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

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The company is looking to research and develop a novel convection moulding process andpipe pup jointing techniques to enable the development of a range of moulded polyethylenepipe fitting profiles (equal tee, elbow, reducers and end caps) between the size of 630mm and2500mm diameter. The current state of art large diameter fittings are produced frompolyethylene, ductile iron and steel. There is no beneficial reason for using steel or ductileiron fittings on polyethylene pipelines due to issues with corrosion and joint failure. In termsof large diameter polyethylene pipe fittings, these are available in two forms,fabricated andmachine from solid although the machined fittings are only available upto 1000mm diameter.The most commonly available large diameter polyethylene pipe fittings are manufactured byfabricating large diameter pipe sections. However, with this method of manufacture thestructural 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 fullpressure rated large diameter polyethylene pipe fittings are produced by machining the fittingfrom a solid piece of polyethylene block, but only upto 1000mm diameter. Large diameter fullpressure rated polyethylene pipe fittings manufactured from solid cost anything from £12,000for 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 withhigh cost of machined fittings the company has identified moulding techniques and fittingdesigns which will reduce the cost of manufacture to 50% of existing machined fittings whilstproviding a design which provides external structural re-enforcement.