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![TECHNICAL INFORMATION
BUTT-FUSION WELDING OF POLYETHYLENE PIPE
Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500
Welding Guideline
4. Welding Parameter
The control parameter of welding cycle was shown on the figure2. They are reference to DVS 2207-1:1995 and
NEN 7200 (VEG-85) the international welding standard. In cases of used the calculation method or/and
recommended values from the standard.
Pressure
(bar)
P1
P3
P2
T1
T2
T3
T4
T5
Time
(minute or second)
Table1. Welding Parameter and control for calculation method and recommended values to be used
Description
Parameter
Calculation
Recommended
Values
0
1. Heating temperature
200 - 220 C
Figure3.
2
_
2. Alignment pressure
(bar) (P1) 0.15 ± 0.01 N/mm A1 / A2 x 1.5
3. Alignment time (Bead Created)
(T1) Until bead created Until bead created
Table3.
follow item 4
follow item 4
4. Bead height
(mm.)
0.5 + (0.1 x e)
0.5 + (0.1 x e)
5. Heating-up pressure
(bar) (P2) ≤ 0.02 N/mm2
A1 / A2 x 0.2
6. Heating-up time
(sec.) (T2) 10 x e
10 x e
Table3.
7. Changeover time
(sec.) (T3) 3 + (0.01 x OD)
3 + (0.01 x OD)
Table3.
8. Joining pressure built-up time (sec.) (T4) 3 + (0.03 x OD)
3 + (0.03 x OD)
Table3.
2
9. Joining pressure
(bar) (P3) 0.15±0.01 N/mm
A1 / A2 x 1.5
10. Minimum cooling time
(min.) (T5) 3 + e
3+e
Table3.
11. Minimum bead width
(mm.)
3 + (0.50 x e)
3 + (0.50 x e)
12. Maximum bead width
(mm.)
5 + (0.75 x e)
5 + (0.75 x e)
Remarks: OD = Outside Diameter (mm.), e = Wall Thickness (mm.)
A1 = Pipe section area (mm2) by calculation formula: [(OD2– ID2)/4]
A2 = Hydraulic cylinder section area (mm2) by calculation formula: [(Number of hydraulic cylinder) x (iD2Cylinder– OD2Shaft)/4]
Page 6 of 22
TAP-352802-TEC-BUTT WELDING-52R2
th
Issue Date 25 MAY 2009
Figure2. Process stages of butt-fusion welding relation between pressure and time](https://image.slidesharecdn.com/tapweldingguidelineenglish-140303071106-phpapp02/85/Tap-welding-guideline_english-6-320.jpg)
![TECHNICAL INFORMATION
BUTT-FUSION WELDING OF POLYETHYLENE PIPE
Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500
Welding Guideline
5. Welding Cycle Calculation (in case of welding operation by manual machine)
Pressure Calculation for the welding machine
Welding Pressure
P (Cylinder) = P (Pipe) x (A1/A2) …………………………. [exclude drag force]
A1 = HDPE Pipe section area ………………. (mm2)
A2 = Hydraulic cylinder section area ……….. (mm2)
P (Pipe) = 0.15 N/mm2 or 1.5 ……………………… (bar) [for P1 and P3]
= ≤ 0.02 N/mm2 or 0.2 …………………… (bar) [for P2]
P (Cylinder) = Operating pressure of welding machine (bar.)
1) Calculation for HDPE Pipe section area: A1 = (OD2-ID2) / 4 (mm2)
Case1. HDPE pipe 315 mm. wall thickness 15.0 mm. PN 6.3 SDR 21
A1 = 3.142x(3152-(315-(2x15))2) / 4
= 14,139.00 mm2
Case2. HDPE pipe 400 mm. wall thickness 19.1 mm. PN 6.3 SDR 21
A1 = 3.142x(4002-(400-(2x19.1))2) / 4
= 22,858.64 mm2
2) Calculation for Hydraulic cylinder effective area of welding machine
Hydraulic cylinder effective area: A2 = No. of cylinder x (ID2cylinder - OD2shaft) / 4 (mm2)
HDPE Butt-Fusion machine: Model 315
OD of hydraulic shaft = 30 mm. ID of hydraulic cylinder = 40 mm.
Number of hydraulic cylinder = 2
HDPE Butt-Fusion machine: Model 450
OD of hydraulic shaft = 40 mm. ID of hydraulic cylinder = 50 mm.
Number of hydraulic cylinder = 2
A2 = 2 x 3.142 x (502-402) / 4
= 1,413.90 mm.2
Page 9 of 22
TAP-352802-TEC-BUTT WELDING-52R2
th
Issue Date 25 MAY 2009
A2 = 2 x 3.142 x (402-302) / 4
= 1,099.70 mm.2](https://image.slidesharecdn.com/tapweldingguidelineenglish-140303071106-phpapp02/85/Tap-welding-guideline_english-9-320.jpg)
![TECHNICAL INFORMATION
BUTT-FUSION WELDING OF POLYETHYLENE PIPE
Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500
Welding Guideline
OD
e
SDR
[mm.] [mm.] OD/e
90
110
125
140
2.2
2.8
3.5
4.3
5.1
5.4
6.7
8.2
10.1
12.3
15
2.7
3.4
4.2
5.3
6.3
6.6
8.1
10.0
12.3
15.1
18.3
3.1
3.9
4.8
6.0
7.1
7.4
9.2
11.4
14.0
17.1
20.8
3.5
4.3
5.4
6.7
8
8.3
10.3
12.7
15.7
19.2
23.3
41
33
26
21
17.6
17
13.6
11
9
7.4
6
41
33
26
21
17.6
17
13.6
11
9
7.4
6
41
33
26
21
17.6
17
13.6
11
9
7.4
6
41
33
26
21
17.6
17
13.6
11
9
7.4
6
2
T
P1[*]
[C ]
220
220
220
219
218
218
217
215
213
211
209
220
220
219
218
217
217
215
213
211
209
207
220
219
218
217
216
216
214
212
210
208
205
220
219
218
217
215
215
213
211
209
206
204
P2[*]
0.5
0.5
0.5
0.5
1.0
1.0
1.0
1.5
1.5
2.0
2.0
0.5
0.5
0.5
1.0
1.0
1.0
1.5
1.5
2.0
2.0
2.0
0.5
0.5
1.0
1.0
1.5
1.5
1.5
1.5
2.0
2.0
2.0
0.5
0.5
1.0
1
1.5
1.5
1.5
2.0
2.0
2.5
2.5
3
t2
[sec]
t3 Max
[sec]
22
28
35
43
51
54
67
82
101
123
150
27
34
42
53
63
66
81
100
123
151
183
31
39
48
60
71
74
92
114
140
171
208
35
43
54
67
80
83
103
127
157
192
233
3
3
4
5
5
5
6
6
7
8
9
3
4
5
5
6
6
6
7
8
9
10
3
4
5
6
6
6
7
8
9
10
11
4
5
5
6
6
7
7
8
9
10
11
Page 17 of 22
4
t4 P3[*]
[sec]
3
3
4
5
5
5
6
6
7
8
9
3
4
5
5
6
6
6
7
8
9
11
3
4
5
6
6
6
7
8
9
10
12
4
5
5
6
6
7
7
8
10
11
13
5
Bead Width
t5
[min]
3
4
5
6
7
7
10
11
14
16
19
4
5
6
7
9
9
11
14
16
20
23
4
5
6
8
10
10
13
15
18
22
26
5
6
7
10
11
12
14
17
20
24
29
Min. Max.
[mm.] [mm.]
