GLASS REINFORCED PLASTIC
PIPES
CONTINUOUS
MANUFACTURING LINE
Technical
report
Index
1 GENERAL
ON CONTINUOUS GLASS REINFORCED POLYESTER PIPE PRODUCTION
2 G.R.P.
PRODUCT CHARACTERISTICS
2.1 GRP
Pipes Wall Description
2.2 End
Couplings
2.3 Fittings
2.4 Advantages
in G.R.P. Application
2.5 Inspection
and testing
3 RAW
MATERIALS
3.1 Resins
3.2 Glass
Reinforcements
3.3 Auxiliary
Raw Materials
4 FACTORY
DESCRIPTION
4.1 Production
Capacity
4.2 Factory
Layout And Installations
4.2.1 Total Extension
4.2.2
4.2.3 Sand Store and Feeding System
4.2.4 "E" And "C" Glass Fiber Distribution System
4.2.5 Resin feeding and mixing system
4.2.6 Utilities and Ancillary Installations
4.2.7 Electric Installations
4.2.8 Service Buildings
4.2.9 Open Spaces
5 PIPE
MANUFACTURING PROCESS DESCRIPTION
5.1 Continuous
Pipe Technological Process Description
5.2 Manufacturing
production rate (mt/hr.)
6 PRODUCTION
EQUIPMENT
6.1 Continuous
F.W. Machine
6.1.1 Mandrel
6.1.2 Resin dosing station.
6.1.3 Polymerization Oven
6.1.4 Process Parameters Control Device
6.1.5 Computer Control of F.W. Machine
6.1.6 Gauging, chamfering and cutting device
6.1.7 Dust and Styrene suction system
6.1.8 Pipe lifting and supporting planes
6.1.9 Pipe antitorque supporting equipment
6.2 Sleeve Coupling Manufacturing Machine
6.3 GRP
pipe sleeve joint joining equipment
6.4 Maintenance
7 PERSONNEL
REQUIREMENT
7.1 General
7.2 Process
Equipment Personnel
7.3 Fitting
Manufacturing, Prefabrication, Testing and Handling
7.4 Total
Manpower
8 TRAINING
OF LOCAL PERSONNEL
8.1 Location
Of Courses
8.2 Personnel
To Be Trained And Course Duration
8.3 Preliminary
Design
8.4 Know
How And Engineering
8.4.1 Basic Design
9 TECHNICAL
SERVICES AND PLANT COMMISSIONING
9.1 Plant
Erection Supervision
9.2 Start
Up, Commissioning and Training
9.3 Acceptance
Test Procedure
9.3.1 Purpose
9.3.2 Content and method
9.4 General
Assistance
9.5 Running
Assistance
9.6 Training
on Site
10 EXCLUSIONS
FROM THE SUPPLY
11 ACTIVITIES
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 :
-
Continuous line for the continuous production of pipes with
diameters from 300 to 2600
The project covers the
installation of the production facilities relevant to the manufacture of pipes
with diameters ranging from 300 up to
The G.R.P. pipe wall consists of three
layers perfectly adherent with one another, each having different
characteristics and properties in relation to their function. The properties of
chemical resistance and impermeability are, anyway, equivalent for the three
layers which are namely:
§
liner:
It is in direct contact with the conveyed
fluid and guarantees the maximum resistance to the chemical attack from the
fluid itself. Moreover, the liner presents an internal surface particularly
smooth, without defects, cracks or delaminated zones. The liner is composed of
one glass veil and one glass mat tape resin impregnated and is produced in two steps
(inner liner and outer one)
§
filament or mechanical
resistant layer:
Its function is to render the pipe wall
resistant to the stresses due to the design conditions (stresses due to the
internal and/or external pressure, flexural strength due to the external loads
etc.) and generated by transport and laying operations. The thickness of the
filament depend, then, upon the design conditions. The mechanical layer is
composed of winded glass filament roving chopped glass, sand aggregate, glass
mat reinforcement, all polyester resin impregnated.
§
gel coat or external
layer:
It has a thickness of about
The pipe coupling is made by a GRP sleeve
with continuous elastomeric gaskets with double or triple lips.
