178134-P 178134-P

POLYMER COMPOSITE ASIA SDN. BHD. A A Member Member of of Hexagon Hexagon Holdings Holdings Berhad Berhad

FIBER REINFORCED PLASTIC PIPES

ENGINEERED TO INTERNATIONAL INDUSTRIAL STANDARDS

E EUM UM EQUIPMENTI EQUIPMENTI N N

Composites Composites Fabricators Fabricators Association Association

COMPOSITES

E T E UT SS T TU TIIT

PE ET TR P RO OLL

TRUCOR
Polymer Composite Asia Sdn Bhd

FIBER REINFORCED PLASTIC PIPES

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
Power Plants Industrial Oil and Gas Mining Offshore
Building Construction

Marine

Radar

Electrical

Pulp and Paper

Transportation

Recreation

EMI/RFI Testing

Pollution Control

Chemical

Plating

Metal Finishing

Water Treatment

Products & Services Include:

Initial Concept Development Complete Engineering and Design Shop 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 Installation Complete Turn-key Capabilities

POLYMER COMPOSITE ASIA SDN BHD

178134-P A Member of Hexagon Holdings Berhad 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 : pcasales@hexagonholdings.com 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

INTRODUCTION
WHY USE FIBER REINFORCED PLASTIC PIPES ?
CORROSION RATE
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 TrucorFiber 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 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 products going into the line or 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 colorcoded 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.

SMOOTH INTERIOR SURFACE

TRANSLUCENCY

CORROSION RESISTANCE OF TRUCOR

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.

DURABILITY

WEATHER RESISTANCE

COLOUR

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.

INSTALLATION TECHNIQUES

EXTERIOR MAINTENANCE

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 ALUMINIUM TRUCOR 7.85 2.55 - 2.75 1.5 - 1.9

HEAT RESISTANCE

LIGHT WEIGHT

MODIFICATION & REPAIR

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.

MATERIAL & CONSTRUCTION

LAMINATES
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 320F, 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. Laminate Construction 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. 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 Isophthalic Bispherol Vinylester Novolac Vinylester Chemical Environment Max Operating Temp. F Celsius Mild Chemical 180 82 Strong Acid, Chemical 250 121 Strong Acid, Solvents, 250 121 Chemicals Strong Acid, Alkali, 320 160 Chemicals, Solvents

TRUCOR CONTACT - MOULDED AND FILAMENT WOUND PIPE LAMINATE CONSTRUCTION FOR CORROSION RESISTANCE AND STRENGTH
INNER SURFACE .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 corrosionresistance when combined with the best resin for the specific chemical conditions. INTERIOR LAYER 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. STRUCTURAL LAYERS 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. EXTERIOR SURFACE LAYER 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.

MATERIAL & CONSTRUCTION

MANUFACTURING METHODS
PCA offers two standard types of FRP laminate construction for piping and duct systems: Filament Wound, and Contact Molded. Filament Wound Construction 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 54 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. Contact Moulded Construction 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.

Spray-up 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

MATERIAL & CONSTRUCTION

MATERIAL & CONSTRUCTION PHYSICAL PROPERTIES
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. Nominal Properties of FRP Laminates Property Specific Gravity Tensile Strength, psi Flexural Strength, psi Compressive Edge Strength, psi Flexural Modulus of Elasticity, psi Tensile Modulus of Elasticity, psi Poisson's Ratio Impact Strength, ft-lb lzod Thermal Conductivity Btu - in./hr - ft -F Linear Coefficient of Expansion in./in./ F - ASTM D696 Heat Distortion Temperature (Resin), F @ 264 psi ASTM D 648 Barcol Hardness Dielectric Strength 68 F (volts/mil) ASTM D149 Light Transmission Light Stability
2

Contact Molded 1.5 - 1.8 8,000 - 18,000 16,000 - 22,000 18,000 - 24,000 0.7 - 1.0 x 10 0.8 - 1.1 x 10 0.33 30 - 40 1.3 - 1.8 15 - 20 x 10
-6 6 6

Filament Wound 1.8 - 2.1 25,000 - 50,000 (Hoop) 20,000 - 40,000 (Hoop) 20,000 - 24,000 1.8 - 3.2 x 10 (Hoop) 2.0 - 3.5 x 10 (Hoop) 0.9 - 1.4 x 10 (Axial) 0.33 40 - 50 1.3 - 1.8 12 - 16 x 10
-6 6 6 6

180 - 320 27 - 45 450 - 500 Translucent UV Inhibited

180 - 320 27 - 45 450 - 600 Translucent UV Inhibited

POLYMER COMPOSITE ASIA SDN BHD

MATERIAL & CONSTRUCTION FILAMENT WOUND PIPE DATA CHART

Nom Nom Dia Dia in. mm (D) (d)

2 3 4 6 8 10 12 14 16 18 20 24 26 28 30 36 42 48 54 60 66 72 t v l l l l l = = 50 75 100 150 200 250 300 350 400 450 500 600 650 700 750 900 1050 1200 1350 1500 1650 1800

50 psig t v
5.5 5.5 5.5 6.5 6.5 6.5 7.5 9.0 10.0 10.0 11.5 13.0 14.0 15.5 1.2 0.9 0.6 0.7 0.6 0.4 0.6 0.6 0.6 0.4 0.4 0.4 0.4 0.4