4.1
4.4
4.8
5.2
5.6
5.7
6.4
7.1
81
9.2
10.5
4.4
4.7
5.1
5.7
6.2
6.3
7.1
8.0
9.2
10.6
12.2
4.6
5.0
5.4
6.0
6.6
6.7
7.6
8.7
10.0
11.6
13.4
4.8
5.2
5.7
6.4
7.0
7.2
8.2
9.4
10.9
12.6
14.7
6.7
7.1
7.6
8.2
8.8
9.1
10.0
11.2
12.6
14.2
16.3
7.0
7.6
8.2
9.0
9.7
10.0
11.1
12.5
14.2
16.3
18.7
7.3
7.9
8.6
9.5
10.3
10.6
11.9
13.6
15.5
17.8
20.6
7.6
8.2
9.1
10.0
11.0
11.2
12.7
14.5
16.8
19.4
22.5
TAP-352802-TEC-BUTT WELDING-52R2
th
Issue Date 25 MAY 2009
1](https://image.slidesharecdn.com/tapweldingguidelineenglish-140303071106-phpapp02/85/Tap-welding-guideline_english-17-320.jpg)
![TECHNICAL INFORMATION
BUTT-FUSION WELDING OF POLYETHYLENE PIPE
Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500
Welding Guideline
160
180
200
225
e
SDR
[mm.] OD/e
4.0
4.9
6.2
7.7
9.1
9.5
11.8
14.6
17.9
21.9
26.6
4.4
5.5
6.9
8.6
10.2
10.7
13.3
16.4
20.1
24.6
29.9
4.9
6.2
7.7
9.6
11.4
11.9
14.7
18.2
22.4
27.4
33.2
5.5
6.9
8.6
10.8
12.8
13.4
16.6
20.5
25.2
30.8
37.4
41
33
26
21
17.6
17
13.6
11
9
7.4
6
41
33
26
21
17.6
17
13.6
11
9
7.4
6
41
33
26
21
17.6
17
13.6
11
9
7.4
6
41
33
26
21
17.6
17
13.6
11
9
7.4
6
T
[C ]
219
218
217
216
214
214
212
209
207
205
203
219
218
216
215
213
213
210
208
206
204
202
218
217
216
214
212
211
209
207
205
203
201
218
216
215
213
211
210
208
205
204
202
201
2
P1[*]
P2[*]
0.5
1.0
1.0
1.5
1.5
1.5
1.5
2.0
2.0
2.5
3.0
0.5
1.0
1.0
1.5
1.5
1.5
2
2.0
2.5
2.5
3.0
1
1.0
1.5
1.5
1.5
1.5
2.0
2.0
2.5
3.0
3.0
1
1.0
1.5
1.5
2.0
2.0
2
2.5
2.5
3.0
3.5
3
t2
[sec]
t3
Max
[sec]
40
49
62
77
91
95
118
146
179
219
266
44
55
69
86
102
107
133
164
201
246
299
49
62
77
96
114
119
147
182
224
274
332
55
69
86
108
128
134
166
205
252
308
374
4
5
6
6
7
7
8
9
10
11
12
5
5
6
7
7
7
8
9
10
12
13
5
6
6
7
8
8
9
10
11
12
15
5
6
7
8
8
8
9
11
12
14
16
Page 18 of 22
4
t4 P3[*]
[sec]
4
5
6
6
7
7
8
9
11
12
14
5
5
6
7
7
7
9
10
12
13
16
5
6
6
7
8
8
9
11
12
15
17
5
6
7
8
8
9
10
12
14
16
19
5
Bead Width
t5
[min]
5
7
9
11
13
13
16
19
23
27
33
6
8
10
12
14
14
17
21
25
30
37
7
9
11
13
15
16
19
23
28
34
40
8
10
12
15
17
18
21
26
31
38
45
Min. Max.
[mm.] [mm.]
5.0
5.5
6.1
6.9
7.6
7.8
8.9
10.3
12.0
14.0
16.3
5.2
5.8
6.5
7.3
8.1
8.4
9.7
11.2
13.1
15.3
18.0
5.5
6.1
6.9
7.8
8.7
9.0
10.4
12.1
14.2
16.7
19.6
5.8
6.5
7.3
8.4
9.4
9.7
11.3
13.3
15.6
18.4
21.7
8.0
8.7
9.7
10.8
11.8
12.1
13.9
16.0
18.4
21.4
25.0
8.3
9.1
10.2
11.5
12.7
13.0
15.0
17.3
20.1
23.5
27.4
8.7
9.7
10.8
12.2
13.6
13.9
16.0
18.7
21.8
25.6
29.9
9.1
10.2
11.5
13.1
14.6
15.1
17.5
20.4
23.9
28.1
33.1
TAP-352802-TEC-BUTT WELDING-52R2
th
Issue Date 25 MAY 2009
1
OD
[mm.]](https://image.slidesharecdn.com/tapweldingguidelineenglish-140303071106-phpapp02/85/Tap-welding-guideline_english-18-320.jpg)
![TECHNICAL INFORMATION
BUTT-FUSION WELDING OF POLYETHYLENE PIPE
Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500
Welding Guideline
T
[C ]
6.2
7.7
9.6
11.9
14.2
14.8
18.4
22.7
27.9
34.2
41.5
6.9
8.6
10.7
13.4
15.9
16.6
20.6
25.4
31.3
38.3
46.5
7.7
9.7
12.1
15
17.9
18.7
23.2
28.6
35.2
43.1
52.3
8.70
10.90
13.60
16.90
20.10
21.10
26.10
32.20
39.70
48.50
59.00
217
216
214
211
210
209
207
205
203
201
200
216
215
213
210
208
208
205
204
202
200
200
216
214
211
209
207
206
204
203
201
200
200
215
212
210
208
206
205
203
202
200
200
200
250
280
315
355
41
33
26
21
17.6
17
13.6
11
9
7.4
6
41
33
26
21
17.6
17
13.6
11
9
7.4
6
41
33
26
21
17.6
17
13.6
11
9
7.4
6
40.80
32.57
26.10
21.01
17.66
16.82
13.60
11.02
8.94
7.32
6.02
2
P1[*]
P2[*]
1
1.5
1.5
1.5
2
2
2
2.5
3.0
3.0
3.5
1
1.5
1.5
2
2.0
2.0
2.5
2.5
3.0
3.5
3.5
1.5
1.5
2.0
2.0
2.0
2.0
2.5
3.0
3.0
3.5
4.0
1.50
1.50
2.00
2.00
2.50
2.50
3.00
3.00
3.50
3.50
4.00
3
4
t2 t3 Max t4
[sec] [sec] [sec]
62
77
96
119
142
148
184
227
279
342
415
69
86
107
134
159
166
206
254
313
383
465
77
97
121
150
179
187
232
286
352
431
523
87
109
136
169
201
211
261
322
397
485
590
Page 19 of 22
6
6
7
8
9
9
10
11
13
15
17
6
7
7
8
9
9
11
12
14
16
19
6
7
8
9
10
10
11
13
15
18
21
7
8
9
9
10
11
12
14
17
20
22
6
6
7
8
9
9
11
13
15
18
21
6
7
7
9
10
10
12
14
16
20
23
6
7
8
9
11
11
13
15
18
22
26
7
8
9
10
12
12
14
17
20
24
30
5
P3[*]
Bead Width
t5
Min. Max.
[min] [mm.] [mm.]
