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BES-CO-05-306-01 Thermoplastic Piping Welding Specification Issuing organisation PA&E Sheet 1 / 19 Rev: 1 / 27.04.

2010

THERMOPLASTIC PIPING WELDING SPECIFICATION BES-CO-05-306

Preparer

Date 27.04.2010

Name/Position Gino De Landtsheer / Piping Expert TSG - PTS Name/Position Gino De Landtsheer / Piping Expert TSG - PTS Name/Position Filip Goovaerts / Specs PA&E

Issuer

Date 27.04.2010

Process owner

Date 27.04.2010

Approved

Rev. Description

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BES-CO-05-306-01 TABLE OF CONTENTS 1 1.1 1.2 1.3 1.4 2 2.1 2.1.1 2.1.2 2.1.3 2.1.4 3 4 5 5.1 5.2 5.3 6 6.1 6.1.1 6.1.1.1 6.1.1.2 6.1.1.3 6.1.1.4 6.1.1.5 6.1.1.6 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 7 7.1 7.2 7.3 7.4 7.5 8

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GENERAL .........................................................................................................................3 Validity ...............................................................................................................................3 Review Schedule ...............................................................................................................3 Group Amendment to the Borealis Engineering Specification ............................................3 Objective and Scope..........................................................................................................3 APPLIED STANDARDS ....................................................................................................3 Standards and Regulations................................................................................................4 European Directives ..........................................................................................................4 Applicable Design Codes ...................................................................................................4 Borealis Reference Documents .........................................................................................4 Standards ..........................................................................................................................4 INTRODUCTION ...............................................................................................................5 INSPECTION BEFORE USE .............................................................................................5 CUTTING ..........................................................................................................................6 Weld Preparation Tools .....................................................................................................6 Cutting ...............................................................................................................................6 Cleaning after cutting .........................................................................................................7 WELDING .........................................................................................................................7 Applicable jointing methods ...............................................................................................7 Butt Fusion Welding...........................................................................................................8 Preparation ........................................................................................................................8 Bead-up .............................................................................................................................9 Heat soak ..........................................................................................................................9 Heater plate removal .........................................................................................................9 Fusion jointing ...................................................................................................................9 Cooling ..............................................................................................................................9 Electro Fusion Welding .................................................................................................... 11 Socket Fusion Welding .................................................................................................... 12 Hot Gas Welding ............................................................................................................. 13 Infrared Welding .............................................................................................................. 14 Bead and Crevice Free (BCF) ......................................................................................... 15 Solvent Cement Welding ................................................................................................. 16 Vibration Welding............................................................................................................. 16 WELDING REQUIREMENTS .......................................................................................... 17 General............................................................................................................................ 17 Installation Teams............................................................................................................ 17 Spool assembly ............................................................................................................... 18 Welding Equipment.......................................................................................................... 18 Solvent Cement Welding ................................................................................................. 19 ATTACHMENTS ............................................................................................................. 19

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1
1.1

GENERAL
Validity These design requirements are valid for all BOREALIS Sites. Review Schedule This Engineering Specification shall be reviewed at least every three years. Group Amendment to the Borealis Engineering Specification This Borealis Engineering Specification shall consist of the BES-CO-00-001; Group Amendment to the Borealis Engineering Specifications which are incorporated herein and made part here of by reference. Content for info: General Definitions, Abbreviations, Objective and Scope, Language, Unit System, CE-Marking, PED / ATEX / Quality Assurance / Quality Control, General Basic Design Requirements.

1.2

1.3

1.4

Objective and Scope The purpose of this document is to provide general information for the welding of thermoplastic piping systems, in order to standardize welding procedures and required qualifications. An improved reliability and attain consistency in thermoplastic piping welding should be a result of these requirements. This engineering specification shall be applied to all new process and utility piping constructions, where the use of thermoplastic components is part of the applicable piping class specification or when thermoplastic materials can be an alternative for metallic materials. This Borealis Engineering Specification is providing additional information specific to the welding of Thermoplastic Piping systems. It shall be noted that the basic piping design requirements, specified in the document BER-CO-0-001; General Design Requirements Piping should be used as a minimum requirement basis. The minimum quality and organizational requirements for welding, specified in the document BES-CO-05-002; Piping welding, Fabrication, Installation and Inspection and DVS 2210-1 Industrial Pipelines of Thermoplastic Materials; planning and execution, over ground systems, should be mandatory in case no specific requirements are mentioned in this engineering specification.

