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1 Scope……………………………………..……. 2
2 Conflicts and Deviations………………..……. 2
3 References……………………………..……… 2
4 Definitions……………………………………… 6
5 Material…………………………………………. 6
6 Qualifications of Operators………………..…. 7
7 Butt Fusion Welding of HDPE Pipe……….… 7
8 Preparation and Check List
before Commencing Welding…….…… 10
9 Butt Fusion Welding……………………….... 11
10 Qualification and Quality Control
Testing of Field butt Fusion Welding…. 13
11 Poor Workmanship of Butt Fusion Joint…... 14
1 Scope
This procedure describes the preparation, butt welding and qualification of HDPE pipes
and fittings to ensure that the welded joint performs equal to or greater than pipe. It is
applicable to mechanical and pressure-activated equipment with electrically powered
heater plates. The procedure is intended for butt fusion jointing PE pipes and fittings
that shall be used for gaseous fuels and all water services including transportation of
potable water. Butt welding following this procedure shall be suitable only for pipes
and fittings from the same wall thickness series and from PE4710 /PE100 only.
2.1 Any conflicts between this procedure and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Consulting Services Department of Saudi Aramco, Dhahran.
2.2 Direct all requests to deviate from this procedure in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.
3 References
The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this specification shall comply with the
latest edition of the references listed below, unless otherwise noted.
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
British Standards
BS 4505 Specification for Flanges and Bolting for Pipes,
Valves and Fittings (Metric Series)
BS 5292 Jointing Materials and Components for Installation
using Water, Low Pressure Steam
BS 6920 Suitability of Non-Metallic Products for Use in
Contact with Water Intended for Human
Consumption with Regard to their Effect on the
Quality of the Water Methods of Test
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
4 Definitions
Fusion pressure and cooling pressure: the pressure (in bar) required to provide, on a
given machine and for a given size and rating of pipe, an interface stress of 0.15 MPa or
0.025 MPa as appropriate. This pressure is a function of the ram dimensions and the
efficiency of the machine.
Drag pressure: the minimum pressure (in bar) required to overcome the sliding
frictional drag of the pipe and the machine. This shall be assessed accurately prior to
making each fusion joint and shall be added to the ram pressure. This operation is
normally carried out automatically when fully automatic fusion machines are used.
Bead-up pressure: the sum of fusion and drag pressures required to provide, on a
given machine and for a given size and rating of pipe, an interface stress of 0.15 MPa to
form the initial bead on the end of the pipe against the heater plate.
Heat soak pressure: the pressure required to maintain the pipe in contact with the
heater plate. This is normally the drag pressure.
Bead roll over pressure: the pressure required to provided, on a given machine and
for a given size and rating of pipe, an interface stress of 0.15 MPa. This has the same
value as the initial bead-up pressure.
Plate removal time: the maximum time permitted for the opening of the carriage, removal
of the heating plate and closure of the carriage to bring the two hot pipe ends together.
Standard Dimension Ratio (SDR): The ratio of pipe diameter to wall thickness.
An SDR 11 means that the outside diameter - D - of the pipe is eleven times the
thickness - s - of the wall.
5 Material
Pipes and fittings shall be manufactured from virgin PE4710 / PE100 materials
qualified per ASTM D2837 or ISO 9080. PE100 pipe and fittings materials shall also
meet the requirements of ASTM D3350. Pipes and fittings made from PE4710/PE100
material are fusion compatible, regardless of manufacturer. All pipes and fittings shall
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
6 Qualifications of Operators
All operators who conduct heat fusion jointing or inspect joints in HDPE water and gas
piping shall be qualified/certified by a reputable third party laboratory per BS EN 13067
or equivalent.
Each candidate shall meet the minimum experience level of more than five (5) successfully
completed different jobs.
Before commencing installation, at least three joints prepared by qualified operator shall
pass the requirements of the short term validation tests per ASTM D1599; Quick-Burst
Hydro-testing. Any instantaneous or rapid loss of pressure attributed to the joint shall
constitute failure. Further joints shall be prepared and tested until failure occurs outside
the welded zone or passes the minimum required time.
Saudi Aramco Field Project Inspector shall ensure that all butt fusion welding candidates
provide certifications and identifications document before commencing heat fusion
welding.