9
11
13
16
18
19
23
28
34
42
50
10
12
14
18
20
21
26
31
38
46
56
11
13
16
19
23
24
29
35
43
52
62
12
15
18
22
25
26
32
39
48
58
69
6.1
6.9
7.8
9.0
10.1
10.4
12.2
14.4
17.0
20.1
23.8
6.5
7.3
8.4
9.7
11.0
11.3
13.3
15.7
18.7
22.2
26.3
6.9
7.9
9.1
10.5
12.0
12.4
14.6
17.3
20.6
24.6
29.2
7.35
8.45
9.80
11.45
13.05
13.55
16.05
19.10
22.85
27.25
32.50
9.7
10.8
12.2
13.9
15.7
16.1
18.8
22.0
25.9
30.7
36.1
10.2
11.5
13.0
15.1
16.9
17.5
20.5
24.1
28.5
33.7
39.9
10.8
12.3
14.1
16.3
18.4
19.0
22.4
26.5
31.4
37.3
44.2
11.53
13.18
15.20
17.68
20.08
20.83
24.58
29.15
34.78
41.38
49.25
TAP-352802-TEC-BUTT WELDING-52R2
th
Issue Date 25 MAY 2009
1
OD
e
SDR
[mm.] [mm.] OD/e](https://image.slidesharecdn.com/tapweldingguidelineenglish-140303071106-phpapp02/85/Tap-welding-guideline_english-19-320.jpg)
![TECHNICAL INFORMATION
BUTT-FUSION WELDING OF POLYETHYLENE PIPE
Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500
Welding Guideline
OD
e
SDR
[mm.] [mm.] OD/e
T
[C ]
9.80
12.30
15.30
19.10
22.70
23.70
29.40
36.30
44.70
54.70
11.00
13.80
17.20
21.50
25.50
26.70
33.10
40.90
50.30
61.50
12.30
15.30
19.10
23.90
28.30
29.70
36.80
45.40
55.80
13.70
17.20
21.40
26.70
31.70
33.20
41.20
50.80
213
211
209
206
205
204
202
201
200
200
212
210
208
205
204
203
201
200
200
200
211
209
206
204
203
202
201
200
200
210
208
205
203
202
201
200
200
400
450
500
560
40.82
32.52
26.14
20.94
17.62
16.88
13.61
11.02
8.95
7.31
40.91
32.61
26.16
20.93
17.65
16.85
13.60
11.00
8.95
7.32
40.65
32.68
26.18
20.92
17.67
16.84
13.59
11.01
8.96
40.88
32.56
26.17
20.97
17.67
16.87
13.59
11.02
2
P1[*]
P2[*]
1.50
2.00
2.00
2.50
2.50
2.50
3.00
3.00
3.50
4.00
1.50
2.00
2.00
2.50
2.50
3.00
3.00
3.50
4.00
4.00
2.00
2.00
2.50
2.50
3.00
3.00
3.00
3.50
4.00
2.00
2.00
2.50
3.00
3.00
3.00
3.50
4.00
3
t2 t3 Max
[sec] [sec]
98
123
153
191
227
237
294
363
447
547
110
138
172
215
255
267
331
409
503
615
123
153
191
239
283
297
368
454
558
137
172
214
267
317
332
412
508
Page 20 of 22
7
8
9
10
11
11
13
16
19
21
8
9
10
11
12
12
15
17
20
23
8
9
10
12
13
13
16
19
21
9
10
11
12
14
15
17
20
4
t4
[sec]
7
8
9
11
13
13
15
19
23
27
8
9
10
12
14
14
17
21
25
31
8
9
11
13
15
16
19
23
28
9
10
12
14
16
17
21
25
5
P3[*]
Bead Width
t5
Min. Max.
[min] [mm.] [mm.]
13
16
20
24
28
29
36
44
54
65
15
18
22
27
31
33
40
49
60
72
16
20
24
30
35
36
45
55
66
18
22
27
33
39
41
50
61
7.90
9.15
10.65
12.55
14.35
14.85
17.70
21.15
25.35
30.35
8.50
9.90
11.60
13.75
15.75
16.35
19.55
23.45
28.15
33.75
9.15
10.65
12.55
14.95
17.15
17.85
21.40
25.70
30.90
9.85
11.60
13.70
16.35
18.85
19.60
23.60
28.40
12.35
14.23
16.48
19.33
22.03
22.78
27.05
32.23
38.53
46.03
13.25
15.35
17.90
21.13
24.13
25.03
29.83
35.68
42.73
51.13
14.23
16.48
19.33
22.93
26.23
27.28
32.60
39.05
46.85
15.28
17.90
21.05
25.03
28.78
29.90
35.90
43.10
TAP-352802-TEC-BUTT WELDING-52R2
th
Issue Date 25 MAY 2009
1](https://image.slidesharecdn.com/tapweldingguidelineenglish-140303071106-phpapp02/85/Tap-welding-guideline_english-20-320.jpg)
![TECHNICAL INFORMATION
BUTT-FUSION WELDING OF POLYETHYLENE PIPE
Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500
Welding Guideline
OD
[mm.]
630
710
800
900
1000
e
SDR
T
[mm.] OD/e [C ]
15.40
19.30
24.10
30.00
35.70
37.40
46.30
57.20
17.40
21.80
27.20
33.90
40.20
42.10
52.20
19.60
24.50
30.60
38.10
45.30
47.40
58.80
22.00
27.60
34.40
42.90
51.00
53.30
24.50
30.60
38.20
47.70
56.60
59.30
40.91
32.64
26.14
21.00
17.65
16.84
13.61
11.01
40.80
32.57
26.10
20.94
17.66
16.86
13.60
40.82
32.65
26.14
21.00
17.66
16.88
13.61
40.91
32.61
26.16
20.98
17.65
16.89
40.82
32.68
26.18
20.96
17.67
16.86
209
206
204
202
201
201
200
200
206
205
204
201
200
200
200
206
204
202
201
200
200
200
205
204
201
200
200
200
204
202
201
200
200
200
2
P1[*]
P2[*]
2.00
2.50
2.50
3.00
3.00
3.50
3.50
4.00
2.00
2.50
3.00
3.00
3.50
3.50
4.00
2.50
2.50
3.00
3.50
3.50
3.50
4.00
2.50
3.00
3.00
3.50
4.00
4.00
2.50
3.00
3.50
3.50
4.00
4.00
3
4
t2 t3 Max t4
[sec] [sec] [sec]
154
193
241
300
357
374
463
572
174
218
272
339
402
421
522
196
245
306
381
453
474
588
220
276
344
429
510
533
245
306
382
477
566
593
[*] The calculation is not include drag pressure
Page 21 of 22
9
10
12
13
15
16
19
22
10
11
12
15
16
17
20
11
12
13
16
18
19
23
11
12
15
17
20
21
12
13
16
19
22
23
9
11
13
16
18
19
23
29
10
12
15
17
21
22
26
11
13
16
19
23
24
30
12
15
17
22
26
27
13
16
19
24
29
30
5
P3[*]
Bead Width
t5
[min]
Min.
[mm.]
Max.
[mm.]