A wide range of fittings and special pieces
can be manufactured in G.R.P. They present, therefore, the same
characteristics, both chemical and mechanical, of the pipes. Fittings are
manufactured manually employing male moulds or pipes pieces to be joined
together. Ends of fittings can be bell and spigot type provided with sealing
gaskets or plain type to be joined by welding to adjacent pipes or other
fittings. The normal production of the new factory includes:
-
90° or 45° bends (by
moulds)
-
concentric and eccentric
reducers (by moulds)
-
fixed flanges and stub end
(by moulds)
-
blind flanges (by moulds)
Moreover, other special pieces such as
manholes, flanged pipes equal and reduced tees etc. can be manufactured by
welding together fittings and/or pipes sections.
Glass reinforced plastic pipes represent
the ideal solution for the adduction of any kind of water, chemicals, effluent
and sewers, because they combine the advantage of corrosion resistance, typical
of plastics, with a mechanical strength which can be compared with the steel
one. Typical properties that result in advantages in G.R.P. pipes application
can be summarized as follows:
-
Low weight of pipes
lengths that allows for the use of light laying and transport means.
-
Possibility of nesting of
different diameters of pipe thus allowing additional saving in transport
operations.
-
Length of sections larger
than other materials ones.
-
Easy installation
procedures due to the kind of mechanical bell and spigot joint.
-
Corrosion resistance, both
of the external wall in contact with the conveyed fluid. No protections such as
coating, painting or cathodic are then necessary.
-
Smoothness of the internal
wall that minimizes the head losses and avoids the formation of deposits.
-
High mechanical resistance
due to the glass reinforcement.
-
Absolute impermeability of
pipes and joints both from external to internal and vice-versa.
-
Very long life of the material
virtually infinite, which does not need maintaining.
-
Workability of the
material in site employing simple equipment.
Before starting up production a check is
made on the quality and characteristics of the resins relatively to the
temperature and relative humidity in the production shops.
Optimum values of viscosity and temperature
to be applied to the resin are pre-established, and the percentage of catalyst
to be employed in the production phase is determined.
Controls in the production shops:
-
control of lay-up (unit
weight per square meter of resin and glass, type of resin and type of
reinforcement)
-
internal quality control
-
check on the type of glass
reinforcement used
-
dimensional control of the
positioning of the accessories according to technical specifications
-
check on thickness
-
Check on
post-polymerization treatment (on continuous pipes). Continuous pipes
manufactured are put into an oven having forced circulation of hot air and
undergo heat treatment there. The purpose of this treatment is to complete the
cross-linking of the resinous matrix. The degree of polymerization is directly
related to the percentage of residual styrene monomer, which is established by
laboratory analysis.
-
Chemical tests: The
quantity of styrol in the solution is deduced by comparing its peak with the
peak of precisely known quantity toluene. A maximum of naught point two percent
of free monomer is accepted (naught point five percent is permissible by law).
-
Checking the weights: As
it is withdrawn from the post-polymerization oven the product is weighed to
ascertain the difference between the real weight and the weight foreseen in the
theoretical construction sheets.
-
Checking the Barcol
hardness: Measurement of the hardness gives an indication of the degree of
polymerization. This test is carried out on fifty percent of the products made.
The raw materials employed for the
manufacturing of pipes are mainly polyester resins and glass reinforcements in
the form of veils, chopped strands, woven roving and continuous filaments.
The polyester resins belong to the group of
alkyd resins and present themselves in the form of colorless or slightly amber
viscous liquids. In the commercially available state, the resin composition is
represented by long linear chain, obtained by esterification of dicarboxyl
acids with glycols and then dissolved in one or more saturated liquids
monomers. One of the basic characteristics of polyester resin, is the presence
of unsaturated bonds arising from the use of maleic anydride or other
unsaturated components during the esterification. During pipes or tanks
manufacturing, the resin hardens due to the polymerization reactions between
the unsaturated radicals contained in the polyester chain. The resin then becomes
a cross linked structure and assumes all the characteristics of thermosetting
products such as, for example, the condensate of phenol, melamine or urea with
formaldehyde. Polymerization reactions and hardening of resins, is promoted by
special catalyst systems which are able to act even without the presence of
high temperatures or pressure. The pipes and tanks production is in fact
carried out at ambient temperature and atmospheric pressure. The mentioned
cross linked bond can be represented by the following scheme:
A.B.A.B.A.B.A.B.
