2014 12 05 - Wi PFX GRP 0001

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N: WI-PFX-GRP-0001
WORK INSTRUCTION
Rev.: 00
Date: 07/08/13
STRESS ANALYSIS OF GRP LINES

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WORK INSTRUCTION
WI-PFX-GRP-0001
07/08/13
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Doc. N: WI-PFX-GRP-0001
WORK INSTRUCTION
Rev.: 00
Date: 07/08/13

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INDEX
INDEX..............................................................................................................................................................2
1.
SCOPE AND PURPOSE .........................................................................................................................3
2.
REFERENCE DOCUMENTS ...................................................................................................................3
3.
DEFINITIONS ..........................................................................................................................................3
4.
INTRODUCTION TO ISO 14692 ..............................................................................................................4
5.
GRP - GENERAL INFORMATION ...........................................................................................................5
6.
7.
5.1
JOINING SYSTEMS ............................................................................................................................5
5.2
FAILURES.........................................................................................................................................7
When, where and why do failures occur ............................................................................7
5.2.2
Some failures occur at fittings ............................................................................................7
5.2.3
Most failures occur at joints ...............................................................................................8
5.2.4
Why do joints fail? .............................................................................................................8
5.2.5
Steps to avoid failures .......................................................................................................8
DESIGN DATA ........................................................................................................................................9

6.1
MATERIAL PROPERTIES ....................................................................................................................9
6.2
PIPING DATA ..................................................................................................................................10
SUPPORTS ...........................................................................................................................................11
7.1
8.
5.2.1
SUPPORTS SPACING .......................................................................................................................11
STRESS ANALYSIS ..............................................................................................................................12

8.1
GENERAL .......................................................................................................................................12
8.2
STRESS ANALYSIS RESULTS ...........................................................................................................12
8.3
PRELIMINARY STRESS CALCULATION ................................................................................................12
8.4
CAESAR II ...................................................................................................................................15
8.5
8.4.1
Caesar II Configuration ....................................................................................................15
8.4.2
Special Execution Parameters .........................................................................................16
8.4.3
Piping input ......................................................................................................................17
8.4.4
Load Case options ...........................................................................................................21
MAXIMUM STRESSES ......................................................................................................................22
WORK INSTRUCTION
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Date: 07/08/13

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1. SCOPE AND PURPOSE

The purpose of this work instruction is to define the general principles and the reference Codes and
Standards that are applicable to the stress analysis verification of Glass Reinforced Plastic (GRP) piping.
It provides information for the design, stress calculation and installation of GRP piping systems.
2. REFERENCE DOCUMENTS
Petroleum and natural gas industries Glass-reinforced plastics

(GRP) piping
ISO 14692
3. DEFINITIONS
Anisotropic
Showing different properties when tested along axes in different

directions.
Epoxy
Compound containing at least two epoxy or oxirane rings. Chemically,

an epoxy ring is a three-membered ring containing two carbon atoms
and one oxygen atom.
Failure
Condition caused by collapse, break, or bending, so that a structure or

structural element can no longer fulfill its propose; in case of piping is
the transmissions of fluid throughout the wall of a component or via a
joint.
Fiber
Filamentary material with a finite length that at least is 100 times its
diameter. Normally, filaments are not used individually and are
assembled as twisted (yarn) or untwisted (tow) bundles composing
hundreds of filaments.
FRP
Fiberglass Reinforced Plastic pipe - Term general for a plastic-based

composite that is reinforced with any type of fiber, not necessarily
glass.
GRE
Glass Reinforced Epoxy pipe - Epoxy resin-based composite that is

reinforced with glass fibers.
GRP
Glass Reinforced Plastic - A thermosetting plastic based composite

that is reinforced with glass fibers.
Liner
In a filament-wound component, the continuous resin rich coating on

the inside surface, used to protect the laminate from chemical attack or
to prevent leakage under stress.
LTHS
Long-Term Hydrostatic Strength
Mechanical joint
A joint between GRP piping components which has rubber gasket

seals and does not require any bonding or lamination.
PTFE
Polytetrafluoroethylene
Topcoat
Equivalent to liner on the outer side
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Date: 07/08/13

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4. INTRODUCTION TO ISO 14692

ISO 14692 is an international standard dealing with the qualification of fittings, joints and pipes. It
describes how to qualify and manufacture GRP pipe and fittings and it gives guidelines for fabrication,
installation and operation.
The ISO 14692 consists of four parts:
Part 1 : Vocabulary, symbols, applications and materials
This part gives the terms, definitions and symbols used.
Part 2 : Qualification and manufacture
This part gives requirements for the qualification and manufacture of GRP piping and fittings.
Part 3 : System design
This part gives the design guidelines.
Part 4 : Fabrication, installation and operation
This part gives requirements and recommendations for fabrication, installation and operation of GRP
pipe systems.
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5. GRP - GENERAL INFORMATION

