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Socket and Butt Fusion

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    GF Piping Systems

    JointingTechnology

    Socket and Butt Fusion

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    Socket and Butt Fusion 22007-01-24 GF Piping Systems

    § 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

    Goal

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    Socket and Butt Fusion 32007-01-24 GF Piping Systems

    Table of Contents

    Butt Fusion

    Socket Fusion

    Basics

    Jointing Methods

    4

    3

    2

    1

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    Socket and Butt Fusion 42007-01-24 GF Piping Systems

    Which jointing technology do I use ?

    ???

    Flange Adapter 

    Unions, thread

    Soldering

    Solvent cementPush fit

    Compression

    Electro fusion

    Butt, Socket, IR, BCF fusion

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    Socket and Butt Fusion 52007-01-24 GF Piping Systems

    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 supportto all these questions

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    Socket and Butt Fusion 62007-01-24 GF Piping Systems

    Installation examples

    § Mechanical joints- unions / flanges

    § Solvent cement joints

    § Socket fusion

    § IR and BCF fusion

    § Electrofusion

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    Socket and Butt Fusion 72007-01-24 GF Piping Systems

    BasicsMain parameters P T T

    Main parameters Subordinate parameters

    Pressure

    Temperature

    Time

    Fusion joint strength

    Equalization pressureHeating pressureJointing pressure

    Temperature of the heating element

     Ambient temperatureHeating and equalization timeChangeover and jointing timeCooling time under pressure

    Human factor Pipe storage and handling, Cutting,Facing, Pipe support, Cleaning

     Alignment checkMachine maintenanceetc. etc.

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    Socket and Butt Fusion 82007-01-24 GF Piping Systems

    BasicsHandling of pipes and fi tting

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    Socket and Butt Fusion 92007-01-24 GF Piping Systems

    BasicsWorking environment

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    Socket and Butt Fusion 102007-01-24 GF Piping Systems

    BasicsOverview jointing methods

    Electro fusionPE, PB

    up to d630

    Butt fusionPE, PP, PVDF, PP-n

    up to d1200

    Socket fusionPE, PP, PVDF, PB

    up to d110

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    Socket and Butt Fusion 112007-01-24 GF Piping Systems

    BasicsOverview joint ing methods (System)

    IR fusionPP, PE100, PVDF, PP-n

    up to d 315

    BCF fusionPVDF, PP-n

    up to d 110

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    Socket and Butt Fusion 122007-01-24 GF Piping Systems

    Socket fusion

    Electro fusion

    Butt fusion

    Socket fusion

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    Socket and Butt Fusion 132007-01-24 GF Piping Systems

    Cleanser Tangit KS

    § for cleaning the fusion surfaces

    § clean lint free cleaning tissues/paper is required

    Socket fusionPreparation for fusion

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    Socket and Butt Fusion 142007-01-24 GF Piping Systems

    Socket fusion of PE, PP, PVDF, PB

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    Socket and Butt Fusion 152007-01-24 GF Piping Systems

    Socket fusionPrinciple

    pipefittingspigot

    heater plate

    fitting

    finished fusion

    pipe

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    Socket and Butt Fusion 162007-01-24 GF Piping Systems

    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

    Socket fusionHeating element temperature

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    Socket and Butt Fusion 172007-01-24 GF Piping Systems

    Heating t ime table

    1 2 3 4 5

    Heating Change over  Outer pipe-

    diameter 

    d in mm

    (Maximum

    time)

    s

    fixed

    s

    total

    min

    16 4 6 2

    20 4 6 2

    25 4 10 2

    32 6 10 4

    40 6 20 4

    50 6 20 4

    63 8 30 6

    75 8 30 6

    90 8 40 6

    110

    for PN 10

    SDR 11 2)

    s

    5

    5

    7

    8

    12

    12

    24

    30

    40

    50

    for PN 6

    SDR 17.6 2)

    s

    1)

    1)

    1)

    1)

    10

    15

    22

    30 10 50 8

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

    2) Standard Dimension Ratio = d/s (d= Outer pipe diameter, s=pipe wall thickness)

    Standard values for socket fusion of pipe and fittings of PP (see table of used material)

    Socket fusionTime table for PP

    Cooling

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    Socket and Butt Fusion 182007-01-24 GF Piping Systems

    Socket fusionPreparation

    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

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    Socket and Butt Fusion 192007-01-24 GF Piping Systems

    Socket fusionHand fusion tool

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    Socket and Butt Fusion 202007-01-24 GF Piping Systems

    §  Adjust the fusion temperature at the

    temperature control to 260°C

    § Check temperature at the outer side of 

    the heater bushes with tempil sticks

    (253° and 274°C) or with measuring

    device

    § Protect fusion area from wind, rain etc.

    and wait for correct temperature

    § Clean heater bushes with clean paper 

    Socket fusionPreparation for fusion

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    Socket and Butt Fusion 222007-01-24 GF Piping Systems

    § 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

    Socket fusionProcedure with machine (d > 63mm)