20
24
30
37
44
45
56
67
22
27
34
43
49
51
62
24
31
39
48
55
57
69
27
34
43
51
61
63
31
39
48
57
67
70
10.70
12.65
15.05
18.00
20.85
21.70
26.15
31.60
11.70
13.90
16.60
19.95
23.10
24.05
29.10
12.80
15.25
18.30
22.05
25.65
26.70
32.40
14.00
16.80
20.20
24.45
28.50
29.65
15.25
18.30
22.10
26.85
31.30
32.65
16.55
19.48
23.08
27.50
31.78
33.05
39.73
47.90
18.05
21.35
25.40
30.43
35.15
36.58
44.15
19.70
23.38
27.95
33.58
38.98
40.55
49.10
21.50
25.70
30.80
37.18
43.25
44.98
23.38
27.95
33.65
40.78
47.45
49.48
TAP-352802-TEC-BUTT WELDING-52R2
th
Issue Date 25 MAY 2009
1](https://image.slidesharecdn.com/tapweldingguidelineenglish-140303071106-phpapp02/85/Tap-welding-guideline_english-21-320.jpg)
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- 1. 2009 THAI-ASIA P.E. PIPECO., LTD. BUTT-FUSION WELDING GUIDELINE Butt-fusion technology is classified as a heat pressure related process by which the pipe end material of two different pipes are melted together creating a homogenous pipe structure in their point of meeting. Butt-fusion welding is the most important jointing method for HDPE and MDPE pipes. The method is very simple and reliable. It will be the aim of these document to improve the understanding and basic knowledge of the process of butt-fusion and demonstrate how to create a proper and secure welding structure. THAI-ASIA P.E. PIPE CO.,LTD. 555 Moo18 Pakchong Nakhonratchasima (THAILAND) 30130 6644-328590 to 95 6644-328600 www.tappipe.com e-mail address: info2fac@tappipe.com Editor code: TAP-352802 Document issue date: 25th MAY 2009 Document reversion: 2
- 2. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline Content 1. 2. 3. 4. 5. 6. Scope General Requirement Welding Machine Welding Parameter Welding Cycle Calculation (in case of welding operation by manual machine) Welding Operation Appendix – A – The welding guideline time values of welding operation for High Density Polyethylene Pipe. Appendix – B – The sample of welding protocol form for welding data record. 3 3 4 6 9 12 16 22 Page 2 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 Normative Reference 1. Direction DVS 2207-1:1995 “Welding of thermoplastics” Heated tool welding of pipe, pipeline components and sheet made from PE-HD, page 1 to 4, 6 and 9. 2. Borealis A/S, Polyethylene ART 339 03.04.1998 Ed.1 “Welding of large diameter PE pipe”, page 6.
- 3. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline 1. Scope Butt-fusion technology is classified as a heat pressure related process by which the pipe end material of two different pipes are melted together creating a homogenous pipe structure in their point of meeting. When Thermoplastics material like high density polyethylene (HDPE), medium density polyethylene (MDPE) are heated up to a temperature between 200C to 220C the material will change from a solid to a liquid state under the application of a certain pressure. With regard to the following instructions, suitability within the melt flow rates MFR 190/5 0.3 g to 1.7 g/10 min may be assumed. When two properly cut and heat-softened pipe ends are brought together and held under pressure, they are fuse together, forming a homogenous and tight joint when cooled. Simply in idea and performance, the butt-fusion process demands a high grade of accuracy to give the final product, i.e. the butt weld, a level of quality equal to that of the pipe itself. It will be the aim of these document to improve the understanding and basic knowledge of the process of butt-fusion and demonstrate how to create a proper and secure welding structure. 2. General Requirement The quality of welding joints depends on the qualification of the welder, the suitability of the used equipment and devices as well as on observance to the welding standards. The welding joint can be tested by means of nondestructive and/or destructive methods. Every welder has to be trained and has to be in possession of a valid qualification certificate. The intended application range may be decisive of the kind of qualification. The welding zone must be protected against bad weather influences (e.g. moisture and temperatures below +5 C). If it is ensured by suitable measures (e.g. preheating, tent, heating) that the condition are suitable for welding work may be carried out at any outside temperature insofar as the welder is not hindered in his handling. If necessary, an additional proof must be provided by carrying out sample welds under the mentioned condition. If the semi-finished product is heated up unevenly under influence of sunshine, the temperature compensation in Page 3 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 Butt-fusion welding is the most important jointing method for HDPE and MDPE pipes. The method is very simple and reliable. The principal procedure is following: The two pipes are clamped in a welding machine having a hydraulic system for the movable half of the machine and for the pressure build up. The pipe ends are squared by a special cutter, trimmer or facing tool. An electrically heated metal plate is placed between the pipe ends. The pipe ends are pressured against the hot plate with a specified pressure and for a specified time. When the ends have melted, the hot plate is taken out and the melted ends are pressed against each other to make a butt weld. The welding pressure is specified, and the welding time as well. When the weld has been cooled down, the pipes are taken out from the machine and preparation of the next joint can start.
- 4. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline the area of the welding joint can be reached by covering. A cooling down during the welding process by ventilation has to be avoided, e.g. by closing the pipe-ends during welding. Pipe from coils are oval immediately after uncoiling. The pipe end must be prepared before welding, e.g. by careful heating up with a hot-air equipment and use of a suitable clamping and/or re-rounding device. The connection zones of the components to be welded must be undamaged and have to be free of contamination (e.g. dirt, oil, shavings). The welding work must be monitored. Kind and range of supervising has to be agreed between the contract partners, this is recommended to record the welding data in welding protocols (sample see appendix B) or on data comers. Within the frame of the quality assurance it is recommended to perform and test samples of joints before beginning and during the welding works. The welding machine is major equipment that necessary for qualify welder used to perform the butt-fusion welding process. The good quality and reliable machine would be consideration to use created a proper and secure welding structure. There are many suppliers welding machine in the global market and there are variety model that can be selection depend on the application or installation project requirement. Generally standard welding machine there are the basic machine function and the option up on request such as a welding data record or the data logger, the CNC control unit for full automatic welding machine etc. The standard welding machine component as show on the figure1 and their basic work function are shown on as the following detail: 1. The machine base structure had a dual clamping device with quick action lock guide by two hydraulic cylinders two flexible hoses with quick-action coupling connect the appliance to the hydraulic control. 2. The hydraulic control unit which is control moving the right dual clamping device and precisely controls the jointing force, motor- pump start auto lock pressure by pilot check valve and accumulator. 3. The facing tool or trimmer is attached to the tooling support frame. It is electrically power by a chain or gear drive protected by an all-enclosing aluminum case and automatically delivers chips to the outside. 4. The heater element, there is a teflon coating on the surface plate which is attached to the tooling support frame. There is temperature sensor PT-100 or PT-1000 and digital control equipped with control lamps an ON/OFF switch and extension cable with earthling-contact plug. 5. The clamping inserts consisting of eight haft shells per dimension are available for cover all the range of pipe diameter that is the machine capable to welding such as the welding machine model 315, there are the clamp insert for pipe size 90,110,125,140,160,180,200,225,250 and 280 mm. 6. The carrier case or tooling support frame is for heater element and the facing tool. 7. The stub end and concentric reducer holder is for locking the center position for weld with pipe end. Page 4 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 3. Welding Machine
- 5. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline Heating Plate Facing Tool Electric Control Box Hydraulic Control Unit 1. Machine Base Structure 2. Tool Support Frame 4. Heating Plate 5. Hydraulic Control Unit Figure1. Standard Welding Machine Component (basic machine function) Page 5 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 3. Trimmer or Facing Tool
- 6. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline 4. Welding Parameter The control parameter of welding cycle was shown on the figure2. They are reference to DVS 2207-1:1995 and NEN 7200 (VEG-85) the international welding standard. In cases of used the calculation method or/and recommended values from the standard. Pressure (bar) P1 P3 P2 T1 T2 T3 T4 T5 Time (minute or second) Table1. Welding Parameter and control for calculation method and recommended values to be used Description Parameter Calculation Recommended Values 0 1. Heating temperature 200 - 220 C Figure3. 2 _ 2. Alignment pressure (bar) (P1) 0.15 ± 0.01 N/mm A1 / A2 x 1.5 3. Alignment time (Bead Created) (T1) Until bead created Until bead created Table3. follow item 4 follow item 4 4. Bead height (mm.) 0.5 + (0.1 x e) 0.5 + (0.1 x e) 5. Heating-up pressure (bar) (P2) ≤ 0.02 N/mm2 A1 / A2 x 0.2 6. Heating-up time (sec.) (T2) 10 x e 10 x e Table3. 7. Changeover time (sec.) (T3) 3 + (0.01 x OD) 3 + (0.01 x OD) Table3. 8. Joining pressure built-up time (sec.) (T4) 3 + (0.03 x OD) 3 + (0.03 x OD) Table3. 2 9. Joining pressure (bar) (P3) 0.15±0.01 N/mm A1 / A2 x 1.5 10. Minimum cooling time (min.) (T5) 3 + e 3+e Table3. 11. Minimum bead width (mm.) 3 + (0.50 x e) 3 + (0.50 x e) 12. Maximum bead width (mm.) 5 + (0.75 x e) 5 + (0.75 x e) Remarks: OD = Outside Diameter (mm.), e = Wall Thickness (mm.) A1 = Pipe section area (mm2) by calculation formula: [(OD2– ID2)/4] A2 = Hydraulic cylinder section area (mm2) by calculation formula: [(Number of hydraulic cylinder) x (iD2Cylinder– OD2Shaft)/4] Page 6 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 Figure2. Process stages of butt-fusion welding relation between pressure and time
- 7. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline Alignment of pipe and gap width The joining areas have to be plane with a clean and grease-free tool directly before the welding, so they are plane-parallel in clamped condition. The gap width and the misalignment have to be controlled. The misalignment of the joining areas on the pipe outside respect may not pass the permissible value of 0.1 x wall thickness of pipe. The permissible gap width under alignment pressure is show on Table2. Table2. The maximum gap width is allowance between the treated welding zones. Pipe outside diameter range Gap width (mm.) (mm.) < 355 0.5 400…< 630 1.0 630…< 800 1.3 800…< 1000 13 > 1000 2.0 The treated welding areas should be neither dirtied nor touched by hand, as a retreatment would be necessary then. Shavings fallen into the pipe have to be remove. Welding temperature Figure3. Recommended values for the heating tool temperatures subject to wall thickness Page 7 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 The heating tool temperature is 200 to 220 C. In principle the upper temperature limit is aspired for smaller pipe wall thicknesses, the lower temperature limit for bigger ones. The recommended value is show on figure3.
