Comparisons Between Grp Pipes With Various Metallic by Nadeem

NADEEM AHMED Mobile : +91- 99 44 329 322 E-mail : [email protected]

GRP PIPE COMPARISION OF FEATURE BENEFITS WITH VARIOUS TRADITIONAL PIPES FIT & FORGET PIPING SYSTEM LIGHTWEIGHT, STRONG & DURABLE

Prepared by : N a d e e m A h m e d Mobile : + 91 - 99 44 329 322 E-mail : [email protected]


COMPARISONS BETWEEN GRP PIPES WITH VARIOUS METALLIC , PSC , PVC, HDPE & OTHER PIPES MATERIAL PARAMETERS

GRP

CAST IRON

DUCTILE IRON

MILD STEEL

PSC

PCCP

BWSC

150-260

Min.420

Min.410

Less Hoop tensile strength

410

410

Nil

10

17

-

-

-

ELONGATION %

High Hoop tensile strength -

BRINELL HARDNESS

-

< 230 BHN

< 230 BHN

< 140 BHN

-

-

-

TYPE

Very light weight, Flexible

This is heavy, rigid & brittle pipe.

The pipe ductile, lighter flexible in nature.

This is also a light, flexible type pipe.

High weight, Rigid pipe

High weight, Rigid pipe

High Weight, semirigid pipe

STRENGTH

High strength to weight Ratio

High strength, very low impact resistance

High strength and very high impact resistance

High strength and high impact resistance

Subject to shear & beam breakage

CORROSION

Highly Corrosion resistant

Corrosion resistant

Corrosion resistant

Highly corrosion prone.

Highly corrosion prone

CEMENT MORTAR LINING

Not applicable

Not available

centrifugally applied cement mortar lining

Cement mortar lining is available at site level

Lining & coating

Lining & coating

CML applicable

LAYING & JOINTING TYPE & INSTALLATION

Long laying length (6-18m), double bell coupling, Faster installation

Long laying, Flexible rubber push-on type joints and rigid lead, slow installation

Long Laying, Flexible rubberpush- on type joints (Gasket type), fast installation

Long Laying, Rigid welded joints, Fast installation

Wide range of laying length, flexible Rubber ring (Gasket type), slow installation

Wide range of laying length, welding, slow installation

Medium laying length (4-8m), welding, slow installation

TENSILE STRENGTH (MPA)


Subject to shear & beam breakage Highly corrosion prone

Subject to shear & beam breakage Highly corrosion prone

NADEEM AHMED Mobile : +91- 99 44 329 322 E-mail : [email protected] MATERIAL PARAMETERS

GRP

CAST IRON

DUCTILE IRON

EFFECTIVE SERVICE LIFE & DURABILITY

50-60 Years

Minimum 100 years

Minimum 100 years

Cost effective

Costliest

Costlier

30 to 40 years under proper anticorrosive lining Costly

Less

Higher

High

0.011

0.011 with CML

150 Easier About 5o

SURGE PRESSURE

MILD STEEL

PSC

PCCP

BWSC

Cheaper

Max. 30 Years under proper Maintenance Cheap

High

Higher

Higher

0.011 with CML

0.011 with CML

0.011 with CML

140 with CML Easy 3o -5o

140 with CML Easier 3o -5o

120 with CML Easy NIL

140 Difficult negligible

Low hydraulic surge

High hydraulic surge

Medium hydraulic surge

Medium hydraulic surge




AVAILABLE SIZES IN INDIA (MM)

25-4000

100-1000

100-1100

300-2500

300-2000

300-2000

250-1800

STANDARDS

IS-12709

IS-1536

IS-8329

IS-3589

IS-784

IS-784/EN-642

IS-15155

BASIC COST OF PIPE TRANSPORTATION COST ROUGHNESS COEFFICIENT HW-“C”- VALUE HANDLING DEFLECTION


Max.30 Years under proper Maintenance

0.011 with CML 140 Difficult Negligible

Max.30 Years under proper Maintenance Relatively less Costly High 0.011 with CML 130 Easy Nil


