» Welding and Installing
PT. Jaya Terus Multiniaga is a head for improving polyethylene welding techniques and providing engineering support in Indonesia. We offer full technical support to our customers regarding pipe design, hydraulic and static calculations , welding and installation. With 18 years experience in HDPE pipe installation and our well-trained technicians who certified by ROTHENBERGER ,we fulfill all your needs in HDPE piping system.
PT. Jaya Terus Multiniaga provides initial site survey, preliminary design and opinion of probable cost and complete installation service for PPR & HDPE pipeline projects.
We are specialize in PPR & HDPE :
- large diameter piping, pressure piping, pipeline planning, sizing and performance criteria.
LET US BE YOUR PPR & HDPE PIPING SYSTEMS EXPERTS AND
ANSWER TO YOUR PPR & HDPE PIPING QUESTIONS
we have more than 18 years experience in PPR & HDPE pipes and fittings installation are joined by thermal or mechanical systems.
Thermal butt fusion provides an economical and fast method of delivering a complete, long continuous length of pipe. The fused joints are as strong as the pipe itself, providing a continuous leak proof system.
A-Heat Fusion Joining:
The most important thermal methods are butt-welding and electrofusion welding.
- Butt-Welding: The most widely used method for joining PE pipe is butt fusion. Butt welding is the only option for connecting large pipes with diameter bigger than 500 mm. In this method, the joined faces are heated to welding temperature with hot tool. Then the hot tool is removed and the plasticized pipe ends are pressed together.
- Electrofusion Welding: In electrofusion welding socket fittings containing resistance coils are used to join the pipes.
The quality of the heat fusion weld depends on the competence of welder, the suitability of machinery and equipment used, and welding guidelines.
B- Mechanical joining:
Mechanical compression Fitting has a body which is a pressure-containing component that fits over the outside diameter of polyethylene pipe.
Our well-trained staff have been certified by ROTHENBERGER from Germany and perform the welding process August 2009.
Our qualified and expert technicians use high-tech welding machines (we mainly use MCA Calder and Rothenberger ) to enhance the efficiency, productivity and safety of their job.
PT. Jaya Terus Multiniaga welding staff are available for every given time frame.
C- Socket Fusion Jointing
In this form of fusion jointing, which requires heating tools, the pipe end is inserted into the socket of the fitting : no additional material is used. The pipe end and fitting socket are heated to fusion temperature using a heating bush and a heating spigot, respectively, and are then pushed together.
The pipe end, fitting socket and heating tools correspond together in such a way that the necessary jointing pressure is attained during jointing, resulting in a homogeneous joint.
The basic rule is that only similar materials can be fusion jointed, i.e. PE with PE.
PE socket fusion joints may be used at operating pressures up to a maximum of 10 bar at 20ºC (water).
In socket fusion, attention must be paid to pipe minimum wall thicknesses.
Apart from the tools normally used in plastic pipework construction, such as pipe cutters or a saw with a cutting guide, the socket fusion jointing method requires certain special tools.
Pipe Peeling and Chamfering Tool
This tool serves to calibrate the pipe end and to mark the length of the fusion joint. At the same time it removes the oxidized layer built up as a result of UV radiation, which would otherwise have a detrimental effect on the fusion joint. It is of paramount importance for high-quality joints that the oxidized layer be removed.
Heating Element for Manual Fusion Jointing
The element is heated electrically. The heating bush and spigot are removable. A separate pair is required for each pipe size.
Important : The surfaces of the heating tool which come into cantact with the pipe or the fitting must have a non-stick coating.
Fusion Jointing Machine
A fusion jointing machine is recommended for fittings with a diameter of 63mm or more. It is also better to use such a machine for smaller joints if there is a large number to be made.
The machine should be set up and operated according to the manufacturer’s instructions. The procedure detailed below – including the preparation – is for fusion jointing with the help of a manual jointing tool.
Preparations for Fusion Jointing
Set the temperature of the heating tool to 260ºC. Check the setting. The fusion temperature for PP must be between 250 and 270ºC. To test the thermostat, check the fusion temperature from time to time on the outside of the heating bush, using a fast acting thermoprobe or “tempil” sticks. This is particularly important when working in strong wind.
Use a clean cloth or dry paper to clean the heating bush and the heating spigot. The tools must be cleaned after making each fusion joint.
Cut the pipe square, using either a cutter for plastic pipes or a fine-toothed saw with cutting guide. Deburr the inside edges with a knife.
In the case of pipes in size from 20 to 100mm peel the pipe end until the blades are flush with the pipe end.
Should ovality of the pipe prevent the peeling tool from being properly applied, the pipe must first be rounded (e.g. in a vice or with a screw clamp).
Use a scraper to complete the peeling of any area where ovality impairs the effectiveness of the peeling tool.
If the peeling tool can be pushed onto the pipe without removing any material, then the dimensional accuracy of the pipe’s outside diameter and of the peeling tool should be checked.
Fusion Jointing Procedure
Quickly push first the fitting onto the heating spigot to the correct depth and then the pipe into the heating bush axially, without twisting, and hold firmly. 16mm pipes should be inserted into the heating bush up to the mark previously made. Pipes in size 20 – 110mm should be inserted until the end of the peeled surface is flush with the edge of the heating bush. In fusion jointing machines fixed stops regulate this. The heating times in the table below are measured from the completion of the above. Fusion joints should not be used for pipes whose walls are thinner than those listed in the table.
Pull the fitting and pipe from the heating tools with a “snap off” action as soon as the heating period has elapsed. Paying attention to the alignment marks, immediately push them together axially without twisting. Hold them together for the same duration as the heating period.
All fusion joints must be allowed to cool completely before pressure testing, i.e. as a rule wait about 1 hour after the last joint has been completed.