- 8. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline The control or inspection measurement must be done within the welding area on the heating tool which corresponds to the semi-finished product. For adjusting the temperature balance, the heated tool may be inserted 10 minutes after reaching the set temperature at the earliest, before start the welding process. Table3. Recommended values for the heating tool butt-fusion welding of pipes and fittings from HDPE, at an ambient temperature of approximately 20 C and moderate air flow ( Interim values have to be interpolated). (mm) ≤ 4.5 4.5… 7 7 … 12 12 … 19 19 …26 26 … 37 37 … 50 50 … 70 2 Alignment 3 Heating-up (T2) Bead height on heating tool at the end of the alignment time (alignment with 0.15 N/mm²) Heating-up time =10 x wall thickness (heating-up with < 0.02 N/mm²) (mm) minimum values (second) 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4 Changeover (T3) 5 Joining (T4) Joining Pressure build-up time (second) maximum time 45 45…70 70…120 120…190 190…260 260…370 370…500 500…700 Page 8 of 22 5 5…6 6…8 8…10 10…12 12…16 16…20 20…25 (T5) Cooling time under joining pressure P=0.15 N/ mm² + 0.01 (second) (minute) minimum values 6 6…10 10…16 16…24 24…32 32…45 45…60 60…80 5 5…6 6…8 8…11 11…14 14…19 19…25 25…35 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 1 Nominal wall Thickness
- 9. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline 5. Welding Cycle Calculation (in case of welding operation by manual machine) Pressure Calculation for the welding machine Welding Pressure P (Cylinder) = P (Pipe) x (A1/A2) …………………………. [exclude drag force] A1 = HDPE Pipe section area ………………. (mm2) A2 = Hydraulic cylinder section area ……….. (mm2) P (Pipe) = 0.15 N/mm2 or 1.5 ……………………… (bar) [for P1 and P3] = ≤ 0.02 N/mm2 or 0.2 …………………… (bar) [for P2] P (Cylinder) = Operating pressure of welding machine (bar.) 1) Calculation for HDPE Pipe section area: A1 = (OD2-ID2) / 4 (mm2) Case1. HDPE pipe 315 mm. wall thickness 15.0 mm. PN 6.3 SDR 21 A1 = 3.142x(3152-(315-(2x15))2) / 4 = 14,139.00 mm2 Case2. HDPE pipe 400 mm. wall thickness 19.1 mm. PN 6.3 SDR 21 A1 = 3.142x(4002-(400-(2x19.1))2) / 4 = 22,858.64 mm2 2) Calculation for Hydraulic cylinder effective area of welding machine Hydraulic cylinder effective area: A2 = No. of cylinder x (ID2cylinder - OD2shaft) / 4 (mm2) HDPE Butt-Fusion machine: Model 315 OD of hydraulic shaft = 30 mm. ID of hydraulic cylinder = 40 mm. Number of hydraulic cylinder = 2 HDPE Butt-Fusion machine: Model 450 OD of hydraulic shaft = 40 mm. ID of hydraulic cylinder = 50 mm. Number of hydraulic cylinder = 2 A2 = 2 x 3.142 x (502-402) / 4 = 1,413.90 mm.2 Page 9 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 A2 = 2 x 3.142 x (402-302) / 4 = 1,099.70 mm.2
- 10. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline Calculation Data Table of Case1. Description HDPE Butt-Fusion Machine Hydraulic cylinder effective area OD. HDPE Pipe Pipe wall thickness PN (Nominal Pressure) SDR. (Standard dimension ratio) Area of pipe section Welding Standard Reference Heating Temperature Alignment Pressure Alignment Time (Bead created) Bead height Heating-up pressure Heating-up time Changeover time (Average time) Joining pressure built-up time Joining Pressure Cooling time (Minimum) Range of welding bead width Parameter Model 315 1,099.70 (mm.).2 225 (mm.) 225 (mm.) 315 (mm.) 10.8 (mm.) 16.6 (mm.) 15.0 (mm.) 6.3 (bar.) 10 (bar.) 6.3 (bar.) 21 13.6 21 2 2 7,268.57 (mm. ) 10,869.56 (mm. ) 14,139.00 (mm.2) DVS 2207-1:1995 and (VEG-85) NEN 7200 200 – 220 (0C.) 9.9 (bar.) 14.82 (bar.) 19.28 (bar.) (Until bead created follow item 12) 1.58 (mm.) 2.16 (mm.) 2.00 (mm.) 1.32 (bar) 1.97 (bar) 2.57 (bar) 108 (sec.) 166 (sec.) 150 (sec.) 5.25 (sec.) 5.25 (sec.) 6.15 (sec.) 9.75 (sec.) 9.75 (sec.) 12.45 (sec.) 9.9 (bar) 14.82 (bar) 19.28 (bar) ≥ 13.8 (min.) ≥ 19.6 (min.) ≥ 18 (min.) 8.40–13.10 11.30–17.45 10.50–16.25 (mm.) (mm.) (mm.) Page 10 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
- 11. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline Calculation Data Table of Case2. Description HDPE Butt-Fusion Machine Hydraulic cylinder effective area OD. HDPE Pipe Pipe wall thickness PN (Nominal Pressure) SDR. (Standard dimension ratio) Area of pipe section Welding Standard Reference Heating Temperature Alignment Pressure Alignment Time (Bead created) Bead height Heating-up pressure Heating-up time Changeover time (Average time) Joining pressure built-up time Joining Pressure Cooling time (Minimum) Range of welding bead width Parameter Model 450 1,413.90 (mm2) 400 (mm.) 400 (mm.) 19.1 (mm.) 29.5 (mm.) 6.3 (bar) 10 (bar) 21 13.6 2 22,858.64 (mm ) 34,341.27 (mm2) DVS 2207-1:1995 and (VEG-85) NEN 7200 200-220 (0C) 24.26 (bar) 36.44 (bar) (Until bead created follow item 12) 2.41 (mm.) 3.45 (mm.) 3.23 (bar) 4.86 (bar) 191 (sec.) 295 (sec.) 7.00 (sec.) 7.00 (sec.) 15.00 (sec.) 15.00 (sec.) 24.26 (bar) 36.44 (bar) ≥ 22.1 (min) ≥ 32.5 (min) 12.55–19.32 (mm.) 17.75–27.12 (mm.) Page 11 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
- 12. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline 6. Welding Operation Working Procedure 1. Preparation of welding: before start the welding operation, there are the preparation work as in the general requirements have to complete to make sure, the quality of welding joint is a secure structure. Select the operation area that is suitable to the safety work. Install the protection tent or other equipment to protect the welding zone against rain, sunshine or bad weather (if required) Setting up the welding machine with all accessories according to the welding pipe size. To do checking machine working function by connect a coupling two flexible hoses between the hydraulic control unit and the machine base structure, turn on the main power for hydraulic pump, control a directional valve to move the hydraulic cylinder for built-up pressure test and check all hydraulic oil leakage point. For the heating plate connect to the power source, turn on switch, setting the temperature range 200 - 220 C (in according to figure3) to checking the actual the temperature on the area to do welding. The facing tool or trimmer must be check the cutters, they should be good locking in their position without any crack or a broken part, then connect facing tool to the power source turn on switch to check the revolution. All of the problem or the missing function must be fixed before start the welding operation. Insert two pipes end on both side of the machine clamps, protrude approx. 3-5 cm. from each shell side, clamping and adjust the pipe or piping part, the surfaces to be welding should be parallel to each other. Adjust the alignment of pipe line by tighten or lose bronze nuts on the top aluminum clamps. Secure longitudinal movement of the parts to be welded by taking appropriate measures. Clean outside and inside pipe surface. Insert the facing tool or trimmer between the two pipe ends into the lock position on the welding machine 2. 3. Page 12 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 Step
