Socket and Butt Fusion

Jointing Technology

Socket and Butt Fusion

GF Piping Systems

Goal

2007-01-24

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Overview which jointing methods are offered by +GF+

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Basics of the different jointing methods

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Practical work to get a first impression of the different jointing technologies

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Practice socket and butt fusion by yourself

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Socket and Butt Fusion

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Table of Contents

2007-01-24

1

Jointing Methods

2

Basics

3

Socket Fusion

4

Butt Fusion

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Socket and Butt Fusion

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Which jointing technology do I use ?

Electro fusion

Compression

Butt, Socket, IR, BCF fusion

Push fit

Solvent cement ???

Flange Adapter

Soldering Unions, thread

2007-01-24

GF Piping Systems

Socket and Butt Fusion

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Selection of different fusion methods What is the best solution for my customer? Criteria: § Specification § Application/Material § Site conditions (Trench size, space, safety, ...) § Availability of machines and/or fittings § Cost of total installation § Cost of equipment (investment, rental) § Experience of personal / training levels § Approvals §

Relationship Customer - Sales personal (sales and after sale service)

è GF Piping System has the right products and can give the support to all these questions 2007-01-24

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Socket and Butt Fusion

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Installation examples

Mechanical joints - unions / flanges § Solvent cement joints § Socket fusion § IR and BCF fusion § Electrofusion §

2007-01-24

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Socket and Butt Fusion

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Basics Main parameters P T T Main parameters

Pressure

Temperature

Time

Human factor

Fusion joint strength

2007-01-24

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Subordinate parameters Equalization pressure Heating pressure Jointing pressure Temperature of the heating element Ambient temperature Heating and equalization time Changeover and jointing time Cooling time under pressure Pipe storage and handling, Cutting, Facing, Pipe support, Cleaning Alignment check Machine maintenance etc. etc.

Socket and Butt Fusion

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Basics Handling of pipes and fitting

2007-01-24

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Socket and Butt Fusion

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Basics Working environment

2007-01-24

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Socket and Butt Fusion

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Basics Overview jointing methods Socket fusion PE, PP, PVDF, PB up to d110

Butt fusion PE, PP, PVDF, PP-n up to d1200

Electro fusion PE, PB up to d630 2007-01-24

GF Piping Systems

Socket and Butt Fusion

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Basics Overview jointing methods (System) IR fusion PP, PE100, PVDF, PP-n up to d 315

BCF fusion PVDF, PP-n up to d 110

2007-01-24

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Socket and Butt Fusion

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Socket fusion

Socket fusion

Butt fusion

Electro fusion 2007-01-24

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Socket and Butt Fusion

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Socket fusion Preparation for fusion Cleanser Tangit KS § for cleaning the fusion surfaces § clean lint free cleaning tissues/paper is required

2007-01-24

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Socket and Butt Fusion

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Socket fusion of PE, PP, PVDF, PB

2007-01-24

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Socket and Butt Fusion

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Socket fusion Principle heater plate spigot

pipe

pipe

fitting

fitting

finished fusion

2007-01-24

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Socket and Butt Fusion

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Socket fusion Heating element temperature Temperature of heater plate PE-HD

260°C +/ - 10°C

PP

260°C +/ - 10°C

PVDF

260°C +/ - 10°C

PB

260°C +/ - 10°C

at 20°C ambient temperature

2007-01-24

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Socket and Butt Fusion

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Socket fusion Time table for PP Heating time table Standard values for socket fusion of pipe and fittings of PP (see table of used material) 1 Outer pipediameter

2 Heating for PN 10 SDR 11

d in mm

s

16

5

20

5

2)

4

Change over for PN 6

SDR 17.6 s

2)

5 Cooling

(Maximum time)

fixed

total

s

s

min

4

6

2

4

6

2

4

10

2

25

7

1)

32

8

1)

6

10

4

12

1)

6

20

4

50

12

1)

6

20

4

63

24

10

8

30

6

75

30

15

8

30

6

90

40

22

8

40

6

110

50

30

10

50

8

40

2007-01-24

3

1)

because of too small wall thickness socket fusion technology not recommended.

2)

Standard Dimension Ratio = d/s

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(d= Outer pipe diameter, s=pipe wall thickness)

Socket and Butt Fusion

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Socket fusion Preparation Plastic pipe cutter § ensures that the pipe is cut square

Pipe peeling and beveling § for calibration of the pipe end § for removing the oxidation layer § for indicating the fusion depth

2007-01-24

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Socket and Butt Fusion

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Socket fusion Hand fusion tool

2007-01-24

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Socket and Butt Fusion

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Socket fusion Preparation for fusion

2007-01-24

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Adjust the fusion temperature at the temperature control to 260°C

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Check temperature at the outer side of the heater bushes with tempil sticks (253° and 274°C) or with measuring device

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Protect fusion area from wind, rain etc. and wait for correct temperature

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Clean heater bushes with clean paper

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Socket and Butt Fusion

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Socket fusion Fusion process § § §

§ § §

2007-01-24

Press fitting and pipe on spigot and bush Push firmly and without twisting Observe penetration depth

Remove fitting and pipe carefully Push fitting and pipe quickly together without twisting Align and hold as long as the recommended cooling time lasts Do not pressure test until 1 hour after fusion GF Piping Systems

Socket and Butt Fusion

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Socket fusion Procedure with machine (d > 63mm)

2007-01-24

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Locate pipe and fitting in machine clamps

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Ensure alignment of components

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Bring the two sides of the machine together up to the stops

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Heating time starts

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Open machine sides and remove heater bushing

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Bring components together to make joint

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Holding time = heating time

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Socket and Butt Fusion

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Socket fusion Advantages for using a machine

2007-01-24

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Alignment of fused components

