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FRP Pipe Manufacturing 玻璃钢管道制造
FRP Pipe Manufacturing玻璃钢管道制造
FRP Pipe Construction玻璃钢管道组成
Liner ( Corrosion Barrier)
内衬层（防腐层）Structure
结构层
Corrosion Barrier
FRP Pipe 玻璃钢管道
Liner (corrosion barrier) fabrication 内衬层（防腐层）制作
Un-reinforced layer of resin 树脂层Layer (s) of veil 表面毡层Layers of veil and chopped strand mat
表面毡和短切毡层Liner with additives (abrasion resistance)添加填料内衬（耐磨）Catalyst System固化系统
Liner (corrosion barrier) fabrication内衬层（防腐层）制作
Specific application: 特定应用Corrosion barrier requirements 防腐层要求
Veil (s) 表面毡层Mat (s) 短切毡层Thickness 厚度
Liner (corrosion barrier) fabrication内衬层（防腐层）制作
Specific requirements (abrasion resistance)特定要求（耐磨）
Additives (type, % concentration)填料（类型，百分比）Thickness 厚度Reinforcement 增强材料
Structure 结构层
Properties vary with each type of fabrication性能会随制作工艺而变
Hoop (strength, modulus)环向（强度，模量）Axial (strength, modulus)轴向（强度，模量）Thermal expansion coefficient 热膨胀系数UV degradation 耐紫外光性能
What are the most common methods of FRP pipe manufacturing?玻璃钢管道 常用的制作方法
Contact Molded 接触成型Centrifugal Casting 离心浇铸Filament Wound 缠绕Machine Wound ( Chop Hoop, 0/90, etc.) 机械缠绕
What are the most common methods of FRP pipe manufacturing?玻璃钢管道 常用的制作方法
Contact Molded 接触成型Centrifugal Casting 离心浇铸Filament Wound 纤维缠绕Machine Wound ( Chop Hoop, 0/90, etc.)机械缠绕
Contact Molding接触成型
Used for most applications 应用 广Many combinations: 积层多样化
All chopped strand mat 全部短切毡Alternate layers of : 交替积层
Mat and Woven Roving 毡和方格布Mat and Uni-Directional 毡和单向布Mat and Bi-Directional 毡和双向布Etc. 等等
Contact MoldedStructure接触成型结构chopped strand mat - woven roving
短切毡 方格布
What are the most common methods of FRP pipe manufacturing?玻璃钢管道 常用的制作方法
Contact Molded 接触成型Centrifugal Casting 离心浇铸Filament Wound 纤维缠绕Machine Wound ( Chop Hoop, 0/90, etc.)机械缠绕
Centrifugal Casting离心浇铸
Centrifugal casting is a process used to manufacture pipe by applying resinand reinforcement to the inside of a mold that is rotated and heated, subsequently polymerizing (curing) the resin system.离心浇铸工艺：树脂和增强材料预先在模具内填放好，通过模具的转动和加热来固化树脂。
Ref. AWWA-M45
Centrifugal Casting Process离心浇铸工艺
Pipe has an un-reinforced liner that can vary in thickness. 管道有一层厚度可以变化的纯树脂层。Fittings of these piping systems are typically compression molded 此类管道系统的管件是典型的压力成型。Joints are typically glued with cement compatible with the piping system 管道之间的接合是通过兼容的粘结剂来粘结。
Corrosion Barrier
Centrifugal Casting离心浇铸
Centrifugally CastingPipe has a predetermined number of layers that are inserted into a mold. 将预定的层数插入到磨具中It does not have a wind angle 没有缠绕角Corrosion barrier is typically a resin rich liner without reinforcement. 防腐层通常没有增强材料Pipe is used with compression molded fittings that do not have a corrosion barrier (liner)管道和没有防腐层压力成型管件一起使用
What are the most common methods of FRP pipe manufacturing?玻璃钢管道 常用的制作方法
Contact Molded 接触成型Centrifugal Casting 离心浇铸Filament Wound 缠绕成型Machine Wound ( Chop Hoop, 0/90, etc.) 机械缠绕
Filament Winding 缠绕成型
Filament winding is the process of impregnating glass fiber reinforcement with resin, then applying the wetted fibers onto a mandrel in a prescribed pattern.缠绕工艺：把预浸树脂的增强材料按一定的方式铺放到模芯上。
Ref. AWWA-M45
Filament Winding缠绕成型
The most common angle for filament wound pipe is 54.7 degrees measured from the axial direction.缠绕管道 常用的缠绕角是54.7度。This is the optimum angle because it provides an estimated 2:1 ratio of hoop : axial strength.
