PLASTIC PIPING SYSTEM: An article

Corrosion (deterioration of materials under the influence of an environment) is a big problem in

all operating Process Plants. Many of the failures reported in Plants are because of Corrosion.
Hence given a choice one would be tempted to dispense away with Steel all together as a
material of construction for piping used. Unfortunately it is not practical to undermine the
usefulness of Steel in sustaining the Pressure and Temperature conditions normally foreseen in
any Process Plant. That brings the concept of composite piping constructed from the highly
Chemical Resistant Polymer Compounds as base material, reinforced with suitable fibrous
materials such as Glass which provides it the requisite strength.
PLASTIC MATERIALS:
Basically 3 types of Synthetic Polymer Components have found acceptance in industrial use.

Thermoplastic Materials

Thermosets and

Composite Plastics

Thermoplastics:
The Thermoplastics are Polymer Compounds, which are normally available in crystal form. On
application of heat and pressure these crystals attain the requisite level of flow ability to be able
to attain the desired shape by moulding process. On re-heating the plastic material can once
again undergo the transformation from solid to a flow able state which allows their reprocessing
into the desired shape.
Some of the commonly used Thermoplastic materials are as follows:

Polyvinyl Chloride

Fluor-Plastics

By and large the thermoplastics are structurally weak materials and have limited temperature
endurance.
Thermosets:
The Thermosetting Plastics are Polymer Compound (resins), which are normally available in
liquid form at ambient temperature. On addition of Catalyst and Accelerator these Resins
undergo a chemical transformation into a rigid product that sets into the required shape by
curing process.
Some of the commonly used Thermosetting Plastics are as follows:

Epoxies

Furans

Phenolic

Polyesters Bisphenol, Isophthalic, Halogenated

Polyurethane

Vinyl esters

Even though the Thermosetting Plastics are relatively superior to Thermoplastics in terms of
structural strength and temperature endurance, still in its virgin form they find limited use in
Industrial applications.
Composite Plastics:
It is evident from the foregoing discussion that both Thermoplastics and Thermosetting Plastics
in their virgin form lack ability to sustain the level of mechanical loading normally encountered in
the Industrial applications. An attempt to strike an appropriate balance between the two desired
properties of the material (i.e. Mechanical Strength and Corrosion Resistance) therefore has
always remained a desirable objective. This brought forward the concept of Composite Plastics
where in a reasonable degree of mechanical strength is imparted to the base Polymer which in
itself is adequately resistant to the Chemical Corrosion, by way of reinforcing it with a suitable
reinforcing material.
Most of the commercially available composite materials in the Reinforced Plastic category use a
combination of Thermosetting Plastic Resins (e.g. Polyester, Epoxy, Vinyl Ester etc.) and
Fiberglass or Synthetic Fibres as reinforcing material. In order to provide an ultra-superior
chemical resistance, it is also possible to manufacture a composite material using
Thermoplastic Material (e.g. PVC, PVDF, PP etc.) as a base liner over which the layers of
Thermosetting Resins and Fiberglass are applied to attain the required mechanical strength.
Manufacturing Process:
The composite plastics pipes are commonly produced by one of the following methods:

Custom Contact moulding: It is a manual/ semi-automated process in which the

composite sections are manufactured by application of various layers of resin and Glass
Fibers (in various forms such as surface mat, roving mat, chop-strand mat etc.) either
by Hand Lay-up or by Spray Lay-up method.

Filament Winding: It is a fully automatic process in which an automatic control over

winding angle ( 0 to 90 degree) and winding pressure can be exercised to obtain the
varying degree of Hoop Axial ratio and Glass Resin percentage composition.
Normally a winding angle of 54 3/ 4 Degree provides a 2:1 Hoop Axial ratio which is
condition of optimum internal pressure requirement. By increasing the winding pressure
the Glass Resin proportion could be varied from 80 % 20 % to 60% 40 %. A
composite section of high Glass content will result into high strength and low chemical
resistance and vice versa.

Pultrusion: As the name implies this is a sort of extrusion process by pulling the
filaments through a resin bath tub and subsequently passing it through an extruding die
and then through an atmosphere of controlled elevated temperature. The above

process is commonly used for manufacturing rolled sections such as Angles, Channels
and I Beams etc.

Resin Transfer moulding: The above process is used for specialized applications for
manufacture of sandwich structures with certain core material.

DESIGN CONSIDERATIONS:
The Plastic Piping System consists of Piping Profile fabricated from plain end pipe, plain and
flanged end Fittings (i.e. Elbows and Reducers) and stub-in branch connections. The Flanged
Joints are Stub Ends with loose Backing Flanges. In case of Flanged Tapping Long Stub
Flanges are recommended to be used in place of pipe stub-in and Short Stub Flanges. The pipe
to pipe and pipe to fittings joints are laminated joints. Accessories to Piping System include Soft
Rubber/ CAF Gaskets and Full Threaded Fasteners with Washers. The major considerations for
plastic piping system are listed below:

Owing to weak mechanical properties a minimum of NS 2 line size is recommended for

Plastic Piping. However tapping of small size (i.e. smaller than NS 2) are permitted for
drain/ vent etc. provided the branch connection is adequately supported.

Owing to its large Co-efficient of Thermal Expansion the Plastic Pipelines exhibit a high
tendency to grow under moderate temperatures. This may result into sizable deflection
of the branches and the corners of the Piping Profile. It shall therefore be ensured that
the branch connections are not over stressed, either by providing adequate flexibility on
the branch piping or by fixing the branch points by external means to disallow its
deflection.

If free movement of the corners of the piping profile can be allowed (i.e. e.g. not being
hindered by any other external item) then it is preferable to leave the profile to grow
freely. However if the growth of the profile has any adverse effect on the system stability
(e.g. supports falling off from the external structure) it may be appropriate to restrict the
growth of the sides of the profile by providing fixed supports at various locations as per
Plastic Piping Support recommendations.

Unlike Steel, bellows are not used on Plastic Piping. The thermal stress behaviour is
addressed either by providing in-built flexibility in the system or by arresting the axial
growth of the pipe runs within the pipe length itself. In case the later method is
employed, the pipe may have to be guided at close intervals to avoid failure due to
buckling.

Owing to its weak nature, the plastic piping shall not be supported by a line contact
between the pipe surface and the external structure taking the load. Hence as a general
rule Clamp and Shoe type supports shall be employed on Plastic Piping System.

All concentrated loads (e.g. On-line Valves, Instruments etc.) shall be directly supported
to ensure that the load is transferred to the grade/ external structure without stressing
the piping.

All the valves employed on Plastic Piping shall be provided a Fixed Type Support to
ensure that the Piping is not over stressed in case of jamming of the Valve hand wheel
while operating.

Due to excess thickness of Plastic Pipe (as compared to Steel) it is likely to obstruct the
opening of the flap of Sandwich type Butterfly/ Wafer Check Valve into the pipe. In order
to address the above issue the Spacer Rings (made of same or equivalent material as
pipe) will be employed across the valve. The above Spacer Ring is procured as a
Special Part.

The Plastic Piping System shall be installed with permanent supports in place. Erection
of Plastic Piping with temporary supports is not acceptable.

The pipes shall not be stretched in order to match the terminal ends

The Flange Joints shall be tightened to the specified Torque Value only by employing
Torque Wrench.

As far as possible the Piping profile shall be prefabricated in the Vendors shop at site,
leaving only a few field joints for final fit-up.

In case of FRP Piping with Thermoplastic Liner, the Field Weld will always be located at
the convenient height/ location to allow down hand welding/ jointing.