APPLIED STANDARDS
It shall be CONTRACTORs responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards. When an edition date is not indicated for a code or standard, the latest edition in force at the time of CONTRACTORs commitment shall apply. Intermediate changes or updates/revisions of applied codes, standards, regulations or laws during the course of the project shall be brought to COMPANYs attention. Possible implications for the works shall be discussed. The design and engineering shall satisfy all laws and regulations of the national and/or local authorities of the country in which the EQUIPMENT AND MATERIALS will be located.

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MANUFACTURER is responsible to ensure that all requirements of the regulating authorities are fulfilled. However, CONTRACTOR shall supply all necessary documentation regarding inspection, NDT, etc. to fulfil the PED requirements. 2.1 Standards and Regulations The international codes and standards, to the extent specified herein, form a part of this specification and shall be followed. Some codes or standards (e.g. Euro codes) are still under development and their final number and identification are given below. If the referenced code is not yet available, its preceding pre-code, draft code or relevant national codes covering the same subject shall be followed. In case of conflict, the order of precedence shall be: 1. National and/or local Laws and Regulations applicable at the location of the site. 2. European Directives 3. Applicable Design Codes (ASME BVPC, ASME B31.3, AD2000, BS 5500, EN 13445, EN 13480, etc.) 4. Project specific CATALOGUE DATA SHEETS from the LICENSOR 5. COMPANY specifications Project Specification Local Amendment Common Engineering Specification 6. Reference to international standards (API, NFPA, etc.) The more stringent of two conflicting regulations/standards will prevail. In all cases CONTRACTOR shall inform COMPANY of any deviation from the requirements in the specifications, which is considered to be necessary in order to comply with national and/or local laws and regulations. Deviations from this specification are subject to written approval by COMPANY. After this approval these specifications are integral part of the contract. The standards and codes as listed in 2.1.1, 2.1.2, 2.1.3 and 2.1.4 shall be followed. 2.1.1 European Directives 97/23 EC

Pressure Equipment Directive (PED) for pressure containing equipment and assemblies.

2.1.2

Applicable Design Codes ASME B31.3; Code for Pressure Piping: Process Piping Non-metallic Chapter VII Piping and Piping Lined with Non-metals AD 2000 Code Technical Rules for Pressure Vessels Borealis Reference Documents BES-CO-00-001 Group Amendment to the Borealis Engineering Specifications BER-CO-05-001 General Design Requirements Piping BES-CO-05-007 Pipe classes - ASME BER-CO-05-301 General Design Requirements for Thermoplastic Piping Standards DVS 2207-1

2.1.3

2.1.4

DVS 2207-3

Welding of Thermoplastics Heated Element Butt Welding of pipes, pipeline parts and sheets of PE-HD Welding of Thermoplastics -

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DVS 2207-6

DVS 2207-11

DVS 2207-15

DVS 2208-1 DVS 2208-2 DVS 2209-2 DVS 2210-1 DVS 2211 DVS 2212-1

Hot Gas Welding of Thermoplastics - sheets and pipes Welding Parameters Welding of Thermoplastics Contactless Heated Element Butt Welding of pipes, pipeline parts and sheets; methods machines - parameter Welding of Thermoplastics Heated Element Butt Welding of pipes, pipeline parts and sheets of PVDF Welding of Thermoplastics Heated Tool Welding of pipes, piping parts and sheets of PVDF Machines and equipment for welding of thermoplastic material; heated element welding Welding of thermoplastic materials; machines and equipment for hot-gas welding (not extrusion welding) Hot-gas extrusion welding; requirements to welding machines and equipment Industrial pipelines of thermoplastic materials; planning and execution, over ground pipe systems Filler materials for thermoplastics; scope, designation, requirements, tests Examination of welders, group 1

