RTP Reinforced Pipe Extrusion Line

Thanks to its wide diameter range and adjustable output, the JWG-RTP line meets the demands of various high-pressure and corrosive fluid applications:

Oil & gas gathering pipelines
Typical diameter: 75–250 mm (model JWG-RTP-250)
Case study: A customer in Texas, USA, uses the JWG-RTP-250 to produce 200 mm RTP pipes for a shale gas water gathering system. The reinforced structure withstands 4.5 MPa working pressure, replacing corroded steel pipes. An output of 400–500 kg/h allows 24/7 continuous production with extremely low scrap rates.

High-pressure water injection (mining & desert irrigation)
Typical diameter: 110–315 mm (model JWG-RTP-315)
Case study: A mining company in Chile uses the JWG-RTP-315 to manufacture 250 mm RTP pipelines for tailings water return. The line’s maximum output of 600 kg/h and 238 kW total installed power ensure high productivity, while the reinforcement layer resists abrasion and chemical corrosion.

Municipal & industrial pressure pipelines
Typical diameter: 63–160 mm (model JWG-RTP-160)
Case study: A municipal project in Southeast Asia uses the JWG-RTP-160 to produce 125 mm RTP drinking water mains. The 120–300 kg/h output perfectly matches medium-scale production, and the smooth inner liner prevents biofilm formation.

Chemical & corrosive fluid transport
RTP’s thermoplastic liner (HDPE, PA or PVDF) combined with synthetic fiber or steel reinforcement makes it suitable for acids, alkalis, and produced water.

Key point: The three models cover small to large diameters, allowing you to precisely match production capacity to project output – from 120 kg/h for small trial batches to 600 kg/h for large-scale production.

2.1 High output and stable energy efficiency

The JW575/38 extruder on the two larger models provides excellent melt uniformity even at maximum output, reducing material waste.

2.2 Wide diameter flexibility without changing extruder
JWG-RTP-160: 63–160 mm (one tooling set covers 100 mm range)
JWG-RTP-250: 75–250 mm
JWG-RTP-315: 110–315 mm
This means you only need to adjust the die head and winding unit to produce small and large diameter pipes on the same line – no need to buy a second extruder.

2.3 Reinforcement layer precision
The line integrates servo-controlled winding stations that apply continuous fiber or steel tape reinforcement at a precisely controlled angle (typically ±54.7° for optimal hoop/axial strength). This ensures uniform reinforcement density along the entire pipe length.

2.4 Low total cost of ownership
JW series extruders feature bimetallic barrels and wear-resistant screws – service life is >30% longer than conventional designs when processing abrasive mineral-filled materials.
Modular design facilitates quick cleaning and maintenance.

2.5 Proven reliability
Case study: An oil service company in Nigeria replaced an old European line with the JWG-RTP-250. They reported 22% lower power consumption per ton of pipe (210 kW vs. previous 270 kW) and 98.5% line uptime over 6 months of three-shift operation.

We implement a multi-stage quality control plan compliant with ASTM F2785 (RTP standard) and API 15S specifications.

3.1 Incoming material inspection
Resin: Melt flow index (MFI) and moisture content test (<0.02% required for HDPE)
Reinforcement fiber/steel wire: Tensile strength verification, adhesion coating test

3.2 In-line production monitoring (real-time)

All data is recorded to the PLC system. Any deviation >2% triggers automatic speed adjustment or audible alarm.

3.3 Off-line destructive and non-destructive testing (per shift)
Hydrostatic test
Sample length: 1.5 m
Pressure: 1.5 × rated working pressure (e.g., 6.75 MPa for 4.5 MPa pipe)
Hold time: 1 hour – no leakage or burst.
Burst pressure test
Rapid pressurization until failure. Typical RTP burst strength is 2.5–3 times rated pressure. Our line achieves consistent results: e.g., a 200 mm pipe burst at 12.8 MPa vs. its 5 MPa rating.
Peel test (liner-to-reinforcement adhesion)
Peel strength >150 N/25 mm (per ASTM D903)
Short-term hydraulic creep test
Apply pressure: 1.2 × rated pressure for 24 hours – expansion <3%

3.4 Final appearance and dimensional audit
Every 100 m of pipe, ends are trimmed and a borescope camera checks for delamination, bubbles, or scratches.

3.5 Real QC case study
Customer audit feedback from UAE: After installing the JWG-RTP-315, their QC pass rate increased from 94% to 99.2%. The ultrasonic wall thickness system detected an inner liner under-thickness of 0.15 mm before producing only 10 m of scrap – saving approx. USD 2,500 in a single incident.

Q1: Which model should I choose based on my output target?
A: Refer to the table below:

Note: Output depends on material (HDPE vs. PA12) and number of reinforcement layers. Fiber-reinforced pipes run about 15% slower than pure thermoplastic pipes due to winding time.

Q2: Can I produce both steel-wire-reinforced and aramid-fiber-reinforced pipes on the same line?
A: Yes. The winding unit can quickly change reinforcement creels. For steel wire, we recommend the optional steel wire tension control module (for JWG-RTP-250/315). For aramid or polyester fiber, the standard tensioner works perfectly.

Q3: What is the typical power consumption per ton?
A: Based on field data:
JWG-RTP-160: approx. 530 kWh/ton (at 250 kg/h)
JWG-RTP-250: approx. 500 kWh/ton (at 420 kg/h)
JWG-RTP-315: approx. 475 kWh/ton (at 500 kg/h)
These figures include extruder, vacuum tank, cooling, winding, and puller – among the lowest in the RTP market.

Q4: How do you clean the crosshead when changing color or material?
A: The JWG-RTP series features a swing crosshead and removable mandrel. Procedure:
Stop extruder and purge with cleaning compound (PE wax-based).
Loosen 4 bolts to open the swing head – no full disassembly required.
Pull out the mandrel and wipe with a brass scraper (steel tools prohibited to avoid scratches).
Reassemble – total downtime ≤25 minutes for two operators.

Q5: Which spare parts should I stock?
A: Recommended spare parts kit for 6 months continuous operation:
1 set of heater bands (all zones)
2 screen changer plates and screens
1 spare screw tip (for JW560/40 or JW575/38)
1 set of winding belts (polyurethane, 5 m length)
4 ultrasonic sensor membranes
Most customers also purchase an optional spare vacuum pump for the cooling tank – standard pump MTBF is 8,000 hours, but downtime costs typically justify a spare.

Q6: Do you provide installation and training?
A: Yes. We offer:
Remote commissioning via video call (free)
On-site installation by our engineers (travel and accommodation extra)
3-day operator training covering start/stop procedures, reinforcement angle calibration, and emergency stop recovery. Training manuals and video library included.

Q7: How does the line handle recycled HDPE in the inner layer?
A: The JW575/38 extruder has a grooved feed section and 3.2:1 compression ratio, capable of processing up to 30% recycled HDPE (clean, crushed to 6–8 mm) mixed with virgin material without significant output loss. For higher recycled content, we recommend adding a melt filter (optional).