- 13. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline Step Working Procedure Start the facing tool or trimmer by turn on the control switch. Slowly approach the pipe ends towards the facing tool or trimmer by control the directional valve on hydraulic control unit keeping control pressure a little higher. The cutter will be cut the surface of both pipe end to be clean, plane and parallel. 5. When scraps become continual even and slice shape, the trimming is completion, to finish this operation by decrease the pressure slowly until the facing tool free revolution then switch off. Remove the facing tool or trimmer from welding machine to the support frame and clear the facing scraps from pipe ends. Inspecting the pipe contact surface area of both sides they must be clean and plane, if they are not then repeat the step 3-5 again. During the clearing and inspection must be avoided any contacting with the surface of pipe ends. Recheck the alignment of the pipe line by close both pipe ends together and measure the actual tolerance. The misalignment value between both pipes side that should not over than 10% of pipe wall thickness. The gap width is allowance between the treated pipe end, they do not over than the value that shown on the table2. If they are not in the control tolerance then repeat the step 2-5 again. During the alignment checking in step 6, the welder team must be measured the force or pulling pressure (drag pressure) by see a pressure indicator device and recorded. This pressure must be created to pull the whole work piece moving in between welding process. The drag pressure is the additional value that must be add up to the alignment pressure (P1) and joining pressure (P3) from calculation or machine pressure data for each operation area and every welding joint. The welding team prepared the welding parameter by calculation and/or used the recommended values according to table1, table3 or machine data for the welding operation control. Final check heating plate temperature on the setting range according to step 1. Cleaning the both heating plate side with cleaning agent and insert it’s back to support waiting for welding operation start. 6. 7. 8. Page 13 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 4.
- 14. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline Step Working Procedure 9. Open both pipe ends, to cleaning the both pipe ends between the surface contact welding area by coat with an ethyl-alcohol or other suitable cleaning agent and avoided any contacting to the surface of pipe ends after clean. Re-cleaning, if they are necessary. 10. Starting the welding process in alignment stage by insert the heating plate between both pipe ends, move both pipe ends close together until contact the heating plate. Start to built-up pressure to the alignment pressure level (P1 + drag pressure), maintain the pressure until there are welding seam appear. In this stage uniform bead have been to create between the heating plate and whole circumference of both pipes end. The pressure must be maintained until the bead height according to the calculation value in table1 by visual inspection. Continue to the heating-up stage by reduced pressure and maintain to the heating-up pressure level (P2) along heating-up time (T2). 11. Open the both pipes end, carefully to remove the heating plate without touching to the melted area and control the removing time that should not longer than the changeover time (T3), insert heating plate to the support. 13. Immediately to start joining stage by rapid increase pressure to the joining pressure level (P3 + drag pressure) within the joining pressure built-up time (T4) Uniform beads have been to create whole circumference of pipe joint. Maintain and adjusting to keep the joining pressure constant throughout the cooling time (T5) until the welding joint is cool down and must not be forced by applying water. Page 14 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 12.
- 15. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline 14. 15. Working Procedure Remove the clamps after complete cooling stage. Welding bead of each jointing has to inspection by visual and measure as following: o Both beads should be almost equally dimension. o The bead surface should be smooth and do not shine. o Bead width must be according to the limit dimension. Possible differences in the formation of the beads may be justified by different behavior of the joined materials. All the welding information must be recorded into the data logger, log sheet or welding protocol form. Page 15 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 Step
- 16. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline APPENDIX – A – The welding guideline time value of welding operation for High Density Polyethylene Pipe Pressure (bar) P1 P3 P2 T1 T2 T3 T4 T5 Time (minute or second) Process stages of butt-fusion welding relation between pressure and time This appendix part will be give you the idea information data of the welding time parameter T2, T3, T4 and T5 according to the recommended values on table3. Bead height values by calculation according to the table1. The pressure values P1, P2 and P3 are not show in this appendix, all the pressure should be calculation related to the welding machine specification as shown on the calculation case1 and case2. Furthermore, the welding machine suppliers must be prepare the machine operation manual and all welding parameter control of their machine model for customer. Page 16 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 However all the information of this appendix, they can use to be the data reference.