INTRODUCTION
Different joining techniques are available for thermoplastic piping and the development of new applications is an ongoing process. Depending on the raw material properties and the selected welding techniques, specific instructions and requirements will govern. Therefore a detailed evaluation of the applicable joining process should be performed in collaboration with both the thermoplastic raw material supplier and the manufacturer of the joining equipment. Each joint process requires the following initial steps: Pre-inspection of the material to be joined Cutting of the pipe material Cleaning of pipe components and fittings Joining/welding of piping components Inspection and testing (NDT) of assembled pipe spools and piping assemblies

INSPECTION BEFORE USE


Before use of thermoplastic pipe components and fittings, all items should be inspected for: flaws deep scratches (> 10% of actual wall thickness) excessive warping fine cracks on or under the surface of the plastic material (crazing defects) de-lamination (separation of layers) or any other sign of damages

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In case one or a combination of these previous defects, the operating parameters (maximum operating pressure) can be severely affected. Any concern related to potential defects should result in rejection of the applicable component or assembled pipe spool.

5
5.1

CUTTING
Weld Preparation Tools Fabrication and installation of thermoplastic piping requires an extensive range of high quality tools and equipment, specifically designed for use with thermoplastic material. Tools should be assembled and checked prior to start any welding activity. All necessary equipment and tools shall be available to enable safe handling of pipe materials. Only using these tools, improved reliability and a reduction of the assembly time for making a joint will be achieved. Use of tools, not adapted to perform a high quality assembly, is prohibited.

5.2

Cutting Before cutting activities will take place, the thermoplastic material should be conditioned to the ambient working temperature of the working area or the location where the installation and jointing will take place. Thermoplastic pipe should always be cut with a tool designed for use on the thermoplastic material being installed. It is not recommended to use saws or other cutting equipment that is used for cutting of metals, as the blade construction may snag on thermoplastic or cause an unacceptable build up of heat. In addition, tools used previously to cut metals may contaminate the plastic joining area with grease or oils. It is important to ensure that the pipe is cut square. In case of socket fitting configurations, cutting the pipe square ensures that the pipe will bottom out in the socket. This is essential in the assembly process to get the maximum joint strength. In case of butt fusion joints, a square cut minimises planning before the joint is made. Polyethylene, Polypropylene, ABS and lighter wall PVC-U and PVC-C piping with a diameter of 2 and below shall be cut with ratchet operated cutting shears. For pipe diameters up to 8, a rotary quick release pipe cutter with a cutting wheel, adapted for use with plastic pipe materials, should be used. Pipe with diameters above 8 may be cut with large diameter wheel pipe cutters, fitted with blades adapted for use on thermoplastic materials. The cutter should be fitted with outboard rollers to ensure that the cut remains square. Hand saws with a tooth design, set and hardness specifically adapted for thermoplastic materials may be used, provided that a mitre box or jig is used. The pipe must be checked after this cutting action to ensure a square cut.

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Power tools may be used, provided they are fitted with suitable blades, and run at a cutting speed suitable for the type of material to be cut. After completing the cutting process, the pipe length should be checked for accuracy and any internal or external burrs shall be removed using a de-burring tool, specifically designed for thermoplastic material. The maximum permissible deviations from plane-parallelism at the joining surfaces are: Table 3; Plane-Parallelism Deviations Tolerance Range Pipe outside diameter (mm) < 400 400 Deviation (mm)
0.5 1.0

Chips or swarf shall be removed from the inside of the pipe. The jointing areas of the parts applicable to welding shall be free of any damage or contamination. Polyethylene and Polypropylene pipes stored as coils should be pre-treated to reduce the possible oval distortion due to the rolling action. This can be done by means of heat input and use of a suitable cut pressure or a round installation pressure. 5.3 Cleaning after cutting Basically most thermoplastic joints are of a homogeneous monolithic structure. This means that the joint has the same physical and chemical characteristics as the pipe and the fittings. To avoid any contamination before or during the process of welding and to assure the homogeneous monolithic structure, it is important that joining surfaces should be free of: dirt grease water mould release any other foreign substances

Joining surfaces shall be cleaned as a minimum requirement with a clean cloth. If the applicable surfaces cannot be successfully cleaned with this method, an emery cloth or sandpaper should be used. To remove films of oil or grease only isopropyl alcohol should be used. This solvent will pick up the grease or oil traces and will evaporate off very quickly. Thermoplastic pipe components should be never cleaned with other solvents! The applicable raw material SUPPLIER and welding equipment MANUFACTURERs instructions should govern to determine the proper joint preparation.

