High quality and output in the production of PO pipes ... · Smooth pipe Smooth pipes are used in...

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High quality and output in the production of PO pipes Extrusion systems for large-diameter pipes Engineering Value

Transcript of High quality and output in the production of PO pipes ... · Smooth pipe Smooth pipes are used in...

Page 1: High quality and output in the production of PO pipes ... · Smooth pipe Smooth pipes are used in drinking water supplies and for conveying materials overland. ... pressure loss,

High quality and output in the production of PO pipesExtrusion systems for large-diameter pipes

Engineering Value

Page 2: High quality and output in the production of PO pipes ... · Smooth pipe Smooth pipes are used in drinking water supplies and for conveying materials overland. ... pressure loss,

Smooth pipeSmooth pipes are used in drinking water supplies and for conveying materials overland.

Corrugated pipeEven large-diameter corrugated pipes are relatively lightweight and easy to handle. This makes them extremely cost competitive for applications where they are suitable. Pipes can be produced with diameters of up to approx. 2500 mm.

Wound pipeWinding the profile around a steel drum enables pipes to be manu-factured with diameters of up to approx. 4000 mm.

Facts and figures regarding large-diameter pipe extrusion systems

Applications: drinking water supplies, desalination plants, petrochemical systems and in mining, for example for water outlet channels.

2 Large-diameter pipe systemsFacts and figures

Page 3: High quality and output in the production of PO pipes ... · Smooth pipe Smooth pipes are used in drinking water supplies and for conveying materials overland. ... pressure loss,

High quality and output in the production of PO pipesExtrusion systems for large-diameter pipes

The technological expertise possessed in Extru-sion Technology at KraussMaffei Berstorff is particularly evident in pipe extrusion: As a system provider, we supply complete, integrated system concepts that have enabled us to maintain our position as a global market leader for many years by systematically driving development of our inno-vative products.

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Your advantages at a glance:– Manufacture of large-diameter pipes

with diameters of up to 2500 mm and wall thicknesses of up to 150 mm (practicable)

– Optimized melt flow thanks to the multi-dimensional, computer-assisted design of the spiral geometry and melt channels

– Short flushing and cleaning times– Internal pipe cooling (IPC) with central

supply

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First encounter Impressive large-diameter pipe system

PipeheadLarge-diameter pipehead for produc-ing PO pipes in diameters of up to 2000 mm. Mounting carriage with electrically driven tilt function for easy die-set change

PE 100

Vacuum tankTwo-chamber vacuum tank with cable-driven feed for easier pipe pro-duction start-up; electro-hydraulic length adjustment and spray pipe adjustment

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Cutting unitAutomatic planetary cutter – capable of cutting even thick pipe walls – with electric carriage and universal clamping system

Haul-offTwelve-track caterpillar haul-off, six tracks float-mounted for optimal contact with the pipe, servo motor drive for haul-off tracks

KME single-screw extruder with superordinate C6 control systemMaterials: large-diameter pipes are made from long- lasting, low-sagging PE 100 materials that have been specially developed for this application

Start-up winchFor easier line start-up, with remote control and linked to the cable-driven feed on the vacuum tank

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Page 6: High quality and output in the production of PO pipes ... · Smooth pipe Smooth pipes are used in drinking water supplies and for conveying materials overland. ... pressure loss,

The top priority in pipe extru-sion is to boost output perfor-mance. Almost as important is tight control of meter-weight to reduce material costs.

Cost-effective and reliable solutionKraussMaffei Berstorff systems for large-diameter PO pipe production allow the technical challenges relating to the success criteria of pipe extrusionto be resolved, reliably and cost-effec-tively. Our range of 36D single-screw extruders, with their very high output rates, is optimally designed for use in production with our large-diameter pipeheads. They produce an outstand-ingly homogeneous melt at very low melt temperatures. The KM-RKW 40-2500 large-diameter pipehead is the top-of-the-range model in our range of spiral distributor pipeheads for polyolefin pipe extrusion. This pipehead is capable of producing PO pipes with diameters of up to 2500 mm and wall thicknesses of up

to 150 mm (practicable). In order to keep the wall-thickness tolerances within the tightest possible limits, the pin and the pin connection piece have segmented heating pads, which enable each seg-ment to be controlled manually. The heating pads for the pipehead and the dies are also segmented and thus indi-vidually controllable, and can be used for thermal centering. Pipes in the dimen-sion ranges of KraussMaffei Berstorff large-diameter pipeheads are used mainly in networks carrying drinking water, wastewater or sewage over long distances or to supply large consumers. Other fields of application are salt water desalination plants and cooling water lines for power plants.

