SPIRAL CORRUGATED PIPE MANUFACTURING LINE

 

Spiral Corrugated Pipe

 

General Introduction

 

Now a day, the plastic pipes is widely used to instead of normal galvanized steel pipe, steel pipe and concrete pipe in many application fields:

 

l  In building water drain

l  In building water supply

l  Outdoor water supply

l  Buried water drain

l  Gas transportation

l  Electric cable protective conduit

l  Industry application like anticorrosive

l  Agriculture application like irrigation

 

Among these applications, the buried plastic pipe for drain has a lot of vacancy to be developed. So we think that there will be a great potential market for large size plastic drain pipeline.

 

Depends on the experience of the developed countries in America and Europe, the application of the water drain and waste drain plastic pipe has the largest requirement quantity among all of the plastic pipes. But in China, the application of plastic drainpipe drops behind of other kinds of plastic pipe. One of the main reason for this slowly developing is that the government ignores environmental protection on the past 20 years. Therefore only a few fund is invested on the water drain system, the traditional low-cost concrete pipe is the primary construction material. However, in company with the fast economy development in recent years, government paid more and more attention to the environmental protection especially some provinces owned river or lakes. In some provinces, the local government already issued the policy to promote the usage of the large size plastic drainpipe.

 

Compared with the concrete pipe special the reinforced concrete pipe, the plastic pipe could not only match the property for buried water drainpipe but also has many advantages.

 

Strength and rigidity

 

Apparently plastic drainpipe looks weakly than concrete pipe, but plastic pipe is a kind of flexible pipe not a solid rigid pipe. Under the proper design and installation, the stress is acted on the plastic pipe and the earth around it together. Hence it is no need for plastic drainpipe to have the same strength and rigidity data as the concrete pipe but in fact the plastic pipe could provide the same pressure resistance ability as concrete pipe.

 

The sealing

 

It is difficult for the concrete pipe to keep sealing well. Normally, during the installation, after connect two pipes through the socket, the worker paste a ring of concrete to seal the connection. Because the connection between two pipes is completely not flexible, so it will be damaged and because leaking even the pipe has very small movement. But this kind of movement is unavoidable if considering the ground rising or falling.

 

Having a very smooth inner surface, the resistant of fluid is obviously less than concrete pipe. On other aspects like anticorrosive, life span and wear proof, plastic drainpipe also performance an outstanding advantage compared with steel pipe and concrete pipe. The unit price of plastic drainpipe is higher than concrete pipe, but it is proved by engineering practice that the total project investment is usually lower than traditional concrete pipe if calculating the installation fee and maintenance charge together. So generally, the plastic pipe is a better pipeline with good performance price ratio and plays more and more important role in water drain system.

 

It is pointed out, “In 2005, the plastic pipe will occupy 50% share in the whole pipe market. Among the new building, rebuilding and expanding projects, 70% of the in-building drainpipe must use plastic pipe; 50% of rainwater drainpipe must use plastic pipe and 20% of civil drainpipe must use plastic pipe. In 2010, the relative data should raise to 80%, 70% and 30%.

 

The investment to city drain pipeline is increased rapidly during these years. The investment amount in 1998 is 9.53 times of that in 1990. The percentage of the after-treatment wastewater is increased from 4.24% in 1990 to 16.5% in 1998. From the data we can notice that the polluted water treatment is paid more and more attention.

 

Spiral corrugated is a kind of new generation high performance plastic spiral pipe for large diameter buried drain pipe. It has the characters of light in weight, low cost either in material or the installation, pressure against, high strength, anti-frozen and long service life (50 years). The pipe could widely used in fields of civil water drain, wastewater, communication and irrigation. To reduce the cost, the pipe could also be made by the recycled polyethylene material. These properties make it superior advantages compared with other kinds of drainpipe.

 

Characters:

 

ØAnticorrosive;

The pipe is made by anticorrosive material polyethylene, so it could not be corrosive by the acid, alkali or grease contained in the wastewater. Therefore no need the extra anti-corrosive processing during the installation and can serve for long time.

 

ØImpact against

Since the pipe is flexible, when impact come from outside occur, the pipe can resume the deforming. Even sometimes the groundwork has sunk; the pipe can remain integrated and will not crack.

 

ØWearability

Due to the property of the pipe grading polyethylene, the pipe could be stable working for 50 years under the temperature of 20 centigrade.

