(calculation was done during production of 20 coating pipelines per hour,Ø1420)
1. Decreaseof polyethylene consumption(polypropylene) during usage of centering coupling with minimum coating thickness 3,2 in a welded joint and 3,5 in a pipe body:
- 2 waysof insulation coatingareconsideredin continuous flow. Insulationcoatingconditionsandsetupoftransportlinearewithoutany changes.
Before usage of centering couplings:
|
Pipe id |
Body coating thickness (mm) |
Joint thickness (mm) |
|||
|
900 |
1800 |
2700 |
3600 |
||
|
Pipe 1 |
4,1 |
4,3 |
4,6 |
4,4 |
3,6 |
|
3,5 |
4,5 |
4,9 |
4,6 |
3,2 |
|
|
3,8 |
4,7 |
4,7 |
4,8 |
3,8 |
|
|
4,4 |
4,5 |
4,8 |
5,0 |
4,1 |
|
|
Pipe 2 |
4,3 |
4,3 |
4,7 |
4,5 |
3,7 |
|
3,6 |
4,6 |
5,1 |
4,9 |
3,2 |
|
|
3,9 |
4,7 |
4,8 |
5,0 |
3,8 |
|
|
4,5 |
4,9 |
4,7 |
5,2 |
4,2 |
|
███ -minimumthicknessofpipe
AfterusageofCC:
|
Pipe id |
Body coating thickness (mm) |
Joint thickness (mm) |
|||
|
Pipe 3 |
4,2 |
4,4 |
4,7 |
4,5 |
3,8 |
|
3,9 |
4,7 |
5,1 |
4,8 |
3,6 |
|
|
4,1 |
4,9 |
4,9 |
4,9 |
4,0 |
|
|
4,6 |
4,8 |
5,0 |
5,1 |
4,4 |
|
|
Pipe 4 |
4,5 |
4,6 |
4,9 |
4,6 |
4,0 |
|
4,1 |
4,9 |
5,3 |
4,8 |
3,7 |
|
|
4,2 |
5,0 |
5,0 |
5,1 |
4,2 |
|
|
4,6 |
4,9 |
4,9 |
5,2 |
4,5 |
|
From the setables we can conclude that duringin sulation coating with CC the consumption of coating material sreduces by ≈7-9%
2. Decrease oftransport equipment deterioration of insulation coating line:
- Reduction of transport rollers deterioration - 25%;
- Load reduction to motor-reducer- 20% (because of uneven load distribution to nearest transport rollers). (Replacement cost oftransportrollersisfrom 15 000 to 25 000 rubles per year, replacement cost ofmotor-reducer is from 700 to 1100 thousand rubles per year).
Taking into consideration the data about economy of transport line spare parts there is reduction of machine downtime 1,5÷2% according to experts.
3. Deletion of endpipe truncation damage.
- Reductionoflabour-intensiveness duringhandling of pipe chamfers andendpipe truncation(abrasive wheels)and reduction of brush disks consumption (300 wheels).
(300 cleanup wheels per 24 hours, 1 wheel costs 180 rub.).
Attheexpenseofendpipehandlingreductionit is possible to reduce one worker in a shift.
- On application of protective tape in pipe ends using “VKS-Techno” centering coupling full protection of chamfers and end areas is performed. Handling of end areas can be performed only by knives for polyethylene removal. It excludes the usage of brush disks and handling in brushing machines.
≈1100 brushesх 800 rub. = 900 thousandrublespermonth
Energy resources and spare partscostreduction.
4. Quality
Deletionof“blowhole” defectsbecauseofpipeaxismisadjustmentduringcoating. Decrease of “delamination” defects at the expense of uniform rate of travel in inductivemachineries and directly in insulation coating area.
Economy: thesedefectsmakefrom2%to 2,5% of produced products namely ≈100 pipes per month do not underdo to the repeated limit (removal of insulation and repair).
- absence of lines (marks) in en end pipe truncation (during welding of pipe line joints nondestructive checkcontrol system fixes the areas with lines as a defect “pore” in welded joint).
5. Eliminationof“VKS-Techno” centering coupling fall-out (at the expense of technical feasibility of centering coupling to create an effort till 27,5 MPa)
Whencouplingfellsoutneedsfrom 4 to 12 hourstorepairthedamage of transport line in pipe disconnection area (the cost of spare parts for equipment restoration is from 1100 thousand rubles till 2000 thousand rubles, one hour downtime costs from 60 till 200 thousand rubles (profit for one hour), the cost of staff work is not included).