Internal Pressure Rating of Pipes 75 psig 100 psig t v t v

5.5 5.5 6.5 6.5 6.5 7.5 7.5 9.0 9.0 10.0 11.5 13.0 14.0 15.5 16.5 19.5 3.0 1.9 2.4 1.7 1.2 1.2 0.9 1.2 1.0 1.0 0.9 0.9 0.8 0.7 0.7 1.0 5.5 6.5 6.5 7.5 7.5 7.5 9.0 10.0 10.0 11.5 13.0 15.5 16.5 22.0 20.5 22.0 24.5 5.1 5.6 3.6 4.0 2.8 2.1 1.9 2.6 2.1 2.4 2.0 2.2 1.8 3.3 2.0 1.8 1.9

125 psig v
10.0 9.7 5.6 6.0 4.0 4.4 5.8 4.7 3.7 4.3 4.6 3.4 3.4 3.9 3.9 3.9 3.4 3.4

150 psig v
14.7 14.7 14.7 14.7 19.1 9.7 9.6 9.4 6.3 8.0 8.2 6.8 7.1 6.0 5.9 7.7 6.9 6.4 6.2 5.9 5.7 5.5

5.5 6.5 6.5 7.5 7.5 9.0 10.0 11.5 11.5 13.0 14.0 15.5 18.0 20.5 24.5 26.0 27.0 29.5

5.5 5.5 5.5 5.5 6.5 6.5 7.5 9.0 9.0 10.0 11.5 13.0 14.0 14.5 15.5 19.5 22.0 24.5 27.0 29.5 32.5 35.0

Thickness of pipe wall in mm inclusive 100ml corrosion barrier Vacuum rating in psig (gauge pressure) All internal pressure rating on a factor of safety 10 to 1 All vacuum rating on a factor of 5 to 1 Rating above suitable for operating Temperature of 180 F (82 C) Rating above computed on a standard strain limit of 0.0014 Pipe of other ratings is available upon request

To establish product weight, w (in kg/m), use formula: w = 0.150 D x t where D = diameter in inch t = wall thickness in mm s.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.

MATERIAL & CONSTRUCTION CONTACT MOULDED PIPE DATA CHART

Nom Nom Dia Dia in. Mm (D) (d)

2 3 4 6 8 10 12 14 16 18 20 24 26 28 30 36 42 48 t v = = 50 75 100 150 200 250 300 350 400 450 500 600 650 700 750 900 1050 1200

25 psig t v
4.5 4.5 4.5 5.5 5.5 5.5 5.5 6.0 7.0 7.0 7.0 9.0 9.0 10.0 3.2 1.6 0.9 1.2 0.8 0.6 0.4 0.4 0.5 0.4 0.3 0.4 0.3 0.3

Internal Pressure Rating of Pipes 50 psig 75 psig 100 psig t v t v t v

4.5 5.5 5.5 6.0 7.0 8.0 9.0 9.0 10.0 11.0 12.0 13.0 15.0 18.0 20.0 7.5 6.6 3.4 2.9 3.2 2.9 3.4 2.1 2.0 2.0 2.1 2.2 1.9 2.0 1.9 4.5 5.5 6.0 7.0 9.0 9.0 10.0 11.0 13.0 15.0 17.0 18.0 19.0 23.0 27.0 30.0 14.7 14.7 9.7 8.7 11.6 7.3 6.7 6.2 7.1 6.5 7.1 6.7 6.4 6.4 6.5 6.5 4.5 5.5 6.0 8.0 9.0 10.0 12.0 14.0 15.0 17.0 20.0 22.0 24.0 25.0 30.0 35.0 40.0 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7

125 psig t v
5.5 5.5 7.0 9.0 11.0 13.0 15.0 17.0 19.0 22.0 25.0 27.0 29.0 31.0 38.0 44.0 51.0 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7

150 psig t v
4.5 5.5 6.0 9.0 10.0 13.0 15.0 18.0 20.0 23.0 25.0 30.0 33.0 35.0 38.0 45.0 52.0 61.0 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14 .7 14.7 14.7 14.7 14.7 14.7 14.7

Thickness of pipe wall in mm inclusive 100ml corrosion barrier Vacuum rating in psig (gauge pressure) All internal pressure rating on a factor of safety 10 to 1 All vacuum rating on a factor of 5 to 1 Rating 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 t where D = diameter in inch t = wall thickness in mm s.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.

FULL FACE FLANGES : DIMENSIONS

Trucor flat face flange are manufactured by contact moulding. Laminates are manufactured in accordance with ASTM C582. . 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.

