What is 3PE? 3PE Introduction
Brief Overview
3PE is an innovative and highly effective method of external corrosion protection for steel pipes. It adheres to the prestigious German standard DIN 30670-1991, which dictates the 'Polyethylene Coating of Steel Pipes and Pipe Fittings', along with the SY/T 0413 'Technical Standard for Polyethylene Anticorrosive Coatings of Buried Steel Pipes'. According to SY/T 0413, the external anticorrosive can be structured in either a two-layer or a three-layer composition. The two-layer structure comprises an adhesive base layer topped with polyethylene, known as 2PE. In contrast, the more advanced three-layer structure starts with an epoxy powder base, followed by a middle adhesive layer, and finally an outer polyethylene layer, hence called 3PE. The precise thickness specifications of these protective layers are detailed in Table 1:
Table 1 Dual Process for Anti-corrosion Coating: 1. Initially, any grease, dirt, or impurities clinging to the steel pipe's surface must be meticulously removed. Surface pretreatment involves preheating the pipe to a temperature between 400°C and 600°C. The pre-treatment standards must align with Sa21/2 class as per the 'Rust Grade and Rust Removal Grade of Steel Surface Before Coating'. The surface should achieve an anchor profile depth ranging from 50µm to 75µm, ensuring that all welding slag burrs are thoroughly cleaned.
2. After pretreatment, meticulously cleanse the steel pipe surface of any dust and abrasives. The surface should be checked to prevent moisture, rust, or contamination thrice before coating. Coating should commence within a 4-hour window of pretreatment; otherwise, if rust redevelops, the surface must be re-prepped.
3. Upon completing pretreatment, heat the steel pipe to an ideal coating temperature using medium frequency induction. Apply the epoxy powder coating uniformly across the pipe's surface for maximum efficacy.
4. For coating, the polyethylene and adhesives can be applied via two prominent methods: the longitudinal extrusion process or the lateral winding process. Specifically, for steel pipes with a diameter greater than 500 mm, the lateral winding process is recommended.
5. In the longitudinal extrusion process, a heated steel pipe (whether 2PE or 3PE) receives a powder coat application via die heads of both an adhesive and a polyethylene extruder. This method ensures the steel pipe's outer surface is enveloped with molten adhesive and polyethylene. This precise process guarantees strong adhesion due to high temperatures and subsequent cooling shrinkage, ensuring a seamless bond between all layers. It is crucial that no gaps are present along the weld in this process.
6. During the lateral winding process, the steel pipe rotates through a medium frequency induction heating ring. Two extruders deliver the molten adhesive film tape and molten polyethylene film tape, wrapping the tapes around the heated 2PE steel pipe or the 3PE epoxy-coated steel pipe. This method mandates complete roller compaction of overlapping polyethylene segments and those on weld sides to prevent surface crushing, maintaining excellent layer uniformity.
7. Following polyethylene coating, apply water cooling to ensure the steel pipe's temperature does not exceed 60°C. This cooling phase solidifies the bond among the adhesive, polyethylene, and steel pipe, achieving a robust and durable anticorrosive layer.
8. In the final flourish of the anti-corrosion process, the polyethylene layer at the end of the tube gracefully makes way by being meticulously removed. A precise reserved length of 100~150 mm is maintained at the pipe end, culminating in an artful chamfer, honed to perfection at an angle not exceeding 30 degrees, ensuring seamless integration.
Three: The Essential Trio of Steel Pipes: The formidable base steel pipe stands as a testament to engineering excellence, crafted in strict adherence to the esteemed GB/T9711-1997 "Technical Delivery Conditions for Oil and Gas Industry Transportation Steel Pipe" and the revered API Spec 5L "Transportation pipe Specification". It embodies versatility, available as seamless steel pipe, straight seam submerged arc welded steel pipe, spiral seam submerged arc welded steel pipe, and straight seam high-frequency welded steel pipe. Each variety undergoes rigorous weld heat treatment. Span the spectrum of sizes with diameters ranging from DN 15-DN 1200 and outer diameters from ¢21.3-¢1219. Their walls, robustly thick from 2.8-31.8mm, withstand test pressures of 4.8MPa to 20.7MPa. These pipes are battle-tested through a gamut of assessments: transverse tensile, longitudinal tensile, welded joint tensile, ductility, flattening, bending, fracture toughness, metallographic plug, hydrostatic, and non-destructive tests. Choose from a wide array of steel grades: B (i.e., L245), X42 (i.e., L290), X52 (i.e., L360), X60 (i.e., L415), X70 (i.e., L485), with L485 denoting an impressive total elongation stress of 485 MPa.
