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9 Jointing techniques
9.1 Health and safety regulations
There is always a certain risk of injury when operating with
plastic pipe welding machines. Observation of the following
accident prevention regulations reduces this danger to a
minimum. Non-observation of them can lead to accidents!
Safety instruction
The general industrial hygiene and accident prevention regulations of the
particular country or state in which the device is to be used, are to be
observed.
Wear suitable work clothing
Jointing techniques
9.2 Socket welding
Heating-up Processing
time
time
Coolingdown time
(mm)
(mm)
(sec)
(sec)
(min)
16
20
25
32
40
50
63
75
90
110
125
13
14
15
17
18
20
26
29
32
35
41
5
5
7
8
12
18
24
30
40
50
60
4
4
4
6
6
6
8
8
8
8
10
2
2
2
4
4
4
6
8
8
8
8
Jointing techniques
9.2.2 Socket welding - mechanical
This jointing technique is suitable for d75-125 mm.
The described process is according guidelines DVS 2207 Part 11.
Welding device
The axial movements are brought about
by a transport wheel and a toothed
rod. V-shaped clamping tools of hardened steel are for holding the components independently of their external
diameter. Two V-shaped clamps for pipe
fixation and a single one with insert
stop are for fitting fixation. The two tool
carriages can be aligned axially. The
insertion depth is limited by a stop. The
electronically controlled heating plate
can be swung into the machine.
Illustration 9.1
Illustration 9.2
Heating-up Processing
time
time
Coolingdown time
(mm)
(mm)
(sec.)
(sec.)
(min.)
16
20
25
32
40
50
63
75
90
110
125
13
14
15
17
18
20
26
29
32
35
41
5
5
7
8
12
18
24
30
40
50
60
4
4
4
6
6
6
8
8
8
8
10
2
2
2
4
4
4
6
8
8
8
8
Jointing techniques
9.2.3 Weld-in saddle welding
The Wefatherm weld-in saddles weld both the pipe outer surface and the
wall thickness of the pipe for a reliable joining.
Advantages
- realizing additional tees on distribution lines
- afterwards addition of sensors (thermometer, pressure gauge)
- construction of tees
Weld-in saddles can be used for PP-R and PP-R stabi pipes.
Installation
1. Drill a hole into the pipe with drill
Art. Nr. 5150 30070.
Notice the depth of the drill.
Jointing techniques
9.3 Butt-welding
This jointing technique is suitable for d160-315 mm.
The described process is according guideline DVS 2207 Part11.
Butt-welding is a very economical and reliable jointing technique in
which an additional tool is required to create the non-detachable joint.
Butt-welding is very well-suited to the pre-fabrication of pipe elements
and the construction of special fittings. In butt-welding, the welding surfaces (ends) of the components to be welded are first machined (planed).
This produces coplanar ends that can later be simultaneously pressed
against the heating element. The welding surfaces are then heated by
the heating element (hot plate) and lined up under slight pressure (alignment pressure). Subsequently, heating proceeds under reduced pressure
(heating time) and, after removing the heating element (conversion), the
joint is formed under welding pressure. Table 9.3 provides a schematic
representation of the butt-welding process.
Delta 250B
DVS 2207-11 (02/99)
PP
1
D
(mm)
s
(mm)
160
160
160
160
200
200
200
200
250
250
250
14,6
17,8
21,9
26,6
18,4
22,3
27,4
33,2
22,7
27,8
34,2
SDR
=
D/s
11
9
7,4
6
11
9
7,4
6
11
9
7,4
T
(oC)
*P1
(bar)
210
210
210
210
210
210
210
210
210
210
210
7
13
16
19
18
21
25
30
28
33
39
1,0
1,0
1,55
2,0
1,0
1,5
2,0
2,0
1,5
2,0
2,0
P2
(bar)
t2
(sec)
3
t3 max
(sec)
4
t4
(sec)
*P5
(bar)
5
t5
(min)
1
1
2
2
2
2
3
3
3
3
4
277
315
359
405
320
363
411
456
367
414
463
8
9
10
11
9
10
11
13
10
11
13
13
16
19
23
16
19
23
29
20
24
29
11
13
16
19
18
21
25
30
28
33
39
24
28
34
41
29
35
42
50
35
42
51
Table 9.3 Add to this value the drag pressure of the welding machine
Jointing techniques
9.4 Electrofusion welding
This jointing technique is suitable for d20-315 mm. The descibed process
is according guideline DVS 2207 Part 11.
Installation
1.
2.
3.
4.
5.
At the end of the welding cycle wait for the cooling time. After the cooling
time you can stress the electrofusion joint to the permissible operating
pressure.
d
(mm)
16- 32
40- 63
75-110
125
160-200
250-315
Table 9.4
Cooling time
(min)
10
25
40
45
75
100
Jointing techniques
9.5 Flange jointing
Re-tightening
- Bolt joints which are exposed to extreme thermic cycles
- Only at ambient temperature and pressure
- Consult manufacturers advice about retightening pressure of bolts
Re-tightening, manufacturers advice
Due to the reduced weight and the profile shape of the backing ring the
need to re-tighten the fasteners is eliminated. The unique flange shape,
acting like a 'Belleville washer', brings about the additional energy
storage needed to overcome any thermoplastic material cold flow conditions. The design shape of the flanges is based on FEM calculations
(Finite Element Method) whereby special considerations have been given
to the thermoplastic stub end. For all flanges a safety factor of 2 is guaranteed on the yield strength of the material for the stated Maximum
Operating Pressure (MOP). For increased temperatures (>20C) it remains
advisable to inspect the flange joint periodical and re-tighten the fasteners if necessary.
Illustration 9.4
Bolt tightening
1. Install all the bolts and nuts finger tight,
ensuring at all times that the alignment is
correct.
2. As the first torqueing step, tighten the
bolts in a crisscross sequence as shown in
illustration 9.5. Using a torque wrench
with 20% of the final torque listed in
table 9.5, taking care that points 1 and 2,
are satisfied at all times.
Illustration 9.5
3. In the four remaining steps, repeat step
two four times, each time increasing the
torque by 20% of the final value.
4. After reaching the final torque, use rotational tightening until all bolts
are stable at the final torque value (in general two complete times
around is required).
Always use the crisscross pattern!
DN
(mm)
Bolt hole
Profile gasket
(pacc 16 bar)
O-ring gasket
(pacc 16 bar)
32
40
50
63
75
90
110
125
160
200
250
315
25
32
40
50
65
80
100
100
150
200
250
300
85
100
110
125
145
160
180
180
240
295
350
400
14
18
18
18
18
18
18
18
22
22
22
22
M12
M16
M16
M16
M16
M16
M16
M16
M20
M20 *)
M20 *)
M20 *)
16
16
16
16
16
16
16
16
16
16
16
16
15
20
25
35
40
40
50
50
60
75
95
100
4
4
4
4
4
8
8
8
8
8
12
12
*) Pacc 6 bar for elastomer sealing and accumulated friction factor R = 0,15
Table 9.5 Standard values for torque (DVS 2210 part 1)