6 Large-diameter pipe systemsCost efficiency

Boost output while cutting material costs – with the extrusion systems for large-diameter pipes

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Mature pipehead technology for opti-mized production, compliance with stan-dards and maximum material savingsThe larger the pipe diameter and the thicker the pipe walls, the more it could pay to look at the potential for material savings. The maximum and minimum diameters and wall thicknesses for each pipe size are specified in the relevant standards and pipes must be produced in compliance with them. KraussMaffei Berstorff pipe extrusion systems make it easy to achieve this compliance. They combine the extruder's mature process engineering with the rheologicallyoptimized design of the die and opti-mized calibration and cooling systems. This combination helps the processor to work as closely as possible to the

minimum dimensions specified in the relevant standards and thus to keep meter-weight to a minimum. Considering that, for some types of pipe, the cost of material accounts for up to 90% of total manufacturing cost, keeping weight per meter to a minimum can deliver huge material savings. Depending on the system throughput, the type of material and the relevant standard, the annual savings potential between the minimum and maximum permissible pipe dimen-sions can reach six figures (euros). An extra benefit of producing pipe with pre-cision dimensions and minimal ovality on KraussMaffei Berstorff lines is that the resulting pipe is easier to lay on site, because the perfect fit makes for easier welding.

KM-RKW 39-1600 large-diameter pipehead on a mounting carriage (pivots hydraulically)– Pipe diameter range: 1000 – 1600 mm– Extrusion height: 1650 – 1750 mm– Dimensions (L x W x H): 2.5 m x 5.3 m x 2.9 m– Weight: 39 tons (without die set)– IPC technology for internal pipe cooling

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Your advantages:– High output and good melt homo-

geneity thanks to the KraussMaffei Berstorff process technology

– Increased process reliability and minimized screw and barrel wear

– Innovative IPC technology for internal pipe cooling for improved productivity

– Outstanding price/performance ratio

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8 Large-diameter pipe systemsOperating concept

The spiral distributor system Proven over many years of use and continuously optimized

The aim is to prevent thermal degrada-tion of the material. There is therefore no risk of damage to the extruded pipe through the separation of thermally decomposed material. An additional advantage of the spiral distributor is the short flushing time. Changeover to a different material or color is fast and easy. The spiral distribu-tor channels are designed for minimal pressure loss, so that there is no risk of leakages.

Pipeheads for large pipe are engineered using the tried-and-tested spiral distributor design.

No thermal degradation or leakageAs it enters the pipehead, the melt stream is split by passing through a pattern of holes on its way to the spiral channels. When designing this process, we placed particular importance on creating a flow channel with optimum melt stream.

Technical data

Your advantages:– Optimum flow to the spiral distributor– Low pressure loss– Easy die-set changes because the

pipehead is suspended in the mounting carriage such that it can pivot

– Significant material savings during dimension and color changes

– Significant material savings thanks to minimal wall thickness tolerances

Diameter/wall thickness ratio (standard dimension ratio) Pipehead type KM-RKW

Dimensions based on DIN 8074; DIN 12201

38-1600 39-2000 40-2000 40-2500 51 41 33 26 22 21 17,6 17 13,6 11 9 7,4

630 12.3 15.4 19.3 24.1 28.7 30.0 35.7 37.4 46.3 57.2 70.3

710 13.9 17.4 21.8 27.2 32.3 33.9 40.2 42.1 52.2 64.5 79.3

800 15.7 19.6 24.5 30.6 36.4 38.1 45.3 47.4 58.8 72.6 89.3

900 17.6 22.0 27.6 34.4 41.0 42.9 51.0 53.3 66.1 81.7

1000 19.6 24.5 30.6 38.2 45.5 47.7 56.7 59.3 73.5 90.8

1200 23.5 29.4 36.7 45.9 54.6 57.2 68.0 71.1 88.2

1400 27.4 34.4 42.9 53.5 63.7 66.7 83.0 102.8

1600 31.3 39.2 49.0 61.2 72.7 76.2 94.1 117.6

1800 35.3 44.0 55.1 68.8 81.8 85.8 106.6

2000 39.2 48.9 61.2 76.4 90.9 95.3 118.5

2250 44.1 55.0 68.9 86.0 102.3 107.2

2500 49.1 61.2 76.5 95.5 113.0 119.1

Non-standard diameters and wall thicknesses on request.Throughput range 2000 kg/h, higher throughput on request.

