Dimi Pesudovs, Training Committee
18 March 2003

PIPA has been developing strategy for the role it should play training people working in the pipeline systems industry. The area that requires immediate attention is fabrication and installation. The PIPA Board has issued a direction to develop a strategy for welding of polyethylene pipes.

To gain first hand knowledge of the type of welding courses presented to the industry Dimi Pesudovs attended and participated in a butt welding training offered by Agru Australia Pty Ltd and conducted by Damian Hamilton at Waterways of Singleton.

The course was conducted over two days and covered: Occupational Health and Safety Moulding materials, PE80 and PE 100 Pipes and fittings (sizes, SDR and PN) Australian Standard AS/NZS 4130:2002 DVS 2207 for butt and socket fusion Calculation of welding parameters Factors causing bad welds Practical training in butt and socket welding Theory assessment Practical assessment including tensile testing of welds prepared by students Awarding of certificates

The course was attended by five people from three different organisations in a well structured interactive environment. Course notes were provided and Damian Hamilton explained in detail each segment of the course allowing adequate time for questions and discussions. Critical aspects of the butt welding and socket fusion processes were emphasised and repeated several times.

Practical demonstrations followed which looked straight forward until participants attempted to repeat Damian's example. The Socket fusion exercise produced a complex fabricated piece, incorporating elbows and T-fittings, that looked like something out of "Heath Robertson" collection. The Butt fusion exercise quickly demonstrated the need to fully understand the welding parameter calculations and to correctly apply them to the weld.

Under Damian's guidance the class slowly came to grips with the task and healthy competition started to develop among the participants. By the end of the first day everyone felt confidant that the assessment scheduled for the next day could be passed. The class adjourned to the local pub and the first beer really tasted great.

The second day commenced with some revision followed by a good session on the reasons for bad welds. Damian had a good collection of stories from his many years of experience in the field of projects that had failed through poor understanding of materials, welding parameters and techniques.

Assessment of the theoretical understanding of butt and socket fusion followed. This was an open book exam and all participants passed with flying colours.

The practical assessment was next and here nerves started to play a part. In the practice session before the assessment some forgot to add drag pressure to the welding pressure, others had trouble with soak time and pressure and a few had difficulty with ramp time. In fact every one made mistakes with some part of the welding process.

When the final test came good welds were produced that met approval from Damian's critical eye and passed the tensile strength test.

The course clearly demonstrated there is a right way to weld polyethylene pipe and there are many wrong ways of doing the job. Calculation of the welding parameters is critical and every welder should pay close attention to this part of the job. Good understanding of the equipment and making sure it is in good working order will go a long way towards success. Finally, the welding process must be followed explicitly and that will lead to a result that will satisfy the customer, generate payment for the job and enhance the reputation of the welder and his company.

For Further information please contact :
Plastics Industry Pipe Association of Australia Ltd
Suite 246, 813 Pacific Hwy, Chatswood NSW 2067
or email plasticspipe@pipa.com.au