Desalination 138 (2001) 379384

Performance of reinforced thermosetting resin pipe systems in desalination applications: a long-term solution to corrosion The Arabian Gulf example
Ziad Salibi
Future Pipe Group, Future Pipe Industries, Al-Kalla Building, PO Box 13-5009, Beirut, Lebanon Tel. +961 (1) 806607; Fax +961 (1) 863859; email: fpi@inco.com.lb; z.salibi@future-pipe.com Received 9 February 2001; accepted 22 February 2001

Abstract Throughout the history of desalination piping, corrosion has played a critical role in material choice, overall system design and, of course budget estimates for the life-cycle cost of the plant itself. Reinforced thermosetting resin pipe (RTRP) systems, also known as fiberglass, FRP, GRP or GRE pipe systems, introduced in the 1960s have been used exclusively in an effort to eliminate corrosion. The Arabian Gulf, infamous for its extremes in temperature and corrosive conditions, is a prime showcase for exhibiting the effectiveness of GRP pipe systems in combating corrosion, extending the life of the pipe systems and reducing overall running cost of the plant. Evidence of successful installations using fiberglass pipe systems in desalination applications is extensive since the early 1970s. Modern designs have seen a revolution with respect to the compilation of performance based specifications, in-depth experience across a broad spectrum of applications and the development of advanced manufacturing methods. The versatility of fiberglass systems is seen through its applicability to a number of services and operation conditions. Keywords: Desalination; Fiberglass pipe; Properties; Applications; Advantages; Short- and long-term costs

1. Introduction Countries in the Arabian Gulf region, due to the relative lack of large fresh water aquifers, are dependent upon desalination water to provide for the needs of the ever-burgeoning regional industry and population. Water losses due to

degradation of traditional pipe systems not only present a financial burden to local governments but also deny the people of a much-needed resource. Regional government water authorities, realizing the necessity to minimize such losses through the selection of affordable, non-corrosive

Presented at the European Conference on Desalination and the Environment: Water Shortage. Lemesos, Cyprus, 2831 May 2001. 0011-9164/01/$ See front matter 2001 Elsevier Science B.V. All rights reserved

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pipe systems, have joined with private consortia in conducting research into alternative fiberglass pipe systems. Since its successful installation, fiberglass pipe systems have become the material of choice for consultants, contractors and end-users involved in the regional desalination and water distribution industry. The purpose of this paper is to highlight such experiences and define future applications in all aspects of desalination facility design, which will be the model for future construction. 2. What is a fiberglass pipe system? A fiberglass pipe system is a composite product containing glass fiber reinforcements embedded in, or surrounded by, cured thermosetting resin and could contain aggregate filler such as pure silica sand. There are different methods of manufacturing ranging from the filament winding process, continuous advancing mandrel process as well the centrifugal cast process. A complete range of fittings and specials are available in order to complete the system. Typically, fiberglass pipe systems commonly used in the desalination industry are available in diameters of 25 mm up to 3700 mm and pressures up to 50 bars. Operating temperatures commonly found in seawater, chlorinating, acid cleaning, and brine, among others, are typically designed for temperatures up to 85C. Fiberglass pipe systems can operate continuously in temperatures up to a staggering 110C. Installations above-ground, sub-sea as well as under underground for cover depths of 16 m is possible in fiberglass pipe. 3. Design consideration properties The design procedure of fiberglass pipe system involves establishing the design parameters, mainly design conditions, pipe class

required, installation conditions and the corresponding pipe properties. The basic design conditions needed are: nominal pipe diameter, ND surge and vacuum pressure soil conditions, soil modulus and cover depth live load working pressure, service temperature The pipe properties necessary for performing the design calculations are: nominal reinforced wall thickness and liner thickness, t and tL hoop tensile modulus of elasticity, E H hydrostatic design basis, HDB ring flexural modulus of elasticity, E RF minimum pipe stiffness, F/y long-term bending strength, S b Poissons ratio, h1 1h Design stress or strain values are obtained by reducing the strength limits using appropriate design factors. These design factors assure adequate system performance for the design life of 50 years. The design methods are similar to other materials whereby the objective is to reduce the stresses in the pipe through support arrangement or rerouting. 4. Applications In a typical desalination plant fiberglass pipe systems have been used in the services given in Table 1. 5. Advantages Some of the advantages offered by fiberglass pipe systems are: 1. Completely corrosion proof: Fiberglass pipe systems are resistant to corrosion over their entire design life of 50 years against a variety of aggressive media including seawater, hot brine, acids and other chemicals.

