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.

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.

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

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

Figure 3.1 Methodolgy

CHAPTER 4

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

L3

For mild Steel, E = 200 GPa

For Circular cross section,
d4
I=
64
Column Diameter:
d4 =

64 P L2
E 3
64 * 1000 * 5003

200 * 103 * 3

d = 33.701 mm
Nearest Standard value is 35 mm

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.)

CHAPTER 5
3D MODELLING
5.1 PARTS MODEL

Figure 5.1 Base

Figure 5.2 Column

Figure 5.3 0.25 HP Motor

Figure 5.4 Spring

Figure 5.5 Hole Saw Cutter

Figure 5.6 FRP Pipe

Figure 5.7 Sliding Part

Figure 5.8 Handle

10

5.2 ASSEMBLED VIEW OF THE MACHINE

Figure 5.9 Isometric View

Figure 5.10 Front View

Figure 5.11 Side View

11

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:

14

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

15

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

16

Figure 6.6 Mild Steel Plate

Figure 6.7 G.I. Pipe

17

Figure 6.8 H.S.S. Hole Saw Cutter

Figure 6.9 Spring

18

Figure 6.10 Chuck with key

Figure 6.11 Three Phase 0.25HP Motor

19

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

21

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

23

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)

1500.00

2.

Column (G.I. Pipe)

200.00

3.

Chuck with key

150.00

4.

Hole saw cutter (H.S.S.)

200.00

6.

Base plate (Mild Steel)

300.00

7.

Plate for fixing motor (Mild Steel)

300.00

8.

Bolt and nuts

10.00

Total Amount
Table 8.1 Cost analysis

25

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 18.
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 102106.
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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