5.1
JOINING SYSTEMS
a) Conical-Cylindrical bonded joint

This type of adhesive bonded joint consists of a slightly conical socket and a cylindrical spigot. This joint
allows for an accurate assembly length with narrow tolerance and may be used for above- and
underground pipe systems.
b) Taper/taper bonded joint

The joint consists of a conical socket and a conical spigot. The adhesive is a two component epoxy resin
system, packed in separate containers.
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c) Mechanical O-Ring Lock Joint

The mechanical O-ring lock joint is a tensile resistant type of joint. This restrained type of joint can be
used in unrestrained environments, e.g. aboveground.
d) Laminated joint
The laminate joint is used to join plain-ended pipe sections. After preparation of the pipe surfaces, a
specific thickness of resin impregnated glass reinforcement is wrapped over a certain length around the
pipes to be joined; the thickness and the length of the laminate are related to diameter and pressure.
WORK INSTRUCTION
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e) Flanged joint
To enable connections with steel piping and to allow for easy assembling and disassembling of process
lines.
Glass fiber reinforced epoxy flanges are always flat faced and in view of this, matching flanges should
also be flat faced. The flanged joint is completed by using a gasket.
5.2
FAILURES
5.2.1
When, where and why do failures occur
When
o
Small part of the failures occurs during installation or operation
Most of the failures occur during hydro-testing (pressure testing)
Where
o
Joints (most of the location)
Fittings : bends, tees, reducers
Plane pipe
Why
o
Due to material defects
Defective installation (poor application of cement during installation)
Overloading of material due to shortcomings in design
5.2.2
Some failures occur at fittings
Bends
o
Molded bends (failures occur next to the bend)
Mitered bends (failures at the miter joints)
Tees (failures of the intersection)
Reducers
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5.2.3
Most failures occur at joints
Types of joints
o
Cemented joints
Laminated joints
Mechanical joints
5.2.4
Flanged joints
Lock joints
Why do joints fail?
Only small part of the joint failures are the result of material defection
Most joints failures are duo to:
Defective installation
Excessive loads (damages due to waterhammer, overloaded flanged joint due to

external moments)
Critical items in design

o
Underestimation of load (proper prediction of loads)
Overestimate of joint capabilities (e.g. flanged joints)
Overestimate of system flexibility (prediction of flexibility)
5.2.5
Steps to avoid failures
Identification and assessment of specific critical items in GRP systems
Implement performance based codes
Design by analysis
Proper integration of material properties
Assessment of joint capabilities
Installation
o
Verification of installation: as built conform design
Prior to Hydro-test
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6. DESIGN DATA
MATERIAL PROPERTIES
6.1
Complicated mechanical properties of GRP pipe
Orthotropic material
o
Typical stiffness values

o
Ec = 20 000 MPa (200 000 MPa for Carbon Steel)
Ea = 10 000 MPa
G = 9 000 MPa
High thermal expansion coefficient.

o
Stiffness & strength properties in axial & circumferential direction are different
20 * 10E-06 mm/mm/C (10 for Carbon Steel)
Typical design strength values

o
Scircumferential = 70 MPa
Saxial = 35 MPa
SIFs for fittings are different from metal
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6.2
PIPING DATA
The external diameter and minimum structural wall thickness shall be applied during GRP pipe
stress analysis.
Here below a typical sheet to be sent to the supplier at the beginning of the project and which has
to be completed by him in order to have all information to perform final stress analysis.
The template file is available here: Z:\PIPING_STRESS_PIP_PFX\TECHNIQUE\GRE\Work
Instruction\GRE ISO14692 necessary DATA-rev1.xlsx
GRE MATERIAL DATA SUMMARY
FOR STRESS ANALYSIS CALCULATIONS USING CAESAR II SOFTWARE
IN ACCORDANCE WITH CODE ISO 14692
Date
(A LL CELLS IN GREY SHA LL B E FILLED B Y SUP P LIER)
Supplier
Material Type or Designation
Product Commercial Designation
Pipe Data
Density
Coefficient of Expansion
Design Strain
Kg/m3
mm/m/C
%
Laminate Type
Axial modulus of elasticity

Shear Modulus/Elasticity Modulus
Shear modulus
Ea/Eh*Vh/a
Poisson's ratio Axial/Hoop
Poisson's ratio Hoop/Axial
Part factor f1
Part factor f2
Part factor f3 (Total)

