Thermoplastic Composite Pipe (TCP/RTP) Line System – DN630 TCP-Wave ™ line
The uniqueness and benefits of thermoplastic composite pipe (TCP) not only makes on oil gas operation and subsea infrastructure, but also water application. This section covers thermoplastic composite pipe machine line system process, and technologies behind Banline's bonded fiberglass TCP machine line（TCP-Wave™) , the uniqueness and advantages of bonded thermoplastic composite pipe (TCP - Ultra™ Line ) can be found in the previous article.
This article is applicable for diameter range from OD (outer diameter) 200 - OD 630 under operating pressures up to 3 MPa (30 bar) under continuous production. However it may be used for guidance in the development of larger diameter thermoplastic composite system with higher operating pressures. It is intended to accommodate the possibility of larger diameter TCP pipe and to provide a framework within which future development can take place.
The principal load-bearing components of the TCP is same as RTP, which are high-strength reinforcing members in the form of fiberglass tape, or fiberglass wire, which generally carry load only in tension. The reinforcing process take form of planetary-type wrapping, which is used by Goldstone Machinery , Kraussmaffei etc. and co-axis type wrapping such as Banline Machinery
Fiberglass thermoplastic composite pipe (TCP) liner extrusion
Thermoplastic composite pipe (TCP pipe) and bonded reinforced thermoplastic pipe (RTP pipe) machine line use single screw extruder which designed for top performance in continuous pipe extrusion and ideally suited for PE 100 + pipe, for water application, thermoplastic composite pipe outer diameter produced on the machinery can be between OD 200mm – 630mm.
The fiberglass reinforced TCP/RTP pipe liner fulfill its function of containing the transported fluid, the liner material shall have adequate resistance to degradation from all the components of the fluid. The reinforced pipe liner should also possess sufficient ductility to enable it to withstand the strains imposed upon it during fiberglass TCP/RTP machine line manufacture, storage, and deployment (which may involve reeling or axial loads). It should also be able to resist long-term loads imposed upon it by joints and fittings without excessive creep. Furthermore, it should be capable of withstanding the strains imposed during pressurization and, where appropriate, cyclic pressurization.
Thermoplastic Composite Pipe (TCP) Machine Line Bonding Process
The fiberglass tape wrapping process is quite similar with smaller diameter TCP/RTP pipe, and consist with tape applying machine. Banline TCP-WAVE™ using the newest glassfibre tape wrapping procedure, which is different from wrapping processs in the market such as Ridgeway, Goldstone Group etc. For this new wrapping procedure as we called Co-Axis fiberglass tape wrapping procedure. It means we designed entire glassfiber tape wrapping machine is able to fit OD 200mm – 315mm and OD 400 – 630. Fiberglass tape width contained as 360mm (max) .
fiberglass tape wrapped gaps after wrapping procedure is well solved from Banline TCP-Wave machinery because co-axis designed allowed one fiberglass wrapping machine wraps one fiberglass tape layer of 360mm width.
It is quite important that avoiding gaps or overlapping between each wrapped fiberglass tape because both gaps or overlapped fiberglass tape will impact the fiberglass bonding quality, and lead to inaccurate outer diameter (OD), in another hand, the shape of the fiberglass TCP pipe looks also strange if has defected wrapping procedure.
Thermoplastic composite pipe (TCP pipe) heating process is also redesigned by using fast heating & fast cooling procedure, the heating unit that can adjust heating temperature around the reinforcing pipe, which means Banline TCP-Wave™ line allowed clients to adjust the heating temperature at each side of the pipe for more sufficient heating performance. Banline TCP-Wave™ heating unit is able to heat up to 600 - 800℃ (1112 ℉ - 1472℉) for quality fusion bonding performance. As we know, liner PE is not able to sustain such temperature, therefore, the most ideal solution is fast heating & fast cooling, which able to avoid collapse of the liner. After the thermoplastic pipe heating process, the sufficient and fast cooling process is also quite important before the next wrapping procedure. During our experience, sufficiently fiberglass tape accelerating heating and cooling is an ideal solution.
The composite pipeline outer layer extrusion (Coating process)
The purpose of the cover is to protect the internal components, most especially the fiberglass reinforcement layer, from damage. The outer
layer will generally be applied to the TCP by a process of extrusion, which is also the same process with a general reinforced thermoplastic pipe (RTP pipeline). Although the cover does not contribute significantly to the load-bearing capacity of the TCP under normal working conditions, it is subject to significant strains that arise from the deformation of the underlying components when the fiberglass TCP is pressurized. These strains may be magnified in the vicinity of the end-fittings, due to the restraining effect of the latter.
For fully bonded structure of thermoplastic composite pipe (TCP) , there’s no specific international standard at very beginning, Fiberglass reinforced thermoplastic composite pipe machinery line system designed based on API 15S, ASTM D2105, ASTM D2513, ASTM D2992, ISO TS18226, GB/T 29165. Currenlty, DNVGL-RP-F119 standard has been used for for qualification of TCP for various applications.
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