Four: The Mastery of Interface Welding: 1. The unyielding joint of the base pipe is skillfully welded, following the distinguished GB50236 "Construction and Acceptance Code for Field Equipment and Industrial Pipeline Welding Engineering." Pipes and fittings of matching wall thickness unite seamlessly, ensuring the inner wall's alignment is impeccably flush. The deviation of the inner wall's wrong side is minuscule, not exceeding 10% of the pipe wall's thickness, and always kept below a mere 1 mm.
2. During the coupling of pipes and pipe fittings, the groove's surface must be impeccable, void of any cracks, interlayers, or imperfections. The grooves and their vicinities, spanning 10 mm, are diligently cleared of paint, rust, and burrs, leaving nothing but pristine surfaces.
3. The process measures and welding materials for spot-solid welding of pipelines and fittings must mirror those used in formal welding. Spot welds, precise in length from 10~15 mm and height 2~4 mm, are executed with finesse, not surpassing 2/3 of the pipe wall's thickness. Any discovered defects, such as cracks in the weld, are promptly addressed and remedied.
4. The weld surface quality must unwaveringly adhere to the stringent standards set forth in GB50236 "Field Equipment, Industrial Pipeline Welding Engineering Construction and Acceptance Code."
Five: The Art of Weld Protection 1. The protective outer coating of the welded joint on the pipe body is a masterpiece crafted from hot condensation polyvinyl tape with adhesive. When subjected to the heat of a blowtorch, the tape undergoes a transformative process, morphing into a polyethylene coating that snugly envelops the steel pipe's outer surface. This coating is a paragon of smoothness-free from wrinkles, bubbles, charring, or other defects. The adhesive spills uniformly around the circumference of the heat shrink sleeve, each patch meticulously verified with an EDM leak detector at 15kV. Any pinholes detected are thoroughly repaired and rechecked to ensure compliance. The peeling strength of the heat shrink sleeve at the patch remains formidable, never falling below 50N/cm.
2. Discover the unparalleled protection of our external anti-corrosion coating, which can be enhanced with a polyurea spray on the weld's outer surface. Known for its application in flooring and waterproofing, polyurea is revolutionizing steel pipe protection with its exceptional bond strength and unparalleled corrosion resistance. This cutting-edge material offers solvent-free, pollution-free coating solutions with rapid curing, surpassing traditional high-solid coatings, water-based coatings, and other conventional technologies. Polyurea stands as a modern marvel in anti-corrosion solutions, ensuring longevity and resilience like no other.
Witness the brilliance of polyurea, a high-temperature liquid that transforms into a robust coating through the ingenious A and R component system. Group A, an NCO-terminated semi-prepolymer, combines with Group R's amino polyether amine chain and unique additives to form a dynamic duo. Using specialized jet molding equipment, this mixture adheres to steel pipe surfaces without the need for heating, offering on-site application versatility. Delivering top-tier corrosion resistance, aging resistance, and mechanical strength, polyurea ensures a durable coating with an impressive 30-year service life.
Embrace the future of pipe protection with our two-component, 100% solid content polyurea. This eco-friendly, solvent-free coating ensures no contamination of your carrier medium, meeting rigorous health, safety, and environmental standards. With its superior ability to resist environmental and UV degradation, polyurea is the ideal choice for exterior pipe coatings, promising vibrant, long-lasting colors that enhance aesthetics without fading. Customize your coating to suit your color preferences and enjoy a decorative finish that stands the test of time.
6. Summary The industry-acclaimed 3PE coating process for steel pipes offers exceptional practicality and professionalism, earning the trust of users across sectors such as petroleum, natural gas, chemical industries, and beyond. Its versatility makes it a valuable asset for applications in electric power, HVAC, and municipal engineering. At Hebei Haochen Technology Co., Ltd., we take pride in delivering top-notch services and products for all your 3PE coating needs.
At Hebei Haochen Environmental Protection Technology Co., LTD., we specialize in providing expert solutions for your steel pipe 3PE coating process requirements! Let us enhance your projects with our professional expertise.
Allow us to guide you through the intricate 3PE anti-corrosion steel pipe process with a detailed flow chart demonstration.
Currently under construction: small-caliber 3PE anti-corrosion steel pipes, designed for durability and efficiency.