HDPE pipe is butt fused together using a fusion welding machine. A clamping device
holds the two and ends which are brought in contact with a heating plate. A melt
pattern is formed around both pipe ends. Once the correct temperature is reached, the
heating plate is quickly removed, and the melt ends are pressed together to provide a
leak proof fusion joint that is as strong as or stronger than the pipe itself. Pipe and
fitting surfaces shall be clean and properly prepared to ensure high quality joint.
Before starting welding, the heater plate must be clean, undamaged and at the correct
surface temperature. For cleaning technique, refer to the equipment manufacturer’s
procedure.
Butt fusion welding of HDPE pipes and fittings shall be conducted using
mechanical, pressure-activated, automatic or manual welding equipment per
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
The project engineer shall ensure that the welding equipment to be used on site
has documented periodic maintenance schedule before commencing jointing of
pipe and fittings. Disregard of equipment could result in HDPE joints being
incorrectly welded or operational delays due to equipment frequent breakdown.
The interfacial pressure is constant for all pipe sizes and all butt fusion
machines. However, fusion joining gauge pressure settings are
calculated for each butt fusion machine, which is dependent upon the
outside diameter (OD), dimension ratio (DR) and the piston area of the
fusion machine.
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
The pipe and fittings shall not stick to the surfaces of the heating plate to
avoid excessive cleaning and damage to the heating plate. This is
usually attained by coating the surfaces with colored PTFE (PolyTetra
FluoroEthylene). Colored PTFE is used to easily see and remove HDPE
pieces stuck to the heating plate surfaces.
Release agent of any type shall not be used at any time to avoid
contamination of the joint and its potential failure.
The trimming tool shall be easily mounted and secured within the frame
of the butt fusion jointing machine to produce accurately matched faces.
The trimming blades of the planer shall be sharp, contamination and
defect free cutting edges to provide continuous and uniform thickness.
The trimming blades are sharp and can cut. No attempt shall be made to
remove shavings while it is running. Switch off and remove the
trimming tool from the welding machine before attempting any
maintenance or adjustment.
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
d) Pipe cutter
e) Marker pen for marking beads
f) Bead gauge
g) Saw and saw guide
h) Pipe end cover
i) Clean clothes, preferably of cotton, shall be used to clean and wipe
the pipes before trimming and welding. If contamination cannot be
removed this way, wash the pipe with water and a clean cotton
cloth. If contamination is attributed to oil, 90% or greater
concentration of isopropyl alcohol shall be used on the cotton cloth
to wipe the ends of pipe or fittings to clean contamination.
7.2 Generator
The on-site generator is required to supply power to the heater plate, trimmer and
hydraulic pump. It shall be selected per the butt fusion machine manufacturer to
suit the butt fusion welding machine capacity and heater plate rating.
8.1 The welding area shall be protected from high humidity and windy weather
conditions. At least a tent should be made available to provide shelter during
welding.
8.2 Pipe and fittings including fusion area shall be free from cuts, gouges, deep
scratches, impurities, embedded grit or other defects. Loose contamination shall
be removed by wiping the pipe ends with a lint-free cloth on both inner and
outer surfaces. Damaged pipe and fittings shall not be used.
8.3 Remove excessive necking down at pipe ends or toe-in that could result in weld
misalignment.
8.4 All required tools and equipment are clean and in proper working order.
8.5 When joining coiled pipe, it will be necessary to allow pipe to equalize to the
temperature of its surroundings. Allow pulled-in pipes to relax for several hours
to recover from tensile stresses.
8.6 Before commencing welding, allowance shall be made for the trimming and
melting sequences to ensure correct lengths after welding.
8.7 Pipes must be correctly aligned before making connections. Accurate alignment
could be achieved by ensuring markings on pipes are in line.
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
8.8 Aligned pipe ends should then be brought into contact with the trimming planer
tool until continuous shavings are cut from each end. Loose shavings should be
removed from the welding machine and inside the pipes. Following trimming of
both ends, the pipes shall be checked again for alignment and adjustments made
before commencing welding.
8.9 The Saudi Aramco Field Project Inspector shall ensure that the
qualified/certified welder has a printed list of the correct welding parameters for
the machine and pipes to be welded provided by the pipe and fittings
manufacturer.
8.10 Heating plate surfaces shall be clean, undamaged and at the correct fusion
temperature.
Welding operator shall use all the necessary Personal Safety Equipment including a
hard, protective boots, gloves to protect hands from heater burns and sharp blades and
protective Eye Glasses.
