tap welding guideline_english

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Butt-fusion technology is classified as a heat pressure related process by which the pipe end material of two different pipes are melted together creating a homogenous pipe structure in their point of meeting. Butt-fusion welding is the most important jointing method for HDPE and MDPE pipes. The method is very simple and reliable. It will be the aim of these document to improve the understanding and basic knowledge of the process of butt-fusion and demonstrate how to create a proper and secure welding structure.

THAI-ASIA P.E. PIPE CO.,LTD. 555 Moo18 Pakchong Nakhonratchasima

(THAILAND) 30130

6644-328590 to 95

6644-328600

www.tappipe.com e-mail address: [email protected]

Editor code: TAP-352802 Document issue date: 25th MAY 2009

Document reversion: 2

http://www.tappipe.com/

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005 Quality Management Systems

Q001

Cert. No. NQ767/04 Cert. No. TH04/0500

TECHNICAL INFORMATION BUTT-FUSION WELDING OF POLYETHYLENE PIPE

Welding Guideline

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Content

1. Scope 3 2. General Requirement 3 3. Welding Machine 4 4. Welding Parameter 6 5. Welding Cycle Calculation (in case of welding operation by manual machine) 9 6. Welding Operation 12

Appendix – A – The welding guideline time values of welding operation for High Density Polyethylene Pipe. 16 Appendix – B – The sample of welding protocol form for welding data record. 22 Normative Reference

1. Direction DVS 2207-1:1995 “Welding of thermoplastics” Heated tool welding of pipe, pipeline components and sheet made from PE-HD, page 1 to 4, 6 and 9.

2. Borealis A/S, Polyethylene ART 339 03.04.1998 Ed.1 “Welding of large diameter PE pipe”, page 6.

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1. Scope Butt-fusion technology is classified as a heat pressure related process by which the pipe end material of two different pipes are melted together creating a homogenous pipe structure in their point of meeting. When Thermoplastics material like high density polyethylene (HDPE), medium density polyethylene (MDPE) are heated up to a temperature between 200C to 220C the material will change from a solid to a liquid state under the application of a certain pressure. With regard to the following instructions, suitability within the melt flow rates MFR 190/5 0.3 g to 1.7 g/10 min may be assumed. When two properly cut and heat-softened pipe ends are brought together and held under pressure, they are fuse together, forming a homogenous and tight joint when cooled. Simply in idea and performance, the butt-fusion process demands a high grade of accuracy to give the final product, i.e. the butt weld, a level of quality equal to that of the pipe itself. It will be the aim of these document to improve the understanding and basic knowledge of the process of butt-fusion and demonstrate how to create a proper and secure welding structure. 2. General Requirement Butt-fusion welding is the most important jointing method for HDPE and MDPE pipes. The method is very simple and reliable. The principal procedure is following:

The two pipes are clamped in a welding machine having a hydraulic system for the movable half of the machine and for the pressure build up.

The pipe ends are squared by a special cutter, trimmer or facing tool. An electrically heated metal plate is placed between the pipe ends. The pipe ends are pressured against the hot plate with a specified pressure and for a specified time. When the ends have melted, the hot plate is taken out and the melted ends are pressed against each

other to make a butt weld. The welding pressure is specified, and the welding time as well. When the weld has been cooled down, the pipes are taken out from the machine and preparation of the

next joint can start. The quality of welding joints depends on the qualification of the welder, the suitability of the used equipment and devices as well as on observance to the welding standards. The welding joint can be tested by means of non- destructive and/or destructive methods. Every welder has to be trained and has to be in possession of a valid qualification certificate. The intended application range may be decisive of the kind of qualification. The welding zone must be protected against bad weather influences (e.g. moisture and temperatures below +5 C). If it is ensured by suitable measures (e.g. preheating, tent, heating) that the condition are suitable for welding work may be carried out at any outside temperature insofar as the welder is not hindered in his handling. If necessary, an additional proof must be provided by carrying out sample welds under the mentioned condition. If the semi-finished product is heated up unevenly under influence of sunshine, the temperature compensation in

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the area of the welding joint can be reached by covering. A cooling down during the welding process by ventilation has to be avoided, e.g. by closing the pipe-ends during welding. Pipe from coils are oval immediately after uncoiling. The pipe end must be prepared before welding, e.g. by careful heating up with a hot-air equipment and use of a suitable clamping and/or re-rounding device. The connection zones of the components to be welded must be undamaged and have to be free of contamination (e.g. dirt, oil, shavings). The welding work must be monitored. Kind and range of supervising has to be agreed between the contract partners, this is recommended to record the welding data in welding protocols (sample see appendix B) or on data comers. Within the frame of the quality assurance it is recommended to perform and test samples of joints before beginning and during the welding works.