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C6 control system – flexible system for open-and closed-loop control and monitoring of an extrusion line

With its new, innovative C6 control system, KraussMaffei Berstorff offers fast, direct access at all times to the individual units of an extrusion line, the extruders which work conjointly to produce the product, and to integrated downstream equipment.

in terms of both its operation and its functionality, which have proven successful over a great many years.

Maximum flexibilityThe C6 control system offers the user an incredibly high level of flexibility. The composition of parameter pages can be chosen freely, and display and para-meter texts can be tailored to individual requirements. In addition, the system components can be connected and dis-connected as required.

Fast, secure access management using RFID technologyThe C6 control system allows fast, secure access by means of non-contact iden-tification using RFID readers. Remote diagnostics via the Internet and data interfaces to connect to the company network tip the balance to make the C6 control system the perfect solution for all your extrusion line’s control tasks.

With its numerous monitoring and control functions, the C6 control system ensures optimal production preparation and transparency throughout the production process, thereby satisfying the most stringent requirements for excellent product quality and a high level of process reliability.

Multi-touch technology for intuitive operationThe C6 control system is equipped with the latest multi-touch technology and state-of the-art hardware components. A high-resolution 24-inch full HD screen provides an optimal overview. The intui-tive operation and clear screen layout facilitate fast intervention and provide a comprehensive process overview. Units and functions can easily be operated and activated via the touchscreen display. With the C6 control system, KraussMaffei Berstorff has placed a particular empha-sis on maintaining continuity in the design

Your benefits: – Modern, innovative operating philosophy– Fast, intuitive operation– Highly flexible – Maximum process reliability– Optimal monitoring of integrated

system concepts and standalone machines

– A variety of user-friendly models

Swivel-mounted on switching cabinet (standard version)

Mounted on switching cabinet door, tilting (option)

Mobile version (option)Boom-mounted version (option)

Various operating configurations are available

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10 Large-diameter pipe systemsFurther information on OEE Plus

OEE Plus Boosting cost-efficiency for you

For more information about OEE Plus, visit: www.kraussmaffeiberstorff.com/oeeplus

Availability Performance Quality

High overall equipment efficiency (OEE) is a fundamental prerequisite for your company’s success. KraussMaffei Berstorff’s product portfolio comprises tailored machines and lines along with perfectly matched services that increase the economic efficiency and the sustainability of your production. Benefit from our proven know-how of extrusion technology in any application.

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KraussMaffei BerstorffA strong brand in a unique global group

KraussMaffei GroupComprehensive expertise

Value-proven Extrusion Technology solutionsAround the world, KraussMaffei Berstorff stands for reliable and value-proven solutions in Extrusion Technology. These range from using individual extruders for degassing in polymerization, com-pounding, pipe, profile, film and sheet extrusion, physical foaming and the manufacture of technical rubber articles and intermediates for tire production up to complete extrusion lines. All machines and systems from KraussMaffei Berstorff are custom-configured, for example for the chemical, automotive, construction, packaging or pharmaceutical industry.

Unique selling proposition Technology3

The KraussMaffei Group is the only pro-vider in the world to possess the essen-tial machine technologies for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands: Injection Molding Machinery, Automation, Reaction Process Machinery and Extrusion Technology.

The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our com-prehensive and unique expertise in the industry.

You can find additional information at: www.kraussmaffeigroup.com

There for you around the worldKraussMaffei Berstorff is your partner – from the first planning meeting through development of the best possible techni-cal and business solution up through commissioning, servicing and production of your system. We guarantee high-quality advice, solution expertise, reliable spare parts logistics and fast-reacting service during each phase. Our goal is increasing your success.

Individualized serviceBenefit from KraussMaffei Berstorff’s reliable service. Our customer service team and experienced fitters, technicians and engineers are there for you as quickly as possible and even help on location to optimize your systems and processes and to minimize downtime as much as pos-sible. Rely on our highly skilled repair and spare parts service.

You can find additional information about KraussMaffei Berstorff at: www.kraussmaffeiberstorff.com

The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in light blue. In the white-colored regions, the Group is represented by over 570 sales and service partners.

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Extrusion systems for large-diameter pipes from KraussMaffei Berstorff deliver maximum output and help you to reduce material costs. These top-of-the-range systems for large-diameter PO pipe production are engi-neered to produce large-diameter pipes up to 2500 mm in diameter, with wall thicknesses of up to 150 mm (practicable), both reliably and cost-effectively. As a system provider, we supply you with complete, integrated system concepts that have enabled us to maintain our position as a global market leader by systematically driving development of our innovative products.

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High quality and output in the production of PO pipesExtrusion systems for large-diameter pipes