Hdpe Pipe Connection Methods

POLYETHYLENE PIPE CONNECTION METHODS

BONGING FIXED METHODS :

1)       METODBUTT WELDING WİTH COMBINING METHODS
2)       ELECTRO FUSUION COUPLING WITH COMBINING METHODS

POLYETHYLENE PIPE CONNECTION METHODS

The welding machine used for the joining method with the forehead weld consists of 4 main tools;
1 -) CLAMPLAR :
The hydraulic system is designed to fix and adjust the pipe and / or additional parts to be welded. There are crescent adapters on the apparatus so that they can be worked on different pipes.
2 - ) TRACING UNITS  :
It is used with the aim of cleaning the forehead surface to be welded and cleaning pipes and making pipe lines perpendicular to the axial line so that pipe ends are in full contact with each other.
3-) HEAT UNITS  :
It is a metal plate which ensures that the foreheads that are to be welded are heated to the proper melting temperature.
4-) HYDRAULIC SYSTEM UNIT  :
It is the unit that provides the hydraulic pressure required for all steps during the feeder application, in order to be able to give the horizontal axial movement capability to the clamp.

PREPARATION REQUIRED FOR BUTT WELDING 

NECESSARY WEATHER CONDITIONS : 
Measurement of air temperature ; Air temperature should be minimum + 5 ° C.
Humidity Rate : 
In damp weather, using a tarpaulin should ensure that the moisture in the environment is reduced ,lost most.
Enviroment Heat :
Preheating should be done by reaching to minimum +5 ° C ambient temperature with the help of the heaters of the closed area by closing the welded environment by means of technical applications such as installation of mobile tent or using tarpaulin in cold weather.
Sunshine radiation effect  :
During the forehead welding application, the area to be welded must be exposed to sunlight radiation and the shade should be done in order to prevent the reaction which may occur.
Powder effect  :
The welding process should not be done in dusty environments. If the welding operation is performed in a dusty environment, the necessary precautions should be taken to purify the environment from dust.
Air circulation  :
It is possible to increase the quality of the welding process and to prevent the air circulation inside the pipes by closing the pipe heads.

WHAT SHOULD BE CONSIDERED THE BUTT WELDING PROCESS

TECHNICAL RESTRICTIONS :

  • The outside diameters of the pipes to be welded shall be minimum 50 mm to maximum 1600 mm.
  • The wall thickness of the pipe and additional parts to be welded must be between 5 mm minimum and 100 mm maximum depending on the outside diameter of the pipe..
  • The pipe thicknesses to be combined with the butt weld must be equal, the pipe wall thickness ratio in different cases must not exceed 10%.
  • The butt welding machine must be certified.
  • Butt welding operation must be done in accordance with DVS 2207 standard.

WHAT SHOULD BE IMPORTANT IN APPLICATION :

  • It is necessary to attach the tubes on the clamp in such a way that the axial line of the tubes will be perpendicular and the front faces exactly match each other.
  • The surface of the forehead should be shaved to remove oxides and dirt and cleaned thoroughly with a cleaning solution.
  • After the surface of the forehead is shaved, it should not be touched or contaminated. If it is contaminated, it needs to be trackıng again. After the trackıng, the powder should be cleaned without touching the burr.
  • When iron (heater plate) heat value selection is made, selection should be made according to the standard values table considering the raw material in which the pipe is produced. For the pipes with low meat thickness during the value analysis, the upper temperature value in the table should be selected and for the pipes with high meat thickness, the lower temperature values should be selected.
  • The iron should wait at least 5 minutes after reaching the set temperature value.Iron surfaces should be free from all kinds of dust, plastic residues and oxidation.
  • Ironing surfaces should not be damaged.
  • During the welding operation, the hydraulic unit should be used for the measurements specified in the standard table.
  • The welding pressure test for pressurized pipe systems is carried out according to EN 805 standard.

BUTT WELDING OPERATION APPLIED 

Before starting the welding process, the following steps must be carried out after preparing the welding environment as described above;


The welding temperature to be set is related to the pipe wall thickness, the ironing (heating plate) temperature has an average temperature of 200 - 220 ° C, the welding temperature to be selected is indicated in the table below.

HEAT PRESSURE :
The heating time is the pressure that will be fixed during the heating of the foreheads by placing the iron between the pipe top surfaces and touching the pipe top surfaces to the iron surface, In this process, the contact surfaces of the forehead should be kept under low pressure. The pressure should be fixed at P <0,02 N / mm² during the heating process.
HEAT PRESSURE :
It is important to place the pipe between the pipe front surfaces and wait for the front surfaces to warm up after the necessary pressure is set. This time; HEATING TIME = e • 10 s. (HEATING TIME = PIPE THICKNESS X 10 SECONDS).
LIP HEIGHT :
It is the enlargement of the wall which is formed by applying pressure of P <0,15 N / mm² to the pipe fronts leaning against the iron surfaces. The expanding wall height is calculated as H = 0,55 mm + (0,1 • e). (LENGTH HEIGHT = 0,55 mm + (0.1 X meat thickness)

( Maximum space allowed )

Center error (misalignment), gap width should be checked or not. The gap width should be reduced or even reset as you get closer. Missed places should be no more than 0,1 × meat thickness, this number should not be exceeded.
CHANGE TIME :
It is the time to remove the tubes from the iron and remove the iron from the iron so that the iron lip height reaches to the standard high level under the specified pressure and temperature. The replacement time must not exceed the time specified in the table, otherwise the quality of the weld will decrease as the heated zone will cool down. During this time the heated zone must never be touched, contaminated or impacted.
COMBINING TIME :
At the end of the replacement time, it is the time to pressurize the pipe surfaces to each other immediately after the iron has been removed from the pipes. The elapsed time between the replacement time and the defragmentation time should be close. Combination time pressure P = 0,15 ± 0,01.
COOLING DURING PRESSURE :
It is expected to cool the weld without changing the pressure after the pressurized joining surfaces are joined together. During this time, the pressure must not be changed, the clamps should not be loosened, the pipe should not be moved, and the pipe should never be exposed to impact.
Double lips are formed after the joints of the pipes are made. The shape, straightness, and size of these lips indicate that the weld is made correctly. Depending on the duration of heating, degree, placement, pressure, lip shapes are formed. The K value shown in the figure should be greater than zero. The time required for this is given in the table below (the recommended source parameters).