D Nom Dia (In)

1 1 2 2 3 4 6 8 10 12 14 16 18 20 24 26 28 30 36 42 48 54 60 66 72 84 96

D Nom Dia (mm)

25 38 50 63 75 100 150 200 250 300 350 400 450 500 600 650 700 750 900 1050 1200 1350 1500 1650 1800 2100 2400

O.D. (in)
4 3/8 5 6 7 8 9 11 14 16 19 21 24 25 28 32 34 37 39 46 53 60 66 73 80 87 100 113

L (in)
6 6 6 6 6 6 8 8 10 10 12 12 12 12 12 12 12 15 15 15 15 15 15 15 18 18 18

B.C. (in)
3 1/8 3 7/8 4 5 6 7 9 11 14 17 18 21 22 25 29 31 34 36 42 49 56 62 69 76 82 95 108

No of Holes
4 4 4 4 4 8 8 8 12 12 12 16 16 20 20 24 28 28 32 36 44 44 52 52 60 64 68

Hole (in)
5/8 5/8

Bolt Size (in)

5/8 5/8 5/8 5/8 7/8 7/8 1 1 1 1/8 1 1/8 1 1 1 1 1 1 1 1 1 1 1 2 2

7/8 7/8 1 1 1 1/8 1 1/8 1 1 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 2 2 2 2 2

Dimensions are in inches. Pressure is in inches water gauge. Bolt diameter is hole size minus 1/8 inch.

O.D. B.C.

FRP FULL FACE FLANGE

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.

DN (in)
1 2 3 4 6 8 10 12 14 16 18 20 24

ANSI 150# FF Thickness [mm]

13.31 18.38 21.45 27.89 31.07 35.00 42.94 49.45 49.85 56.67 56.67 60.00 66.14

ANSI 230# FF Thickness [mm]

16.79 23.12 26.91 34.93 38.72 43.40 52.58 61.30 61.52 69.92 69.92 73.37 81.00

STUB END FLANGES

Trucor stub end flanges are designed for use with steel backing flanges. L is a standard dimension. Special lengths are available upon request. Flange thickness dimensions are suitable for 150 psig through 24 in. dia. and 125 psig through 48 in. diameter. D (in)
1 2 2 3 4 6 8 10 12 14 16 18 20 24 26 28 30 36 42 48

O.D. (in)
3 4 4 5 6 8 5/8 10 7/8 13 16 17 5/8 20 1/8 21 23 28 1/8 30 3/8 32 5/8 34 5/8 41 1/8 47 7/8 54 3/8

T( mm)
12.7 12.7 12.7 14.3 15.8 19.0 22.2 25.4 33.3 34.5 38.1 41.3 41.3 44.4 47.6 54.0 58.3 68.3 82.6 88.9

L (mm)
150 150 150 150 150 150 200 200 200 200 250 250 250 250 300 300 300 400 450 450

Do (in) max
2.00 2.62 3.12 3.74 4.74 6.86 8.86 11.24 13.36 15.60 17.82 19.82 22.00 26.44 28.20 30.36 32.52 39.06 45.54 52.08

Dimensions are in mm.

125 psig rating

150 psig rating

O.D.

DO max

STEEL BACKING RINGS

D Pipe Dia.
1 2 2 3 4 6 8 10 12 14 16 18 20 24 26 28 30 36 42 48

I.D. (in)
2 2 7/8 3 3/8 4 5 7 1/8 9 1/8 11 13 5/8 15 7/8 18 1/8 20 1/8 22 5/16 26 11/16 28 30 5/8 32 39 5/16 45 13/16 52 3/8

O.D. (in)
5 6 7 7 9 11 13 16 19 21 23 25 27 32 34 36 38 46 53 59

B.C. (in)
3 7/8 4 5 6 7 9 1/ 3 11 14 17 18 21 22 25 29 31 34 36 42 49 56

T (mm)
12.7 15.8 15.8 15.8 15.8 19.0 19.0 22.2 22.2 34.5 36.5 39.7 42.9 47.6 50.8 52.4 54.0 60.3 66.7 69.9

No. of Holes
4 4 4 4 8 8 8 12 12 12 16 16 20 20 24 28 28 32 36 44

Hole (in)
5/8

Max Pressure psig

150 150 150 150 150 150 150 150 150 150 150 150 150 150 125 125 125 125 125 125

Approx Wt (kg)
1.36 1.81 2.27 2.72 3.18 4.54 6.81 9.09 13.18 14.18 19.54 18.63 21.36 28.63 37.72 46.36 50.45 70.90 94.54 119.54

7/8 7/8 1 1 1 1/8 1 1/8 1 1 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8

Dimensions are in inches. Thickness in mm. Weights are in Kg. Bolt diameter is hole size minus 1/8 inch. Pressure is in psig.

O.D. B.C. T ID

FITTINGS ELBOWS
Trucor smooth turn elbows are contact moulded in sizes from 2 in. Through 36 in.. 2 in. and 3 in. have a centerline radius two times the inside diameter. 4in. through 24 in. Long Radius elbows have a centerline radius 1.5 times the inside diameter. mitered elbows are fabricated from segmented pipe sections and are available in long and short radius configurations. Bends less than 45 are supplied in standard two piece Mitered construction. Extended Elbows available 2in. through 12in. for ease of installation.

C-E

C-E Long Radius 60 Elbow C-E

2 5/16 3 7/16 3 7/16 5 3/16 6 15/16 8 11/16 10 3/8 12 1/8 13 7/8 15 9/16 17 5/16 20 13/16 22 24 26 31 3/16 36 3/8 41 9/16 46 51 15/16 57 1/8 62 3/8

C-E Long Radius 45 Elbow C-E

1 11/16 2 2 3 6 6 3/16 7 7/16 8 11/16 9 15/16 11 3/ 16 12 7/16 14 15/16 16 1/8 17 3/8 18 5/8 22 3/8 26 1/8 29 13/16 33 9/16 37 41 44

C-E Long Radius 30 Elbow C-E C-F

C-E Short Radius 90 Elbow C-E C-F

Long Radius 90 Elbow Dia.

