Tapping Machine Report

CHAPTER 1 INTRODUCTION Tapping is convenient for fitting a branch pipe or a valve to an already existing pipeline where it is not practical to use a standard GRP nozzle or tee fitting. This tapping tapping procedure is founded on extensive research and development work. Stainless steel material is selected as the material for the tapping sleeves to get a service life similar to that of the GRP pipe system. Not all types of tapping sleeves are suitable for this service.

This tapping procedure applies for all properly installed standard GRP pipes Carrying water or water based fluids. The tapping sleeve shall be placed in an area with low local axial pipe stresses. • Hot tapping: Installation of a nozzle or branch pipe on an existing pressurized fluid filled GRP pipeline using a steel sleeve. • Cold tapping: Installation of a nozzle or branch pipe on an existing empty and No pressurized GRP pipeline using a steel sleeve.

For hot tapping, the sleeve is mounted on the pressurized pipe. A valve and a tapping machine containing the cutter are mounted on the sleeve. The valve is opened and a hole drilled. The cutting device is then retracted, the valve closed and the tapping equipment is removed leaving the sleeve and the closed valve. A branch pipe can then be fitted on the valve and the valve opened.

For cold tapping, a branch pipe hole is drilled in a non-pressurized pipe. The tapping sleeve is then mounted around the pipe with the branch aligned with the hole. A branch pipe or valve can then be fitted to the tapping sleeve.

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CHAPTER 2 LITERATURE SURVEY

 Lewis Barton, et al., 2016 have studied the “Mechanical behavior of adhesively bonded polyethylene tapping tees”.  Avinash Parashar, et al., 2013 have experimented “Failure mechanism in adhesively bonded FRP pipe sections with different fibre architecture.  Keith Escoe, et al., 2006 have developed “Chapter Seven – Hot Tapping (Pressure Tapping) and Freezing”.  Keith H. Baratz, et al., 2006 have studied “Vitreous Tapping for Positive Pressure”.  Keith Escoe, et al., 2006 have experimented “Chapter Six – Piping Maintenance and Repairs”.  Mallick, P.K, et al., 1990 have studied “Composite Materials Technology: Processes and Properties”.  Koch C, et al., 2008 have developed “Nanostructured materials: processing, properties and applications”.

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CHAPTER 3 PROBLEM IDENTIFICATION 3.1 PROBLEM STATEMENT  Fiber reinforced plastics (FRP) are a composite consisting of at least two different materials.  The fibres are usually glass, carbon, aramid, or basalt. Rarely, other fibres such as paper or wood or asbestos have been used. The polymer is usually an epoxy, vinyl

ester or polyester thermosetting

plastic,

and

phenol

formaldehyde resins are still in use.  There are only few methods available for making holes like tapping, gas flame cutting, etc… in FRP pipes. Among them taping process is more efficient. Advantages of using Tapping process are: 1. Material can be easily removed. 2. Cost effective. 3. Versatile process. 4. Accurate shapes can be made.

3.2 PROJECT OBJECTIVE The principle objective of the project is  To design a FRP pipe tapping machine.  To model and animate the tapping machine using Solid works®.  To fabricate the tapping machine with accordance to design standards.  To test the working condition of the tapping machine. 3.3 METHODOLOGY

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The methodology for the proposed project is shown in Figure 3.1.

Figure 3.1 Methodolgy CHAPTER 4

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DESIGN CALCULATION 4.1 TORQUE CALCULATION  Power of motor = 0.25 HP = 186.425 Watts  P = 2 π N T / 60 = 2 *3.14 * 1440 * T / 60 T = 186.425 *60 / 9043.2 = 1.24 Nm 4.2 DESIGN OF COLUMN π2 E I Load =

L3

For mild Steel, E = 200 GPa For Circular cross section, π d4 I= 64 Column Diameter: d4 =

64 P L2 E π3 64 * 1000 * 5003

=

200 * 103 * π3

d = 33.701 mm Nearest Standard value is 35 mm

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4.3 DESIGN OF SPRING Force Stiffness = Spring Displacement 300 `

= 100 * 10

-3

= 3000 N/mm

Inner Diameter of spring = 35 mm Length of spring

= 200 mm G d4

No. of Coils, N =

8 K D3 77.2 * 109 (4 * 10-3)4

=

8 * 3000 * (35 * 10-3)3

= 19.21 turns = 20 turns (approx.)

