Polyurethane Process Industries, LLC


Where the customer comes first

10 April 2009

OMS Equipment Helps Protect Deepwater Oil Pipeline in South China Sea 

Latrobe, PA – Sabah Shell Petroleum Co. Ltd. needed a pipeline that could withstand the stresses and near-freezing temperatures of a deepwater oil field in the South China Sea about 75miles (120 km) off the coast of Sabah.

Bredero Shaw, a subsidiary of ShawCor Ltd., had the pipeline coating technology: Fusion Bonded Epoxy (FBE) to protect the pipe from corrosion and ThermoFlo (D), a cast-in-place elastomeric glass syntactic polyurethane-based material, to ensure hydrothermal stability.

Impianti OMS S.p.A., a leading manufacturer of polyurethane equipment, had the machine that could apply the coating.

Last month, Bredero Shaw began using a specially designed OMS Impact 300S low-pressure metering unit to apply its ThermoFlo (D) coating to 25 miles (40 km) of 18-inch diameter pipe for Sabah Shell Petroleum’s Gumusut-Kakap Deepwater Project. The work is being done at Bredero Shaw’s facility in Kuantan, Malaysia, the largest pipe coating facility in the world, with more than 148 acres (600,000 square meters) of plant and pipe storage area.

Featuring a special twin pump arrangement, the special-purpose OMS metering machine is capable of processing up to 300 kg/min. of syntactic formulations containing either polymer or glass microspheres.

Specially designed low-pressure mix head and Impact 300S for pipeline coating application.

Processing the delicate spheres without damage is essential to ensure the required insulation and buoyancy properties of the finished pipe.

Materials are stored in two temperature-conditioned day tanks: a 538-gallon (2,000-liter) tank for Isocyanate and a 1,320-gallon (5,000-liter) tank for Polyol. Both tanks are equipped with thermoregulation units, automatic level controllers and agitators to ensure the materials are always processed at the correct temperature.

Mass flow meters and closed loop output and ratio control guarantee accurate control of the mix quality throughout the lengthy pouring cycle of the cast-in-place process. A special software program helps the operator build up and reduce delivery rates at the start and end of the molding process by enabling a controlled ramp up start / ramp down end of the pouring cycle.

The OMS metering unit was installed as part of a processing line designed by Bredero Shaw. The line completed testing in December and began operation this year. The coated pipe is scheduled for offshore installation in 2010 once engineering has been completed for construction of the Gumusut-Kakap facility. Sabah Shell Petroleum has estimated the processing capacity at 150,000 barrels of oil per day.


10 APRIL 2009

OMS and PPI to Emphasize Insulating Panels and Elastomers at NPE2009

Latrobe, PA – In keeping with the NPE2009 emphasis on energy conservation and emerging technologies, polyurethane equipment maker Impianti OMS S.p.A. will exhibit technology used in the production of insulating panels and elastomers.

"The demand for insulating panels and elastomeric products has grown steadily over the past few years, and it just keeps increasing," said Mark Clark, general manager of Polyurethane Process Industries, LLC, (PPI), the exclusive distributor of OMS equipment and systems in the United States.

"Our high-pressure equipment is used in the continous production of insulating panels for the building and commercial refrigeration industries," Clark said. "Our low-pressure and microdosing equipment is used with elastomers in the production of everything from gaskets to dialysis filters."

The OMS Group and PPI will exhibit jointly in Booth S5052, South Hall of McCormick Place, Chicago, Ill. throughout the June 22-26 run of NPE2009. The display will include high- and low-pressure foam mixing and metering technology, as well as such end-product samples as elastomer parts, insulating panels and viscoelastic (memory) foam.

Low-pressure OMS mixing head for micro-dosing.

Insulating Panels for Energy Conservation and Efficiency

For years, the OMS Group has been at the forefront of developing highly personalized technical solutions and turnkey systems for the discontinuous and continuous production of flexible, metal and rigid sandwich insulating panels of PUR/PIR foam, phenolic resin, preformed core materials such as EPS and mineral fiber lamellas.

The list of OMS-installed systems includes plants for the continuous production of flexible substrate panels for roofing, cavity wall insulation and ducts for air conditioning systems; panels faced with rigid gypsum, cement or wood products for residential construction elements, roof panels, thermo-ventilated roof systems, etc.; and metal faced composites for cold storage, industrial roof and wall construction applications.

Demand for insulation with improved thermal and fire properties fed tremendous growth in the number of continuous panel plants over the last few years. This year, in recognition of this ever-growing demand and the company's 40th anniversary, OMS Group launched OMS Automation, an engineering division dedicated to developing material handling equipment for panel production.

Rising energy costs and energy conservation incentive programs likely will keep demand high in the future. Some early entrants into panel manufacturing also are looking for ways to reduce costs with newer technology.   

"Some panel manufacturers and many commercial refrigeration manufacturers have been using 'froth' foam, which doesn't require the use of high- or low-pressure metering machinery," Clark said. "Their initial equipment costs were low, but inaccurate process control resulted in poor foam quality and high chemical costs because of waste. So now these processors are starting to look at high-pressure metering systems and two-component traditional foam."

During NPE2009, OMS will display its Y2K 10 straight, high-pressure mixing head, which is ideal for continuous and discontinuous panel production. The compact Y2K 10 head is designed to accurately control chemical temperature, pressure and mixing for superior chemical usage and foam density control. The head instantly dispenses mixed chemicals as soon as a pour cycle is actuated and instantly stops the pour cycle, eliminating chemical waste.  

Elastomers: One of the Fastest Growing Plastics Industry Sectors

Elastomers are used to make such a wide range of products, from hard in-line skate wheels to rubbery gaskets and the spongy foams in running shoes, that this broad family of polymers has become one of the fastest growing sectors in the plastics industry.

