant, especially withlarge diameter pipe, in an axially guided system.Even a slight lateral movement, however, will relieve stresses significantly in a lightly guided system. In most systems, supporting and guiding FRP pipe to allow for expansion movement is thesimplest and most economical approach. The following guidelines should be followed:
* Elbows should be free to move, unless they are close-coupled to a fixed flange connection.
* Guides should be a minimum of 10 x pipe diameter away from elbows.
* Anchors or fixed connections should be at least 20 x pipe diameter away from free moving elbows.
* Each system should be anchored, restrained or guided to insure that it remainsin its intended position.
Expansion Joints
Many types of expansion joints can be usedwith FRP piping systems. Since FRP pipingdevelops lower thermal end forces than steel(approximately 3% to 5% the amount of schedule 40 steel pipe), the expansion joints mustbe activated by low forces. Various elastomeric bellows type expansion joints are suitable for FRP piping systems.
As a general guideline, an expansion joint thatoperates with an activational force of less than F a
should be selected. This will limit axial pipe stressto 1,000 psi which is well within design limits.
F = 1,000 Aa
2A = Cross sectional area of pipe, in
The expansion joint must be installed to accommodate the amount of expansion and contraction that may beexperienced, both axially and laterally. From previousdiscussions, the total expansion movement can be calculated and an appropriate expansion joint can beselected. At the time of installation, a preset must be determined based on installation and operating temperatures. The amount of preset may be calculatedas follows:
Length of Preset, in = M (T - T )i min
(T - T ) max min
M = total related expansion joint movement, in.T = installation temperaturei
T = minimum temperaturemin
T = maximum temperaturemax
Guides must be installed to insure that the pipemovement will be directed into the expansion joint. Recommended spacing to the first guide is 4 x pipe diameter with the second guide spaced 10 x pipe diameter beyond the first. This spacing will limit anyangular twist on the expansion joint.
Expansion Loops
Expansion loops may be used as a means to accommodate pipe expansion and /or contraction.Design is based on the stress developed in a cantileverbeam assuming a concentrated load at the free end.This approach is often too cumbersome for a processpiping system and is more suitable for long runs of straight piping where space is not a problem. Two guides must be used on each side of the expansion loop to maintain alignment. Elbows and torsion are alsogood sources of compliance within a system that maybe considered.
The friction of fluid flowing in a pipe causes a drop in pressure which is approximately proportional tothe velocity squared, and is directly proportional tothe effective length of the pipeline and the friction factor. In calculating friction loss for FRP pipe, a Manning roughness coefficient of 0.009 and a WilliamsHazen roughness coefficient of 150 is commonlyused for water service application.
The effective length of a pipeline is the total lengthof straight pipe plus the equivalent length of allfittings and valves which add resistance to the system.
FLOW PROPERTIESFLOW PROPERTIES
FLOW PROPERTIES
FITTING FRICTION LOSS
Equivalent length of straight pipe for head lossthrough fittings
To convert gallons per minute to cubic feet per second, divide by 448.8To concert gallons per minute to millions of gallons per day, divide by 694.4.To convert friction loss in psi to feet of head, divide by 0.433. 1 US Gal = 0.833 Imp Gal =3.785 litres.
Trucor FRP underground piping is a flexible conduit and must be analyzed as such when The safety factor for buckling will be in accordance designing for burial. with AWWA C950 Section A2.5. When integral
stiffeners are used, a safety factor of 3 will be used In a underground installation the external soil load for the stiffener section. Stiffener spacing will not above the pipe causes a decrease in the vertical exceed two pipe diameters.diameter of the pipe and a corresponding increase in the horizontal diameter of the pipe. The The hoop flexural modulus will be used in horizontal movement of the pipe walls into the soil calculating external loading design and will be material at the sides of the pipe develops a determined by test (ASTM D-790 or ASTM D-passive resistance that acts to help support the 2412) or developed by laminate theory and external load. The resistance of the soil is affected supported by tests.by the type of soil and its density and moisture content. The higher the soil resistance, the less the pipe will deflect. Proper installation techniques Design Criteriaare necessary to develop the passive soil The following parameters are to be supplied by the resistance required to prevent excessive pipe owner for consideration by PCA during the detail deflections. Proper bedding support and backfill design :are required for satisfactory sealing of the bell and spigot joints most commonly used. • Operating temperature of the line fluid.