If any of the parameters in the table are not followed, the forehead operations must be do again.

Butt Welding Methods Welding Errors


Lip width too much

Extreme heating; Extra joining force
The middle part of the lip difference are too much Extra joining force;missing heating; Pressure during heating
Lips area is sraight Extra joining force; extra heating

Uniform on the lip non-lip

Incorrect placement; Defective heating system wrong equipment; insufficient tracıng 
Very small ocur lips Missing heating; missing joining force
The formation of irregular lips on the outer surface of the pipe (not to be overlaid)The gap formed in the middle part of the lip is minimal
Insufficient heating and insufficient combining pressure
Lot of space formed in the middle part of the lip
Insufficient heating and extra joining force
 Very big occur lips It occurs because of too much heating time.
The outer edges of the formed lips form a square Pressure was applied during heating
Lip surface rough It is contaminated with hydrocarbons during welding.

Welding Machine Maintenance

  • Make sure the welding source to which the forehead welding machine is connected works properly
  • The plates should be kept clean. Clean the clothes with cotton cloths at the appropriate temperature.
  • Tracıng must be sharp. The knife can be used on both sides If it is broken, you can use the other side or you know the blades.
  • There should be no scratches, damage or impact on the plates.
  • The oil level in the oil reservoir of the machine must be checked. To avoid damaging the hydraulic pump, good quality hydraulic oil must be used.

Problems Encountered in Welding Operations/Reasons/Solution

PROBLEMREASONSOLUTION

A temperature that differs from the set temperature working in the interval.
Example: If it is set to 215 ° C work betwee 190-230

Corruption of hysteresis setting

Press down and up on the machine together for 5 seconds. HYSI must be 1 or 3.not chage ıf this value.

Compared to PFA letters on the machine display

This can be caused by the breakdown of the thermocouple wire at the bottom of the forehead welding machine, removal or short circuit.

Starting from checking the heater control device, the terminated cable, which is stainless steel wire in the wires that feed the forehead welding machine, has a broken and non-contact area. You can cut the broken cable and add 1 or 0.75 cable. The problem will be solved when the PFA on the machine screen goes off.

The press machine is pressed on the walking button and the hydraulic engine is not running.

Problem of the with the tube, If there is a problem with the hose connections or if the valve is blocked, this problem
It may come to fruition.

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application (PN4)

Outside diameter 
DN(mm)

Meat thickness
S(mm)
Lip height
h(mm)
Serbest ısıtma
süresi
t1(saniye)
Isıtıcının geri
çekilme süresi
t2(saniye)
Kaynak basıncına
ulaşma süresi
t3(saniye)
Basınç altında
soğuma süresi
t4(saniye)
Toplam kaynak
süresi
t5(dakika)
63 2 0.5 20 5 5 6.0 6.5
75 2.3 0.5 23 5 5 6.0 6.6
90 2.8 0.5 28 5 5 6.0 6.6
110 3.4 0.5 34 5 5 6.0 6.7
125 3.9 0.5 39 5 5 6.0 6.8
140 4.3 0.5 43 5 5 6.0 6.9
160 4.9 1.0 49 5 5 6.6 7.6
180 5,5 1.0 55 5 5 7.6 8.7
200 6.2 1.0 62 6 6 8.7 9.9
225 6.9 1.0 69 6 6 9.8 11.2
250 7.7 1.5 77 6 6 10.8 12.3
285 8.6 1.5 86 7 7 11.9 13.6
315 9.7 1.5 97 7 7 13.2 15.1
355 10.9 1.5 109 8 8 14.7 16.7
400 12.3 2.0 123 8 8 16.3 18.7
450 13.8 2.0 138 9 9 18.1 20.6
500 15.3 2.0 153 9 9 19.8 22.6
560 17.2 2.0 172 9 10 21.9 25.1
630 19.3 2.5 193 10 11 24.3 27.9
710 21.8 2.7 327 11 24 27.2 33.2
800 24.5 3.0 368 12 27 30.3 37.1
900 27.6 3.3 414 13 30 33.9 41.5
1000 30.6 3.6 459 14 33 37.4 45.9
1200 36.7 4.2 551 16 39 44.7 54.7
1400 42.9 4.8 644 19 45 55.6 67.3
1600 49 5.4 735 20 51 59.4 72.8

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application (PN6)

Outside diameter  
DN(mm) 

