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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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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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Installation examples

§ Mechanical joints- unions / flanges

§ Solvent cement joints

§ Socket fusion

§ IR and BCF fusion

§ Electrofusion

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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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BasicsHandling of pipes and fi tting

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BasicsWorking environment

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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 fusion

Electro fusion

Butt fusion

Socket fusion

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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 fusion of PE, PP, PVDF, PB

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Socket fusionPrinciple

pipefittingspigot

heater plate

fitting

finished fusion

pipe

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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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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 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 fusionHand fusion tool

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§  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 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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§ 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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Butt fusion

Electro fusion

Butt fusion

Socket fusion

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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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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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§ 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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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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§ 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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§ 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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§  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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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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Machine and ToolsSG Line

SG 160 SG 315

SG 315-SSG 110

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Machine and toolsWM line

WM 315

WM 500

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Machines and toolsHydraulically operated machines (GF line)

GF line

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

KRA 63

PPC 250

KS 1600

KS 355

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