Beruflich Dokumente
Kultur Dokumente
FITINGS
ON-HOLD POINTS
N
Revised
on Page
LIST OF ATTACHMENTS
N
Description
Date
30.06.2014
Page
Date
Page
Date
Contents
GENERAL DATA.......................................................................................................................................
PROCEDURE..............................................................................................................................
1.1
Welding methods.......................................................................................................................
1.1.1
Butt welding.................................................................................................................................
1.1.2
1.1.3
GENERAL DATA
PROCEDURE
1.1
Welding methods
1.1.1
Butt welding
This welding procedure can be done only with special equipment. The ends of the pipes or fittings
are fixed in the special mechanical adaptors of the welding equipment which has a special mechanical
or hydraulic unit that allows movement and maintaining pressure on the pipe ends. The energy
necessary for welding is transferred via a heating plate with controlled temperature. After removing
the plate, the elements to be welded are pressed against each other with a specific pressure without
any other added material. These steps are represented bellow in figure 1.
Welding preparation
Before beginning the weld the temperature of the heating element will be checked. This can
be done with the help of a surface temperature measuring device. In the case of automated butt
welding equipment, temperature control is done automatically and welding can be done only after the
required temperature is reached. To prevent cooling through the extremities of the pipes by the air
current, the ends will be shut. To obtain optimum welds, the heating element will be cleaned when
necessary with clean paper soaked with ethylic alcohol. The surface of the heating element must be
intact in the work area. The pipes will be aligned axially before fixing in the welding equipment. Easy
axial movement of the welded elements will be assured by using rollers or pendulum suspension. The
extremities of the pipes to be welded must correspond; ovals will be adjusted with appropriate
equipment. The surface to be welded will be milled before welding with clean equipment as to be
parallel after fixing. Deviations from parallel must not exceed the values presented in table 1.
Table 1: Maximum space width between milled surfaces
Pipe exterior diameter
Maximum space width
[mm]
[mm]
under 355
0, 5
400 - 630
1, 0
630-800
1, 3
800-1000
1, 5
over 1000
2, 0
Alignment
The surfaces to be welded are moved towards the heating element until they are joined parallel
and completely to it. This is can be seen in the welding seam. Alignment is complete when the height
of the welding seam is the same all around the pipe. Alignment is complete when the height of the
weld seam corresponds to the values in table 2
Table 2: Guide values for butt welding at 20C
Wal
Alignme
Heating
l
nt
Heating
thic
Minimum
time= 10 x
kne
seam
wall
ss
height (0,
thickness [s]
[mm]
15
N/mm 2)
Time for
removing
heating
plate [s]
Joinin
g
Time
for
creatin
g
joining
pressur
e [s]
Minim
um
coolin
g time
( 0,
15
0, 01
N/mm
2
)
4.
5
5-6
6-8
8 - 10
10 - 12
12 - 16
16 - 20
20 - 25
5.
5
5-6
6-8
8-11
11-14
14-19
19-25
25-35
6.
6
6-10
10-16
16-24
24-32
32-45
45-60
60-80
[mm]
1.
under 4, 5
4, 5 - 7
7 - 12
12 - 19
19 - 26
26 - 37
37 - 50
50 - 70
2.
0, 5
1, 0
1, 5
2, 0
2, 5
3, 0
3, 5
4, 0
3.
45
45 - 70
70 - 120
120 - 190
190 - 260
260 - 370
370 - 500
500 - 700
[min]
In this faze the surfaces to be welded are preheated at a constant pressure of 0,15 N/mm2.
Alignment pressure will be exerted during the entire alignment period.
Heating
With electro fusion welding the welding surfaces (pipe exterior and electro couple interior) are
heated to weld temperature via electric current passing through embedded wires, close to the interior
surfaces of the electro couple. By heating the pipe a dilatation of the material (precisely calculated)
takes place and produces the necessary pressure for welding. The parameters of the welding and the
current necessary for the electro couple are controlled and registered by the welding equipment. The
electro couple contains a bar code which contains the necessary information for welding. Guide
values of these parameters are found in the following table:
Exterior
diameter
[mm]
0C
min
20
25
32
40
50
63
90
110
125
160
180
20C
30C
40C
min
max
min
max
min
max
min
17
26
17
26
17
26
17
26
10
17
26
17
26
17
26
17
26
10
17
35
17
33
17
31
17
26
10
17
37
28
49
26
45
25
44
23
42
15
41
67
39
65
38
62
36
60
15
29
51
71
113
66
106
62
100
58
94
20
42
69
125
193
117
181
110
171
103
160
20
168
254
159
240
150
227
141
215
30
75
120
206
311
194
295
184
280
175
266
30
264
401
250
381
238
363
227
346
30
134
206
298
455
283
433
270
412
257
394
30
17
26
17
26
max
10C
Minimum
cooling
time [min]
max
179
270
346
521
329
496
314
474
300
453
30
371
560
353
534
337
510
322
488
30
218
329
278
423
314
478
364
547
390
588
Welding preparation
The pipe must be clean in the welding area. After cutting to desired length the surface of the pipe
is scrapped on a length greater than that inserted into the electro couple. Thus, it can be seen after
the welding has ended that this operation has been executed.
The scrapped surface is degreased with a special napkin that contains isopropyl alcohol or similar.
The electro couple is removed from its bag, without touching the interior. The ends of the pipes must
be cut perpendicular with adequate equipment. The ovalnes of the pipe must not be greater than 1,5
% of the exterior diameter. If necessary adequate equipment must be used to bring them back to
round shape. The electro couple is inserted onto the pipe without excessive force and afterwards the
ends of the pipe are fixed in a specialized device so as not to move during welding. The electro
couple should be easy to insert. The contactors for linking to the welding device must be accessible.
The bar code is then read to give the device the necessary data about the electro couple.
Welding execution
The cables of the welding equipment are connected to the electro couple. The equipment is
operated according to manufacturer instructions. After welding and cooling time have passed, the
fixing device is opened. Some electro couples allow visual checking of the weld, melted polyethylene
is seen in specially designed areas or there are 1, 2 small indicators that rise to the surface of the
electro couple if the welding was successful.
1.1.3
These so called saddle fittings have a support surface for fusion, a branch with a threaded lid
(used for guiding the knife when making the hole in the pipe on which the fitting is mounted) and the
actual connecting branch. For electro fusions welding the following steps are taken:
Step 1: Marking the fusion surface of the pipe (main pipe) to which you are connecting
- dirt and impurities are cleaned with a clean cloth;
- without removing the fitting from its package, it is placed on the main pipe. The contour is marked
clearly and continuously around the connection fitting.
Step 2: Preparing the fusion surface of the pipe to which the connection is made
- a scrapper is used to take off a layer of 0,2-0,4 mm from the marked surface;
- all the polyethylene remains must be removed. The clean surface must not be touched.
- the hydraulic test will be done on sections of maximum 500-1000 m, ensuring all fittings are in
place;
- all testing equipment will be checked before testing;
- each section tested will be closed-off at the ends and anchored so as to resist to the forces that
appear during testing;
- all joints will be cleaned to easily see any leaking;
- emptying all air in the pipe is important for the accuracy of the test and thus the filling of the pipes
must be done in a controlled way, eliminating the air while filling it and pressurizing it.
The following steps will be taken for testing:
- pumping equipment will be installed at the lowest end;
- evacuation valves and airing valves are mounted on the lowest respectively the highest end of the
pipe;
- the air vent are opened;