Composit is a family owned organization, in business since We. 1

Transcription

1

2 Composit is a family owned organization, in business since We pioneered production of rubber pipelines in Russia, and we steadily grown to be the one largest company in this field. Our specialty is rubber pipelines and pipe bends with the diameter of 102 to 902 mm designed for transportation of abrasive compounds for dredging as well as for one processing products (concentrates, middlings, tailings etc.) of mining and dressing plants, extraction and tailings sections. All the compounds we use in production is our know-how ensuring you get the most advanced, most dependable products around. 1

3 RUBBER PIPELINE FEATURES Composit is focused on satisfying customer s specific and we develop and produce rubber-fabric pipelines ø from 102 to 920 mm. We are using flexible manufacturing technology that allows as to deliver custom products for our clients. 2

4 MAIN TECHNICAL FEATURES: Working pressure up to 2 MPa, bending radius up to ten diameters, working vacuum up to 0.08 MPa are provided by the product design. Maximum lenght of one section totals 10.0 m. PIPELINE CLASSIFICATION: pressure pipeline, pressure-suction pipeline, suction pipeline. PIPELINE CAN BE OPERATED in the temperature range from 50 C to +80 C in operating environment: process water, acid and alkaline diluted solutions, abrasive compound. PIPELINES ARE MANUFACTURED AS FOLLOWS Onshore and offshore options, of various float designs depending on environment: dredging or mining. PRODUCT LIFETIME: is ensured by wear-resistant inner layer, the compounds of which is depending on operating environment. RUBBER COMPOUNDS are manufactured in-house using high quality raw materials with highly controlled manufacturing process. Pipelines produced by our company have a lifetime as much as 5 times longer and the weight as much as times less compared to steel pipelines. Use of Composit s pipelines is much more advantageous compared to steel ones since economic and process benefits may be achieved, i.e.: buoyancy, longness, flexibility, lack of ball connections (ensures reduced hydraulic losses up to 20 per cent); easy to mount and dismantle that enables to make use of the pipeline in small rivers and offshore areas, as well as in hard-to-reach places in ore mining and dressing plants; applied as part of floating fake dredge ship enables to reduce energy intensity of the hydrotransport up to 15 per cent and operating costs; less vibration resulting from delivery pumps, compensation of heat, linear and temperature expansion; reduced costs of routine maintenance due to the improved wear-resistance of the inner working layer. 3

5 PIPELINE DESIGN FEATURES OUTLINE OF PRESSURE PIPELINE STRUCTURAL FABRIC FRAME ensures pipe strength and uniform distribution of inner loads WEAR-RESISTANT RUBBER LAYER, the composition of which is determined depending on handled medium EMBEDDED STEEL PART ensures durable and impermeable connection INTERMEDIATE RUBBER LAYER, which bonds frame fabric layers OUTER RUBBER LAYER protects the pipeline from mechanical, chemical and natural exposures 4

6 Reinforced pipelines can be mounted in high load areas (connection points to dredge ship, shore discharge pipe, pressure pipes, hydro cyclones etc.) BENEFITS OF REINFORCED PIPLINE: reinforced flange design is more robust and secure; extra strain is removed during axial pipeline motion; much more easy to mount. Inner diameter, mm inches Outer diameter, mm inches Flange size, mm connecting Working pressure, MPa Reinforced flange х / / х / / х / х / / х / х / х / х / х / / х / / х / / х / / х / / х / / х / / х / х / х / / х / / х 30 up to 2,0 up to 1,0 Conventional design flange Tailor-made design can be manufactured based on customer s dimensions. 5

7 SUCTION PIPELINES Suction pipeline is a link between soil pump and dredge ship submersible device, as well as in-line of pressure pumps and suction filters. SUCTION PIPELINES are vacuum-operated and are one of the most essential components of the pump station. The above are intended for steady, smooth water connection with least losses, as well as of abrasive, sand-gravel mixtures, and slurries to pumps. Suction pipelines are applied as a flexible joint during immersion and lifting of dredge ship s draghead, as well as in suction drum of pressure pumps of Mining Processing Plants. Required radial stiffness and rigidity of arms is ensured by equipping arms with reinforcing elements that carry main load and prevent pipeline collapsing. 6

