Fiberglass Reinforced Plastics (FRP) - Wermac.org

FRP vs GRP: Difference Between FRP and GRP

FRP stands for Fiber Reinforced Plastic while GRP stands for Glass Reinforced Plastic. The name makes it clear that there is a change in the reinforcing fiber. But both FRP and GRP are normally used to denote the same plastic products.

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Introduction

In recent years, FRP has been widely used in process, water and chemical industries due to their high resistance to corrosion.

FRP pipes are also increasingly used for the transport of Water, Oil, Fuel, Glycol, Wastewater, Sewer, etc. As a result, the demand for FRP pipes is continuously increasing.

The service life is usually very high, in the range of 50 years. Thus, the total cost of FRP pipes for life becomes cheaper as compared to metal pipes.

What is FRP?

The full form of FRP is a composite material consisting of a polymer matrix reinforced with fibers. So, an FRP pipe is a pipe manufactured of FRP material by contact molding or filament winding method. Various types of resins like thermosetting polyester, epoxy, phenolic resin, etc are used to get specific FRP pipe properties in the final product.

The most widely used reinforcement is the fiberglass. As a corrosion-resistant alternative to metallic piping, the FRP piping system has found worldwide application.

Common Fibers include:

• Glass is a very good insulating material and, when blended with the matrix, forms fiberglass or glass reinforced plastic. Compared to carbon fiber, it is both less strong and rigid and less brittle and expensive.
• Carbon based fiber reinforced plastics offer high tensile strength, chemical resistance, stiffness, and temperature tolerance along with low thermal expansion and weight. The carbon atoms form crystals which lie mostly along the fiber’s long axis. This alignment makes the material strong by making the ratio of strength to volume high.
• Aramid is a fiber component that results in robust and heat-resistant synthetic fibers. It finds wide applications in many industries.

By selecting FRP as the pipe and fittings materials, include flanges, elbows, tee's, crosses, reducers etc., the need for internal lining, external coating, and cathodic protection can easily be eliminated. FRP piping system is available in a wide range of sizes starting from 1 inch to above 100 inches.

More than just FRP pipe systems

Besides pipelines, storage tanks, towers, grids on walkways, profiles (like steel profiles) etc. are also manufactured from FRP. Below a description of a storage tank

Introduction

FRP storage tanks are divided into vertical storage tanks and horizontal storage tanks. The winding material selection of storage tanks must be appropriate, quality priority, and price consideration.

In the actual production, the tank wall structure of the FRP-wound storage tank is generally an inner liner layer, a strength layer and an outer surface layer.

Material and resin selection

Due to the different functions of the layers, the materials are selected differently, and the inner liner is directly in contact with the medium, and the material selection is correct or not, which plays a key role in controlling the leakage of the wound storage tank.

To use vinyl resin if store acidic medium, to use bisphenol A resin if store alkali medium, to use alkali-free glass fiber if need to be water and alkali resistant, to use medium-alkali glass fiber if need to be acid-resistant , and the inner liner is made of surface felt and chopped together to reinforce to increase the amount of glue and enhance the impermeability.

The strength layer mainly meets the strength and stiffness requirements of the storage tank. Material selection should fully consider that the selected resin matrix must have good penetrability with the glass fiber for winding to form a dense structural layer; the outer surface is in direct contact with the external environment, and the material is selected according to the aging resistance requirement.

Application:

FRP tanks can be used to store tanks of various media. They are resistant to pressure, corrosion, ageing, long service life, light weight, high strength, impermeability, heat insulation, insulation, non-toxicity and smooth surface. It is widely used in coatings, pharmaceuticals, building materials, chemicals, pigments, resins, food, scientific research and other industries.

Drawbacks of FRP

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• FRP is not recommended for carrying fluid with temperature more than 100 degrees celsius
• Slight degradation from UV rays is found to occur which can be reduced by using pigments, dyes, UV stabilizers, fillers, etc in the resin system

Reference(s) ..

www.frpwt.com
HeBei WeiTong FiberGlass Co., Ltd.

www.versteden.com
Versteden fiberglass piping systems

www.fibrex.com
FIBREX FRP piping systems

Some Codes and Standards for FRP

• ASTM D, Standard Specification for Contact-Molded “Fiberglass” (Glass Fiber-Reinforced Thermosetting Resin) Corrosion Resistant Pipe and Fittings, ASTM. West Conshohocken, PA
• ASTM D, Obtaining Hydrostatic or Pressure Design Basis for Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Fittings. ASTM, West Conshohocken, PA
• ASME B31.3 Process Piping. ASME, New York, NY
• ASTM D, Specification for Contact Molded Fiberglass (Glass-Fiber Reinforced Thermosetting Resin) Flanges. ASTM, West Conshohocken, PA
• ISO , Glass fibre reinforced thermosetting plastics (GRP) pipes and fittings - Nominal diameters, specified diameters and standard lengths
• ANSI AWWA C950-, This standard describes the fabrication and the testing of nominal 1-in through 156-in (25-mm through 4,000-mm) fiberglass pipe and joining systems for use in both aboveground and belowground water systems. Service and distribution piping systems and transmission piping systems are included
• AWWA M45, Selection, installation, and maintenance of fiberglass pipe in potable water systems
• ISO -1, Petroleum and natural gas industries - Glass-reinforced plastics (GRP) piping

