Discover the incredible capabilities and advantages of Fiberglass Reinforced Polymer pipe in managing corrosive and abrasive fluids, gases and vapors.

1. FRP Piping and Equipment for the
Chemical & Pharmaceutical Industries
By
Phillip Bureman
KC Area Sales Engineer
PBureman@Cortrol.com

2. Industrial
Cooling Water
Sulfuric Acid Pipe
Waste Water Pipe
Examples
of FRP
Fiberglass
Reinforced
Polymer
Rectangular Duct
for municipal WW

3. Who is Cortrol Process Systems
• Phil Bureman - KC Area Sales Engineer
• Steve Shrout – Sales Mgr, also in KC
• Cortrol is based in Tulsa, OK
– Sister companies with same owner:
• Fluid Technology Corp (FTC), Des Moines, IA
• Frontier Plastic Fabricators (FPF), Tulsa, OK
• Geography: North TX & LA all the way to Canada
• Cortrol and FTC are the midwest distributors for FRP
pipe and related products produced by National Oil
Well Varco
– NOV: $10B Annual Global Revenue, 60k employees
– US production in Sand Springs, OK & Little Rock, AR
What does Cortrol Offer?

4. What does Cortrol Offer?
Corrosion Control Via Non-Metallics
• FRP Pipe & related fittings
• FRP & Polyethylene storage tanks & containment
• FRP valves & Lined pumps
• Mag drive & pneumatic diaphragm pumps
• PTFE lined pipe & hose
• FRP buildings, grating, ladders, etc
• Custom FRP fabrication via Frontier Plastic
Fabricators
What brands does Cortrol Carry?

5. Cortrol Brands
ANSIMAG
Who are your Customers?

6. • FRP Tanks, Scrubbers, Ducts
• FRP Valves
• FRP Grating, Structural, Handrail
• FRP Buildings, Covers
• Polyethylene Tanks
• PTFE Lined Steel Pipe
• Lined Valves
• In-Line Sampling Systems
• PTFE Lined FRP Pipe
• Seal less, Mag Drive Pumps
• Diaphragm Pumps
• Teflon® Hose Assemblies
• PTFE & Rubber Expansion Joints
• Reactor Dip Pipes / Spargers
• Pinch Valves, Pressure Gage Isolators
• Triple-Offset Butterfly Valves
Other Cortrol Products –

7. • LF Manufacturing
– Custom Fabricated
– Filament Wound or
Contact Molded
– Diameters to 2’-15’6”
– ASME RTP-1 Certified
– Double Wall Tanks
– Stacks, Flumes, Flume
Scrubbers, Ducts
Other Cortrol Products –
FRP Tanks

8. • Manual, On/Off, or Control
– Ball Valves
• 1"-10"
• Vinyl Ester / Epoxy
• Ceramic Lined available
– Butterfly Valves
• 2" - 12"
– High Strength Vinyl Ester Body
– PTFE, PE, EPDM Lined
• 14" - 42"
– Vinyl Ester Body / Disk
– Double Offset
• Check Valves
– Ball Check 1' - 10"
– Swing Check 3" - 12"
–
Other Cortrol Products –
PureFlex FRP Valves

9. • Assmann
– Linear and Cross-Linked
PE
– Single and Double Wall
Tanks
– Capacities to 12,000 gal.
– Chem Feed Stations
Other Cortrol Products –
Polyethylene Tanks

10. • Kentec
– Grating
– Hand Rails
– Structural
– Ladders / Platforms
– Stair Treads
• Jacobs Manufacturing
– Buildings
– Doors
– Pump Covers
– Weir Plates, Launder Covers
– Tank Roofs
Other Cortrol Products –
FRP Structural

11. • Pinch Valves from ½” to 30”
• Pressure Isolator Rings from
½” to 48”
• Duckbill Check valves from 1”
to 72”
Other Cortrol Products - Onyx

12. • Triple Offset Butterfly
Valves
• Manual / Automated /
Control
• Check Valves
• Combination Valves
Other Cortrol Products – Adams Valves

13. • Ramparts
– Air-Operated, Single
Diaphragm
– 1½” to 6” size
– up to 70% solids
– Flows to 300 gpm
– Discharge head to 100 psig
• ANSIMAG
– Seal less, Magnetic Drive
– ETFE or PFA Lined
– Flows to 1450 gpm
– Discharge head to 350 psig
Other Cortrol Products – Pumps
ANSIMAG

