TIPS TO SIMPLIFY EF WELDING
Are you searching for electrofusion welding tips? Looking for that magic piece of advice wrapped up in an easy to watch video? Achieving good electrofusion welds is not quite that simple but you have come to the right place!
The best tip to achieving good EF welds is summed up in two simple words: “precision” and “accuracy”. Whether you are installing a 16mm coupler or a 1000mm fitting, precision and accuracy is crucial at every step of the process. A good weld is about following all the recommended steps, having the right precise tools to do the job and taking the time to use them accurately.
It may sound simple but quality electrofusion welds are literally built on precision (being exact) AND accuracy (being correct).
“Precision” is about instruments and their parameters.
As an example, vernier calipers will measure precise peel depth during pipe prep down to 0.02 mm. A metal rule is precise to 1 mm. That makes it perfect for witness marks but rules (!) it out for gauging precise peel depth.
Here is where “accuracy” steps in – the correct tool used correctly.
PIPA – the Plastics Industry Pipe Association of Australia – has created electrofusion industry guidelines, called POP001. It outlines the precison tools, accurate measurements and correct procedures (Best Practice) for EF welding.
Following the Best Practice steps in POP001 is the by far the best tip for achieving quality electrofusion welds.
Click here to read or download a copy… It has plenty of easy to understand diagrams and documents all the steps and measurements you need for successful electrofusion.
PLASSON created the SmartFuse EF system to deliver a framework to support the precision and accuracy required for successful electrofusion welding.
This system includes SmartFuse fittings with accurate welding parameters preloaded, robust welding control boxes which automatically detect weld parameters for all SmartFuse fittings and a free mobile app to guide installation and record key details, like GPS location, fitting type and barcode, for easy downstream management.
SmartFuse fittings have in-built resistors that feed accurate weld parameters to the SmartFuse control box once the fitting is connected. No manual entry and no scanning means it is not only faster to set up each and every weld but the potential for inaccurate input errors is eliminated.
The SmartFuse mobile app also helps make welding more accurate and precise. When using the app, installers are guided through weld steps, prompted to double-check settings and asked to confirm and record with photos of each step.
All visual records are stored along with details of the fitting being installed, precise location, installer ID, control box weld data and even the temperature on the day!
Weld data can be saved on site via USB, which is handy in remote areas with limited internet access, or, if you are using the SmartFuse App, data can be automatically uploaded to the cloud.
This gives managers and asset owners a real-time comprehensive picture of what is happening on any job, anywhere, anytime
QUICKER AND SMARTER WELDING
Weld times for PLASSON fittings are specific to the type of fitting. This is automatically detected by the SmartFuse control box. By combining all the elements in the SmartFuse system – the fittings, weld control box and SmartFuse App – users benefit from automatically loading of correct settings and recording of all weld activity.
On top of this, the safe storage of records is also take care as with the SmartFuse App all data can be automatically uploaded to the cloud to your preferred storage provider. Click here to find out how to sign up for a free SmartFuse App account..
The use of the SmartFuse system does not remove the requirement for EF installers to be certified. SmartFuse is designed to support certified electrofusion installers to work efficiently and accurately as well as helping by automatically recording detailed weld data for future reference.
See how SmartFuse fittings and welding control boxes work in this handy demo video:
EF TIPS TO SAVE TIME, MONEY AND HASSLES ON ANY JOB
No-one wants to re-do welds so the best way to save time, money and hassles is to ensure each and every weld is done according to best practice. The key to good electrofusion welding is contained in the POP001 guidelines for electrofusion installation.
POP001 was put together by PIPA, the Plastics Industry Pipe Association of Australia to detail the best practice processes and parameters for electrofusion welding. Following these steps will help ensure quality, long-lasting and reliable pipe connections, helping you be a better installer and achieve more reliable, leak-free EF welds.
This quick install video shows how the steps outlined in POP001 apply in the field.
PLASSON has developed the SmartFuse system to help make electrofusion welding simplier. All SmartFuse fittings have built-in resistors that automatically load the correct weld parameters for the fitting into PLASSON SmartFuse electrofusion weld machines.
Welding is made even easier thanks to the SmartFuse app. It not only guides and prompts installers to complete all of the best practice steps in POP001, the SmartFuse app records this information and the weld record either on USB or in the cloud.
It is important to know and understand all the steps outlined in POP 001 as omitting steps or failing to complete processes adequately can undermine weld quality and lead to failed pipelines.
The processes outlined in POP001 are known as best-practice. It is crucial to always follow best-practice as failure to do so can open operators up to claims of negligence and compromise insurance cover.
For a full copy of POP001, click here…
PLASSON ELECTROFUSION 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.