Meat thickness
S(mm) 
Lip height
h(mm) 
Free heating time
t1(second) 
Back of the heater Withdrawal time 
t2(second) 
Time to reach welding press
t3(second) 
Cool-down time under pressure
t4(second) 
Total duration
t5(minute) 
50 1.8 0.5 18 5 5 6.0 6.5 63 2.4 0.5 24 5 5 6.0 6.6 75 2.7 0.5 27 5 5 6.0 6.6 90 3.3 0.5 33 5 5 6.0 6.7 110 4 0.5 40 5 5 6.0 6.8 125 4.5 1.0 45 5 5 6.0 6.9 140 5.1 1.0 51 5 5 7.0 8.0 160 5.8 1.0 58 6 6 8.1 9.2 180 6.5 1.0 65 6 6 9.2 10.5 200 7.2 1.5 72 6 6 10.2 11.6 225 8.2 1.5 82 6 6 11.2 12.8 250 9.1 1.5 91 7 7 12.1 13.8 280 10.1 1.5 101 7 7 13.1 15.0 315 11.4 1.5 114 8 8 14.4 16.6 355 12.9 2.0 129 8 8 16.9 19.3 400 14.5 2.0 145 9 9 18.5 21.2 450 16.3 2.0 163 9 10 20.3 23.3 500 18.1 2.0 181 10 11 22.1 25.5 560 20.3 2.5 203 10 12 25.3 29.0 630 22.8 2.5 228 11 13 27.8 32.0 710 25.7 3.1 386 12 24 30.7 3.7 800 29 3.4 435 13 27 35.0 42.9 900 32.6 3.8 489 14 30 38.6 47.5 1000 36.2 4.1 543 16 33 42.2 52.1 1200 43.5 4.9 653 19 39 45.0 56.8 1400 50.7 5.6 761 21 45 30.7 74.5 1600 58 6.3 870 26 51 68.0 83.8

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application (PN8)

Outside diameter  
DN(mm) 

Meat thickness
S(mm) 
Lip height
h(mm) 
Free heating time
t1(second) 
Back of the heater Withdrawal time 
t2(second) 
Time to reach welding press
t3(second) 
Cool-down time under pressure
t4(second) 
Total duration
t5(minute) 
50 2.4 0.5 24 5 5 6.0 6.6 63 3 0.5 30 5 5 6.0 6.7 75 3.6 0.5 36 5 5 6.0 6.8 90 4.3 0.5 43 5 5 6.0 6.9 110 5.3 1.0 53 5 5 7.3 8.3 125 6 1.0 60 6 6 8.4 9.6 140 6.7 1.0 67 6 6 9.5 10.8 160 7.7 1.5 77 6 6 10.8 12.3 180 8.6 1.5 86 7 7 11.9 13.6 200 9.6 1.5 96 7 7 13.1 15.0 225 10.8 1.5 108 8 8 14.6 16.6 250 11.9 1.5 119 8 8 15.9 18.1 280 13.4 2.0 138 8 9 17.6 20.1 315 15 2.0 150 9 9 19.4 22.2 355 16.9 2.0 169 9 10 21.6 24.7 400 19.1 2.5 191 10 11 24.1 27.6 450 21.5 2.5 215 11 12 26.9 30.8 500 23.9 2.5 239 11 13 29.6 34.0 560 26.7 3.0 267 12 14 32.8 37.7 630 30 3.0 300 13 16 36.7 42.2 710 33.9 3.9 509 15 24 41.3 50.5 800 38.1 4.3 572 18 27 52.6 62.8 900 42.9 4.8 644 19 30 55.6 67.1 1000 47.7 5.3 716 20 33 58.6 71.4 1200 57.2 6.2 858 25 39 67.2 82.6 1400 66.7 7.2 1001 33 45 76.7 94.7 1600 76.2 8.1 1143 42 51 87.5 108.1

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application (PN10)

Outside diameter  
DN(mm) 

Meat thickness
S(mm) 
Lip height
h(mm) 
Free heating time
t1(second) 
Back of the heater Withdrawal time 
t2(second) 
Time to reach welding press
t3(second) 
Cool-down time under pressure
t4(second) 
Total duration
t5(minute) 
40 2.4 0.5 24 5 5 6.0 6.6 50 3 0.5 30 5 5 6.0 6.7 63 3.8 0.5 38 5 5 6.0 6.8 75 4.5 1.0 45 5 5 6.0 6.9 90 5.4 1.0 54 5 5 7.4 8.5 110 6.6 1.0 66 6 6 9.4 10.7 125 7.4 1.5 74 6 6 10.5 11.9 140 8.3 1.5 83 7 7 11.6 13.2 160 9.5 1.5 95 7 7 13.0 14.8 180 10.7 1.5 107 7 7 14.4 16.5 200 11.9 1.5 119 8 8 15.9 18.1 225 13.4 2.0 134 8 9 17.6 20.1 250 14.8 2.0 148 9 9 19.2 22.0 280 16.6 2.0 166 9 10 21.3 24.3 315 18.7 2.0 187 10 11 23.7 27.1 355 21.1 2.5 211 11 12 26.4 30.3 400 23.7 2.5 237 11 13 29.4 33.7 450 26.7 3.0 267 12 14 32.8 37.7 500 29.7 3.0 297 13 16 36.4 41.8 560 33.2 3.0 332 15 17 40.5 46.6 630 37.4 3.5 374 18 22 52.1 59.0 710 42.1 4.7 632 19 24 55.1 66.3 800 47.4 5.2 711 20 27 58.4 71.0 900 53.3 5.8 800 22 30 63.3 77.5 1000 59.3 6.4 890 27 33 69.3 85.1 1200 70.6 7.6 1059 36 39 81.3 100.2 1400 82.4 8.7 1236 45 45 93.3 115.4 1600 94.1 9.9 1412 54 51 105.3 130.6

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application (PN12,5)

Outside diameter  
DN(mm) 