8 REINFORCING ELEMENT, ensuring loadwithstandability Inner diameter, mm inches Outer diameter, mm inches Working vacuum, MPa Approx. weight, kg/m psf Flange size, mm connecting /8 7 5, х / /8 9 6, х / /8 11,9 8, х / , х / / , х / / , х / / , х / / х 22 up to 0, / / , х / / , х / / , х / / , х / , х / / , х / / , х / / , х 30 The minimum bend radius R=10D Tailor-made design can be manufactured based on customer s dimensions. 7

9 OFFSHORE PIPELINES float Inner diameter, mm inches Outer diameter, mm inches Working pressure, MPa / / / / / / / / / / / / / / / / / / / / /8 up to 2,0 up to 1, / / / Tailor-made design can be manufactured based on customer s dimensions. 8

10 OFFSHORE PIPELINE IS USED for transportation of abrasive compounds on the water surface. The float provides floatability and covered with protective alarming material. Pipeline design ensures bending radius of up to 10 inner diameters, in this case, no ball joints should be used. Lack of hydraulic losses and low resistance to abrasive compounds flow enable to considerably improve the efficiency of the hydraulic system. Composit s floating pipelines are durable and handy in transportation, installation and operation. 9

11 OFFSHORE PIPELINES with plastic float Foam material Inner diameter, mm inches Outer diameter, mm inches Working pressure, MPa / / / up to 2, / / / / / / / / /8 up to 1, / / / /8 Tailor-made design can be manufactured based on customer s dimensions. 10

12 Composit s experts developed and implemented an innovative float design, offering cutting-edge operational properties compared to its counterparts. The float is made of wear-resistant plastic and filled with foam material. Due to this feature such design is adapted to various exposures; it is more reliable and durable. It prevents float motion along the pipeline, and efficiently combats wave loads. During the development of the product design it was considered to lay a power cable and have it properly fixed in the float. The offshore pipeline with plastic float made by Composit is a well-proven and successful solution for using at rivers and seas. 11

13 REINFORCED PIPELINES with expanded bending angle (bending radius up to 10 inner diameters) Pressure pipeline with expanded bending angle Reinforced flange pipeline in operation 12 THESE PIPELINES ARE USED IN HIGH LOAD ENVIRONMENTS, which require improved pipe s flexibility, strength and robustness to linear motions. It is achieved through the pipeline s and flange s designs, as well as by application of materials with special properties. This product is successfully applied as a flexible insertion between steel pipelines based on pontoons, as a link between a hydraulic loader and shore discharge pipe, in discharge spurs, instead of bends in ore mining and dressing plants. Inner diameter, mm Inches Outer diameter, mm Inches Working pressure, MPa mm Flange size, connecting kg/m Tailor-made design can be manufactured based on customer s dimensions. Approx. weight, / / х / х , / / х 22 19,5 13, up / х ,4 to / /8 2, х , / / х , / / х , / / х 26 44,5 29, / / х 30 47, / / х , / /2 up х to / /8 1, х , / х , / / х p

14 RUBBER COMPENSATORS Rubber compensators. General view Rubber compensator ø720 in action RUBBER COMPENSATORS ARE DESIGNED: to compensate pipeline temperature expansion; to prevent steel pipe destruction during pipe collapsing; to neutralize misalignment in pipe systems due to mounting works; to isolate vibration loads of running machinery and transported medium flows; to protect sensitive components and units from forces generated by the running pipeline; to tighten various type pipelines; to produce flexible insertions of various types. Rubber compensators are made of durable wear-resistant rubber. It provides for additional resistance to exposure of abrasive hydraulic compounds and steady pressure resistance over long time. Range of rubber compensators covers ø102 to 920 mm. 13

