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David Clayton Product Manager

FUSION PROVIDA

CHESTERFIELD DUCTILE GROUP HEADQUARTERS EQUIPMENT

DUCTILE IRON PIPE YARD

PIPE SYSTEMS Hire & Repair NDC WAREHOUSE FUSAMATIC

EXPORT WAREHOUSE NDC & EXPORT

Severn Trent Services

Manufacturing Capabilities
Automatic Butt Fusion Machines Electrofusion Control Boxes Electrofusion Fittings Fabricated & Spigot Fittings Polyethylene Pipe Production PetroFuse Aquaculture Landfill Systems

Why is Polyethylene used


Easily formed into complex shapes by extrusion, injection moulding etc. Good working temperature range (-20 to +50 C) Corrosion resistance / Chemical resistance Good strength to weight ratio Reduced transportation & handling costs Easily joined ( E/F & B/F) Flexibility of buried system Pipe system is only as good as its joints

NO DIG TECHNIQUES

PIPE INSERTION

PIPE BURSTING

Electrofusion / Butt Fusion


Molecular Joint - Joint Strength Equivalent to Pipe. Fully End Loaded System. Flexibility. Corrosion resistance.

Degree of quality control & traceability


50 Year Life

Cross Section of a Coupler


Fusion Zone

Terminal Pin

End Cold Zone

Pipe Stop

Centre Cold Zone

PRODUCTION PROCESS

Cross Section of a Tapping Tee

THREAD
STACK

TERMINAL PIN COLD ZONE

FUSION ZONE

PRODUCTION PROCESS

Criteria For E/F Jointing


Clean surfaces (interface) Steady electrical / heat input Generate melt pressure Heat soak time Minimal tensile load / movement Cooling period

Joint Assembled Prior to Fusion


Gap between the pipe and . coupler

Joint at the End of Incubation Period


Molten polymer Coupler & pipe touching

End of the Joint Consolidation Phase


Expanded pool of molten polymer
Frozen polymer in cold zone

Completed Electrofusion Joint


High strength electrofusion weld Shrinkage accommodating inward movement of pipe

Quality Checks
Ensure cleanliness of the joint area.
Check around the joint area for visual signs of scraping.

Check fusion indicators have risen.


Check that no molten material or wire has exuded from the fitting. Check saddles are square to the main. Take printout of joint data.

Fusion Indicators
Cooling & Inspection

Electrofusion joining of PE pipes

Current Profile

Pipe Not Scraped

Incorrect Scraping

Over Insertion

Under Insertion

Misalignment

Pipe Ends Not Cut Square

Wire Movement

Moisture

Scraping

Good Jointing Practice


Check equipment Scrape pipe Use clamps Adhere to fusion / cooling time Check joint OPERATOR AWARENESS

EF Fitting Failure Mechanisms


Joint Failure
>99% of reported EF fitting failures are a direct result of some form of poor site practice.

Ductile Creep Rupture


High pressure short failure times (20C tests). Attributable to tensile strength of resin.

Slow Crack Growth


Lower pressures, longer failure times (80C tests). Attributable to SCG susceptibility of resin.

DUCTILE RUPTURE

SLOW CRACK GROWTH

Butt Fusion

Butt Fusion Machine

1) CHASSIS
2) TRIMMER 3) HEATER 4) POWER UNIT 5) TIMER

Key Parameters for Butt Fusion


Temperature Pressure Time Distance Sequence

Standard Cycle for Butt Fusion


ISO 11414 : 1996(E)

Phase 1 Phase 2 Phase 3 Phase 4

Phase 5

Phase 6

Manual Input Butt Fusion


Great results when done correctly, however heavily relied on a good operator carrying out the job correctly. Poor operators could Reduce time at each stage Miscalculate pressures Over or under heat pipe ends Miss stages out, such as trimming Ignore instructions for dummy welds

Look up table for Manual Butt Fusion

New Developments Automatic Butt Fusion

Data Storage
Individual record for each joint Can be printed or downloaded

All joint statistics displayed on the printout


Summary of joint status given

If the material properties are correct it is impossible for a bad joint to go un-noticed

All beads shall be removed and assessed

Joint Analysis

Review Joint Records

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