Meat thickness
S(mm) 
Lip height
h(mm) 
Free heating time
t1(second) 
Back of the heater Withdrawal time 
t2(second) 
Time to reach welding press
t3(second) 
Cool-down time under pressure
t4(second) 
Total duration
t5(minute) 
40 3 0.5 30 5 5 6.0 6.7 50 3.7 0.5 37 5 5 6.0 6.8 63 4.7 1.0 47 5 5 6.3 7.3 75 5.6 1.0 56 5 5 7.8 8.9 90 6.7 1.0 67 6 6 9.5 10.8 110 8.1 1.5 81 6 6 11.3 12.9 125 9.2 1.5 92 7 7 12.6 14.4 140 10.3 1.5 103 7 7 14.0 15.9 160 11.8 1.5 118 8 8 15.8 18.0 180 13.3 2.0 133 8 9 17.5 20.0 200 14.7 2.0 147 9 9 19.1 21.8 225 16.6 2.0 166 9 10 21.3 24.3 250 18.4 2.0 184 10 11 23.3 26.7 280 20.6 2.5 206 10 12 25.8 29.6 315 23.2 2.5 232 11 13 28.8 33.1 355 26.1 3.0 261 12 14 32.1 36.9 400 29.4 3.0 294 13 16 36.0 41.4 450 33.1 3.0 331 15 17 40.4 46.4 500 36.8 3.0 368 16 19 44.8 51.5 560 41.2 3.5 412 19 23 54.5 62.1 630 46.3 3.5 463 19 24 57.7 66.1 710 52.2 5.7 783 22 24 62.2 76.0 800 58.8 6.4 882 27 27 68.8 84.4 900 76.2 7.1 993 32 30 76.2 93.8 1000 73.5 7.9 1103 39 33 84.4 104.0

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application (PN16)

Outside diameter  
DN(mm) 

Meat thickness
S(mm) 
Lip height
h(mm) 
Free heating time
t1(second) 
Back of the heater Withdrawal time 
t2(second) 
Time to reach welding press
t3(second) 
Cool-down time under pressure
t4(second) 
Total duration
t5(minute) 
32 3 0.5 30 5 5 6.0 6.7 40 3.7 0.5 37 5 5 6.0 6.8 50 4.6 1.0 46 5 5 6.2 7.1 63 5.8 1.0 58 6 6 8.1 9.2 75 6.8 1.0 68 6 6 9.7 11.0 90 8.2 1.5 82 6 6 11.4 13.0 110 10.0 1.5 100 7 7 13.6 15.5 125 11.4 1.5 114 8 8 15.3 17.4 140 12.7 2.0 127 8 8 16.8 19.2 160 14.6 2.0 146 9 9 19.0 21.7 180 16.4 2.0 164 9 10 21.0 24.1 200 18.2 2.0 182 10 11 23.1 26.5 225 20.5 2.5 205 10 12 25.7 29.5 250 22.7 2.5 227 11 13 28.2 32.4 280 25.4 2.5 254 12 14 31.3 36.0 315 28.6 3.0 286 13 15 35.1 40.3 355 32.2 3.0 322 14 17 39.3 45.2 400 36.3 3.0 363 16 19 44.2 50.8 450 40.9 3.5 409 18 23 54.3 61.8 500 45.4 3.5 454 19 24 57.1 65.4 560 50.8 4.0 508 21 25 60.8 70.0 630 57.2 4.0 572 25 29 67.2 77.0 710 64.5 7.0 968 31 32 74.5 91.7

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application (PN20)

Outside diameter  
DN(mm) 

Meat thickness
S(mm) 
Lip height
h(mm) 
Free heating time
t1(second) 
Back of the heater Withdrawal time 
t2(second) 
Time to reach welding press
t3(second) 
Cool-down time under pressure
t4(second) 
Total duration
t5(minute) 
25 3 0.5 30 5 5 6.0 6.7 32 3.6 0.5 36 5 5 6.0 6.8 40 4.5 1.0 45 5 5 6.0 6.9 50 5.6 1.0 56 5 5 7.8 8.9 63 7.1 1.5 71 6 6 10.1 11.5 75 8.4 1.5 84 7 7 11.7 13.3 90 10.1 1.5 101 7 7 13.7 15.6 110 12.3 2.0 123 8 8 16.3 18.7 125 14 2.0 140 9 9 18.3 20.9 140 15.7 2.0 157 9 10 20.2 23.2 160 17.9 2.0 179 10 11 22.7 26.1 180 20.1 2.5 201 10 11 25.3 29.0 200 22.4 2.5 224 11 12 27.9 32.0 225 25.2 2.5 252 12 14 31.1 35.7 250 27.9 3.0 279 13 15 34.3 39.4 280 31.3 3.0 313 14 16 38.3 44.0 315 35.2 3.0 352 15 18 42.9 49.3 355 39.7 3.5 397 18 22 53.6 60.9 400 44.7 3.5 447 19 24 56.7 64.9 450 50.3 4.0 503 20 25 60.3 69.4 500 55.8 4.0 558 24 28 65.8 76.0 560 62.2 4.0 622 29 31 72.2 83.6

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application(PN 25)

Outside diameter  
DN(mm) 