15 RUBBER PIPE BENDS COMPOSIT MANUFACTURES RUBBER PIPE BENDS with inner diameter from 102 mm to 630 mm, with working pressure up to 2 MPa, option designs of 45, 60, 90. These products are designed for hydromechanization, mining and processing industry and are intended for transportation of abrasive compounds; in dressing plants for pipelines supplying rocks for further processing, for process piping in pump and compressor stations. Rubber pipe bends are intensively used in ore-dressing and processing plants in exit points of hydro cyclones batteries, pressure pumps for direct pipeline sections, for hydro cyclone drainage and tailing sections of ore-dressing and processing plants. Rubber pipe bends are designed as a pipeline part for smooth flow change of supplied media. The above are intensively used for infrastructures in order to pipe avoid uneven areas. Pipe bends can be operated in the following media: process water, acid and alkaline solutions, abrasive compounds. 14

16 RUBBER-LINED ITEMS Composit produces a variety of rubber-lined items such as: rubber-lined steel collectors rubber-lined steel cross-type sections rubber-lined steel T-type sections rubber-lined steel bends All rubber-lined items are produced using wear-resistant rubber compounds created and manufactured by Composit. The lifetime of such rubber-lined products is much longer then the steel analogs and using Composit's items can reduce the number of emergency stops and thus ensures better performance. We are focused on client's needs and ready to develop and produce rubberlined products according customer's drawings. 15

17 On 4th October 2002 CJSC SPA Composit implemented Quality Management System (QMS), in conformity with IS ISO 9001:2000. For seven years the Certification Association Russian Register, a special certification institution of the Russian Maritime Register of Shipping, being one of the leading Russian certification bodies, stated during the inspection examination, and in November 2008 during resumed examination re-stated again that the QMS of a group of entities within SPA Composit is effective, and business conducted by it departments complies with the stated ISO 9001:2000, as well as it complies with requirements of documentation developed based on the above standard. In 2009 due to transition of the Company to the new version of IS ISO 9001:2008, and due to а restructuring of redundant branches (business reappropriation), the management of the Certification Association Russian Register, having reviewed examination results dd. 18th-20th November2009 (examination report Nr ), resolved to re-issue Compliance Certificates according to version IS ISO 9001:

18 KAZAKHSTAN RUSSIA AZERBAIJAN UKRAINE BELARUS KURSK Atyrau Astana Zhezkazgan Karaganda Karagaily Balkhash Poltava Nikolaev Krivoy Rog Baku Minsk Pinsk Ust-Kamenogorsk Murmansk Naryan-Mar Norilsk Anadyr Noviy Urengoi Khanty-Mansiysk Surgut Nizhnevartovskк Krasnoyarsk Irkutsk Yakutsk Khabarovsk Arkhangelsk Petrozavodsk Rybinsk Moscow Voronezh Ryazan Vladimir Kazan Yekaterinburg Tyumen Omsk Tomsk Kemerovo Novosibirsk Samara Togliatti Astrakhan Volgograd Uralsk Ufa Chelyabinsk Miass Rostovon-Don Sochi Primorsko- Akhtarsk Kirov Noviy Urengoi St. Petersburg Mogilev Saratov Orenburg Tula Perm Magadan Strezhevoy Dubai UNITED ARAB EMIRATES DPRK Pyongyang OF SUCCESS GEOGRAPHY Anadyr Arkhangelsk Astrakhan Vladimir Voronezh Volgograd Yekaterinburg Irkutsk Kazan Kemerovo Kirov Krasnoyarsk Magadan Moscow Murmansk Miass Nizhnevartovskк Nizhniy Novgorod Novosibirsk Noviy Urengoi Norilsk Omsk Orenburg Perm Primorsko-Akhtarsk Rostov-on-Don Rybinsk Ryazan Samara Saratov St. Petersburg Sochi Surgut Togliatti Tomsk Tula Tyumen Ust-Kamenogorsk Ufa Khabarovsk Khanty-Mansiysk Chelyabinsk Yakutsk Astana Atyrau Balkhash Zhezkazgan Karagaily Karaganda Uralsk Baku Minsk Mogilev Pinsk Krivoy Rog Nikolaev Poltava Dubai Seoul