GRP
PIPE PLANT
GLASS REINFORCED PLASTIC PIPES
PROJECT
PROPOSAL
CONTINUOUS MANUFACTURING LINE
AND RELATED KNOW – HOW
1. GENERAL
The present proposal covers the
implementation of a new factory for the manufacture of glass reinforced plastic
(G.R.P.) pipes through the establishment of
a:
1.1.line
for the continuous production of pipes with diameters from 300 to
1.2.line
for the continuous production of pipes with diameters from 300 to
1.3.laboratory
equipment
1.4.know
- how
2.
SCOPE OF SUPPLY
The supply includes
following equipment:
continuous filament winding machine equipped for pipe
production range from dn 300 up to dn
2600 and DN 300 UPTO 600
fully computer controlled,
based on the continuous filament winding process,
fully in compliance with
A.S.T.M. code D 2996 (Standard Specification for Filament Wound Reinforced
Thermosetting Resin Pipes) type 1, grade 2, class E,
and ASTM D3517, ASTM D3754,
ASTM 3262, BS 5480:1990, AWWA C950, AWWA Manual M45
The manufacturing of
continuous pipe is carried out through a
mandrel formed by winding a continuous steel band over an horizontal
beam provided with supporting disks sized according to the diameter of the pipe
required. The steel band moves in the axial way sliding over the ball bearings
inserted in beam grooves. At the end of
the mandrel, the steel band is guided by exit head into the mandrel inner tube,
which supports the exit head. On the
opposite end of the mandrel near the cam, the steel band is wound on the
mandrel again. In this way the steel band forms a smooth surface mandrel with
simultaneous advancing in the axial direction.
The glass fiber laminate is
applied onto the moving mandrel according to the following procedure.
Firstly a release film, e.g. polyester film, is wound
on the mandrel, followed by a surfacing mat, both of them supported by proper
winders. Glass roving together with chopped glass, sand aggregate, polyester
resin are applied simultaneously on the proper mandrel positions according to
design specifications. At the end, a layer of surfacing mat is applied.
According to the process
philosophy, the layer applied next to the steel tape provides the required
chemical resistance (inner layer), while the material supplied over the liner
layer represents the mechanical resistant outer layer. The laminate building-up
can thus easily be made in compliance with the appropriate design by
controlling the amount and position of various materials applied.
After the pipe curing in the
curing oven, the pipe is automatically cut
and calibrated to the required length
and diameter by a suitable
rectifying unit. The calibration of
pipes length lower than 12 mts (standard length for pipe bars) can be easily
made by moving the lifting tables which support the pipe closer to the
rectifying unit.
The main equipment includes:
-main
casing with supporting bearings and
drive gearbox unit for the shaft
-cam
plate
-shaft for ND 300 - 600
-shaft for ND 700 - 2600
-liner and structure
choppers
-sand
dosing system
-curing oven with lamps
-heavy
pipe support
-pipe
antitorque device
-rectifying
unit complete with cutter and grinder
-
lifting tables
-pipe
acceleration unit
-centralized computer
control system
-dust and vapor suction
system
-pipe weighing beams
-Aluminum beams
steel band
Resin
dosing station .
The
resin is supplied and applied to the mandrel surface by means of two special
feeders equipped with suitable gauged holes.
One
feeder is foreseen for liner layer and other for mechanical structure layer.
Such
feeders contain resin which is already mixed with catalyst in the due
proportion.
Mixing
operations are carried out in two different mixers, one for each feeder.
Resin
and catalyst are delivered separately to the mixers by means of double head
dosing pumps.
One
pump is foreseen for liner resin and catalyst delivery , the other is foreseen
for mechanical structure resin and catalyst delivery .
The
quantity of resin and catalyst required, depends on the mandrel speed and
technological process .
The
system includes:
- double head resin –catalyst pump for liner layer
- double head resin –catalyst pump for mechanical resistant layer
-
No.2 dynamic mixing devices equipped with stirrers controlled by electric
motors (one for liner and one for mechanical resistant layer)
-
n.2 resin feeders (one for liner and one for mechanical resistant layer)
-
complete piping ,valves , filters from dosing pumps up to the mixing devices
-
safety valves , damphers
-
non return valves
SLEEVE
MANUFACTURING AND GROOVING MACHINE:
covering diameters range from 300 to 2600 allowing the
internal machining of the sleeves in a suitable manner to house the sealing
gaskets. It is used for the cutting of the pipes for the use of the sleeve.