Long term hydrostatic strength
Allowable design stress
r (bi-axiale stress ratio)
Short term axial strength at the 0 :1 condition
Short term axial strength at the 2 :1 condition
Long term axial strength at the 0:1 condition
Long term axial strength at the 2:1 condition
Temp
Ea
Eh
G
20
60
90
20
60
90
f1
f2 (sust.)
f2 (therm)
f2 (occ)
f3
LTHS
Sh
r
Sas (0:1)
Sas (2:1)
Sa (0:1)
Sa (2:1)
Units
120 C
Mpa
Mpa
Mpa
Mpa
Mpa
Mpa
Mpa
Mpa
Mpa
Fittings Data:
Laminate Type
r (bi-axiale stress ratio) (elbows & tees)

Elasticity modulus Hoop and Axial
Allowable design stress elbows
Allowable design stress tees
Temp
r
Eh/Ea
S elbow
S tee
Units
120 C
Mpa
Mpa
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7. SUPPORTS
7.1
SUPPORTS SPACING
The supports shall be spaced to limit sag (< 6 mm).

The span support is different from metallic piping systems.
The maximum span lengths suggested for simply supported GRP pipes and full of water will be provided
by Supplier.
Heavy valves have to be supported independently from the pipe to avoid overloading in both horizontal
and vertical directions and so reduce bending stresses on adjacent pipe.
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8. STRESS ANALYSIS
8.1
GENERAL
GRE/ GRP pipe expands due to pressure & temperature different from steel
Pipe/ Fitting dimensions and properties different from metal
GRE/ GRP pipe is orthotropic, axial and circumferential stiffness are different
GRE/ GRP systems require dedicated supporting
A stress analysis is required for systems listed below:
Pipes > 6
Pipes subject pressure surge, slug and two phase flow conditions
Pipes connected to sensitive equipment
8.2
STRESS ANALYSIS RESULTS
In the cases where the flexibility of the piping system under examination is found to be insufficient
to absorb the imposed thermal expansion, the here below listed provisions shall be adopted, in
the following order of preference:
Changes in piping layout
Reinforcement of fittings (elbows / tees)
Installation of expansion joints
In case of underground GRE system, special care has to be taken with small branch connections.
Sometimes, foam needs to be installed around small tees and part of the branch pipe to allow
displacement.
8.3
PRELIMINARY STRESS CALCULATION
The information required for stress analysis, such as pipe wall thickness and external diameter,
are provided by supplier. Nevertheless with no information at the beginning of a project,
preliminary input data can be taken as a first approach.
Thickness of GRE fittings can be estimated by taking 1.5 * pipe thickness.
For GRP preliminary stress calculations, input data listed below shall be considered:
Material properties:
Material selection in Caesar
Corrosion
Density
(20) FRP
0 mm
1.85 kg/dm3
WORK INSTRUCTION
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Pipe Data:
Temperature (C)
20
65
90
100
Axial modulus of elasticity : Ea (MPa)
10500
8950
8000
7550
Shear modulus : Eh (MPa)
20500
18100
16200
15375
Ea/Eh*Vh/a
0.33
0.32
0.32
0.32
Long term hydrostatic strength LTHS (MPa)
200
146
117
105
Allowable design stress Sh (MPa)
125
125
110
102
r: bi-axiale stress ratio
0.52
0.52
0.52
0.52
Short term axial strength at the 0:1 condition as(0:1) (MPa)
65
Short term axial strength at the 2:1 condition as(2:1) (MPa)
125
Long term axial strength at the 0:1 condition al(0:1) (MPa)
32.5
32.5
28.6
26.5
Long term axial strength at the 2:1 condition al(2:1) (MPa)
63
63
55
51
Temperature (C)
20
65
90
100
r (elbows & tees)
Elasticity modulus Hoop and Axial : E (MPa)
20000
18000
16000
15000
Allowable design stress elbow Selbow (MPa)
80
80
70
65
Allowable design stress Tees Stee (MPa)
64
64
56
52
Fittings Data:
For other temperatures, the mechanical properties are calculated by interpolation.
WORK INSTRUCTION
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Stress envelop:
al(0:1))
al(1:1)
al(2:1)
Base
f2
32.5
63
63
0.67
0.83
0.89
SUS
0.67
22
42
42
OPE
0.83
27
52
52
OCC
0.89
29
56
56
al(1:1)
al(2:1)
al(0:1)
hl(2:1)
WORK INSTRUCTION
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8.4
CAESAR II
The thicknesses used for stress analysis are mechanical thicknesses, it means that the liner and
the top coat are not included.
8.4.1
Caesar II Configuration
The material properties are all overridden by Kaux Special execution parameters or Caesar
Input data.
BS 7159 Pressure Stiffening: keep Design Strain as per Code.
Exclude F2 From UKOOA bending stress: TRUE as per ISO 14692 (automatically TRUE if ISO
14692)
Use FRP Flexibilities: Useful only in you have FRP with non-FRP-code calculation.
(automatically TRUE if ISO 14692)
Use FRP Sif: Useful only in you have FRP with non-FRP-code calculation. (automatically TRUE if
ISO 14692)
WORK INSTRUCTION
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8.4.2
Special Execution Parameters
Enter the thermal expansion of the GRP pipe as per supplier pipe data.
Enter the FRP ratio Eh/Ea (as per supplier pipe data)
The FRP laminate type has to be filled in the Kaux or in the bend type input
Textbox. For ISO 14692, the only choice is 3-CSM & Multi Filament.
WARNING: Empty value 3-CSM & Multi-Filament
WORK INSTRUCTION
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8.4.3
Piping input
al(0:1) : Long Term Axial Stress at 0:1 Stress Ratio Hoop stress is 0 at this point.
al(1:1) : Long Term Axial Stress at 1:1 Stress Ratio hl(1:1) = al(1:1)
hl(1:1) : Long Term Hoop Stress at 1:1 Stress Ratio
al(2:1) : Long Term Axial Stress at 2:1 Stress Ratio - hl(2:1) = 2 * al(2:1)
hl(2:1) : Long Term Hoop Stress at 2:1 Stress Ratio
Qs : Qualified Stress for Joints, Bends and Tees
r : Bi-Axial Stress Ratio for Bends, Tees and Joints
A1 : Partial Factor for Temperature. As per ISO 14692-3 (7.4.2), if the operating
WORK INSTRUCTION
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temperature is less than or equal to 65C, then A1 = 1.