Explore the cutting-edge medium frequency technology employed in our 3PE anti-corrosion steel pipes, ensuring superior performance.
Our 3PE anti-corrosion steel pipe production line features a state-of-the-art large cyclone powder recovery system for optimal efficiency.
Experience the advanced engineering of our spray water room within the 3PE anticorrosive steel pipe production line, designed for precision.
Step into our sophisticated spray room for 3PE anti-corrosion steel pipe production, where innovation meets reliability.
Our seamless steel pipe surface inner wall cleaning process ensures impeccable preparation for anti-corrosion coating.
Discover the outstanding epoxy spraying effects achieved in our 3PE anti-corrosion steel pipe production line, elevating protection standards.
Our 3PE anti-corrosion steel pipe production line excels in outside polyethylene spraying, offering unparalleled protective layering.
The 3PE anticorrosive steel pipe production line is complemented by a high-performance grinding machine, ensuring flawless results.
The showcased case exemplifies the superior craftsmanship of our 3PE anti-corrosion steel pipe production line's spray-finished products.
Trust in our quality and expertise. For inquiries regarding our anti-corrosion steel pipe production line, reach out to Hebei Haochen Environmental Protection Technology Co., LTD. Our team is committed to addressing your needs with utmost professionalism.
FAQ:
Explore our comprehensive company problem summary, detailing insights into common inquiries and solutions.
1. What do you do? Where is your company?
reply:
Hebei Haochen Environmental Protection Technology Co., Ltd. stands at the forefront of industrial innovation, specializing in state-of-the-art pipeline anti-corrosion automatic spraying lines. Our repertoire includes the advanced 3PE anti-corrosion steel pipe production line, an expansive large-caliber 12-meter coated plastic steel pipe automatic production line, a compact six-meter small-caliber coated plastic steel pipe production line, as well as a highly efficient automatic tube coating production line. Strategically located in the heart of Hebei Cangzhou City, Qingxian Wang Town Shop Development Zone, our facilities are designed to meet the highest standards of excellence in production and service.
2. What distinguishes Hebei Haochen Environmental Protection Technology Co., Ltd. from others in the industry?
reply:
At Hebei Haochen, we deliver bespoke, all-encompassing equipment installation services, leveraging cutting-edge domestic technology in our spraying equipment. This ensures substantial improvements in production efficiency while conserving time, materials, and labor, setting us apart in the market.
3. Why is your online presence limited and lacking additional introductions?
reply:
We proudly operate as a high star reputation seller on Made in China online, anchoring our credibility in the marketplace.
4. Is your focus solely on promotion without profit? Will increased popularity lead to price hikes?
reply:
As an emerging platform, our initial promotional efforts are aimed at resource integration to earn customer trust. Moving forward, we pledge to uphold our service excellence and maintain competitive pricing, ensuring superior service across our automatic production line of coated steel pipes.
5. Does your company truly provide assistance with design and installation, or is it merely nominal?
reply:
We offer complimentary design and installation services with no upfront fees. Our process ensures satisfaction with the final design plan before any contracts are signed, providing peace of mind and transparency.
6. When shopping online, I prefer reputable platforms. What assurance can your new platform offer?
reply:
As a nascent platform, we are actively engaging in pre-launch promotional activities. Our offerings include comprehensive after-sales support services, ensuring customer satisfaction and reliability. Our commitment to quality mirrors our initial launch, providing a robust array of after-sales support services to back any purchase.
7. How long does it take to design the drawings?
reply: Our dedicated design team delivers thorough and precise drawings within 10-15 business days following your equipment request, ensuring quality and satisfaction.
8. What are your payment terms?
reply: We accommodate diverse payment preferences by offering bank counter transfers, POS machine credit card payments, and cash, empowering you to choose the method that best suits your needs. Our platform also supports payment methods endorsed by Made in China Network.
9. How would you describe your company's design capabilities? reply: With a team of seasoned professionals boasting over seven years of experience in large-scale spray line design, we masterfully utilize CAD and SOLIDWORKS software, ensuring our design capabilities meet and exceed expectations.
10. How is your company's reputation perceived?
reply: Hebei Haochen Environmental Protection Technology Co., Ltd. has successfully manufactured hundreds of spray lines domestically, forging excellent partnerships with clients. We adhere to the ethos of 'a customer, a lifetime friend,' ensuring our service is seamless and ongoing, transforming transactions into lasting relationships.
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