Axial reinforcement device (ARD)

Bassam Al Soufi
Manufacturing Meeting 2012, Dresden, Germany
21 May 2012
Confidentiality

All the content in this presentation is proprietary and

strictly confidential. It must not in any form be shown,
copied, reproduced or distributed to outside parties
without written approval by Flowtite Technology AS.

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Pipe specifications

GRP Pipe

Biaxial Pipes Uniaxial Pipes

High chop Cross

Axial Tape
content ARD winding

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Operating principle

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Dry test

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Machine development

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Machine development

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Why to use Axial Reinforcement Device

• Cost Efficiency.
• Continuous supply of axial reinforcement.
• Structural Efficiency.
• Plant does not need to keep large stock of axial tape.

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Machine flexibility

• Axial roving length is from 160mm to 390mm.

• Roving text can be any thing from 600 to 4800 (tested up to 2400).

• Total number of axial roving that can be fed at a time is 5 roving ends.

• Rotor RPM can be between 300 rpm and 1500 rpm.

• Machine can deliver 7 kg/min of axial reinforcement (5 ends of 2400

hoop, 390mm axial fiber length, & 1500rpm).

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Wet run trials

450mm pipes

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Wet run for actual project

1100mm pipe for customer

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Biaxial pipes comparison

mid term testing:

• Comparison test for different methods of producing Axial pipes.

• Axial tape Vs. high chop Vs. ARD.

• Total of 6 trials are conducted and 4 pipes are produced for each trial.

• Pipe specifications was: DN 600, PN 10 bar, min. SN 2500.

• Different glass type, glass text and different fiber length was used.

• Total of 16 pipes (4 trials) was produced using ARD machine.

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Short term test

The following test scenario is proposed for the trials:

• Register stiffness & axial tensile for all trials.

• Burst test 3 samples 2 meter each from each trial.

• Establish a 1000 Hr. HDB line for All trials.

• Recording of pipe weeping.

• The target is to establish a starting point for comparing the properties

of ARD axial pipes to other axial pipes produced by different methods.

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 Basic axial tensile results from the 6 trials

S.N Trial number TEXT of axial Length of Avg axial Pipe stiffness 5%
roving axial roving tensile (Mpa) deflection (Pa)

01 200mm
ARD Trial-1 2012KSA17-1 1200 156.92 4136

02 200mm
ARD Trial-2 2012KSA17-2 2400 164.42 4419

03 200mm
ARD Trial-3 2012 KSA17-3 2400 157.75 4764

04 390mm
ARD Trial-4 2012 KSA17-4 2400 150.08 4414

05 200mm
AXIAL TAPE Trial-5 2012 KSA17-5 N/A 191.25 5463

06 N/A
HIGH CHOP Trial-6 2012KSA17-6 N/A 139.92 4331

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Future development plan

• Equipment development
• Link the machine to the winder speed
• Add one more screen in the HMI of the winder to control the ARD
• Install 5 roving alarms (detector) to increase chopper speed in case of
axial roving cut.
• Product development
• Make complete design of biaxial pipes using ARD machine for different
diameters
• Study possible limitations of the use of ARD machine if any
• Develop costing module for ARD pipes
• Develop long-term tests data

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Raw material saving

• cost of 1Kg of axial tape = $ 1.79

• cost of 1Kg of 2400 hoop roving = $ 0.99
• cost of 1KG of chop glass = $ 1.18
• saving in axial reinforcement (ARD Vs. Axial tape) = 44.7%
• saving in axial reinforcement (ARD Vs. high chop) = 16.1%
• average percentage of axial tape in axial above ground pipe is 18%.
• overall saving in the pipe cost is 8 – 10 % based on pipe diameter.

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Machine customers

• AFIL requested quotation for 3 ARD machines

• ATC made complete set of drawings for the ARD machine after
modification.
• Drawings and BOM sent to different suppliers for quotations.

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