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CHAPTER 5 3D MODELLING 5.1 PARTS MODEL

Figure 5.1 Base

Figure 5.2 Column

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Figure 5.3 0.25 HP Motor

Figure 5.4 Spring

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Figure 5.5 Hole Saw Cutter

Figure 5.6 FRP Pipe

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Figure 5.7 Sliding Part

Figure 5.8 Handle

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5.2 ASSEMBLED VIEW OF THE MACHINE

Figure 5.9 Isometric View

Figure 5.10 Front View

Figure 5.11 Side View

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CHAPTER 6 FABRICATION OF MACHINE 6.1 OPERATIONS DONE:  Welding  Gas cutting  Drilling  Grinding  Turning 6.1.1 WELDING Welding using a welding kit (Figure 6.1) is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the work pieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. In our project, we used welding for the joining of the various parts and components.

Figure 6.1 Welding Kit 6.1.2 GAS CUTTING

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The gas cutting used is oxy-acetylene gas cutting/welding. In oxy-acetylene welding/cutting, however, the gases are what make the flame itself. Acetylene gas is quite flammable, and combined with oxygen, which by itself does not burn but speeds up the oxidation or burning of any other fuel, makes one of the hottest possible gas flames (5600-6300° F), suitable for the rapid welding, cutting or heating of most ferrous and non-ferrous materials. Although all compressed gasses pose some shop hazards because of the pressure inside the bottles, oxygen and acetylene are considerably more dangerous to work around, and require much more caution and close attention to safety rules. The Gas cutting apparatus (Figure 6.2) is used for cutting of MS pipes to the desired shapes which we require and joined them to our design.

Figure 6.2 Gas Cutting Apparatus 6.1.3 DRILLING

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Drilling (Figure 6.3) is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed against the work piece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the work piece, cutting off chips from the hole as it is drilled. We used this process inn our fabrication to attach the motor to the sliding part and column to the base.

Figure 6.3 Drilling

6.1.4 GRINDING:

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Grinding is a material removal process accomplished by abrasive particles that are contained in a bonded grinding wheel rotating at very high surface speeds. The grinding wheel (Figure 6.4) is usually disk-shaped, and is precisely balanced for high rotational speeds. We used this process to grind the burrs that are produced during gas cutting.

Figure 6.4 Grinding Wheel

6.1.5 TURNING

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Turning (Figure 6.5) is a machining process in which a cutting tool, typically a non-rotary tool bit, describes a helical toolpath by moving more or less linearly while the workpiece rotates. The tool's axes of movement may be literally a straight line, or they may be along some set of curves or angles, but they are essentially linear It is used to reduce the diameter of the work piece. In turning the work piece is first fitted in the chuck and the tool is settled at right angle to the face of the work piece and turning operation is done. Turning operation was used to fabricate the handle used in the assembled machine.

Figure 6.5 Turning

6.2 PARTS USED

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Figure 6.6 Mild Steel Plate

Figure 6.7 G.I. Pipe

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Figure 6.8 H.S.S. Hole Saw Cutter

Figure 6.9 Spring

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Figure 6.10 Chuck with key

Figure 6.11 Three Phase 0.25HP Motor

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CHAPTER 7 TESTING OF MACHINE 7.1 CONSTRUCTION The construction of the machine is simple as it requires only small and less components. The framework made of MS pipe plays the principle and primary element of the machine. The spring is used for the return of the machine after the hole has been made. Thus, all the components are attached to the framework with means of welding and clamping, thus by this way our fabrication is carried out. 7.2 WORKING Our working is also a simple process. The three phase supply is given to the motor with proper ground connection. The FRP (Fibre Reinforced Plastic) Tube is clamped in the base of the machine using G Clamps. The hole saw cutter is placed in the chuck and tightened using the key and the supply is switched on. The Hole is made on the FRP pipe by pressing the handle by using human hand force and the return is brought by the help of the spring. Thus a hole is produced. The size of the hole can be varied by changing the diameter of the hole saw cutter.