2 3 4 6 8 10 12 14 16 18 20 24 26 28 30 36 42 48 54 60 66 72

C-E
4 6 6 9 12 15 18 21 24 27 30 36 39 42 45 54 63 72 81 90 99 108

C-F
10 12 12 15 18 21 24

C-F
8 5/16 97/16 107/16 113/16 1215/16 1411/16 16 3/8

C-F
7 11/16 8 8 9 12 12 3/16 137/16

2 7/16 3 3/16 4 4 13/16 5 5/8 6 7/16 7 8 1/16 9 5/8 10 7/16 11 12 1/16 14 16 7/8 19 5/16 21 11/16 24 1/8 26 28 15/16

8 7/16 9 3/16 10 1013/16

6 8 10 12 14 16 18 20 24 26 28 30 36 42 48 54 60 66 72

12 14 16 18

EXTENDED ELBOWS

C-F C-F C-F C-F

90 Elbow

60 Elbow

45 Elbow

30 Elbow

TEES, CROSSES AND LATERALS TEE

C-E C-E
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.

C-E

CROSSES
C-E C-E

45 LATERAL
C-E
C-E

D
C-E

X L

D
2 3 4 6 8 10 12 14 16 18 20 24 26 28 30 36 42 48

C-E
6 7 8 10 12 14 16 18 20 21 22 24 26 28 30 33 36 39

D
2 3 4 6 8 10 12 14 16 18 20 24 26 28 30 36 42 48

L
16 18 20 24 30 34 38 42 46 50 54 60 64 68 72 84 96 108

X
6 6 6 8 10 10 12 12 14 14 16 18 18 18 20 22 24 26

C-E
10 12 14 16 20 24 26 30 32 36 38 42 45 48 52 62 72 82

Dimensions are in inches.

Dimensions are in inches.

FITTING REDUCERS
Tapered reducers are contact molded with a standard slope in concentric or eccentric configurations. Length is calculated as follows : L = 2 (D1 - D2) Centerline offset of eccentric reducers is calculated as follows : E = (D1 - D2) Special dimensions are available.

FLANGED REDUCERS
Stub end flanges, duct flanges and full face drilled flanges can be provided on the large end of all reducers. an additional flange fitting is required on the small end. Flanged reducers can be provided in configurations shown below, with any flange type.

D 1 x D2 3x2 3 x 1.5 4x3 4x2 6x4 6x3 6x2 8x6 8x4 8x3 10x8 10 x 6 10 x 4 12 x 10 12 x 8 12 x 6 14 x 12 14 x 10 14 x 8 16 x 14 16 x 12 16 X 10 18 X 16 18 X 14 18 X 12 18 X 10

L 2 3 2 5 5 7 10 5 10 12 5 10 15 5 10 15 5 10 15 5 10 15 5 10 15 20

a 6 6 6 6 6 6 6 8 6 6 8 8 6 10 8 8 10 10 8 12 10 10 12 12 10 10

D1 x D2 20 x 18 20 x 16 20 x 14 24 x 20 24 x 18 24 x 16 26 x 24 26 x 20 26 x 18 28 x 26 28 x 26 28 x 20 30 x 24 30 x 20 30 x 18 30 x 16 36 x 30 36 x 24 42 x 36 42 x 30 48 x 42 48 x 36 54 x 48 54 x 42 60 x 54 60 x 48

L 5 10 15 10 15 20 5 15 20 5 10 20 15 25 30 35 15 30 15 30 15 30 15 30 15 30

a 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 15 15 15 15 15 15 15 15 15 15

Dimensions are in inches.

Dimensions are in inches.

CONCENTRIC REDUCER
a D1 L a

ECCENTRIC REDUCER
a L a

D2

D1
E

D2

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 flanges have 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 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
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 BUTT JOINTS 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 thermal expansion 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 prior to working with these materials.

PIPE SYSTEMS DESIGN

The design of Fiberglass Reinforced Plastic piping systems should be performed by persons experienced in the fundamentals of piping stress analysis as well as composite materials. PCA maintains a complete staff of professional engineers and designers to assist in the design process. Differences Between FRP and Steel Pipe Design Yield FRP composites do not yield. Consequently, plastic deformation cannot be relied upon to distribute loads and relieve stress. FRP structures are much more flexible than steel due to the lower modulus of elasticity. Tensile modulus of FRP ranges from approximately 1 to 4 million psi compared to about 30 million psi for steel. Mechanical properties of FRP drop rapidly at elevated temperatures. Most resins used by PCA are suitable for use up to 212F. Special resins and designs allow FRP to be used up to 320F. in certain environments. There is little strength reduction, or brittleness at low temperatures. Contact molded pipe and fitting laminates are designed in accordance with ASTM C-582. In contact moulded pipe design, the standard 100 mil inner surface and interior layer is considered a structural element of the laminate and is included in wall thickness calculations. In certain chemical environments such as hot wet chlorine and chlorine dioxide, additional material is added to the interior layer as a corrosion allowance and is not included in structural calculations. Filament wound pressure pipe laminates are manufactured with a helical winding angle of 54 . Wall thickness are considered suitable for operating temperatures to 180F with premium grade polyester and vinyl ester resins. Contact moulded pipe and fitting designs are design with safety factor of 10. The formula for wall thickness is : t = Pr S/SF