COMPARISONS OF FEATURES BENEFITS BETWEEN GRP PIPE WITH D.I. PIPES MATERIAL PARAMETERS CORROSION RESISTANCE COST INSTALLATION COST MAINTENANCE LIFE UNDERGROUND APPLICATION PROCESS PARAMETER FOR MANUFACTURING WEIGHT HANDLING SPECIFIC GRAVITY HAZEN WILLIAMS COEFFICIENT WALL THICKNESS

GRP PIPE

DUCTILE IRON PIPE

Excellent corrosion resistance. No external/ Very poor corrosion resistance. Hence wrapping, Internal coating or wrapping is required. coating, Cathodic protection is required to prevent 15% Lower than Ductile Iron

-

Light duty tools are required due to light Heavy duty tools, Fork lift, crane required due to weight. Hence substantial cost saving on heavy weight. Hence installation cost will be Less maintenance is required

Periodical maintenance is required.

GRP pipes are designed for 50 Year of life.

Due to corrosion the life of the pipe is 10 – 15

GRP pipe is not attacked by the organic The life of the under ground DI pipe is reduced matters present in the soil due to the organic matters present in the soil Varies from case to case and hence Only one type for all applications properties can be fixed depend upon the Very light. Nearly 1/4th of DI pipe

Heavy

Handling is very easy since very light in

Difficult, due to heavy weight

1.8 – 1.9

7.05

150 (Hence less head loss)

120

Lesser wall thickness due to proper fiber For a particular pressure rating, wall thickness is orientation higher than GRP



COMPARISONS OF FEATURES BENEFITS BETWEEN GRP PIPE WITH MILD STEEL PIPES MATERIAL PARAMETERS CORROSION RESISTANCE

GRP PIPE

MS PIPE

Corrosion is the Major problem with MS pipes. To minimize Totally corrosion resistant. No external/ internal coating or corrosion additional epoxy coating is required. Cathodic wrapping is required. protection is required

HAZEN WILLIAMS COEFFICIENT (“C” VALUE)

150 C Value Highest among different piping materials due to smooth inner surface of GRP Pipes Higher C value gives lower head loss and reduces the pumping cost.

120 C Value

LIFE

GRP pipes are designed for 50 Years of life.

Due to corrosion the life of the pipe is 10 – 15 years

SPECIFIC GRAVITY

1.8 – 1.9 Very light. Nearly 1/4th of MS pipe for the same specification. Handling is very easy since very light in weight

7.85

WEIGHT HANDLING

no

maintenance

is

required

for

Very Heavy Difficult, due to heavy weight GRP

External coating may peel off in due course of time due to rough handling and environment. Periodical maintenance is required.

MAINTENANCE

Practically pipes.

UNDERGROUND APPLICATION

GRP pipe is not attacked by the organic matters present in The life of the underground pipe is reduced due to the the soil organic matters present in the soil

INSTALLATION COST

Heavy-duty tools, Forklift, Crane etc. are required Light duty tools are required due to lightweight. due to heavy weight. Hence installation cost will Hence substantial cost saving on installation. be higher



COMPARISONS OF FEATURES BENEFITS BETWEEN GRP PIPE WITH PVC PIPES MATERIAL PARAMETERS TENSILE STRENGTH MODULUS OF ELASTICITY SPECIFIC GRAVITY WALL THICKNESS CORROSION RESISTANCE RELATIVE COST PROCESS PARAMETER FOR MANUFACTURING MAINTENANCE LIFE UNDERGROUND PIPING APPLICATIONS

GRP PIPE Hoop tensile strength: 300 - 375 MPa Hoop Tensile modulus: 20000-30000 GPa 1.8 – 1.9 Lesser wall thickness due to high strength and excellent stiffness and proper fiber orientation Good 15% cost saving higher diameter pipes (above 10 inches) Varies from case to case and hence properties can be fixed depend upon the application by varying fiber orientation. GRP pipes are designed for 50 Year of life hence no maintenance is required GRP pipe are designed for 50years of life

PVC PIPE 50 MPa 3000 GPa 1.4 – 1.45 For a particular pressure rating, wall thickness is much higher than GRP Poor against alkali medium Only one type for all applications Periodical maintenance is required. Life of PVC pipe is 5 – 8 years depending upon the service condition