In the demanding and highly specialized environment of chemical processing industries, selecting the right piping material is crucial. The choice directly impacts the safety, efficiency, and longevity of the entire system. Given the harsh conditions and the presence of corrosive substances, materials that can withstand these challenges are essential. Fiberglass-reinforced plastic (FRP) piping has emerged as a superior choice for handling corrosive chemicals, offering numerous advantages over traditional materials such as carbon and stainless steel, lined steel, expensive alloys and  nonreinforced thermoplastics.

Chemical plants often deal with a variety of aggressive substances, including wastewater, concentrated brines, acids, bases, and solvents. Traditional materials tend to degrade under such conditions, leading to frequent maintenance, potential leaks, and system failures. FRP piping, however, is designed to eliminate corrosion-related failures and resists chemical attack, making it an ideal solution for these environments.

This blog delves into the pivotal role of fiberglass piping in chemical processing industries. We will explore how FRP piping meets the stringent demands of corrosive environments, and examine the overall benefits it brings to chemical plants. By understanding these advantages, industry professionals can make informed decisions that enhance the performance and reliability of their piping systems.

Outstanding Chemical Resistance

One of the primary reasons fiberglass piping is favoured in chemical processing industries is its exceptional resistance to corrosion. Traditional piping materials like carbon and stainless steel are prone to corrosion when exposed to harsh chemicals, leading to frequent maintenance, leaks, and system failures. In contrast, fiberglass piping is inherently resistant to a wide range of chemicals, including acids, alkalis, and solvents. This resistance ensures the integrity of the piping system, reducing the risk of leaks and extending its lifespan. Fiberglass piping also offers excellent external corrosion resistance due to its non-metallic structure, preventing problems caused by harsh environments inside and outside of chemical facilities. External corrosion under insulation caused by trapped moisture is eliminated.

Superior Structural Integrity

Fibreglass piping combines lightweight construction with high strength and durability thanks to its glass-reinforced structural wall. Its robust nature allows it to withstand high-pressure and high-temperature environments commonly found in chemical processing plants. Support spans are more similar to steel than they are to nonreinforced thermoplastics. This durability ensures that the piping system can handle the demanding conditions without compromising performance. Additionally, the lightweight nature of fiberglass piping simplifies installation and reduces labour costs, making it a cost-effective solution for chemical plants.

Ensuring Safety

Safety is paramount in chemical processing industries, and fibreglass piping excels in this aspect. Its non-conductive properties reduce the severity of galvanic corrosion by functioning as an electrical insulator, making it an especially good choice for use in systems with heat exchangers that use exotic alloys. Moreover, fiberglass piping does not corrode or deteriorate over time, reducing the likelihood of hazardous chemical spills. Fiberglass piping is a reliable choice for maintaining a secure and efficient chemical processing environment.

Cost-Effective Upkeep

The high resistance to corrosion and chemical attack means that fiberglass piping requires minimal maintenance compared to traditional materials. Chemical plants can benefit from reduced downtime and lower maintenance costs, as there is no need for frequent inspections, repairs, or replacements. This low maintenance requirement translates to increased operational efficiency and cost savings over the lifecycle of the piping system. Most of our piping systems are expected to provide trouble-free operation for decades when installed as part of a prudent design.

Versatile and Customizable

Fiberglass piping is highly versatile and can be customized to meet the specific needs of chemical processing applications. It can be fabricated in various diameters, lengths, and configurations to suit different plant layouts and process requirements. This flexibility allows for the creation of tailored solutions that optimize the efficiency and performance of the chemical processing system.

Eco-Friendly Solution

In addition to its functional advantages, fiberglass piping also offers environmental benefits. It is produced using less energy compared to traditional materials, resulting in a 30% reduction of carbon footprint in manufacturing when compared to metallic pipe. Furthermore, its long lifespan and minimal maintenance needs reduce the environmental impact associated with frequent replacements and repairs. This makes fiberglass piping an environmentally friendly choice for chemical processing industries aiming to meet sustainability goals.

Conclusion

Fiberglass piping plays a crucial role in the chemical processing industries, offering unmatched resistance to corrosion, high durability, enhanced safety features, and low maintenance requirements. Its versatility and environmental benefits further solidify its position as the ideal choice for handling corrosive chemicals in chemical plants. By choosing fiberglass piping, chemical processing industries can ensure a reliable, efficient, and cost-effective piping system that meets the demanding needs of their operations.

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