Moreover, the grooving is used in order to rectify the slot for the toroidal O’ Ring or Reka O’ Ring
Pipe sleeve
joining machine
allows
the operators to join the GRP plain end section and the sleeve joint. The
machine is equipped with one movable and one fixed frame. The movable frame is connected
with hydraulic cylinder, while the fixed frame is assembled on main support
beams. Depending on the pipe length, the fixed frame is moved and fixed by pins
in range from 6 up to
The
frames are designed to allow joining operations on GRP pipes from DN 300 up to
DN 2600
The
pipe and sleeve are placed between both frames. Through the movable frame, the
sleeve is forced on the pipe end. After assembling, the pipe is unloaded by
hydraulic supports .
LINE FOR THE PRODUCTION OF CONTINUOUS PIPES ND 300 - 600
The
main equipment includes:
main casing
with supporting bearings and drive gearbox unit for the shaft
cam plate
shaft
for ND 300-600
Aluminum beams
steel
band
liner
and structure choppers
sand dosing system with heating device
racks for roving
curing oven
with lamps
heavy pipe support
lifting tables
pipe acceleration unit
rectifying unit complete with cutter and grinder
centralized
computer control system
dust
and vapor suction system
pipe
weighing beams
Approximate overall dimensions of the machine:
height of mandrel axle
width of machinery (framework area)
width of machinery (in other areas)
height of upper platform
width of raw materials (distribution area)
mechanical resist. layer
distance liner-mech.layer
Resin dosing
station
The
resin is supplied and applied to the mandrel surface by means of two special
feeders equipped with suitable gauged holes. One feeder is foreseen for liner
layer and other for mechanical structure layer. Such feeders contain resin
which is already mixed with catalyst in the due proportion. Mixing operations
are carried out in two different mixers, one for each feeder. Resin and
catalyst are delivered separately to the mixers by means of double head dosing
pumps. One pump is foreseen for liner resin and catalyst delivery , the other
is foreseen for mechanical structure resin and catalyst delivery . The quantity
of resin and catalyst required, depends on the mandrel speed and technological
process .
The
system includes:
double head resin –catalyst pump for liner layer
double head resin –catalyst pump for mechanical resistant layer
No.2
dynamic mixing devices equipped with stirrers controlled by pneumatic motors
(one for liner and one for mechanical resistant layer)
n.4
loading cells for resin daily tanks (tanks excluded)
- n.2 resin feeders (one for liner
and one for mechanical resistant layer)
complete
piping ,valves , filters from dosing pumps up to the mixing devices
safety
valves , damphers
non
return valves
TESTING AND
LABORATORY EQUIPMENT
HYDROSTATIC TESTING MACHINE ON PIPES
Equipment for the hydrostatic
testing of GRP pipes with diameters up to 1400. The test is carried out on the pipe
bar before joining with the sleeve, according to BS 5480 standards, appendix K
and M. The machine has been designed to test pipes ND
HYDROSTATIC TESTING MACHINE ON COUPLINGS
Equipment for the hydrostatic testing of GRP sleeve
couplings with diameters up to 1400 that allows to test the single sleeves. The
test consists on checking the tightness within the ring and the tightness ring. The machine is
composed by one set of plugs for the test, two heads supporting the plugs, an
oil – pressure system for the closing of the plugs, a hydraulic unit and one
electrical board.
PIPE STIFFNESS TEST
PIPE STIFFNESS
TEST on
pipes up to ND
SPLIT DISK machine for the execution of
burst test on GRP pipes ND from DN 300 to
LABORATORY
EQUIPMENT consisting of:
n.1 multipoint measuring unit, 8 input channels with
software
n.1 balance 0.01 gr. precision
n.1 balance 0,1 mgr. precision
n.1 muffle furnace max.
n.1 oven, temperature range from
n.1
barcol impressor, 934 type
n.1
variable displacement pressure pump, P= 200 bar
n.1
pressure transducer
5. SERVICES
OPERATING
technological documentation :
The operating instructions on the GRP pipes production process developed by the
Supplier shall be provided by means of technical documentation concerning the
operation and maintenance of the machinery,
the design, the production, short
term testing for quality control. Regarding the fittings equipment, the supply
of fittings equipment is not provided for this range of DN.
The
technical documentation includes a preliminary layout of the plant based on its
working flow-sheets, as well as the complete list of machines and tools needed
for production and relevant to both process and facilities.
Based
on the above, the supply of the operating technological documentation shall
consist of the following documents referred to the plant:
Machinery
assembly drawings
Operating
and maintenance Handbook
Detailed
Description Of The Process
Starting
The Plant
Design
of pipe required for the test run
Drawings
and specifications on civil works and general services to be provided locally
Drawings
and specifications on raw materials storage and distribution system to be
provided locally
All
the above documents will be supplied in English language in two copies.
technical
Services And Plant Commissioning consisting of a
skilled supervision of the works relevant to the erection and start-up of the
plant. These services will be provided for a maximum period of 45 days by a team of experts as follows:
- 1
plant superintendent.
- 1
continuous filament winding machine specialists.
