Cepex Sales Folder

12/2006

07
PE100 Fittings
1

07 PE100 Fittings

Cepex Sales Folder

Introduction
PE fittings for PE100 pipe unions (3rd generation PE) Any PE pipeline design for fluid conduction and distribution is possible by choosing the appropriate combination of accessories. Unions: - Electrofusion. Quick and easy welding technique for non-detachable unions. This union is obtained by means of resistances located inside the fittings.

- Butt welding. The pipes and/or the fittings are aligned under pressure onto a heating element, then, the parts are joined under pressure after the heating plate has been removed.

07 PE100 Fittings

Cepex Sales Folder

Introduction: PE pipes
The use of PE pipes is very spread, because of the many advantages they present, some of which we could emphasize: - Lightness - Flexibility - High impact and corrosion resistance - Long lasting life - Due to less frictional resistance, less pressure losses. - Freeze and radiation resistant - Weathering resistance In addition to these properties, the PE100 is the higher density and higher resistance polyethylene available, which makes it ideal for more demanding applications.
3

07 PE100 Fittings

Cepex Sales Folder

Advantages & Disadvantages

The PE100 is a structurally superior polyethylene Use of polyethylene wide spreading Very good chemical resistance Reduced thermal expansion Ideal for underground installations due to its flexibility Welded unions offer very good reliability and safety Comfortable and easy use of the welding tools on the electroweldable fittings

Cost: electrowelding machines and tools and electroweldable fittings are expensive The welding process requires following precise procedures High expansion coefficient Non-detachable unions
4

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings

Electroweldable fittings: Sizes: from D.20 to D.400 Sockets, elbows, tees, reducers, caps, flange adaptor sockets, unions, flanges. Butt welding fittings: Sizes: from D.25 to D.400 Elbows, tees, reducers, caps, clamp saddles. SDR-PN equivalence: SDR 11 PN 16 SDR 17 PN 10 Welding machinery & tools: For electrofusion (multi-voltage / manual) or butt welding (electric / hydraulic) and all the required tools.
5

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 valves

PE100 PE100 compact ball valve - 100% PE100 made valve - D32 - D180 - PN10

PE100 PE100 PVC-U / PVC-C

PVC-U or PVC-C industrial ball valve - With PE100 sockets for butt welding (or electrofusion with electroweldable long spigots) - D16 - D110 - PN16/PN10 according to size

PP-H

Industrial butterfly valves (new generation) - Includes a PP-H disc. The PP-H has properties (thermal and chemical resistance) that make it specially adapted to PE piping installations - Assembly with flanges - PN10
6

07 PE100 Fittings

Cepex Sales Folder

Range

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: Electrofusion welding

8

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: electrofusion welding

- All electrofusion fittings employ the same basic principle. -Plain pipes are jointed by means of electrofusion (EF) fitting incorporating an electrical heating coil which when electrically activated for the appropriated time by EF welding machine, melts the surface of the pipe&fitting together resulting in complete fusion of the pipe and EF fitting

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: electrofusion welding

Welding indicators (witness or informer). Indicates that the weld is correct. Tips. They connect the socket to the welding machine.

Welding areas

10

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: electrofusion welding

11

07 PE100 Fittings

Cepex Sales Folder

Electrofusion welding operation

1. Pipe cutting. For the pipe cutting, a suitable cutter for plastics must be used. The pipes are to be cut square with this cutting tool. If the pipe is not cut at right angles, this results in contact between heating coils and the pipe, which causes uncontrolled flow of molten due to overheating. (illustrated in Fig. 1) 2. Marking and scrapping of the fusion zone: Fusion zone which is the insertion depth of fitting, must be marked with a marker on the pipe end or on the spigot end. (illustrated in Fig. 2) Cepex couplers have their own stoppers at the center so that the insertion depth can be determined easily. In order to remove the oxide layer of the pipe, scrape carefully the fusion zone using a hand scraper. (illustrated in Fig. 3)

12

07 PE100 Fittings

Cepex Sales Folder

Electrofusion welding operation

The prepared surface must be protected against unfavorable weather conditions. After that,the internal edge must be deburred and the outher edge rounded off as illustrated in fig. 4 3. Getting Rid of Ovalization The ovality of the pipes in the fusion zone mustnt be more than 1.5 % of the outer diameter of the pipe. If necessary, reround clamps must be used 4. Degreasing of the Fusion Zone: The prepared end or spigot end and internal face of coupler must be degreased with a suitable cleaning agent and a white absorbent and non fibrous paper. (illustrated in Fig. 5). As a cleaning agent; trichloroethane or alcohol can be used (The alcohol content mustnt be less than 96% by volume).

