High Purity Systems Welding and Inspection Seminar Presented by: Roger Govaert Asahi/America Inc.
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Transcript of High Purity Systems Welding and Inspection Seminar Presented by: Roger Govaert Asahi/America Inc.
![Page 1: High Purity Systems Welding and Inspection Seminar Presented by: Roger Govaert Asahi/America Inc.](https://reader035.fdocuments.us/reader035/viewer/2022062314/56649cad5503460f9496ff4d/html5/thumbnails/1.jpg)
High Purity Systems
Welding and Inspection Seminar
Presented by:Roger GovaertAsahi/America Inc.
![Page 2: High Purity Systems Welding and Inspection Seminar Presented by: Roger Govaert Asahi/America Inc.](https://reader035.fdocuments.us/reader035/viewer/2022062314/56649cad5503460f9496ff4d/html5/thumbnails/2.jpg)
Welding Techniques
Socket Fusion
Butt Fusion
IR Fusion
HPF (Electrofusion), BCF & SIB
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Socket Fusion
Align/Prepare Material
Insert and Heat
Join and Cool
Heater
InsertsCoupling
Material
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Socket FusionLimitations
Can not be Visually Inspected from OutsideExcessive internal Cracks and CrevicesRepeatability is limitedLimited Size Ranges
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Butt Fusion Theory
TIME
PR
ES
SU
RE
Initial Melt Pressure
Heat Soak Time & PressureChange Over
Ramp Up Pressure
Cool Down Time
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Butt Fusion Process
Plane Material
Align Material
Apply Heat
Join Material
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Butt & IR Fusion ASTM D 2657
“(B)ring the melted ends together immediately with sufficient force to form a uniform flash (bead)… This is the most critical part of the whole joining procedure. If the components are brought together with too much force, all molten material may be pushed out of the joint and cold material brought into contact forming a “cold” joint. If too little force is used, only the melt beads may be fused…”
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Butt Fusion Result
Cross Sectional View
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Butt FusionLimitations
Material in Contact with Heating Element*Possible Source of Contamination
Smaller Crevice/Bead than Socket Fusion, but not small as possible
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IR Fusion Theory
TIME
PR
ES
SU
RE
Heat Soak (Pressure of Clamps on Heater, Not Material)
Change Over
Ramp Up Pressure
Cool Down Time
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IR Fusion Theory
Plane Material
Align Material
Apply Heat
Join Material
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IR Fusion Result
Cross Sectional View
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Butt & IR Fusion Importance of Pressure Control
Normal WeldNormal Weld
Material inWeld Zone
Failure mode: COLD JOINTFailure mode: COLD JOINT
No Materialin Weld Zone
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Melt Flow IndexDefinition
Melt Flow Index measures the rate of extrusion of molten resins, through a die of specified length and diameter, under prescribed conditions of temperature, load, and piston position in the barrel, as the timed measurement is being made.
ASTM D 1238
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Melt Flow IndexImportance to Welding and Weld Inspection
The melt flow index is measured to determine the flow behavior of thermoplastic materials.
Different indexes within thermoplastic families and groupings display different welding characteristics.
The higher the index, the larger the bead under constant parameters
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Solef® HP PVDF ResinMelt Flow Indexes for Purad by Asahi/America
Pipes 1010/0001 MFI = 4 - 7 g/10min
Fittings (2-1/2” - 12”) 1008/0001 MFI = 22-27 g/10min
Fittings (1/2” - 2”) 1009/0001 MFI = 12-16 g/10min
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GF PVDF ResinMelt Flow Indexes for Sygef®
Pipes Kynar 740®
MFI = 2 - 2.5 g/10min
Fittings (1/2” - 9”) Solef® 1008/0001 MFI = 22-27 g/10min
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PolyPure® Resin Melt Flow Index
RA 130E random co-polymer natural polypropylene Test Cond. 190/5, MFI = 0.5 g/10min Test Cond. 230/2.16, MFI = 0.3
g/10min Test Cond. 230/5, MFI = 1.25 g/10min
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IR Weld Inspection Common Causes for Failure
AlignmentEnvironmentIncorrect ParametersImproper PlaningImproper Joining
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IR Weld Inspection Alignment
Symptom: Joining Areas are offset by greater than 10% of wall thickness.
