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1.1 Equipment Description:
The product and process is strictly according to the advanced standard and using digital control system. The Final product is for different medium of different kind of GRP pipes
1.2 Process Description:
1.2.1 Lining Making:
Firstly paste the de-molding agent on the mandrels and then wrap film (PET or PP) on it. thereafter, the first plies of fiberglass reinforcements are winded and retain a very high percentage of corrosion resistant resin by resin spraying device. This operation enables a fully impermeable wall to be obtained with a high resistance to chemicals.
1.2.2 Filament Winding with sanding:
The structural part of the pipe is made by the filament winding of continuous fiberglass roving impregnated with resin. The pitch of the winding spiral and, thereby, the angle formed between the rovings and the axis of the pipe are determined during the design work and depends on the stresses to be withstood. At the same time as filament winding is taking place. The silica sand is to be included in the pipe layer from bottom with terry line cloth.
1.2.3 External Curing
To prevent the resin from dropping, the curing operation is carried out while the pipe is rotating in its own axis. Curing of FRP pipe is made by special infrared heating device.
1.2.4 Pipe Trimming
Before de-molding, FRP pipe is placed on the rectifying machine for rectification of the ends and for machining of the grooves for O-ring and lock joints, where required.
The pipe is extracted from the mandrel; this operation takes place in a special working station controlled by a hydraulic system which allows to automatically carrying out the different working phases.
1.2.6 Hydrostatic Testing
Manufacturing of the pipes is subjected to constant checking. The checks are carried out on the raw materials, at each production phase and, lastly, on the finished product. The mechanical strength of finished products is tested periodically on lengths of pipe chosen at random from standard products. The test consists in reproducing the conditions which the pipes will have to undergo during working and also, in a dimensional check. The inspected pipe, if accepted, is indelibly marked with indications relevant to manufacturer lot, manufacturing date, diameter, pressure class and then is sent to the factory stockyard waiting for shipping.
1.2.7 Design Data:
Winding angle 45-90 degree,
Control mode Manual / Semi automatic / Automatic
Precision of lining up filament ±1 mm
Filament feed speed 85m/min max.
Winding type cross and hoop direction
Resin type Unsaturated polyester
Filament Creel Tension adjustable
Digitalized display precision: 0.01mm,
Sand adding thickens 15mm/layer max.,
1.2.8 Finished products Specification:
Effective Length 12 meters
Output 84 km /year of Dia.600mm pipe (6 bar and SN=5000)
1.2.9 Raw Material Resin
Isopthalic resin Viscosity=3.5~4 poises
Reactivity = medium
Good chemical inertness coupled to high mechanical strength in the laminate
Urthopthalic resin Viscosity=4~5 poises
Reactivity = medium to high
Good mechanical strength in the laminate, suit for transport any kind of water
Vinyl ester Resin Be suitable for hot high corrosive product to be handled and conveyed.
BOPET or BOPP film 10~30um thickness, 50mm width, for fist lining layer liner
Helpful for demoulding process
E Glass tape Veil type, for lining layer
200mm width, 30~35 gsm
E Glass CSM tape Mat type, for second layer of liner
200mm width, 375~450gsm
E Glass direct roving 2400 tex or 4800 tex
Auxiliary Raw Material
Accelerator solution of cobalt naphtenate in styrene
Inhibitor 10% solution of ter-tutyl-catechol in styrene
Silica sand provide stiffness for pipe and save production cost
Material Supply System 1 person / per shift
Lining Machine 2 persons / per shift
Filament Winding System 3 person / per shift
Curing System (External Curing) 1 persons / per shift
De-molding System 2 persons / per shift
Pipe Trimming System 2 persons / per shift
Hydrostatic Testing Machine 3 persons / per shift
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