Maverick

Leading the way

FRP Technology and Innovation

Delivering
Technology and Innovation
FRP Engineering
Fiberglass Reinforced Plastic (FRP) has established
itself as the material of choice for many corrosive
applications. FRP has proven to be a dependable
and cost-effective material of construction for critical
process equipment for many years. This proven
history of success has been developed over time,
based on sound FRP engineering practices and an
attention to detail throughout the engineering, fab-
rication and construction processes. As with all ma-
terial solutions, a comprehensive understanding of
the material is required to ensure safe and reliable
solutions. The anisotropic material properties of FRP
are dependent on the raw materials and laminate
construction for the specific component design.
For this reason, the material behavior and design
of the equipment or systems can vary significantly
from traditional construction materials, such as steel
and concrete.
PROVEN FRP EQUIPMENT DESIGNS
n Process Piping
n Storage Tanks
n Stacks
n Pressure Vessels
n Chimney Liners
n Ductwork
n Large Dia. Field Fabricated Tanks
FEA of the Pressure Vessel Nozzle
70% of FRP piping failures can be attributed to:
n Lack of understanding of the material
n Insufficient Engineering
n Improper or Deficient Pipe Supports
Experience is Key, Execution is Imperative
The Maverick Team has over 150 years of combined
FRP engineering experience, providing successful
corrosion resistant solutions for heavy industry. We
specialize in the optimization and reliable perfor-
mance of FRP systems for critical services, meeting
all necessary Codes and standards from ASME,
ASTM and EN. Our FRP engineering expertise is
unmatched in the industry. Our goal is to eliminate
the owner’s concerns for FRP by providing cost
effective and problem-free FRP solutions.
FRP ENGINEERING SERVICES
n Material and Equipment Specifications
n FRP Equipment and System Design
n Pipe Stress Flexibility Analysis
n Pipe Support and Structural Design
n Finite Element Analysis
n Buried Piping Design
n Failure Analysis and Investigation
Pipe Stress Analysis of FRP Piping
providing
integrated solutions
system engineering
For every project, it takes a comprehensive Whether metallic or non-metallic, system arrange-
approach to assure success. The materials of con- ments should be designed with a clear understand-
struction may change, but the recipe for success ing of all of the design influences. These influences
stays the same. are realized at the equipment connections and
transitions. Some engineering considerations which
n Descriptive and Detailed Specifications must be qualified and satisfactorily addressed are:
n Comprehensive System Engineering
n Qualified and Experienced Fabricators
n
Thermal Expansion
n Quality Control and Supervision
n Nozzles Loads on Tanks and Vessels
in Fabrication and Installation
n Flexibility of Supporting Structures
n An Integrated Pipe Support System
n Quality Assurance from start to finish
FRP may expand 2 to 3 times that of metals at typical
The right materials of construction must be specified
process temperatures, 120°F to 180°F. To ensure
with a clear description of expectations, tolerances,
reliable system performance a detailed analysis is
quality and performance. Qualified vendors
required. Unplanned outages and down-time should
must be selected to ensure quality fabrication of
not be acceptable or expected.
equipment. As with all projects, quality control
and quality assurance during the fabricatio
Maverick is your best resource to minimize your
and installation processes are critical in meeting
risk and ensure your material choices withstand
project expectations. When the material of con-
the test of time.
struction is FRP or a dual laminate, the process
should be the same, but sometimes the Plant
CONSULTING SERVICES
Owner or their Engineering Representatives may
not have all of the necessary expertise in-house. n Project Specifications
When it comes to FRP and dual laminates these n System Engineering and Design
issues cannot be left to chance. Maverick has n Vendor Shop Audit for Qualification
the materials, engineering and construction n Recommendation of Qualified Vendors
expertise to support your project for any one n Review of Vendor Design Documents
area of concern or throughout the entire project. n Shop Surveillance
n Field Quality Assurance Inspection
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RELIABLE SOLUTIONS FOR MINERAL PROCESSING
The demand for raw metals is increasing worldwide.
Expectations for processing plant performance
and production is increasing as well. From a cor-
rosion standpoint, mineral processing services
can be extremely aggressive and demanding
on materials of construction. FRP is an excellent
material of construction for acid handling and
metal concentrate process equipment and piping
required for hydrometallurgy. Where temperatures
become elevated, dual laminates may be the optimal
material choice.
The material selection process should not be
trial and error. Selecting the best and most cost-
effective materials of construction for these services
is essential in meeting processing plants’ objectives
of dependable and low maintenance service.
The Maverick Team can guide plant operations
in making reliable and safe material choices.
Maverick engineers and inspectors are able to work
with plant personnel to develop comprehensive
solutions to maximize plant production by reducing
maintenance and unplanned down time.
There are a variety of services conditions in material
processing including solvents, acids, caustics and
slurry mixtures.
Piping, tanks and other process equipment can be
designed for:
n Corrosive Services
n Abrasive Services
n Conductive Services
Regardless of the material, system arrangements
should be designed with a clear understanding of
all of the design influences. These influences are
realized at the equipment connections and structures.
Some engineering considerations which must be
qualified and satisfactorily addressed are:
n Managing Thermal Expansion and Contraction
n Designing Pipe Supports for the Defined Loads
n Understanding the Flexibility of the Structures
n Designing for the Determined Tank Nozzle Loads
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CONSULTING SERVICES
n Material Selection and Specification
n System Optimization
n Review of Vendor Design Documents
n Shop Surveillance
n Field Quality Assurance Inspection
n Failure Investigation and Corrective Measures
Solutions for the Power Utilities Industry

