1. WELD POLYETHYLENE (PE) PIPE USING FUSION METHOD
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What do I have to do
• Prepare for work
• Determine welding requirements
• Weld and pressure test pipes
• Clean up.
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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.
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Polyethylene pipes
• PE80B – MDPE (medium density polyethylene)
• PE80C – HDPE (high density polyethylene)
• PE100 – HPPE (high performance polyethylene)
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5. Thermal properties of polyethylene
Expansion
Thermal conductivity
Temperature effects on pipes
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6. Fusion welding methods
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Butt welding /4
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8. Electro fusion welding
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9. Heated tool socket welding
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General conditions
Weather conditions will effect the weld
Protect the weld area
Check the temperature
Clean the heating element
Planning and subsequent checking
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11. Check the wall alignment and gap
misalignment on the outside must not exceed 10% of the thickness of the wall.
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12. Setting the fusion pressure
FA = Pressure to make joint
FB = Pressure required to move the pipes together plus machine resistance
FA + FB = jointing force
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Joint and cool
Leave parts in the fusion jointing machine at fusion pressure until the end of the cooling period.
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14. 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
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15. 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.
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Tools required
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17. Pipe peeling and chamfering tool
removes the oxidised layer built up as a result of UV radiation,
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18. Fusion jointing machine
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19. 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
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20. Fusion jointing procedure
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21. Butt fusion time cycles
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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.
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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
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OH&S
• personal protective clothing and equipment
• use of tools and equipment
• workplace environment and safety
• hazard control
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25. 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.
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26. 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.
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Questions 1
1. Name the group of plastics that polyethylene belongs to.
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Question 2
State three types of polyethylene pipe used for plumbing services.
(a)
(b)
(c)
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Question 3
3. Name three types of fusion welding processes.
(a)
(b)
(c)
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Question 4
Briefly describe butt welding of polyethylene pipe
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Question 5
Briefly describe socket fusion welding of polyethylene pipe.
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Question 6
State two minimum requirements for fusion jointing of polyethylene pipe.
(a)
(b)
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Question 7
7. When should you protect the fusion area when you are welding polyethylene pipe?
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Question 8
8. State the temperature that you complete fusion jointing of polyethylene pipe.
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Question 9
How do you clean the heating element of a fusion welding tool?
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Question 10
State five requirements for correct technique for fusion welding of polyethylene pipe.
(a)
(b)
(c)
(d)
(e)
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Question 11
List two points for the inspection of a fusion weld.
(a)
(b)
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Question 12
State the temperature required for a successful socket fusion weld.
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Question 13
Outline the requirements after the fusion welding requirements are completed.
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Question 14
State where off cuts and leftovers should be placed on the site.
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