14. Cortrol Customers
What is FRP?

15. So What Is FRP Pipe?
• FRP Is Fiberglass Reinforced Polymer
• FRP is NOT Plastic!
• The Polymer is formed from catalyzed thermoset
resins
• FRP does not Corrode & Resist Chemical Attack
– Inside & Outside
• Excellent Abrasion Resistance
• FRP Does Not Scale
• Smooth interior  Excellent Flow Efficiency
• Very High Strength to Weight Ratio
• Can be heat traced and insulated
Let me tell you more about FRP..…

16. FRP is a Highly Engineered & Structured product
• Fiberglass
• Two major types of
thermoset resin
• Three major types of
manufacturing
• Special finishes available
• Various methods of joining
• Cortrol & NOV will assist
you in choosing the best
FRP pipe for your needs
 Fiberglass provides
Structure &
Strength
 The resin provides
protection from
corrosion, chemical
attack and scaling
Let’s talk more about the resins…..
Today’ Agenda

17. • Epoxy
Handles temperature to 275 ˚F
Handles water, caustics, solvents, brine, petroleum products,
and many acids
• Vinyl Ester
Handles temperature to 225˚F
Handles water, chlorides, concentrated acids, and oxidizing
agents
• Optional Finishes
Extra Abrasion Resistant
Improved electrical conductivity
Two Major Resins to match specific
performance requirements
How is FRP Manufactured?

18. How Is FRP Pipe Manufactured?
• 3 Primary Manufacturing Methods
–Filament Winding
–Centrifugal Casting
–Hand Layup
• Let’s first discuss the Filament
Winding Process

19. Filament Winding Process
Non-Woven Fibers used in
Filament Wound FRP Pipe
It would
be cool to
see a
video, Phil

20. Filament Winding Video
What’s the final product?

21. FRP Products produced by Filament Winding
Red Thread
F-Chem
Green
Thread
• Red Thread/Green Thread Epoxy
 Workhorse of Water/Waste Water
 2” – 42” Ø
 225OF, 232 to 600 psig
 NSF Listed
 Green Thread® - 20 mil liner
• F-Chem (used in HDR’s St Joseph Project)
 Very Customizable: Brine, Chem Waste
 Vinyl Ester, Polyester or Epoxy
 14” – 84” Ø
 250OF, 150 psig
 NSF Listed
ID Controlled
What about those specialty finishes ?

22. Also via NOV, we offer extremely abrasion
resistant FRP Pipe
• Silver Streak®
– Epoxy pipe with abrasion resistant additive
– 1” – 24” Ø
– 225OF, 232 psig
– Bell & Spigot Joining
– Limestone & gypsum slurries & FGD fluids
• Ceram Core®
– Alumina bead lined epoxy
– 6” – 16” Ø
– 225OF, 232 psig
– Self-Aligning Flange Joints
– Bottom ash, sand lines and mine tailings
Centrifugal Casting is a
significantly different process

23. • Fiber Glass also can be woven into sheets of varying
structure and density
Centrifugal Casting
Surfacing Veil
Resin to Glass Ratio
90%/10%
Chopped Strand Mat
Resin to Glass
Ratio 70%/30%
Woven Roving
Resin to Glass
Ratio 50%/50%
Maximum Resistance To Chemical Attack
Maximum Structural Strength
Centrifugally Cast FRP Pipe can have all three glass types

24. FRP Pipe Method of Manufacturing -
Centrifugally Cast

25. FRP Pipe Method of Manufacturing -
Centrifugally Cast Pipe
Glass Cloth / Woven roving Chopped Matt & Surfacing Veil Glass rolled onto Mandrel
Oven insertion Mandrel Removal Resin Injection

26. Centricast
CL-2030
Centricast
RB-2530
Z-Core
 1-14” Ø, OD Controlled
 Typical Maximum 150 psig
 100 mil pure resin liner
 Vinyl Ester or Epoxy Resins
 Centricast handles up to
250OF
 Z-Core proprietary epoxy to
275OF
 Strong Acids & Caustics,
Solvents, Process Solutions
FRP Pipe Method of Manufacturing
Centrifugal Casting
OD Controlled
The 3rd Method is Hand Layup

27. • Individual Layers Of Veil,
Chopped Strand Mat, Woven
Roving are laid over mandrel
while resin is rolled or sprayed.
• Suitable for custom pipe / fittings
Custom Contact Molded (Hand-Lay Up)
from Frontier Plastic Fabricators
What about Fittings ?

28. FRP Fittings & Flanges from NOV & FPF
Can be compression molded from glass fibers and resin but can also be
made via filament winding or hand layup
More about Joining Methods?