Modulus -

Temperature -

P = pressure, psig r = pipe radius, in. s = ultimate tensile strength SF = safety factor of 10 Filament Wound Pipe Laminate properties vary with the winding angle. The design of filament wound FRP pressure pipe can be optimized to produce the 2:1 hoop to axial stress ratio needed for a fixed joint pressure pipe system. The winding angle required to produce this ratio is 54 as measured from the pipe axis. Wall thickness for the filament wound portion of the laminate may be calculated by the following formula : t = Pr EhZ P = pressure, psig r = pipe radius, in. Eh = Hoop tensile modulus Z = allowable strain

Orthotropic Properties - Most FRP mechanical properties vary directionally and depend on loading conditions. Steel, is isotropic and has equal properties in all directions. Safety Factor FRP piping is designed with safety factors ranging from 5 to 10. More appropriately called a design factor, these relatively high numbers are used to compensate for :

Strength reduction due to long term chemical exposure. Discontinuity stresses. Manufacturing variables. Product Design Trucor FRP pipe and fittings are designed and custom manufactured for specific applications. The following design criteria are followed :

PIPE SYSTEMS DESIGN

Vacuum conditions must be considered for all FRP pipe 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 piping systems. A safety factor is normally applied to collapse or buckling conditions. The winding angle of filament would piping will affect hoop and axial properties. If a system will operate only under vacuum conditions, either without possibility of internal pressure or with a low internal pressure, the winding angle may be increased to improve hoop properties for buckling resistance. External stiffeners may be manufactured on pipe 18 in. Diameter and larger to provide buckling resistance. Collapse Pressure, Pc, for unstiffened pipe may be calculated by the following formula: Pc = 2.2 ER (t/d)3 Collapse Pressure, Pc for stiffened pipe may be calculated by the following formula: Pc = 0.92 Et2 5R Lr1.5 Design Pressure, External = Pck/F Pc = Collapse Pressure, psi E = hoop flexural modulus, psi R = strength retention at temperature F = Safety factor r = 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 stiffeners may be calculated by the following formula: I = SFLd3Pc 24E

Expansion
The coefficient of thermal expansion for FRP is between two and three times the rate of steel, depending on glass content and orientation. A design coefficient for contact moulded pipe, having a low glass content, is 18 x 10-6, while high glass content filament wound pressure pipe has a design coefficient of 16 x 10-6 for axial expansion: Internal pressure will also cause FRP pipe to expand as the pipe is strained. Expansion and contraction of FRP piping must be recognized and taken into account during 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 by anchors or in underground installations, no movement takes place and the expansion stresses are absorbed in the pipe wall laminate. Stress can be calculated as follows: S = Ea x DL = E abDT L Ea = Modulus of elasticity L = Length b = Thermal coefficient of expansion DT = Temperature differential oF

PIPE SYSTEMS DESIGN

Anchor Force can be calculated as follows: F= SA F = Force, Ibs S = Stress, axial A = Cross-sectional area of pipe, in.2 Example: 24m. Dia.x 0.5in. Wall contact moulded pipe anchored and operating o with a DT of 100 F. S = (1 x 106) x ( 18 x 10-6) x 100 = 1,800 psi Force = 1,800 x p(25 - 24 ) = 69, 237 Ib 4 Example above illustrates that anchoring pipe to restrain thermal expansion develops stresses less than 10% of the ultimate compressive stress of the FRP laminate. However, the thrust force may be significant, especially with large 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 the simplest 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 remains in its intended position.
2 2

Fa = 1,000 A A = Cross sectional area of pipe, in2 The expansion joint must be installed to accommodate the amount of expansion and contraction that may be experienced, both axially and laterally. From previous discussions, the total expansion movement can be calculated and an appropriate expansion joint can be selected. At the time of installation, a preset must be determined based on installation and operating temperatures. The amount of preset may be calculated as follows: Length of Preset, in = M (Ti - Tmin) (Tmax - Tmin) M = total related expansion joint movement, in. Ti = installation temperature Tmin = minimum temperature Tmax = maximum temperature Guides must be installed to insure that the pipe movement 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 any angular 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 cantilever beam assuming a concentrated load at the free end. This approach is often too cumbersome for a process piping 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 also good sources of compliance within a system that maybe considered.

Expansion Joints
Many types of expansion joints can be used with FRP piping systems. Since FRP piping develops lower thermal end forces than steel (approximately 3% to 5% the amount of schedule 40 steel pipe), the expansion joints must be activated by low forces. Various elastomeric bellows type expansion joints are suitable for FRP piping systems. As a general guideline, an expansion joint that operates with an activational force of less than Fa should be selected. This will limit axial pipe stress to 1,000 psi which is well within design limits.

