MODULE FOR CABLE CROSSLINKING

The module is designed for radiation crosslinking of polyethylene cable. The module has inbuilt equipment that allows cross-linking of polymers simultaneously over the entire circumference. Thanks to the technology used, the uniformity of the dose obtained is guaranteed and, as a result, the uniformity of the crosslinked material.

COMPLEX CONSISTS OF 4 MODULES:
1. RADIATION MODULE:
electron accelerator, radiation shield (to be filled with concrete or metal crumb), built-in conveyor system
2. ELECTRONIC EQUIPMENT MODULE
3. COOLING SYSTEM
4. MONITORING AND CONTROL SYSTEM

The complex is equipped with various systems for supplying products to the irradiation zone. Depending on the supply systems, the complex can produce the following products:
1. Cable
2. Heat shrink sleeves
3. Shrink wrap
4. Heat resistant pipes for heating and hot water
5. Polyethylene foam sheets
6. Film for greenhouses, resistant to ultraviolet
7. Heavy-duty polymer products
8. Sterilization of materials up to 5 mm thick
9. Other materials
MODULE CONFIGURATION
Electron accelerator: energy 1 to 5 MeV, power from 20 kW to 100 kW, operates in E-beam mode.

Radiation shield: Depending on the premises area and technical requirements of the customer, different materials may be used for radiation shield: concrete or metal.

Ozone exhaust system: there are two possible options for removal of ozone:
1. an exhaust system into the atmosphere where it will decompose within minutes, and
2. ozone decomposition process with catalysts.

Emergency shutdown system: in case of any accidental event the electron accelerator will be switched off automatically.

In-built cable handling device: speed is adjustable and controlled remotely.

Fire safety system: triggered in emergency situations. Electron accelerator will be switched off and fire extinguishing system will be turned on, in automatic or manual mode.

Control system: dosimetry, conveyor speed control, electron accelerator control, fire extinguishing, cooling, ventilation and emergency shutdown of the accelerator.
TECHNICAL SPECIFICATION
Module dimensions:
2.5m x 2.5m x 5m (metal shielding)
4,5m x 4,5m x 5m (concrete shielding)
Electricity consumption: up to 450 kW per hour, depending on the electron accelerator installed
Module productivity: depends on the type of treated products
Crosslinking of pipes and sleeves
Beamcomplex modules are designed for radiation cross-linking of polyethylene pipes and couplings. The module has unique equipment that allows to cross-link polymers simultaneously along the whole circumference of a pipe. The uniformity of the received dose and, consequently, the uniformity of the cross-linked material are guaranteed by the technology employed.
The pipe diameter can be up to 400 mm and the thickness of the wall can reach up to 25 mm.
According to this method, the production of pipes is divided into two separate stages: the production of pipes on conventional pipe lines and the subsequent processing by high energies from electron accelerators.

In order to obtain uniform cross-linking of the pipe along both the thickness and perimeter, the accelerator must have special outlet windows for electron beams. For pipes with a wall thickness of 10 m accelerators with an energy of 3 MeV are required, for 5 mm thickness it is advisable to use accelerators with the energy of 5 MeV and electron beam power of 50-100 kW.
MATERIAL PROPERTIES RESULTING FROM IRRADIATION
  • 1
    Chemical properties
    Metal-plastic pipes become resistant to the effects of various chemical solutions.
  • 2
    Shape "memory"
    After bending the metal-plastic pipes retain the initial shape, which facilitates and accelerates the assembly of fittings and further work with the pipe.
  • 3
    Durability
    The inner layer of metal-plastic pipes is made of high-strength cross-linked polyethylene. This ensures virtually no deterioration even at high flow rates. High resistance allows carrying out water supply pipelines with high internal pressure. Also, metal-plastic pipes are resistant to multiple, sharp pressure and temperature drops.
  • 4
    Expansion ratio
    Due to the aluminum layer, the coefficient of linear expansion of the metal-plastic pipes is 0.025 mm / (mChK).
  • 5
    Heat resistance
    It allows employing pipes for the installation in hot water systems.
  • 6
    Electrical safety
    The special design of the fittings allows terminate electrical contact and put a barrier for premature destruction of the system due to the impact of electric fields.
  • 7
    Environment friendly
    Metal-plastic pipes have no contra-indications for use in any type of drinking water pipelines. Due to the fact that the outer layer of the pipe is also cross-linked polyethylene or polypropylene, there is no need to protect the pipe the outside against the corrosion, and there is no need to paint it.
Despite the fact that all polymer pipes have common technical and operational characteristics, certain types of pipes (PE, PP, PVC, PEX and metal-plastic) also have their own distinctive features. Metal-plastic pipe is a five-layer construction of three main and two bonding layers. The inner layer of the pipe is made of cross-linked polyethylene. On the surface, a layer of special glue is applied, connecting polyethylene with aluminum. The aluminum layer is made of a special foil with a thickness of 0.4 mm, with a butt weld across the entire length. Welding of aluminum buttocks allows obtaining a pipe with an ideally circular cross section. On the surface of aluminum, another layer of special glue is applied, which binds aluminum to the outer layer of plastic PE-Xs. The entire pipe is linked via bombarding electrons on both internal and external layers. In total, there are three methods for cross-linking of polyethylene: a chemical method with peroxide (PE-Xa), a chemical method by silicone (PE-Xb), and a physical method by electron irradiation (PE-Xs). In order to achieve the same quality, the percentage of peroxide crosslinking should be 70%, silane - 65%, electronically - 60%.