. .
C C
. .
A.B.A.B.A.B.A.B.
.
C
.
A.B.A.B.A.B.A.B.
where:
A represents a polyoxydryl alcohol .
B represents an unsaturated acid
C represents an unsaturated product such as
styrol
By varying the nature of the components of
the resin (that is, by using glycols of different types and acids with a higher
or lower weight) it is possible to obtain resins having different mechanical,
thermal or chemical properties. The most employed resin in pipes manufacturing
are the following:
·
Polyester resins based on
bisphenol or bisphenol A in a solution of styrol monomer.
Viscosity = 3.5 - 4 poises.
Reactivity = medium.
This type of resin provides good chemical
inertness coupled to high mechanical strength in the laminate.
·
Polyester resins based on
isopthalic acid in a solution of styrol monomer.
Viscosity = 4 - 5 poises.
reactivity = medium to high.
This kind of resin assures good mechanical
strength to the laminate and is the best solution, both under the point of view
of economics, reliability and resistance for manufacturing goods to be used to
transport any kind of water.
·
Vinylester resins in a
solution of styrol monomer.
This resin is employed when hot high
corrosive products have to be handled and conveyed.
All the employed resins are, in any case,
thermosetting type that means that the shape of the products, assumed after the
polymerization, is not affected by heating and then high stability at
temperature is assured. The same or different resins, if compatible, can be
employed to manufacture the various layers of pipes.
Glass fibers are produced in the form of
continuous filament, as per the following briefly described process. Various
components are mixed together in order to obtain a basic compound characterized
by a definite composition. The compound is then sent to a furnace, where is
melted at high temperature so as to produce glass. The molten glass is then
drawn into precision size controlled thin filaments. Filaments are successively
processed into roving, mat, yarn or cut strands that are the basic
reinforcements for the thermosetting resins. Glass necessary to produce pipes
are the following:
·
"C" glass tape.
It is in the form of veil with continuously
and uniformly distributed fibers over the whole surface and with a porosity and
stiffness such as to enable handling in the cutting and applying operations.
The veil is packed in rolls and presents
itself as a tape
The main characteristic of the veil is the
high chemical resistance and is, in fact, employed to manufacture the first
layer of the liner of pipes (inner liner).
·
"E" glass
chopped strand mat tapes.
It consists of chopped glass fibers not
woven. The chopped fibers are distributed without any preferential orientation
but in order to assure a regular specific weight to the tape.
The fibers are bonded together with a
polyester base binder. The mat tapes packed in rolls, present a width of
·
"E" glass
filament roving.
It consists of strand of continuous glass
filament roving supplied in rolls. More parallel strands are employed to
manufacture the mechanical resistant layer of pipes. Density or size of roving
is defined in grams per kilometer of single filament (
Filaments are sized with a special sylan
finish that imparts a taping effect to improve the efficiency in winding
operations.
·
"E" glass woven
roving tapes.
It is a tissue made of strands of
continuous filament roving oriented in the two main directions.
They are treated with binders in order to
impart excellent adaptability to the shape of the moulds without any wrinkling,
empty spaces or irregular dripping of the resin to be applied.
The woven roving tapes are employed to
manufacture the mechanical resistant layers of hand made fittings.
The auxiliary raw materials are necessary,
in limited quantities, to promote or inhibit the polymerization reactions in
order to better control and select the working phases both for pipes.
Ultraviolet rays inhibitor agents are employed to increase the already great
resistance to weathering.
The main auxiliary raw materials are
namely:
·
Catalyst for polyester
resins: 50% solution of methyl ethyl ketone peroxide in dimethylphtalate.
·
Accelerator : solution of
cobalt naphtenate in styrene.
·
Inhibitor : 10% solution
of ter-butyl-catechol in styrene.
·
Thixotropic agent :
micronized silica gel.
·
Solution of paraffin in
styrene.
·
Polyvinyl alcohol.
·
U. V. rays inhibitor.
·
Silica sand
Range of producible pipes and factory
capacity, are sized in order to satisfy the local needs of potable water lines
and networks, irrigation and sewer systems.
