Thursday, 24 November 2011

Start a GRP & FRP Pipes Manufacturing Unit



  

(228). Start a GRP & FRP Pipes Manufacturing Unit

Fiber Tech Grip Pipes are manufactured by widely used helical filament winding method. Grip Pipes manufactured by filament winding method utilise continuous glass strand roving impregnated with polyester resin and helically wound on rotating mandrel at a specified winding angle. The winding process is continuous in bi-directional layers until the desired wall thickness is achieved. Grip pipes manufactured by filament winding offers better physical properties in comparison with other method so Grip Pipes manufactured with helical filament winding method will have longer services life whthout affecting the cost of supply.


Features & Advantages of GRP Pipes, FRP Pipes

CORROSION RESISTANCE Fiber Tech GRP Pipes manufactured with composite material glass fibre and polyesterresin. GRP is an inert material providing excellent resistance to corrosion, high chemical resistance and high weathering resistance.

NON-TOXICITY the filament winding manufacturing technology togather with the process of polymerisation and vaporisation enables Fiber Tech GRP Pipes to be made in exact conformity to the laws in forces, governing the construction of pipe that will have to be in contact with potable water and food stuffs.

HYDRAULIC EFFICIENCY Fiber Tech GRP Pipes with very smooth internal surface provides high "c" value to carry high flow at a very low frictional head loss and offers better pumping cost & saves electricity.

LONGER SERVICES LIFE Hydraulic design basis (HDB) of Fiber Tech GRP Pipes is such that, even after continuous service of 50 years, it will be having safety factor of 1.8 times of its pressure class. Thus, Fiber Tech GRP Pipes will have longer service life, reliability and durability with much lower life cycle cost compare to C.I., STEEL, G.I. and P.S.C. Pipes.

SURGE PRESSURE High resistance to surge pressure Fiber Tech GRP Pipes provide higher resistance surge pressure with high stiffness offering very less chance of bursting of pipe due to water hammer compare to steel and C.I. Pipes.

LIGHT WEIGHT Fiber Tech GRP Pipes have lower strength to weight ratio while in comparing with other material. it is light in weigh by 1/10 of P.S.C. 1/5 of steel and 1/8 of C.I. Thus, Fiber Tech GRP Pipes provide easy and faster installation, handling, modification and repairs.

LOW THERMAL AND ELECTRICAL CONDUCTIVITY Fiber Tech GRP Pipes have excellent thermal insulating properties and there is no need for the pipes to be insulated externally to maintain the temperature inside the pipe. Even cathodic protection is also not required for GRP Pipes.

Potable Water & Raw Water Supply

Fiber Tech GRP Pipes Pipes are ideal for the transportation of potable & raw water supply Our GRP piping system is highly suitable against conventional materials like Ductile iron, Mild steel & Cement pipes because of its non toxicity & inert properties against presence of any turbidity, migration of chemical additives, absorption of UV rays, presence of heavy metal.


Effluent & Seweage Water Supply

Fiber Tech GRP Pipes are ideal for the transportation of corrosive disposal of effluents & sewerage. The smooth interior surface of GRP Pipes eases the flow of any kind of fluid. The corrosion resistance of pipe is also very much important in such applications. Light weight and long length, a high level of stiffness & simple installation are all important factor to choose Fiber Tech GRP Pipes in application like alum and ferric chloride.


Chemical & Fertilizer Plants

Fiber Tech GRP Pipes are manufactured using suitable polyester or vinyl ester thermosetting resin & fibre glass reinforcement. GRP is the construction materiel of choice for handling a wide variety of corrosive chemicals gases due to it´s resistance aggressive chemical media.

The chemical resistance together with high mechanical strength & excellent temperature resistance makes Fiber Tech GRP Piping system & ducting networks as most preferred product in many area of chemical industry.


Even at a large diameter its relative light weight makes installation easy and fast, resulting in cost saving in support construction and cost saving system installation Where complex engineering and pipe work is called, Fiber Tech prefabricated Pipe spools result in faster & cost saving system installation.

Fiber Tech GRP Piping can be installed for long term services basis in phosphoric & sulphuric acid plants for process, product and waterlines. Fiber Tech GRP Piping can be used for acid solution, alkali solutions, waste water treatment, salt solution, pollution control, raw water waste water, steam condensate, demineralized water gas lines, ducts, slurry line etc.


Desalinational Plants

Fiber Tech GRP Pipes are used to transfer highly corrosive sea water at high pressure & high temperature over long service periods. Fiber Tech GRP Pipes can be used for multistage flash evaporator, reverse osmosis plant, for steam condensate and rain water harvesting.


Offshore Oil Production

Fiber Tech GRP Pipes can be used for cooling water, product water, oil skimming, soil drain system, water purification, oil separation, fire fighting systems.


Refinery, Petrochemical & Petroleum Plant

Fiber Tech GRP Pipes can be used in power plants due to it´s high pressure & temperature resistance. Fiber Tech GRP Pipes is an ideal for hot water lines, condensate & thermal water lines conveying of fresh water, hot water, waste water, cooling water (raw brackish and sea water).


Power Plant

Fiber Tech GRP Pipes an assured solution for brine condensate & sea water, fire fighting system, waste water, systems As well as cross country pipe line in refinery & petroleum plant. Fiber Tech GRP Pipes are ideal for chlorine gas from electrolytic cell also.


Design and Engineering

Design and engineering of composite material involves specialized knowledge. Most engineers are very familiar with steel systems. Composites are more complex material requiring specialized technology and experience.