6
6.1

WELDING
Applicable jointing methods Depending on the material, size of the pipe, the intended application and service conditions, different joining methods for thermoplastic piping are available.
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The piping design process should include the evaluation of the application of the different jointing methods. It can be possible to have combinations of welding methods, resulting in the most cost-effective solution for the required level of quality. The following table lists for a variety of pipe materials the applicable welding processes which can be used. Table 1; Welding Processes Overview for Thermoplastic Materials Butt f u s i o n Electro f u s i o n Socket f u s i o n X X X X X X X X X Hot gas IR BCF Solvent c e m e n t

PP X X X PE X X X PB X X PVC-U PVC-C PVDF X X ABS ECTFE X X = welding process that can be used

X X

In addition to fusion welding techniques, there are a number of mechanical methods that may be used for joining thermoplastic pipe. These include: Compression fittings Flange and gasket assemblies Push-fit sockets Grooved Threaded O-ring Bell and spigot adhesive bonding (Reinforced Thermoset Resin material) Butt-strap adhesive bonding (Reinforced Thermoset Resin material)

These connection methods for Thermoplastic piping are not part of this engineering specification. 6.1.1 Butt Fusion Welding Butt fusion welding (DVS 2207-1 / 2207-11 / 2207-15), also known as hot plate welding, is one of the main welding techniques for thermoplastic piping. The butt fusion process can be split-up in six phases of progress: 6.1.1.1 Preparation The pipe ends are clamped and planed to ensure that they are flat and square. The alignment of the pipe end is checked. Joining surface shall be free of any pigtails or shavings.

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6.1.1.2 Bead-up The trimmed and aligned pipes are pressed against the heater plate using the 'initial' bead-up pressure to have a good thermal contact. The pressure is maintained until the pipe starts to melt and a uniform bead is formed on each end due to the internal pressure forces which are pushing the material outwards. The formation of these 'weld beads' will be at the outside and inside pipe surfaces. The size of the bead depends on the material and pipe diameter. 6.1.1.3 Heat soak After the initial bead-up, the pressure is reduced to a value sufficient only to maintain the pipe in contact with the hot plate. This allows the melt depth to increase without increasing the size of the weld beads. The pipe ends must maintain contact with the heater plate at the soak pressure for the specified soak time, which increases with diameter and wall thickness. 6.1.1.4 Heater plate removal When the heat soak time is completed, the pipe ends are retracted from the heater plate, and the heater plate removed. This is sometimes known as the 'dwell time' and should be as short as possible. The heating plate should be taken away without any sign of damage or pollution. 6.1.1.5 Fusion jointing Immediately after removing the heater plate, the hot pipe ends are pushed together at the same pressure as used during the initial bead-up stage. In case of large wall thicknesses, the jointing pressure is reduced after a well defined time frame (seconds) has elapsed. Depending on the material characteristic, this time frame shall be defined after consulting the raw material supplier. 6.1.1.6 Cooling Finally, after the jointing phase, the weld is allowed to cool whilst the joint pressure/secondary pressure is maintained for a specified time, depending of the material characteristics and the size. Pressure testing of butt fusion welds can only be performed if the applicable cooling down process is completely finalized. As a minimum, this shall not be less than one hour after performing the last weld. Graph 1; Butt Fusion Welding Sequence

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Advantages Alignment between components part of the welding process is controlled Pipe to pipe joints are possible, without having the requirement of a connecting socket. Application range Butt fusion welding is applicable to pipe sizes from 50mm to 2000mm. Disadvantages But fusion welding can only applied on piping components which have the same wall thickness. Under no circumstances, the faced ends should be touched, during the butt fusion process. This to avoid contamination of the welding area and to prevent burning injuries. But fusion welding is the only joining technique that can be taking into consideration for directional drilling applications and close-fit lining applications in existing piping. Equipment Manual, automatic and semi-automatic butt fusion machines are available. Automatic machines feature electro-hydraulic controlled pipe clamps, trimmer and heater plate, with full data recording of weld parameters.

