PIPES INDUSTRIAL CONSULTANCY
PIC Know-How
PIC’s New Developed Design and Manufacturing Processes

PIC has made different developments in GRP piping / coupling joint designs and processes for continuous and centrifugal cast manufacturing processes. The new pipe design and process is now available to authorized users for continuous filament winding process on the Internet. The user (based on his location and current raw material unit cost) can now get the optimized raw material quantities (BOM) for each pipe class (Diameter “DN”, Pressure Rating “PN”, Stiffness Class “SN or STIS”, and Pipe Series “Liner Type, Production Length per Rotation) for the subject GRP project during the quotation stage based on the new developed design and process. Once the order is obtained, the user can get the detailed manufacturing process for any of the subject project pipe classes.


Any non-standard size, pressure class and stiffness class can be requested and sent to the authorized user.
The new optimized design and process is available for different machine types, different unit production rates per rotation and for different types and thicknesses of pipe liners.
The pipe diameter range from 300 to 4000 mm, pressure class up to 32 bar and standards stiffness classes are covered. Any combination of standard or non-standard classes can be provided.

Two additional services can also be provided. The 1st is a prerequisite to use the new process and the 2nd is an optional or required depending on the manufacturer level of knowledge and expertise of his production engineers and crews. These are:

  1. Modifying Raw Material Application Zone of the machine to ensure the new design raw material consumption and projected product properties are obtainable
  2. Training of the manufacturing facility production staff on different subjects, including:                                                                                                                                                                                                      
    1. Understanding the basis of the new design and process
    2. How to Control / adjust the Product Thickness to be "+/- 0.1" mm at early stages of production run

 

Continuous Filament Winding “CFW” Process and Pipe Performance Improvements

  

IDENTIFYING & VERIFYING "FIVE" AREAS OF

(FP 2.1) CONTINUOUS FILAMENT WINDING (CFW) PROCESS IMPROVEMENTS

THAT HAVE POSITIVE COST & PERFORMANCE IMPACTS

AND

DEVELOPING A NEW OPTIMIZED CFW PIPE LAYERS DESIGN & PROCESS

WITH THE NEEDED WINDER MODIFICATIONS

 

ABSTRACT

This report summarizing the results of detailed research and testing programs done on Glass Fiber Reinforced Plastic (GRP or FRP) Pipes manufactured using Continuous Filament Winding (CFW) Process in continuation of previous work done on Centrifugal Cast (CC) Process development. In both cases, the main target was to obtain perfect raw material distribution (Chop and Hoop Glass) for each pipe type layer to improve pipe properties.

The results of the R & D program in CFW Process can be summarized as follows:

  • Identify and verify the current deficiencies in both chop and hoop glass distribution in pipe layers in all known main manufacturers or knowFhow process suppliers worldwide regardless of the comparison between any of the currently used processes
  • Provide solution for each deficiency
  • Provide more accurate tool for predicting mechanical properties
  • Identify the needed relatively simple machine modifications to better control the distribution and matching the resulting pipe properties with the predicted properties
  • Optimize the pipe design (pipe layers individual thicknesses) while keeping the same required level of safety factors
  • Develop the needed software to generate full series of pipe diameter, pressure and stiffness class (DN / PN / SN) combinations based on the required liner thickness and its curing method
  • Reflecting the effect of plant location current material price range variations on the choice of the most optimum pipe layers combinations
  • Making the final optimum design and process available to authorized users on the internet
  • Possibility to develop the full range for any combination of nonFstandard requirements for liner thickness, pressure and/or stiffness class

The results of the above developments and tools are:

  1. Reduced total raw material cost to obtain required PN/SN combinations
  2. Improved raw material wet-out product quality and production efficiencies
  3. Faster control of pipe thickness to a tighter design / nominal range
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