RTP Line Upgrade & Retrofit

RTP Line Service

RTP Line Upgrade & Retrofit

Existing RTP lines can often be improved without replacing every module. The practical route is to audit the current process, identify the bottleneck and then upgrade the winder, heating, jacket, cooling, haul-off, coiling or control system that limits quality, output or product range.

RTP production line layout used as a reference for upgrade and retrofit planning

When an upgrade makes sense

Output bottleneckThe line cannot reach the target output because one module limits line speed or stability.
Winding qualityTape tension, angle repeatability or layer placement varies during acceleration.
Heating / jacket issuesBonding, diameter or surface quality is unstable across the product range.
Coil qualityThe coiler limits coil size, causes ovality or cannot handle the required pipe stiffness.
New product rangeThe existing line cannot handle a new diameter, pressure class, tape type or jacket material.
Controls and dataRecipes, alarms, traceability or remote support are outdated or unreliable.

Upgrade modules

Module Typical upgrade What must be checked
Winding Servo axes, tension control, guide system, recipe management, additional winding capacity Pipe range, tape data, layer schedule, mechanical space and control compatibility
Heating and activation Zone control, airflow, exhaust, temperature measurement, line-speed compensation Material window, oven length, utility capacity and product temperature requirement
Jacket extrusion Extruder, cross-head die, sizing, cooling and diameter feedback Jacket material, output, pipe range and existing drive/control interface
Haul-off and cutting Caterpillar haul-off, encoder synchronization, planetary cutter, cut-length control Line speed, pipe stiffness, cut accuracy and downstream coiler interface
Coiling Coil geometry, tension control, cutover, handling and packaging Bend radius, coil weight, floor space and transport limits
Controls and quality PLC/HMI, recipes, data logging, diameter gauge and traceability interface Existing PLC brand, network, sensor availability and required records

Retrofit process

1. Line audit

Review layout, equipment list, PLC, drives, utilities, product range and current bottlenecks.

2. Gap analysis

Compare current capability with the target pipe matrix, output and quality records.

3. Feasibility and layout

Check mechanical space, utility capacity, control interface and shutdown plan.

4. Implementation

Supply and integrate the selected modules with the existing line where technically feasible.

5. Re-commissioning

Dry run, material trials, recipe validation and operator handover after the upgrade.

New-line baseline for comparison

The confirmed BENK RTP line baseline is 50–200 mm ID / 63–250 mm OD, 1.6–6.4 MPa standard pressure, 120–350 kg/h, 0.5–8 m/min, 401.5 kW installed power and 33 equipment items / 34 machines. A retrofit does not automatically reach every value; the final scope depends on the existing equipment and utilities.

Retrofit feasibility must be confirmed by an audit. Reusing existing frames, drives or utilities can reduce cost, but incompatible components can also limit performance or create safety and quality risks.

Start with the bottleneck, not a parts list

Send the existing line layout, equipment list, PLC brand, pipe range and target output. BENK will identify which modules can be upgraded and what must be replaced.

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