 

ØAnti-freezing

The pipe could still keep working without leaking under the circumstance of minus 60 centigrade buried underground.

 

ØLight in weight

The weight of the spiral-corrugated pipe is only 1/8 of the concrete pipe in same diameter, and the 2/3 of normal spiral pipe. So it is very convenient for transportation and installation.

 

ØInstallation cost down

Because of the light and convenient connection method, so installation could save much more working time and cost.

 

ØEasy connection

The heat shrinkage connection is simple and prompt.

 

ØExcellent fluidity

The polyethylene plastic pipe offers a low friction coefficient, so it has very good liquid flowing property for medium transportation.

 

ØPressure against

The pipe is reinforced by the corrugation structure results a good pressure against and can withdraw the cars, trucks driving over it.

 

ØRecycle

The polyethylene material could be recycled and add into the new raw material to make the spiral corrugated pipe.

 

ØLow investment

The equipment for making the pipe is only 1/4 of the normal corrugated pipe making machine but the pipe has the same structure.

 

Physical Performance

Items

Unit

Value

Remarks

Density

g/cm2

0.95～0.96

 

Impact Strength

Kg.cm/cm2

13

 

Tensile Strength

MPa

22

 

Extension Rate

%

500

 

Specific Heat

Kcal/kg ℃

0.55

 

Heat Conductivity

W/cm    ℃

0.25

 

Soften Point

℃

121

 

Melting Point

℃

138

 

Lowest Working

Temperature

℃

Over -60℃

 

Poisson Ratio

——

0.45

 

Water Absorb

%

0.008

 

Inner Voltage

Kv/mm

48

 

Linear Expansion

Cm/cm    ℃

11×10－5

 

 

Product Standards

 

The spiral corrugated pipe is qualified followed the standards of corrugated pipe ISO9969

 

Connection

The connection of the spiral-corrugated pipe is easy and no need for various kinds of fitting, thus decrease the investment of injection molding machine. There have three kinds of connecting method.

 

Heat Shrinkage Conduit

Clear the section of the pipe to be connected, insert the pipe into a heat-shrinkage-conduit from both ends, the pipe is butt contacted. Heating the conduit by flame blowgun for a few minutes, the conduit will be shrunk under the high temperature then connect and seal the two pipes.

 

Electric Fusion Band

Butt connect two pipes then bind joint with an electric fusion band, use the stainless steel coat to fix the band and the joint. Get the electric power from a portable battery, the polyethylene sheet will be fusion and connect the pipes. The electric fusion band is made of polyethylene sheet and electric resistant wires on it. The diameter of wire, power kilowatt and the thickness or length of the polyethylene sheet is specified in the installation manual direction according to material melting property.

 

Polyethylene Flange Connection

Welding the flange with the pipe body through plastic butt-welding, then connect two flanges with bolts. There are some resistance wires are buried on the flange surface, so next step is to get power to the resistance wire, the end of the flange will be melted and become into integrated.

 

Raw Material

The primary raw material to make the spiral corrugated pipe is polyethylene. The requirement of the material is specified by buried drainpipe European standards PREN13476-1 published in 1999. Although the buried drainpipe is working with few or none pressure, but refer to the required parameters specified by the standards, the demand is equal to PE63 class material. (PE63 pipe material tested under conditions of 80 centigrade, Ring Rigidity 3.2 Mpa, 1000 hours) In China it is easy to find many qualified local material suppliers. Due to the unique structure of spiral-corrugated pipe, the actual ring rigidity is higher than normal solid polyethylene pipe. And in working practice the material could contains part of recycled polyethylene or polypropylene, so the material cost of the pipe could be cutdown obviously.

 

Output capacity

The production line is designed for three shifts continuous running (24 hours). Deducting maintenance, repairing time, calculate with 280 working days annually, 24 hours per day, then the effective working time is 6700 hours. The output of the machine is average 320 kg per hour, the rate of finished products is 98%, the effective running time during the working hours 85%, and thus we get the result of 1800 tons product per year. If convert to diameter 600mm pipe, then you can get 65,000 meters pipe.

 

Circumstance evaluation

 

The production line will not create any wastewater, exhaust gas, dust and vibration. The noise inside the workshop is below 80 db and outside shop is below 60 db. So it is said that the factory will not create pollution to its circumstance.

 

 

Processing Flow chat