GRP Pipe

GRP/FRP pipe are now being accepted all over in Chemical, Petroleum, Gas, Water Transportation, Sea Water, Sewerage, etc. GRP/FRP pipes are competing with conventional material like Ductile Iron, Epoxy Coated MS, PVC, and HDPE because of its major advantage of being non-corrosive in nature and long life with proper selection of resin. EFG Composites pipes are ranging from 200 mm dia. up to 2600 mm dia.
Pipe Structure
The structure of EFG Composites GRP pipe wall consists of several layers.

• Internal and external protective layers
• Reinforcing layers
• Stiffness layers
• Barrier layers
• Transition layers

Each layer consist of polyster resin reinforcement, a continous fiber glass element, and filling materials.The internal protective layer has a high resin content which account for EFG Composite, GRP Pipe excellent chemical resistance.

Raw Materials- The main raw materials used in EFG Composites GRP pipe manufacture are Fibre glass, both continuous and ‘chop’ fibers, siliceous sand. This is used as a filler in the reinforcing and stiffness layers and provides both longitudinal and peripheral strength.

Polyester resin

Manufacturing

EFG Composites is able to produce GRP pipes using two different automated manufacturing processes

Continuous filament winding

Centrifugal casting

Continuous Filament Winding- production principle is based on a continuous process, technologically, the winding process its taking place on a rotating mold, compound from a continuous steal belt. The helical movement of the steel band, on the machinery cylinder, allows the pipe translation in the winding process, with a precise speed, set thru the Logic Control System (PLC). All manufacturing parameters – e.g. machine speed, temperature etc. – and product characteristics – e.g. diameter, stiffness, pressure class – are tightly controlled. Multiple sensors and cameras monitor the production process and relay real time data to the filament winding machine’s control unit. Curing of EFG Composites GRP pipes takes place in a carefully controlled heated environment. Once the pipe has cured it is cut to length. The pipe can be cut to any length between 0.3 and 12mtr.

Centrifugal Casting- use of state-of-the-art software engineering enables pipe parameters to be set via a simple computer interface. Raw materials are introduced, layer by layer, into a heated rotating mould with centrifugal forces up to 80G.After the pipe has been removed from the mould, it is automatically fed through the cutting and chamfering machine, and the coupling station. The pipe is then packed and stored or shipped.

Material Properties- The properties and the pipes comportment against external and internal factors can be classified and guided upon the following parameters:

Stiffness- Stiffness refers to the ability of a pipe to withstand both external loads and negative internal pressures. ISO standards measure material stiffness in N/m2

Pressure-ISO standards rate pressure pipes by nominal pressure (PN) in bars. Standard ranges of EFG Composites GRP pipes are manufactured to the following PN ratings: PN1. PN6, PN10, PN16, PN20, PN25, and PN32.The AWWA C950 standard rates pipe pressures in psi units.Psi: 50, 100, 150, 200, and 250.

Flow Velocity- - The maximum recommended flow velocity for a standard GRP pipe is v = 48/[ ƪ]0.33 Where: v = fluid speed [ft./sec], ƪ=fluid density [lb/ft3 ].The fluid density for water is 62,4 lb/ft3.As a general rule, a maximum flow velocity of 3m/sec is recommended for GRP pipes in normal operating conditions

Roughness- A pipe’s hydraulic properties have a major impact on the energy losses along its length and are a major factor in deciding the optimal pipe profile for a project. The following flow coefficients should be used:
C = 150, Hazen-Williams method.
k =0,029, Colebrook-White method.
n = 0,009, Manning method.

Poisson-efficient/ratio- EFG Composites GRP pipes the Poisson coefficient/ratio ranges from 0.22 to 0.29.

Temperature Resistance- majority of fluids flow through EFG Composites GRP pipes at 35ºC. The impact of temperature on pipe performance can also be affected by other factors such as flow velocity, pressure and abrasion. When transporting liquids between 35ºC and 50ºC, it is recommended that the pipe’s pressure rating is reduced by one class e.g. a PN16 pipe would be de-rated to PN10.

Thermal Expansion Co-Efficient- thermal expansion coefficient represents the proportion of the relative emphasis of a dimension (the ratio between the dimension variation and the initial dimension).

Product Range- composites supply GRP pipes in a range of standard lengths, diameters, pressure ratings and stiffness (listed below). The flexibility of EFG Composites manufacturing processes means that intermediate sizes, pressure ratings and stiffness can be produced for specific projects.

Diameters- Composites GRP pipes are produced after standards dimensions. Intermediate diameters are available in accordance with the customer needs.

EFG Composites GRP pipes can be manufactured in a variety of combinations according with the three principle parameters- diameter pressure and stiffness.