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 precision tooling, PLASSON’S electrofusion range helps deliver better electrofusion welding.
PLASSON 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 electrofusion fittings are engineered to deliver quality electrofusion welds.
TECHNOLOGY THAT WORKS FOR YOU
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.
The SmartFuse app 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.
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
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….
PLASSON POLYMATIC PLUS CONTROL BOX: OVERVIEW
The PLASSON SmartFuse system has been created to systemise installation and to simplify EF welding. PLASSON’S SmartFuse Polymatic Plus EF weld control unit is a workhorse that delivers ease and speed without breaking the bank.
THE 001 WAY TO BETTER ELECTROFUSION WELDS
TIPS TO SIMPLIFY EF WELDING
Are you searching for electrofusion welding tips? Looking for that magic piece of advice wrapped up in an easy to watch video? Achieving good electrofusion welds is not quite that simple but you have come to the right place!
The best tip to achieving good EF welds is summed up in two simple words: “precision” and “accuracy”. Whether you are installing a 16mm coupler or a 1000mm fitting, precision and accuracy is crucial at every step of the process. A good weld is about following all the recommended steps, having the right precise tools to do the job and taking the time to use them accurately.
It may sound simple but quality electrofusion welds are literally built on precision (being exact) AND accuracy (being correct).
“Precision” is about instruments and their parameters.
As an example, vernier calipers will measure precise peel depth during pipe prep down to 0.02 mm. A metal rule is precise to 1 mm. That makes it perfect for witness marks but rules (!) it out for gauging precise peel depth.
Here is where “accuracy” steps in – the correct tool used correctly.
PIPA – the Plastics Industry Pipe Association of Australia – has created electrofusion industry guidelines, called POP001. It outlines the precison tools, accurate measurements and correct procedures (Best Practice) for EF welding.
Following the Best Practice steps in POP001 is the by far the best tip for achieving quality electrofusion welds.
Click here to read or download a copy… It has plenty of easy to understand diagrams and documents all the steps and measurements you need for successful electrofusion.
PLASSON created the SmartFuse EF system to deliver a framework to support the precision and accuracy required for successful electrofusion welding.
This system includes SmartFuse fittings with accurate welding parameters preloaded, robust welding control boxes which automatically detect weld parameters for all SmartFuse fittings and a free mobile app to guide installation and record key details, like GPS location, fitting type and barcode, for easy downstream management.
SmartFuse fittings have in-built resistors that feed accurate weld parameters to the SmartFuse control box once the fitting is connected. No manual entry and no scanning means it is not only faster to set up each and every weld but the potential for inaccurate input errors is eliminated.
The SmartFuse mobile app also helps make welding more accurate and precise. When using the app, installers are guided through weld steps, prompted to double-check settings and asked to confirm and record with photos of each step.
All visual records are stored along with details of the fitting being installed, precise location, installer ID, control box weld data and even the temperature on the day!
Weld data can be saved on site via USB, which is handy in remote areas with limited internet access, or, if you are using the SmartFuse App, data can be automatically uploaded to the cloud.
This gives managers and asset owners a real-time comprehensive picture of what is happening on any job, anywhere, anytime
QUICKER AND SMARTER WELDING
Weld times for PLASSON fittings are specific to the type of fitting. This is automatically detected by the SmartFuse control box. By combining all the elements in the SmartFuse system – the fittings, weld control box and SmartFuse App – users benefit from automatically loading of correct settings and recording of all weld activity.
On top of this, the safe storage of records is also take care as with the SmartFuse App all data can be automatically uploaded to the cloud to your preferred storage provider. Click here to find out how to sign up for a free SmartFuse App account..
The use of the SmartFuse system does not remove the requirement for EF installers to be certified. SmartFuse is designed to support certified electrofusion installers to work efficiently and accurately as well as helping by automatically recording detailed weld data for future reference.
See how SmartFuse fittings and welding control boxes work in this handy demo video:
ENGINEERING AN “O” SO RELIABLE FITTING
How PLASSON compression fittings work is a bit of a yarn that starts way back in 1896. Unless you are a trivia junkie, it will probably come as news that one of the most critical precision mechanical components ever developed was patented on May 12, 1896. That was when a Swedish patent for the O-ring was awarded to J.O. Lundberg. Niels A. Christensen was granted a US patent for his O-ring design in 1937.
Like all good ideas, it came to the attention of some pretty big players. The O-ring quickly became the standard seal for hydraulics in the military. The top brass set out the standard sizes and basic design guidelines that remain in use today.
The humble O-ring delivers a reliable seal through compression and that is why PE pipe joiners that seal via O-rings are described as compression fittings.