FLOW PROPERTIES
The friction of fluid flowing in a pipe causes a drop in pressure which is approximately proportional to the velocity squared, and is directly proportional to the 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 Williams Hazen roughness coefficient of 150 is commonly used for water service application.

PIPE CAPACITY
Contents Wt 1.30 3.08 5.42 12.25 21.76 34.01 48.93 66.69 87.02 110.20 136.04 195.90 229.91 266.67 306.10 440.81 559.94 783.58 991.97 1,224.39 1,481.47 1,763.15 2,399.77 3,134.42

Capacity Dia. 2 0.61 3 1.40 4 2.46 6 5.56 8 9.88 10 15.44 12 22.22 The effective length of a pipeline is the total length 14 30.28 of straight pipe plus the equivalent length of all 16 39.51 fittings and valves which add resistance to the 18 50.04 system. 20 61.77 24 88.95 26 104.39 FITTING FRICTION LOSS 28 121.08 30 139.10 Equivalent length of straight pipe for head loss FLOW PROPERTIES 36 200.15 through fittings 42 272.41 Dia. 90 Smooth 45 Smooth Tee 48 355.79 Turn Elbow Turn Elbow Entering 54 450.30 Run 60 555.94 2 3 2 11 66 672.67 3 5 4 16 72 800.56 4 6 5 21 84 1,089.63 6 10 7 32 96 1,423.20 8 14 10 42 Diameter is in inches. 10 16 12 55 12 20 15 65 Weight is in lbs per ft, water. 14 24 16 75 16 26 19 85 Capacity is in gallon per ft. 18 30 21 100 20 34 24 110 24 40 30 130 30 50 35 160 36 60 42 200
Length is in feet. Diameter is in inches.

PIPE FRICTION LOSS (WILLIAMS AND HAZEN FORMULA)

To convert gallons per minute to cubic feet per second, divide by 448.8 To 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.

PIPE SYSTEM DESIGN

UNDERGROUND PIPING
Trucor FRP underground piping is a flexible conduit and must be analyzed as such when designing for burial. In a underground installation the external soil load above the pipe causes a decrease in the vertical diameter of the pipe and a corresponding increase in the horizontal diameter of the pipe. The horizontal movement of the pipe walls into the soil material at the sides of the pipe develops a passive resistance that acts to help support the external load. The resistance of the soil is affected 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 are necessary to develop the passive soil resistance required to prevent excessive pipe deflections. Proper bedding support and backfill are required for satisfactory sealing of the bell and spigot joints most commonly used. The deflection of a buried flexible pipe depends on the soil load above the pipe (which is a function of the depth of burial), live loads over the pipe, the stiffness of the pipe, the passive resistance of the 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 the pipe (bedding constant). An initial maximum pipe deflection of 3% is recommended with an allowable long term deflection of 5% maximum. These deflections may be calculated using the Spangler equation. Trucor FRP Underground piping is designed using the methods given in AWWA C950. 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. The safety factor for buckling will be in accordance with AWWA C950 Section A2.5. When integral stiffeners are used, a safety factor of 3 will be used for the stiffener section. Stiffener spacing will not exceed two pipe diameters. The hoop flexural modulus will be used in calculating external loading design and will be determined by test (ASTM D-790 or ASTM D2412) or developed by laminate theory and supported by tests. Design Criteria The following parameters are to be supplied by the owner for consideration by PCA during the detail design : Operating temperature of the line fluid. Operating, surge, vacuum and test pressures. Live loads (wheel loads). Max./min. burial depth and trench width. Description of the soil properties and trench preparation.

Soil Properties The following soil properties will be used for design of the pipe unless specified otherwise : Soil density - 120 pcf. Deflection lag factor - 1.5. Deflection bedding constant - 0.083. Soil reaction modulus - 1,000 psi. Local water table, below bottom of pipe. Requirements for thrust blocks or anchors shall be considered.

PIPE SYSTEM DESIGN

LOAD COMBINATIONS
PCA will analyze the following load combinations : Design pressure at maximum burial depth. Design pressure plus live loads at minimum and maximum burial. Burial and live load conditions, plus vacuum (if applicable). Burial and live loads for empty pipe. Pre-burial hydrotest requirement. All structural analysis will include both membrane and hoop bending effects in the pipe wall. Thrust Blocks Trucor bell and spigot joined FRP piping may require thrust blocks for axial restraint. All changes in direction, including bends, tees and laterals, must be restrained. Cast in place concrete blocks are often used for buried piping and can be used in combination with tie rods and thrust collars for above ground piping. Hydrostatic thrust loads at a bend can be calculated as follows : T = 2PASin /2 T= P= A= = Thrust, lb Pressure, psi Cross sectional pipe area, in.2 Angle of bend in degrees Design of restraint must consider soil strength, stability and location of the water table. Effective thrust blocks must totally encapsulate the pipe fitting and must have : Adequate bearing area to resist the thrust. The bearing surface against undisturbed soil. The resultant thrust vector passing perpendicularly through the center of the bearing surface.

