The Continuous Filament Winding (CFW) technology is the ideal solution when Glass Reinforced Polyester (GRP) pipes are used for water transmission and distribution, desalination plants, cooling systems in power plants, irrigation projects, sewage etc.
CFW Technology Advantages
The CFW technology is intended for high production volumes. GRP pipes manufactured with CFW technology are used in most civil applications, whether gravity, pressure below ground or above ground.
The CFW process has the following advantages:
- High production capacity.
- Low raw materials consumption.
- Low fixed cost per end product.
- Low total production cost per end product.
- Wide range of diameters.
The Technobell CFW technology is distinguished by the following advantages:
- High production capacity
Very high pipe production speeds reaching 60 m/h, resulting in considerable reduction of pipe production cost and delivery times.
- Proven technology
Advanced know-how and optimized pipe design confirmed by long term testing according to international standards enable our clients to be competitive on the market.
- Built-in experience
The Technobell CFW technology is a result of years of experience in pipe production and pipelines installation. This experience is available to our clients also as a service provided by our specialists.
- Automated and reliable production process
Computer controlled CFW machine guarantees stable and high production quality and minimizes the human error factor.
- Diameter range from 300 up to 4000 mm
A wide range of diameters and a unique system for diameter change resulting in 40% operation time reduction for all diameters.
- Minimized waste during production
Improved raw materials distribution system guarantees high pipe quality and low waste.
- Low production cost
An important advantage, perhaps the most important from the investor’s point of view is a combination of all other advantages and is the end goal of our technology. Making the process reliable will result in less production failures, increasing the production capacity will decrease the manufacturing time, minimizing the waste will reduce the use of raw materials and having a wide production range will decrease the investment size. All this advantages put together will result as the ultimate advantage, i.e. production cost reduction on one side and profit increase on the other side.
CFW Production Lines
Technobell offers custom-made solutions for GRP pipes production from 300 mm to 4,000 mm:
CFW1200: 300 – 1200 mm pipes
TECHNICAL DATA
CFW1200 area and height required:
Width: 11 m
Length: 26 m
Height: 5 m (under bridge crane)
Utility requirements:
Max. power supply = 3 x 400 V / 50-60 Hz
Max. installed power CFW1200 = 150 kW
Max. compressed air consumption = 8 bar – 4 m3/min
CFW2600: 300 – 2600 mm pipes
TECHNICAL DATA
CFW2600 area and height required:
Width: 13 m
Length: 29 m
Height: 7 m (under bridge crane)
Utility requirements:
Max. power supply = 3 x 400 V / 50-60 Hz
Max. installed power CFW2600 = 190 kW
Max. compressed air consumption = 8 bar – 6 m3/min
CFW3000: 300 – 3000 mm pipes
TECHNICAL DATA
CFW3000 area and height required:
Width: 13 m
Length: 29 m
Height: 7.3 m (under bridge crane)
Utility requirements:
Max. power supply = 3 x 400 V / 50-60 Hz
Max. installed power CFW3000 = 190 kW
Max. compressed air consumption = 8 bar – 6 m3/min
CFW4000: 400 – 4000 mm pipes
TECHNICAL DATA
CFW4000 area and height required:
Width: 16 m
Length: 31 m
Height: 7.7 m (under bridge crane)
Utility requirements:
Max. power supply = 3 x 400 V / 50-60 Hz
Max. installed power CFW4000 = 260 kW
Max. compressed air consumption = 8 bar – 6 m3/min
CFW machine types
CFW process description
Process description
The main principle of continuous advancing mandrel process is to use glass fiber reinforcements in the circumferential direction of pipe. Hoop rovings provide strength to GRP pipe against circumferential and external loads. Chop rovings inside of pipe structure empower the strength against longitudinal loads and multi direction loads. Silica sand is used in the pipe core and enables the pipe to have a sandwich structure. In some special cases, vinylester and other resins can be used instead of polyester resins.
High level of automation
The CFW Machine is completely digitally controlled by an advanced PLC controller. All machine operations and the dosing system are controlled by computer. Remote connection can also be used for off-site support and troubleshooting thus allowing the client to save time and run the production smoothly 24/7.
Production line
All continuous filament winding pipe production operations are performed on the CFW Machine. The GRP pipe is produced continuously, cut at the required length, the spigot diameter is calibrated on-line and the pipe is immediately ready for testing and installation.
Technobell also designs and supplies various CFW Auxiliary Machines (Pipe Hydro-Testing Machine, Sleeve Grooving Machine, Off-line Rectification Machine, Sleeve Hydro-Testing Machine, Sleeve Joining Machine and Pipe Transport Trolley) and the Universal Testing Machine.
3D CFW production line video
General CFW production line layout
CFW machine
Raw material and spare parts storage area
Fitting production area
Pipe Hydro-Testing Machine (PHTM)
Sleeve Grooving Machine (SGM)
Off-line Rectification Machine (ORM)
Sleeve Hydro-Testing Machine (SHTM)
Sleeve Joining Machine (SJM)
Pipe Transport Trolley (PPT)
General layout of a CFW production line.
CFW auxiliary machines
The Universal Testing Machine (UTM) is used to test the tensile stress and compressive strength of materials. It can perform many standard tensile and compression tests on materials, components, and structures such as:
- axial tensile according to ASTM D 638,
- hoop tensile for DN >250 mm up to 2000 mm – split disc method according to ASTM 2290,
- hoop tensile for DN > 2000 mm up to 4000 mm – short strip method according to ISO 8521 method D,
- flexural strength according to ASTM D 790,
- compression according to ASTM D 695 and
- pipe stiffness according to ASTM D 2412.
Universal testing machine
GRP FITTINGS
Another advantage of the GRP pipe system offered by Technobell are customised fittings.
Technobell know-how and equipment enables the manufacturing of a full range of GRP fittings such as:
- elbows,
- tees,
- reducers (concentric, eccentric),
- flanges (fix, loose, blind),
- wyes,
- sleeve joints and
- others.
GRP pipe fittings cover many components that connect pipe ends for in-line, offset, multi-port, and mounting configurations.
Fitting cross sections are circular in shape to mate with the pipe sections they are connecting. They are used in pressurized applications and non-pressure applications such as drainage, waste, and vent systems.
Different types of GRP fittings
TYPICAL GRP JOINT TYPES
GRP pipes are joined with:
- GRP Sleeve,
- GRP Flanges,
- GRP Lamination – welding and
- others.
Different types of GRP joint types