SMARTFUSE FOR RELIABLE, LONG-LASTING PIPELINES

SmartFuse might just look like a product name etched into PLASSON fittings but it represents our commitment to high quality, reliable electrofusion welding – for installers, asset owners and those who rely on what comes down the pipes.


Over the last 50 years, metallic pipelines have been increasingly replaced by thermoplastic systems such as polyethylene, or PE. This is due to the significant advantages of PE like environmental resistance, especially corrosion, low maintenance demands and ease of installation; PE pipelines can even endure earthquakes.


Most newly installed water, sewage and gas distribution pipelines will be PE pipelines and they are increasingly being joined by electrofusion or EF.  Electrofusion is considered the most reliable method of joining gas-carrying pipes.  In fact, the gas industry was where EF was first used since gases can be hazardous if not secured properly.

Plasson EF couplers for welding poly pipe


SMARTFUSE: THE KEY TO RELIABLE LONG-LASTING INFRASTRUCTURE

Given the obvious need for reliable, long-lasting infrastructure, developing high quality electrofusion fittings and systems for installation has been a PLASSON priority.
 

With specialized control boxes, reliable electrofusion fittings and SmartFuse tooling, the SmartFuse electrofusion system helps deliver better electrofusion welding.


PLASSON SmartFuse electrofusion fittings range from options for small diameter poly pipe, like 16mm and 20mm, to options for large diameter civil water and waste water pipes at 400mm to 800mm, 900mm and even 1000mm.

Electrofusion delivers reliable results on small and large diameter poly pipe. EF is also suitable for pipes with a small diameter since it does not shrink the inner diameter of the pipe.  So whether welding a 32mm to 1/2″ brass transition fitting or a saddle onto 63mm blue stripe pipe, PLASSON SmartFuse fittings are engineered to deliver quality electrofusion welds.

the benefits of PLASSON Australia EF branch saddles

SMARTFUSE: TECHNOLOGY THAT WORKS SMARTER SO YOU DON’T WORK HARDER



The SmartFuse system offers fully automated welding and, when paired with the SmartFuse app, delivers image capture and cloud storage for all weld records. With the click of a button, weld data is stored and accessible, anywhere, anytime.


SmartFuse helps lower operational costs, reduces mistakes and joins can be easily traced and identified via the GPS data that is part of every SmartFuse weld record.


PLASSON is committed to innovation in the EF field. As a future focused company, we are continually working to improve what we offer, to facilitate better electrofusion welding, deliver enhanced asset management and asset visibility.

SmartFuse for guided EF weld from PLASSON Australia
WELD SMARTER


SmartFuse is one way PLASSON are helping raise the bar in electrofusion

EF WELDING: HOW PIPE OVALITY PREVENTS GOOD WELDS

The non-brittle and flexible characteristics of polyethylene make it ideal for many pressure and non-pressure applications. Those useful characteristics also mean PE pipe can alter shape. Ovality generally known as ‘out of roundness’ is one of the most common issues found in PE pipe. One of the best tips to ensure a quality electrofusion weld is to ensure that polyethylene pipe is not out-of-round before attempting the electrofusion process.

To determine if out-of-round conditions exists measure the pipe diameter in numerous directions across the pipe end with a tape measure. If the measurements exceed the maximum tolerance, a re-rounding clamp or device must be used to bring the pipe back to a round condition.

HOW DOES POLYETHYLENE PIPE BECOME OUT-OF-ROUND?

MANUFACTURING
Installers need to confirm that polyethylene pipe matches all dimensional requirements for the job and the fitting being installed and that the pipe does not exceed the allowed ovality. If ovality is greater than allowed you must take steps to re-round the pipe.

STORAGE
Polyethylene pipe that is warehoused for a period of time or stacked on top of each other can experience ovality issues (more pronounced with large diameter pipe).

TIME
Large Diameter Polyethylene pipe will tend to relax a little during storage due to a combination of its weight and its natural flexibility.

INSTALLATION
Mechanical forces experienced during some trenchless installation techniques such as Pipe Bursting or Directional Drilling can temporarily leave the polyethylene pipe elongated and out-of-round.

PREVIOUS INSTALLATION
Polyethylene pipe that has been underground for awhile is subjected to earth loads. These earth loads can cause the pipe to sag and/or become out-of-round.

WHY IT IS KEY TO ADDRESS PIPE OVALITY FOR ELECTROFUSION INSTALLATIONS

One of the most critical functions of the electrofusion process is to seal the gap between the pipe and the fitting and to build up interfacial pressures for the fusion process to take place. If this gap is not sealed and interfacial pressures cannot build up, there is no way for the electrofusion joint to effectively achieve the high quality fusion it was designed for.

If a pipe is out-of-round the initial concern is that the surface area of the pipe may not adequately come in contact with the fusion zone of the electrofusion fitting. This could result in the electrofusion fittings cold zones, which are designed to contain the material generated in the melt pool, allowing the molten material to escape out of the fusion area without producing any melt penetration. This is a key concern when installing tapping and branch saddles since they do not fully encircle the pipe like an electrofusion coupling.

HOW TO CORRECT OUT-OF-ROUND PIPE

First, determine if out-of-round conditions exists. This can be done visually for extreme cases or by measuring the pipe diameter in numerous directions across the pipe end with a tape measure. If the measurements exceed the maximum tolerance, a re-rounding clamp or device must be used to bring the pipe back to a round condition.

The following table shows the approved dimensions for PE100 pipe:

The PLASSON range includes high quality tools to prepare pipe correctly for electrofusion, inlcuding re-rounding clamps. Click here to see PLASSON’s tooling range….