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Accurate penetration stops for heating and fusion phase

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Mechanical fusion force Recommended if d > 63mm

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Faster change over phase

Socket and Butt Fusion

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Socket fusion Guidelines and quality check

2007-01-24

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German Association of Welding technology (DVS)

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Guidelines of DVS 2207 (heater plate socket fusion)

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Bead has to be visible and uniform over the whole circumference

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Check penetration of pipe

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Check alignment of pipe and fitting

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Socket and Butt Fusion

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Butt fusion

Socket fusion

Butt fusion

Electro fusion 2007-01-24

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Socket and Butt Fusion

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Butt fusion Principle Pressure (N/mm²)

Jointing pressure

Alignment pressure

0.15

Heating pressure

0.01

Alignment Heating time time

2007-01-24

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Join ting time

Time Cooling and jointing time

Socket and Butt Fusion

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Butt fusion Preparation for fusion

Ü Wall Offset Ds s

Ds max. = 0.1 x s

® max. 10% wall offset allowed depending on the pipe wall thickness

Ü Maximum GAP (gap between the two parts to be welded) a Ds max. = 0.5 mm with Butt fusion (Ds max. = 0.2 mm with IR fusion)

Ü Wall thickness incorrect

2007-01-24

GF Piping Systems

(must be same SDR value) correct

Socket and Butt Fusion

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Butt fusion Preparation for fusion Set welding temperature at temperature control § Check temperature at the heater plate § Clean heater plate always with lint free tissue before every fusion § Set fusion force according to machine operating manual §

Heater plate temperature according to DVS 2207:

Set temp. value Material PP 210°C PE 210°C PVDF 240°C

2007-01-24

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min.

max.

200°C 200°C 232°C

220°C 220°C 248°C

Socket and Butt Fusion

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Butt fusion Pressure calculation Material

Equalization pressure Heat soak pressure

PE PP PVDF

0.15 N /mm² 0.10 N /mm² 0.10 N /mm²

0.02 N /mm² 0.01 N /mm² 0.01 N /mm²

Equalization force = jointing force = Ftotal = FA+FB FA= A x p (surface A x specific jointing pressure p) FB= specific dragging pressure or force Fusion pressure = Fusion force FA / piston area of machine Jointing pressure = fusion pressure + dragging pressure Attention: Fusion pressure is always related to used machine (see operating manuals for corresponding pressure tables)

2007-01-24

GF Piping Systems

Socket and Butt Fusion

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Butt fusion Example fusion table §

Use the equalization- and fusion pressures from operating manual

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Example of fusion times from table for HDPE material

Fusion table/guidelines of DVS 2207/1 for HD-PE Wall thickness

mm

< 4,5

2007-01-24

1

2

3

4

5

Equalisation

Heat Soak

Change-over

Fusion

Cooling

time until maximum pressure reached

Colling time at fusion pressure p = 0,15 N/mm² ± 0,01

s

min (minimum value)

Bead height on the heating element after equalization time (equalization at 0,15 N/mm²)

Heat soak time = 10 x wall thickness (heat soak at 0,02 N/mm²)

mm (minimum values)

s

s (maximum time)

0,5

45

5

5

6

4,5 – 7,0

1,0

45 – 70

5–6

5–6

6 – 10

7,0 – 12,0

1,5

70 – 120

6–8

6–8

10 – 16

12,0 – 19,0

2,0

120 – 190

8 – 10

8 – 11

16 – 24

19,0 – 26,0

2,5

190 – 260

10 – 12

11 – 14

24 – 32

26,0 – 37,0

3,0

260 – 370

12 – 16

14 – 19

32 – 45

37,0 – 50,0

3,5

370 – 500

16 – 20

19 – 25

45 – 60

50,0 – 70,0

4,0

500 – 700

20 – 25

25 – 35

60 – 80

GF Piping Systems

Socket and Butt Fusion

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Butt fusion Equalization/Heating §

Melt the pipe and fitting ends until a defined bead height is reached under equalization pressure

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Reduce pressure to heat soak pressure

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Following the heat soak time under heating pressure

Pressure (N/mm²) 0,15

Equalization pressure

Heat soak pressure

0,01 Equalization time

2007-01-24

GF Piping Systems

Heat soak time

Socket and Butt Fusion

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Butt fusion Fusion- /Cooling time §

After the heating time the heater plate has to be removed

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Bring molten surfaces in contact as quickly as possible

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The fusion is carried out at the same pressure as the equalization

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Cooling pressure remains the same as the fusion pressure Jointing pressure

Time Jointing time

2007-01-24

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Cooling and jointing time

Socket and Butt Fusion

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Butt fusion Quality check and guidelines

K

2007-01-24

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K>0

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Double bead over whole circumference ?

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Misalignment less than 10% of wall thickness

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Guidelines according to DVS 2207 (German Welding Association)

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Socket and Butt Fusion

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Machine and Tools SG Line SG 160

SG 110

2007-01-24

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SG 315

SG 315-S

Socket and Butt Fusion

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Machine and tools WM line WM 315

WM 500

2007-01-24

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Socket and Butt Fusion

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Machines and tools Hydraulically operated machines (GF line) GF line

2007-01-24

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Socket and Butt Fusion

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Machine and tools SUVI® System

SUVI® 50

SUVI® 400

for the GF line up to 1200 mm

for GF line up to 630 mm

SUVI® WIN-WELD 2007-01-24

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Socket and Butt Fusion

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Cutting machines and tools KRA, PPC 250, KS 355, KS 1600 PPC 250

KRA 63 KS 1600

KS 355 2007-01-24

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Socket and Butt Fusion

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Machines and tools Band saws BS 450, BS 630, up to 1200

BS 450

BS 630 2007-01-24

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Socket and Butt Fusion

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