• Operating, surge, vacuum and test pressures.The deflection of a buried flexible pipe depends on • Live loads (wheel loads).the soil load above the pipe (which is a function of • Max./min. burial depth and trench width.the depth of burial), live loads over the pipe, the • Description of the soil properties and trench stiffness of the pipe, the passive resistance of the preparation.soil at the sides of the pipe, the time consolidation characteristics (deflection lag factor) of the soil, and the degree of support given to the bottom of Soil Propertiesthe pipe (bedding constant). The following soil properties will be used for
design of the pipe unless specified otherwise :An initial maximum pipe deflection of 3% is recommended with an allowable long term • Soil density - 120 pcf.deflection of 5% maximum. These deflections
• Deflection lag factor - 1.5.may be calculated using the Spangler equation.
• Deflection bedding constant - 0.083.• Soil reaction modulus - 1,000 psi.Trucor FRP Underground piping is designed using • Local water table, below bottom of pipe.the methods given in AWWA C950.• Requirements for thrust blocks or anchors shall be considered.The pipe wall thicknesses are designed giving
structural credit to the corrosion liner and design is strain limited using appropriate tensile and flexural moduli. Most underground installation utilize gasketed bell and spigot joints which eliminate axial loads due to internal pressure. Therefore, the winding angle used in manufacturing the pipe can be increased to increase hoop properties and decrease axial properties. In any event, a minimum axial tensile modulus of 500,000 psi should be maintained.
Maximum allowable membrane strain for internal pressure shall be .0017 in./in. and combined hoop strain for sustained loading shall be .0024 in./in. Combined hoop strain for transient loading shall not exceed .0028 in./in.
UNDERGROUND PIPING
PIPE SYSTEM DESIGN
PCA will analyze the following load combinations : Design of restraint must consider soil strength, stability and location of the water table. Effective
Design pressure at maximum burial depth. thrust blocks must totally encapsulate the pipe Design pressure plus live loads at minimum fitting and must have : and maximum burial. Burial and live load conditions, plus vacuum Adequate bearing area to resist the thrust. (if applicable). The bearing surface against undisturbed Burial and live loads for empty pipe. soil. Pre-burial hydrotest requirement. The resultant thrust vector passing
perpendicularly through the center of the All structural analysis will include both membrane bearing surface. and hoop bending effects in the pipe wall.
Trucor bell and spigot joined FRP piping may If the soil is unstable or the installation is below the require thrust blocks for axial restraint. All changes water table, tie rods or other means to ensure in direction, including bends, tees and laterals, stability may be required.must be restrained. Cast in place concrete blocks are often used for buried piping and can be used in Safe Bearing Pressure, Sp, of soils ranges from 0
2combination with tie rods and thrust collars for for quicksand to over 100,000 lbs/ft for solid, hard above ground piping. rock. Hard clay, coarse sand and gravel range
2from 8,000 to 10,000 lbs/ft . A complete list of Hydrostatic thrust loads at a bend can be these ratings can be found in soils engineering calculated as follows : handbook and in "Marks Mechanical Engineers'
Handbook." Actual values should be defined by the Project Geotechnical Engineer.T = 2PA Sin Ø/2
The soil bearing area required for restraints are T = Thrust, lbcalculated as follows :P = Pressure, psi
2A = Cross sectional pipe area, in.A = T/SØ b p
2A = bearing area, ft bT = Thrust, lbThe need for thrust blocks and their design is the
2S = Allowable soil bearing pressure, lb/ft responsibility of the engineering agency designing p
the piping system.Restraint must be installed before hydrostatic testing of the pipe.Hydrodynamic loads are normally small in
comparison to hydrostatic loads, however, they must also be considered by the design engineer.
