Project Overview
When the existing Mild Steel (MS) piping system at Rahimafrooz Globatt Ltd. experienced severe corrosion failure due to continuous exposure to Sulfuric Acid (H₂SO₄), immediate action was required to prevent production disruption and further damage.
FiberXperts Enterprise received an urgent service request to design, manufacture, and install a corrosion-resistant FRP header pipe system. Our team successfully completed the fabrication, delivery, and installation within 24 hours, allowing the client to resume operations with minimal downtime.
Client Challenge
The existing MS piping network was exposed to a highly corrosive sulfuric acid environment, resulting in:
Severe internal corrosion of the MS header pipe
Increased risk of leakage and acid contamination
Potential production shutdown
Safety concerns for plant personnel
Urgent need for a corrosion-resistant replacement
The client required a fast and reliable solution capable of withstanding continuous H₂SO₄ exposure.
Emergency Response
Upon receiving the immediate service call, FiberXperts Enterprise mobilized its fabrication and installation team to execute the project on an emergency basis.
Scope of Work
Site assessment and dimensional verification
Design of corrosion-resistant FRP header pipe system
Manufacturing of FRP header pipe and associated components
Delivery to the client facility
On-site installation and commissioning
Quality inspection and testing
Technical Specifications
Parameter | Specification |
Application | Sulfuric Acid (H₂SO₄) Service |
Existing System | Mild Steel (MS) Piping |
Failure Cause | Acid-Induced Corrosion |
Replacement Material | Fiberglass Reinforced Plastic (FRP) |
Resin System | Vinyl Ester & Isophthalic Resin |
Fabrication Method | Hand Lay-Up / Industrial FRP Lamination |
Installation Time | Within 1 Day |
Warranty | 2 Years Service Warranty |
Project Team
The project was executed by a specialized rapid-response team consisting of:
1 Project Engineer
1 FRP Technician
2 Expert FRP Fabricators
Despite the emergency nature of the assignment, the team completed the entire scope efficiently while maintaining quality standards.
Why FRP Was Selected
FRP was chosen because it offers:
Excellent resistance to sulfuric acid
Long service life in corrosive environments
Lightweight construction
Reduced maintenance requirements
Lower lifecycle costs compared to MS systems
High structural integrity and reliability
The combination of Vinyl Ester Resin and Isophthalic Resin provided enhanced chemical resistance and long-term durability for the application.
Results Achieved
Immediate Benefits
Successful replacement of failed piping system
Production downtime minimized
Improved operational safety
Elimination of corrosion-related failure risks
Reliable acid handling capability restored
Long-Term Benefits
Superior corrosion resistance
Reduced maintenance costs
Extended service life
Increased process reliability
Backed by a 2-year service warranty
Project Outcome
FiberXperts Enterprise successfully manufactured, delivered, and installed a complete FRP header pipe solution for Rahimafrooz Globatt Ltd. within a single day following an emergency service request. The new FRP system now provides dependable sulfuric acid handling while protecting the client from the recurring corrosion issues associated with traditional MS piping.