In recent years, increased environmental regula-

tions have lead coal fired power utilities to embrace
new scrubbing technologies. Wet Flue Gas Des-
ulfurization (FGD) scrubbing technologies involve
limestone slurry solutions which are abrasive and
corrosive in nature. Carbon steel and alloy mate-
rial options are generally not reliable or sustain-
able for this service. The power industry has found
FRP to be a reliable and cost-effective material solu-
tion for wet FGD applications. As the power utili-
ties have gained confidence in FRP through proven
success, the applications for FRP have expanded
throughout the process.

n Abrasion Resistant Piping for Slurry Service

n Reagent and Gypsum Storage Tanks
n Chimney Liners
n Large Diameter Ductwork
n Large Field Fabricated Scrubber Vessels

FRP has become a significant component of the

processes at many power generation stations.
Many of these process services involve exposure
to both corrosive and abrasive chemical environ-
ments. For this reason, monitoring the condition of
FGD process equipment is critical in meeting per-
formance expectations. An annual Maintenance
Assessment Program, which includes visual inspec-
tions and other non-destruction testing measures, is
necessary to predict equipment reliability and long
term performance.

Maverick is a full service FRP engineering and

inspection company that can support your project
from design concept throughout the life of the plant.

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RELIABLE SOLUTIONS FOR CHEMICAL PROCESSING
Today’s advanced chemicals create many demand-
ing challenges for process piping and equipment
materials of construction. The chemistry involved
in the manufacture of the world’s chemical produc-
tion is vast and ever more diverse. Similarly, han-
dling the by-products of these processes is equally
complex. The material challenges of these severe
and hazardous services quickly lead engineers
away from the traditional materials of construction,
such as carbon steel and stainless steel. Advanced
alloys can be a very expensive option, straining
the ever tightening capital and operating budget.
In comparison to these alternatives, FRP is a relia-
ble and budget friendly material option. Consider-
ing the proven corrosion resistant performance of
FRP and the significant cost advantage over many
other materials, FRP is a very attractive material of
construction in today’s economic environment.
FRP has experienced proven success in the chemi-
cal process industry for over 50 years. This success
has been achieved over time with increased knowl-
edge of the material and proven design practices.
Today FRP is relied on as the first choice of materi-
als for many corrosive chemical process systems.
The first steps to maximizing the benefits and
service life of FRP and dual laminates are:
n Specifying the Best Materials of Construction
n Detailed Engineering and Design Validation
n Demanding the Best Fabrication Practices
n Documentation of the Entire Process
Once operating, reliable production is critical to
plant performance. Unplanned outages and down-
time are undesirable. To minimize exposure to these
costly events, a well thought out Maintenance As-
sessment Program is necessary. The Maintenance
Assessment Program should be a plan of in-service
and out-of-service inspections and testing to moni-
tor the condition of the plant’s FRP and dual lami-
nate process piping and equipment. The goal is
to develop a time history of the condition of the
CONTACT US
equipment, through annual or bi-annual inspec-
tions. This will provide information to the plant op-
erations personnel so that they can make timely
decisions regarding operating conditions, equip-
ment maintenance or replacement, allowing them
to respond in a planned manner.
Solutions for Desalination & Seawater Systems
The need for water for public consumption and
industrial processing continues to grow with the
world’s population and demands. Seawater has
been used for power and processing plant cooling
water systems for over 40 years. As the demand
for renewable sources of fresh water continues to
expand, desalination is becoming a very attractive
method to develop renewable sources of water.
Where carbon steel and stainless steel struggle
with corrosion concerns, fiberglass reinforced
plastic (FRP) is a natural material solution for sea-
water services. FRP performs better than all other
materials for handling fluids with chlorides in their