3. Welding Machine The welding machine is major equipment that necessary for qualify welder used to perform the butt-fusion welding process. The good quality and reliable machine would be consideration to use created a proper and secure welding structure. There are many suppliers welding machine in the global market and there are variety model that can be selection depend on the application or installation project requirement. Generally standard welding machine there

are the basic machine function and the option up on request such as a welding data record or the data logger, the CNC control unit for full automatic welding machine etc. The standard welding machine component as show on the figure1 and their basic work function are shown on as the following detail:

1. The machine base structure had a dual clamping device with quick action lock guide by two hydraulic cylinders two flexible hoses with quick-action coupling connect the appliance to the hydraulic control.

2. The hydraulic control unit which is control moving the right dual clamping device and precisely controls the jointing force, motor- pump start auto lock pressure by pilot check valve and accumulator.

3. The facing tool or trimmer is attached to the tooling support frame. It is electrically power by a chain or gear drive protected by an all-enclosing aluminum case and automatically delivers chips to the outside.

4. The heater element, there is a teflon coating on the surface plate which is attached to the tooling support frame. There is temperature sensor PT-100 or PT-1000 and digital control equipped with control lamps an ON/OFF switch and extension cable with earthling-contact plug.

5. The clamping inserts consisting of eight haft shells per dimension are available for cover all the range of pipe diameter that is the machine capable to welding such as the welding machine model 315, there are the clamp insert for pipe size 90,110,125,140,160,180,200,225,250 and 280 mm.

6. The carrier case or tooling support frame is for heater element and the facing tool. 7. The stub end and concentric reducer holder is for locking the center position for weld with pipe end.

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Figure1. Standard Welding Machine Component (basic machine function)

5. Hydraulic Control Unit

3. Trimmer or Facing Tool 4. Heating Plate

1. Machine Base Structure

Facing Tool Heating Plate

Hydraulic Control Unit

Electric Control Box

2. Tool Support Frame

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4. Welding Parameter The control parameter of welding cycle was shown on the figure2. They are reference to DVS 2207-1:1995 and NEN 7200 (VEG-85) the international welding standard. In cases of used the calculation method or/and recommended values from the standard.

Figure2. Process stages of butt-fusion welding relation between pressure and time

Table1. Welding Parameter and control for calculation method and recommended values to be used Description Parameter Calculation Recommended

Values 1. Heating temperature 200 - 220 0C - Figure3. 2. Alignment pressure (bar) (P1) 0.15 ± 0.01 N/mm2 A1 / A2 x 1.5 _

3. Alignment time (Bead Created) (T1) Until bead created follow item 4

Until bead created follow item 4

Table3.

4. Bead height (mm.) 0.5 + (0.1 x e) 0.5 + (0.1 x e) - 5. Heating-up pressure (bar) (P2) ≤ 0.02 N/mm2 A1 / A2 x 0.2 - 6. Heating-up time (sec.) (T2) 10 x e 10 x e Table3. 7. Changeover time (sec.) (T3) 3 + (0.01 x OD) 3 + (0.01 x OD) Table3. 8. Joining pressure built-up time (sec.) (T4) 3 + (0.03 x OD) 3 + (0.03 x OD) Table3. 9. Joining pressure (bar) (P3) 0.15±0.01 N/mm2 A1 / A2 x 1.5 - 10. Minimum cooling time (min.) (T5) 3 + e 3 + e Table3. 11. Minimum bead width (mm.) 3 + (0.50 x e) 3 + (0.50 x e) - 12. Maximum bead width (mm.) 5 + (0.75 x e) 5 + (0.75 x e) -

Remarks: OD = Outside Diameter (mm.), e = Wall Thickness (mm.)

A1 = Pipe section area (mm2) by calculation formula: [(OD2– ID2)/4]

A2 = Hydraulic cylinder section area (mm2) by calculation formula: [(Number of hydraulic cylinder) x (iD2Cylinder– OD2

Shaft)/4]

P1

P2

P3

T1 T2 T3 T4 T5

Pressure

(bar)

Time

(minute or second)

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Alignment of pipe and gap width The joining areas have to be plane with a clean and grease-free tool directly before the welding, so they are plane-parallel in clamped condition. The gap width and the misalignment have to be controlled. The misalignment of the joining areas on the pipe outside respect may not pass the permissible value of 0.1 x wall thickness of pipe. The permissible gap width under alignment pressure is show on Table2.

Table2. The maximum gap width is allowance between the treated welding zones. Pipe outside diameter range

(mm.) Gap width

(mm.)

< 355 0.5

400…< 630 1.0

630…< 800 1.3

800…< 1000 13

> 1000 2.0

The treated welding areas should be neither dirtied nor touched by hand, as a retreatment would be necessary then. Shavings fallen into the pipe have to be remove. Welding temperature The heating tool temperature is 200 to 220 C. In principle the upper temperature limit is aspired for smaller pipe wall thicknesses, the lower temperature limit for bigger ones. The recommended value is show on figure3.