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Semi-automatic machines offer some of the benefits of auto joining equipment, with optional data logging facilities. 6.1.2 Electro Fusion Welding Electro Fusion Welding is also known as resistive implant welding. This technique one of the most common used for the joining of polyethylene gas and water pipes and pressure systems. The electro fusion welding process involves the use of a moulded socket fitting containing an electrical resistive heating coil. The prepared pipe ends are inserted into the sockets and clamped. An internal stop at the centre of the fitting prevents the pipe ends from meeting. An electrical current is then passed through the coil for a pre-set time. Heating of the surrounding polymer and heat transfer to the pipe wall takes place. Cold zones at the ends of the fitting contain the melt in the central section, allowing a high melt pressure to develop and the formation of a homogeneous joint. Fusion indicators are commonly designed into the fitting. If sufficient melt pressure has been generated, the indicators will protrude, giving the operator a visual indication that the welding process has been carried out successfully. If the indicators fail to protrude, then the welded fitting shall be cut out from the pipeline, and a new fitting shall be welded in place. Important pipe preparation stages: The pipe ends must have finished squared ends. This ensures that the central cold zones function to contain the melt. The pipe surfaces to be joined must be properly scraped to reveal uncontaminated material. The tolerances in the electro fusion joining process are narrow, resulting in little or no relative movement between the pipe and the coupler. Therefore, any contamination on the pipe surface is retained at the joint interface, which can significantly reduce the strength of the joint. The pipe and fitting should be clamped during welding to eliminate relative movement. This ensures that the molten polymer is contained at the fusion interface, allowing the development of a strong joint. The electro fusion joining process can be split-up in three phases of progress: initial heating and fitting expansion heat soaking and creation of joint cooling of joint The first two points are commonly indicated as fusion time

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Advantages electro fusion welding is suited to installations where access is difficult, such as in trenches or around other pipes. electro fusion welding can be used to join different grades of the same material (e.g. MDPE to HDPE) with electro fusion welding a difference in wall thickness can be accommodated. electro fusion welding can be used to join certain types of multiple layer pipes (e.g. nylon lined polyethylene pipe) easy to use for repairs. Application range Electro fusion welding is applicable to pipe sizes from 16mm to 800mm. Remarks Only if the appropriate procedures are followed, contamination and disturbance effects that might inhibit the fusion mechanism will be minimised. 6.1.3 Socket Fusion Welding Socket fusion welding is a widely used technique for assembling plastics piping systems using injection moulded fittings. No consumables are required. The pipe ends must be calibrated in first place by means of the peeling and chamfering tool. This preparation step removes at the same time the oxidised layer on the outside surface of the pipe. Removing the oxidised layer before welding is essential, as this can have a detrimental effect upon the final joint strength. The chamfering process produces a bevel on the leading edge of the pipe, which aids entry into the socket fusion fitting during the welding process. The welding cycle consists of a heating phase and a cooling/welding phase. A metal socket, mounted on a hot plate, heats the outside circumference of the pipe.

Figure 1; Socket Welding Preparation of The Welding

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Heating occurs along a defined length which will vary depending on the size of pipe and fitting being welded. A metal spigot on the opposite side of the hot plate simultaneously heats the inside surface of the injection moulded fitting. The length of the heated region is the same as that for the pipe.

Figure 2; Socket Welding Alignment and Pre-Heating Both fitting and pipe are heated for a well defined length of time after which the heated socket/spigot tooling is removed and the pipe is pushed into fitting. Pipe and fitting are left for a predetermined time to cool and form a weld.

