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Utilities - Continual Improvement PE Welding Electro Fusion Pressure Testing Steve Gordon
32

PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Aug 26, 2018

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Page 1: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Utilities - Continual Improvement

PE Welding

• Electro Fusion

• Pressure Testing

Steve Gordon

Page 2: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

PE Jointing Fusion Welding

Page 3: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Electrofusion Welding of PE

Ideally, this System Should perform like this:

Page 4: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Service Failures of Electrofusion Joints

And not this:

Page 5: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Electrofusion Fitting Failures

• Majority of problems seen are:

• Unsatisfactory training• Poor welding practices: Clamping (Misalignment),

Scraping, Moisture and Contamination• Poor or unsuitable equipment• Excessive pipe ovality

Page 6: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Training perception of trench welding?

Page 7: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Reality

…. in Summer

Page 8: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Understanding Electro Fusion Welding Principles

• Prepare

• Align

• Cook

• Cool

Page 9: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Why do we scrape pe pipes?

Pigmentation

UV Stabiliser Packages

Oxidisation 1,2,3

Page 10: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

SCRAPING

What type is suitable?

Page 11: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

PREFERRED METHOD

Mechanical scrapers provide a uniformed removal of between 0.2 to 0.4mm during pipe end preparation

Page 12: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Hand Scraping

Page 13: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

CONTAMINATION

Page 14: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

CONTAMINATION

When contamination is present on the pipe or coupler, fusion becomes increasing more difficult to achieve!

Page 15: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

WIS 4 32 08

>75% Ductile and K > 1.7 Pass Satisfactory

<75% Ductile and K > 1.7 Technical failure Problems very unlikely

<75% Ductile and 1.2<K<1.7 Non-critical failure Problems unlikely

<75% ductile and K < 1.2 Critical failure Problems likely

Page 16: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

CONTAMINATION

The use of protective shelters prevents additional contamination entering the

jointing area!

Page 17: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

ALIGNMENT - OVALITY

Suitable alignment clamps can assist with re-rounding of

pipe

Page 18: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

MISALIGNMENT

Page 19: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

MISALIGNMENT

5

Pipe misaligned into EF fitting

During fusion heat & pressure create movement of wires

Page 20: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

MISALIGNMENT

6,7,8

Page 21: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Clamping/ Misalignment• Misalignment• Wire movement• Overheating

Page 22: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Why Audit – what do we find?

Page 23: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Improving Site Quality

• Site PE Audits, Testing and coaching• Giving clients and partners an understanding of the quality being installed. • Highlights any potential failures

Page 24: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

ENERGY GRAPH: DUCTILE JOINT

Elongation (mm)

Forc

e (N

)

16,17,18,19

Page 25: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

ENERGY GRAPH: BRITTLE JOINT

Elongation (mm)

Forc

e (N

)

20,21,22

Page 26: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Lab UKAS Schedule –Failure Investigation

Page 27: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Pressure Testing

Page 28: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Type 2 Test Analysis

n< 0.04

0.04 < n < 0.050.05 < n < 0.080.08 < n < 0.10

n > 0.10

AssessmentAir Indicated

Pass Compacted GroundPass Intermediate Ground

Pass Exposed PipeLeakage Indicated

Page 29: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Expected PE Decay Curves

Decay Time/ Pressurisation Time = Regression Time

HPPE (PE100) SDR 11 (16 bar)

16

17

18

19

20

21

22

23

24

0 2 4 6 8 10 12 14 16

Pres

sure

(bar

)

Leak Suspected

Air Suspected

Compacted

Intermediate

Without constraint

0.04

0.05

0.08

0.10

Slipline/ PIM

Backfilled

DecaySlopes

Page 30: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Type 2 Test: Analysis

0

5

10

15

20

0 20 40 60 80 100 120 140 160Elapsed Test Time (min)

Pres

sure

(bar

)

RampTime

1 x 8 x 20 x

n1 n2

Page 31: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Pressure Test Equipment: Loggers

GPS Data Log Technology (ANT Hire)•No more down time for operator as test is remotely accessed•Remote dialling access allows instant results for critical tests •Validation of test data and location is confirmed•Individual web access (paper-less trail) Professional analysis at lower costs (Exova)

Pressure Test

Page 32: PE Welding • Electro Fusion • Pressure Testing Steve Gordon · PE Welding • Electro Fusion • Pressure Testing Steve Gordon. PE Jointing ... Slipline/ PIM Backfilled Decay

Thank you

Questions?