Bonded TCP/RTP Extrusion Line System – DN630 Water Supply


Bonded fiberglass reinforced thermoplastic pipe (as called TCP /RTP ) is the next generation of composite pipe mostly used in the oil gas industry. The bonded RTP (TCP) diameter range covers DN 50 – DN 110 with more than 30Mpa for oil gas industry, DN 200 – DN 630 with up to 3.5Mpa for water supply field. There is no doubt that the fiberglass TCP pipe is able to save raw material up to 40% composite pipe by comparing it with polyethylene pipe. 30% raw material saving by comparing with steel wire reinforced pipe(SRTP).

After we successfully developed fiberglass reinforced thermoplastic composite pipe ( Fiberglass TCP) with continuous production covers DN 50 – 160, we were thinking to develop larger size fiberglass TCP pipe (up to DN 630), which also can benefit the water application field. 

There is no doubt that the fiberglass TCP pipe is able to save raw material up to 40% composite pipe by comparing it with polyethylene pipe. 30% raw material saving by comparing with steel wire reinforced pipe(SRTP).

I think it would be great to give you a brief overview of the development of DN 200 – DN 315, DN 400 – DN 630 fully bonded fiberglass reinforced thermoplastic composite pipe (TCP) machinery line with continuous production. Our project with the largest pipe manufacture CHINA LESSO Group Holdings (HKG.2128)in China. 

The inner layer and cover layer  of  TCP pipe use single screw extruder designed for top performance in continuous pipe extrusion and ideally suited for PE 100 + pipe. Liner(inner layer ) co-extrusion still applicable in Banline fiberglass TCP machinery line system. For instance, 5 layers of co-extruded pipes for TCP pipe with the structure from the inside to the outside: PE-RT/adhesive/EVOH/adhesive/PE-RT.  

When we developed our first generation of TCP pipe machinery, we would like to push the limitation of the wrapping machine first. Therefore we redesign the entire wrapping system, which is different than other fiberglass wrapping machines (planetary-wrapping machine) providers in the current market such as Goldstone, Kraussmaffei. Our wrapping machine is called Co-Axis wrapping machine, which is suitable for single roll of fiberglass tape width from 90 mm – 360 mm. Especially for larger diameter fiberglass TCP pipe, technically, the fiberglass tape width shall be around 1000mm in order to reach 55° wrapping angle, it’s too wide to reach that according to current tape technology. Taking into account that it is easy to make fiberglass tape, and the glassfiber tape wrapping process is controllable, Banline TCP- Wave™ line is applicable for one piece 360mm width of fiberglass tape for DN 200 – DN 630 bonded fiberglass reinforced thermoplastic composite pipe (TCP). It looks impossible that single piece of 360mm fiberglass tape can be used in planetary-designed fiberglass tape wrapping machine.  

According to our previous analysis, There’s un-even gaps or overlaps between each wrapped fiberglass tape by using planetary-type fiberglass wrapping machine, which will have impact on bonding performance such as inaccurate outer diameter (OD), etc. Adjusting each bobbin angle and position is another challenge for planetary-type wrapping machine, and will cost a lot of time. Therefore, we redesign the wrapping machine that makes it easier to adjust, and applicable for larger fiberglass tape in order to push the boundary of this technology. Banline Co-Axis wrapping technology allows clients to adjust wrapping angle more easily to solve wrapped fiberglass tape gap problems, and be ready for the next fiberglass tape bonding procedure. Therefore, the entire fiberglass tape wrapping system had been redesigned, and make it easy to use and control in order to suit the different market. 

Banline oil gas use TCP-Ultra™ and water application use TCP-Wave™ machinery line system wrapping machine advantages can briefly be introduced as :

1.Able to produce TCP/RTP pipe diameter range up to DN 630 ( DN 50 – 160, DN 200 -315, DN400 – 630)

2.Minimize the occurrence of wrapped fiberglass tape gaps after the fiberglass tape wrapping procedure. 

3.Single piece fiberglass tape width is applicable from 90 mm – 360 mm, fiberglass tape width fully adjustable based on clients’ needs, and TCP/RTP design.