Z. Salibi / Desalination 138 (2001) 379384 Table 1 Types of desalination plant fiberglass pipe systems used System Seawater intake and discharge Seawater supply, recycle and discharge Water box vent and drain Seawater supply to blending plant Product water forwarding, suction and discharge Demineralization system Fire-fighting system Potable water system Pressure, Temp., Diameter, bar C mm 1.0 10.0 1.0 10.0 Vacuum, 10.0 6.0 6.0 16.0 60 60 105 40 50 8003700 6001600 25100 150250 4001400 F-glass 2.54 Ductile iron 7.6 Steel 7.83

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Table 2 Strength to unit weight ratio of fiberglass pipe systems Material Density, g/cm3 Tensile strength, MPa 3448 420 1034 Specific strength 104 cm 1357 55 132

50 50 50

100200 25350 1501400

2. Installation advantages: Fiberglass pipe systems are easy to install due to their light weight (1/4 the weight of metal pipe), manufactured in longer sections up to 18 m with a variety of available joints restrained and unrestrained. 3. Strength to weight ratio: Fiberglass pipe systems have excellent strength to unit weight ratio as shown in Table 2. 4. Maintenance free: Free cathodic protection, re-coating of joints or any other form of corrosion protection is not needed over the systems entire service life (50 years). 5. Very low internal friction: Initial low friction coefficient and the hydraulic characteristics of the fiberglass pipe do not change with time, which considerably affects the long-term running pumping costs. 6. Excellent fatigue resistance: Specifically under cyclic loading, as described in the test methods of ASTM D-2992, Method A. 7. Fire resistance: Fire tests conducted show that fiberglass pipe systems are capable of withstanding a hydraulic pressure of 6 bars after a

harsh test of a propane burner, 650850C flame temperature for a period of 15 min. 8. Spooling: Factory-made complex pipe junctions can be made, thus reducing extensively the number of field joints. Fabricated spools can be pre-tested in the workshop. In addition, it provides en enormous freedom in design of complicated layouts. 9. Surge pressure: Due to the flexibility of fiberglass pipes, surge pressure waves are substantially lower than steel as can be seen from the calculation below. For a typical 10-bar, 500-mm NB system, the following results are found for the propagation speed of a pressure wave using Joukowskys equation:

Steel: Pipe outside diameter: 508 mm Pipe structural wall thickness (Sch. 10): 6.35 mm Cp = wave propagation speed: 1095 m/s Ductile iron: Pipe outside diameter: 508 mm Pipe structural wall thickness (k=7): 7.00 mm Cp = wave propagation speed: 1077 m/s GRP: Pipe outside diameter: 500 mm

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Pipe structural wall thickness: 7.94 mm Cp = wave propagation speed: 500 m/s Apparently, due to the larger flexibility of the GRP material, the wave propagation speed in the 500-mm NB GRP pipe is about half the value of that for the ductile iron and for steel pipe. 6. Cost considerations The objective of this section will be to discuss fiberglass pipe and the cost reductions implied by using it. 6.1. Corrosion Engineers generally accept that the conditions in the Middle East are severe and have contributed to a growing record of conventional pipe product failures. In the case of concrete and cement-lined steel pipe, the corrosion damage is mainly due to classic sulfate and chloride solution attack. With sulfate solutions, the chemical reactions taking place form some compounds having a greater volume than those initially present. This causes expansion and deterioration of the cement paste. With chloride solutions, corrosion of the reinforcement is the major cause of deterioration. Also, crystallization of this chloride salt takes places in the pores of the paste and aggregate. Such crystallization creates pressure and the resulting cracking in the pores causes deterioration. Fiberglass pipe has enjoyed widespread use as a transmission line for seawater as well as industrial cooling systems, intakes and discharge lines at many large desalination plants in the Gulf and the Middle East. There is no question that fiberglass pipe has been successful in all typical phases of water transmission applications, and many not so typical. Indeed, its long-term cost performance is unparalleled by any traditional materials.

