METHOD STATEMENT FOR BUTT FUSION WELDING OF

HOPE PIPES AND FITTINGS

Butt Fusion Welding
Only approved, well maintained machines and trained and certified Technicians should
be deployed.

Equipment

Generator to power the machine's heater, trimmer and hydraulic pump.

Welding machine of suitable size, including clamp frame, clamp shells, trimmer and an
electrically operated Hydraulic pump.

Pipe Support Rollers I Cut pieces of pipes.

Pipe end covers {for use during inclement weather only)

Welding tent {for use during inclement weather only)

Clean, dry, lint-free cloth.

Calibrated digital thermometer.

Timer

Pre-welding checks
Before commencing a welding operation, check
that:

Know the correct welding parameters for the machine and pipe being welded.
{These are normally on the machine's data plate. If In doubt, refer to manufacturer/
supplier of HOPE Pipes).

The generator is in good operating condition and the power output is without voltage
fluctuations .

The pipes to be welded are of the same material and SDR (wall thickness).
Dummy welds
Before a welding session, a dummy weld may have to be carried out to clean the
heater plate. The welding process (see instructions below) should be followed up to
the heat soak stage, at which point the weld may be aborted. Any dirt will be
transferred from the heater plate to the pipe end which, when cold can be re-trimmed
for welding .

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Fusion Welding Procedure Pipe end

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preparation
1.
Place the welding machine on a clean, dry surface such as a board. In inclement
weather the machine shall be enclosed within a tent.

2.

Open fully the machine carriage.

3.

Place pipes to be joined on rollers to ensure free movement during welding .

Refer Photo No.1.

4.

Ensure pipes are correctly aligned and adjust rollers as necessary. Clean

5.

pipe ends, taking care to remove embedded grit.

6.

Fit pipe trimmer and place pipes on the welding clamp with pipe ends touching
trimmer . Refer photo No.2

7.

Tighten pipe clamps.

8.

Start trimmer and close machine carriage.

9.

Trim pipe ends until a running swart strip of full pipe wall thickness is produced.

10.

Stop machine and remover trimmer.

11.

Remove swart. Do not touch planed surfaces.

12.

Check visually that both pipe ends are completely trimmed. Bring

13.

pipe ends together, check for alignment and gaps.

14.

If necessary adjust rollers, re-trim and check again.

15.

Determine drag pressure for the weld by noting pump pressure required to active the
machine.

Making the weld:

1.

Place heater plate in machine and close carriage. Refer photo No.3

2.

Apply the correct bead-up pressure (including drag pressure).

3.

When initial bead has reached required size around each pipe end, reduce gauge pressure to
specified heat-soak pressure (or zero if none is needed). Refer photo No.4

4.

Heat-soak period begins as soon as bead-up pressure is released. Set cheater to the right soak
time for the pipe.

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5.

Open carriage and carefully remove heater plate.

6.

Within maximum plate removal time, close carriage, bringing molten pipe ends
together. Refer photo No.5

7.

Apply correct fusion pressure (including drag pressure}.

8.

Check and maintain fusion pressure during in-machine cooling time.

9.

Carefully remove welded pipe string from clamps and allow to cool before
stressing the joint excessively or de-beading. Refer photo No.6

Post-welding checks:
1.

Check that bead sizes are uniform.

Butt Fusion Registration Log Sheet

Before, during and after welding operation, significant parameters viz. pipe dimensions
& Pressure Rating, Welding Temperature, Heating & Cooling Period, etc have to be
recorded in a Butt Fusion Welding Log Sheet. Refer attached format.