Assembly Process
Smartpipe: The System and Assembly Process
Smartpipe is a high-pressure reinforced thermoplastic pipe (RTP) system developed to help operators renew aging pipeline infrastructure. It is composed of:
A corrosion-resistant thermoplastic liner
A high-strength reinforcement layer
A durable outer jacket
Embedded fiber-optic sensing can be integrated directly into the pipe, providing continuous monitoring capabilities that support long-term integrity management.
Using a mobile manufacturing facility, Smartpipe is produced onsite and fed into the pipeline through a single entry excavation. The pipe is C-formed during installation to allow passage through the host pipeline, then re-rounds after placement to create a close-fit rehabilitation solution while minimizing excavation and construction impacts.
Manufacturing Process
HDPE Core Pipe
The process starts with 50 ft lengths of high-density polyethylene (HDPE) pipe in sizes between 6 in and 16 in.
Fusion Process
The fusion process creates a single continuous pipeline, enabling virtually unlimited manufacturing lengths.
High Strength Fiber
A high strength braided Poly Crystalline Fiber is added in helical and contra helical orientations, with multiple layers depending on the pressure of the pipe design.
High Strength Pulling Tapes
High strength pulling tapes are then added to the exterior of the pipe to give the pipe axial capacity to be pulled inside the host pipe.
Retention Windings
Retention windings are applied around the pipe to secure the high strength reinforcement fibers and pulling tapes in their position.
Fiber Optics System
The fiber optic system gives us the ability to carry out 24-7 remote monitoring of the pipeline system for leak detection and 3rd party intrusion monitoring.
LDPE Protective Wrap
A Low Density Poly Ethylene (LDPE) Wrap is then added to the exterior of the pipe to give it a robust protective cover.
C-Forming
To maximize internal diameter, Smartpipe is C-formed prior to insertion, reducing its circumference by approximately 30%. After installation, it is re-rounded to create a close fit within the host pipeline.
High Strength Tape Braiding
The High Strength Pull Tape is then braided into a high-strength rope, which is used for the host pipe pull-in.