composition. We have inspected many seawater
systems that have been in operation for over
30 years and still find them to have substantial
remaining life.
Maverick has designed FRP seawater systems for
an anticipated life of 50 years, in diameters up
to 10 ft. (3 m). FRP is the material of choice for
many desalination and seawater process systems.
In smaller diameters, system pressures approaching
500 PSI can be achieved in seawater transport
pipelines. Due to the advancements in materials
technology, FRP continues to expand to meet new
and more demanding processes.
With a comprehensive project plan, FRP continues
to be the first material of choice for desalination
and seawater systems. Maverick offers the cer-
tainty of executing a proven plan for success by
providing:
n Detailed specifications
n Detailed engineering
n Qualified vendor selection
n Inspection through fabrication
n Inspection throughout the installation
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Providing FRP Inspection Services
Inspection is an integral component of project qual-
ity assurance. Quality Assurance (QA) starts with
fabrication shop audits to qualify capable vendors.
Once fabrication begins periodic in-progress shop
inspections or continuous shop surveillance can
ensure that all materials used and all steps of fab-
rication are in compliance with the project and
executed with best practices. In the construction
phase, an onsite FRP inspector may work as the
Owners FRP QA representative to observe for com-
pliance over site FRP construction activities, such
as field fabrication of large diameter FRP tanks,
installation shop fabricated FRP tanks, installation
of lining materials in concrete vessels and piping
assembly throughout the plant.
The reliability of process plant equipment is criti-
cal to production efficiency. To ensure peak perfor-
mance of operating systems, most process plants
develop inspection programs for equipment critical
to plant operations. An inspection program should
include visual inspection as well as non-destructive
test (NDT) inspection elements. While NDT evalua-
tion is a useful tool, there is no substitute for hands-
on evaluation and an experienced eye.
Maverick’s inspection team has over (10) ten in-
spectors averaging over 20 years of experience
in FRP and Dual Laminate construction. Inspection
capabilities include:
n Visual inspection
n Material Testing
n Strength Prediction
using Ultrasonic methods
n Thermal Imaging
n Failure Investigation
Through years of training and experience, the
Maverick Team has developed an unmatched
knowledge of FRP construction and condition as-
sessment. The goal of an FRP assessment program
is to provide in-service and out-of-service assess-
ments to present a reliable picture of the current
condition of FRP process plant piping and equip-
ment. This process identifies immediate concerns
and provides information regarding the condition
of the plant’s FRP equipment, so that plant opera-
tors can develop the necessary maintenance plan
for future outages.
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Providing FRP Inspection Services

The Maverick team can assist plants in developing

an inspection plan that will give plant operators
greater confidence in their FRP equipment through:

n Condition Assessment
n Risk Based Assessment
n Comprehension Maintenance Assessment
Program

Once detailed specifications and engineering are

complete, Maverick’s Inspection Team can help en-
Blisters should be watched and may require repair. sure quality fabrication and installation. Inspection
services may be employed at various stages of the
fabrication, installation and operation, including:

n Shop Qualification Audits

n Fabricated Inspection
n Shop Surveillance
n Site Construction Quality Assurance
n Outage Coordination and Planning

Inspection of Dual Laminates.

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 We Build Confidence in FRP
Maverick Applied Science, Inc. is an internationally recognized engineering company,
focusing on process piping and equipment. Our engineering team has a unique and proven
expertise in composite materials for corrosive applications. A comprehensive engineered
approach can best ensure trouble-free service from your Fiberglass Reinforced Plastics (FRP/
GRP), Dual Laminate and Thermoplastic systems. With system engineering and pipe supports,
we can be your best resource for success.

CONTACT US

Maverick Applied Science, Inc.