29. • Bell & Spigot (Red/Green Thread)
– Matched-Taper Joint secured with
Epoxy Adhesive
– Stronger than pipe itself in both
internal pressure and axial tension
– Resists movement; allows next joint
without waiting for cure
FRP Methods of Joining
• Threaded & Bonded (T.A.B)
– Double-lead threading ensures an
extra secure adhesive connection &
alignment
– Resists movement; allows next joint
without waiting for cure
– Mostly used in petroleum
applications

30. FRP Methods of Joining
 Flanged (available for most FRP)
• Available for all piping systems
• FRP flanges can be connected to steel
pipe
 Socket Joint (Centri-Cast & Z-Core)
• Straight adhesive joint with positive stop
lands
• Simplifies precise makeup of complex
piping configuration
 Butt-Wrap (F-Chem)
• Ends of fittings butted together
• Wrapped with multiple layers of Resin
saturated mat and/or woven roving
Are there specifications for FRP ?

31. What About Specifications?
All FRP Products sold by NOV and FPF are Produced and Tested
per National and Global Specifications
• ASTM 2996: Filament Wound
• ASTM 2997: Centrifugally Cast
• Tested under methods ASTM 2992
• ASME 31.1 Power Piping
• ASME 31.3 Process Piping
• NM-2 (a new ASME spec)
– NOV helped lead this spec development
• Factory Training/Certification Available for
Installers
Let’s talk about some of the reasons why you might consider FRP instead of steel…

32. • FRP has a much smoother surface  Less
friction  better pump efficiency
• No corrosion or scaling & resists abrasion
– Corrosion resistance in the pipe interior & exterior
surfaces
– Handles Low & high pH fluids, vapors and gases
– Resists microbial induced corrosion (MIC)
– Resists Oxygen corrosion & Chloride SCC
Why consider FRP Vs Steel?
Why is this important ?

33. FRP’s Smooth Surface & Lack of Corrosion
Maintains Pipe Life & Pumping Efficiency
Scaling can also affect flow efficiency

34. • FRP Does not support scale formation
• FRP does not bond with suspended or dissolved solids
• No pipe diameter loss over time
Why consider FRP Vs Steel?
FRP has no cathodic or anodic surface charges
Used
Green
Thread
FRP
Sch 40
Steel w
1/2” scale
8.34” ID New
54.81 sq In
7.98” New
50.00 sg In New
6.98” ID Scaled
38.26 sq In Scaled
A 23.5 % loss of pipe area
due to ½” of scale
Are there other advantages?
Help Me

35. • Lowest installation costs vs steel & steel alloys
o FRP’s lighter weight reduces the need for heavy duty supports &
allows for longer pipe spans, which also reduces the number of
required supports
o Less need for large cranes in potentially tight areas
o Faster & Safer installation than steel welding
 No open flame hot work
o Less need for expansion loops & pipe anchors
• Let us help with estimates
o Some contractors can’t make accurate estimates
o Some contractors like the extra hours spent installing steel
Why consider FRP Vs Steel?
Let’s look at an example

36. 0
5
10
15
20
25
30
35
75˚F 100˚F 125˚F 150˚F 175˚F 200˚F
Feet
Length of Support Span
For 8” Pipe based on allowable ½” pipe deflection
Cent. Cast FRP Filament Wound FRP Sch 40 Steel
PVC HDPE 13.5 SDR
FRP Cast pipe
normally
offers longer
spans than
steel!
FRP Wound
pipe has
similar
performance
even at high
temperatures

37. RFP Thermal
Expansion can easily
be guided and
restrained
• Fewer & Less Robust
Anchors are
Required
@ 100oF Increase in
Temperature of 4” FRP
cast pipe has more
thermal Expansion but
MUCH less Thermal
End Loading
Applicable to
bigger pipe?

38. Why FRP?
As the pipe get larger, the FRP Advantage Gets Even Better!
2865 8951 14309 17673
1,023 2,575 3,464 3962
30,237
90,712
151,187
211,661
0
50000
100000
150000
200000
250000
90˚F 130˚F 170˚F 210˚F
LbsForce 8” Pipe Restrained Thermal end loads, installed at 70OF
Cent. Cast FRP Filament Wound FRP Sch 40 Steel

39. • 2-13 pH waste water from plant to settling pond, (3) 6”Ø x 1725’
(5,175’ total)
• Total cost for Carbon Steel material, installation, supports - $750K
• Filament Wound Epoxy Piping
– 60% reduction in pipe support cost
– 25% reduction in number of pipe supports
– 100% reduction in expansion joints
– (20% reduction in pipe and fittings)
– 75% reduction in anchor points
– 50% reduction in cost of anchors
– 25% reduction in number of field joints
• Total cost for FRP material, installation, supports - $260K
Application -
Process Wastewater from Zinc Mfg., OK

