110-550mm PE Insulation Pipe Extrusion Line,Automatic tube cutting

gas/oil /water pipeline Puf Pre-Insulated Pipe PE shell casing plastic Machinery

Technical Prameters:

HDPE Jacket Process Flow:

1. Vacuum Feeding of PE Granules: The raw PE granules are automatically fed into the system via vacuum suction.
2. Hot Air Drying: The granules are dried using hot air to remove moisture, ensuring optimal extrusion quality.
3. Extrusion Plasticizing: The dried granules are plasticized through the extruder, heated and mixed to form a molten plastic mass.
4. Mold Shaping: The molten plastic is shaped into the desired pipe profile by passing through the extrusion die.
5. Vacuum Sizing: The pipe is then subjected to vacuum sizing, adjusting its dimensions to precise specifications.
6. Water Cooling: The pipe is cooled rapidly by immersion in a water tank to solidify its shape and structure.
7. Pulling Out: The solidified pipe is pulled out of the cooling tank at a controlled speed.
8. Cutting: The pipe is cut to the desired length using a precision cutting machine.
9. Carrier Laying-off: The cut pipes are then neatly laid off onto a carrier for further handling or packaging

Composition of Equipments:

1. Hopper Dryer
2. Single Screw Extruder
3. Extrusion Mould Die
4. Head Bracket
5. Vacuum Calibration Device
6. Water Cooling Tank
7. Haul-off Unit
8. Planetary Cutting Machine
9. Pipe Bracket
10. Loader
11. PLC (Programmable Logic Controller)

The production steps of the insulation layer for a pre-insulated pipe, specifically focusing on the polyurethane (PU) foam insulation, are outlined below in detail:

1. Formation of the Casing Structure:
   • The steel pipe is first inserted into the high-density polyethylene (HDPE) outer protection pipe, creating a casing structure.
   • Supports are evenly arranged in the annular space between the steel pipe and the HDPE outer pipe to maintain a uniform distance and prevent the two pipes from touching directly.
   • The two ends of the casing are sealed with flanges to ensure that the polyurethane foaming material will be contained within the space during the injection process.
2. Preparation of the Steel Pipe Surface:
   • Prior to the injection of the insulation material, the surface of the steel pipe undergoes pre-treatment such as shot blasting or blast cleaning. This step removes any impurities, rust, or scale, providing a clean and suitable surface for optimal adhesion of the polyurethane insulation.
   • Additionally, corona treatment of the polyethylene pipe shell's surface may also be performed to enhance its adhesion properties.
3. Injection of Polyurethane Foaming Material:
   • The casing structure is hoisted onto a foaming platform specifically designed for this purpose.
   • A high-pressure foaming machine is used to inject the polyurethane foaming material into the casing. The material expands and fills the entire annular space between the steel pipe and the HDPE outer pipe.
4. Curing and Formation of the Insulation Layer:
   • Once the polyurethane material is injected, it undergoes a curing process. During this time, the material foams and solidifies, forming a dense and durable insulation layer.
   • The curing time and conditions are carefully controlled to ensure that the insulation layer achieves optimal thermal and mechanical properties.
5. Removal of Sealing Structures and Final Inspection:
   • After the insulation layer has fully cured, the sealing structures (flanges) at both ends of the casing are removed.
   • The completed pre-insulated pipe is then inspected for any defects or imperfections in the insulation layer or the overall structure.
   • If the pipe meets the required specifications, it is ready for further processing or shipment.

The strong ties between the steel pipe, polyurethane insulation, and jacket pipe not only provide rigidity but also ensure that the insulation layer remains in place and performs optimally over its lifetime. The surface preparation of the steel pipe and the corona treatment of the HDPE shell contribute significantly to the overall quality and performance of the pre-insulated pipe.

gas/oil /water pipeline Puf Pre-Insulated Pipe PE shell casing plastic Machinery Advantages:The inclusion of PUF (Polyurethane Foam)

1. Increased Operational Reliability and Availability:
   • Remote condition monitoring of PUF insulation enables real-time tracking of the insulation's integrity and performance. This ensures that any issues, such as leaks or deterioration, are identified and addressed promptly, minimizing downtime and enhancing overall operational reliability.
2. Simplified Construction, Maintenance, and Repair:
   • The use of PUF insulation simplifies pipeline construction as it reduces the complexity of the installation process. Maintenance and repair activities are also streamlined, as the insulation material is easily accessible and can be repaired or replaced with minimal disruption to the pipeline's operation.
3. Extended Service Life:
   • PUF insulation significantly increases the service life of pipelines, offering a lifespan of 30-40 years compared to traditional insulation methods that typically last 5-10 years. This longer lifespan translates into reduced replacement costs and improved asset utilization.
4. Reduced Heat Losses:
   • By effectively insulating the pipeline, PUF insulation minimizes heat losses to as low as 8%, significantly outperforming traditional insulation methods that often suffer from heat losses of 30-40%. This enhanced thermal efficiency leads to lower energy consumption and reduced operating costs.
5. Capital Cost Savings:
   • The cost-effectiveness of PUF insulation is further evident in the reduction of capital costs by 15-20%. This is primarily due to the elimination of the need for concrete channels and chambers for valves, which are often required in traditional pipeline systems.
6. Reduced Operating Costs:
   • The improved thermal efficiency and reduced heat losses lead to a significant reduction in operating costs. Specifically, the use of PUF insulation can result in operating cost savings of up to 9 times compared to traditional systems.
7. Lower Repair Costs:
   • The durability and resilience of PUF insulation reduce the frequency and severity of repairs, leading to a 3-fold decrease in repair costs. This not only saves money but also minimizes the inconvenience and downtime associated with repairs.