Figure 3; Socket Welding Joining and Cooling Advantages socket fusion welding is easy to use with a short learning curve. fast joining and cooling Application range Depending upon the size of the pipe, this process can either be carried out by hand (for pipe sizes up to 50mm OD) or on a manual machine, similar to a manual butt fusion welding machine, for pipe sizes typically between 63mm and 150mm OD. 6.1.4 Hot Gas Welding Hot gas welding (DVS 2207-3) is a manual process and can be applied to most thermoplastics. Equipment for hot gas welding is relatively simple and easy in use. In its simplest form, the main component is a hand-held welding gun consisting of an integral blower, a heating element with thermostat and a set of interchangeable nozzles for directing hot gas at the work piece. Usually, the gun is fed with air, although for some applications nitrogen gas is used. The temperature of the hot gas stream is typically in the range 200-400C. Table 2; Recommended Gases and Temperatures for Hot Gas Welding Welding temperature (C) (hot gas stream) PVC-U PVC-C PP PE
330-350 360-410 280-330 300-350

Welding gas
Air Air Air/Nitrogen Air/Nitrogen

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(*) At ECTFE melting temperature, hydrogen chloride and hydrofluoric are released. The workplace must be ventilated well. Welders should wear eye and hand protection. (**) Resin temperature to be limited to 220C for PE and PP. A filler rod made of the same polymer as the components to be welded should be used (DVS 2211). Like many manual processes, its success depends greatly on operator skill. With the heated gas directed towards the joint, local melting or softening of the components and filler rod take place. A weld is formed when the joint region and filler rod fuse and then cool to ambient temperature. For thicker sections, extrusion welding is used. Filler material is separately heated in the barrel of a hand-held extruder. Softened or molten material is extruded through a PTFE die into the joint which has been pre-heated using a hot gas gun mounted on the extruder barrel. The main advantage of hot gas welding is that the equipment is portable. However, the process can be slow and weld quality is operator dependent. Fabrication of containment vessels and pipe work are the main applications. Application range Hot gas welding is limited, due to the lower pressure sustaining capabilities (maximum operating pressure range < 4 bar), to welding of small branches to the run pipe, such as drain and vent connections or instrument take off points. Increasing the pressure sustaining capabilities can be achieved with application of an additional fibreglass reinforcing wrap. This method should be avoided and only be used if other solutions cannot be applied. Hot gas welding can be used to repair small leaks at joints in solvent welded or fusion welded thermoplastic piping systems. In case of steady stream leakages repairs are not possible, resulting in cutting out and replacement of the failing part. 6.1.5 Infrared Welding Two approaches for the welding thermoplastic materials with infrared technology are used. Both are based on the principle of hot plate welding. Non-contact hot plate (DVS 2207-6) This system uses an electrically heated metal plate which, in some cases, is coated with a ceramic. The hot plate is heated to a temperature between 310C and 530C, depending on the thermoplastic to be welded, and the size of the welding machine. When the parts to be welded are brought in close proximity to the hot plate, (typically 1.52.0mm) but without touching, they heat up due to radiation and convection and subsequently soften and melt. The plate then withdraws and the parts are forced together to form a weld.

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Infrared lamp welding (DVS 2207-6) The standard heater plate is replaced with two banks of short wave infrared emitters clamped and spring-loaded on either side of a movable platen. Input power can be higher compared with conventional hot plate welding, resulting in weld times that are significantly shorter. This technique is also capable of handling large surface area products, as it is a simple operation to add more emitters to the heating bank. High power short wave infrared emitters are more efficient and effective than infrared emitters. Due to high power density, developed at a lower operating temperature, the energy transfer is more efficient than halogen emitters, while its lower mass filament makes it more responsive than ceramic emitters. Advantages Infrared fusion welding is a contact-free process, which eliminates the possibility of contamination during the melting process of the components. Pipe faces sticking to the heater plate can be avoided. Infrared fusion welding is resulting in a weld bead reduced in size since the area of material softened is substantially smaller. The pipe bore is kept as large as possible and this minimises the possibility of a reduction in the flow rate of the media within in the pipe. The smaller weld bead reduces the probability of service-induced deposits, building-up on the surface. Application range Manual IR welding machines are available in the following typical sizes: 20-63mm 63-225mm 6.1.6 Bead and Crevice Free (BCF) The Bead and Crevice Free welding method is used for clean and super-clean condition applications (e.g. ultra pure PVDF piping systems). In contradiction to all previous mentioned welding methods, no weld bead is produced, resulting in a full size internal pipe bore diameter for the complete piping assembly. The pipes are placed in a clamping arrangement, which is also the heater assembly. An inflatable insert is placed inside the pipe, so that it covers the joint area. As the polymer around the joint melts, it cannot deform outwards because it is constrained by the collar nor inwards because it is constrained by the insert. In addition, the thermal expansion, caused by the heating of the joint area, cannot be accommodated by movement of the pipes, because they are clamped. When the joint is heated, an expansion of the materials occurs, which applies axial loading to the pipes, aiding fusion and the formation of a high quality joint. After a predetermined time period, the heat supply to the clamping equipment is switched off and the joint cools. Application range BCF welding machines are available for pipe sizes between 20 and 63mm
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6.1.7