A2 : Partial Factor for Chemical Resistance. As per IOS 14692-3 (7.4.3), if the normal
service fluid is water, then A2 = 1.
A3 : Partial Factor for Cyclic Service. Refer to ISO 14692-3 (7.4.4)
System design factor : The System Design Factor (SDF) is multiplied by the Occasional
Load Factor (k) to generate the value of f2 (f2 = SDF * k), the Part Factor for Loading. By
default the SDF is 0.67.
Loading Type
Load Duration
System
Design Factor
(SDF)
Occasional
Load Factor
(k)
Part Factor
For Loading
(f2)
Example of
loading type
Occasional
Short-term
0.67
1.33
0.89
Hydrotest
Sustained
Including
Thermal Loads
Long-term
0.67
1.24
0.83
Operating
Sustained
Excluding
Thermal Loads
Long-term
0.67
1.00
0.67
Sustain
k : Thermal Factor. In the absence of further information, the thermal factor k should be
taken as 0.85 for liquids and 0.8 for gasses
WORK INSTRUCTION
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Fittings - Bends
Different external diameter and thickness shall be specified for the bends (provided by the
supplier).
The laminate type affects the calculation of flexibility factors and stress intensification
factors (only for BS 7159 and UKOOA codes). For ISO 14692 only type 3 filament wound laminate is considered.
WORK INSTRUCTION
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Fittings - Tees
Different external diameter and thickness shall be specified for the tees (provided by the
supplier).
Three types of tee are available in Caesar input (Tee, Qualified Tee, Joint). As per ISO
14692-3 (D.2.3.4), if the tee is fabricated according to ISO, then specify Qualified Tee
as type of tee (pressure stress multiplier will be equal to 1).
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8.4.4
Load Case options
Occasional load factor shall be noted. If they are equal to zero, the allowable loads will
not be indicated in the output results files and will be equal to zero.
By this way, CAESAR will put the occasional load factor to default values corresponding
to the code, for example here with ISO 14692:
1 * 0.67
1.24 * 0.67 = 0.83 for Operating Case
1.33 * 0.67 = 0.89 for Occasional Case
= 0.67 for Sustained Case
Note:
If the GRE CAESAR file has been generated from a metallic pipe network CAESAR file,
then the occasional load factors may be equal to zero, then no allowable stress will be
calculated in the outputs. A way to avoid this, is to delete the file._J, then to rerun the
CAESAR file and so a new file._J will be created with correct occasional load factor
values.
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Date: 07/08/13

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8.5
MAXIMUM STRESSES
LOAD CASES
Case
N
SUSTAINED (PIPE FULL) WEIGHT+

DESIGN PRESSURE
W+P1(+H)
WEIGHT (no contents)

