WELD POLYETHYLENE (PE) PIPE USING FUSION METHOD James Langston south west Tafe page

James Langston south west Tafe page What do I have to do • Prepare for work • Determine welding requirements • Weld and pressure test pipes • Clean up. James Langston south west Tafe page 293 and 294 1/1

James Langston south west Tafe page Introduction Fusion welding requires the ends of the pipes to be heated until the plastic becomes molten, and holding the joints in contact as they cool and solidify. James Langston south west Tafe page 295 1/2

James Langston south west Tafe page Polyethylene pipes • PE80B – MDPE (medium density polyethylene) • PE80C – HDPE (high density polyethylene) • PE100 – HPPE (high performance polyethylene) James Langston south west Tafe page 295 2/2

Thermal properties of polyethylene Expansion Thermal conductivity Temperature effects on pipes James Langston south west Tafe page 296 1/1

Fusion welding methods James Langston south west Tafe page 297 1/4

James Langston south west Tafe page Butt welding 297 2/4 James Langston south west Tafe page

Electro fusion welding James Langston south west Tafe page 297 3/4

Heated tool socket welding James Langston south west Tafe page 297 4/4 and 298

James Langston south west Tafe page General conditions Weather conditions will effect the weld Protect the weld area Check the temperature Clean the heating element Planning and subsequent checking James Langston south west Tafe page 299 1/1

Check the wall alignment and gap misalignment on the outside must not exceed 10% of the thickness of the wall. James Langston south west Tafe page 300 1/3

Setting the fusion pressure FA = Pressure to make joint FB = Pressure required to move the pipes together plus machine resistance FA + FB = jointing force James Langston south west Tafe page 300 2/3

James Langston south west Tafe page Joint and cool Leave parts in the fusion jointing machine at fusion pressure until the end of the cooling period. James Langston south west Tafe page 300 3/3

Carrying out the pressure test All fusion joints must be allowed to cool completely before pressure testing. Note All pipes to be tested as stated in AS3500 James Langston south west Tafe page 301 1/4

Heated tool socket fusion method the pipe end is inserted into the socket The pipe end and fitting socket are heated to fusion temperature (276° C ± 5° C) and are then pushed together. James Langston south west Tafe page 301 2/4

James Langston south west Tafe page Tools required James Langston south west Tafe page 301 3/4

Pipe peeling and chamfering tool removes the oxidised layer built up as a result of UV radiation, James Langston south west Tafe page 301 4/4

Fusion jointing machine James Langston south west Tafe page 303 1/2

Preparation for fusion jointing The fusion temperature must be between 250°C and 270°C. Cut and deburr pipe Peel the pipe Clean the pipe with cleaner or trichoroethane James Langston south west Tafe page 302 2/2

Fusion jointing procedure James Langston south west Tafe page 304 1/1

Butt fusion time cycles James Langston south west Tafe page 305 1/1

James Langston south west Tafe page Regulations Conforming with workplace operations and procedures. Understanding the operating principles of reticulation systems. Ensuring the quality of materials used. Controlling handling procedures. Using and maintaining equipment. Paying attention to specifications. James Langston south west Tafe page 306 1/2

James Langston south west Tafe page Regulations Plumbers or gasfitters are required to use only approved materials They must comply with the installation requirements of AS3500 health hazards can result if their installation practices are outside the guidelines of AS 3200 James Langston south west Tafe page 306 2/2

James Langston south west Tafe page OH&S • personal protective clothing and equipment • use of tools and equipment • workplace environment and safety • hazard control James Langston south west Tafe page Page307 to 311

Butt fusion welding process • Clean pipe ends and heater faces • Square the two opposite pipe ends. • Check pipe end alignment in clamps. • Verify proper heater temperature. • Insert heater plate between opposite pipe ends use only enough force to maintain contact. James Langston south west Tafe page 311 1/1

Butt fusion welding process • Heat as required, allowing for weather . • Remove heater plate and bring the heated pipe end together quickly, being careful not to slam, Apply sufficient pressure to form a ‘double rollback bead’. • Maintain pressure while allowing the joint to cool. • Allow joint to cool an additional five minutes prior to removing joint from fusion jig. • Inspect joint for quality. James Langston south west Tafe page 312 1/1

James Langston south west Tafe page Questions 1 1. Name the group of plastics that polyethylene belongs to. James Langston south west Tafe page 316 1/3

James Langston south west Tafe page Question 2 State three types of polyethylene pipe used for plumbing services. (a) (b) (c) James Langston south west Tafe page

James Langston south west Tafe page Question 3 3. Name three types of fusion welding processes. (a) (b) (c) James Langston south west Tafe page

James Langston south west Tafe page Question 4 Briefly describe butt welding of polyethylene pipe James Langston south west Tafe page

James Langston south west Tafe page Question 5 Briefly describe socket fusion welding of polyethylene pipe. James Langston south west Tafe page

James Langston south west Tafe page Question 6 State two minimum requirements for fusion jointing of polyethylene pipe. (a) (b) James Langston south west Tafe page

James Langston south west Tafe page Question 7 7. When should you protect the fusion area when you are welding polyethylene pipe? James Langston south west Tafe page

James Langston south west Tafe page Question 8 8. State the temperature that you complete fusion jointing of polyethylene pipe. James Langston south west Tafe page

James Langston south west Tafe page Question 9 How do you clean the heating element of a fusion welding tool? James Langston south west Tafe page

James Langston south west Tafe page Question 10 State five requirements for correct technique for fusion welding of polyethylene pipe. (a) (b) (c) (d) (e) James Langston south west Tafe page

James Langston south west Tafe page Question 11 List two points for the inspection of a fusion weld. (a) (b) James Langston south west Tafe page

James Langston south west Tafe page Question 12 State the temperature required for a successful socket fusion weld. James Langston south west Tafe page

James Langston south west Tafe page Question 13 Outline the requirements after the fusion welding requirements are completed. James Langston south west Tafe page

James Langston south west Tafe page Question 14 State where off cuts and leftovers should be placed on the site. James Langston south west Tafe page