54.7度是 佳的缠绕角，因为这角度能提供大约的环向与轴向强度比为2:1。
Filament Winding缠绕成型
The higher the wind angle in a cylinder, the higher its hoop strength; however, this also creates a weaker axial strength. 缠绕角越大，环向强度就越大；然而这会降低轴向强度。Higher wind angle is not very desirable for pipe since the axial strength is very important for span calculations.大缠绕角对管道是不合适的，因为轴向强度对管道跨距计算是非常重要的。
Filament Wound Pipe缠绕管道
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What are the most common methods of FRP pipe manufacturing?玻璃钢管道 常用的制作方法
Contact Molded 接触成型Centrifugal Casting 离心浇铸Filament Wound 缠绕Machine Wound ( Chop Hoop, 0/90, etc.) 机械缠绕
Machine Wound 机械缠绕
All machine wound (other than helical winding)所有积层都是机械缠绕（除了螺旋缠绕）
Chop / Hoop0/90 0度/90度两个缠绕角度Continuous winding 连续缠绕
What are the most common methods of FRP fittings manufacturing?在玻璃钢配件制作中，什么工艺是 常用的？
Contact Molding 接触成型Compression Molding 压力成型
note: no corrosion barrier 注意：不是防腐层Filament Wound 缠绕Other wound techniques
(i.e. all woven roving) 其它缠绕工艺（全方格布缠绕）
Joints 接头
Butt and Strap 对接Glued Joints 胶接接头
Bell and Spigot, 承插式Coupling/pipe 管接式Taper / Taper 锥形式
Flange – Flange 法兰连接
Joints 接头
Butt and Strap 对接Glued Joints 胶接接头
Bell and Spigot, 承插式Coupling/pipe 管接式Taper / Taper 锥形式
Flange – Flange 法兰式
Butt and Strap Joint 对接接头
Prepared Surface
Butted Joint
Butt and Strap Joint 对接接头
4t L3"
putty corrosion barrier
t
End Cap 端面包覆
Ref. Dow Chemical Co.
一层特定的表面毡
图A 表面毡切平的管子堵头
图B 表面毡包覆管子堵头
边角弄圆
一层特定的表面毡
图C 边角弄成锥形并用表面毡包覆
特定的防腐层
表面毡
特定的表面毡
腻子
图D 胶衣包覆
胶衣层
来源：陶氏化学公司
Butt and Strap Joint 对接接头
Corrosion BarrierPutty
Offset
Butt and Strap Joint Offset 对接接头偏移
Joints 接头
Butt and Strap 对接Glued Joints 胶接接头
Bell and Spigot, 承插式Coupling/pipe 管接式Taper / Taper 锥形式
Flange – Flange 法兰式
Glued Joint胶接接头Bell and Spigot承插式
Adhesive Joint
Joints 接头
Butt and Strap 对接Glued Joints 胶接接头
Bell and Spigot, 承插式Coupling/pipe 藕联式Taper / Taper 锥形式
Flange – Flange 法兰式
Glued Joint胶接接头
Coupling
CementPipe
Glued Joint胶接接头( pipe not shaved)管道不切削
Coupling
CementPipe
Joints 接头
Butt and Strap 对接Glued Joints 胶接
Bell and Spigot, 承插式Coupling/pipe 管接式Taper / Taper 锥形式
Flange – Flange 法兰式
Glued Joint (Taper – Taper)胶接接头（锥形式）
Glued Joint胶接接头Taper – Taper 锥形式
Ref. AWWA M-45, Source: Smith Fiberglass Products Inc
Flange to Flange Joints Flange to Flange Joints 法兰式接头法兰式接头
Ribbed Elastomeric Gaskets 有棱橡胶垫圈
Ref. CT Gasket & Polymer Co.
Ribbed Elastomeric Gaskets有棱橡胶垫圈
Ref. CT Gasket & Polymer Co.