Fiber Tech offers advanced engineering technology to design GRP Pipes. Each Fiber Tech GRP Pipes are custom engineered by our in house team of engineers to take care of customer´s application, requirements and performance variables. Experienced experts monitor all aspects of design, engineering, manufacturing and quality control.

The process begins with our unique "design to technology" computer Analysis and modeling including critical variables like internal pressure, external ressure, specific gravity/density of fluid. This result in an efficient, safe and quality pipes, which precisely satisfies customer´s specifications.


Quality & Testing

With a clear focus on Quality Assurance System and with strict adherence to ASTM D 3517 (1986), ASTM D 2992 (1987), ASTM D 3681 (1994), ASTM D 3754, AWWA C 950 (1981), AWWA M-45, BS 5480 (1990), IS 12709 (1994) & IS 14402 (1996) design and testing codes, we are keen to produce the high quality GRP Pipes.

In addition to monitoring by the various authorities, all our product are subject to stringent controls during manufacturing. Apart from usual controls on raw materials and online quality check Fiber Tech GRP Pipes are tested at in house testing laboratory for longitudinal strength test, hoop tensile strength test, beam strength test, stiffness test, hydro test and Pipe soundness test.


Field Services

Fiber Tech GRP Pipes offer the advantage of easier on-site services and maintenance. Fiber Tech makes the most of this advantage by providing any time field services by dedicated team.

We are concern for the long term performance of GRP Pipe system, our highly trained customer oriented experts and technicians are able to provide right solution for easy and faster site installation.


Joint

GRP Pipe joints can be divided in two categories:


  1. Unrestrained joint, withstand hoop pressure only.
  2. Restrained joint, which can resists longitudinal force and hoop pressure.


Unrestrained Joints
coupling or socket & spigot gasket: Joint this joint is provided with grooves either on spigot or in the socket to retain an elastomeric gaskets for better water tightness.

Restrained Joints
  1. Butt & strap joint: These type of joints are permanent joints and widely used in all over the world for joining the GRP Pipeline. it consists of hardening of impregnated glass, chop standard mat, woven roving mat and tissues it is laminated according to specified thickness and width depend upon th design pressure class, thus offering the continuity in hoop and axial directions.
  2. Fixed flanged joint
  3. Stub end with steel loose flange

Auxiliary Raw Materials 
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

G.R.P. PRODUCT CHARACTERISTICS 
GRP Pipes Wall Description 
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: 
ƒ 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) 5
ƒ 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. 
ƒ gel coat or external layer: 
It has a thickness of about 0.2 mm and consist of pure resin without glass 
reinforcement. It guarantees the complete impregnation of the peripheral fibers, 
thus yielding the external pipe surface completely free of protruding fibers and well 
finished. The external coating is always added with ultraviolet rays inhibitor in order 
to prevent the nearly negligible weathering effects. 

2.2 End Couplings 
The pipe coupling is made by a GRP sleeve  with continuous elastomeric gaskets with 
double or triple lips. 

2.3 Fittings 
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.

GRP production technology
We are specialized in engineering, commerce and turnkey basis projects in the field of composite pipes and tanks. We offer feasibility studies, up to date design, construction, assistance to erection, start-up, training, running assistance, development of new composites products and know-how of GRP, GRE pipes and tanks production lines by the following processes:


GRP Pipe Production Factory - CFW LINE| Print |
Machines in the factory can be disposed according to the factory building or special client requirements. Layout drawing shows typical factory arrangement.factory2600 
Pos.    Description
1    Tools Cleaning Room
2    Resin Mixing Room
3    Dosing Pump Room
4    Bridge Crane – 10 tons
5    CFW2600 Machine
6    Resin Storage 4 x 50m3
7    Vapours Suction Ventilator
8    Dust Filter
9    Pipe Transport Equipment
10    OGM2600 Offline Grinding Machine
11    SGM2600 Sleeve Grooving Machine
12    SHTM2600 Sleeve Hydrotesting Machine
13    SJM2600 Sleeve Joining Machine
14    PHTM2600/640 Pipe Hydrotesting Machine
15    Laboratory
16    Air Compressor
17    Main Power Panel
18    Main Control Console
19    Diesel Electric Generator
20    Electro Station
21    Fittings Production Area
22    Pipe Testing Area
23    Catalyst Storage Area
24    Accelerator Storage Area
Factory covered area and height required:
  • Width = 36m
  • Length = 78m
  • Height = 7,5 (under crane hook)
Factory outside uncovered area required:
  • Area = 25000 m2
Utilities requirements:
  • Power  Supply = 3 x 400V / 50 Hz
  • Production Line Installed Power =App. 400 kW
  • Max. Compressed Air Consumption = 8 bar - 6 m3/min
  • Emergency Diesel Generator = 240 kW
The complete CFW production factory requires approximately 60 employees for the production in 3 shifts (24h per day). They are divided in the following positions:
  • 1 production manager
  • 4 machine captains on CFW machine
  • 16 machine operators on CFW machine
  • 4 machine operators on the SGM machine
  • 4 machine operators on the SHTM machine
  • 6 machine operators on the PHTM machine
  • 2 machine operators on the SJM machine
  • 1 quality control manager
  • 4 quality control operators
  • 4 mechanical and electrical maintenance workers
  • 4 store keepers
  • 10 workers in the fitting manufacturing shop
logotb
TECHNOBELL  LIMITED 
Talbot House,
204-226 Imperial Drive
HARROW
MIDDLESEX HA2 7HH
GREAT BRITAIN 
Tel.             +447900080990      
E-mail: technoadtechnobell-ltd.com 


1 comment:

  1. Nice information posted here. One can also get the details of steel fiber manufactures only at Precision Drawell.

    ReplyDelete