Because their physical properties often rely on complete and precise control of the temperature, pressure and amount of chemical components that are mixed, engineering grade and high-temperature elastomers required specialized machinery to process them repeatedly and reliabily.

OMS Group manufactures a range of standard medium- and high-temperature machines, as well as purpose-built material handling equipment, for making elastomeric products and coatings. OMS recently designed and installed a low-pressure metering unit that is being used to apply an elastomeric glass syntactic polyurethane-based material to pipe destined for a deepwater ocean oil field. OMS also has developed a fully integrated micro-metering plant for gasket production using thixotropic materials.

"At NPE we will display a low-pressure mix head that is perfect for gasket, filter and small parts produced from elastomers," Clark said.

The C2 Micro Dosing Mix Head features:

  • Output range of 2 to 20 gm/sec.
  • An internal pneumatic piston that actuates both chemical pistons together to eliminate "lead/lag" problems.
  • Chemical reciculation through the jacketed mix head for optimum temperature control.
  • Fixed orifices to control chemical pressure.



PPI Expands Panel Production System Offerings in the United States

LATROBE, PA – Polyurethane Process Industries, LLC, (PPI) can now offer complete design, equipment and technical support for construction of continuous and discontinuous panel production lines in the United States thanks to a new engineering divsion launched by OMS Group.

Last month, OMS Group announced the creation of OMS Automation, a fully in-house division that will focus on the design and construction of dedicated cutting and handling systems for composite panel production, including:

  • Longitudinal and transverse cutting units.
  • "In-flight" cross-cutting machinery.
  • Horizontal and vertical cooling conveyors.
  • Unloading and stacking manipulators.
  • Packing and palletizing lines.
  • Special solutions for specific customer production requirements.

"This new division reinforces OMS's position as a leading supplier of panel production plants worldwide," said Mark Clark, general manager of PPI, which is the exclusive distributor of OMS equipment in the United States. "Now, through the assistance of OMS Automation, we can supply turnkey, rigid and flexible foam panel production systems throughout the United States."

OMS Automation has the ability to ensure that all ergonomic, functional and energy-related aspects of a production line are considered and optimized during creation of a fully integrated system. The division's engineers will be able to study production requirements and supply solutions for all types of panel processes and substrates, including paper- or metal-faced panels, PIR or PUR types of polyurethane foam, phenolic foam or rockwool bonded with polyurethane adhesive, Clark said.

OMS Group launched OMS Automation in January on the occasion of the company's 40th anniversary.

Vertical cooling conveyor

Suction-equipped, pick-and-place manipulator for conveying and stacking panels.

The new division brings an innovative mentality and natural synergy to OMS Group's 40 years of know-how and patented production technologies. It also gives customers the benefit of dealing with a single, reliable experienced supplier for all of their equipment needs, OMS Sales Manager Eraldo Greco said.

"We believe our technology and quality to be second to none in the market, and we can proudly list all the most important manufacturers in Europe and around the world as not only customers, but also as partners with whom we have worked and cooperated to bring their most ambitious projects to fruition," Greco concluded.

For more information about PPI's polyurethane manufacturing systems, visit our Turnkey PU Systems page.


7 JANUARY 2009

The New ECOPlus High-Pressure Metering Machine Provides Better Processing Control to Polyurethane Manufacturers on a Budget

LATROBE, PA – Polyurethane Process Industries, LLC, (PPI) has introduced a new high-output, high-pressure metering machine that provides better processing control to North American polyurethane manufacturers on a budget. 

The new compact ECOPlus metering machines, which were developed by OMS Group, deliver outputs up to 475 lbs./minute and offer more standard features than other economically priced models, including: 

  • Variable speed motors controlled by an Allen-Bradley MicroLogix series PLC, which allows output variations without manual intervention.
  • Fixed-displacement axial piston pumps with double seals for low maintenance.
  • Jacketed, pressurized tanks with low-speed agitators for improved temperature control.
  • L-style mix head with chemical/hydraulic separation and adjustable cleanout piston stroke for optimum mixing.

 “With the ECOPlus, you get a lot of performance for a relatively low price,” said Mark Clark, general manager of PPI, which is the exclusive dealer of OMS equipment in the United States. 

“The machines are suitable for virtually any polyurethane application. And there are a lot of features on a standard ECOPlus that are not available, or available only as pricey options, on other basic metering machines,” Clark said.

OMS designed the ECOPlus for flexibility, reliability, easy operation and low maintenance. 

The ECOPlus frame is compact, with components mounted for easy access. The control system is completely self-diagnostic, continuously checking that all variables are within the correct pre-set operating ranges. If a variable falls outside its range, the ECOPlus will signal an alarm and display a clear text message indicating the cause of the problem and what the operator should do to maintain safe working conditions. The control also keeps track of items that require routine maintenance. 

The operator can carry out nearly all operations without leaving the pour station. All operating parameters and machine variables, including outputs, are set and displayed on a monochromatic touchscreen panel mounted with the mix head at the end of the boom. If the ECOPlus is configured with two mix heads, the touchscreen is placed at the main operating panel. 

The Rotary Power metering pumps and a control system based on Allen-Bradley technology and components ensures worldwide availability of parts and service. Because the pump output is adjusted via an inverter and the PLC, the pumps have fewer seals and parts to maintain. 

“There are a number of accessories available to make operation and maintenance even easier,” Clark said. “We can add fill pumps, closed-loop flow control, magnetic couplings on the metering pumps or any of dozens of other available options to make the ECOPlus fit a specific application or workflow.”