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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
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CepexSalesFolder12/2006
07PE100 Fittings
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▪ 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.
Introduction
Cepex Sales Folder07PE100 Fittings
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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 isthe higher density and higher resistance polyethylene available, which makes it idealfor more demanding applications.
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Advantages & Disadvantages
The PE100 is a structurally superior polyethylene Use of polyethylene wide spreadingVery good chemical resistanceReduced thermal expansionIdeal for underground installations due to its flexibilityWelded unions offer very good reliability and safetyComfortable and easy use of the welding tools on the electroweldable fittings
Cost: electrowelding machines and tools and electroweldable fittings are expensiveThe welding process requires following precise proceduresHigh expansion coefficientNon-detachable unions
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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 16SDR 17 – PN 10
Welding machinery & tools:▪ For electrofusion (multi-voltage / manual) or butt welding (electric / hydraulic) and all the required tools.
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Cepex PE100 valves
Cepex Sales Folder
PE100 compact ball valve- 100% PE100 made valve- D32 - D180- PN10
PVC-U / PVC-C
PVC-U or PVC-C industrial ball valve- With PE100 sockets for butt welding (or electrofusionwith electroweldable “long spigots”)- D16 - D110- PN16/PN10 according to size
PE100
PE100
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
PP-H
PE100
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Range
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Cepex PE100 fittings:
Electrofusion welding
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Cepex Sales Folder
- 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
Cepex PE100 fittings: electrofusion welding
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Cepex Sales Folder
Cepex PE100 fittings: electrofusion welding
Tips. They connect the socket to the welding machine.
Welding indicators (“witness or informer”). Indicates that the weld is correct.
Welding areas
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Cepex PE100 fittings: electrofusion welding
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▪ 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)
Electrofusion welding operation
Cepex Sales Folder
▪ 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)
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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
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▪ 3. Getting Rid of OvalizationThe ovality of the pipes in the fusion zone mustn’t 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 mustn’t be less than 96% by volume).
Electrofusion welding operation
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Cepex Sales Folder
▪ 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)
Electrofusion welding operation
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Features & advantages
-100% PE100 made ball valves.-PVC-U/PVC-C ball valves with long spigot sockets for welding.- Industrial butterfly valves with PP-H discs.
Compatible with Cepex valves
All the required elements easily availableWelding machines (multivoltage) and tools available on the market.
Allows material changes in the installation.Stainless steel transition fittings available
Reliable welding.Welding indicators on each node
Easy, quick and comfortable installationFusion parameters are transferred to the machine from this label either manually or by using the barcode reader. (automatic-reading machinery required)
One fitting is compatible with SDR11, SDR17 / PE100, PE80 pipes.Interior fusion of pipe and socket
AdvantageFeature
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Cepex PE100 fittings:
Butt welding
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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.
Cepex PE100 fittings: butt welding
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Cepex Sales Folder
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 coolingThe value of the parameters vary with the kind of material used, dimensions and temperature. The pipe manufacturer usually specifies the welding parameters.
Cepex PE100 fittings: butt welding
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Cepex PE100 fittings: butt welding
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Pipe/pipe
Pipe/fitting
Cepex PE100 fittings: butt welding
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Electrically driven butt welding device
Cepex PE100 fittings: butt welding
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▪ 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).
Installation
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Pipe positioning in the welding machine
Installation
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Facing
Installation
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Max. 0,5mmAdjustment tolerance
Installation
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Max. 10% of the whole thickness Alignment tolerance
Installation
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Heating of the pipes
Installation
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Fusion of both ends
Installation
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> 0
L
= =
Mín MáxWeld bracelet inspection
Installation
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All the required elements easily availableWelding machines (multivoltage) and tools available on the market.
-100% PE100 made ball valves.-PVC-U/PVC-C ball valves with long spigot sockets for welding.- Industrial butterfly valves with PP-H discs.
Compatible with Cepex valves
AdvantageFeature
Adapted to different conduction systemsTwo butt welding ranges: SDR11 y SDR17
Allows material changes in the installation.Stainless steel transition fittings available
Adapted to different installation necessitiesLong type fitting (or short under order)
Cepex Sales Folder
Features & advantages
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▪ Welding done almost automatically
▪ The thickness increases with the weld: no strength loss.
▪ Keeps the pressure in the pipe constant.
▪ The diameter of the pipe increases with the diameter of the fittings, interior diameter stays the same.
▪ Needs great ability to ensure good welding.
▪ The union weakens as the thickness diminishes during the welding process.
