4 SKZ

GERMAN PLASTIC INSTITUTE
Quality - Training -
Research - Qualification
Training & Certification
Ensuring successful HDPE pipe welding

for sustainable infrastructure
Dipl.-Ing. Benedikt Reith

Plastic Engineering
Cell +971 50 4580232 | Mail ben@skz-me.com

1961 Establishment
of the South-German
Plastics Center
SKZ
1972 Opening of
branch office by
Stuttgart
1990 Opening of
branch office in
Halle
1991 Opening of
branch office in
Peine


DVGW = German Association for Gas and Water
Welding of
pipes
pipeline components
Training for
plastic pipe welders
welding supervisors

Testing of Pipe Connections, Material, long term

Component tests
Short-term tests (e.g. torsion shear test, peeling tests)

Long-term tensile tests in a wetting agent bath at increased temperature
Long-term hydrostatic pressure test
Material analysis by DSC, IR and microscopy
Tensile creep test
Welding factor

What will we learn

Definition of Pipe Welding & Installation
Reality Construction Site
Current Situation UAE / Middle East (Reasons)

Solutions based on experience in order
to achieve sustainable Pipe Welding
Training & Certification for HDPE Pipe Welders

Definition of Installation
Inspection
Pipe Delivery
Preparation for
Welding
Welding
Process
Pipe Storage
Pipe Alignment
Documentation
Pipe Handling
Pipe Laying
Pressure Test

Storage of HDPE Pipes

Handling of HDPE Pipes

Lifting Belt

Laying of HDPE Pipes
Pipe Supports

Alignment of HDPE Pipes

Important Points for the

Welding Process
Welding Conditions
Pipe Alignment
Preparation of the Pipe Ends
Welding Parameters
Welding Reports
Professional Equipment
Skilled Welder

Welding Process: Butt-Fusion

Welding Process: Butt-Fusion
Source: Picture SKZ Training Documents GW 330

Welding Process: Electro-Fusion


Pressure Test
Source: Picture SKZ Training Documents GW 330

Reality Construction Site

Wrong preperation

Missing inspection of the

delivered Pipe Material

Dangerous Pipe Storage

Wrong Pipe Storage (ovality)

Wrong Pipe Storage (damages)

Wrong handling of HDPE Pipes

Wrong laying of HDPE Pipes



Terrible bedding of HDPE Pipes

Bad alignment of HDPE Pipes



Current Situation
Middle East
Reasons:
Existing Standards needs to be more specific
Strict enforcement of Standards through
supervision needs to be improved
Contractors are not specialized/certified
Welders are not trained/certified

Cost of poor Installation
Loosing Money
Loosing Time
Loosing Reputation
Loosing future Projects

Article, AUG 20, 2011 AME Info The ultimate middle east business resource
GCC states must address water shortage issues as populations soar
estimated
thatGulf
leaking
pipes
Water has always been a valuable commodity in the desert.
But today, with
nations
account
for upgovernments
to 50 % of the
boasting robust population growth and ever-soaring demand
for utilities,
water
lossa in
someoccurrence
parts of the
must act immediately to ensure that water shortages don't
become
regular
across the region.
region an alarming statistic
the Gulf's infrastructure is just a

Per capita water consumption in the GCC is already the highest infew
the world,
withold.
Abu
decades
Dhabi leading the charge with the average resident consuming 550 litres each day. does
not include water used for agriculture and landscaping.
It has been estimated that leaking pipes account for up to 50% of the water loss in some
parts of the region - an alarming statistic when you consider that a great deal of the Gulf's
infrastructure is just a few decades old.
"An important element is to significantly reduce the amount of water lost from the
distribution network
Source: http://www.ameinfo.com/273913-more1.html

Preventive Action
Implementing and enforcing
high Standards for Contractors & Welders
Enhance the Quality of the Pipe Network
Reduce Water Losses & Maintenance Works
Save Energy & Money

Training Centre|UAE

Systematic Training Program

BASIC Training
Certified HDPE Pipe Welder GW330 (5 days)
ADVANCED Training
Certified HDPE Pipe Welding Supervisor GW331 (5 days)
EXTENDED Examination
GW330 / GW331 (Re-fresher courses 1 day)

The new Training Centre in Dubai is a fully equipped facility that offers
theoretical courses covering various topics related to plastics, as well as a state of
the art welding work shop, providing you with practical training and hands-on
experience in welding and testing techniques for pipes and plastic products.

The training program is specially designed for engineers and consultants

involved in the design, specifications and supervision of plastic pipeline projects,
site supervisors responsible for monitoring onsite welding activities and welding
technicians performing onsite welding and installation of HDPE pipe networks.

Butt-Fusion Welding

Calculation of Welding Time and Pressure

Electro-Fusion Welding

Manual Bending Test

Technological test DVS 2203 part 5 and DVS 2203 part 2

SKZ Laboratory /Wuerzburg (Germany)

Certified HDPE Pipe Welder GW330

High Standards for HDPE Pipe Welding.
Who will benefit?
Client
sustainable pipe network
Contractor
welding skills, earlier finished sites
Plastic Pipe Manufacturer
good reputation
Pipe Welder
safety, skills
You get what

you pay for!

Conclusion
The systematic Training
and Certification will
contribute to the quality
and longevity of the
underground
infrastructure of HDPE
pipes, increasing the
value of construction
projects and
considerably extending
their service life

You have further questions?

Please feel free to contact the SKZ
SKZ Middle East

P.O. Box: 33260
Dubai UAE
Phone: +971 4 8845001 / Fax: +971 4 8845002
info@skz-me.com / www.skz-me.com

4 SKZ

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GERMAN PLASTIC INSTITUTE

Training & Certification

Ensuring successful HDPE pipe welding

Dipl.-Ing. Benedikt Reith

GERMAN PLASTIC INSTITUTE

GERMAN PLASTIC INSTITUTE

GERMAN PLASTIC INSTITUTE

DVGW = German Association for Gas and Water

GERMAN PLASTIC INSTITUTE

Testing of Pipe Connections, Material, long term

Short-term tests (e.g. torsion shear test, peeling tests)

GERMAN PLASTIC INSTITUTE

What will we learn

Current Situation UAE / Middle East (Reasons)

GERMAN PLASTIC INSTITUTE

GERMAN PLASTIC INSTITUTE

Storage of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Handling of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Laying of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Alignment of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Important Points for the

GERMAN PLASTIC INSTITUTE

Welding Process: Butt-Fusion

GERMAN PLASTIC INSTITUTE

Welding Process: Butt-Fusion

Source: Picture SKZ Training Documents GW 330

GERMAN PLASTIC INSTITUTE

Welding Process: Electro-Fusion

GERMAN PLASTIC INSTITUTE

GERMAN PLASTIC INSTITUTE

Source: Picture SKZ Training Documents GW 330

GERMAN PLASTIC INSTITUTE

Reality Construction Site

GERMAN PLASTIC INSTITUTE

GERMAN PLASTIC INSTITUTE

Missing inspection of the

GERMAN PLASTIC INSTITUTE

Dangerous Pipe Storage

GERMAN PLASTIC INSTITUTE

Wrong Pipe Storage (ovality)

GERMAN PLASTIC INSTITUTE

Wrong Pipe Storage (damages)

GERMAN PLASTIC INSTITUTE

Wrong handling of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Wrong laying of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Wrong laying of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Wrong laying of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Terrible bedding of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Bad alignment of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Bad alignment of HDPE Pipes

GERMAN PLASTIC INSTITUTE

Bad alignment of HDPE Pipes

GERMAN PLASTIC INSTITUTE