HDPE BUTT-FUSION WELDING

CONTENT

Item Page

Processing of HDPE Butt-Fusion Welding 1

Parameter for HDPE Butt-Fusion Welding 5

Sample calculation 6

DVS 2207-1 Welding of Thermoplastics. Heated tool welding of pipes, pipeline components and
sheets made from PE-HD

SFS 3115:E Plastic pipe water tightness test for pressure pipeline
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TECHNICAL INFORMATION Quality Management Systems
Q001
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005
Cert. No. TH04/0500

Processing guidelines – Heating element butt welding (1)

Step Working Procedure Views

1. - Assemble welding equipment (Prepare tools and machinery),
Control welding devices.

- Install welding tent or similar device (If necessary)

2 - Clamp and adjust the pipe or piping part –the surfaces to be

welding should be plane-parallel to each other.
- Secure longitudinal movement of the parts to be welded by
taking appropriate measures.
- Clean outside and inside surfaces

4 - Assemble the clamp and the same time check alignment of

pipe.

5 - Fit the facing toll between the two pipe ends,

6 - Start the facing tool engine.

- Slowly approach the pipe ends towards the facing tool by
means of acting on the hydraulic control unit keeping a
TAP-TEC-BUTT WELDING-50R1

pressure a little higher then the inertial pressure. During this

operation adjust the pressure from higher to lower.
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Q001
Cert. No. NQ767/04
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Cert. No. TH04/0500

Processing guidelines – Heating element butt welding (2)

Step Working Procedure Views
7 When scraps become continual even and slice shape, finish
facing, then switch off the facing tool engine. Avoid from
contacting from with the faced pipe ends.

8 Remove the facing tool and place it into the support. And
cleaning the faced pipe ends.

9 Check tolerance alignment of the both pipe ends

: Maximum tolerance = (e) x (wall thickness : mm.)
pipe Outside Diameter Maximum tolerance
(OD) (e)
≤ 350 0.5
400… < 630 mm. 1.0
630…< 800 mm. 1.3
800…≤ 1000 mm. 1.5
10 Cleaning the both pipe ends, Heating plate. And start the
heating plate for worm up.

11 Check temperature Working temperature = 195 – 220 oC.

12 Measure the work piece pulling force or pressure. F pulling force
TAP-TEC-BUTT WELDING-50R1

P pulling pressure

13 Measure the force or pressure for heating time F heating time = F pulling force + F table
P heating time ~ 0.01 N/mm2 F welding = F pulling force + F table
P welding = 0.15 N/mm2 P heating time = P pulling pressure + P table
P welding = P pulling pressure + P table
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TECHNICAL INFORMATION Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500

Processing guidelines – Heating element butt welding (3)

Step Working Procedure Views
14 After the facer milling finishes, put the heating plate (already
heated) for heating the pipe plane.

15 - Fit the heating plate toll between the both pipe ends, the
pressure maintained unit the joining faces completely onto
the heating element. By this moment a bead must have been
created surrounding the whole circumference of both pipes.

16 Reduce adjusting pressure = 0.01 – 0.02 N/mm2 and let pass

by the heating time according to reference values table.

17 Remove heating plate and join the surfaces to be welded-

keep adjusting time as short as possible

18 Continuously increase adjusting pressure for the joining

process until the required value is reached.
TAP-TEC-BUTT WELDING-50R1
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Cert. No. TH04/0500

Processing guidelines – Heating element butt welding (4)

Step Working Procedure Views
19 Maintain the adjusting pressure until the welding seam has
cooled down.

20 Remove clamps after the required cooling time.

21 After joining a bead surrounding the whole circumference

must have been created.

Furthermore, the welding bread has to be inspected with a

view to the following “
- Both beads should be almost equally sized.
- The bead surface should be smooth
Possible differences in the formation of the beads may be
justified by different flowing behaviour of the joined materials.

TAP-TEC-BUTT WELDING-50R1
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Parameter for HDPE Butt-Fusion Welding

Parameter for HDPE Butt-Fusion Welding

According to standard DVS2207 8/95

P1 P3

P2

T1 T2 T3 T4 T5

Pressure – Time Diagram for Butt-Fusion Welding

Description Calculation Parameter

1. Heating temperature 200 - 220 0C 0
200 - 220 C
2. Pressure for bead created (P1) A1 / A2 x 1.5 (bar) 0.15 ± 0.01 N/mm2
3. Alignment Time (Bead Created) (T1) Until bead created follow item 4 Until bead created follow item 4
4. Height of bead (Welding Seam) (mm.) 0.5 + (0.1 x e) mm. 0.5 + (0.1 x e) mm.
5. Pressure-up time (P2) A1 / A2 x 0.2 (บาร) ≤ 0.02 N/mm2
6. Heating Time (T2) 10 x e (sec.) 10 x e (sec.)
7. Time remove heating plate (T3) 3 + (0.01 x OD) : sec. 3 + (0.01 x OD) : sec.
8. Time to increase Joining pressure (T4) 3 + (0.03 x OD) : sec. 3 + (0.03 x OD) : sec.
9. Joining pressure (P3) A1 / A2 x 1.5 (bar) 0.15±0.01 N/mm2
10. Cooled down Time (T5) 3 + e (min.) 3 + e (min.)
11. minimum wide of welding seam (mm.) 3 + (0.50 x e) mm. 3 + (0.50 x e) mm.
12. maximum wide of welding seam (mm.) 3 + (0.75 x e) mm. 3 + (0.75 x e) mm.
TAP-TEC-BUTT WELDING-50R1

Remarks : OD = Outside Diameter (mm.)

e = Wall Thickness (mm.)
A1 = Pipe section area (mm2) = π(OD2 – ID2)/4 (mm2)
A2 = Hydraulic cylinder section area (mm2) = 2π(ID2 – OD2)/4 (mm2)
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Calculation guidelines – HDPE Butt Fusion Welding

Conforming to Standard DVS 2207
1) Calculation for Welding Pressure HDPE Pipe

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. are welding pressure for HDPE Pipe.
= ≤ 0.02 N/mm2 or 0.2 bar. Are soak pressure for the heating plate
element. By this moment a bead must have been created surrounding
the whole circumference of both pipes.
P (Cylinder) = Welding Pressure (bar.)