Crosslinking of polyethylene is the process of formation of transverse and longitudinal bonds between long polymer molecules under the influence of intense electron bombardment. In the case of physical cross-linking, the polyethylene pipe is irradiated with hard X-rays. This process is very productive; its speed is 80 m / min. Polyethylene obtained as a result of physical cross-linking is marked as PEX-C.
Under the influence of accelerated electrons and secondary gamma radiation, chemical bonds break down, facilitates formation of free radicals which, in turn, recombine creating cross-links between macromolecules.

According to this method, the production of pipes is divided into two separate stages: the production of pipes on conventional pipe lines and the subsequent processing by high energies from electron accelerators. In order to obtain even cross-linking of the pipe along both the thickness and perimeter, the accelerator must have special sweeps of electron beams. For pipes with a wall thickness of 10 mm, accelerators with an energy of 3 MeV are required, for 5 mm accelerators with an energy of 5 MeV with capacity about 50-100 kW.
Сross-linking of heat shrink tubes and couplings
The use of heat shrinkage is based on the shape memory effect. It is achieved by radiation exposure. For instance, if the polymer is placed in a powerful beam of electrons there is a connection of neighbouring macromolecules with each other at the molecular level.
This technology is called cross-linking. After this process the polymer becomes more elastic, and the product, when heated, acquires its original shape and initial dimensions.

APPLICATION AND BENEFITS OF SHRINK TUBES
  • 1
    Isolation from the corrosive environment of metal and water pipes.
  • 2
    Improvement of the ergonomics of the tool handles and sports equipment, by using ribbed or ribbed tubes.
  • 3
    Longitudinal sealing of bundles of cable. In addition to external insulation, due to a special tape, the space between the cores is completely filled and isolated.
  • 4
    Advanced chemical qualities that prevent imflammation of cable
Cable crosslinking
Crosslinked polyethylene (PEX) is one of the most used materials for insulation manufacturing for power cable and signal cable.
Its unique strength properties, water resistance, heat resistance, resistance to mechanical stress, enable us to create materials having higher reliability and durability comparing to traditional materials.

  • 1
    High reliability.
  • 2
    Lower costs on reconstruction and maintenance of cable lines.
  • 3
    Low dielectric losses (dielectric loss factor 0.001 instead of 0.008).
  • 4
    Greater throughput due to an increase in the permissible heating temperature of the conductors.
  • 5
    Increased resistance to heat pressure.
  • 6
    Low moisture absorption.
  • 7
    Environment friendly cable laying and maintenance (absence of lead, oil, bitumen).
  • 8
    Better resistance to oil and chemicals.
  • 9
    Better resistance to hydrolysis.
  • 10
    Higher flexural strength (alternate bending strength).
  • 11
    Better abrasion properties.
  • 12
    Improved resistance to stress cracking.
The module is designed for radiation crosslinking of polyethylene cable. The module has inbuilt equipment that allows cross-linking of polymers simultaneously over the entire circumference. Thanks to the technology used, the uniformity of the dose obtained is guaranteed and, as a result, the uniformity of the crosslinked material.

POLYMER PIPES PROPERTIES ARISING FROM IRRADIATION TREATMENT
Chemical properties
Plastic pipes are resistant to various chemical reactions, ultraviolet radiation, have the properties of a heat-resistant material that does not support combustion.

Form saving
After bending, the plastic pipes retain their desired shape, which facilitates and accelerates the assembly of fittings and further work with the pipe.

Wear resistance
The inner layer of plastic pipes is made of high strength cross-linked polyethylene. This ensures an almost complete absence of wear even at high flow rates. High strength allows water pipelines with high internal pressure. Also, plastic pipes are resistant to repeated, sudden changes in pressure and temperature.



Heat resistance
It allows the use of pipes for the installation of hot water systems.

Environmental friendliness
Plastic pipes have no contraindications for use in any type of piping for drinking water. Due to the fact that the outer layer of the pipe is also crosslinked with polyethylene or polypropylene, there is no need to protect the pipe from the outside.
ADVANTAGES OF ELECTRON BEAM PROCESSED CABLES
1
Minimum bend radius during cable laying (at least15 Dn), lower weight, which makes it easier to lay
on difficult routes.
2
Low dielectric losses (dielectric loss factor 0.001 comparing to 0.008).
3
Higher cable performance due to an increase in the permissible heating temperature of the
conductors
4
Higher rated short-circuit current.
5
Low moisture absorption.
6
Better resistance to oils and chemicals.
7
Better hydrolysis resistance.
8
Increased flexural strength (reserve flexural strength).
9
Improved abrasion properties.
10
Increased resistance to stress cracking.
11
Ultraviolet radiation resistance;
12
Higher flame resistance.
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