pipe coiling tech - redefining pipe installations

PCT Ltd

Redefining Pipe Installations

PCT Ltd - The Company

PCT LtdSpecialist in coiling technology and provider of innovative

coiling solutions for plastic pipe, wire rope and sub-sea umbilical & power cables.

Over 23 years experience in coiling HDPE pipeHQ in UK with wholly owned subsidiaries in USA and

ChinaDesign & development in UK with manufacture in UK, USA

and China.48 employees, includes 24 degree qualified engineers

Directors and senior engineers each have 20+ years experience in design and supply of innovative complex

machine solutions for a variety of industries; sub-sea/off-shore, military, plastic pipe, wire rope…

PCT Ltd – Plastic pipe equipment solutions

Primary technologies for PE pipe;High speed automatic coiling for small diameter pipe – 250m/min


Primary technologies for PE pipe;Fully automated coil packaging & robotic palletising


Primary technologies for PE pipe;– High speed auto spoolers for small diameter pipe, tube & hose


Primary technologies for PE pipe;Low Ovality Technology – unique coiling & reeling technique for large

diameter HDPE pipe

PCT Ltd – Equipment solutions for other industries

Examples of recent & current projects;650t & 490t SWL drum take-up stands for wire rope


Examples of recent & current projects;400t SWL drum spooler for sub-sea umbilical


Examples of recent & current projects;Well intervention system


Examples of recent & current projects;Loading arm & carousel for sub-sea umbilical manufacture


Examples of recent & current projects;Deck handing system for sub-sea power cable installation

PCT Ltd – profile customers

http://www.globalmarinesystems.com/

http://www.oceaneering.com/

http://duco.intuitiv.net/default.htm

http://www.flexpipesystems.com/main/home.html

http://www.viega.com/xchg/en-com/hs.xsl/index.html

Proposed Ranges:Coiling DN160 to DN250Reeling DN160 to DN450

Why is there a need to produce such large coils ?What are the benefits ?

Reduction of installation costs

Reduction in environmental impact of the pipe installation

Increase reliability of the pipe line as a long term investment

HSSE – Health Safety Security Environment

PCT Ltd – Redefining Pipe Installations


Time taken to lay the pipe

Number of people required

Amounts of equipment required

Transport of pipes

Reduction of installation costs


Less time required to string pipe

Reduction in personnel, plant and equipment on Right of Way

Less disturbance to Landholder or Highways

Reduction in environmental impact of the pipe installation


Increase reliability of the pipe line as a long term investment

reduction in potential damage at stock yard and on delivery

less handling

less UV impact on pipe

reduction in number of joints will reduce the ‘probability’ of joint failure

environment in which welds are made is highly significant


HSSE – Health Safety Security Environment

Elimination of risks through engineered solution

Significant personnel reductions remove risk of injuries

Reduction in amount transportation requirements

PCT Ltd – Low Ovality Technology

Low Ovality Technologywhat is it and what it enables...

This is a unique method of coiling High Density Polyethylene Pipes, developed by Pipe Coil Technology Ltd, which enables pipe to be coiled with greatly reduced amounts of ovality or to allow coiling at much smaller diameters whilst maintaining acceptable amounts of ovality.

Low Ovality Technology has been specifically developed for use with polyethylene pipe, in particular gas and water pressure pipe. It can be used on all pipe sizes presently supplied in coils and it enables larger diameters to be coiled that have only previously been supplied in sticks lengths due to transport limitations of coil size. Low Ovality Technology is mainly used in the range DN90 to DN250 and in SDR thickness from 11 to 21

What is unique about the way we coil and reel the pipe ?


LV is used extensively by European gas and water pipe extruders in the pipe size range DN90 to DN200. It will shortly be available for pipes up to DN315 and is used by RTP manufacturers to keep pipes ready for speedy installation methods such as de-spooling whilst ploughing directly into the ground in one operation.


0

10

20

30

40

50

60

1000 2000 3000 4000 5000 6000 7000 8000

Stre

ss M

pa

ID mm

Induced Stress vs Coil ID

315 SDR 13.6 No Sqeeze

315 SDR 13.6 Squeeze

315 SDR 21 No Squeeze

315 SDR 21 Squeeze


180 SDR 11 Squeeze

160 SDR 13.6 Squeeze

160 SDR 13.6 No Squeeze


160 SDR 21 Squeeze


SDR STANDARD COILING LOW OVALITY COILING

9 12 10.3

11 15 11.1

13.6 16 11.4

17 17.75 13.2

21 20.9 16.6

Minimum Coiling Ratios


Low Ovality: Test ResultsEffects of LV on material properties

Quantifying measurements to check for detrimental effects on pipe

• No creasing, crazing or cracking with or without aid of magnification

• 80°C / 5.42Bar (circumferential stress of 4.5MPa) for 165 hours without fail

• Pass Elongation & Tensile tests as of clause 5.2 of ISO6259-3


Quantifying measurements to check for detrimental effects on pipe

• Electrofusion Joint Strength tested in accordance with Table D.1, Annex D of

GIS/PL2 following conditioning of both components at -5ºC and fusion using

minimum power (37.8v)

