CORROSION PROOF FIBERPIPE PIPE SYSTEMS: SOLUTION EXAMPLES FOR THE CHEMICAL INDUSTRY
Fibreglass is on the rise in pipeline construction – especially in the chemical industry. As the material is not just corrosion proof but also resistant to heat and mechanical stress, its lightweight and advantageous processing characteristics enable fast assembly processes which also have cost benefits.
The pipes from the fibreglass pipe specialist Fiberpipe from Stolberg (Germany) are manufactured in association with worldwide partners and are fully compatible with existing systems thanks to their ISO dimensions. Customisations are also part of our core business.
The following examples show how fibreglass pipe systems and parts have established themselves in the chemical industry.
The company: Kali + Salz GmbH (K+S) is one of the top manufacturers of special and standard fertilisers, plant care and salt products and hires around 12,000 employees. K+S has used corrosion proof pipe systems made from epoxy resin for more than 25 years. Many of the areas of application known today were successfully implemented here for the very first time. The experience that Fibercast centrifugally cast pipes have been resistant to brine of up to 120°C for more than 20 years, is proved here everyday.
The task and its solution: in 2006, a new cover had to be implemented for a hot clarifier system for the “Werra” plant in Philippsthal which contained hot, highly concentrated salt brine at a temperature of 95°C for the sedimentation of undissolved parts. The specifications included a span width of around 6.7 metres and a loading capacity of 350 kg per m². In addition, an incline of around 2 º and a non-slip class R 12 surface had to be complied with.
As the service life of the previous constructions made from rubberised steel was unsatisfactorily short, Fiberpipe was commissioned with the planning as a specialist for corrosion-free parts. The expertise concerning which resins are resistant to the vapours was brought into the construction proposals by the company, which also considered the structural specifications, manholes and other removable assembly parts.
K+S decided on a construction from T-sections with a covering made from vinyl ester resin profile plates. Fiberpipe was responsible for executing the full order including the disassembly of the old covering. All of the work was fully completed within just three weeks.
The company: The Raffinerie Oberrhein refinery in Karlsruhe is Germany's largest refinery and one of the most modern and powerful in Europe. Every year, around 1,000 employees refine around 16 million tonnes of crude oil for high quality products such as petrol, diesel, fuel oil, propylene and bitumen.
The task and its solution: in 2006, the company planned to renovate the existing waste water pipelines. As the entire canalisations had to be corrosion proof, lockable and pressure resistant, Fiberpipe was their first contact partner. An optimum compromise had to be found between resistance, temperature resilience, pressure resistance and ease of assembly.
Together with the customer, Fiberpipe developed a customised pipe system. For the awarding of the contract, it was crucial that Fiberpipe did not just deliver material but also carried out the assembly. Fiberpipe performed all of the relevant engineering services for this contract. The solutions implemented by Fiberpipe present a wide range of DN 400 pipelines for water transport up to operational demands of up to 125°C and 16 bar pressure.
The company: the refinery in Ingolstadt, Bavaria, manufactures a wide range of high quality mineral oil products, whereby the complex processes are controlled and monitored using the latest digital process control. The company is particularly experienced with corrosion in pipelines.
The task and its solution: in 2006, the task was to develop a special pipe system for draining tank pits. The challenge was that the pipes had to be resistant to both normal waters and the stored products in order to be able to rule out damage to personnel and the environment in the case of emergency. Fiberpipe quickly included the resin suppliers in the development of the system band and was thus able to supply a reliable product with optimum characteristics for this special case. Convenient for the customer: preparation, delivery and assembly were carried out by a single source as a complete service through Fiberpipe.
The company: as a subsidiary of Celanese Corporation, Celanese Chemicals is a leading manufacturer of acetyl products and dispersions. The company headquartered in Dallas in the US state of Texas employs around 5,000 employees worldwide and achieved a turnover of around $ 4.3 billion in 2005. Celanese Chemicals operates production plants in North and Central America, South East Asia and Europe.
The task and its solution: as part of a complete plant reconstruction at the Oberhausen site, a DN 600 pipe was sought which was corrosion proof against vapours at 120°C. As the resistance of normal steels is not sufficient, Fiberpipe was chosen for its glassfibre pipes which met the demands.
The full detailed engineering was carried out by Fiberpipe – including a stress analysis, design of the mounting concept, preparation of drawings, acquisition of components, certifications and turnkey installation of the vapour pipelines. Due to precise planning, the assembly time and thus the duration of the plant downtime were able to be kept to an absolute minimum.
The company: as a multinational company in the sector of special chemicals, Degussa hires around 44,000 employees. At the Wesseling site, 1,500 members of staff work on an area of 330,000 m², the production is supported by a modern site service. The plant has been a regular Fiberpipe customer since 2004.
The task and its solution: Fiberpipe has carried out diverse projects since 2004. A crucial advantage for Degussa is that Fiberpipe can quickly and easily readapt its product range to changing needs. The quick availability of the required product quantities and qualities up to the DN 300 nominal size simplifies all project planning procedures.
The standard pipe system from Fiberpipe is designed according to ISO dimensions. In addition to the full compatibility of the various pipe systems, the advantage is the applicability of standard components as supports.
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The company: the Ingolstadt power plant of the E.ON-Kraftwerke GmbH is operated with heavy fuel oil. The blocks offer a capacity of 386 megawatts each and are above all used to cover the peak and average loads.
The task and its solution: short notice works are sometimes necessary in the power blocks from time to time. Flexibility, the ability to carry out the assembly works in compliance with the highest safety requirements and speed were crucial in the selection of the commissioned service provider. If unforeseen repairs are to be carried out in the flue gas desulphurisation, these must usually be carried out immediately and in the case of ongoing operation and if required with protective equipment. Here Fiberpipe provides a repair service with contractually agreed lead times of up to 24 hours. The standard pipe system from Fiberpipe is designed according to ISO dimensions. In addition to the full compatibility of the various pipe systems, the advantage is the applicability of standard components as supports. The fact that the light weight GRP pipes also allow a faster assembly and processing than standard pipe systems, also saves on time and therefore costs in all works. Fiberpipe also performs a similar service for the Großkraftwerk Mannheim AG.
The company: Lurgi AG headquartered in Frankfurt am Main is one of the leading companies in the area of plant construction and process engineering. In the context of the constant decrease of fossil raw materials, Lurgi is working on processes for obtaining fuels from biomass. In the near future, all plant components including wood and other remains should be able to be used in the latest biofuel plants.
The task and its solution: as a global player, Lurgi was not just looking for a system specialist for corrosion proof pipelines in 2006 – these also needed to be supplied worldwide. Due to its vast number of partners across the world, Fiberpipe corresponded to the required profile. Whether pipelines for fire extinguishing and cooling water or transport pipelines for acids and brine – Fiberpipe ensures that the products desired are not only available at short notice in Europe, but also in North and South America, Asia and Australia.