Figure3. Recommended values for the heating tool temperatures subject to wall thickness

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The control or inspection measurement must be done within the welding area on the heating tool which corresponds to the semi-finished product. For adjusting the temperature balance, the heated tool may be inserted 10 minutes after reaching the set temperature at the earliest, before start the welding process. Table3. Recommended values for the heating tool butt-fusion welding of pipes and fittings from HDPE, at

an ambient temperature of approximately 20 C and moderate air flow ( Interim values have to be interpolated).

1 2 3 4 5

Nominal wall Thickness (mm)

Alignment Bead height on heating tool at the end of the alignment time (alignment with 0.15 N/mm²) (mm) minimum values

Heating-up (T2) Heating-up time =10 x wall thickness (heating-up with < 0.02 N/mm²) (second)

Changeover (T3)

(second) maximum time

Joining

(T4) Joining Pressure build-up time (second)

(T5) Cooling time under joining pressure P=0.15 N/ mm² + 0.01 (minute) minimum values

≤ 4.5 4.5… 7 7 … 12 12 … 19 19 …26 26 … 37 37 … 50 50 … 70

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

45 45…70 70…120 120…190 190…260 260…370 370…500 500…700

5 5…6 6…8 8…10 10…12 12…16 16…20 20…25

5 5…6 6…8 8…11 11…14 14…19 19…25 25…35

6 6…10 10…16 16…24 24…32 32…45 45…60 60…80

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5. Welding Cycle Calculation (in case of welding operation by manual machine) Pressure Calculation for the welding machine

1) Calculation for HDPE Pipe section area: A1 = (OD2-ID2) / 4 (mm2)

Case1. HDPE pipe 315 mm. wall thickness 15.0 mm. PN 6.3 SDR 21 A1 = 3.142x(3152-(315-(2x15))2) / 4

= 14,139.00 mm2

Case2. HDPE pipe 400 mm. wall thickness 19.1 mm. PN 6.3 SDR 21 A1 = 3.142x(4002-(400-(2x19.1))2) / 4

= 22,858.64 mm2

2) Calculation for Hydraulic cylinder effective area of welding machine

Hydraulic cylinder effective area: A2 = No. of cylinder x (ID2cylinder - OD2

shaft) / 4 (mm2)

HDPE Butt-Fusion machine: Model 315 OD of hydraulic shaft = 30 mm. ID of hydraulic cylinder = 40 mm. Number of hydraulic cylinder = 2

A2 = 2 x 3.142 x (402-302) / 4

= 1,099.70 mm.2

HDPE Butt-Fusion machine: Model 450 OD of hydraulic shaft = 40 mm. ID of hydraulic cylinder = 50 mm. Number of hydraulic cylinder = 2

A2 = 2 x 3.142 x (502-402) / 4

= 1,413.90 mm.2

Welding Pressure P (Cylinder) = P (Pipe) x (A1/A2) …………………………. [exclude drag force] A1 = HDPE Pipe section area ………………. (mm2) A2 = Hydraulic cylinder section area ……….. (mm2) P (Pipe) = 0.15 N/mm2 or 1.5 ……………………… (bar) [for P1 and P3] = ≤ 0.02 N/mm2 or 0.2 …………………… (bar) [for P2] P (Cylinder) = Operating pressure of welding machine (bar.)

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Calculation Data Table of Case1. Item Description Parameter

1 HDPE Butt-Fusion Machine Model 315 2 Hydraulic cylinder effective area 1,099.70 (mm.).2 3 OD. HDPE Pipe 225 (mm.) 225 (mm.) 315 (mm.) 4 Pipe wall thickness 10.8 (mm.) 16.6 (mm.) 15.0 (mm.) 5 PN (Nominal Pressure) 6.3 (bar.) 10 (bar.) 6.3 (bar.) 6 SDR. (Standard dimension ratio) 21 13.6 21 7 Area of pipe section 7,268.57 (mm.2) 10,869.56 (mm.2) 14,139.00 (mm.2) 8 Welding Standard Reference DVS 2207-1:1995 and (VEG-85) NEN 7200 9 Heating Temperature 200 – 220 (0C.) 10 Alignment Pressure 9.9 (bar.) 14.82 (bar.) 19.28 (bar.) 11 Alignment Time (Bead created) (Until bead created follow item 12) 12 Bead height 1.58 (mm.) 2.16 (mm.) 2.00 (mm.) 13 Heating-up pressure 1.32 (bar) 1.97 (bar) 2.57 (bar) 14 Heating-up time 108 (sec.) 166 (sec.) 150 (sec.) 15 Changeover time (Average time) 5.25 (sec.) 5.25 (sec.) 6.15 (sec.) 16 Joining pressure built-up time 9.75 (sec.) 9.75 (sec.) 12.45 (sec.) 17 Joining Pressure 9.9 (bar) 14.82 (bar) 19.28 (bar) 18 Cooling time (Minimum) ≥ 13.8 (min.) ≥ 19.6 (min.) ≥ 18 (min.) 19 Range of welding bead width 8.40–13.10

(mm.) 11.30–17.45

(mm.) 10.50–16.25

(mm.)