- fusion was carried out satisfactorily

- amps monitored throughout the test were satisfactory

- results were satisfactory with peel strengths up to 100%

Low Ovality: Test ResultsEffects of squeeze on material properties


Manufactured pipe so far

We have 10 Low Ovality Coiling Machines in use presently in Europe & North America coiling Reinforced Thermoplastic Pipes (RTP), HDPE (PE100) and MDPE (PE80) pipe (equivalent to PE4710 & PE3608 respectively)

Manufacturers have been using LV™ for the last 5 years and are proud to use the effects of LV in their marketing presentations to show that their pipe is supplied with less than 5% ovality . Around 4000Km of pipe have been produced in coil form using LV Technology so far.

DN180 has been successfully coiled with wall thickness ratios of SDR11 to SDR21

Coils have been produced at 12:1 (coil ID : pipe diameter) with ovality still remaining in required tolerance bands governed by ISO Standards

All the above tests are in relation to free standing coils that are banded. We know that reeled pipes are far less stressed than coil pipes and will withstand higher extremes of ambient temperature. There have been no detrimental reactions from LV technology on the pipe to date and this is considered far less stressful than some techniques used presently in pipe installation.

PCT Ltd


Reeling – Proposed lengths

Pipe Length on Reel Weight of pipe Reel Size

DN160 SDR 13.6 4600 m 22.2 t 4.4 wide x 6.4 high

DN160 SDR 21 4000 m 17.2 t 4.4 wide x 6.4 high






DN315 SDR 13.6 780 m 17 t 4.4 wide x 5.2 high


DN315 SDR 13.6 800 m 17 t 3.0 wide x 6.4 high


PCT Ltd - Operational & Technical Reeling & De-reeling Overview

Reeling


Drum Handling


Drum Handling at extrusion site


Drum packaging


De-reeling Transport to site


De-reeling

Hook up to Low Ovality re-rounding & straightening trailer


De-reeling

Threading pipe end into Low Ovality re-rounding & straightening system


De-reeling

Laying out pipe


De-reeling

Handling pipe end


Reel size range for one design of LV Reeling machine


Once delivered to site the pipe can be laid out on site ready for installation or the reel can be made to unwind 30m ahead of the plough.

PCT Ltd - fast laying of pipe for ploughing-in installations

PCT Ltd – comparison in laying 3km of DN315

STRINGING WELDING

3 stringing

crews

+10 welding

crews

=

1 stringing

crew

+1 welding

crew =

TOTAL

42 men

3 Trucks, 3 Cranes

10 weld machines

9 men

2 Trucks, 1 weld

machine

PCT Ltd / Tubi PTY Ltd partnership

Portable extrusion line technology-Maximizing coil and reel size potential-Minimizing transportation of pipes-Operational zone of 25 to 50Km


Portable plant can be packed up in 48 hours and moved to new site to follow the line of installations

PROJECT GAS GATHERINGSYSTEMS (KMS)1Shell (Shell Australia LNG) 15,000 kmOrigin (APLNG) 15,000 kmQGC (QCLNG) 14,000 kmSantos (GLNG) 12,000 kmTable 8: Gas Gathering Systems by ProjectNote 1: gas and water gathering systems.Source: (Queensland Government 2010), (Queensland Gas Corporation 2009), (Santos 2009), (Arrow Energy 2008)


Total number of welds required:2,500,000 minimum

It is estimated that the length of the pipeline network will exceed 50,000 km for the identified four projects, with one kilometre of pipeline having between 50 and 80 weld points

Example comparison project of installation of PE pipe – over 50,000Km of DN160 & DN315

- Existing method of delivery

-Tubi Pty Ltd / PCT Ltd portable extrusion plant and reeled pipe method of pipe deliveryThe same 50,000km can be installed with around 67,000 welds

“One butt fusion weld for every 37 butt fusion welds using stick lengths”


Thank you

References:Tubi Pty LtdUponor UK LtdWalter Föckersperger GmbH

Pipe Coil Technology Ltd

2nd Floor Pametrada Building

Oceana Business Park

Davy Bank

Wallsend

Tyne & Wear, UK

NE28 6UZ

pipe coiling tech - redefining pipe installations

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