Research and development of a novel convection moulding process and butt fusion pipe pup jointing system capable of producing large diameter (630mm to 2500mm) high density polyethylene pipe fittings of various designs and profiles

The company is looking to research and develop a novel convection moulding process and
pipe pup jointing techniques to enable the development of a range of moulded polyethylene
pipe fitting profiles (equal tee, elbow, reducers and end caps) between the size of 630mm and
2500mm diameter. The current state of art large diameter fittings are produced from
polyethylene, ductile iron and steel. There is no beneficial reason for using steel or ductile
iron fittings on polyethylene pipelines due to issues with corrosion and joint failure. In terms
of large diameter polyethylene pipe fittings, these are available in two forms,fabricated and
machine from solid although the machined fittings are only available upto 1000mm diameter.
The most commonly available large diameter polyethylene pipe fittings are manufactured by
fabricating large diameter pipe sections. However, with this method of manufacture the
structural integrity is reduced, the operating pressure of the pipe has to be reduced (de-rated)
sometimes by up 80% reducing the efficiency of the pipeline. The only current art full
pressure rated large diameter polyethylene pipe fittings are produced by machining the fitting
from a solid piece of polyethylene block, but only upto 1000mm diameter. Large diameter full
pressure rated polyethylene pipe fittings manufactured from solid cost anything from £12,000
for a 630mm fitting. As manufacture using conventional injection moulding is cost prohibitive
£5m + for the moulding machine and tooling to mould 630mm + diameter fittings and with
high cost of machined fittings the company has identified moulding techniques and fitting
designs which will reduce the cost of manufacture to 50% of existing machined fittings whilst
providing a design which provides external structural re-enforcement.