butt fusion machine manufacturer

RIYANG FUSION MANUFACTURING LIMITED
ABOUT FUSION

RIYANG fusion machines are capable of fusing a variety of different types and sizes of thermoplastic pipes.

BUTT FUSION MACHINE
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WHY USE HDPE
High Density Polyethylene Pipe (HDPE) and fittings are quickly becoming the material of choice among engineers, contractors and customers for a wide variety of industry applications including municipal, industrial, energy, geothermal, marine, mining, landfill, HVAC, gas, oil, mining and agricultural applications.HDPE is a thermoplastic pipe made from material that can be melted and reformed. It is rugged, flexible, and durable.  It has outstanding chemical and environmental stress crack resistance.

1.CORROSION RESISTANCE

Corrosion is one of the most costly problems associated with metal piping systems. It occurs both inside and outside the pipe and affects hydraulic efficiency. Many cities treat their water to help slow rust and pitting that is inevitable with metal pipes. Others choose costly cathodic protection, plastic coating, or sleeving to try and extend the service life of the pipe.

Unlike traditional metal infrastructure products, HDPE pipe does not rust, rot or corrode. It is resistant to biological growth. This means an extended service life and long term cost savings.

2.HIGH STRENGTH AND EXTREME DURABILITY

HDPE pipe is flexible and ductile, not rigid. It has outstanding resistance to fatigue. Unlike other plastic pipes, it is designed and pressure rated to handle the kind of occasional and recurring surge events that are common in water distribution systems. HDPE pipe is a safe and durable product ideal for your piping infrastructure. The service life of HDPE is estimated to be between 50 to 100 years, depending on application, design and installation.

3.Fusion Joints

Heat fusion welded jointing methods create a completely homogeneous joint which is as strong as, or stronger than the pipe itself. This eliminates jointing chemicals (like in PVC pipe) or rubber seals which can fail over time, also solving root intrusion problems, and provides pipeline integrity where installed in unstable ground.

4.Superior Flow

Because high-density polyethylene pipe is smoother than steel, cast iron, ductile iron, or concrete, a smaller diameter HDPE pipe can produce an equivalent volumetric flow rate at the same pressure. It has less drag and a lower tendency for turbulence at high flow rates. HDPE’s superior chemical resistance and non-stick surface characteristics nearly eliminate scaling and pitting, preserving the excellent hydraulic characteristics throughout the pipe system’s service life.

5.COST EFFECTIVE

High-density polyethylene pipe installations are cost effective and have long term cost advantages due to its physical properties, leak free joints and vastly reduced maintenance costs. This relates to savings in replacement costs for generations to come. The properties of PE also allow unique installation methods, such as Horizontal Directional Drilling, Pipe Bursting, Slip-lining, Plough and Plant, Submerged or Floating Pipe, etc.

6.Trenchless Installation

Traditional piping systems are installed by open cut (digging a ditch), resulting in traffic and environmental disruption. HDPE can be installed using this traditional open-cut method or by utilizing eco-friendly trenchless technology. For trenchless installation, a horizontal directional machine bores a continuous hole beneath the ground. When the drilling head reaches the end of the bore, the pipe is attached and pulled back through the hole.

It is much easier to handle and install lightweight HDPE pipe vs. the heavier, rigid PVC or metallic pipe segments, allowing for cost advantages in the construction process.

WHERE IS HDPE USED

Natural Gas Distribution

HVAC And Mechanical Systems

Potable Water Delivery

Fire Suppression Systems

Greywater And Sewer Lines

Geothermal Installations

Water Distribution And Transmission

FUSION PROCESS
Generally speaking, HDPE pipe is butt fused by applying heat to prepared pipe ends and then pushing the pipe ends together with a pre-determined force to make a permanent butt fusion joint. It is a very simple process utilizing a properly sized butt fusion machine for the pipe size to be joined.

1.Clamping the pipes in the butt fusion machine.

2.Facing the pipe ends to ensure clean, parallel for the heating process.

3.Heating the pipes according to the butt fusion standard, removing the heater once the heating criteria achieved.

4.Jointing the pipes at the pre-determined force. And keep the pressure held for the time required by standard.

HOW TO CALCULATE

To properly fuse the thermoplastic pipes and ensure the weld quality, the operator is always obliged to find the right fusion pressure and time under the welding standard which requested by the project.

You could consult with our sales to ask for the welding table for Riyang butt fusion machine (Riyang fusion pressure calculator is on the way), or you could use other fusion pressure calculator APP to work out the pressure and time.This page will indicate how to calculate the fusion pressure and time manually, we will use the standard ISO21307:2017 as an example.

EXAMPLE

Standard: ISO21307:2017 Single Low-pressure

Machine: Riyang Basic Butt Fusion Machine V315

Pipe: OD315, SDR17

Step 1

Check below illustration for single low-pressure fusion jointing cycle.

Key

Xtime

Ypressure

P1bead-up pressure

P2heat soak pressure

P3fusion jointing pressure

t1bead-up time

t2heat soak time

t3heater plat removal time

t4time to achieve fusion jointing pressure

t5cooling time in the machine under pressure

t6cooling time out of the machine

Step 2

Check out the formula of the gauge pressure calculation

Where

GPis the gauge pressure (bar);

IPis the interfacial pressure (MPa);

ACis the total effective piston area, given by the manufacturer of butt fusion machine (mm2)

ASis the interfacial surface area (mm2)

DPis the drag pressure

Note: The interfacial pressure is the amount of force per unit of pipe area required to butt fuse the pipe or fitting ends.

Note: The interfacial pressure is the amount of force per unit of pipe area required to butt fuse the pipe or fitting ends.

Step 3

Refer to below tables for phases , parameters and values for single low-pressure fusion jointing procedure

Note:

1.(en + 3) This is the cooling time for the butt joint when still in the machine and under pressure. Cooling time may be shortened and should be lengthened depending on ambient temperature (approximately 1% per 1℃)

2.(d) A cooling time out of the machine and before rough handling maybe recommended.

Step 4

Now using all information and formula above we will calculate all values by maximum

en= dn/ SDR = 315mm / 17 = 18.52 mm

P1= P3 0.19 x {π x (dn-en) x en}÷2000 x 10} + 5 (for example) = 21 bar

P2DP = 5 bar

t1= bead-up size 0.5 + 0.1 x 18.52mm = 2.3 mm

t2(13.5 ± 1.5) x 18.52 = 278 s

t310 s

t43 + 0.03 x 315 = 12.5 s

t50.015 x 18.522- 0.47 x 18.52 + 20 = 16 min

t6d

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RIYANG FUSION MANUFACTURING LIMITED

Riyang fusion machine has been applied to more than 60 countries and regions in the fields of polyethylene pipe manufacturers, gas construction projects, irrigation projects, mining and civil installations, etc.MOER

Contact us

For support or any questions:

info@riyang-welding.com

call us: +86 13588820387