Meat thickness
S(mm) 
Lip height
h(mm) 
Free heating time
t1(second) 
Back of the heater Withdrawal time 
t2(second) 
Time to reach welding press
t3(second) 
Cool-down time under pressure
t4(second) 
Total duration
t5(minute) 
20 3 0.5 30 5 5 6.0 6.7 25 3.5 0.5 35 5 5 6.0 6.8 32 4.4 0.5 44 5 5 6.0 6.9 40 5.5 1.0 55 5 5 7.6 8.7 50 6.9 1.0 69 6 6 9.8 11.2 63 8.6 1.5 86 7 7 11.9 13.6 75 10.3 1.5 103 7 7 14.0 15.9 90 12.3 2.0 123 8 8 16.3 18.7 110 15.1 2.0 151 9 9 19.5 22.4 125 17.1 2.0 171 9 10 21.8 25.0 140 19.2 2.5 192 10 11 24.2 27.8 160 21.9 2.5 219 11 12 27.3 31.3 180 24.6 2.5 246 12 13 30.4 34.9 200 27.4 3.0 274 13 15 33.7 38.7 225 30.8 3.0 308 14 16 37.7 49.3 250 34.2 3.0 342 15 18 41.7 47.9 280 38.3 3.5 383 18 22 52.7 59.7 315 43.1 3.5 431 19 23 55.7 63.6 355 48.5 3.5 485 20 25 59.1 67.9 400 54.7 4.0 547 24 27 64.7 74.7 450 61.5 4.0 615 29 31 71.5 82.7

Kuzeyboru HDPE100 Pipes Parameters of Butt Welding Application (PN32)

Outside diameter  
DN(mm) 

Meat thickness
S(mm) 
Lip height
h(mm) 
Free heating time
t1(second) 
Back of the heater Withdrawal time 
t2(second) 
Time to reach welding press
t3(second) 
Cool-down time under pressure
t4(second) 
Total duration
t5(minute) 
16 3 0.5 30 5 5 6.0 6.7 20 3.4 0.5 34 5 5 6.0 6.7 25 4.2 0.5 42 5 5 6.0 6.9 32 5.4 1.0 54 5 5 7.4 8.5 40 6.7 1.0 67 6 6 9.5 10.8 50 8.3 1.5 83 7 7 11.6 13.2 63 10.5 1.5 105 7 7 14.2 16.2 75 12.5 2.0 125 8 8 16.6 18.9 90 15 2.0 150 9 9 19.4 22.2 110 18.3 2.0 183 10 11 23.2 26.6 125 20.8 2.5 208 11 12 26.1 29.9 140 23.3 2.5 233 11 13 28.9 33.2 160 26.6 3.0 266 12 14 32.7 37.6 180 29.9 3.0 299 13 16 36.7 42.1 200 33.2 3.0 332 15 17 40.5 46.6 225 37.4 3.5 374 18 22 52.1 59.0 250 41.5 3.5 415 19 23 54.7 62.3 280 46.5 3.5 465 19 24 57.8 66.3 315 52.3 4.0 523 22 26 62.3 71.8 355 59 4.0 590 27 30 69.0 79.8 400 66.7 4.0 667 33 33 76.7 88.9

ELECTRO FUSION COUPLER WELDING METHOD

Electrofusion welding the pipes to be joined, and / or additional components, which are used as connection members to each other by using EF sleeve is welded with the art. In this embodiment the pipe disposed on the EF sleeve located inside the resistance wire of the electrical current heating the pipe surface and the sleeve bond is intended to do the resistance heating of the pipes with the outer wall heats and wall thickness pipe higher than the wall of the sleeve of the heat pipes than remains low, creating a potential difference between these welding process, the pressure in the welding zone.

ELECTRO FUSION COUPLER WITH MACHINES AND EQUIPMENT REQUIRED FOR JOINING METHOD :

1-) Electro Fusion welding Machine :

For the welding process parameters to be entered along with the necessary electric current should sleeve is a device that period
2-) Pipe Cleaning Apparatus :
Be connected to the sleeve and dirt scraped from the surface of the oxide equipment that are required to. 
3-) Pipe Clamp Set :
Taken perpendicular to the horizontal axis of the pipe so that pipes which cutting cutter, that is used to check the squareness of a 90 ° miter, and m are as auxiliary apparatus. 
4-) CLAMPLAR :
Allowing the removal of pipe clamps are ovoid.
5-) PLASTİK TOKMAK :
Manşonun yerleştirilmesi için gerekli olan yardımcı ekipmandır.

PRELIMINARY PREPARATION FOR ELECTRO FUSION WELDING

  • Fulfillment of eligibility check Electrofusion sleeve (diameter control, PN value control, eye control sleeve inner and outer strength, etc.) 
  • Welding operations necessary for adjusting the ambient temperature 
  • Resources from the ambient dust, moisture, oil, etc. elimination of such inconvenience 
  • Bad weather conditions, snow, rain, wind, sunlight, radiation, etc. In such cases, the closure of the media

MATTERS TO BE CONSIDERED IN APPLICATION OF ELECTRO FUSION WELDING: 

  • The tube being welded in electrofusion welding method should be made ​​of the same material. 
  • The pipes to be welded MFI (melt flow rate) value (190 ° C / 5 kg for test value) 0.2 to 1.3 g / min must be between 10.
  • Tubes with different MFI values ​​are not welded. 
  • Resources of the ambient air temperature should be between 5 ° C and 50 ° C. 
  • Elekrtofüzyo DVS 2207 standard should be based on the source. 

ELECTRO FUSION WELDING PARAMETERS VALUES :

For electrofusion welding machine, welding the sleeve to be used for parameter values ​​must be entered. To be entered, this information will be used on the sleeve separately and the device's barcode reading feature of the device to read barcodes in the form and manually entered to writing on the sleeve as a label has been applied, often large-scale sleeve these barcodes also card-shaped sleeves in the package is located.

