PE Hot Tapping and PE Line Stopping Services for HDPE Pipelines

The PE electrofusion branch saddle structure diagram of Xinyu Feihu Pipeline Technical Equipment Co.,Ltd. is shown below. The product is connected to the pipe by electrofusion connection, which can be applied to fields such as water supply and gas transmission pipelines.

Before using the Xinyu Feihu ’s PE electrofusion branch saddle, please carefully read

the following instructions and strictly follow them for construction operations:

Step 1: Open the product packaging, check if the product specifications and appearance meet the usage requirements, and carefully read the operating manual .

Notes ：

◆ After opening the packaging, it is necessary to ensure that the welding surface of the product is clean and not contaminated by mud, water, etc;

◆ It is necessary to confirm whether the product specifications meet the requirements.

Step 2: Clean the welding surface of the pipe, mark the welding area on the pipe, and scrape off the oxide layer on the welding surface of the pipe

Notes ：

◆ Specifications which are not bigger than dn90 are only used for SDR11 series pipes, other specifications can be used for SDR11 or SDR17 series pipes at the same time;

◆ The scraping of the oxide layer on the welding surface of the pipe must be sufficient, uniform, and smooth, without producing obvious grooves, unevenness, or defects that affect the welding quality and performance;

◆ Ensure that the pipe and PE electrofusion branch saddle welding surface are dry and clean, without obvious water marks or impurities such as mud and sand.

Step 3: Attach the welding surface of the saddle fitting to the welding surface of the pipe with the oxide layer scraped off, and tighten it with bolts.

Notes ：

◆ Pay attention to whether the installation direction of PE electrofusion branch

saddle is correct ；

◆ Ensure that the welding surface of the PE electrofusion branch saddle matches the welding surface of the scraped oxide layer on the pipe;

◆ When using a wrench to tighten the bolt to fix the PE electrofusion branch saddle, the locking force should be appropriately large, and there should be no obvious gap between the arc surface of the PE electrofusion branch saddle body and the surface of the pipe.

Step 4: Connect the electric fusion welding machine, input the welding process, confirm it is correct, and then start welding.

Notes ：

◆ It is necessary to use a regular welding machine that meets the requirements of national standards;

◆ There are two welding methods available:automatic scanning and manual input based on the bar code on the PE electrofusion branch saddle;

◆ Reliable measures must be taken to introduce static electricity underground and prevent adverse consequences caused by static electricity;

◆ During the welding process, personnel must maintain a distance of no less than 1 meter from the welded parts to prevent personal injury caused by accidents such as spraying during the welding process;

◆ During welding, it is not allowed to move the fittings or apply external force to the welded parts.

Step 5: Check the quality of the welded joint after welding is completed and cooled.

Notes ：

◆ Mainly observe whether there are any abnormal phenomena during the welding

process and cooling period;

◆ After cooling, conduct a preliminary inspection and judgment on the condition of the welding surface, observe if there are any abnormalities, and if necessary, replace the fittings and reweld.

Step 6: Branch line overall pressure test.

Notes ：

◆ When using a PE electrofusion branch saddle to add a branch on a main pipeline that is already in operation, after welding and sufficient cooling (preferably not less than 4 hours), the added branch line must undergo an overall pressure test before drilling, and it ’s forbidden to perform drilling before passing the test.

Step 7: After passing the branch line pressure test, replace the air with inert gases such as nitrogen.

Notes ：

◆ After the main pipeline is drilled, the fuel gas will quickly enter the branch line and mix with the original gas in the branch line. In case of accidents, there is a risk of explosion or detonation. Therefore, after the branch line pressure test is qualified, before the main pipeline is drilled under pressure, the air in the branch line must be replaced with inert gases such as nitrogen.

Step 8: Use a special wrench to rotate the built-in drilling tool in the PE electrofusion branch saddle to drill holes in the pipe.

Notes ：

◆ After the welding of the PE electrofusion branch saddle body is completed and fully cooled (should be more than or equal to 4 hours), and the branch line has undergone pressure testing and inert gas replacement, drilling of the pipe can be2carried out. Before drilling, the medium pressure in the main pipeline must be reduced to less than or equal to 0.2MPa;

◆ When drilling, the hexagonal socket on the wrench must be fully inserted into the bottom of the hexagonal groove on the upper end of the cutter;

◆ When turning the wrench, apply even force and always keep the wrench perpendicular to the upper end face of the cutter;

◆ When encountering significant resistance during the drilling process, the cutter can be reversed appropriately before continuing to drill downwards;

◆ When the cutter is about to complete the drilling work, the torque will significantly decrease. At this time, it is necessary to continue rotating the cutter until the resistance of the cutter suddenly increases again (at this time, the cutter is in contact with the limit device of the PE electrofusion branch saddle body, making it difficult to continue drilling downwards, and the torque increases sharply), in order to avoid incomplete drilling. However, at this time, no more force should be applied to continue drilling downwards to prevent the cutter thread and outer surface from getting stuck in the contact surface with the saddle product, resulting in the inability to retract the cutter or damaging the quality of the welding surface.

◆ After drilling through the pipe, retract the cutter to a position slightly lower than the upper end face of the PE electrofusion branch saddle body;

◆ During the drilling process, it is necessary to avoid damaging the upper surface of the PE electrofusion branch saddle body, which may affect its sealing performance with the electrofusion end cap.

Step 9: Cover the upper end of the PE electrofusion branch saddle body with an electrofusion end cap, tighten it with tools such as pliers, and then perform electric fusion welding on the electrofusion end cap .

Notes ：

◆ Before installing the electrofusion end cap back into the PE electrofusion branch saddle body, ensure that the inside of the electrofusion end cap and the matching area of the PE electrofusion branch saddle body are clean and free of impurities to avoid affecting the sealing performance;

◆ Ensure that the O-ring seal on the electrofusion end cap is installed in place and not detached from the O-ring groove;

◆ Use tools to tighten the electrofusion end cap, and use a professional leak detector to check and confirm that there is no gas leakage at the electrofusion end cap；

◆ Using an electric fusion welding machine, perform electric fusion welding on the electrofusion end cap according to the welding process parameters marked on the electrofusion end cap (the oxide layer on the welding surface of the electrofusion end cap and PE electrofusion branch saddle body has been removed in the factory and does not need to be scraped off on site, and other welding precautions are the same as those for ordinary electric fusion fittings).

Solemn statement :

● The above construction steps can be applied to both pressurized and unpressurized pipeline situations. When welding under pressure, it is advisable to first reduce the pressure of the pipeline medium to less than or equal to 0.2MPa;

● When there is pressure inside the pipeline, it is necessary to close the pipeline or reduce the pressure inside the pipeline to less than or equal to 30.2MPa before drilling ；

● Before drilling under pressure, it is necessary to replace the air in the branch line that has passed the pressure test with inert gas；

● When working under pressure, please take anti-static measures, pay attention to ventilation, and prepare safety protection measures such as fire protection;

● When operating with gas, operators must wear anti-static clothing and shoes, and explosion-proof lighting equipment must be used for night work;

● Other operations shall be carried out in accordance with the relevant construction specifications for PE pipelines.

TEL/FAX:86-790-6869686

E- mail: xyfhpipeline@gmail.com

Xinyu Feihu Pipeline Technical Equipment Co.,Ltd.