- 17. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline OD e SDR [mm.] [mm.] OD/e 90 110 125 140 2.2 2.8 3.5 4.3 5.1 5.4 6.7 8.2 10.1 12.3 15 2.7 3.4 4.2 5.3 6.3 6.6 8.1 10.0 12.3 15.1 18.3 3.1 3.9 4.8 6.0 7.1 7.4 9.2 11.4 14.0 17.1 20.8 3.5 4.3 5.4 6.7 8 8.3 10.3 12.7 15.7 19.2 23.3 41 33 26 21 17.6 17 13.6 11 9 7.4 6 41 33 26 21 17.6 17 13.6 11 9 7.4 6 41 33 26 21 17.6 17 13.6 11 9 7.4 6 41 33 26 21 17.6 17 13.6 11 9 7.4 6 2 T P1[*] [C ] 220 220 220 219 218 218 217 215 213 211 209 220 220 219 218 217 217 215 213 211 209 207 220 219 218 217 216 216 214 212 210 208 205 220 219 218 217 215 215 213 211 209 206 204 P2[*] 0.5 0.5 0.5 0.5 1.0 1.0 1.0 1.5 1.5 2.0 2.0 0.5 0.5 0.5 1.0 1.0 1.0 1.5 1.5 2.0 2.0 2.0 0.5 0.5 1.0 1.0 1.5 1.5 1.5 1.5 2.0 2.0 2.0 0.5 0.5 1.0 1 1.5 1.5 1.5 2.0 2.0 2.5 2.5 3 t2 [sec] t3 Max [sec] 22 28 35 43 51 54 67 82 101 123 150 27 34 42 53 63 66 81 100 123 151 183 31 39 48 60 71 74 92 114 140 171 208 35 43 54 67 80 83 103 127 157 192 233 3 3 4 5 5 5 6 6 7 8 9 3 4 5 5 6 6 6 7 8 9 10 3 4 5 6 6 6 7 8 9 10 11 4 5 5 6 6 7 7 8 9 10 11 Page 17 of 22 4 t4 P3[*] [sec] 3 3 4 5 5 5 6 6 7 8 9 3 4 5 5 6 6 6 7 8 9 11 3 4 5 6 6 6 7 8 9 10 12 4 5 5 6 6 7 7 8 10 11 13 5 Bead Width t5 [min] 3 4 5 6 7 7 10 11 14 16 19 4 5 6 7 9 9 11 14 16 20 23 4 5 6 8 10 10 13 15 18 22 26 5 6 7 10 11 12 14 17 20 24 29 Min. Max. [mm.] [mm.] 4.1 4.4 4.8 5.2 5.6 5.7 6.4 7.1 81 9.2 10.5 4.4 4.7 5.1 5.7 6.2 6.3 7.1 8.0 9.2 10.6 12.2 4.6 5.0 5.4 6.0 6.6 6.7 7.6 8.7 10.0 11.6 13.4 4.8 5.2 5.7 6.4 7.0 7.2 8.2 9.4 10.9 12.6 14.7 6.7 7.1 7.6 8.2 8.8 9.1 10.0 11.2 12.6 14.2 16.3 7.0 7.6 8.2 9.0 9.7 10.0 11.1 12.5 14.2 16.3 18.7 7.3 7.9 8.6 9.5 10.3 10.6 11.9 13.6 15.5 17.8 20.6 7.6 8.2 9.1 10.0 11.0 11.2 12.7 14.5 16.8 19.4 22.5 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 1
- 18. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline 160 180 200 225 e SDR [mm.] OD/e 4.0 4.9 6.2 7.7 9.1 9.5 11.8 14.6 17.9 21.9 26.6 4.4 5.5 6.9 8.6 10.2 10.7 13.3 16.4 20.1 24.6 29.9 4.9 6.2 7.7 9.6 11.4 11.9 14.7 18.2 22.4 27.4 33.2 5.5 6.9 8.6 10.8 12.8 13.4 16.6 20.5 25.2 30.8 37.4 41 33 26 21 17.6 17 13.6 11 9 7.4 6 41 33 26 21 17.6 17 13.6 11 9 7.4 6 41 33 26 21 17.6 17 13.6 11 9 7.4 6 41 33 26 21 17.6 17 13.6 11 9 7.4 6 T [C ] 219 218 217 216 214 214 212 209 207 205 203 219 218 216 215 213 213 210 208 206 204 202 218 217 216 214 212 211 209 207 205 203 201 218 216 215 213 211 210 208 205 204 202 201 2 P1[*] P2[*] 0.5 1.0 1.0 1.5 1.5 1.5 1.5 2.0 2.0 2.5 3.0 0.5 1.0 1.0 1.5 1.5 1.5 2 2.0 2.5 2.5 3.0 1 1.0 1.5 1.5 1.5 1.5 2.0 2.0 2.5 3.0 3.0 1 1.0 1.5 1.5 2.0 2.0 2 2.5 2.5 3.0 3.5 3 t2 [sec] t3 Max [sec] 40 49 62 77 91 95 118 146 179 219 266 44 55 69 86 102 107 133 164 201 246 299 49 62 77 96 114 119 147 182 224 274 332 55 69 86 108 128 134 166 205 252 308 374 4 5 6 6 7 7 8 9 10 11 12 5 5 6 7 7 7 8 9 10 12 13 5 6 6 7 8 8 9 10 11 12 15 5 6 7 8 8 8 9 11 12 14 16 Page 18 of 22 4 t4 P3[*] [sec] 4 5 6 6 7 7 8 9 11 12 14 5 5 6 7 7 7 9 10 12 13 16 5 6 6 7 8 8 9 11 12 15 17 5 6 7 8 8 9 10 12 14 16 19 5 Bead Width t5 [min] 5 7 9 11 13 13 16 19 23 27 33 6 8 10 12 14 14 17 21 25 30 37 7 9 11 13 15 16 19 23 28 34 40 8 10 12 15 17 18 21 26 31 38 45 Min. Max. [mm.] [mm.] 5.0 5.5 6.1 6.9 7.6 7.8 8.9 10.3 12.0 14.0 16.3 5.2 5.8 6.5 7.3 8.1 8.4 9.7 11.2 13.1 15.3 18.0 5.5 6.1 6.9 7.8 8.7 9.0 10.4 12.1 14.2 16.7 19.6 5.8 6.5 7.3 8.4 9.4 9.7 11.3 13.3 15.6 18.4 21.7 8.0 8.7 9.7 10.8 11.8 12.1 13.9 16.0 18.4 21.4 25.0 8.3 9.1 10.2 11.5 12.7 13.0 15.0 17.3 20.1 23.5 27.4 8.7 9.7 10.8 12.2 13.6 13.9 16.0 18.7 21.8 25.6 29.9 9.1 10.2 11.5 13.1 14.6 15.1 17.5 20.4 23.9 28.1 33.1 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 1 OD [mm.]