The proposed factory
is sized for an average manufacturing capacity of 12000 ton/year of finished fiberglass
pipes with average diameters of 300 -
2600 mm, dia.
The factory should cover a rectangular
shape plane area of about
The manufacturing unit consists of steel or
reinforced concrete structure shed of rectangular shape plan and is divided
into a process area and service zones.
The shed of the process area is sustained
by two rows of columns providing
The floor is made of leveled concrete
The shed covers the following
installations:
-
Process area for pipes:
Process area for pipes
including bell coupling
One
overhead traveling crane (5 tons capacity)
Fittings manufacturing
area
-
Services areas:
Resin mixing room
Glass storage area
Warehouse (shelves, welding and drilling
machine, grinders and tools, spare parts).
Quality control laboratory
Dressing rooms, showers and toilets
Pressure test equipment for pipes
Sand storage silos should have at least 150
ton capacity. The sand is transferred to the filament winding machine sand
distributor by means of a screw feeder.
The fiberglass coils are assembled on steel
frames and the fiber threads are fed to the filament winding machine through
ring guides and tensioning device.
Resins are stored in suitable underground
tanks (120 ton capacity at least) and are conveyed to the daily feeding tank by
means of polyethylene pipes.
There, resins are added with Cobalt
Naphtenate and mixed by means of electric blade stirrers, driven by the control
panel of the continuous F.W. machine, with continuous electronic control of the
operation in respect of temperature and flow of various components.
By means of suitable dosing pumps, resin
are then pumped and conveyed to mixers where they are further added with
organic peroxide and then, by free-fall, used in the production process.
The manufacturing shed should be completed
with the following utilities and ancillary installations:
·
Fire fighting network,
hydrants and hose reel boxes.
·
Wall mounted powder or CO2
extinguishers.
·
Fire fighting diesel pump
(one unit).
·
Fire fighting electric
jockey pump (one unit).
·
Concrete raw water
reservoir.
·
Potable water network.
·
Raw water pump (one unit).
·
Raw water network.
·
Sewer network.
·
Shed venting systems.
·
Glass powder suction system.
·
Hydraulic test equipment
facilities.
·
Two frontal fork lift 3
ton capacity and one side fork lift 10 ton.
·
Fence and gates.
The positioning of the utilities equipment
is shown on drawing attached herein. Brief description of some utilities is
given here below:
·
concrete reservoir:
The concrete reservoir contains the water
necessary for the fire fighting system and raw water consumption. Water to the
reservoir is fed by means of a 2" pipe sectioned, at factory battery
limits, by locked open gate valve installed in pit.
The capacity of the reservoir is about
·
fire fighting system:
The fire fighting station is composed of
one diesel engine operated pump and an electric motor jockey one. The diesel engine
is provided with its own fuel daily tanks.
Foreseen head and flow rate of the diesel
engine pump are respectively
When pressure in the fire fighting network
reduces below 3 bar, the diesel pump automatically starts and will be stopped
by manual operations. Hydrants are distributed along the 8" fire fighting
ring, each provided with two hose connections.
The hoses are contained in boxes located
nearby the hydrants.
·
compressed air system:
Envisaged flow rate is 5,000 l/min. at 7
bar. Compressed air piping, inside the shed, is composed of 2" pipes rings
running on steel structures and provided with 1" shed crossing pipes,
installed inside the ducts and wall mounted connections.
·
potable water:
The potable water is fed by a 2" pipe,
sectioned at factory battery limit by a gate valve installed in pit and is
directly conveyed in the factory network.
Potable water feeds the office building
area, the toilets of the shed and the test and laboratory rooms.
The total electrical power installed is 400
KVA and considering a contemporaneity of 75% the required power is 300 KVA
about.
The main electric installations inside the
fence of the factory are then the following:
- General electric switch board and control
panels.
- Power sockets (
- lighting system inside and outside the
shed.
- earthing system.
The diesel generator is located under an
own steel shelter and is completed with its own daily tank. Lighting inside the
shell is realized by means of roof mounted mercury vapors lamps, 250 W each.
Every six meters of shed, two lamps are foreseen.
The following buildings are envisaged to be
installed inside the factory area:
- One prefabricated or masonry building
suitable for the accommodation of 10 employees and one manager. The building is
provided with office furniture and toilet.