Solvent Cement Welding Welding of polymers occurs when the polymer chains at the surface of one component are mobile enough to entangle with chains in the other component. Usually, thermal energy is applied to raise the temperature of the polymer above the appropriate transition temperature. Above these transition temperatures, polymer chains are mobile and if two components are brought into intimate contact, polymer chain entanglement will occur, resulting in a weld. In solvent welding, a solvent is applied which can temporarily dissolve the polymer at room temperature. When dissolvement occurs, the polymer chains are free to move in the liquid and can entangle with other similarly dissolved chains in the other component. After sufficient time, the solvent will permeate through the polymer and out into the environment, so that the chains lose their mobility. This leaves a solid mass of entangled polymer chains which constitutes a solvent weld. The joint must be fully cured before pressure can applied. The solvent cement joining process can be split-up in two phases of progress: cleaning of parts and applying of solvent bringing into intimate contact for a predetermined period The cement typically contains the solvent for the polymer, together with a small quantity of the polymer to give the cement the consistency of syrup, making application easier.

Application range Industrial use of organic solvents should be limited as much as possible. Therefore solvent welding should be avoided. Polypropylene, polyethylene, PVDF and ECTFE materials may not be joined together using solvent cements or adhesives. 6.1.8 Vibration Welding Vibration welding is a relatively new welding process, using the mechanism for generating heat by the interaction of two rubbing surfaces. This is produced by the linear motion of one of the parts relative to the other, whilst a force is applied between them. Once molten material has been generated at the joint interface, the vibration is stopped and the parts are aligned. The force is maintained as the weld cools and consolidates. Advantages vibration welding allows the reduction of the weld/cooling phase by 95% less effect of contamination, as the scrubbing action during vibration welding should tend to move any contamination away from the interface self-regulating weld temperature, making overheating impossible easier production of branches lower energy consumption

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7
7.1

WELDING REQUIREMENTS
General Welding shall only start after approval by COMPANY of all applicable welding procedure specifications and procedure qualification records. All materials to be joined must be completely clean and the surface scraped, if required, to remove any surface deterioration (e.g. UV damage). It is recommended that polypropylene is scraped in all circumstances. Before starting any welding operation, all involved piping should be drained/vented and dried completely (if applicable). All thermoplastic welding processes shall be performed in dry and clean areas, protected from adverse weather conditions that may affect weld quality. Welding activities should be performed only with an ambient temperature above 5C. In case welding is performed in outdoor conditions, temporary shelters or tents shall be installed to completely enclose the working area. The preferred ambient working temperature is in the range of +5C to +45C. Temperature conditioning of a fusion welding area can be achieved by protecting the working area by a tent or similar device. A continuous temperature logging system of the enclosed working area should be in place to check the applicable conditions. Any indication of quality loss due to influence of external parameters should result in performing sample welding seams under the given conditions.

7.2

Installation Teams Before commencing any welding activity, the CONTRACTOR must ensure that each member of the installation team has received training in the applicable thermoplastic welding processes used for the materials to be installed (DVS 2212-1 or equivalent). Where necessary, refresher training sessions should be arranged to update the knowledge of the installation team and to provide the necessary information, required by the applicable installation material. This information process must be organized with the piping material SUPPLIER, since application parameters can be slightly different according the type of raw material. Team members should be aware about the correct handling of the thermoplastic material. Welding shall be done under supervision of qualified personnel and only by certified welders. Each welder should make at least two test joints, before a certificate will be issued. This certificate should have a validation period limited in time. Each approved welder shall be allocated an identification marking or number with which he/she should mark each pipe weld. Marking shall be of permanent, weatherproof type (e.g. painted markings, bar coding), compatible to the thermoplastic base material. Piping lay-out drawings or the applicable isometrics shall serve as weld maps, identifying each required weld with a unique weld number and the welders number after com pletion of the applicable weld.