Thrust Blocks
= Angle of bend in degrees
LOAD COMBINATIONS
PIPE SYSTEM DESIGN
SLING CLAMP CLEVIS
SUPPORTS & HANGERS
Trucor FRP pipe and duct should be installed in accordance with project specifications and rules of good practice for supporting metal pipe. FRP is strong, lightweight and easy to install. Care must be taken to avoid impact damage, point loads and damage to inner surfaces which may lead to premature failure.
Rigging and handling must be done with nylon slings or padded cable. Cables and chains must not bear directly against the pipe wall. Handle with care to ensure long life and trouble free service.
Fabricated steel hangers and, supports should be manufactured to fit the outside diameter of the FRP pipe and duct being used. We recommend that all hangers and supports be lined with an elastomeric pad (Shore 'A' Pipe anchors are used to restrain pipe movement hardness 50-70) to conform at any surface irregularities against thrust loads and thermal expansion. 360° FRP and to provide uniform bearing support. trust collars are laminated to the pipe on either side of an
anchor support to restrain the pipe. These collars can It is essential that each installation be reviewed to be installed in the shop or the field and are also used ensure the proper location and fit of all supporting with riser clamps for vertical support.elements. Maximum recommended support spacing for Trucor FRP pipe is shown on the following page. For specific applications, contact PCA Engineering Department for a custom design.
PCA can supply all types of hangers, supports, anchors and clamps for your FRP systems. Alloy or mild steel materials are available with prime paint, specialty coatings or galvanized finish to meet project specifications.
Pipe Saddle Supports may be either fixed or guided, as required by the system design. These are normally 180° bottom supports with a 180° retainer band. Guided supports allow slight axial or lateral movement due to thermal expansion.
All valves, regulators, flow meters or other components used in FRP piping systems should be independently supported to prevent overstressing the FRP pipe and fittings. One common method is to use a flange hanger or support as shown below.
Three basic configurations of pipe hangers are used :Sling, Clamps and Clevis. These hangers do not restrain axial or lateral movement.
Pipe Supports and Hangers
Anchor and Guides
Flange/Component Support
FLANGE/ COMPONENT SUPPORT
INSTALLATION
Elastomeric Pad, Typical
Fixed
Guided
PIPE SUPPORTS & HANGERS
FRP Thrust Collars
ANCHORS & GLIDES
PIPE SUPPORT SPACING
Recommended support spacing for filament wound and contact moulded pressure pipe is shown in the tables below. Table are based on the following assumptions:
= 180° support saddle using colour coding noted on chart below.
Saddle width = ¼ dia1 Saddle width = / dia3
Contact PCA for saddle width design= Maximum deflection = span / 360.= Simple support conditions.
= 180°F maximum temperature.= Wind and seismic effects are not considered.= Specific gravity of contents, 1.2.= Correction Factors on support spans for different Fluid specific gravities.
Flange assembly should be done in accordance with standard rules of good practice. Proper alignment and fit up must be maintained in order to avoid undue stress on the flange. Flat face FRP flanges and duct flanges MUST be bolted to flat face companion flanges, with full gaskets. If raised face flanged equipment is connected to FRP flanges, a hard plastic or metal spacer ring must be added to provided a flat connection surface.
FRP stub ends with steel backing flanges may be connected directly to raised face or flat face steel flanges but must not be connected to flat face FRP flanges. Ring gaskets should be used with FRP stub ends.
Bolting material should be specified by the user in accordance with plant practice. Thread lubricants should be applied to all bolts, except Teflon coated bolts, used on pressure piping. ANSI Type B, plain washers, regular series must be used against FRP and cast steel flanges.