- One prefabricated building for resin
drums depository (20 x
- Two block houses (2,5 x
Moreover, a cover for vehicles is foreseen
(40 x
Not covered spaces extend for about
The factory area is fenced and provided
with one main and two services gates.
The manufacturing process is based on the
filament winding technique and complies 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 process proceeds step by
step as follows:
The continuous production of GRP pipes
through the filament winding process, avails itself of a mandrel which surface
is made of a steel tape moving longitudinally with a speed depending on the
tape width.
The band is elycoidally wound on suitable
supporting bearing placed along the mandrel.
A defined number of pushers, driven by a
suitably shaped cam plate, moves the steel band longitudinally.
A special mylar release film, protecting
the surface of the mould and useful during extraction operations, is applied to
the mandrel. Then, a ply of chemical resistant "C" glass is laid up
the mandrel. This glass reinforcement, suitably impregnated with liquid resin,
will be the chemical-resistant inner liner of the pipe, being rich in resin
(90% resin, 10% glass) and having a predetermined thickness.
The final layer (external liner) will have
the same characteristics as first.
Two other layers are applied between the
first and the last ones:
a - an anti-diffusion barrier made of 70%
of resin and 30% of chopped glass (second liner)
b - a mechanical resistant layer which
thickness, composition and glass yarns disposal depend on the mechanical
characteristics required for the pipe
These internal layers consist of the
following raw materials:
- Resin
- Chopped glass yarns
- Continuous glass yarns (roving)
- Silica inserts, if needed.
The continuous roving, circumferentially
wound, assures the required circumferential resistance, while the function of
the chopped glass (chopped glass yarns 25-
The silica inert, when applied, increases
the stiffness characteristics and the pipe wall thickness, without exceeding
the quantity of glass foreseen.
The chopped roving is laid on the pipe
surface through the slit of a hopper placed upon the mandrel. The glass yarns
conveyed from the feeding units are then chopped using a suitable cutter. The
required quantity of chopped glass applied to the pipe wall will be achieved by
combining the cutter rotating speed (quantity of chopped glass produced) with
the mandrel surface translating speed (being finally the rotating speed of the
mandrel).
The continuous glass yarns, supplied by the
feeding units, are hoop-wound on the manufacturing pipe by driving the roving
through some tensioning devices, thread guides and distributing rack. The
required quantity of continuous roving can be obtained by defining the suitable
number and substance of yarns, while disposal of yarns in the different pipe
section layers can be suitably arranged by modifying the position of the yarns in
the thread guides and in the distribution rack.
The silica inert, if required, is applied
through the slit of a hopper placed upon the mandrel and is batted by modifying
the rotating speed of a knurled cylinder placed peripherally to the hopper.
The resin is supplied and applied to the
mandrel surface by means of two special feeders equipped with suitable gauged
holes. One of the feeders supplies the resin required for the manufacturing of
the chemical resistant inner liner and anti-diffusion barrier. The other has
the function of supplying the resin for the mechanical resistant layer and
external liner. The adoption of two feeders for the manufacturing of the
different layers allows using two resins for the same pipe bar.
The 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 batching pumps. The quantity of resin and
catalyst required, as for other raw materials, depends on the mandrel speed and
is defined through a suitable electronic batching system.
Polymerization of the resin (hardening of
the product) is carried out in an oven with 4 differentiated areas with radiant
heating units. For each area the heat to be supplied can be controlled so that
the assure the maintaining of the required values of jellification, isothermal
peak and post-polymerization in the oven.
The production line is equipped with
gauging and automatic cutting device.
The pipe cutting at the required length is
made by means of a diamond disc tool following the progress of the product.
After cutting, the pipe bar is
automatically moved away through three lifting tables
Whenever required, pipes manufactured are
subjected to an hydraulic pressure test: each pipe bar is filled with water and
then, by means of a suitable press, its internal pressure is increased up to
1.5 or 2 times more than the nominal pressure the pipe should withstand. The
press structure is able to withstand a max. axial thrust of 1000 ton.
Moreover, all pipes produced are subjected
to a careful quality control by means of systematic non-destructive tests as:
- Thickness measurement
- Barcol hardness measurement
- Visual examination
In addition to the above, some samples are
subjected to the following destructive tests:
- Parallel plate press test
- burst test
- Fire resistance test
- Axial tensile stress test
- Axial and circumferential bending test.
