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Getting to know bonded fiberglass tcp pipe and machinery Production Technology -part 01

The landscape of TCP (Thermoplastic Composite Pipe) pipeline production is witnessing a significant transformation, particularly in addressing the limitations of pipe diameter sizes. Conventionally, mainstream production lines in the TCP market have been restricted to manufacturing pipes with a maximum diameter of DN 200. These constraints stem from challenges in continuous wrapping, technical conditions, and production efficiency.

However, Banline, in collaboration with its U.S. team, has made a breakthrough in TCP pipeline production technology. They have developed a new fiberglass tape wrapping machine capable of producing bonded fiberglass pipes with diameters up to DN 630. This innovative technology holds immense potential not just for the oil and gas industry but also for water supply systems.

Core Pipe Production in TCP Pipeline Production Technology

The core pipe's production is a critical phase in TCP pipeline production technology. It involves the selection of liner materials that are resistant to degradation from the fluid being transported. These materials must possess sufficient ductility to endure manufacturing stresses, storage, and deployment, including reeling or axial loads. Long-term resistance to joint and fitting loads without excessive creep, as well as strain tolerance during pressurization, are also vital.

EVOH (Ethylene Vinyl Alcohol Copolymer), known for its superior barrier performance against hydrocarbons, is a favored material for lining, especially in oil applications. This material surpasses HDPE (High-Density Polyethylene) and nylon 6 in barrier performance, making it an excellent choice for safe and durable fuel system components.

TCP pipeline production technology commonly employs thermoplastic materials like PE (Polyethylene), PE-X (Cross-Linked Polyethylene), PA-11 (Polyamide 11), and PVDF (Polyvinylidene Fluoride) for gaseous fuel transport. For hot water applications, multilayer co-extrusion technology is used to create a barrier layer with EVOH, addressing the issue of oxygen permeability in plastics like PE-X and PE-RT as temperatures rise.

Banline's TCP-Ultra production line exemplifies the advancements in TCP pipeline production technology. It leverages polymers such as PE, PA12, and PVDF, along with glass or carbon fibers for reinforcement. The integration of these materials ensures a strong, durable bond between the layers, crucial for the pipe's overall performance.

Design and Functionality of Planetary Tape-Wrapping Equipment

This specialized equipment is engineered for wrapping multiple layers of tape, such as Kevlar or glass, around plastic liners. These layers are essential in the production of Reinforced Thermoplastic Pipe (RTP) and Thermoplastic Composite Pipe (TCP).

A notable feature of these machines is their ability to apply multiple tapes simultaneously through heads that are often provided in pairs. These pairs rotate in opposite directions to counterbalance the rotational forces created during tape application. The machines can incorporate up to 16 RTP taping units, enabling the creation of numerous reinforcement layers. This technology finds extensive application in sectors such as oil and gas, as well as in the water and district heating industries.

Challenges Faced by Planetary Tape-Wrapping Equipment

A primary limitation of these machines lies in their capacity to handle fiberglass tape widths. Generally, they accommodate narrower tapes and smaller reels, typically in the range of 50mm to 60mm. This restriction is largely attributed to the challenges posed by larger and heavier tape rolls, which would introduce greater weight and inertia, demanding significant mechanical modifications for their management.

planetary wrapping machine gaps

Quality Control and Adjustment Techniques

The uniformity of tape spacing on the wrapped pipes serves as a preliminary indicator of the machine's performance. Deviations in spacing or overlaps in tape layers necessitate complex adjustments, involving detailed examination and calibration of each wrapping reel. Such irregularities may also manifest as uneven traces on the pipe's surface. To address these issues, two approaches are commonly employed: reducing the number of wrapping units, for instance, from four reels to two or less; and fine-tuning the angle and position of each wrapping unit. Although using multiple reel units poses greater challenges in achieving even tape distribution, ongoing experimentation has shown that with proper adjustments, this method remains a viable option.

Innovative co-axis wrapping machine in bonded fiberglass TCP wrapping machine by Banline

Addressing the constraints of traditional planetary-wrapping machines, Banline introduces a novel wrapping method for producing Thermoplastic Composite Pipe (TCP). Distinct from the multi-head, narrow tape application of planetary systems, Banline's equipment utilizes a singular, large roll of fiberglass tape. This unique approach brings forth several key benefits:

Streamlined Wrapping Process with Enhanced Uniformity

Banline's use of a single, large tape roll simplifies the wrapping procedure significantly. This method facilitates a smoother application of fiberglass tape around the pipe, effectively minimizing or eliminating gaps. Such uniformity is vital for the structural soundness of TCP, ensuring consistent quality in the final product.

Simplified Angle Adjustment for Precision

 In contrast to the intricate angle adjustments required in planetary-wrapping machines, Banline's system demands the calibration of just one angle. This streamlined process not only eases the operational complexity but also guarantees a more accurate and uniform tape application.

comparison between co-axis and planetary wrapping machine

Capability to Handle Wider Tape Widths

Unlike its planetary counterparts, Banline's machine can accommodate broader fiberglass tape widths. This feature not only boosts the efficiency of the wrapping process but also expands the range of pipe sizes and specifications that can be manufactured.

Designed for Large-Diameter Pipes

Tailored for large-diameter TCP production, Banline's co-axis wrapping machine expertly handles single-piece fiberglass tapes up to 360mm wide. This capacity is particularly important for creating larger pipes (DN 200 – DN 630), as it ensures even heating throughout the thermoplastic liner and reinforcement layers, a critical aspect in manufacturing larger pipes.

Surpassing Planetary Machine Limitations

Banline’s method effectively overcomes the shortcomings of planetary-wrapping machines by accommodating a wider range of fiberglass tape sizes (90mm – 360mm). Their co-axis technology provides fine control over wrapping angle and tape tension, ensuring thorough fusion bonding with the polyethylene pipe's inner and outer layers. This advancement markedly elevates the quality and efficiency of TCP manufacturing, especially for pipes with larger diameters.

comparison between co-axis and planetary wrapping machine

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