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Calculation Data Table of Case2. Item Description Parameter

1 HDPE Butt-Fusion Machine Model 450 2 Hydraulic cylinder effective area 1,413.90 (mm2) 3 OD. HDPE Pipe 400 (mm.) 400 (mm.) 4 Pipe wall thickness 19.1 (mm.) 29.5 (mm.) 5 PN (Nominal Pressure) 6.3 (bar) 10 (bar) 6 SDR. (Standard dimension ratio) 21 13.6 7 Area of pipe section 22,858.64 (mm2) 34,341.27 (mm2) 8 Welding Standard Reference DVS 2207-1:1995 and (VEG-85) NEN 7200 9 Heating Temperature 200-220 (0C) 10 Alignment Pressure 24.26 (bar) 36.44 (bar) 11 Alignment Time (Bead created) (Until bead created follow item 12) 12 Bead height 2.41 (mm.) 3.45 (mm.) 13 Heating-up pressure 3.23 (bar) 4.86 (bar) 14 Heating-up time 191 (sec.) 295 (sec.) 15 Changeover time (Average time) 7.00 (sec.) 7.00 (sec.) 16 Joining pressure built-up time 15.00 (sec.) 15.00 (sec.) 17 Joining Pressure 24.26 (bar) 36.44 (bar) 18 Cooling time (Minimum) ≥ 22.1 (min) ≥ 32.5 (min) 19 Range of welding bead width 12.55–19.32 (mm.) 17.75–27.12 (mm.)

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6. Welding Operation

Step Working Procedure

1. Preparation of welding: before start the welding operation, there are the preparation work as in the general requirements have to complete to make sure, the quality of welding joint is a secure structure. Select the operation area that is suitable to the safety work. Install the protection tent or other equipment to protect the welding zone against rain, sunshine or bad

weather (if required) Setting up the welding machine with all accessories according to the welding pipe size. To do

checking machine working function by connect a coupling two flexible hoses between the hydraulic control unit and the machine base structure, turn on the main power for hydraulic pump, control a directional valve to move the hydraulic cylinder for built-up pressure test and check all hydraulic oil leakage point. For the heating plate connect to the power source, turn on switch, setting the temperature range 200 - 220 C (in according to figure3) to checking the actual the temperature on the area to do welding. The facing tool or trimmer must be check the cutters, they

should be good locking in their position without any crack or a broken part, then connect facing tool to the power source turn on switch to check the revolution.

All of the problem or the missing function must be fixed before start the welding operation. 2. Insert two pipes end

on both side of the machine clamps, protrude approx. 3-5 cm. from each shell side, clamping and adjust the pipe or piping part, the surfaces to be welding should be parallel to each other.

Adjust the alignment of pipe line by tighten or lose bronze nuts on the top aluminum clamps. Secure longitudinal movement of the parts to be welded by taking appropriate measures. Clean outside and inside pipe surface.

3. Insert the facing tool or trimmer between the two pipe ends into the lock position on the welding machine

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4.

Start the facing tool or trimmer by turn on the control switch. Slowly approach the pipe ends towards the facing tool or

trimmer by control the directional valve on hydraulic control unit keeping control pressure a little higher.

The cutter will be cut the surface of both pipe end to be clean, plane and parallel.

5.

When scraps become continual even and slice shape, the trimming is completion, to finish this operation by decrease the pressure slowly until the facing tool free revolution then switch off.

Remove the facing tool or trimmer from welding machine to the support frame and clear the facing scraps from pipe ends.

Inspecting the pipe contact surface area of both sides they must be clean and plane, if they are not then repeat the step 3-5 again.

During the clearing and inspection must be avoided any contacting with the surface of pipe ends. 6. Recheck the alignment of the pipe line by close both pipe

ends together and measure the actual tolerance. The misalignment value between both pipes side that

should not over than 10% of pipe wall thickness. The gap width is allowance between the treated pipe end,

they do not over than the value that shown on the table2.

If they are not in the control tolerance then repeat the step 2-5 again.

7. During the alignment checking in step 6, the welder team must be measured the force or pulling pressure (drag pressure) by see a pressure indicator device and recorded.

This pressure must be created to pull the whole work piece moving in between welding process. The drag pressure is the additional value that must be add up to the alignment pressure (P1) and joining

pressure (P3) from calculation or machine pressure data for each operation area and every welding joint.

8. The welding team prepared the welding parameter by calculation and/or used the recommended values according to table1, table3 or machine data for the welding operation control.

Final check heating plate temperature on the setting range according to step 1. Cleaning the both heating plate side with cleaning agent and insert it’s back to support waiting for welding operation start.