Both destructive and non destructive tests
are carried out according to ASTM (American Society for Testing and Materials)
standards.
The quality control on the final product is
preceded by a careful production process and raw materials control. For
example, with respect to resin, controls are made on viscosity, reactivity,
styrene content, elongation to rupture. With respect to silica inerts,
granulometry, humidity content, silica and iron content are checked. For glass,
controls are made on external aspect, humidity content, losses after calcining,
roving stiffness, resistance to grinding.
xxxxxxx
Production
on 3 shifts x 220 working days
xxxxxxxx
The manufacturing of continuous pipe is
carried out by a continuous mandrel. This is formed by winding a continuous
steel tape over an horizontal beam. The steel tape translates in the axial
direction while the mandrel is rotating. The steel tape returns at the end of
the beam and is driven into the mandrel inner empty section. It is then wound
onto the opposite end of mandrel again. In this way the steel tape forms a
smooth surface mandrel rotating with simultaneous advancing in the axial
direction.
The laminate is applied onto the moving
mandrel.
First a release film, e.g. polyester film,
is wound on the mandrel, followed by a surfacing mat. Filament winding,
together with chopped glass, sand aggregate and polyester resin are applied
simultaneously. Finally a new layer of surfacing mat is applied.
According to the process philosophy, the
layer applied next to the steel tape represents the chemical resistant inner
layer, while the material supplied next to the curing ovens is 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 curing oven, the pipe is
automatically cut to required length by a suitable sawing unit.
No moulds are required in the continuous
pipe production process but only a mandrel which diameter can be modified
according to requirements.
The main components of mandrel are:
- Steel tape
- Aluminum stripes
- Disc plate support
- Steel tape return device
- Main shaft (two sizes are supplied to
cover ND 300-600 and 700-2600)
- Steel tape tensioning device
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:
-
-
The polymerization oven is placed on line
with the advancing mandrel.
There are 9 longitudinal heating and
reflecting sections placed over 18000 angle arc.
Each segment can be shifted ………..
The oven is equipped with suction hood for
styrene emission and heat over flow system.
The control and supervision of production
cycle is made by computer connected to a PLC device controlling physical
variable as material parameters (flow, temperature, tensioning etc.) and heat
flow of oven and connected to a CNC device controlling the operation of
filament winding machine.
It is possible to control the production
process through the following parameters:
-
Gauging, chamfering and cutting operations
are automatically made without any personnel requirement, by means of a tool
holding trolley, placed out of polymerization oven, having the same
longitudinal advancement speed of the pipe.
Such trolley is able to …………
Powders coming from gauging, chamfering and
cutting operations are automatically sucked and conveyed to a particular device
providing, ………………..
After curing and when exiting from the
polymerization oven, the pipe is supported by three planes equipped with
free-wheels ensuring rotation and advancement of the pipe itself.
The second plane is equipped with a special
device rotating the pipe during cutting operation.
After cutting, the three planes
simultaneously translate along pipe direction, …………….
This equipment is of great importance for
the production of heavy weight FRP pipes (large diameters and high stiffness).
The system consists of a double twin wheels
acting as additional supporters of the pipe during its rotation and yelding a
positive torque balancing the negative momentum caused by the pipe rolling
friction.
The following materials are supplied:
- Rubber coated wheel …………..
The sleeve couplings are made by resin
impregnated E glass roving wound on a steel wheel mandrel over which a
elastomeric gasket with double or triple lips has been placed.
These wheel mandrels are made of two half
pairs: one half is assembled on a axle rotating by mean of motovariator and the
other half assembled on a piston axle of a pneumatic cylinder.
As soon as the axle of the piston is
backward it moves back half with mandrel and therefore the bell coupling can be
extracted.
The bell coupling machine has two
manufacturing positions to be operated at the same time and it is assembled as
follows:
·
two rotation axles
assembled ……………..
This machine allows the operators to join
the FRP plain end section to the sleeve joint bell coupling.