Best design optimization possible between meeting internal pressure class and stiffness Not suitable for Underground application requirement with fiber orientation and sand aggregate addition



COMPARISONS OF FEATURES BENEFITS BETWEEN GRP PIPE WITH HDPE PIPES MATERIAL PARAMETERS TENSILE STRENGTH

GRP PIPE

HDPE PIPE

Hoop tensile strength: 300 - 375 MPa

60 MPa

Hoop Tensile modulus: 20000-30000 GPa

5000 GPa

SPECIFIC GRAVITY

1.8 – 1.9

0.95

WALL THICKNESS

Lesser wall thickness due to high strength and For a particular pressure rating, wall thickness is excellent stiffness and proper fiber orientation much higher than GRP

MODULUS OF ELASTICITY

CORROSION RESISTANCE RELATIVE COST PROCESS PARAMETER FOR MANUFACTURING MAINTENANCE

UNDERGROUND PIPING APPLICATIONS

Good

Good

15% cost saving higher diameter pipes (above 200mm)

-

Varies from case to case and hence properties can be fixed depend upon the application by Only one type for all applications varying fiber orientation. GRP pipes are designed for 50 Year of life Periodical maintenance is required. hence no maintenance is required Best design optimization possible between meeting internal pressure class and stiffness Uneconomical requirement with fiber orientation and sand thickness. aggregate addition


design

calling

for

very

high


COMPARISONS OF FEATURES BENEFITS BETWEEN GRP PIPE WITH D.I. /M.S / PVC / HDPE PIPES MATERIAL PARAMETERS

CORROSION RESISTANCE

MAINTENANCE

LIFE

UNDERGROUND APPLICATION

GRP PIPES

DI PIPES

MS EPOXY COATED

PVC PIPES

HDPE PIPES

Very Good

Very poor corrosion resistance. Hence inside cement lining is required. For outside corrosion protection wrapping, coating, Cathodic protection is required

To avoid inside corrosion, additional epoxy coating is required. For outside corrosion protection wrapping, coating, Cathodic protection is required

Poor against alkali medium

Good

Very Less Maintenance is required

External coating may peel off in due course of time due to rough handling and environment Periodical maintenance is required.

GRP pipes are designed for 50 Years of life

Due to corrosion the life of pipe is 15 – 20 years

Best design optimization possible between meeting internal The life of the underground DI pressure class and pipe is reduced due to external stiffness requirement corrosion with fiber orientation and sand aggregate addition

External coating may peel off in due course of time due to rough handling and Repair is not possible environment Periodical maintenance is required. Life of PVC pipe is Due to corrosion the life of the 5 – 8 years depend pipe is 10 – 15 years upon the service condition

Life of HDPE pipe is 5 – 6 years depend upon the service condition

The life of the underground pipe is reduced due to external corrosion

Uneconomical design calling for very high thickness.


Not suitable for Underground application

Repair is not possible


VARIOUS PIPE WALL – SPECIFIC GRAVITY



COEFFICIENT OF THERMAL EXPANSION



THERMAL CONDUCTIVITY



SURGE & WATER HAMMER – SURGE WAVE CELERITY



SAVE LIFE COSTS - SAVING TIME & MONEY



REAL TIME DATA – LIFE COST OF GRP PIPE VS MILD STEEL PIPE DN 1400 MM

DN 1400 MM

DN 1300 MM

DN 1200 MM

MILD STEEL PIPE

GRP PIPE

GRP PIPE

GRP PIPE

HEAD MTR

105

60

82

115

PUMP KW

3,156

1,803

2,464

3,456

PIPE COST RS CR

18.75

15.68

13.75

12.10

PUMP COST RS CR

0.27

0.15

0.21

0.29

INSTALL COST CR

16.02

10.83

9.96

8.39

COMPARISION

100%

81%

87%

101%

POWER COST

2.03

1.16

1.59

2.22

ANNUITY Af= 0.106 AT 10% FOR 30 YEARS

19.17

10.94

14.95

20.97

PROJECT COST

33.19

26.77

28.91

20.97

COMPARISON

100%

81%

87%

101%

DESCRIPTION



GRP PIPE DEFULT PROPERTIES & ADVANTAGE GRP PIPE PROPERTIES

ADVANTAGES

Absolute resistance to corrosion by carbon dioxide and water Sweet-gas corrosion (CO2) Sour-gas corrosion (H2S) Oxygen corrosion (O2) Mixed corrosion