13

07 PE100 Fittings

Cepex Sales Folder

Electrofusion welding operation

5. Inserting of the pipe end or spigot end into the coupler: Inserting of the pipe end or spigot end into the coupler must be done without causing any tilting with respect to each others. (Fig. 6)

6. Fusion: Provided that the information given in the operating instructions are followed step by step and there is no problem, the fusion process can be started after data of the coupler is set to the fusion control unit by manually or by means of bar-code reader. (Fig. 7)

14

07 PE100 Fittings

Cepex Sales Folder

Features & advantages

Feature Fusion parameters are transferred to the machine from this label either manually or by using the barcode reader. (automatic-reading machinery required) Interior fusion of pipe and socket Stainless steel transition fittings available Welding indicators on each node Advantage Easy, quick and comfortable installation One fitting is compatible with SDR11, SDR17 / PE100, PE80 pipes. Allows material changes in the installation. Reliable welding. -100% PE100 made ball valves. -PVC-U/PVC-C ball valves with long spigot sockets for welding. - Industrial butterfly valves with PP-H discs. All the required elements easily available

Compatible with Cepex valves

Welding machines (multivoltage) and tools available on the market.

15

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: Butt welding

16

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: butt welding

Butt welding is a common union method for PE and PP pipes. This type of welding process has to be carried out by experienced professionals. The welding operation instructions provided by the manufacturer have to be followed carefully. Butt welding can be used on 1600mm diameter pipes. Butt welding has to be performed by means of a welding device. The end of the pipes that have to be welded have to be centred and held together in the welding device, after this the end-sections have to be cleaned and rust-free and then levelled. The pipes and/or the fittings are aligned under pressure onto a heating element: the parts are then joined under pressure after the heating plate has been removed. Part of the melted material will show up as a round bracelet.(see installation Fig.). The joint will have to cool off under pressure. The weld edges are usually left at the end of the joint.
17

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: butt welding

Fusion parameters for butt welding: The strength of welded joint depends on the way the welding has been done. The cleaning of the surfaces welded, thus how the use of correct parameters of weld during the weld is important. The most important parameters are: Metal plate temperature Pressure inside the bearings necessary heating time Re-adjustment time (delay time before removing the heating plate) Welding pressure Time of cooling The value of the parameters vary with the kind of material used, dimensions and temperature. The pipe manufacturer usually specifies the welding parameters.

18

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: butt welding

19

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: butt welding

Pipe/pipe

Pipe/fitting

20

07 PE100 Fittings

Cepex Sales Folder

Cepex PE100 fittings: butt welding

Electrically driven butt welding device

21

07 PE100 Fittings

Cepex Sales Folder

Installation
Butt welding: the manufacturer will provide to the customer a table with the pressure and temperatures required to weld different diameters; this data is introduced in the welding machine, and the welding is then done semi-automatically (but requires human presence to ensure a correct finishing).

22

07 PE100 Fittings

Cepex Sales Folder

Installation
Pipe positioning in the welding machine

23

07 PE100 Fittings

Cepex Sales Folder

Installation
Facing

24

07 PE100 Fittings

Cepex Sales Folder

Installation
Adjustment tolerance Max. 0,5mm

25

07 PE100 Fittings

Cepex Sales Folder

Installation
Max. 10% of the whole thickness Alignment tolerance

26

07 PE100 Fittings

Cepex Sales Folder

Installation
Heating of the pipes

27

07 PE100 Fittings

Cepex Sales Folder

Installation
Fusion of both ends

28

07 PE100 Fittings

Cepex Sales Folder

Installation
Weld bracelet inspection

Mn

Mx

>0

=
29

07 PE100 Fittings

Cepex Sales Folder

Features & advantages

Feature Long type fitting (or short under order) Two butt welding ranges: SDR11 y SDR17 Stainless steel transition fittings available Advantage Adapted to different installation necessities Adapted to different conduction systems Allows material changes in the installation. -100% PE100 made ball valves. -PVC-U/PVC-C ball valves with long spigot sockets for welding. - Industrial butterfly valves with PP-H discs. All the required elements easily available

Compatible with Cepex valves

Welding machines (multivoltage) and tools available on the market.

30

07 PE100 Fittings

Cepex Sales Folder

Electrofusion

Butt welding

Welding done almost automatically The thickness increases with the weld: no strength loss. Keeps the pressure in the pipe constant.

Needs great ability to ensure good welding. The union weakens as the thickness diminishes during the welding process. The systems pressure is 20% reduced when butt welding used; so, to maintain PN 10, SDR11 has to be used (which is more expensive and cannot be used for PN 16) . Interior pipe diameter diminishes.

The diameter of the pipe increases with the diameter of the fittings, interior diameter stays the same.

31

07 PE100 Fittings

Cepex Sales Folder

Electrofusion

Butt welding

More economical fusion-welding machine but need to add couplers in each union (more expensive with a lot of system unions). Machinery suitable for all diameters. Process used on small diameters. Large diameters do exist but are very expensive. Higher fusion speed.