If the soil is unstable or the installation is below the water table, tie rods or other means to ensure stability may be required. Safe Bearing Pressure, Sp, of soils ranges from 0 for quicksand to over 100,000 lbs/ft2 for solid, hard rock. Hard clay, coarse sand and gravel range from 8,000 to 10,000 lbs/ft2. A complete list of these ratings can be found in soils engineering handbook and in "Marks Mechanical Engineers' Handbook." Actual values should be defined by the Project Geotechnical Engineer. The soil bearing area required for restraints are calculated as follows : Ab = T/Sp Ab = bearing area, ft 2 T = Thrust, lb Sp = Allowable soil bearing pressure, lb/ft 2 Restraint must be installed before hydrostatic testing of the pipe.

The need for thrust blocks and their design is the responsibility of the engineering agency designing the piping system. Hydrodynamic loads are normally small in comparison to hydrostatic loads, however, they must also be considered by the design engineer.

INSTALLATION

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.

SLING

CLAMP

CLEVIS

Pipe Supports and Hangers

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' hardness 50-70) to conform at any surface irregularities and to provide uniform bearing support. It is essential that each installation be reviewed to ensure the proper location and fit of all supporting 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. PIPE SUPPORTS & HANGERS Elastomeric Pad, Typical

Anchor and Guides

Pipe anchors are used to restrain pipe movement against thrust loads and thermal expansion. 360 FRP trust collars are laminated to the pipe on either side of an anchor support to restrain the pipe. These collars can be installed in the shop or the field and are also used with riser clamps for vertical support. ANCHORS & GLIDES FRP Thrust Collars

Flange/Component Support
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. FLANGE/ COMPONENT SUPPORT

Fixed

Guided Three basic configurations of pipe hangers are used : Sling, Clamps and Clevis. These hangers do not restrain axial or lateral movement.

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 = dia Saddle width = 1/3 dia Contact PCA for saddle width design = Maximum deflection = span / 360. = Simple support conditions. FILAMENT WOUND PRESSURE PIPE Dia
. 20 . 25 . 30 . 36 . 41 8.0 9.5 10.0 10.5 10.5 10.5 10.5 10.5 10.5 10.5 11.0 9.5 7.5 8.5 10.0 11.0 11.5 11.5 12.0 12.0 12.0 12.0 12.0 12.0 12.5 11.0 9.0 9.0 11.0 12.0 12.5 13.0 13.0 13.0 13.0 13.0 13.5 13.5 13.5 13.5 12.0 10.5 9.0 9.5 11.5 12.5 13.5 14.0 14.0 14.5 14.5 14.5 14.5 14.5 15.0 15.0 14.0 12.5 11.0 . 46 2 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48

= = = =

180F 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. Sp. Gr. 1.0 1.2 1.4 1.6 1.8 Multiplier 1.10 1.00 0.93 0.87 0.81

. 51 . 56 . 62 . 67 . 72 . 77 . 82 . 88 . 93 . 98 1.03

13.0 14.5 15.0 15.0 15.5 15.5 15.5 15.5 16.0 16.0 16.0 16.0 14.5 12.5

15.5 16.0 16.0 16.5 16.5 16.5 16.5 17.0 17.0 17.0 16.0 14.0

17.0 17.0 17.0 17.5 17.5 17.5 17.5 18.0 18.0 18.0 15.5

18.0 18.0 18.0 18.5 18.5 18.5 18.5 18.5 17.0

19.0 19.0 19.5 19.5 19.5 19.5 20.0 19.0

20.0 20.0 20.0 20.5 20.5 21.0 20.5

21.0 21.0 21.5 21.5 21.5

22.0 22.0 23.0 23.5 22.0 23.0 23.5 24.5 22.0 23.0 24.0 24.5 25.0 25.0

CONTACT MOULDED PRESSURE PIPE

Dia 2 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 . 18 . 25 . 29 . 37 . 41 . 49 7.0 8.0 8.0 8.5 8.5 8.5 9.0 9.0 9.0 8.0 9.0 10.5 11.5 12.0 12.0 12.0 12.0 12.0 12.0 12.0 10.0 8.5 9.5 11.0 12.5 13.0 13.0 13.0 13.5 13.5 13.5 13.5 13.0 11.0 8.5 11.0 12.5 14.0 15.5 16.0 16.0 16.0 16.0 16.0 16.5 16.5 15.0 12.0 10.0 Wall Thicknes s . 56 . 64 . 68 . 76 . 80 . 88 . 95 1.00 1.10 1.26 1.38

14.5 16.0 16.5 17.0 17.0 17.0 17.0 17.0 17.0 17.0 14.5 11.0 10.0 9.0

17.5 18.0 18.0 18.5 18.5 18.5 18.5 19.0 19.0 17.0 14.5 12.1 10.5

19.5 19.5 19.5 20.0 20.0 20.0 20.0 20.0 17.5 14.5 12.0

20.0 21.0 21.0 21.0 21.0 21.5 21.5 20.0 16.5 16.5 14.0

21.5 21.5 22.0 22.0 22.0 22.0 22.0 18.0 15.5

23.0 23.0 23.0 23.0 23.0 23.5 20.0 17.5

23.0 23.5 23.5 25.0 24.0 24.0 21.0 18.5

24.0 24.0 25.0 25.0 25.0 22.5 19.5

25.5 26.0 26.0 26.0 24.5 20.0

26.0 27.5 26.5 26.5 25.5 21.5

29.0 27.5 27.5 26.5 22.5

29.0 30.0 28.0 24.0

30.0 30.0 30.0 25.5

=Diameter and thickness are inches. =Span is in feet.