1.1) Calculation for HDPE Pipe section area : HDPE Pipe section area (A1) = π (OD2-ID2) / 4 (mm2)

Ex 1. HDPE Pipe dia. 315 mm. PN 6.3 Wall thickness 15.0 mm.
A1 = 3.142x(3152-(315-(2x15))2) / 4
= 14,139.00 mm2

Ex 2. HDPE Pipe dia. 400 mm. PN 6.3 Wall thickness 19.1 mm.
A1 = 3.142x(4002-(400-(2x19.1))2) / 4
= 22,858.64 mm2

1.2) Calculation for Hydraulic cylinder effective area (HDPE Butt-Fusion Machine)

HDPE Butt-Fusion Machine : Model 315

Hydraulic cylinder effective area : A2 = 2 π (ID2cylinder - OD2connecting rod) / 4 (mm2)
OD Hydraulic connecting rod = 30 mm. ; ID Hydraulic cylinder = 40 mm. ; 2 = Number of Hydraulic cylinder

A2 = 2 x 3.142 x (402-302) / 4
= 1,099.70 mm.2
TAP-TEC-BUTT WELDING-50R1

HDPE Butt-Fusion Machine : Model 315

Hydraulic cylinder effective area : = 2 π (ID2cylinder - OD2connecting rod) / 4 (mm2)
OD Hydraulic connecting = 40 mm., ID Hydraulic cylinder = 50 mm.

A2 = 2 x 3.142 x (502-402) / 4
= 1,413.90 mm.2
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TECHNICAL INFORMATION Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500

Calculation guidelines – HDPE Butt Fusion Welding (2)

Result of calculated HDPE Butt-Fusion Welding parameter

Item Description Parameter

1 HDPE Butt-Fusion Machine Model 315
2 Hydraulic cylinder effective area 1,099.70 (mm.).2
3 OD. HDPE Pipe 225 (mm.) 225 (mm.) 315 (mm.)
4 Pipe wall thickness 10.8 (mm.) 16.6 (mm.) 15.0 (mm.)
5 PN (Nominal Pressure) 6.3 (bar.) 10 (bar.) 6.3 (bar.)
6 SDR. (Standard dimension ratio) 21 13.6 21
2 2
7 HDPE Pipe section area 7,268.57 (mm. ) 10,869.56 (mm. ) 14,139.00 (mm.2)
8 Ref. Welding Standard Method DVS 2207
9 Heating Temperature 200 – 220 (0C.)
10 Pressure for bead created 9.9 (bar.) 14.82 (bar.) 19.28 (bar.)
11 Alignment Time (Bead created) (Until bead created follow item 12)
12 Height of bead created (Welding seam) 1.58 (mm.) 2.16 (mm.) 2.00 (mm.)
13 Pressure-up 1.32 (bar) 1.97 (bar) 2.57 (bar)
14 Heating Time 108 (sec.) 166 (sec.) 150 (sec.)
15 Time to remove heating plate 5.25 (sec.) 5.25 (sec.) 6.15 (sec.)
16 Time to increase joining pressure 9.75 (sec.) 9.75 (sec.) 12.45 (sec.)
17 Joining Pressure 9.9 (bar) 14.82 (bar) 19.28 (bar)
18 Cooled down time ≥ 13.8 (min.) ≥ 19.6 (min.) ≥ 18 (min.)
19 Wide of welding seam 8.40 – 11.10 (mm.) 11.30 – 15.45 (mm.) 10.50 – 14.25 (mm.)
TAP-TEC-BUTT WELDING-50R1
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TECHNICAL INFORMATION Quality Management Systems
Q001
Cert. No. NQ767/04
005
Cert. No. TH04/0500

Calculation guidelines – HDPE Butt Fusion Welding (3)

Result of calculated HDPE Butt-Fusion Welding parameter

Item Description Parameter

1 HDPE Butt-Fusion Machine Model 450
2 Hydraulic cylinder effective area 1,413.90 (mm2)
3 OD. HDPE Pipe 400 (mm.) 400 (mm.)
4 Pipe wall thickness 19.1 (mm.) 29.5 (mm.)
5 PN (Nominal Pressure) 6.3 (bar) 10 (bar)
6 SDR. (Standard dimension ratio) 21 13.6
2
7 HDPE Pipe section area 22,858.64 (mm ) 34,341.27 (mm2)
8 Ref. Welding Standard Method DVS2207 8/95
9 Heating Temperature 200-220 (0C)
10 Pressure for bead created 24.26 (bar) 36.44 (bar)
11 Alignment Time (Bead created) (Until bead created follow item 12)
12 Height of bead created (Welding seam) 2.41 (mm.) 3.45 (mm.)
13 Pressure-up 3.23 (bar) 4.86 (bar)
14 Heating Time 191 (sec.) 295 (sec.)
15 Time to remove heating plate 7.00 (sec.) 7.00 (sec.)
16 Time to increase joining pressure 15.00 (sec.) 15.00 (sec.)
17 Joining Pressure 24.26 (bar) 36.44 (bar)
18 Cooled down time ≥ 22.1 (min) ≥ 32.5 (min)
19 Wide of welding seam 12.55 – 17.32 (mm.) 17.75 – 25.12 (mm.)
TAP-TEC-BUTT WELDING-50R1