Welding machine is very expensive (would be profitable only if used often). Straight union (pipe-pipe union) does not need fitting. Heavy machinery and different for large and small diameters. This method is used overall for large diameters where electrofusion cannot be used. Under D.90, pipe walls are to thin and make the whole butt welding process difficult. Longer welding time.
32

07 PE100 Fittings

Cepex Sales Folder

Summary

Size Small diameters Electrofusion

- recommended < D90 - D90-D315: electrofusion or butt welding, depending on the cost, welding speed, instalation, etc. - expensive > D315

Fusion cost

Operation

Reliability

High when many unions

Automatic (barcode reader)

Welding indicators

Large diameters Butt welding

- not recommended < D90 - D90-D315: electrofusion or butt welding, depending on the cost, welding speed, instalation, etc. - specially indicated > D315

High

Difficult

Visible unions (very reliable if verified by an expert)

33

07 PE100 Fittings

Cepex Sales Folder

Certificates
Polyethylene fittings sold by Cepex are certificated by DVGW for water and gas.

34

07 PE100 Fittings

Cepex Sales Folder

Applications
Residual water transportation Purifying and water treatment Solids transportation Industrial plants Drinkable water and gas distribution irrigation systems

Preparation for butt welding

Butt welding finished

35

07 PE100 Fittings

Cepex Sales Folder

Applications

36

07 PE100 Fittings

Cepex Sales Folder

Comparative table (vs. Competition)

Cepex Tega / Varios Pais Espaa

GF Elgef Suiza Electro + Tope PE100 20-500 40V 20-500 SI Muy buena Medio-alto DVGW, IIP www.piping.geor gfischer.com

Friatec Frialen Alemania Electro PE100 20-710 40V SI Buena Medio-alto www.friatec.de

FIP Durafuse Italia Electro + Tope PE100 / PE80 20-400 40V 25-315 SI Buena Medio-alto DVGW, IIP, ... www.fipnet.it

Agru Agruline Austria Electro + Tope PE100 / PE80 20-400 40V 20-315 SI Muy buena Alto OVGW, DVGW www.agru.at

Plasson / Fusion Fusamatic Israel / UK Electro PE100 20-400 SI Muy buena Medio-alto DVGW, IIP, ... www.plasson.com www.fusiongroup.co.uk

Uponor Aldyl Finlandia Electro PE100 20-315 40V NO Buena Medio -

Geco Elofit Italia Electro + Tope PE100 20-630 40V 25-400 SI Buena Medio DVGW, IIP, ...

Plastitalia

Banninger

Italia Electro + Tope PE100 / PE80 20-400 20-1000 SI Buena Medio IIP, KIWA, ...

Alemania Tope PE100 25-400 SI Buena Medio DVGW, IIP, ...

Gama Electro + Tope Materiales Medidas electrofusin Voltaje Medidas tope Maquinaria soldadura Esttica Nivel de precio Certificaciones PE100 20-1000 varios 20-450 SI Buena Medio DVGW

Otros www.cepex.com

www.uponoraldyl www.gecosystem www.plastitaliasp www.baenninger. .com.ar .com a.com de

37

07 PE100 Fittings

Cepex Sales Folder

Comparative table (vs. Competition)

Cepexs Strengths Cepexs weaknesses according to the competition
Commercialized product from Turkey (Tega)

How to refute them

Electroweldable fittings - Very large range: electroweldable sockets, available with different wall thicknesses (PNs) allows us to give specific solutions to specific needs. - DVGW certification (Germany) - Water and gas - Own made welding machines (Tega), even with an incorporated GPS. - Very competitive prices.

Certificated product DVGW (Alemania) Company with great experience in gas distribution.

Products with different voltages (not only 40 V)

This is no problem with the units used nowadays internationally (bar-code reading).

Butt welding - Complete range (figures and sizes) from Tega and Banninger. - Long spigot version, compatible with electroweldable sockets. - SDR11 & SDR17 - DVGW certification (Germany) - IIP certification (Banniner) - Welding machines (Acuster) electrically or hydraulically driven - Very competitive prices.

Commercialized product from Turkey (Tega)

Certificated product DVGW (Alemania) Company with great experience in gas distribution.

38

07 PE100 Fittings

Cepex Sales Folder

CAD
3D/2D CAD Library - Free 3D & 2D downloadable products on www.cepex.com. - Complete Cepex product range available. - Multiformat. - Multilingual.

39

07 PE100 Fittings

Cepex Sales Folder

40

Cepex Sales Folder

12/2006
01 PVC Pressure Fittings 02 PP Compression Fittings 03.s Ball Valves [STD] Series NEW! 03.i Ball Valves [IND] Series NEW! 03 Ball Valves 04 Check Valves 05.s Butterfly Valves Standard Series NEW! 05.i Butterfly Valves Industrial Series NEW! 05.c Butterfly Valves Classic Series 06 Valve Boxes Pro Series 07 PE100 Fittings 08 PVC Flexible Pipe 09 Actuated Valves 10 Hydraulic Valves 11 Filtration A Plastics Market B Fluid Dynamics C Plastic Types D Union Types E Quality Tests

COPYRIGHT CEPEX HOLDING, S.A. Av. Ramon Ciurans, 40 Pol. Ind. Congost - Parcella 6 08530 La Garriga (Barcelona) Spain cepex@cepex.com www.cepex.com

41