The
above team will also undertake training of operating personnel at site for a
maximum period of four weeks..
THE KNOW –
HOW AND TECHNOLOGICAL ASSISTANCE
KNOW – HOW
AND TECHNOLOGICAL DOCUMENTATION and license agreement: The know-how and technological
documentation include the design , production
testing, handling and installation of the product developed by the
supplier shall be provided together with a license covering the use of such
know – how .
Based
on the above document, the supply of the know-how and engineering shall consist
of the following documents that will be supplied in English language.
PIPE
ENGINEERING HANDBOOK
General
design and specification
Buried
pipe design
HDB
hydrostatic design bases and obtaining HDB
Pipe
engineering manual
PIPE
DESIGNS PROGRAM WITH SOFTWARE
PIPE
OPERATING HANDBOOK
Environment
Report
Sleeve
Coupling
Reinforced
– Overlay Joints and Repairs
Installation
of pipes
Buried
Pipe installation specification
Making
sleeve Joints
Making
Field – Weld Joints
Hydraulic
test on site
Making
of fittings
QUALITY
CONTROL AND TESTING HANDBOOK
Quality
control organization
Quality
control procedure
Testing
the resins
Testing
the Glass Reinforcements
Testing
the Auxiliary materials
Testing
the Laminates
GRP
pipes in contact with water intended for human consumption
ASTM
standards for workshop test like split disks, stiffness, burst
ASTM
standards for long term test like 2992,3563 and BS 5488 for creep test
BSI
standards
TECHNO
– COMMERCIAL HANDBOOK
Terminology
Raw
materials
Resins
Glass
Reinforcements
Auxiliary
raw materials
GRP
pipes
GRP
pipes: calculation report on buried pipe
GRP
pipes : submarine pipes
GENERAL AND RUNNING
ASSISTANCE AND TRAINING ON SITE
We will supply you with all
standards, specifications and shop drawings relevant to pipes of each class,
diameter and service pressure series
We will also supply you
with:
Advice on and assistance
in the latest practices in the pipe manufacturing field, with special emphasis
on the development of the products
Advising on the
manufacturing techniques and optimum use of the buyer’s machinery and equipment
Advising on the
appropriateness and opportunity of acquiring new equipment as well as on the
sourcing of the most suitable supplier thereof;
Advising on the
development and diversification of the Products and on their applications;
Advising in the
execution of short and long term testing on the Product, in the execution of
Hydrostatic Design Basis (HDB) according to ASTM standards, in the execution of
tests on the product according to API standards.
Advising on the
formulation and implementation of safety standards
Advising in the
formulation and implementation of environmental protection standards
Sourcing of raw
materials supply
Technical audit and
evaluation pf the Buyer ‘s plant and recommendations for improvement.
Moreover our design
office will be at your disposal for studies relevant to special applications,
as well as technical and organization problems relevant to the applications of
the above pipes.
SYSTEM
ENGINEERING
The seller shall supply all standards ,
specifications and shop drawings relevant to pipes of each class, diameter and
service pressure series.
Moreover, the seller’s design office will be at
disposal for studies related to special applications as well as technical and
organization problems due to the applications of the above pipes, fittings and
test.
With reference to the mechanical and hydraulic
design of piping, the seller will supply the following:
Layout of the pipeline
Stress analysis on single section of pipeline
Design specification on pipes (ND, NP, stiffness)
on specials (fittings) and on supports to foundations.
The rate for this performance will be 600 euro/day.
We shall place at your
disposal, for the length of time specified above, our experienced personnel as
needed for the running operations of the plant. Furthermore we will supply all
information relevant to any technological advancements of our Italian
operations, so that the plant could benefit of it.
A rate of 600 euro/day
according to Anima international rate, due to Seller’s employees (including
those of its subcontractor performing any work under the present agreement),
during any period of time while they are providing such services, in addition
to the traveling from and to the territory from their normal work bases.
We will assist the
customer in training with two specialists, in customer's plant, for a period of
four weeks. The rate for extending the activity of our specialists for more
then two weeks will be of 600 euro /day.
EQUIPMENT
TO BE SUPPLIED LOCALLY AT CLIENT’S CHARGE
-
Purchase of industrial area, urbanized and leveled, with connection to power,
telephone and water system,
-
construction of industrial buildings and offices
-
warehouse and maintenance equipment
(electric, electronic, mechanical)
-dust
suction equipments for cutting and rectifying units on continuous machines for accessories and sleeve cutting and chamfering
-
ventilation unit equipment for continuous machine accessories laminate
-
main resin storage, daily mixing and distribution system
The
following facilities should be provided on site and should be at customer’s
charge
- travel crane
- frontal fork lifts and side fork lift
fire
fighting network and hydrants
air
compressor and compressed air network
electric
transformer