Cause: Misalignment, lack of alignment control or inspection
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IR Weld Inspection Misalignment
Symptom: Angular Deviation
Cause: - Faulty Alignment- Improper Planing- Improper Clamping
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IR Weld Inspection Environment, Heat or Parameters
Symptom: Inconsistent Bead Size or Excessive Weld Notch intruding into joining area
Cause: - Excessive Draft- Improper Heat- Wrong Weld Parameters
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b1 b2
IR Weld Inspection Uniformity
Symptom: Non-uniform welding beadCause: Non-angular joining surfaces resulting in diversely built-up welding beads locally or all along the weld length, caused by improper planing or inconsistent heatingAcceptable variation of the beads = b1 0.5 x b2
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IR Weld Inspection Uniformity
Symptom: Narrow, excessive welding bead. Excessive and sharp-edged welding bead locally or all along weld length or weld circumference.
Cause: Inadequate welding parameters.- Too much joining force or - Too quick joining- Wrong Weld Parameters
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IR FusionPolyPure & PP Inspection / Bead Size
2019181716151413121110987654 321 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Bea
d S
ize
(b) m
m
Wall Thickness (S) mm
Allowable bead size as Allowable bead size as measured on outside beadmeasured on outside bead(recommendation - only)(recommendation - only)
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IR Fusion UF2000 Semi-Automated Welders
UF2000-1 1/2” - 2” UF2000-2 2 1/2” - 10”
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IR Fusion UF2000 Semi-Automated Welders
Programmed ParametersComputer Monitored
PressureSemi-Automated ProcessIntegrated PrinterReliable Welds
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IR Fusion SP Automated Welders
SP-110 1/2” - 4” SP-250 2 1/2” - 10”
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IR Fusion SP Automated Welders
Automated Fusion ProcessTouch Screen OperationControls and Monitors:
Welding ParametersHeatingJoining Force and Time
Computer MemoryEngineered for PureBond®
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IR Fusion SP Automated Welders
Touch Screen Control
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IR Fusion SP Automated Welders
Weld Info Documentation
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IR Fusion SP Automated Welders
Magnetic Clamps
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IR Fusion SP Automated Welders
Quick & Easy Alignment Control
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IR Fusion SP Automated Welders
Quality, Uniform Welds
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HPF Fusion Theory
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HPF Fusion Process
Plane Material
Insert Coupling
Align Material
Insert Balloon
Scan Size Code
Complete Weld
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HPF Fusion Result
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HPF Fusion Weld Time Comparison
0
200
400
600
800
1000
1200
1/ 2" 3/ 4" 1" 1 1/ 4" 1 1/ 2" 2"
HPFwithBalloon
HPFWithoutBalloon
BCF
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HPF Fusion Labor Comparison
Size Pipe Fittings WeldCount
½” 200’ 25 37
1’ 1000’ 75 136
1 ½” 500’ 50 81
2” 1500’ 75 166
Total Amount of Welds = 420Total Amount of Welds = 420
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HPF Fusion Labor Comparison Cont.
Welding Time Time Savings (hours)
Size HPFWith
Balloon
HPFWithoutBalloon
BCF Timesavings
withballoon
TimeSavingswithoutballoon
½” 4.1 .93 6.75 3 6
1” 23 7.9 31 8 23
1 ½” 18 6.75 24 6 17
2” 45 16 48 3 32
Total 90.1 32 109.75 20 78
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IR Fusion Sample QA Log
Date:Operator:Machine Type:Machine SN#:Coupon Material PVDF PP PPn E-CTFE PFA
Size½” (20mm)¾” (25mm)1” (32mm)
1 ¼” (40mm)1 ½” (50mm)2” (63mm)3” (90mm)4” (110mm)
Inspector:Print Name Signature Date
Place WeldCoupon Labels
Here
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HP SystemsThank You