The machine is equipped by one shifting end
plate in order to operate for different FRP pipe section length and pipe
diameter; it can be applied for length ranging from 2 mt up to 16 mt and for
diameter ranging from
The equipment consists of the following
main mechanical parts:
-
Here below is reported a short description
of the machine:
After the system has been settled according
to the requested pipe length by shifting horizontally the shifting end table,
the pipe is supported by the two lifting tables and positioned by adjusting
vertically the pipe so as to move the centerline pipe to the end plates and
sleeve joint center point.
When the GRP pipe and the sleeve joint are
definitely positioned, the fixed end plate operates hydraulically in such a way
to develop the thrust requested by the sleeve joint bell coupling friction
during the joining stage.
Mechanical maintenance needed by the plant
shall depend on the effective working hours and on the pipe diameters produced.
Maintenance usually consists of: ……………
Staff and workers requirement for the G.R.P.
pipes factory is set here below.
Plant Management And General Services
Personnel
|
Qualification |
Required
number |
|
- Manager |
1 |
|
- Accounting |
1 |
|
- Secretariat |
1 |
|
- Storekeeper |
1 |
|
- Forwarder |
1 |
|
- Guard and drivers |
2 |
|
- Technical service |
1 |
|
Total |
8 |
|
Qualification |
Continuous
line (required
number for three shifts) |
|
- Foreman |
3 |
|
- F.W. operator |
9 |
|
- bell operator |
6 |
|
- Electricians and mechanics |
2 |
|
Total |
20 |
|
Qualification |
Continuous line (required number for
three shifts) |
|
- Foreman and leading operator |
1 |
|
- Laboratory operator – quality
control |
2 |
|
- Workers |
3 |
|
Total |
6 |
The personnel of the factory is then
composed as follows:
- manager 1
- superintendent 3
- clerks/ workers 30
Course of training in management, operation
and maintenance of the new factory, will be………..
Training courses will be held at Buyer’s
factory directly on equipment, ,
On the basis of the personnel requirements
for the factory correct operation and managing, it is considered ….
KNOW HOW,
ENGINEERING DESIGN AND DOCUMENTATION SUPPLIED
It includes a preliminary layout of 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.
This preliminary design will be
consolidated into a Technical Report, which will include also all data relevant
to production yields, as well as a detailed costs estimate.
Based on the above document, the supply of
the know-how and engineering shall consist of the following documents referred
to the plant as described in the Technical Report.
·
Design Of Civil Works
·
Mechanical Design
·
Electrical Design
·
Executive And Detailed
Design Work
·
Machines To Be Supplied –
Technical Description
·
Operating Handbook
·
Engineering Handbook
All the above documents, except the ones
for mass-produced equipment, will be supplied in English language.
We will supervise the works relevant to the
erection of the plant.
Start up and commissioning of the whole
plant will be provided by a team of experts as follows:
- 1 plant superintendent.
- 1 continuous filament winding machine
specialist.
The above team will also undertake training
of operating personnel at site in order to enable them to operate the machine
independently and in optimum way .
The purpose of the acceptance tests is to
prove completeness,.
The technicians of both parties shall carry
out in customer's country
Definition
of idle test run:
At first, each machine and equipment
supplied by us shall be tested.
Definition
of production run:
During the production run one (1) piece of
typical products, shall be manufactured by.
Test
time
Both parties shall complete the tests
within.
We will supply you with all standards,
specifications and shop drawings relevant to pipes of each class, diameter and
service pressure series.
Moreover our design office will be.
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.
We will assist the customer in training the
latter's specialists, in customer's plant, for a period.
Purchase of industrial area, urbanized and
leveled, with connection to power, telephone and water system, construction of
industrial buildings and offices are not included in the supply.
Moreover, the following general services
and utilities should be provided on site and should be at Customer's charge:
-
-
PROGRAM BAR CHART
0 APPROVAL
OF THE CONTRACT
1 CONSTRUCTION
OF PROCESS MACHINERY IN
2 DESIGN OF
THE PLANT
3 CONSTRUCTION
OF BUILDING AND UTILITY PLANT IN LICENSEE’S COUNTRY
4 TRANSPORTATION
OF PROCESS MACHINERY AND LOCALLY MANUFACTURED EQUIPMENT TO THE INSTALLATION
SITE
5 ASSEMBLY
6 TESTING
AND START-UP