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    Socket and Butt Fusion 232007-01-24 GF Piping Systems

    Socket fusion Advantages for using a machine

    § Alignment of fused components

    § Accurate penetration stops forheating and fusion phase

    § Mechanical fusion forceRecommended if d > 63mm

    § Faster change over phase

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    Socket and Butt Fusion 242007-01-24 GF Piping Systems

    § German Association of Welding technology (DVS)

    § Guidelines of DVS 2207 (heater plate socket fusion)

    § Bead has to be visible and uniform over the wholecircumference

    § Check penetration of pipe

    § Check alignment of pipe and fitting

    Socket fusionGuidelines and quality check

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    Socket and Butt Fusion 252007-01-24 GF Piping Systems

    Butt fusion

    Electro fusion

    Butt fusion

    Socket fusion

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    Socket and Butt Fusion 262007-01-24 GF Piping Systems

    Butt fusionPrinciple

    Pressure

    (N/mm²)

    0.01

    0.15

    Time Align-menttime

    Heating pressure

    Jointingtime

    Cooling and jointing t ime

    Heating time

     Al ignment pressure Jointing pressure

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    Socket and Butt Fusion 272007-01-24 GF Piping Systems

    Butt fusionPreparation for fusion

    Ds

    s   s max. = 0.1 x s

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

    ÜWall Offset

    aa

    ÜMaximum GAP (gap between the two parts to be welded)ÜMaximum GAP (gap between the two parts to be welded)

     s max. = 0.5 mm with But t fusion(Ds max. = 0.2 mm with IR fusion) s max. = 0.5 mm with But t fusion(Ds max. = 0.2 mm with IR fusion)

    incorrect correct

    ÜWall thickness (must be same SDR value)

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    Socket and Butt Fusion 282007-01-24 GF Piping Systems

    § 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 m in . max.

    Material

    PP 210°C 200°C 220°C

    PE 210°C 200°C 220°C

    PVDF 240°C 232°C 248°C

    Butt fusionPreparation for fusion

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    Socket and Butt Fusion 292007-01-24 GF Piping Systems

    Equalization force = jointing force = Ftotal = FA+FBFA= 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

     Attent ion: Fusion pressure is always related to used machine (seeoperating manuals for corresponding pressure tables)

    Material Equalization pressure Heat soak pressure

    PE 0.15 N /mm² 0.02 N /mm²

    PP 0.10 N /mm² 0.01 N /mm²

    PVDF 0.10 N /mm² 0.01 N /mm²

    Butt fusionPressure calculation

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    Socket and Butt Fusion 302007-01-24 GF Piping Systems

    § 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

    1 2 3 4 5

    Wal l t hi ckness Equal isat ion

    Bead height on theheating element afterequalization time(equalization at 0,15

    N/mm²)

    Heat Soak

    Heat soak time= 10 x wall thickness(heat soak at0,02 N/mm²)

    Change-over Fusion

    time until maximumpressure reached

    Cooling

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

    mm mm(minimum values)

    s s(maximum time)

    s min(minimum value)

    < 4,5 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 – 3226,0 – 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

    Butt fusionExample fusion table

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    Socket and Butt Fusion 312007-01-24 GF Piping Systems

    § Melt the pipe and fitting ends until a defined bead height isreached under equalization pressure

    § Reduce pressure to heat soak pressure

    § Following the heat soak time

    under heating pressure

    Pressure

    (N/mm²)

    0,15

    0,01

    Equalization

    pressure

    Heat soak

    pressure

    Equalization

    timeHeat soak time

    Butt fusionEqualization/Heating

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    Socket and Butt Fusion 322007-01-24 GF Piping Systems

    §  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

    Butt fusionFusion- /Cooling time

    Jointing pressure

    Cooling and

     jo inting time

    Join-

    ting

    time

    Time

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    Socket and Butt Fusion 332007-01-24 GF Piping Systems

    Butt fusionQuality check and guidelines

    § K > 0

    § Double bead over whole circumference ?

    § Misalignment less than 10% of wall thickness

    § Guidelines according to DVS 2207 (German Welding Association)

    K

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    Socket and Butt Fusion 342007-01-24 GF Piping Systems

    Machine and ToolsSG Line

    SG 160 SG 315

    SG 315-SSG 110

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    Socket and Butt Fusion 352007-01-24 GF Piping Systems

    Machine and toolsWM line

    WM 315

    WM 500

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    Socket and Butt Fusion 362007-01-24 GF Piping Systems

    Machines and toolsHydraulically operated machines (GF line)

    GF line

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    Socket and Butt Fusion 372007-01-24 GF Piping Systems

    Machine and toolsSUVI® System

    SUVI® 50for the GF line

    up to 1200 mm

    SUVI® WIN-WELD

    SUVI® 400for GF line

    up to 630 mm

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    Socket and Butt Fusion 382007-01-24 GF Piping Systems

    Cutting machines and toolsKRA, PPC 250, KS 355, KS 1600

    KRA 63

    PPC 250

    KS 1600

    KS 355

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