WNC+H
OPERATING At Tdesign max with Hull

Deflection
W+T1+D3+P1+H
OPERATING At Tdesign min with Hull

Deflection
W+T2-0.5D3+P1+H
OPERATING At Tdesign max

W+T1+P1+H
OPERATING At Tdesign min
W+T2+P1+H
OPERATING At Tmaxi ope
W+T3+P1+H
HYDROTEST (PIPE FULL)
WEIGHT+HYDROTEST
WIND X
WW+HP(+H)
11
U2
12
U3
13
D3
14
STRUCTURAL DEFL. DUE TO ACC. X

D4
15
STRUCTURAL DEFL. DUE TO ACC. X

D5
16
ACCELERATION Z
HULL DEFLECTION (Sagging)
CONCENTRATED FORCE
F1
ACCELERATIONS
17
U = ([U1] +[U2] +[U3] )
18
STRUCTURAL DEFLECTIONS
2
2
D = ([D4] +[D5] )
19
SUSTAINED + WIND X
(W+P1(+H))+WIN 1
20
SUSTAINED + WIND Y
(W+P1(+H))+WIN 2
21
SUSTAINED + OCC FORCE

(W+P1(+H))+F1
22
SUSTAINED + ACCELERATION
(W+P1(+H))+U
23
SUSTAINED + MAX DISPL.

(W+P1(+H))+D
SOCC
MPa
10
ACCELERATION Y
SSUS SOPE
MPa MPa
WIN 2
U1
Allowable stresses
ACCELERATION X
Calculated
stresses
MPa
WIN 1
WIND Y
Node
24
Stress
ratio

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STRESS ANALYSIS OF GRP LINES

STRESS ANALYSIS OF GRP LINES

STRESS ANALYSIS OF GRP LINES

SCOPE AND PURPOSE .........................................................................................................................3

REFERENCE DOCUMENTS ...................................................................................................................3

INTRODUCTION TO ISO 14692 ..............................................................................................................4

GRP - GENERAL INFORMATION ...........................................................................................................5

JOINING SYSTEMS ............................................................................................................................5

Some failures occur at fittings ............................................................................................7

Most failures occur at joints ...............................................................................................8

Why do joints fail? .............................................................................................................8

Steps to avoid failures .......................................................................................................8

DESIGN DATA ........................................................................................................................................9

MATERIAL PROPERTIES ....................................................................................................................9

PIPING DATA ..................................................................................................................................10

SUPPORTS SPACING .......................................................................................................................11

STRESS ANALYSIS ..............................................................................................................................12

STRESS ANALYSIS RESULTS ...........................................................................................................12

PRELIMINARY STRESS CALCULATION ................................................................................................12

Caesar II Configuration ....................................................................................................15

Special Execution Parameters .........................................................................................16

Piping input ......................................................................................................................17

Load Case options ...........................................................................................................21

MAXIMUM STRESSES ......................................................................................................................22

STRESS ANALYSIS OF GRP LINES

1. SCOPE AND PURPOSE

Petroleum and natural gas industries Glass-reinforced plastics

Showing different properties when tested along axes in different

Compound containing at least two epoxy or oxirane rings. Chemically,

Condition caused by collapse, break, or bending, so that a structure or

Fiberglass Reinforced Plastic pipe - Term general for a plastic-based

Glass Reinforced Epoxy pipe - Epoxy resin-based composite that is

Glass Reinforced Plastic - A thermosetting plastic based composite

In a filament-wound component, the continuous resin rich coating on

Long-Term Hydrostatic Strength

A joint between GRP piping components which has rubber gasket

Equivalent to liner on the outer side

STRESS ANALYSIS OF GRP LINES

4. INTRODUCTION TO ISO 14692

Part 1 : Vocabulary, symbols, applications and materials

This part gives the terms, definitions and symbols used.

Part 2 : Qualification and manufacture

Part 3 : System design

This part gives the design guidelines.

Part 4 : Fabrication, installation and operation

STRESS ANALYSIS OF GRP LINES

5. GRP - GENERAL INFORMATION

a) Conical-Cylindrical bonded joint

b) Taper/taper bonded joint

STRESS ANALYSIS OF GRP LINES

c) Mechanical O-Ring Lock Joint

STRESS ANALYSIS OF GRP LINES

When, where and why do failures occur

Small part of the failures occurs during installation or operation

Most of the failures occur during hydro-testing (pressure testing)

Joints (most of the location)

Fittings : bends, tees, reducers

Due to material defects

Defective installation (poor application of cement during installation)

Overloading of material due to shortcomings in design

Some failures occur at fittings

Molded bends (failures occur next to the bend)