APPLICATION OF ELECTRO FUSION WELDING:

Electrofusion welding cleaning is the first plan, or a dirty surface oxide resources that will be applied in accordance with generally poor quality and standards would be inappropriate. 

- Receipt of the tube to be welded of the pipe should be cut perpendicular to the horizontal axis, 
- Located in the central part of the sleeve pipe to be welded thresholds measured by the meter from outside to inside 
- These measures will be marked on the pipe 
- Marked blasting the area and so on. without tools, by means such as exaggerated so that the pipe surface is scraped from oxides and dirt is cleaned. (Pipes scraping 0,1 -, 0,7 mm should be.) 
- After etching of the pipe surface is cleaned with the cleaning solution. (Alcohol etc.) 
- If you have cleaned the pipe ovality in the pipe ovality is corrected with the help of clamps. 
- Prepared to be welded onto the pipe sleeve completely passed with the help of plastic mallet. 
- Other tubes and pipes with couplings have been taken to build on each other, to the point marked on the sleeve until the other pipe is made to pass. 
- Of the last transaction of the sleeve between the two pipes are intended to be placed symmetrically on an equal basis. 
- After the completion of the linking process Clutches electrofusion welding machine is connected to the socket on the sleeve. 
- To Electrofusion machine connected to the sleeve of the parametric values ​​by entering the welding process has been started 
- During the welding process and the impact should not be exposed pipes should definitely play.


CONNECTION WITH ELECTROFUSE COUPLINGS

The electrofusion source is a technique for boiling the pipe and / or additional parts to be joined together using an EF sleeve which is used as a joining element.

In this application, it is aimed to connect the sleeve surfaces with the pipe surfaces by heating the resistance wires in the EF sleeve located on the pipe with electric current. With the heating of the resistances, the heat of the outer pipe of the pipe rises and the temperature of the sleeve wall, which is higher than the meat thickness of the pipe, is lower than that of the pipe, and this potential difference realizes welding operation by forming pressure in the welding area. The pipes can be combined with the EF source even if they have different wall thicknesses. EF welding can be done in pipes with a diameter range Q 20 - Q 1600 mm. EF welding is used in systems that require more safety.

Reasons for using the electrofusion welding method
- Provides ease of application in terms of repair of small or large damaged pipes.
- EF provides ease of application even in tight spaces.
- The inside diameter of the pipe does not come down.
- EF welding application is fast. - It is possible to exit directly from the main pipe using EF welding.
- Fusion welding tools and machine ease of use.
- They are both lightweight and low cost.
- No resistance at the base in the welding zone.
- It is a reliable and easy-to-apply welding method in pressurized fluids that responds to the needs of gas and water distribution companies.
- It can be used anywhere during the entire network construction phase, under pressure connections and in repairs.
- Fusion welding is automatic, it does not require too much operator skill.
- Not too much excavation and require filling.
- The electrofusion technique ensures the use of long distances of pipes up to 125 mm in diameter.

MACHINERY AND EQUIPMENT REQUIRED FOR THE METHOD OF JOINTING WITH ELECTROFUSE MOUNTING

1-) Electrofusion welding machine:
Controls of machines manufactured as electronic computers are provided by microprocessors. It is the device that supplies the required electric current within the required time period together with the parameters for welding operation.information can be entered into the machine either with barcodes or manually.
2-) Pipe cleaning apparatus:
The oxide layer, which is formed over time and adversely affects welding ability, is the equipment of various types and sizes used to clean layers such as oil, dirt and moisture.
3-) Pipe setting (cutting) apparatus:
The cutter, which cuts the pipe foreheads perpendicular to the horizontal axis of the pipe, and cuts the ends of the long or uncut pipes to the welding process, is an auxiliary device such as 90 ° miter and meter which is used to control the rigidity.
4-)Clamps :
They are handcuffs that allow the ovality of the pipes to be removed. It is used to prevent stresses that can occur during welding
5-) Plastic knocker :
Ancillary equipment needed to place the sleeve.

ELECTROFUSE WELDING PARAMETER VALUES

Electrofusion welding machines are required to enter the parameter values of the sleeve to be used for the welding operation. As the wall thickness increases, the warm-up increases over time.Other words, there are different heating and cooling times for each diameter. The information to be entered is applied as a barcode on the cuff to be used and a label on the cuff so that the device can be read by the barcode reading feature and can be entered manually. Usually in larger diameter sleeves this bar code is also in card-shaped sleeve. When the time written on the barcode, the barcode reader terminal automatically reflects on the screen. The heating and cooling times should be applied on the barcode on each electrofusion fitting as specified.

Evaluation of tensile-separation tests of bonded samples based on ambient temperature.
The above table was tested according to different ambient temperatures. Tests based on ambient temperature have shown that the end result affects the quality. Generally, the duration of assembly is given by practitioners regardless of the standards. Non-adherence to standards generally leads to reductions in weld quality. However, depending on the temperature of the joining environment, the duration of the source is not increased or decreased, it supports the findings that it should not be merged at temperatures below -15 ° C, which are also mentioned in the standards and literature. or unforeseen situations where intervention is required for this reason, high quality assemblies can be achieved by increasing or decreasing assembly times. In this case, it is not necessary to construct or repair any PE natural gas pipelines in areas with severe winter conditions, ie temperatures below these temperatures, but this is not the case in practice, and in unexpected situations where intervention is required, high quality consolidations can be achieved by increasing or decreasing the assembly times.

PRESSURE TEST

The pressure test should be started at least one hour after the welding operation is finished, after the pipes have completely cooled down. The pressure test is carried out in accordance with DIN 4279/1. 1.5 x PN pressure is applied on the welded pipe. At this pressure value 10 min. If there is no fall throughout, the test results in success.