- 19. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline T [C ] 6.2 7.7 9.6 11.9 14.2 14.8 18.4 22.7 27.9 34.2 41.5 6.9 8.6 10.7 13.4 15.9 16.6 20.6 25.4 31.3 38.3 46.5 7.7 9.7 12.1 15 17.9 18.7 23.2 28.6 35.2 43.1 52.3 8.70 10.90 13.60 16.90 20.10 21.10 26.10 32.20 39.70 48.50 59.00 217 216 214 211 210 209 207 205 203 201 200 216 215 213 210 208 208 205 204 202 200 200 216 214 211 209 207 206 204 203 201 200 200 215 212 210 208 206 205 203 202 200 200 200 250 280 315 355 41 33 26 21 17.6 17 13.6 11 9 7.4 6 41 33 26 21 17.6 17 13.6 11 9 7.4 6 41 33 26 21 17.6 17 13.6 11 9 7.4 6 40.80 32.57 26.10 21.01 17.66 16.82 13.60 11.02 8.94 7.32 6.02 2 P1[*] P2[*] 1 1.5 1.5 1.5 2 2 2 2.5 3.0 3.0 3.5 1 1.5 1.5 2 2.0 2.0 2.5 2.5 3.0 3.5 3.5 1.5 1.5 2.0 2.0 2.0 2.0 2.5 3.0 3.0 3.5 4.0 1.50 1.50 2.00 2.00 2.50 2.50 3.00 3.00 3.50 3.50 4.00 3 4 t2 t3 Max t4 [sec] [sec] [sec] 62 77 96 119 142 148 184 227 279 342 415 69 86 107 134 159 166 206 254 313 383 465 77 97 121 150 179 187 232 286 352 431 523 87 109 136 169 201 211 261 322 397 485 590 Page 19 of 22 6 6 7 8 9 9 10 11 13 15 17 6 7 7 8 9 9 11 12 14 16 19 6 7 8 9 10 10 11 13 15 18 21 7 8 9 9 10 11 12 14 17 20 22 6 6 7 8 9 9 11 13 15 18 21 6 7 7 9 10 10 12 14 16 20 23 6 7 8 9 11 11 13 15 18 22 26 7 8 9 10 12 12 14 17 20 24 30 5 P3[*] Bead Width t5 Min. Max. [min] [mm.] [mm.] 9 11 13 16 18 19 23 28 34 42 50 10 12 14 18 20 21 26 31 38 46 56 11 13 16 19 23 24 29 35 43 52 62 12 15 18 22 25 26 32 39 48 58 69 6.1 6.9 7.8 9.0 10.1 10.4 12.2 14.4 17.0 20.1 23.8 6.5 7.3 8.4 9.7 11.0 11.3 13.3 15.7 18.7 22.2 26.3 6.9 7.9 9.1 10.5 12.0 12.4 14.6 17.3 20.6 24.6 29.2 7.35 8.45 9.80 11.45 13.05 13.55 16.05 19.10 22.85 27.25 32.50 9.7 10.8 12.2 13.9 15.7 16.1 18.8 22.0 25.9 30.7 36.1 10.2 11.5 13.0 15.1 16.9 17.5 20.5 24.1 28.5 33.7 39.9 10.8 12.3 14.1 16.3 18.4 19.0 22.4 26.5 31.4 37.3 44.2 11.53 13.18 15.20 17.68 20.08 20.83 24.58 29.15 34.78 41.38 49.25 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 1 OD e SDR [mm.] [mm.] OD/e
- 20. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline OD e SDR [mm.] [mm.] OD/e T [C ] 9.80 12.30 15.30 19.10 22.70 23.70 29.40 36.30 44.70 54.70 11.00 13.80 17.20 21.50 25.50 26.70 33.10 40.90 50.30 61.50 12.30 15.30 19.10 23.90 28.30 29.70 36.80 45.40 55.80 13.70 17.20 21.40 26.70 31.70 33.20 41.20 50.80 213 211 209 206 205 204 202 201 200 200 212 210 208 205 204 203 201 200 200 200 211 209 206 204 203 202 201 200 200 210 208 205 203 202 201 200 200 400 450 500 560 40.82 32.52 26.14 20.94 17.62 16.88 13.61 11.02 8.95 7.31 40.91 32.61 26.16 20.93 17.65 16.85 13.60 11.00 8.95 7.32 40.65 32.68 26.18 20.92 17.67 16.84 13.59 11.01 8.96 40.88 32.56 26.17 20.97 17.67 16.87 13.59 11.02 2 P1[*] P2[*] 1.50 2.00 2.00 2.50 2.50 2.50 3.00 3.00 3.50 4.00 1.50 2.00 2.00 2.50 2.50 3.00 3.00 3.50 4.00 4.00 2.00 2.00 2.50 2.50 3.00 3.00 3.00 3.50 4.00 2.00 2.00 2.50 3.00 3.00 3.00 3.50 4.00 3 t2 t3 Max [sec] [sec] 98 123 153 191 227 237 294 363 447 547 110 138 172 215 255 267 331 409 503 615 123 153 191 239 283 297 368 454 558 137 172 214 267 317 332 412 508 Page 20 of 22 7 8 9 10 11 11 13 16 19 21 8 9 10 11 12 12 15 17 20 23 8 9 10 12 13 13 16 19 21 9 10 11 12 14 15 17 20 4 t4 [sec] 7 8 9 11 13 13 15 19 23 27 8 9 10 12 14 14 17 21 25 31 8 9 11 13 15 16 19 23 28 9 10 12 14 16 17 21 25 5 P3[*] Bead Width t5 Min. Max. [min] [mm.] [mm.] 13 16 20 24 28 29 36 44 54 65 15 18 22 27 31 33 40 49 60 72 16 20 24 30 35 36 45 55 66 18 22 27 33 39 41 50 61 7.90 9.15 10.65 12.55 14.35 14.85 17.70 21.15 25.35 30.35 8.50 9.90 11.60 13.75 15.75 16.35 19.55 23.45 28.15 33.75 9.15 10.65 12.55 14.95 17.15 17.85 21.40 25.70 30.90 9.85 11.60 13.70 16.35 18.85 19.60 23.60 28.40 12.35 14.23 16.48 19.33 22.03 22.78 27.05 32.23 38.53 46.03 13.25 15.35 17.90 21.13 24.13 25.03 29.83 35.68 42.73 51.13 14.23 16.48 19.33 22.93 26.23 27.28 32.60 39.05 46.85 15.28 17.90 21.05 25.03 28.78 29.90 35.90 43.10 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 1
- 21. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline OD [mm.] 630 710 800 900 1000 e SDR T [mm.] OD/e [C ] 15.40 19.30 24.10 30.00 35.70 37.40 46.30 57.20 17.40 21.80 27.20 33.90 40.20 42.10 52.20 19.60 24.50 30.60 38.10 45.30 47.40 58.80 22.00 27.60 34.40 42.90 51.00 53.30 24.50 30.60 38.20 47.70 56.60 59.30 40.91 32.64 26.14 21.00 17.65 16.84 13.61 11.01 40.80 32.57 26.10 20.94 17.66 16.86 13.60 40.82 32.65 26.14 21.00 17.66 16.88 13.61 40.91 32.61 26.16 20.98 17.65 16.89 40.82 32.68 26.18 20.96 17.67 16.86 209 206 204 202 201 201 200 200 206 205 204 201 200 200 200 206 204 202 201 200 200 200 205 204 201 200 200 200 204 202 201 200 200 200 2 P1[*] P2[*] 2.00 2.50 2.50 3.00 3.00 3.50 3.50 4.00 2.00 2.50 3.00 3.00 3.50 3.50 4.00 2.50 2.50 3.00 3.50 3.50 3.50 4.00 2.50 3.00 3.00 3.50 4.00 4.00 2.50 3.00 3.50 3.50 4.00 4.00 3 4 t2 t3 Max t4 [sec] [sec] [sec] 154 193 241 300 357 374 463 572 174 218 272 339 402 421 522 196 245 306 381 453 474 588 220 276 344 429 510 533 245 306 382 477 566 593 [*] The calculation is not include drag pressure Page 21 of 22 9 10 12 13 15 16 19 22 10 11 12 15 16 17 20 11 12 13 16 18 19 23 11 12 15 17 20 21 12 13 16 19 22 23 9 11 13 16 18 19 23 29 10 12 15 17 21 22 26 11 13 16 19 23 24 30 12 15 17 22 26 27 13 16 19 24 29 30 5 P3[*] Bead Width t5 [min] Min. [mm.] Max. [mm.] 20 24 30 37 44 45 56 67 22 27 34 43 49 51 62 24 31 39 48 55 57 69 27 34 43 51 61 63 31 39 48 57 67 70 10.70 12.65 15.05 18.00 20.85 21.70 26.15 31.60 11.70 13.90 16.60 19.95 23.10 24.05 29.10 12.80 15.25 18.30 22.05 25.65 26.70 32.40 14.00 16.80 20.20 24.45 28.50 29.65 15.25 18.30 22.10 26.85 31.30 32.65 16.55 19.48 23.08 27.50 31.78 33.05 39.73 47.90 18.05 21.35 25.40 30.43 35.15 36.58 44.15 19.70 23.38 27.95 33.58 38.98 40.55 49.10 21.50 25.70 30.80 37.18 43.25 44.98 23.38 27.95 33.65 40.78 47.45 49.48 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 1
- 22. TECHNICAL INFORMATION BUTT-FUSION WELDINGOF POLYETHYLENE PIPE Quality Management Systems Q001 Cert. No. NQ767/04 005 Cert. No. TH04/0500 Welding Guideline Page 22 of 22 TAP-352802-TEC-BUTT WELDING-52R2 th Issue Date 25 MAY 2009 APPENDIX – B – The sample of welding protocol form for welding data record