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9. Open both pipe ends, to cleaning the both pipe ends between the surface contact welding area by coat with an ethyl-alcohol or other suitable cleaning agent and avoided any contacting to the surface of pipe ends after clean.

Re-cleaning, if they are necessary.

10. Starting the welding process in alignment stage by insert the heating plate between both pipe ends, move both pipe ends close together until contact the heating plate.

Start to built-up pressure to the alignment pressure level (P1 + drag pressure), maintain the pressure until there are welding seam appear.

11. In this stage uniform bead have been to create between the heating plate and whole circumference of both pipes end.

The pressure must be maintained until the bead height according to the calculation value in table1 by visual inspection.

Continue to the heating-up stage by reduced pressure and maintain to the heating-up pressure level (P2) along heating-up time (T2).

12. Open the both pipes end, carefully to remove the heating plate without touching to the melted area and control the removing time that should not longer than the changeover time (T3), insert heating plate to the support.

13.

Immediately to start joining stage by rapid increase pressure to the joining pressure level (P3 + drag pressure) within the joining pressure built-up time (T4)

Uniform beads have been to create whole circumference of pipe joint.

Maintain and adjusting to keep the joining pressure constant throughout the cooling time (T5) until the welding joint is cool down and must not be forced by applying water.

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14. Remove the clamps after complete cooling stage. Welding bead of each jointing has to inspection

by visual and measure as following: o Both beads should be almost equally

dimension. o The bead surface should be smooth and

do not shine. o Bead width must be according to the limit

dimension. Possible differences in the formation of the beads may be justified by different behavior of the joined

materials. 15. All the welding information must be recorded into the data logger, log sheet or welding protocol form.

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APPENDIX – A – The welding guideline time value of welding operation for High Density Polyethylene Pipe

Process stages of butt-fusion welding relation between pressure and time This appendix part will be give you the idea information data of the welding time parameter T2, T3, T4 and T5 according to the recommended values on table3. Bead height values by calculation according to the table1. The pressure values P1, P2 and P3 are not show in this appendix, all the pressure should be calculation related to the welding machine specification as shown on the calculation case1 and case2. Furthermore, the welding machine suppliers must be prepare the machine operation manual and all welding parameter control of their machine model for customer. However all the information of this appendix, they can use to be the data reference.

P1

P2

P3

T1 T2 T3 T4 T5

Pressure

(bar)

Time

(minute or second)

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OD [mm.]

e

[mm.]

SDR OD/e

T

[C ]

1 2 3 4 5 Bead Width

P1[*] P2[*] t2 [sec]

t3 Max [sec]

t4 [sec]

P3[*] t5 [min]

Min. [mm.]

Max. [mm.]

90

2.2 41 220 0.5 22 3 3 3 4.1 6.7

2.8 33 220 0.5 28 3 3 4 4.4 7.1 3.5 26 220 0.5 35 4 4 5 4.8 7.6 4.3 21 219 0.5 43 5 5 6 5.2 8.2 5.1 17.6 218 1.0 51 5 5 7 5.6 8.8 5.4 17 218 1.0 54 5 5 7 5.7 9.1 6.7 13.6 217 1.0 67 6 6 10 6.4 10.0 8.2 11 215 1.5 82 6 6 11 7.1 11.2 10.1 9 213 1.5 101 7 7 14 81 12.6 12.3 7.4 211 2.0 123 8 8 16 9.2 14.2 15 6 209 2.0 150 9 9 19 10.5 16.3

110

2.7 41 220

0.5

27 3 3

4 4.4 7.0 3.4 33 220 0.5 34 4 4 5 4.7 7.6 4.2 26 219 0.5 42 5 5 6 5.1 8.2 5.3 21 218 1.0 53 5 5 7 5.7 9.0 6.3 17.6 217 1.0 63 6 6 9 6.2 9.7 6.6 17 217 1.0 66 6 6 9 6.3 10.0 8.1 13.6 215 1.5 81 6 6 11 7.1 11.1 10.0 11 213 1.5 100 7 7 14 8.0 12.5 12.3 9 211 2.0 123 8 8 16 9.2 14.2 15.1 7.4 209 2.0 151 9 9 20 10.6 16.3 18.3 6 207 2.0 183 10 11 23 12.2 18.7

125

3.1 41 220 0.5 31 3 3 4 4.6 7.3 3.9 33 219 0.5 39 4 4 5 5.0 7.9 4.8 26 218 1.0 48 5 5 6 5.4 8.6 6.0 21 217 1.0 60 6 6 8 6.0 9.5 7.1 17.6 216 1.5 71 6 6 10 6.6 10.3 7.4 17 216 1.5 74 6 6 10 6.7 10.6 9.2 13.6 214 1.5 92 7 7 13 7.6 11.9 11.4 11 212 1.5 114 8 8 15 8.7 13.6 14.0 9 210 2.0 140 9 9 18 10.0 15.5 17.1 7.4 208 2.0 171 10 10 22 11.6 17.8 20.8 6 205 2.0 208 11 12 26 13.4 20.6