Flange to Flange Joints 法兰式接头
Never bolt up a full face flange to araised face flange unless: 除了以下条件，平面法兰不能与突面法兰直接用螺栓拧紧A full face situation has been developed平面情况已经变成
Using an annular ring spacer 使用环孔垫圈Using a metallic spacer to prevent flange bending 用金属垫片防止法兰弯曲Using a special spool 使用专用管段
Using an annular ring spacer使用环孔垫圈
平面垫圈
玻璃钢管道金属管道
金属法兰
托环
托环
Using a metallic spacer to prevent flange bending 使用金属垫圈防止法兰弯曲
环形垫圈
金属管道
衬塑金属垫圈
平面垫圈
玻璃钢管道
Using a special spool使用特殊管段
对接
支撑法兰
活套法兰连接突面
平面法兰连接平面法兰
Summary 总结Joints 接头
Butt and Strap joints are the most reliable in a FRP piping system 对接接头是玻璃钢管道系统中 可靠的连接方法Taper / Taper joint 锥形式接头Shaved fit pipe joints 切削管道接头Coupling joints that do not require interference fit are less reliable. 不需要过盈连接的管接式接头是不可靠的Flange – Flange joints require proper torque, proper gaskets and a full face condition. 法兰对接需要合适的扭矩、垫圈和平面条件
FRP Pipe 玻璃钢管道
Custom 客户定制管道Contact Molded 接触成型Filament Wound 缠绕Machine Wound 机械缠绕
Commodity (Standard piping systems) 商品化管道（标准的管道系统）
Centrifugal Casting 离心浇铸Filament Wound 缠绕Machine Wound 机械缠绕
What is the difference?Commodity vs. Custom商品化管道与客户定制管道有何区别？
Commodity Pipe 商品化管道
Commodity pipe is built to a pre-determined pressure. 通用管道的承受压力是预先决定的Pipe systems are built to fit multiple applications. 管道系统适合多种应用Design is typically based on HDT (Hydrostatic Design Basis) Design factor is 3 or 4. 设计是基于流体静力学设计基础，设计安全因素为3或4。
Commodity Pipe 商品化管道
Fittings do not necessarily offer the same corrosion barrier as the pipe. 配件不必具有管道的同等防腐功能Joints can be (bell and spigot or tapered) glued, or butt and strap (depending on the diameter). 接头连接方式多样，可以是胶接（承插式、锥形式）或对接（取决于直径大小）。
Custom Pipe 客户定制管道
Custom pipe is typically designed for the application. 客户定制管道是为特定应用设计的。Resin is specified for each job 树脂由应用要求来指定Corrosion barrier is designed for the application. 防腐层是为应用要求特定设计的Design factor is typically is specified by the customer. 设计安全因素是由客户指定的
Custom Pipe 客户定制管道
Most joints in custom pipe are butt and strap. 客户定制管道中的大多数接头是对接的Fittings are contact molded 管件是接触成型制作的Design factor (safety factor) specified by the user设计安全因素由客户指定
Summary 总结Many factors influence the success of FRP pipe applications 许多因素影响玻璃钢管道的成功应用
Resin compatibility 树脂相容性Corrosion barrier 防腐层Laminate composition 积层组成Pipe-Fitting-Joint systems 管道－管件－接头系统Strain behavior vs. application 应用中的应变行为
Summary (contd.) 总结
Understanding the difference in manufacturing methods. 知道制作方法的区别Proper Pipe specification (s) 正确的管道规范Minimum Standards (design criteria, safety factors, etc.) 低标准（设计标准，安全因素等）
Summary (contd.) 总结
Custom vs. Commodity, which is the right choice客户定制管道与商品化管道，那个是合适的选择Which is the proper joint system for the application那个连接方式是合适的
Summary (contd.)总结
Proper (shop and field) inspection 车间和现场合理的检查Qualified personnel (field assembly) 现场安装由专业人员操作Documentation (level of quality, material data, etc.) 必要的文件（质量水平，材料数据等）
Summary 总结
Ref. Future Pipe Ind.
Summary 总结
Ref. Future Pipe Ind.
Things to Remember 切记的事情
End capping of joints is a requirement for those joints where an inside overlay can not be applied.在内部搭接无法实现的场合，接头需要端面包覆。If no end capping is specified, the cut edges must be protected with a resin coat. 如果没有指定要端面包覆，那么切面必须用一层树脂保护。
Which pipe is right for the application ? 那种管道适合特定的应用？
Review the needs for your application评估应用要求Decide whether commodity pipe fits those needs. 判断商品化管道是否适合Is reliability a big factor? 大安全系数可靠吗？Custom pipe is more expensive but offers a higher degree of reliability 客户定制管道价格更加贵，但可靠性更高。
Which pipe is right for the application ?那种管道适合特定的应用？
Is strain corrosion important? 应变腐蚀重要吗？Resin corrosion guides are typically based on strain free data. 树脂防腐指导数据通常是基于没有应变的数据。Industry experience is based on 0.001 strain 工业经验是基于0.001的应变Commodity pipe is not designed with 0.001 strain for all applications 商品化管道不是为所有应用设计成0.001的应变
Right product for the right application按应用环境选择 合适的产品
Questions ???问题？？？