PLASSON seals due to a simple solution
PLASSON took the original O-ring from 1896 and did something simple but clever with it. By placing the O-ring into a special groove machined into the inside of each fitting, the PLASSON O-ring is always in the optimum position for sealing.
This innovative design means the fitting seals water-tight as soon as the pipe passes through the O-ring. With PLASSON compression fittings, you only tighten the nut to prevent the pipe and fitting from moving apart, or blowing out, under pressure. The design also means the O-Ring can’t fall out and be damaged, contaminated or lost during installation.
The O-ring is a donut-shaped ring (technically, a toroid) with a circular cross section made from different elastomers.
PLASSON compression fittings can have Nitrile NBR O-rings or EPDM O-rings, which has a better chemical resistance than NBR, or Vitron seals, which offer better chemical resistance than EPDM.
The name Viton is a trademark and refers to fluorocarbon O-rings, or FKM/FPM for short. This material has an excellent tolerance for high temperatures, resistance to oils, fuels and hydraulic fluids as well as aromatics and solvents.
O-rings seal by mechanical deformation (caused by compression) which creates a barrier to a fluid’s potential leak path between two closely mated surfaces.
Applying fluid pressure pushes the O-ring against the groove wall on the low-pressure side, increasing the sealing force. At higher pressures, the O-ring deforms to a “D” shape, increasing the contact area further.
The range of PLASSON compression fittings includes small 16mm and popular residential plumbing fittings at 20mm, 25mm and 32mm right up to large 63mm couplers for civil water and waste water pipelines.
PLASSON compression fittings are easy to install – just take a look at our install video:
USING THE SMARTFUSE APP: IT’S FREE!
PLASSON SmartFuse app is designed to make electrofusion simpler and more efficient. And it is 100% free to use and always will be.
PLASSON SmartFuse offers a weld recording and reporting system. When using the app, installers are not only guided through systemised welds, the app ensures photos record each step.
These visual records are stored along with details for the fitting being installed, the precise location, the installer’s ID, all control box weld stage times and data and even the temperature on the day!
This data can be saved on site via USB, which is handy in remote areas with limited internet access, or automatically in the cloud.
This gives managers and asset owners a real-time comprehensive picture of what is happening on any job, anywhere, anytime.
CLICK TO SEE THE SMARTFUSE APP SIMPLIFY ELECTROFUSION
FULL BORE BALL VALVES
Want valves and flow control options that are leak-proof, corrosion-resistant to replace your old traditional metal valves?
PLASSON Ball valves are made of quality UV resistant materials so they are resistant to corrosion. Being full bore means they also offer excellent functionality, reliability and long system life.
Available in both long and short handle options, PLASSON Ball Valves are designed to stand up to Australian conditions and cope well in corrosive environments.
PLASSON valves have been keeping Australia flowing for over 40 years
All PLASSON ball valves operate under a range of temperatures and pressures. Made from tough, UV resistant materials, our valves also cope with aggressive fluids and are corrosion-resistant.
Our Ball Valves are quick and easy to install. A simple on/off action puts flow control at your finger tips. The range also includes a lockable option for situations were security is key.
PLASSON LONG AND SHORT HANDLED BALL VALVES
With high quality injection moulded plastic components and NBR O-rings, PLASSON valves deliver years of reliable service.
PLASSON QCV – IT’S EASY TO GO WITH THE FLOW
Who doesn’t want simple and cost-effective control of their water… life is complicated enough as it is! That’s why PLASSON developed the
Quick Coupling Valve. This handy device allows pressurized water to be turned off and on with a simple click in key.
Usually installed at ground level, the QCV internal valve is normally closed so water does not leak out. The valve is activated by lifting the flipcap and inserting the “KEY”. On top of the key you can insert a sprinkler or a hose.
QCV’s deliver cost-effective irrigation and stock watering without complicated systems or software.
Click here to watch our simple install video…
SMARTFUSE 180 EF CONTROL BOX: OVERVIEW
PLASSON’s SmartFuse 180 is an entry-level electrofusion welding machine designed to weld PLASSON fittings up to DN180. Features include:
• Lightweight, weighs less than 14 kg
• Compact (470 x 370 x 180 mm)
• Bluetooth enabled for smartphones using PLASSON SmartFuse App
• Use app to automatically determine and record welding parameters
• 10 Amp plug
• Tough weather-proof carry case
• 3 m lead
SEE WHAT IS IN THE BOX: PLASSON SMARTFUSE 180
NOTE: To achieve quality EF welds, it is key to use tooling specficially designed to EF welding and to follow all best practice procedure outlined in POP001.
It is also important to ensure equipment, such as EF welding control boxes, that require calibration has been calibrated. PLASSON recommends control boxes are serviced every 12 months or after 200 hours of use, which ever comes first.