Introduction:
Composite pipe wrapping enhances the structural integrity of High Density Polyethylene Pipes (HDPE). These are used for onshore applications. This process involves wrapping pipes with high-tensile, composite materials.
Solution:
Composite pipe wrapping is a new technology used to strengthen pipes through composite ‘tape’. A pipe is first wrapped, than additionally coated with a protective layer to protect the composite and keep it in place. This creates one of the most strongest and fortified HDPE pipes currently available in the market.
composite coating pusher
Key Features:
- Stronger than standard HDPE pipe or tube.
- Enhanced structural integrity of composite pipe.
- Non steel application.
- Suited for liquid, gas and slurries including corrosive products.
- The strength of composite with the ease of poly.
- Delivers 2-3x greater pressure performance in a lighter and stronger poly pipe.
- Safely works with operating pressures of 350, 550 and 750 psi, respectively.
- No-leak fused connections for a wide range of gas, liquids, and slurries including highly corrosive.
- protective layer can be environmentally friendly (HDPE) shredded recycled granules.
Benefits:
- This quality of pipes approaches the mechanical characteristics of steel pipe.
- Lower installation costs.
- Decreased operating costs.
- Significantly reduced carbon intensity.
How it Works:
- First, the pipes are cleaned and prepared to ensure the composite materials adhere properly. To achieve optimal coating results, a pipe is straightened if needed before the process. After that, the pipe is sanded to prepare it for the tape layers.
- Before tape can be applied, the pipe first needs to be cooled to a minimum temperature, in order to let it shrink. This cooling has a double edged purpose. The second one is that is makes the pipe suited for, and resistant to cold temperatures.
- Now, the pipe is ready for wrapping with the composite tape. This partially happens automated and partially manually. The operator applies the first bit of tape to assure adhesion, and cuts it at the end. The rest of the tape along the middle of the pipe is applied automated. This is done in layers, adjusted to the pressure class it needs to reach in the final product.
- After wrapping, the composite materials undergo a curing process, in which they are heated. This process combines the base pipe with the earlier applied tape. The full pipe is heated until it “grows” through the tape layers. As soon as the tape and the base pipe are combined the heating process is stopped and the pipe will be cooled.
- The final process is to protect the wrapped pipe with a protective layer. This is done in a continues process in which a pipe pusher pushes the pipes through a ring die in which the protective layer is applied. This is an extruder HDPE layer created by an extruder. At the end of the protective layer line the pipes are cut before they will be transported to the outbound.
- In the outbound the pipes will be cut to length and the ends of the pipes will be cut straight. The pipes will be bundled before they leave the plant
The Full Scope:
The HDPE wrapping plants houses all equipment to convert a standard HDPE (High density polyethylene) pipe to a strengthened composite pipe. In which the base pipe is cleaned, wrapped, heated and cooled to enhance the strengthening. And converted by a protective layer to protect the taped pipe and make it visually attractive.
All equipment in Plant:
- Tilting beam with stopper;
- Pipe indexing system (on 4 positions);
- IR Straigthening station;
- Rotation rollers (on 4 positions);
- Sanding System;
- Diabolo conveyor (on 4 positions);
- Chain conveyor (on 2 positions);
- Body tape applicator system;
- End tape applicator system;
- IR heating system;
- Pipe pusher;
- IR Pre heating system;
- Coating extruder system;
- Pipe cooling system;
- Sleeve cutter system;
- Pipe end removal system.
composite coating cutter
Optional:
An optional addition that integrates with the existing systems to provide comprehensive management and oversight, enhancing efficiency and productivity. Advantage for this is process times are shortened. Insight into process parameters, which when temperatures are of the utmost importance, is a good fit.
More information?
Do you want to optimize performance and reduce risk? Handling equipment is the solution for you! Send an email to sales@selmers.com or call +31 (0)251 211 999, or fill in a contact form via www.selmers.com/contact and we’ll get back to you.