40. • Transport of acid waste streams
from the process facility to the on-
site wastewater treatment system.
• Vinyl Ester Piping
• The varying nature of the acid
waste stream requires a product
that is resistant to a wide variety
of corrosive fluids.
• Versatility of the system, as well as
the ease of installation, made the
products an outstanding choice
Application -
Process Waste Stream (Semiconductor)

41. • Piping System Handles A Variety
Of Chemicals In The Customer’s
Sanitary Drainage System.
• Approximately 25,000 Feet Of
Epoxy Cast Pipe &Fittings, Sizes
1”-12”
• System Was Chosen For Its
Applicability To A Wide Range Of
Corrosive Chemicals, Ease Of
Installation, And Outstanding
Track Record In Similar
Applications.
Application - Pharmaceutical Sanitary Drain
Lines, CA

42. • Transport of
Fermentation Waste in
Pharmaceutical
Environment
• 6” Cast Epoxy Pipe &
Fittings
Application –
Fermentation Waste - Illinois

43. • Chilled and hot water lines for heating
and air conditioning system.
• Approximately 22,600 feet of Filament
Wound Epoxy Pipe, plus fittings.
• Light weight of the piping made it
easier to handle and minimized the
structural load on the building.
• Assembly of on-site prefabrications
allowed faster installation.
• Insulation thickness reduced
• Pipe is corrosion resistant to
condensate return
Application –
Chilled and Hot Water Piping, WI

44. • Three 800 Ton Chillers
• Steel Pipe Required Cleaning Of
The Strainers Every Three Days,
And Excessive Rust Flakes Were
Caught In The Condenser
Tubes.
• Steel Pipe Replaced With
Filament Wound Epoxy Pipe
• Strainers & Decks cleaned 3-4
times per year
Application –
Hospital Chilled Water System, IA

45. • Up to 36” FRP pipe
• 2000+ total feet of pipe
• 200+oF Air Supply to Aerobic Digesters
Aeration Piping, St. Joseph's MO

46. • Approximately 9,000 feet of
Centricast® RB epoxy cast pipe
and related fittings,
– 6” and 8” diameters
• Much of this pipe is suspended
from high trestles.
– The piping’s light weight, robust
design, easy installation, and superior
support spacing were key factors
• Don’t underestimate the value
from ease & speed of assembly &
improved safety when working
with light loads
Application - Siphon piping of municipal waste sludge to
multiple large clarifiers, Cleveland, OH

47. • FRP is Versatile: NSF Water & CIP Acids
• Odor control vent piping and Clean-In-Place (CIP)
piping.
• NSF approved, backwash water for membrane
water treatment equipment.
• Sodium hypochlorite, citric acid, and sulfuric acid
in pH ranges of 2-12, 150°F, and up to 150 psi
service conditions.
• Over 570’ of filament wound epoxy and vinyl
ester pipe,
• Over 349 plain-end and flanged-end vinyl ester
and epoxy fittings
• And over 425 prefabrication shop joints
completed at Frontier Plastic Fabricators
Application - CIP Piping for Membrane Water
Treatment – Waxahachie, TX

48. • Waste sludge for incineration
• 21,000 feet of 8” Ø Filament Wound
pipe and fittings designed to provide a
350 psi pressure rating
• ¾” trap rock as a base and cover
material. A 31,500 lb. earth load test
was conducted with no evidence of
interior damage and minimal
deflection validating the design.
• Installation of 400 to 600 feet per day
using manual labor and a single front-
end loader. Try doing that with Steel?
Application - Waste Sludge Force Main, Hartford, CT
FRP can “take abuse from the outside” too!

49. • Domestic Wastewater—Primary Clarifier Effluent pH: 6 to 9
• Peak flow per Trough: 1,865 gpm, Temperature: 0°C to 40°C
• Over 600’ of filament wound vinyl ester pipe, pre-fabricated with
precision mounted rectangular flanged drain boxes
Application - Primary Clarifier Effluent Drain
Piping, Dallas, TX
Another Example of FRP Versatility

50. Any Final Questions??
Comments?
Requests for Something New?

51. Cortrol Process Systems, Inc.
4518 West 56th St.
Tulsa, OK 74157
Phone 800-652-6789
www.cortrol.com
Thank You!