Gaskets should be made of elastomeric material having a Shore A Durometer of 50 - 60. Minimum thickness should be as follows :
1• /8 in. through 20 in. diameter3• /16 in. for 24 in. diameter through 36 in.
Diameter• ¼ in. for 42 in. diameter and larger
Systems to be operated or tested over 100 psig should use reinforced gasket material to prevent extrusion of gasket caused by high bolt torque.
FLANGE ASSEMBLY
FRP Stub EndFlanges
Ring Gasket
Steel BackingFlange
FlatWasher
Spacer Ring
RaisedFace Flange
Full Gasket
Flat Washer
FRP Flat Face Flange
RAISED FACE TO FLAT FACE FLANGE CONNECTION
FLAT FACE FLANGE CONNECTION
STUB ENDS WITH BACKING FLANGES
Full Gasket
Flat washer
INSTALLATION
INSTALLATION
BOLT TORQUE
Maximum Bolt Torque For Pressure Piping
Bolt Size in. Torque ft - lb1/2 155/8 253/4 40
7/8 65
1 100
1 1/8 140
1 1/4 200
1 1/2 320
1 3
/4 600
2 880
= Based on a 12,000 psi bolt stress.= Use ANSI Type B washers, regular series.
1
4
3
2
1
5
4
82
6
3
7
15
9
4
8
122
6
10
3
7
11
15
9
13
4
8
12162
6
10
14
3
7
1115
15
9
13
17
4
8
1216
2026
10
14
18
3
7
11
1519
15
9
13
17
21
25
4
8
12
16
2024
282610
14
18
22
26
3
7
11
1519
23 27
Follow similar patterns for flanges with a greater number of bolts.
Tighten bolts of 50% of required torque in sequence shown. Repeat tightening in the same sequence until required torque is reached.
Maximum torque is not required for low pressure systems.
Trucor FRP pipe is a flexible conduit. Procedures diameter.for site preparation and placement are similar to
• Shore, sheet, brace, or otherwise support those used for other types of flexible materials. trench walls as required for safety of personnel The light weight and long laying lengths of Trucor working in the trench.FRP pipe are definite advantages which generally
permit installation cost savings over other materials.
Proper installation procedures are required to develop the passive soil resistance necessary The following guidelines should be followed when to prevent excessive pipe deflections.installing FRP pipe :
! Investigate soil conditions along the proposed pipe line route and confirm that they are as defined in the design specifications.
• Excavate pipe trench to 6 in. below pipe invert with a width of 1.5 dia to 1.6 dia. Clearance at sides of pipe should not exceed 20 in. and proper trench conditions must be maintained.
• Grade and compact trench bottom, maintaining the elevation 6 in. below pipe invert.
• Keep trench free from water.
• Place and shape a 6 in. thick layer of the specified bedding material such as crushed stone or crushed gravel per ASTM C33, gradation 67 (grain size 3/4 in. to 3/16 in.). Coarse, well-graded sand containing less than 10% fines when compacted to 90% Standard Proctor density may also be used.
• Provide bell holes at each joint location for bell and spigot pipe. Provide access holes at joint locations for all field joints.
• Place pipe sections on bedding and align with survey instruments. Stabilize pipe with small amounts of backfill under the haunches and complete joining.
• Carefully backfill and compact any voids or pockets.
• Continue backfilling and compacting in 6 in. to 12 in. layers to an elevation at least 6 in. above top of pipe. All bedding and backfill material is to be thoroughly compacted to at least 95% Standard Proctor, ASTM D-698. Do not operate compaction equipment over pipe.
• Four feet of native backfill above specified backfill is generally required for traffic loads (H-20). Installation under highways and railways requires special consideration.
