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Proper Use of Fabricated Fittings&
Fusion Methods for Transition Connections
John MurphyBlair Supply
Agenda
Butt Fusion vs. Electrofusion
Proper Use of Fittings
Types Of Transition Fittings
Restraining Fittings & Pipe Movement
Hands on Fusion Demo
HDPE MARKET - WATERHDPE MARKET - WATER
EUROPE 70 – 75% HDPE MARKET PENETRATION
RUSSIA 90% HDPE MARKET PENETRATION
U.S.3% HDPE MARKET PENETRATIONGROWING STEADILY
ELECTROFUSION vs. BUTT FUSION
ELECTROFUSION vs. BUTT FUSION
EUROPEAN MARKET85% ELECTROFUSION FITTINGS15% BUTT FUSION FITTINGSUP TO 18” IN MOLDED BUTT FITTINGSUP TO 12” IN EF TEES, ELBOWS, CAPS
US MARKET15% ELECTROFUSION85% BUTT FUSIONUP TO 12” IN MOLDED BUTT FITTINGSSTILL DEVELOPING EF TEES, ELBOWS, CAPS(LIMITED SIZES CURRENTLY OFFERED)
What is Butt Fusion? The Joining of two ends of HDPE pipe or fittings
Pipe Ends are Heated to 395 – 420 degrees
Pipe Ends are joined together to mold into one and
allowed to cool
Beads are same inside and outside of pipe
Butt Fusion Procedures
•Pipe Cutting, Square Ends•Proper Alignment Into Machine
•Fusion Temperature
•Fusion Pressure
•Cooling Time
Butt Fusion MachineCF14 , 1” – 4” Size
City of Courtland WWTP Up‐GradesCF‐28 Machine 2”IPS – 8” DIPS
Village of Sodus, Water Intake ExtensionCF620 Machine 6” IPS‐ 20DIPS
Village of Sodus, Water Intake Extension
MJ Adapters IPS & DIPS With & W/O StiffenersAccessory Kits C110 HD Gland, Gaskets, & Long Tee Botls
NPT Threads Up to 4” Male & Female Carbon & Stainless
Transition Fittings
Butt Fuse Fittings
What is Electrofusion ?? This technique involves preparing the outside surface of a pipe end, and inserting the Electrofusion fittings onto the pipe. The inside of the fitting has a copper coil that will heat to specific temperature when connected to EF processor . The melts from the two components flow together and fuse as the joint cools
Couplers 1/2” - 48” IPS 4” – 30” DIPS SDR 6 to SDR 32.5 Available
Specialty Fittings 90’s, 45’s & Tees Reducers & Flex Restraints
Branch Saddles 2” x 2” – 48” x 36” SDR 9 to SDR 32.5 Fusions Available NEW: Saddles with Electrofusion Outlets
IntegriFuse EF Fittings
IntegriFuse Electrofusion Fittings
Cutting Pipe Ends
Cut pipe at right angles
Marking the Fusion Zone
Measure the fusion zone
Scraping the fusion zone This operation ensures removal of oxide layer, which will increase melt flow
during the fusion process. It is critical that the oxide layer be removed completely; otherwise it may cause cold welding resulting in leakage.
Mechanical Scraper Manual Scraper
Deburring/Beveling Ends
Debur or Bevel pipe ends
Cleaning the Fusion Zone
Insert the Pipe into the Coupler
An assembly, which is stressed, may result in defective joint. Ensure that both pipes are inserted into the fitting and the two ends are meeting
each other in the center of the coupler (the cold zone). The maximum allowable gap between the two pipes is to be less than > ½”. If there are stops, push all the way to the stops.
Mis-Alignment- Unacceptable FusionPossible Causes: Inadequate Clamping or
Restraint during fusion.
Mis-Stab- Unacceptable FusionPossible Causes: Failure to mark and monitor
stab depth.
Short Stab- Unacceptable FusionPossible Causes: Failure to mark and monitor
stab depth.
Exposed Wire- Unacceptable FusionPossible Causes: Pipe Ovality, Flat Spots,
Undersized Pipe, Binding
Melt Out- Unacceptable FusionPossible Causes: Pipe Ovality, Flat Spots,
Undersized Pipe, Binding
Good Fusion- Acceptable.
Cool Time
The Cooling time is a critical step in determining the successful fusion of the EF Coupler to the pipe.
The Cooling Time is indicated by “Cool” on the coupler and is the amount of time required prior to examination, movement, and pressurization of the coupler.
After the Cooling time is finished, you are required to perform a flashlight test, in which the installer views the coupler/pipe interface to check for remaining gaps or wires that can be seen.
Utilize a metal hose clamp or plastic electrical tie to check the coupler/pipe interface to make sure that the tie or claps stops at the first wire.
The EF Fitting can be fused a maximum of 3 times if necessary, after the cooling time.
FLEX RESTRAINT ELECTROFUSION Designed for use on HDPE pipe 6" IPS/DIPS - 63" IPS Used to Create Thrust Restraints To minimize Pipe Expansion & Contraction
Water Park – Discovery Cove (Disney)
Village of Macedon WWTP Improvements 2013
Fusion Demo & QuestionsResources
Blair Supply , www.blairsupplyusa.com
Integrity Fusion Products, www.integrityfusion.com