140

3.5 41 220

0.5

35 4 4

5 4.8 7.6 4.3 33 219 0.5 43 5 5 6 5.2 8.2 5.4 26 218 1.0 54 5 5 7 5.7 9.1 6.7 21 217 1 67 6 6 10 6.4 10.0 8 17.6 215 1.5 80 6 6 11 7.0 11.0

8.3 17 215 1.5 83 7 7 12 7.2 11.2 10.3 13.6 213 1.5 103 7 7 14 8.2 12.7 12.7 11 211 2.0 127 8 8 17 9.4 14.5 15.7 9 209 2.0 157 9 10 20 10.9 16.8 19.2 7.4 206 2.5 192 10 11 24 12.6 19.4 23.3 6 204 2.5 233 11 13 29 14.7 22.5

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OD [mm.]

e

[mm.]

SDR OD/e

T

[C ]


P1[*]

P2[*]

t2 [sec]

t3 Max [sec]

t4 [sec]

P3[*] t5 [min]

Min. [mm.]

Max. [mm.]

160

4.0 41 219 0.5 40 4 4 5 5.0 8.0 4.9 33 218 1.0 49 5 5 7 5.5 8.7 6.2 26 217 1.0 62 6 6 9 6.1 9.7 7.7 21 216 1.5 77 6 6 11 6.9 10.8 9.1 17.6 214 1.5 91 7 7 13 7.6 11.8 9.5 17 214 1.5 95 7 7 13 7.8 12.1 11.8 13.6 212 1.5 118 8 8 16 8.9 13.9 14.6 11 209 2.0 146 9 9 19 10.3 16.0 17.9 9 207 2.0 179 10 11 23 12.0 18.4 21.9 7.4 205 2.5 219 11 12 27 14.0 21.4 26.6 6 203 3.0 266 12 14 33 16.3 25.0

180

4.4 41 219

0.5

44 5 5

6 5.2 8.3 5.5 33 218 1.0 55 5 5 8 5.8 9.1 6.9 26 216 1.0 69 6 6 10 6.5 10.2 8.6 21 215 1.5 86 7 7 12 7.3 11.5 10.2 17.6 213 1.5 102 7 7 14 8.1 12.7 10.7 17 213 1.5 107 7 7 14 8.4 13.0 13.3 13.6 210 2 133 8 9 17 9.7 15.0 16.4 11 208 2.0 164 9 10 21 11.2 17.3 20.1 9 206 2.5 201 10 12 25 13.1 20.1 24.6 7.4 204 2.5 246 12 13 30 15.3 23.5 29.9 6 202 3.0 299 13 16 37 18.0 27.4

200

4.9 41 218 1 49 5 5 7 5.5 8.7 6.2 33 217 1.0 62 6 6 9 6.1 9.7 7.7 26 216 1.5 77 6 6 11 6.9 10.8 9.6 21 214 1.5 96 7 7 13 7.8 12.2 11.4 17.6 212 1.5 114 8 8 15 8.7 13.6 11.9 17 211 1.5 119 8 8 16 9.0 13.9 14.7 13.6 209 2.0 147 9 9 19 10.4 16.0 18.2 11 207 2.0 182 10 11 23 12.1 18.7 22.4 9 205 2.5 224 11 12 28 14.2 21.8 27.4 7.4 203 3.0 274 12 15 34 16.7 25.6 33.2 6 201 3.0 332 15 17 40 19.6 29.9

225

5.5 41 218

1

55 5 5

8 5.8 9.1 6.9 33 216 1.0 69 6 6 10 6.5 10.2 8.6 26 215 1.5 86 7 7 12 7.3 11.5 10.8 21 213 1.5 108 8 8 15 8.4 13.1 12.8 17.6 211 2.0 128 8 8 17 9.4 14.6 13.4 17 210 2.0 134 8 9 18 9.7 15.1 16.6 13.6 208 2 166 9 10 21 11.3 17.5 20.5 11 205 2.5 205 11 12 26 13.3 20.4 25.2 9 204 2.5 252 12 14 31 15.6 23.9 30.8 7.4 202 3.0 308 14 16 38 18.4 28.1 37.4 6 201 3.5 374 16 19 45 21.7 33.1

of 22


Q001



Welding Guideline

TAP-

3528

02-T

EC-B

UTT

WEL

DING

-52R

2 Iss

ue D

ate 2

5th MAY

200

9

OD [mm.]

e

[mm.]

SDR OD/e

T

[C ]


P1[*]

P2[*]

t2 [sec]

t3 Max [sec]

t4 [sec]

P3[*] t5 [min]

Min. [mm.]

Max. [mm.]