• After installation, deflection or elongation of pipe should be less than 3% of the inside
Hydrostatic testing, as required by project specifications, may be commissioned either as a shop test, or preferably as a field test of the assembled system. Testing procedures must not induce loads into the pipe for which it was not designed. The maximum test pressure shall be approved by PCA. All anchors and supports must be in place before testing.
The pressure should be gradually increased to the specified test pressure, blanked off and observed for a period of 30 minutes. During this time the line pressure must not drop by more than 5 psig and no significant leakage should occur.
Following the pressure test, the line should be emptied and thoroughly inspected.
Trucor® pipe, duct and fittings are easily fabricated on the job site and assembled with the various joint types previously described. However, it is much more efficient and cost effective to prefabricate the components in our factory thereby minimizing field labour cost.
Our Engineering Department can easily work from plans and elevations or isometrics to develop individual spool drawings. Standard FRP components and joints are located and identified to provide clear assembly information to our Manufacturing Department and to minimize the total cost of the spool section.
PCA's general pipe fabricating tolerances for prefabricated FRP piping assemblies through 36 in. diameter are as follows :
Dimensional Tolerances
FABRICATED (SPOOLED) PIPING
Linear Tolerance Squareness Tolerance
Angularity and Rotational Tolerance
The tolerances on linear dimensions Squareness of end cuts, shall not deviate (intermediate or overall) apply to the face to more than + 1/8 in. up to and including 24 in. face, face to end, and end to end diameter and 3/16 in. for all diameters above measurements of fabricated straight pipe 24 in.and headers: center to end or center to face of nozzles or other attachments. These tolerances are not cumulative.
Alignment of facings, or ends shall not Linear tolerances are + 1/8 in. for sizes 10 in, deviate from the indicated position and under, + 3/16 in. for sizes 12 in. through measured across any diameter more than 24 in., and + ¼ in. for sizes 26 in. through 36 3/64 in. per ft.in.
Rotation of flanges, from the indicated Linear tolerances for sizes over 36 in. are position measured as shown shall be a subject to tolerances of +¼ in., increasing by 1maximum of /16 in.1+ /6 in. for each 12 in. in diameter over 36 in.
Cumulative effects of tolerances on fittings or flanges, when joined without intervening pipe segments, causes deviations in excess of those specified above. Tolerances on these dimensions are to be based on tolerances of the fittings or flanges involved.
FABRICATED PIPING
All stress calculations are based on an average safety factor of 10 to 1. An extensive research program on short term burst test, performed on production pipe, indicates that PCA production method of making pipe will give an actual safety factor of 10 to 1.
After installation is completed the system should be tested for leaks by filling the pipe with water and pressurizing to 1½ times the pipe's rated pressure. Testing with compressed air or gasses is dangerous and must be avoided.
Because of the relatively low modulus of elasticity of reinforced plastics piping system should be protected against the occurrence of high vacuums in operation. It full vacuum can occur under normal operating conditions 125 psi pressure rated pipe should be used. At this rating, pressure pipes will withstand full vacuum in 2 in. through 24 in.diameters valve operating up 180°F. Vacuum protection can be accomplished by using vacuum breakers or stand pipes. All vacuum lines should be supported by 180°. saddles and free from any external loads.
An outstanding advantage in the use of Trucor® Pipe is its smooth interior surface which minimizes resistance to fluid flow. When the proper Trucor series of resin is used, the pipe interior surface remains smooth throughout its entire service life.
Where the customer wishes to position instruments such as thermometers in Trucor® Pressure Pipe, it is recommended that a 1in. Trucor® Pipe Stub with flanged end be strapped into the line. The mating flange can then be adapted to secure the instrumentation securely in position. Cleanouts and flushing connections should also be made by strap joining a flanged pipe stub of the desired diameter.