SPACE WIDTH

The inner diameter of the sleeve is produced approximately 1.1% larger than the outer diameter of the pipe to be joined. Permitted space widths are approximately given on the tablature. As the sleeve starts to heat, the space between the pipe and the sleeve decreases due to thermal expansion. The increase in the amount of molten material provides the pressure to help the sleeve and the tube adhere to each other completely.

Pipe Diameter QD mmSpace Witdh mm
≤ 3550.5
400 … < 6301.0
630 …<8001.3
800 … ≤ 10001.5
> 10002.0

- It should be noted that the gap width between the sleeve and the pipe is equal throughout the entire circumference before EF welding preheating.
- Tap the cuff mouth to prevent heat losses.
- Close the pipe ends -Enter pre-heating parameters in the EF welding machine.
- Preheating.
- Check the space. the voids are still not smaller than 2 mm, repeat preheating. If the voids are less than 2 mm, perform the electrofusion welding operation.

ELECTROFUSION WELDING FOR PRELIMINARY PREPARATIONS

- Conformity check of electrofusion sleeve (diameter control, PN value control, cuff internal and external durability eye check etc.)
- Setting the ambient temperatures required for welding
- Dust, humidity, oil etc. from the welding source. To remove inappropriate situations such as
- Snow, rain, wind, sunshine radiation, etc. in bad weather conditions. Close the environment in such situations.

ELECTROFUSION WELDING STAGES WHICH MUST BE MONITORED

1. First, the place to be welded is scraped and cleaned.
2. The part of the pipe to be inserted into the sleeve is marked.
3. The pipe ends are fixed by passing through the sleeve.
4. Electricity application.
5. Removal of cooling and fixing.

ELECTROFUSION WELDING APPLICATIONS

  • The surface to be welded is cleaned before starting the welding process.

  • The foreheads of the pipes to be welded should be cut perpendicular to the horizontal axis of the pipes. If it is not properly cut, the resistance elements on the sleeve will not touch the pipe in some areas. This causes overheating and uncontrolled flow of molten material and is not a healthy source. (Shown below).


Negative effect of uncut tube ends

  • The pipe restraint in the middle part of the sleeve to be welded is measured from the outside to the inside by the meter.
  • This weld area dimension is marked on the pipe.

  • Marked area is blasted etc. With the help of such tools, it is scraped without much exaggeration, and the surface of the pipe is cleaned from oxides and cores. (Pipe scraping should be between 0,1 - 0,7 mm).

  • Aning of the electrofusion source is the first plan, the source to be applied to an oxidized or dirty surface is generally of poor quality and inadequate to standards. First, the part going into the sleeve is cut and the dust, pipe pieces, etc. left on it. Cleaned. After cleansing, it should not be touched by hand, and the cleaning work must be done with custom made hand tools. Trichloroethane or 90% isopropyl alcohol may be used for cleaning.

  • If there is ovality in the cleaned pipes, the pipe ovality is corrected with the help of clamps. Permissible ovality is 1.5% of the outside diameter. Clamp can be used to eliminate ovality.
  • The sleeve to be welded on the prepared pipe is completely passed. After passing through, the pipe should turn easily in the sleeve. he pipe should not be exposed to any bending stress.
  • The head of the pipe which has been passed through the other pipe and the sleeve is connected to each other until the sleeve reaches the marked point on the other pipe.

  • It is aimed to place the sleeve equally symmetrically between the two pipes by the last finishing process. Align and tighten the pipe.

  • After the cuff connection is complete, the electrofusion welding machine is connected to the sockets on the sleeve.

  • In the electrofusion machine, the barcode of the connecting sleeve is read and parametric values are entered to start the welding process.

  • During the welding process, the pipes must not be moved and should not be exposed to impact.
  • Slow cooling of the connection after welding also affects performance positively.

ATTENTION TO ELECTROFUSION WELDING METHODS

  • The pipes to be welded in the electrofusion welding method must be manufactured from the same raw material.
  • The MFI (melt flow rate) value of the pipes to be welded should be between 0.2 and 1.3 gr / 10 min (for 190 ° C / 5 kg test value). Pipes with different MFI values can not be welded.
  • The air temperature of the welding environment should be between 5 ° C and 50 ° C. - Safety precautions should be taken and should be done to those who have received welding training.
  • The surface to be welded should not be touched by hand.
  • He electrophoresis source should be made according to DVS 2207 standard.
  • If EF welding is stopped and cooling does not take place, welding will not be continued if the power is cut while the welding is done. The process is stopped, it has to be done again.
  • When welding, the temperature ratings of the pipes should be the same. For example, one side should not stay in the shade on one side of the sun.
  • If there is an error while welding, the PE material may jump. So be careful to stand at least 1 meter away from welding.

Repair by Electrofusion Welding Method

  • Damage to the pipelines can easily be done even if the area is difficult to with the electrofusion welding method.
  • The soil on the damaged part of the pipes is opened to the side where the pipes can flex freely from the place where the deterioration occurs.
  • In case of minor damage, the damaged part is cut, the welding is done by using the sleeve (the stoplity is broken and used as a sliding sleeve).
  • In the case of pipes with large damage, the damaged part is cut off.
  • The length of the pipe to be added is calculated and the sleeve of the sleeve is broken between the two ends of the pipe part to be added and the pipe to be restored and the sliding sleeve is used and the electrofusion is welded. The welded areas should not be watered until the welding process has ended and the cooling process has been completed.