Advantages of GRP Pipes

• Corrosion Resistant- GRP pipes do not require linings, coatings, cathodic protection, wraps or other forms of corrosion protection. Maintenance cost is low.
• Hydraulic Conduction- Smooth inside wall of GRP pipes provides savings from pipe diameters and from electrical energy consumptions in pumping lines. (Colebrook White k=0,001 Hazen Williams c=155 Manning n=0,008)
• Non-Toxicity- The filament winding manufacturing technology together with the process of polymerization and vaporization enables Fiber Tech GRP Pipes to be made in exact conformity to the laws in forces, governing the construction of pipe that will have to be in contact with potable water and food stuffs.
• Low Thermal and Electrical Conductivity- EFG Composites GRP Pipes have excellent thermal insulating properties and there is no need for the pipes to be insulated externally to maintain the temperature inside the pipe. Even cathodic protection is also not required for GRP Pipes.
• Quality of Fittings- Fittings have the same characteristics of GRP pipes as they are produced from the same materials.
• Resistivity- GRP pipes do not conduct electricity and are not affected from induction flows.
• Elasticity- The elastic characteristic of GRP pipes enables the accommodation to earth movements. For this reason GRP pipes are preferred in seismic zones. Elasticity also reduces the quantities of bends used in the project.
• Deviation in Fittings- The tolerance of deviation in the fittings decrease the bends required in the projects. The tolerable degrees are 3o for DN300-500 mm, 2o for DN600-900 mm, 1o for DN1000-1800 mm and 0,5o for DN>1800 mm
• Extremely Smooth Bore- Low friction loss means less pumping energy needed and lower operating costs.
• Smooth Internal Surface- Excellent hydraulic properties and the pipe comportment, during the exploitation stage, are among the first advantaged to be capitalize on operation stage. The protective purpose of the smooth internal surface allows high transportation speeds of the liquid inside the pipe, maintaining in the same time a high abrasion resistance.
• Light Weight -The EFG Composites GRP pipe systems weight brings the following advantages
• 4 times lighter than the steel pipes
• 10 times lighter than the concrete pipes
• They are easy and fast to install, due to the reduce weight
• Heavy equipment not required, for manipulation, transport and installation.
• Due to the light weight it is feasible for relining application
• Chemical resistance
• SUPERLIT GRP Systems have a high chemical resistance.
• All products made by non-ferrous materials.
• Have an extended life time, with minimum maintenance cost.
• Can be used in high pH media.
• The material is not conductive; it does not react at induction current.
• Does not require extra protective layers.
• Cavities in the pipe wall structure do not appear, as a result of the corrosion.
• Do not require cathodic protection.

Application

• Irrigation networks and drainage applications.
• Drinking water networks and water distribution pipelines
• Sewerage projects network, collector lines.
• Sewerage projects force mains.
• Pressure Pipelines for hydroelectric power stations.
• Storm water drainage.
• Cooling water supply and discharge in power stations.
• Pipelines to carry the chemical wastes.
• Relining Applications
• Pipelines to remove the industrial wastes
• Reservoir for chemical plants and drinking water
• Discharge lines of the sea

GRP Pipes made from major raw materials fiberglass + Isopthalic Resin. GRP Pipes can be used for applications of temperature up to 600 Degree Celsius. The standard fittings includes flanges, couplings, and elbows, Tees, Reducers, Spool, Saddle and End Caps Industries & Markets.

SL.NO	FEATURES	BENEFITS
1	Inherent Corrosion Resistance	• Long, maintenance-free service life • No add-on linings or coatings to damage, repair, inspect or maintain. • Hydraulics don’t change • Lowest Life Cycle cost
2	Smooth I.D.	• Superior hydraulic characteristics • High flow capacity • Significant energy savings in pumped systems
3	Lightweight	• Less expensive equipment for handling
4	Long Length Sections	• Fewer joints to assemble
5	Resilient Inner Liner	• Excellent abrasion and crack resistance
6	Computer Controlled Production	• Consistent high quality pipe • Reduced risk with fewer problems
7	High Stiffness, Solid Pipe Wall with High Compressive Load Capacity	• Easy to bury using routine methods • Predictable performance • Easily handles deep covers
8	Gasket-Sealed, Push-Together Joints	• Fast, fool-proof assembly • No bonding agents, bolts or welding needed
9	Leak-free Joints	• Zero infiltration, lower treatment costs • No ground water pollution
10	Smooth, Dimensionally Consistent O.D.	• Field length adjustments easy – pipe may be cut anywhere along length and assembled with gasket joint • Lowest jacking loads