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BES-CO-05-306-01

Rev: 1/ 27.04.2010

Sheet 18 / 19

A full weld traceability file shall be available and kept up to date in accordance with the progress of the assembly activities. This file should include as a minimum: Welding Procedure Specifications (WPS) of each applicable welding process Procedure Qualification Records (PQR) Welders Performance Qualifications (WPQ), including validation time frame. Welding quality control sheets with identification plan of inspected welds Applicable NDE procedures NDE inspection reports Hydrostatic inspection report

All procedures included in this weld traceability file must be approved and signed by COMPANY. 7.3 Spool assembly To facilitate the spool assembly and assure a good alignment during the weld activities, the use of guides, pipe rollers or support is recommended. Using this kind of tools will reduce the drag forces on the involved pipe materials. The areas to be welded should be cleaned immediately before the welding with a clean, fat-free planning tool. Misalignment of joining areas should not exceed the range of 0.1 times the wall thickness at the outside surface of the pipe. 7.4 Welding Equipment Fusion welding equipment (DVS 2208-1 / DVS 2208-2 / DVS 2209-2) shall be regularly serviced and calibrated by manufactory trained technicians. This guarantees the reliability and reduces the down-time by faulty equipment. At any time, each type of welding equipment shall be accompanied with an up to date service record, stating: Date of last inspection Inspection company, including name and signature of the inspector Calibration results Date of next scheduled inspection.

Any equipment without a services record available at the equipment location will be removed from the job site. To allow full welding traceability, welding equipment with storage facilities of weld records should be selected in preference. Fusion welding equipment should be assembled according the manufacturers instructions and taking into account all requirements to allow safe working practices. Fusion welding equipment shall be protected adverse weather conditions. All precautions mentioned in Section 7.1; General to avoid these conditions should be taken. In order to avoid high local stresses and deformations in the pipe applicable to the welding process, the clamping devices should surround the pipe outer surface as parallel as possible to the welding plane.

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.

BES-CO-05-306-01

Rev: 1/ 27.04.2010

Sheet 19 / 19

Care shall be take that a clamping action should not result in any change to the circular geometry of the pipe. Special clamping devices should be used in case of fusion butt welding of fittings (e.g. welding neck flanges, stub flanges, etc.). This is to prevent any possible deformation of the pipe. Guide elements should be used to ensure, together with the clamping devices, the gap width requirements (measured on cold jointing surfaces). The sliding surfaces of guide elements should be protected against corrosion by means of hard chrome plating. Before starting a welding process, the required heating temperature of the heating element should be checked and compared with the required temperature, indicated in the welding procedure. A welding process can only be started if the heating element has maintained the required heating temperature for at least 10 minutes. The heating plate/element should be cleaned before starting a welding action. This should be done with appropriate cleaning products, specified by the welding equipment supplier. In any circumstance, the coating of the heating element must be free of any damage or dirt within the applicable working (heating) radius sector. To avoid possible damaging of the heating plate, it is recommended to put the heating plate, after cooling down, immediately into the protecting holder. 7.5 Solvent Cement Welding Solvent cement primers and cleaner contain volatile solvents, with fumes heavier than air. Good ventilation of the work areas is essential to prevent the build up of fumes in enclosed spaces. In case fume extraction is used, the extraction inlet should be positioned at the floor level, or immediately below the working area. Protective eyewear and solvent resistant gloves shall be used in all circumstances. Solvent cements are highly flammable. Therefore open fire, sparks, heater equipment or smoking shall not be permitted in the working area. For environmental reasons, discarded solvent containers should be foreseen. Brushes, paper or clothes containing traces of solvent cement cleaner or primer should collected separately and stored in sealed containers. Under no conditions solvents shall not be poured into the drainage system. Accidental spillage should be cleaned immediately in order to prevent contamination of piping and fittings or any risk to the environment may occur. In case solvents are stored in cold conditions, a gradual conditioning of the solvents to the workplace temperature level shall be taken into account.

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