Pipe Coiling Tech - Redefining Pipe Installations

PCT Ltd
Redefining Pipe Installations

PCT Ltd - The Company
PCT Ltd
Specialist 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 pipe
HQ in UK with wholly owned subsidiaries in USA and
China
Design & 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

Fully automated coil packaging & robotic palletising
– High speed auto spoolers for small diameter pipe, tube & hose

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

400t SWL drum spooler for sub-sea umbilical

Well intervention system

Loading arm & carousel for sub-sea umbilical manufacture

Deck handing system for sub-sea power cable installation
PCT Ltd – profile customers
PCT Ltd – Redefining Pipe Installations
Proposed Ranges:
Coiling DN160 to DN250
Reeling 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
Reduction of installation costs
Time taken to lay the pipe
Number of people required
Amounts of equipment required
Transport of pipes
Reduction in environmental impact of the pipe installation
Less time required to string pipe
Reduction in personnel, plant and equipment on Right of Way
Less disturbance to Landholder or Highways

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
What is unique about the way we coil and reel the pipe ?
Low Ovality Technology
what 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
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.
Induced Stress vs Coil ID

60
50
315 SDR 13.6 No Sqeeze

40
315 SDR 13.6 Squeeze
315 SDR 21 No Squeeze
Stress Mpa
315 SDR 21 Squeeze

30
180 SDR 11 Squeeze
20 160 SDR 13.6 Squeeze
160 SDR 13.6 No Squeeze
10
160 SDR 21 Squeeze
0
1000 2000 3000 4000 5000 6000 7000 8000
ID mm
Minimum Coiling Ratios
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
Low Ovality: Test Results

Effects 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
Low Ovality: Test Results

Effects of squeeze on material properties
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%
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
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
Laying out pipe
De-reeling
Handling pipe end
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 - fast laying of pipe for ploughing-in installations
PCT Ltd – comparison in laying 3km of DN315
STRINGING WELDING TOTAL
42 men
3 stringing + 10 welding = 3 Trucks, 3 Cranes
crews crews 10 weld machines
9 men
1 stringing
crew
+ 1 welding
crew
= 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
Example comparison project of installation of PE pipe – over 50,000Km of DN160 & DN315
- Existing method of delivery

PROJECT GAS GATHERING It is estimated that the length of the pipeline
SYSTEMS (KMS)1 network will exceed 50,000 km for the identified four
Shell (Shell Australia LNG) 15,000 km projects, with one kilometre of pipeline having
Origin (APLNG) 15,000 km between 50 and 80 weld points
QGC (QCLNG) 14,000 km
Santos (GLNG) 12,000 km
Table 8: Gas Gathering Systems by Project Total number of welds required:
Note 1: gas and water gathering systems. 2,500,000 minimum
Source: (Queensland Government 2010),
(Queensland Gas Corporation 2009), (Santos 2009),
(Arrow Energy 2008)
-Tubi Pty Ltd / PCT Ltd portable extrusion plant and reeled pipe method of pipe delivery
The 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
Pipe Coil Technology Ltd

2nd Floor Pametrada Building
Oceana Business Park
References: Davy Bank
Tubi Pty Ltd Wallsend
Uponor UK Ltd Tyne & Wear, UK
Walter Föckersperger GmbH NE28 6UZ

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PCT Ltd

Redefining Pipe Installations

Primary technologies for PE pipe;

Primary technologies for PE pipe;

Primary technologies for PE pipe;

Examples of recent & current projects;

Examples of recent & current projects;

Examples of recent & current projects;

Examples of recent & current projects;

Examples of recent & current projects;

Reduction of installation costs

Reduction of installation costs

Time taken to lay the pipe

Number of people required

Amounts of equipment required

Reduction in environmental impact of the pipe installation

Less time required to string pipe

Reduction in personnel, plant and equipment on Right of Way

Less disturbance to Landholder or Highways

Increase reliability of the pipe line as a long term investment

reduction in potential damage at stock yard and on delivery

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

Low Ovality Technology has been specifically developed for use

LV is used extensively by European gas and

Induced Stress vs Coil ID

315 SDR 13.6 No Sqeeze

315 SDR 21 Squeeze

Minimum Coiling Ratios

SDR STANDARD COILING LOW OVALITY COILING

Low Ovality: Test Results

Low Ovality: Test Results

Manufactured pipe so far

Reeling – Proposed lengths

Drum Handling at extrusion site

De-reeling Transport to site

Reel size range for one design of

STRINGING WELDING TOTAL

Portable extrusion line technology

Portable plant can be

- Existing method of delivery

Pipe Coil Technology Ltd

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