Dimensions appearing in this bulletin generally conform to the S.P.I. standards for loose pipe and fittings, current at the time of printing. The design information, installation and chemical recommendations presented in this catalog are based on testing, engineering, and installation experience, and are reliable to the best of our knowledge. Field supervision is available, where desired, at a per job charge to assist in engineering and installation. Neither the furnishing of published or special design and installation information, nor supervision, however, shall constitute PCA's acceptance of the customer's design, or a guarantee of either design or performance. The terms under which PCA does guarantee pipe are set forth in the written quotation as well as in PCA's Standard Contract Terms and Conditions.
Size for all Trucor® Pipe is specified by the internal diameter.
Trucor® Pipe can be fabricated in any size diameter up to 96 inches. Sizes not listed in pages 7 & 8, Section III, require special engineering or production method. Wall thickness and laminate construction for these larger diameters will be specified by PCA's Engineering Department.
Trucor® Pipe is manufactured in 10 ft. and 20 ft. lengths, depending on size and wall thickness. While longer lengths can be supplied through standard joining methods, transportation limitations usually dictate the maximum length.
All Trucor® Pipe Fittings are made with contact moulding method. The complete line of Trucor® Fittings is available in 25, 50, 75, 100, 125 and 150 psi. Higher pressure rated fittings are available upon request.
Trucor® Sweep Elbows in diameters up to 12 in. are moulded in one-piece 90° sweep with a continuous radius. Sweep Elbows over 12 in. in diameter are supplied as specials to meet customer requirements. All Trucor® sweep elbows over 4inches diameter have a standard centreline radius equal to 1½ times the diameter. They also offer a smooth interior surface to eliminate turbulence, reduce friction, and assure long service life. Elbow thickness and construction correspond to construction of the pressure pipe itself.
Mitered Elbows are produced from Trucor® Pressure Pipe in either 3 or 5 - piece construction. These elbows are used primarily where a centerline radius other than the standard is required. They are also used for pipe with a diameter greater than 12 in.
The maximum operating temperatures are 250°F for most Trucor® Polyester Pipe, depending on the type of chemical service. PCA engineers will analyze all conditions and make specific recommendations for operating temperatures. Special resin would be used for operating conditions up to 320°F.(Refer to Section II (Material & Construction)
All Pipe Systems, should be designed for maximum operating line pressure anticipated during the service life of the system. Although Trucor® Pipe will withstand pressure over 500 psi, it is recommended that reinforced plastic systems should be limited to 150 psi maximum operating pressure
VACUUM CONSIDERATION
FRICTION LOSS THROUGH TRUCOR® PIPE & FITTINGS
INSTRUMENTATION & OTHER CONNECTIONS
STANDARDS & TECHNICAL ASSISTANCE
PIPE SIZES
PIPE DIAMETERS OVER 24 INCHES
PIPE LENGTHS
FITTINGS
SWEEP ELBOWS
MITERED ELBOWS
OPERATING TEMPERATURES
OPERATING PRESSURES
TEST PRESSURES
Applicable Specifications and Standards1. ASME RTP-1, Reinforced Thermoset Plastic Corrosion Resistant Equipment2. ASTM C-582, Standard Specification for Contact Molded Reinforced Thermosetting Plastic (RTP) Laminates for
Corrosion Resistant Equipment.3. ASTM D2563, Standard Practice for Classifying Visual Defects in Glass Reinforced Plastic Laminate Parts.4. ASTM D638, Test Method for Tensile Properties of Plastics.5. ASTM D-3567, Practice for Determining Dimensions of “Fiberglass” Pipe and fittings.6. ASTM D-695, Test Method for Compressive Properties of Rigid Plastics.7. ASTM D-2583, Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor.8. ASTM D-2996, Standard Specification for Filament Wound “Fiberglass” Pipe
CONFORMANCE WITH INDUSTRY STANDARDS
STANDARDS
OUR PRESENCE IN THE INDUSTRY
We exploited all areas where FRP pipes could possibly substitute for other materials in terms of handling, service and maintenance. Our records revealed that efforts over the past years are encouraging, forging us ahead into new frontiers.
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