Technology of efficient production of pipes in polyurethane foam insulation
Technology of efficient production of pipes in polyurethane foam insulation
5 manufacturing areas
Manufacturing of
PE and ZP
sheath pipes
For PE sheath manufacturing we use the feed supplied by "SIBUR Holding" PJSC. By means of a LIANSU extruder, PE granules are formed to tubes with a diameter of 125 to 1,200 mm. Prior to insulation application, the jackets are treated with corona discharge, whereas each batch is inspected instrumentally.
ZP jackets are made with SPIRO machine tools of galvanized strip. We check the zinc plating by three parameters: compliance of strip thickness, crimping strength and tightness of the lock joint, coating quality.
Preliminary cleaning,
assembly and molding of
pipe assemblies
The steel tubes are purchased directly from manufacturers. Prior to PUF layer application, we shotblast the surface up to Grade 3.
It will not suffice, just to prepare the steel tubes and the jackets, the insulation must also be of high quality. The key quality criterion is the density, which must be at least 60 kg/m3, as per GOST 30732-2020. We use PUR components of American and Russian suppliers - Dow Chemical and ISOLAN.
After aligning supports and RRCS conductors are set, the jacket is pulled-over onto the tube, after that, the assembly is conveyed to a thermal stabilization chamber for stable and uniform PUF distribution. After the assembly of the pipe, the operator sets the required tilt of the table to properly vent the air from the annular space and for even foam distribution.
Cutting, welding of metal,
painting and preparation
of fittings
The manufacturing commencement of fittings includes cutting of steel tubes to nozzles and shaped chamfering. Then, the nozzles are welded with subsequent NDT of the welds.
The butt-welding of PE-jacket segments for fitting insulation is performed on modern hydraulic equipment. The welding parameters are automatically registered and recorded to a journal. The mirror process allows for the achievement of the required tightness and strength of the weld joint.
Final assembly and
insulation of fittings
We manufacture monthly appr. 17,000 fittings from 32 to 1,020 mm diameter. We add to the truck load of pipes the corresponding number of fittings, for you to commence the installation at once.
Manufacturing of JIK's,
centering supports and
their segments
Compressed air in press gauges transforms polyethylene blanks into heat-shrinkable sleeves of the required diameter. Then they are packed to protect them from external influences.
In the same workshop, we form foam packs with the required proportion of components (isocyanate and polyol) for each product diameter. Ideal proportions are calculated by a technologist in a laboratory.
Inspections and checks
are an our important
manufacturing stage
We manage to achieve an ultimately low rejection percentage of 0.42%. In order to achieve such a result, we carry out:
- Instrumental inspections of incoming materials and components;
- Daily checks for compliance with GOST 30732-2020 and our internal standards;
- Daily checks of finished goods for density and delamination;
- Ultrasound and radiography NDT of welds.
an ultimately low rejection percentage of only 0.42%
Our manager will communicate you to finalize the details. SEND AN INQUIRY