Output ranges from 5 to 2,000 Kgs per minute with up to 6 components
CTM design and assemble high performance PU elastomer casting machinery for the offshore industries for the manufacture of the following offshore components:
Cable & flow-line protection systems, Bend stiffeners, Bend restrictors, Drill Riser Buoyancy Modules.
Our offshore machinery range also includes High Performance Syntactic Foam metering units (G.S.P.U.) for the thermal protection of
Wellheads, Xmas trees, Manifolds, Jumpers, Spool pieces, Flow line ends, Riser ends, Terminations Flange connections.
Multi Component Hydraulic Mixing Head
6 components mixing head
Safety in mind
Key features when working on the mixer and barrel.
A mechanical interlock with switched feed back ensures that the mixing head motor cannot run which is complemented with an electrical isolation switch so as to ensure complete safety when carrying out routine maintenance.
System pressures at the mixing head
Process pressures are monitored directly at the mixing head.
The pressure gauges use Profibus PA to communicate with the main control system thus allowing for pressure trending to be created and stored.
Components injector control
Up to 6 component injectors can be mounted onto a common valve manifold.
The system is modular therefore allowing more injectors to be added at a future date
Each injector is independently operated by the machine control system.
The system is designed to enable different PU systems to be processed from the appropriate pump and tank modules
Mixing head injector control unit
Self contained unit mounted within the mixing head main support frame.
System pressure indicator with feed back to the control system.
Integral pressure safety relief valve.
Differential oil pressure switch so that the pump only runs when required.
Oil level & temperature indicator.
Further key features of CTM’s mixing technologies.
Multi point isocyanate injection ports.
All steel construction with anti corrosion coating.
Control of pouring and recycling pressures via a single pressure adjuster.
Water heated mixing head body.
Jacketed & water heated stainless steel feed and return hoses.
Inverter driven mixing head motor c/w fully programmable speed control depending upon selected out.
Fully variable mixing rate change from minimum to maximum output during pouring phase.
High torque mixing head drive belt with belt tensioning idler pulley thus avoiding any side loads on the mixer shaft
Flow Rate & Output Control System
Pump & flow meter modules
Completely modular thus allowing additional modules to be installed at a future date.
Each module houses the metering pumps, mass flow meters, safety pressure control system, servo valves, & a control unit with a dedicated PLC.
The metering unit modules house two magnetically driven Kracht precision metering pumps which can run in single pump or twin pumps mode so as to allow for maximum output change whilst pouring.
Highly variable output range control
Close up view of pneumatically driven servo controlled flow isolation valve showing switched feed back unit mounted to the top of the valve.
These valves are automatically configured depending upon selected output required during pouring.
Precision components monitoring systems
Each pump module features an Endress & Hauser mass flow meter thus enabling the CTM control system to monitor several key parameters.
Precise component flow rate directly in Kgs
Actual component ‘inline’ temperature
All measured system parameters are monitored and logged by the control system via a Profibus PA network.
Components Storage and Conditioning System
Precision components conditioning systems
Components level system.
Components pressure & vacuum system.
Components vacuum cycle isolation valves.
Components temperature management system.
Components over pressure safety system.
Components blending system.
Components vacuuming system.
Components loading system.
Precision components level control system
We employ Endress & Hauser level monitoring systems which deliver continual component level information to the main control system through a profibus PA network. This system ensures that pouring weights that exceed the component tank content are not possible.
In Addition the system offers the following features
Percentage level display on main control display.
Non contact system.
Feed back system for safe and automated degassing cycle.
Recorded history of component tank content & level of vacuum achieved.
Precision components pressure & vacuum control system
Components pressure monitoring.
Components vacuum monitoring.
Components vacuum cycle feed back.
The pressure and vacuum condition of the component is constantly sent back to the main control system via a Profibus PA network.
Precision components pressure & vacuum control system
Components pressure is directly managed by the main control system by communication with the installed proportional pressure control system.
Components vacuum level is directly managed by the main control system.
A fully automated components vacuum cycle can be programmed directly from the main control system.
Vacuum control system
Fully automatic vacuum cycles are achieved by using servo controlled isolation vacuum valves.
This valve is fitted with switched feed back so as to ensure that the main control system is able to control and manage the appropriate vacuum level required.
Vacuum delivery system
Fully automatic vacuum is achieved by using a Becker vacuum pump.
The Becker vacuum pump runs continually during any component de gassing cycle.
Appropriate vacuum level is both managed and controlled by the main control system
Process heating system
Fully automatic heating is achieved by using a suitably rated self contained process heating unit.
The heating unit has an integral heat exchanger coupled to a separate shared chiller unit (not shown) so as to provided an accurate temperature control system.
Components blending system
An appropriate level of component blending is achieved by the use of a suitably designed component agitation unit.
Full pressure and vacuum sealing is achieved by the use of a suitable shaft seal system.
Components loading system
Suitably rated component loading pumps provide the required rate of component re-filling.
The Main Control System
Control system overview
The main menu page of the HMI is the main gateway to navigating the full CTM control system.
The following pages are accessed from this page.
Component A. controls
Component B. controls
Component C. controls
Component A. temperature & conditioning controls
Component B. temperature & conditioning controls
Component C. temperature & conditioning controls
Current cycle data
Last cycle data
Power meter data
Wet weight verification
Control system interface
The gateway to CTM advanced control technology
Components vacuum control system
From this page it is possible to program the vacuuming cycle for each component.
This feature enables the possibility to complete overnight vacuum conditioning of materials in a safe manner.
System data acquisition system
From this page it is possible to acquire store & record in graphic format all key parameters of the metering CTM unit
All measured parameters are available for external analysis.
Chemical system data storage
From this page it is possible to define the parameters of the raw material being processed.
Both OH and NCO values can be entered so as to enable the control system to make the final required adjustments so as to attain the optimum mix ratio.
System alarm status
From this page it is possible to view all possible alarm conditions.
The CTM on board VPN system enables CTM to access these pages so as to provide in time remote support on all machine parameters and overall equipment status.
Metering pumps set up
From this page it is possible to view the status of all metering pumps.
Again the on board VPN system enables CTM to access these pages so as to provide in time remote support on all machine parameters and overall equipment status.