1915 24th Avenue East
Palmetto, FL 34221
Tel: +1 941 721 1800 Fax: +1 941 721 1864
THE LEADER IN ENGINEERING
AND SUPPORTS FOR NON-METALLIC PIPE

Though they are sometimes overlooked, appropriate
pipe supports are a critical component in ensuring the
safety and long term reliability of piping systems. Their
purpose is to protect the pipe, provide the proper restraint
and ensure the intended functionality of the piping system.
Maverick Applied Science Inc. is an engineering firm
focused on the use of FRP and thermoplastics as materials
of construction for piping applications in corrosive and
abrasive services. That focus also includes the design
and supply of pipe supports.
Since 1999, Maverick has provided the best-designed
pipe supports available. Our supports meet or exceed
all industry standards and are designed in 3D, using
Solid EdgeTM to guarantee the best fit, fabrication and
installation accuracy. Because of our deep understanding
of the behavior of non-metallic materials in piping systems,
our supports ensure optimal performance, functionality
and safe operation in the demanding environments of
heavy industry.

For a detailed description of Maverick’s hundreds of standard and custom pipe supports, request a catalog
at our website: www.maverickappliedscience.com. Click on Pipe Support Catalog tab. Or, to discuss your
particular needs, call us at (941) 721-1800, extension 306.
THE LEADER IN ENGINEERING
AND SUPPORTS FOR NON-METALLIC PIPE

Transition points and complex system arrangements

often cause stress concentrations. Maverick uses
Intergraph’s® Caesar II® software for pipe stress
analysis when piping is subject to high temperature
fluctuations, for complex pipe runs or when equipment
is sensitive to external loads.

External loads at tank nozzles and equipment

connections can sometimes be a concern. To evaluate
these, Maverick performs finite element analysis
using FemapTM with NXTM Nastran® to verify system
integrity at equipment connections. When in doubt, a
comprehensive evaluation is the best way to ensure
success.

For a detailed description of Maverick’s hundreds of standard and custom pipe supports, request a catalog
at our website: www.maverickappliedscience.com. Click on Pipe Support Catalog tab. Or, to discuss your
particular needs, call us at (941) 721-1800, extension 306.
THE LEADER IN ENGINEERING
AND SUPPORTS FOR NON-METALLIC PIPE

Maverick designs and provides custom supports for

virtually any need.

With over 150 years of combined design experience

and over 200 years of combined fabrication and
inspection experience, Maverick provides engineer-
ing and inspections for domestic and international
companies. Maverick engineers and inspectors provide:

n Material and Equipment Specifications

n Pipe Stress Analysis
n Equipment Design

n Finite Element Analysis

n Pipe Support Design and Supply

n Shop Inspection

n Outage Inspection

n Construction FRP Quality Assurance

n Material Testing

For a detailed description of Maverick’s hundreds of standard and custom pipe supports, request a catalog
at our website: www.maverickappliedscience.com. Click on Pipe Support Catalog tab. Or, to discuss your
particular needs, call us at (941) 721-1800, extension 306.
THE LEADER IN ENGINEERING
AND SUPPORTS FOR NON-METALLIC PIPE

P14 S15B
Riser Support Flange Linestop
(36” – 60” Diameter) (12” – 30” Diameter)

This Riser Support can be fabricated from many
different materials, most often carbon steel. It
supports the weight of the pipe and allows freedom
of lateral movement. Riser Supports are also available
in sizes 1" - 30" and can also accommodate larger
pipe and duct as well.
This Linestop supports the weight of the pipe, allows
freedom of lateral movement and limits axial move-
ment. It is also available for other sizes of pipe and
in different materials depending on need.

There are dozens of typical pipe supports designed
to carry dead weight loads and restrain the pipe for
a host of thermal and dynamic loads. In addition,
designs for specialized pipe supports are virtually
unlimited.
Choosing the correct supports for any piping system
can be relatively simple or extremely complex. In all
cases, proper selection, design and construction are
critical to the integrity of the piping system and the
safety of those who depend on it for their safety.

For a detailed description of Maverick’s hundreds of standard and custom pipe supports,
request a catalog at our website: www.maverickappliedscience.com. Click on Pipe Support
Catalog tab. Or, to discuss your particular needs, call us at (941) 721-1800, extension 306.

1915 24TH Avenue E., Palmetto, FL 34221

(941) 721-1800
www.maverickappliedscience.com