ELECTROFUSE WELDING MISTAKES AND REASON

1. Pipes and fittings not protected from bad weather conditions
Weather conditions affect other welding methods as well as EF welding methods. Protected against weather conditions, the pipes and fittings are protected from bad effects, such as unwanted and weld quality, such as contamination and wetting of the weld zones, without warming from sunlight.
2. Compressed Air - Gas Flows and Compression in the Pipe
Before and after welding, check whether there is compressed air in the pipe. amaged pipe sections are replaced or cuff welds are found on live lines. If the gases entering the pipe from the choking zone are not removed during the welding period, the rising pressure affects the welding zone.
3. The weld preform shall be suitable for welding the ambient temperature
Low or high ambient temperature (between 5 ° C and 50 ° C) affects welding quality. Improper ambient temperature results in reduced quality and reduced pipe life. When setting the welding duration, the outdoor temperature is taken into account and it is assumed that the pipes and fittings are close to this temperature. However, if the application is performed at different temperatures, the welding time will be low or the welding process will be low.
4. Turning off the power during the source, Stopping etc. Resuming the Half Stopped Source in Situations
The resource can not be completed due to unexpected problems or mistakes in the EF welding operation. his may be caused by power interruption, stopping the source in the wire, disconnecting the voltage, or removing the fittings from the welding socket. In this case, it can not be resumed from the source process. After the fittings have cooled down, it is necessary to replace the welding process from the beginning. However, if the operator has not fully understood the electrofusion welding parameters, they will weld the same time without cooling the weld. In such processes, the quality of the welding is deteriorated and visible errors are occurring.
5. Exposure to Welding Zone
During welding operation and cooling, the welding area should not be exposed to any load. Since the pipes have changed shape, it has to be corrected before welding. 
6. Not cleaned enough in the cleaning stage
One of the most important conditions for the success of the EF technique is that the division to be welded is clean. The cleanliness of the division to be welded has a direct effect on quality. After the part to be welded is scraped off and the clean face is removed, chips, dust, etc. are removed from the pipe surface. The dirt should be cleaned. The cleaned parts should not be touched by hand. Otherwise welding will not occur but the welding is completed and the overflow areas of the fittings will indicate that the welding is finished.r.
7. Correction of pipe ends before welding
Tubing ends must be straightened before welding. This can be done with the pipe adjusting device. If the ends of the pipes are not straightened, the places that do not match the heating resistance wires will become unhealthy due to the low temperatures and the corresponding locations, and will not be a quality source.
8. Wrong Selection of Resource Count or Stress Low
The order to be able to make a healthy weld, the pressure and heat that will form the heat should be given to the resistors. If the heat period is too high, it will melt and flow too much, and the material may flash. If the heating period is insufficient, a gap is formed and the welding operation does not occur. These times are determined under laboratory conditions and written on barcodes. If this period is not followed, the desired result can not be reached.
9. Combination of Pipes Produced for Different Welding Methods by EF Method
The pipes manufactured for the fore weld are normal tolerance (Class B) pipes. Precision tolerant (class A) pipes are used for electrofusion welding. he outer diameter tolerances of the pipes used for fore weld are not accurate.
10. EF Filling of the Pipes in the Coupling Element Used in the Welding System and Gap Between the Pipes in the Coupling Element or Vertically Uncut Pipe Holes.
EF welding should be done taking into account the fittings. Because, if there is a gap between the pipes, the melt flows through the material during the process.
11. The Use of Pipes and Fittings Manufactured from Different Materials
Is the material melt between the inner surface of the sleeve and the inner surface of the pipe in order to perform the treatment in the welding system. The melt amount of the material varies depending on the raw material properties of the material. When two different raw materials are used with fittings and pipes, the weld quality is reduced because the melting rate is not equal.
12. Errors arising from the Fittings used
EF welding machine materials are sometimes faulty. Like fittings of pipe ends, there is also an out-of-standard error in fittings. In the case of operations with incorrect fittings, the results experienced on the ends of the oval pipe are encountered. The life of the fittings is not limitless.
13. Excessive driving of pipes inside the sleeve
The depth is calculated before starting the EF welding process. That is, the portion of the tube into which the sleeve is to be inserted is identified and marked. If assembled without marking, an error occurs in welding operation. If the pipe is not fully inserted, it will flow. If the pipe is inserted more than necessary, the welding is completed in terms of external appearance, but the strength will be reduced because the other part is not fully inserted.

Caring for the Fusion Welding Machine

  • Lose the machine after you finish working. Wait for the welding machine to cool off after pulling the plug.
  • After cooling has taken place, remove fittings and replace neatly.
  • Wipe the EF welding machine with a cloth.
  • If you have extension cables, collect them and remove them.
  • Pick up the EF welding machine's cable and place it in the box.
  • Collect the EF welding machine welding apparatuses and put them in the box.

Contact with KUZEYBORU

Kuzeyboru İletişim
Mavi Piksel
Kuzeyboru Plastik Sanayi ve Ticaret Limited Şirketi
Organize Sanayi Bölgesi 1.Cadde 2.Sokak No:33/A
Aksaray-TURKEY
+90 (382) 266 23 03 (Pbx)
info[at]kuzeyboru.com.tr

Our Working Hours

  • Monday: 9:00 - 18:00
  • Tuesday: 9:00 - 18:00
  • Wednesday: 9:00 - 18:00
  • Thursday: 9:00 - 18:00
  • Friday: 9:00 - 18:00
  • Saturday: 9:00 - 13:00
  • Sunday: Closed
Back to Top