250

6.2 41 217 1 62 6 6 9 6.1 9.7

7.7 33 216 1.5 77 6 6 11 6.9 10.8 9.6 26 214 1.5 96 7 7 13 7.8 12.2 11.9 21 211 1.5 119 8 8 16 9.0 13.9 14.2 17.6 210 2 142 9 9 18 10.1 15.7 14.8 17 209 2 148 9 9 19 10.4 16.1 18.4 13.6 207 2 184 10 11 23 12.2 18.8 22.7 11 205 2.5 227 11 13 28 14.4 22.0 27.9 9 203 3.0 279 13 15 34 17.0 25.9 34.2 7.4 201 3.0 342 15 18 42 20.1 30.7 41.5 6 200 3.5 415 17 21 50 23.8 36.1

280

6.9 41 216

1

69 6 6

10 6.5 10.2 8.6 33 215 1.5 86 7 7 12 7.3 11.5 10.7 26 213 1.5 107 7 7 14 8.4 13.0 13.4 21 210 2 134 8 9 18 9.7 15.1 15.9 17.6 208 2.0 159 9 10 20 11.0 16.9 16.6 17 208 2.0 166 9 10 21 11.3 17.5 20.6 13.6 205 2.5 206 11 12 26 13.3 20.5 25.4 11 204 2.5 254 12 14 31 15.7 24.1 31.3 9 202 3.0 313 14 16 38 18.7 28.5 38.3 7.4 200 3.5 383 16 20 46 22.2 33.7 46.5 6 200 3.5 465 19 23 56 26.3 39.9

315

7.7 41 216 1.5 77 6 6 11 6.9 10.8 9.7 33 214 1.5 97 7 7 13 7.9 12.3 12.1 26 211 2.0 121 8 8 16 9.1 14.1 15 21 209 2.0 150 9 9 19 10.5 16.3

17.9 17.6 207 2.0 179 10 11 23 12.0 18.4 18.7 17 206 2.0 187 10 11 24 12.4 19.0 23.2 13.6 204 2.5 232 11 13 29 14.6 22.4 28.6 11 203 3.0 286 13 15 35 17.3 26.5 35.2 9 201 3.0 352 15 18 43 20.6 31.4 43.1 7.4 200 3.5 431 18 22 52 24.6 37.3 52.3 6 200 4.0 523 21 26 62 29.2 44.2

355

8.70 40.80 215

1.50

87 7 7

12 7.35 11.53 10.90 32.57 212 1.50 109 8 8 15 8.45 13.18 13.60 26.10 210 2.00 136 9 9 18 9.80 15.20 16.90 21.01 208 2.00 169 9 10 22 11.45 17.68 20.10 17.66 206 2.50 201 10 12 25 13.05 20.08 21.10 16.82 205 2.50 211 11 12 26 13.55 20.83 26.10 13.60 203 3.00 261 12 14 32 16.05 24.58 32.20 11.02 202 3.00 322 14 17 39 19.10 29.15 39.70 8.94 200 3.50 397 17 20 48 22.85 34.78 48.50 7.32 200 3.50 485 20 24 58 27.25 41.38 59.00 6.02 200 4.00 590 22 30 69 32.50 49.25

of 22


Q001



Welding Guideline

TAP-

3528

02-T

EC-B

UTT

WEL

DING

-52R

2 Iss

ue D

ate 2

5th MAY

200

9

OD

[mm.]

e

[mm.]

SDR OD/e

T

[C ]


P1[*]

P2[*] t2 [sec]

t3 Max [sec]

t4 [sec]

P3[*] t5 [min]

Min. [mm.]

Max. [mm.]

400

9.80 40.82 213 1.50 98 7 7 13 7.90 12.35

12.30 32.52 211 2.00 123 8 8 16 9.15 14.23 15.30 26.14 209 2.00 153 9 9 20 10.65 16.48 19.10 20.94 206 2.50 191 10 11 24 12.55 19.33 22.70 17.62 205 2.50 227 11 13 28 14.35 22.03 23.70 16.88 204 2.50 237 11 13 29 14.85 22.78 29.40 13.61 202 3.00 294 13 15 36 17.70 27.05 36.30 11.02 201 3.00 363 16 19 44 21.15 32.23 44.70 8.95 200 3.50 447 19 23 54 25.35 38.53 54.70 7.31 200 4.00 547 21 27 65 30.35 46.03

450

11.00 40.91 212

1.50

110 8 8

15 8.50 13.25 13.80 32.61 210 2.00 138 9 9 18 9.90 15.35 17.20 26.16 208 2.00 172 10 10 22 11.60 17.90 21.50 20.93 205 2.50 215 11 12 27 13.75 21.13 25.50 17.65 204 2.50 255 12 14 31 15.75 24.13 26.70 16.85 203 3.00 267 12 14 33 16.35 25.03 33.10 13.60 201 3.00 331 15 17 40 19.55 29.83 40.90 11.00 200 3.50 409 17 21 49 23.45 35.68 50.30 8.95 200 4.00 503 20 25 60 28.15 42.73 61.50 7.32 200 4.00 615 23 31 72 33.75 51.13