▪ The system’s 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.
Electrofusion Butt welding
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Cepex Sales Folder
▪ 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.
Electrofusion Butt welding
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Cepex Sales Folder
Visible unions (veryreliable if verified by
an expert)DifficultHigh
Large diameters- not recommended < D90
- D90-D315: electrofusion or buttwelding, depending on the cost, welding
speed, instalation, etc. - specially indicated > D315
Butt welding
Welding indicatorsAutomatic (bar-code reader)
High whenmany unions
Small diameters- recommended < D90
- D90-D315: electrofusion or butt welding, depending on the cost, welding speed,
instalation, etc. - expensive > D315
Electrofusion
ReliabilityOperationFusion costSize
Summary
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Certificates
▪ Polyethylene fittingssold by Cepex are certificated by DVGW forwater and gas.
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Applications
▪ Residual water transportation▪ Purifying and water treatment▪ Solids transportation▪ Industrial plants▪ Drinkable water and gas distribution▪ irrigation systems
Preparation for butt welding
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Butt welding finished
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Applications
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Comparative table (vs. Competition)
Cepex Sales Folder
Cepex GF Friatec FIP Agru Plasson / Fusion Uponor Geco Plastitalia BanningerTega / Varios Elgef Frialen Durafuse Agruline Fusamatic Aldyl Elofit
Pais España Suiza Alemania Italia Austria Israel / UK Finlandia Italia Italia Alemania
Gama Electro + Tope Electro + Tope Electro Electro + Tope Electro + Tope Electro Electro Electro + Tope Electro + Tope Tope
Materiales PE100 PE100 PE100 PE100 / PE80 PE100 / PE80 PE100 PE100 PE100 PE100 / PE80 PE100
Medidas electrofusión 20-1000 20-500 20-710 20-400 20-400 20-400 20-315 20-630 20-400 -
Voltaje varios 40V 40V 40V 40V - 40V 40V - -
Medidas tope 20-450 20-500 - 25-315 20-315 - - 25-400 20-1000 25-400
Maquinaria soldadura SI SI SI SI SI SI NO SI SI SI
Estética Buena Muy buena Buena Buena Muy buena Muy buena Buena Buena Buena Buena
Nivel de precio Medio Medio-alto Medio-alto Medio-alto Alto Medio-alto Medio Medio Medio Medio
Certificaciones DVGW DVGW, IIP - DVGW, IIP, ... OVGW, DVGW DVGW, IIP, ... - DVGW, IIP, ... IIP, KIWA, ... DVGW, IIP, ...
Otros www.cepex.com www.piping.georgfischer.com www.friatec.de www.fipnet.it www.agru.at www.plasson.com www.uponoraldyl
.com.arwww.gecosystem
.comwww.plastitaliasp
a.comwww.baenninger.
de
www.fusiongroup.co.uk
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Certificated product DVGW (Alemania)Company with great experience in gas distribution.
Commercialized product from Turkey (Tega)
Butt welding- Complete range (figures and sizes) from Tegaand 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.
This is no problem with the units used nowadays internationally (bar-code reading).
Products with different voltages (not only 40 V)
Certificated product DVGW (Alemania)Company with great experience in gas distribution.
Commercialized product from Turkey (Tega)Electroweldable fittings
- Very large range: electroweldable sockets, available with different wall thicknesses (PN’s) 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.
How to refute themCepex’s weaknesses
according to thecompetition
Cepex’s Strengths
Cepex Sales Folder
Comparative table (vs. Competition)
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CAD
▪ 3D/2D CAD Library
- Free 3D & 2D downloadableproducts on www.cepex.com.
- Complete Cepex product rangeavailable.
- Multiformat.
- Multilingual.
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CepexSalesFolder12/2006
COPYRIGHT © CEPEX HOLDING, S.A.
Av. Ramon Ciurans, 40Pol. Ind. Congost - Parcel·la 608530 La Garriga (Barcelona) [email protected]
01 PVC Pressure Fittings02 PP Compression Fittings03.s Ball Valves [STD] Series NEW!03.i Ball Valves [IND] Series NEW!03 Ball Valves04 Check Valves05.s Butterfly Valves Standard Series NEW!05.i Butterfly Valves Industrial Series NEW!05.c Butterfly Valves Classic Series06 Valve Boxes Pro Series07 PE100 Fittings08 PVC Flexible Pipe09 Actuated Valves10 Hydraulic Valves11 Filtration
A Plastics MarketB Fluid DynamicsC Plastic TypesD Union TypesE Quality Tests