MACHINERY | PIPE JOINING
Borouge PE100 DR21 pipe. This varied in thickness from 3 to 3.75in, which added to the alignment, heat soak and cool time. Initial test fusions were conducted to undergo bend back testing. It was decided to remove all the internal bead formations to create a smooth surface and check for proper alignment. Fusions began at the base of the mountain with
Right: The TracStar iSeries will raise
performance and reliability in pipe fusion, says McElroy
McElroy’s MegaMc 1600 and the Talon joining two 40ft sticks of pipe together. A flatbed truck moved these 20,000lb, 80ft sections up the mountain. Once they were staged, the Talon was placed on a low-loading trailer for the nine-mile trip up the mountain to begin fusing. The Talon managed to fuse four joints each day – and sometimes reached as high as six per day. Water was flowing in the pipeline in July, after taking less than two months to complete – which beat the time allotted for fusion. Altogether the Talon performed 155 fusions, and 120 of those were high on that mountain.
Lifting performance Recently, McElroy also introduced its latest TracStar iSeries – which it says will bring a new level of performance and reliability to pipe fusion. The three models in the series retain the TracStar’s rugged, self-contained tracked vehicle while adding new features, says McElroy. “The iSeries is an evolution inspired by the feedback we have received from those on the front lines of fusion,” said Geoff Koch, vice president of product development at McElroy. “We believe this will move the fusible pipe industry forward in the water, mining and natural gas distribution sectors.” The iSeries is powered by the new FusionGuide
control system, which offers three levels of control – from operator-controlled to completely automat- ic, machine-controlled operations. These were added to reduce common user errors and to improve productivity. A DataLogger 7 is integrated with the iSeries, and enhanced guided workflow takes the operator deep into the fusion process. It also ensures that each fusion joint is recorded and complies with the fusion standard. The TracStar 630i, 900i and 1200i cover three
size ranges from 8in IPS to 48in OD (225mm- 1200mm). All are equipped with a new, quieter engine that meets US Tier 4 and EU Stage V
34 PIPE & PROFILE EXTRUSION | May 2021
environmental regulations while providing greater torque. The system pressure was raised to more than 3,000 psi for more powerful ground drive, pipe lifts and other functions that use higher levels of pressure.
Socket systems Pipe joining machinery usually attaches one section of pipe to the next, but Baruffaldi has developed a number of systems that join a socket to the end of the pipe. Its Primac-branded SRM and IAM-S machines both work inline and are positioned after the cutting saw. When a section of pipe needs the socket, it is diverted
from the extrusion line. An automatic pick-and-place unit positions the socket at
one end of the pipe. The SRM is a welding machine for corrugated
pipes, that joins the socket to the pipe using a patented heat-welding system; the IAM-S is a friction welding machine for both smooth and corrugated pipes and uses a spin welding system. Both machines can be equipped with a device
that automatically tests welding quality and triggers an alarm in case of anomalies. Sockets can be added to pipes without affecting
extrusion line speed, and welds will keep their integrity even if the pipe is stored for a long time or laid incorrectly. In 2019, Baruffaldi studied a new pipe handling system in which a pipe section and socket can be tilted off the side of the machine – to roll along inclined supports and temporarily held under the machine – or automatically unloaded onto a palletiser unit, according to the customer’s needs. The socket welding machines cover pipe diameters from OD 32mm to OD 630mm for the IAM-S and OD 110mm to OD 1200mm for the SRM. Pipes can be of any length up to 12m. Baruffaldi can also customise machines to meet specific customer needs.
PVC for potable water Italy-based Benvic has developed a new grade of PVC for making injection-moulded pipe fittings. The IA608 grade had to work at pressures up to
25MPa while ensuring chemical contact compli- ance with potable water – with no emissions. It is made from a high molecular weight PVC resin and
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IMAGE: MCELROY
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