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7.3 FABRICATED FRP TAPPING MACHINE

Figure 7.1 Assembled Front View of FRP Tapping Machine

Figure 7.2 Assembled Side View of FRP Tapping Machine

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7.4 ADVANTAGES  Design flexibility  Faster production  Labour savings  Small Dimensional tolerances can be achieved  Good Surface finish  Lower material wastage  Low capital investment  Material can be removed in a single pass  Versatile process  Time saving

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7.5 APPLICATIONS FRP pipes are of major interest for various offshore and onshore applications as it promises higher performance than ordinary PVC and Steel pipes, and cost savings over traditional methods. Some of the major applications of the FRP tapping include:  Fitting of Pressure Gauge  Making Branch Connections(Like T-joints)  Line stops  Bypassing of pipelines

Figure 7.3 Pressure gauge fit

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Figure 7.4 Making Branch Connections (Like T-joints)

Figure 7.5 Line stops

Figure 7.6 Bypass

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CHAPTER 8 COST ANALYSIS The cost estimation for the proposed project is shown in the table 8.1

Sl. No

Purchase of Material

Quantity

Amount {Rs.}

1.

Motor (0.25HP Three phase)

1

1500.00

2.

Column (G.I. Pipe)

2

200.00

3.

Chuck with key

1

150.00

4.

Hole saw cutter (H.S.S.)

2

200.00

6.

Base plate (Mild Steel)

1

300.00

7.

Plate for fixing motor (Mild Steel)

1

300.00

8.

Bolt and nuts

4

10.00

Total Amount Table 8.1 Cost analysis

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2660.00

CHAPTER 9 CONCLUSION

The main fabrication of the proposed machine was to reduce the work of the labor involved and to minimize the time required for making hole in a FRP pipe. We have faced many difficulties while fabrication of the machine. We also worked heavily on machining the parts so as to sustain the weight of the motor and clamping it to the plate. We also inculcated the knowledge of basic mechanical components and we understood the teamwork effort.The proposed machine can be used for making bypass in pipelines and also can be used for fitting of accessories like pressure gauges and line stops. We are very proud to show off that we have successfully completed our project with full commitment and enthusiastic energy. We are also happy to show our invention to and for the goodwill of our country.

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REFERENCES  Lewis Barton, Martin Birkett, “Mechanical behavior of adhesively bonded polyethylene tapping tees”, International Journal of Adhesion and Adhesives, Volume 66, April 2016, Pages 1–8.  Avinash Parashar, Pierre Mertiny, “Failure mechanism in adhesively bonded FRP pipe sections with different fibre architecture”, Composites Part B: Engineering, Volume 47, April 2013, Pages 102–106.  A. Keith Escoe, “Chapter Seven – Hot Tapping (Pressure Tapping) and Freezing”, Piping and Pipelines Assessment Guide, 2006, Pages 414 – 448.  Mallick, P.K. and Newman, S., “Composite Materials Technology: Processes and Properties”, Hansen Publisher, Munish, 1990.  Koch C, “Nanostructured materials: processing, properties and applications’, William Andrew Publication, 2008.  John C. Halpin, “Primer on Composite Materials Analysis” Techomic Publishing Co., 1984.  Brent Strong. A, “Fundamentals of Composites Manufacturing: Materials, Methods, and Applications”, Society of Manufacturing Engineers, 2008.  Jack R. Vinson and R. L. Sierakowski, “The Behavior of Structures Composed of Composite Materials”, Kluwer, 2008.  Derek Hull,”An Introduction to Composite Materials’’, 1981.

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