Before commencing welding, the welding sequence, heating and cooling times
and fusion pressures should be written down for each pipe diameter using Form 1
in Appendix A, for quick reference during the welding cycle. However, some
machines have all the welding parameters on them to refer to.
After setting up all the welding parameters provided by the pipe and fittings
manufacturer, the following procedure shall be adopted:
● Clean the inside and outside of pipe or fitting and place in the clamps with
the ends against the trimming tool.
● Align by clamping the pipe or fitting ends with the stamped markings at the
top and in line. This is to obtain the best match in diameter. Also, pipes
jointed with the markings at the top help identification when the pipes are in
trench.
● Tighten the pipe/fitting clamps gradually to grip and re-round the pipes.
Pipe or fitting ends should protrude past the clamps enough so that trimming
will be complete. Bring the ends together and align as necessary.
● Start trimming both surfaces until there is minimal distance between the
fixed and movable clamps. Keep the shaving tool turning whilst opening the
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
beading tool, for each size of pipe in line with BS EN 12007. The beads and
joint shall be numbered/coded using permanent marker pen.
9.3 Butt Fusion Welding of Pipes and fittings with Different Wall Thickness
Butt Fusion welding between pipes and fittings shall be conducted provided that
all components have the same outside diameter with minimum wall thickness
that shall not be more than 25%.
Before proceeding with welding and at any change of pipe size or weather conditions,
trial joints shall be made to ensure that all machine settings and welding procedure
result in quality weld for the site conditions.
Moreover, at the discretion of the project engineer and during all the welding stages, a
randomly selected butt joint (or a number of joints) can be destructively tested in order
to assess joint quality and give confidence in the quality of the pipeline being laid.
Cut samples taken from the weld shall be subjected to tensile tests in accordance with
ISO 13953. The failure shall be ductile rather than brittle and meet a minimum tensile
strength of 20 MPa.
For pipe sizes of 6 in. (150 mm) or less, joints shall be made to form a specimen
length between the end closures not less than five times the outside diameter of
the pipe, but in no case less than 12 in. (300 mm). For larger sizes, the
minimum length including the joint shall be not less than three times the outside
diameter, but in no case less than 30 in. (760 mm). Unless otherwise stated, five
specimens shall be tested for each size.
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
The joints shall be left to cool for no less than 60 minutes before conducting the
following qualification tests.
At least 3 joints that passed the visual test shall be subjected to short time
hydraulic pressure test per ASTM D1599, Procedure B. The contractor shall
conduct this test at premises of the pipe and fittings manufacturer.
The test shall be specifically conducted to assess the integrity of each joint at a
temperature of 23, ±2°C. To determine that the joint complies with a minimum
burst requirement, the minimum allowable time to failure is 60 seconds
however, the time to failure may be extended beyond 60 seconds yielding a
more conservative result. If one of the joint failed the test, the qualification and
quality control testing shall be repeated after re adjusting the welding
parameters, until all the three joints pass the test.
Except for third party damage, butt fusion joint is as strong as the pipe and almost all
failed joints are attributed to poor workmanship. The major threat to HDPE pipeline
integrity other than third party damage is poor fusion jointing. Axial or bending
stresses caused by thermal expansion or contraction, or ground movement will increase
the risk of failure of poor joints.
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
Defects within the welded joint arising from poor installation practice will act as stress
raisers and initiation sites for stress crack growth. Joint subjected to internal pressure,
severe misalignment and bending will results in propagation of the stress crack leading
to premature failure and leakage of the transported fluid. Premature joint failure due to
these installation practices is common.
Revision Summary
8 October 2013 New Saudi Aramco Engineering Procedure.
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Document Responsibility: Non-Metallic Standards Committee SAEP-394
Issue Date: 8 October 2013 Field Butt Fusion Welding and Qualification of
Next Planned Update: 8 October 2018 Polyethylene Pipe and Fittings for Water and Gas Services
Appendix A
Form 1 - Butt Heat Fusion Joint Record
Machine type :
Serial No. :
Time : Date :
Joint number :
Job No. : Operator Full Name and Certification No.:
Pipe or pipe and fitting size and manufacturer´s Name:
Joint cycle :
Actual Permissible
Butt Fusion Welding Parameters Units
Value Values
Bead pressure ( no drag )
Joint pressure ( no drag ) Bar
Drag Bar
Heater temperature °C
Bead-up pressure Bar
Initial bead size mm
Heat soak time sec.
Heat soak pressure Bar
Dwell time (change-over time) sec.
Fusion pressure Bar
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