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 2600 mm through the filament winding technology

1.2.line for the continuous production of pipes with diameters from 300 to 600 mm through the filament winding technology

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 12 m

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                                    1250 mm

width of machinery (framework area)               5000 mm

width of machinery (in other areas)                  2000 mm

height of upper platform                                 2000 mm

width of raw materials (distribution area)           2500 mm     liner  400

mechanical resist. layer                                  1200 mm

distance liner-mech.layer                                900 mm

 

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 2400 mm, testing pressure 20 bar.

 

 

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 1400 mm, high precision load cell capacity 50 kN with applied force accuracy 0.5% according to ASTM E4, EN 10002-2, DIN 51221, BS 1610

                                                                                                                                                                                                                                                                                                                                                                                     

SPLIT DISK TESTING EQUIPMENT

SPLIT DISK machine for the execution of burst test on GRP pipes ND from DN 300 to 1400 mm, with applied force accuracy 1% in Range of Full Scale to 2.5% of Full Scale, exceeding requirements of ASTM E4, EN 10002-2, DIN 51221, BS 1610. Machine capacity: 40 ton.

 

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. 1000°C.

n.1 oven, temperature range from 5°C to 300°C.

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

General Assistance

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.

Running Assistance

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.

Training on Site

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

 

 

 

 

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