Unquestionably, a corrosion-resistant material has far greater value than that subject to deterioration from corrosion. The question becomes, how do you quantify that value? How should that value be considered in the initial evaluation and specification of construction material for a project? To get those answers, all costs associated with the pipeline system over its anticipated life cycle must be considered. In order to reach some reasonable conclusions regarding which costs should be included in the pipe material evaluation, we need to look at all the costs associated with a pipe system over the expected life of the project. Such costs include short-term costs and long-term costs. Below are the advantages for both categories when using fiberglass pipe. 6.1.1 Short-term costs Fiberglass pipe has not been available as long as other materials such as steel, yet it is being specified for numerous applications. And well it should when these benefits are considered: Fiberglass pipe can be produced in 12-m or longer sections to speed installation and eliminate up to 75% of the joints in a system when compared to other traditional materials such as concrete or steel. Fewer joints mean fewer areas of care after performing the joint and of potential leakage. Fiberglass pipe is lightweight, and as such results in less expensive installation, labor and machinery. No requirement of any additional painting or cathodic protection for the system. Availability of engineering support to optimize all design parameters, both for underground as well as for aboveground and sub-sea installations. 6.1.2. Long-term costs The long-term costs, which always accrue to the owner of the system, can be put in the

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following categories: Pumping costs are reduced due to a low friction coefficient. Emergency repairs are non-existent due to its corrosive-resistant properties. Rehabilitation costs or replacement costs are negligible. Routine maintenance costs are negligible. All of the above costs are real costs, which will, over the life of the pipe system, be encountered. The magnitude of these costs and the time frame in which they occur are related to the initial material choice and to the method of installation. In almost all cases, the long-term costs are related to the initial material choice and effects of corrosion on the material used. We have chosen an example of the superior advantages of the fiberglass pipe through calculating the reduced friction losses and associated power cost to further enhance our views. A case study of a power and desalination plant in Qatar is taken Ras Abu Fontas B. We have calculated the reduced friction losses and its associated pumping cost savings. 6.2. Power cost savings for a desalination plant Ras-Abu Fontas desalination plant, Qatar: 5 MSFE units Total system flow rate: 100,000 m3/h Systems considered: seawater, product water potable water The following assumptions are made: Fluid: Water at 40C Average pump efficiency: 80% Head loss (in meters of fluid column) is calculated from the Darcy-Weisbach equation:

The friction factor f is calculated from:

Pipe roughness, k; kSteel = 0.076 mm, and kFiberglass = 0.01 mm. 6.2.1. Seawater system Intake (four parallel line): Flow rate: 425,000 m3/h Diameter: 1900 mm Length: 42000 m Head loss: Steel, 13 m; GRP, 9 m Energy savings: 2.5106 kWh/y Supply to units: Flow rate: 718,000 m3/h = 126,000 m3/h Diameter: 2500 mm/1300 mm Length: 600 m/160 m Head loss: Steel, (1.0 + 0.6) m; GRP, (0.7 + 0.4) m Energy savings: 483103 kWh/y + 56103 kWh/y 6.2.2. Product water system Flow rate: 12,000 m3/h (two lines) Diameter: 1200 mm Length: 210,000 m Head loss: Steel, 20 m; GRP, 14 m Energy savings: 1.0106 kWh/y 6.2.3. Potable water system Flow rate: 394 m3/h Diameter: 150 mm Length: 1200 m Head loss: Steel, 134 m; GRP, 86 m Energy savings: 400103 kWh/y At a rate of 0.04 USD/kWh, the total energy saving per year = US $177,000.00.

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7. Symbols Cp D f g HL k L Wave propagation speed Diameter Friction factor Gravitational force Head loss Pipe roughness Line length

P Re V Greek

Pressure drop Reynolds number Velocity

Fluid density Fluid velocity