INSTALLATION

FLANGE ASSEMBLY
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. diameter 3/16 in. for 24 in. diameter through 36 in. Diameter in. for 42 in. diameter and larger FLAT FACE FLANGE CONNECTION Full Gasket Flat washer

RAISED FACE TO FLAT FACE FLANGE CONNECTION Full Gasket Spacer Ring FRP Flat Face Flange Raised Face Flange Flat Washer

Systems to be operated or tested over 100 psig should use reinforced gasket material to prevent extrusion of gasket caused by high bolt torque.

STUB ENDS WITH BACKING FLANGES Ring Gasket FRP Stub End Flanges Steel Backing Flange Flat Washer

INSTALLATION

BOLT TORQUE
Maximum Bolt Torque For Pressure Piping

Bolt Size in. 1 /2

5 3 7

Torque ft - l b 15 25 40 65 100 140 200 320 600 880

11 7 3 18 3 14 10 7

11

15 1

5 9 13 4 8

/8 /4

/8 1 1 1 /8 1 /4 1 /2 1 /4 2
3 1 1

16 1

12

15

19

5 9 13 17 4 8 12

= Based on a 12,000 psi bolt stress. = Use ANSI Type B washers, regular series.

14 10 6 2 20 16

4 23 27 1 5

7 3 6 2

1 5 3 26

19 15 11 7 4

9 13 17 21 25 4 8 12 16

22 18 14

11 7 3 10 6 2

1 5 9 4 8 12

10 6 2 28

24

20

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.

INSTALLATION

BURIED PIPE INSTALLATION

Trucor FRP pipe is a flexible conduit. Procedures for site preparation and placement are similar to those used for other types of flexible materials. The light weight and long laying lengths of Trucor FRP pipe are definite advantages which generally permit installation cost savings over other materials. The following guidelines should be followed when installing FRP pipe : ! Investigate soil conditions along the proposed pipe line route and confirm that they are as defined in the design specifications. diameter. Shore, sheet, brace, or otherwise support trench walls as required for safety of personnel working in the trench. Proper installation procedures are required to develop the passive soil resistance necessary to prevent excessive pipe deflections.

Trench Width Carefully compact backfill under pipe haunches Backfill

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 (H20). Installation under highways and railways requires special consideration. After installation, deflection or elongation of pipe should be less than 3% of the inside

6" to 12"

D 0.7 D Trench Grade

0.05D Maintain Water Level Below Bedding During Installation Trench Bottom

Secondary Pipe Zone Backfill Primary Pipe Zone Backfill Bedding Foundation Zone

INSTALLATION

Hydrostatic Testing
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.

FABRICATED PIPING

FABRICATED (SPOOLED) PIPING

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.

Dimensional Tolerances
PCA's general pipe fabricating tolerances for prefabricated FRP piping assemblies through 36 in. diameter are as follows :

Linear Tolerance
The toler ances on linea r dimen sions (intermediate or overall) apply to the face to face, face t o end, and en d to en d measurements of fabricated straight pipe and headers: center to end or center to face of nozzles or other attachments. These tolerances are not cumulative. Linear tolerances are + 1/8 in. for sizes 10 in, and under, + 3/16 in. for sizes 12 in. through 24 in., and + in. for sizes 26 in. through 36 in. Linear tolerances for sizes over 36 in. are subject to tolerances of + in., increasing by + 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.

Squareness Tolerance
Squareness of end cuts, shall not deviate more than + 1/8 in. up to and including 24 in. diameter and 3/16 in. for all diameters above 24 in.

Angularity and Rotational Tolerance

Alignment of facings, or ends shall not deviate from the indicated position measured across any diameter more than 3/64 in. per ft. Rotation of flanges, from the indicated position measured as shown shall be a maximum of 1/16 in.

STANDARDS
CONFORMANCE WITH INDUSTRY STANDARDS
Applicable Specifications and Standards 1. ASME RTP-1, Reinforced Thermoset Plastic Corrosion Resistant Equipment 2. 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

PIPE SIZES
Size for all Trucor Pipe is specified by the internal diameter.

PIPE DIAMETERS OVER 24 INCHES

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.

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.

PIPE LENGTHS
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.

After installation is completed the system should be tested for leaks by filling the pipe with water and pressurizing to 1 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 180F. 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.

TEST PRESSURES

VACUUM CONSIDERATION

FITTINGS
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.

SWEEP ELBOWS
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 1 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.

FRICTION LOSS THROUGH TRUCOR PIPE & FITTINGS

INSTRUMENTATION & OTHER CONNECTIONS

MITERED ELBOWS
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.

OPERATING TEMPERATURES
The maximum operating temperatures are 250F 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 320F. (Refer to Section II (Material & Construction)

STANDARDS & TECHNICAL ASSISTANCE

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.

OPERATING PRESSURES
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

APPLICATIONS

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.

FRP PIPE FOR SEAWATER & CRUDE OIL

UPVC/PVC PIPE FOR CHLORINATION

FRP PIPE FOR POWER STATION

FRP PIPE FOR CHEMICAL PLANT