500

12.30 40.65 211 2.00 123 8 8 16 9.15 14.23 15.30 32.68 209 2.00 153 9 9 20 10.65 16.48 19.10 26.18 206 2.50 191 10 11 24 12.55 19.33 23.90 20.92 204 2.50 239 12 13 30 14.95 22.93 28.30 17.67 203 3.00 283 13 15 35 17.15 26.23 29.70 16.84 202 3.00 297 13 16 36 17.85 27.28 36.80 13.59 201 3.00 368 16 19 45 21.40 32.60 45.40 11.01 200 3.50 454 19 23 55 25.70 39.05 55.80 8.96 200 4.00 558 21 28 66 30.90 46.85

560

13.70 40.88 210

2.00

137 9 9

18 9.85 15.28 17.20 32.56 208 2.00 172 10 10 22 11.60 17.90 21.40 26.17 205 2.50 214 11 12 27 13.70 21.05 26.70 20.97 203 3.00 267 12 14 33 16.35 25.03 31.70 17.67 202 3.00 317 14 16 39 18.85 28.78 33.20 16.87 201 3.00 332 15 17 41 19.60 29.90 41.20 13.59 200 3.50 412 17 21 50 23.60 35.90 50.80 11.02 200 4.00 508 20 25 61 28.40 43.10

of 22


Q001



Welding Guideline

TAP-

3528

02-T

EC-B

UTT

WEL

DING

-52R

2 Iss

ue D

ate 2

5th MAY

200

9

OD

[mm.]

e

[mm.]

SDR OD/e

T

[C ]


P1[*]

P2[*]

t2 [sec]

t3 Max [sec]

t4 [sec]

P3[*] t5 [min]

Min. [mm.]

Max. [mm.]

630

15.40 40.91 209 2.00 154 9 9 20 10.70 16.55 19.30 32.64 206 2.50 193 10 11 24 12.65 19.48 24.10 26.14 204 2.50 241 12 13 30 15.05 23.08 30.00 21.00 202 3.00 300 13 16 37 18.00 27.50 35.70 17.65 201 3.00 357 15 18 44 20.85 31.78 37.40 16.84 201 3.50 374 16 19 45 21.70 33.05 46.30 13.61 200 3.50 463 19 23 56 26.15 39.73 57.20 11.01 200 4.00 572 22 29 67 31.60 47.90

710

17.40 40.80 206

2.00

174 10 10

22 11.70 18.05 21.80 32.57 205 2.50 218 11 12 27 13.90 21.35 27.20 26.10 204 3.00 272 12 15 34 16.60 25.40 33.90 20.94 201 3.00 339 15 17 43 19.95 30.43 40.20 17.66 200 3.50 402 16 21 49 23.10 35.15 42.10 16.86 200 3.50 421 17 22 51 24.05 36.58 52.20 13.60 200 4.00 522 20 26 62 29.10 44.15

800

19.60 40.82 206 2.50 196 11 11 24 12.80 19.70 24.50 32.65 204 2.50 245 12 13 31 15.25 23.38 30.60 26.14 202 3.00 306 13 16 39 18.30 27.95 38.10 21.00 201 3.50 381 16 19 48 22.05 33.58 45.30 17.66 200 3.50 453 18 23 55 25.65 38.98 47.40 16.88 200 3.50 474 19 24 57 26.70 40.55 58.80 13.61 200 4.00 588 23 30 69 32.40 49.10

900

22.00 40.91 205

2.50

220 11 12

27 14.00 21.50 27.60 32.61 204 3.00 276 12 15 34 16.80 25.70 34.40 26.16 201 3.00 344 15 17 43 20.20 30.80 42.90 20.98 200 3.50 429 17 22 51 24.45 37.18 51.00 17.65 200 4.00 510 20 26 61 28.50 43.25 53.30 16.89 200 4.00 533 21 27 63 29.65 44.98

1000

24.50 40.82 204

2.50

245 12 13

31 15.25 23.38 30.60 32.68 202 3.00 306 13 16 39 18.30 27.95 38.20 26.18 201 3.50 382 16 19 48 22.10 33.65 47.70 20.96 200 3.50 477 19 24 57 26.85 40.78 56.60 17.67 200 4.00 566 22 29 67 31.30 47.45 59.30 16.86 200 4.00 593 23 30 70 32.65 49.48

[*] The calculation is not include drag pressure

of 22


Q001



Welding Guideline

TAP-

3528

02-T

EC-B

UTT

WEL

DING

-52R

2 Iss

ue D

ate 2

5th MAY

200

9

APPENDIX – B – The sample of welding protocol form for welding data record

tap welding guideline_english

Documents