Very long useful service life Reduced costs Reduced environmental risks Internal and external surfaces free from corrosion/deposits/wax No protective liners or encasements required Cost savings No cathodic corrosion protection required

Low self-weight (approx. 50% lighter than steel)

Reduced installation costs Light and easy to handle Reduced personnel and material requirements Simple, quick installation

Smooth internal pipe surface, Hazen Williams C=150 Low surface roughness values Internal liner surface roughness 23um

Improved flow rates and speeds Increased pump efficiency or fewer pumps needed Avoidance of incrustation on inner pipe surfaces Improved hydraulic values Minimum pressure losses



GRP PIPE USAGE IN DIFFERENT APPLICATION FIELDS

Water Distribution (civil and industrial) Sewer Systems (urban and industrial) Irrigation Networks Water Intakes for Cooling Water Systems Waste Water Outfalls to sea Sub-sea Pipelines Process Lines for Industrial plants Fire Fighting Networks Corrosive Fluids and Vent Gas Stacks Wells Casing, Wells Pump Risers and Screen Penstocks & Hydro power plant Pipes for Ships and Offshore applications Water supply lines Waste water treatment system Seawater outfalls & Transport of corrosive fluids Desulphurisation systems & Desalination plants , Industrial sewage Cooling water system & District cooling projects and Etc.



MECHANICAL PROPERTIES OF GRP PIPE WITH STEEL PIPE MATERIAL PARAMETERS

GRP PIPE

STEEL PIPES

FLEXURAL STRENGTH PSI (MPA)

55,000 (379)

***

FLEXURAL MODULUS PSI (GPA) TENSILE STRENGTH PSI (MPA) TENSILE MODULUS PSI (GPA) DENSITY (KG/M³) THERMAL CONDUCTIVITY BTU IN/FT² HOUR ˚F (W/M˚ K)

42,500,000 (29) 50,000 (343) 4,250,000 (29) 0.06 (1.7) 0.277 (0.04)³

*** 60,000 (414) 30,000,000 (207) 0.28 (7.8)² 348 (50.2)³

SPECIFIC GRAVITY& STRENGTH OF MATERIALS MATERIAL PARAMETERS

GRP PIPE

STEEL PIPES

CAST IRON PIPE

PVC PIPE

SPECIFIC GRAVITY ( 1 )

1 .8 - 2.1

7.84

7.34

1 .4

TENSILE STRENGTH ( MPA)

160 - 320

380

187

50 - 60

SPECIFIC STRENGTH

100 - 168

48.5

25.5

36.8



THE SOLUTION TO CORROSION PROBLEMS IS GRP PIPE !

FACE CORROSION PROBLEM IF YOU USE OTHER THEN GRP PIPE – LIKE BELOW Corrosion is a natural redox process that oxidizes metals to their oxides and sulfides. In chemical terms, corrosion is the reverse of isolating a metal from its oxide or sulfide ore; in electrochemical terms, the process shares many similarities with voltaic cells. Damage from corrosion to cars, ship, buildings, and bridges runs into tens of billions of rupees annually, so it is a major problem in much of the world.



ADVANTAGES OF GRP PIPE Long life 50 yearr design life Low maintenance costs (none) Lowest lifecycle costs No coatings or linings to maintain No need for cathodic protection No need for chemical soil analysis Unaffected by salt water Unaffected by chlorides & sulphates Unaffected by stray currents Unaffected by soft water Corrosion Proof throughout





ONLY FIT AND FORGET PIPING SYSTEM- GRP PIPE

THANK YOU.......NADEEM AHMED Prepared by : N a d e e m A h m e d Mobile : + 91 - 99 44 329 322 E-mail : [email protected]

Comparisons Between Grp Pipes With Various Metallic by Nadeem

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