Jointing

Technology

Socket and Butt Fusion

GF Piping Systems

Goal

2007-01-24

Overview which jointing methods are offered by +GF+

Basics of the different jointing methods

Practical work to get a first impression of

the different jointing technologies

Practice socket and butt

fusion by yourself

GF Piping Systems

Socket and Butt Fusion

Table of Contents

2007-01-24

Jointing Methods

Basics

Socket Fusion

Butt Fusion

GF Piping Systems

Socket and Butt Fusion

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

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)

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

GF Piping Systems

Socket and Butt Fusion

Installation examples

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

2007-01-24

GF Piping Systems

Socket and Butt Fusion

Basics
Main parameters P T T
Main parameters

Pressure

Temperature

Time

Human factor

Fusion joint strength

2007-01-24

GF Piping Systems

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

Basics
Handling of pipes and fitting

2007-01-24

GF Piping Systems

Socket and Butt Fusion

Basics
Working environment

2007-01-24

GF Piping Systems

Socket and Butt Fusion

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

GF Piping Systems

Socket and Butt Fusion

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Socket fusion

Socket fusion

Butt fusion

Electro fusion
2007-01-24

GF Piping Systems

Socket and Butt Fusion

12

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

2007-01-24

GF Piping Systems

Socket and Butt Fusion

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Socket fusion of PE, PP, PVDF, PB

2007-01-24

GF Piping Systems

Socket and Butt Fusion

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Socket fusion
Principle
heater plate
spigot

pipe

pipe

fitting

fitting

finished fusion

2007-01-24

GF Piping Systems

Socket and Butt Fusion

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

260C +/ - 10C

PP

260C +/ - 10C

PVDF

260C +/ - 10C

PB

260C +/ - 10C

at 20C ambient temperature

2007-01-24

GF Piping Systems

Socket and Butt Fusion

16

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

16

20

2)

Change over
for PN 6

SDR 17.6
s

2)

5
Cooling

(Maximum
time)

fixed

total

min

10

25

1)

32

1)

10

12

1)

20

50

12

1)

20

63

24

10

30

75

30

15

30

90

40

22

40

110

50

30

10

50

40

2007-01-24

1)

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

2)

Standard Dimension Ratio = d/s

GF Piping Systems

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

Socket and Butt Fusion

17

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

GF Piping Systems

Socket and Butt Fusion

18

Socket fusion
Hand fusion tool

2007-01-24

GF Piping Systems

Socket and Butt Fusion

19

Socket fusion
Preparation for fusion

2007-01-24

Adjust the fusion temperature at the

temperature control to 260C

Check temperature at the outer side of

the heater bushes with tempil sticks
(253 and 274C) or with measuring
device

Protect fusion area from wind, rain etc.

and wait for correct temperature

Clean heater bushes with clean paper

GF Piping Systems

Socket and Butt Fusion

20

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

Locate pipe and fitting in machine clamps

Ensure alignment of components

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

Heating time starts

Open machine sides and remove heater bushing

Bring components together to make joint

Holding time = heating time

GF Piping Systems

Socket and Butt Fusion

22

Socket fusion
Advantages for using a machine

2007-01-24

GF Piping Systems

Alignment of fused components

Accurate penetration stops for

heating and fusion phase

Mechanical fusion force

Recommended if d > 63mm

Faster change over phase

Socket and Butt Fusion

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Socket fusion
Guidelines and quality check

2007-01-24

German Association of Welding technology (DVS)

Guidelines of DVS 2207 (heater plate socket fusion)

Bead has to be visible and uniform over the whole

circumference

Check penetration of pipe

Check alignment of pipe and fitting

GF Piping Systems

Socket and Butt Fusion

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Butt fusion

Socket fusion

Butt fusion

Electro fusion
2007-01-24

GF Piping Systems

Socket and Butt Fusion

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Butt fusion
Principle
Pressure
(N/mm)

Jointing pressure

Alignment pressure

0.15

Heating pressure

0.01

Alignment Heating time

time

2007-01-24

GF Piping Systems

Join
ting
time

Time
Cooling and
jointing time

Socket and Butt Fusion

26

Butt fusion
Preparation for fusion

Wall Offset
Ds
s

Ds max. = 0.1 x s

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

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)

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
210C
PE
210C
PVDF
240C

2007-01-24

GF Piping Systems

min.

max.

200C
200C
232C

220C
220C
248C

Socket and Butt Fusion

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Butt fusion
Pressure calculation
Material

Equalization pressure Heat soak pressure

PE
PP
PVDF

0.15 N /mm
0.10 N /mm
0.10 N /mm

0.02 N /mm
0.01 N /mm
0.01 N /mm

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

29

Butt fusion
Example fusion table

Use the equalization- and fusion pressures from operating manual

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

Equalisation

Heat Soak

Change-over

Fusion

Cooling

time until maximum

pressure reached

Colling time at fusion

pressure p = 0,15
N/mm 0,01

min
(minimum value)

Bead height on the

heating element after
equalization time
(equalization at 0,15
N/mm)

Heat soak time

= 10 x wall thickness
(heat soak at
0,02 N/mm)

mm
(minimum values)

s
(maximum time)

0,5

45

4,5 7,0

1,0

45 70

56

56

6 10

7,0 12,0

1,5

70 120

68

68

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

Reduce pressure to heat soak pressure

Following the heat soak time

under heating pressure

Pressure
(N/mm)
0,15

Equalization
pressure

Heat soak
pressure

0,01
Equalization
time

2007-01-24

GF Piping Systems

Heat soak time

Socket and Butt Fusion

31

Butt fusion
Fusion- /Cooling time

After the heating time the heater plate has to be removed

Bring molten surfaces in contact as quickly as possible

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

Cooling pressure remains the same as the fusion pressure

Jointing pressure

Time
Jointing
time

2007-01-24

GF Piping Systems

Cooling and
jointing time

Socket and Butt Fusion

32

Butt fusion
Quality check and guidelines

2007-01-24

K>0

Double bead over whole circumference ?

Misalignment less than 10% of wall thickness

Guidelines according to DVS 2207 (German Welding Association)

GF Piping Systems

Socket and Butt Fusion

33

Machine and Tools

SG Line
SG 160

SG 110

2007-01-24

GF Piping Systems

SG 315

SG 315-S

Socket and Butt Fusion

34

Machine and tools

WM line
WM 315

WM 500

2007-01-24

GF Piping Systems

Socket and Butt Fusion

35

Machines and tools

Hydraulically operated machines (GF line)
GF line

2007-01-24

GF Piping Systems

Socket and Butt Fusion

36

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

GF Piping Systems

Socket and Butt Fusion

37

Cutting machines and tools

KRA, PPC 250, KS 355, KS 1600
PPC 250

KRA 63
KS 1600

KS 355
2007-01-24

GF Piping Systems

Socket and Butt Fusion

38

Machines and tools

Band saws BS 450, BS 630, up to 1200

BS 450

BS 630
2007-01-24

GF Piping Systems

Socket and Butt Fusion

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