Safe and correct installation in electrofusion: Lessons from the recent incident in Australia

The safe and proper use of electrofusion equipment, in combination with the correct installation of fittings and pipes, is essential in industries relying on piping systems, particularly when these systems are used to transport gas, water, or other critical fluids. While electrofusion technology offers a reliable and efficient means to join polyethylene (PE) pipes, recent incidents, like the one in Australia where a coupler exploded due to improper installation, once again highlight the importance of stringent safety standards and proper training for installation professionals.

The Australia Incident: A stark reminder of installation risks

On July 22, 2024, an explosion occurred at Cadia Mine, NSW, during an electrofusion welding task involving HDPE components. Two workers were extending a pipeline in a tunnel when a welding process went awry, leading to a severe incident. The investigation found that abrasive sanding pads and paper towels were used to clean pipe ends, which likely contributed to the explosion. After completing the welding, the workers left the area; upon their return, they noticed smoke, and shortly after, an explosion occurred, scattering debris over 60 meters. Fortunately, no injuries were reported.

The incident underscores the critical need for proper preparation and adherence to safety protocols during electrofusion welding. Using inappropriate cleaning methods, such as abrasive grinders, can introduce significant risks, emphasizing that correct procedures must be followed to ensure safe installation.

Understanding electrofusion technology

Electrofusion technology involves the use of a special fitting with embedded heating elements that, when energized, fuse the fitting to the pipe. This method creates a strong, leak-proof joint ideal for gas and water distribution systems. The process is praised for its efficiency, reliability, and minimal environmental impact compared to other jointing methods. However, achieving a perfect joint requires meticulous attention to detail during installation.

One of the widely recognized systems in this technology is the ELGEF Plus electrofusion system by GF Piping Systems. ELGEF Plus fittings are known for their superior quality, robust design, and ease of installation. They come with precise fusion indicators and are designed to work seamlessly with electrofusion units, ensuring consistent results when used correctly. However, as with any high-quality system, the outcome heavily relies on proper installation practices.

Key steps in the electrofusion process include:
 

• Preparation of pipe surfaces: Mechanical peeling the pipe surfaces is essential to remove the oxidized layer and any contaminants that can compromise the fusion process. Electrofusion welding technology requires a UV layer free surface to establish a strong welded connection between the pipe and fittings.

Proper cleaning of the pipe surfaces is crucial in the electrofusion process. Only approved sharp bladed peeling tools should be used to remove the oxidized layer, ensuring a clean and smooth surface for fusion. Insuring a consistent minimum peel chip thickness min. 0.2mm is essential to a strong bond. (The recent incident in Australia highlights the dangers of using improper surface preparation methods or tools, such as abrasive grinders, which can introduce contaminants and compromise joint integrity. Incorrect preparation can lead to weak bonds, increasing the risk of failures and, in extreme cases, explosions.) Following manufacturer-recommended instructions is essential to ensure safe and reliable installations.

Did the installer check the SDR rating capability between electrofusion coupler and pipe? If the pipe was a thin-walled low pressure pipe this can lead to heat penetrating the pipe wall.

• Alignment and clamping: Proper alignment and clamping ensure that the pipe and fitting remain in position during the heating and cooling phases. The ELGEF Plus system is designed with clear visual guides to help installers align the components correctly.

• Fusion cycle: The electrofusion unit controls the heating cycle, ensuring that the right amount of electrical energy is applied for the correct duration. GF Piping Systems’ electrofusion system works optimally when the machine is set according to the fitting’s specific requirements by considering the ambient temperature. This can easily be done by simply scanning the barcode on the fitting to identify the correct parameters. Deviations from the prescribed settings can lead to incomplete fusion or overheating, degrading the material. Units must be calibrated yearly. The ELGEF Plus fittings are equipped with limited path fusion indicators that indicate that the welding has been carried out. Also, due to the fittings’ design, they do not allow any melt flow to the outside.

• Cooling time: Allowing the joint to cool undisturbed is crucial. Our electrofusion units (MSA) also indicate the cooling time as an extra safety feature.

Common installation errors and their consequences

While electrofusion offers numerous benefits, its effectiveness hinges on the correct execution of each installation step. Unfortunately, errors are not uncommon, often due to insufficient training or pressure to complete installations quickly.

Common mistakes include:

• Ensuring the pipe and electrofusion fittings are compatible and attention the minimum pipe wall thickness is observed to meet the electrofusion couplers SDR rating.

• Inadequate mechanical peeling: Failure to properly peel the pipe surface is one of the most frequent errors. This oversight leaves behind contaminants that prevent a complete bond, leading to weak joints prone to leaks or failures under pressure. Installers must check the consistency of the peel chip and the thickness to insure the oxidized or contaminated surface has been removed 0.2mm minimum above 63mm fittings.

• Incorrect clamping: Inadequate or improper clamping during the fusion process can cause misalignment, resulting in joints that are not fully fused. This misalignment creates weak points that can fail and cause fires under operational stresses.

• Overheating or underheating: Incorrect manual settings on the electrofusion unit can result in either overheating, which degrades the material, or underheating, which results in an incomplete fusion. Ensure electrofusion units are calibrated yearly.

• Premature handling: Moving or disturbing the joint before it has fully cooled can introduce stress fractures or misalignments that compromise the joint’s integrity.

The consequences of these errors can be severe, ranging from minor leaks to catastrophic failures like the one recently observed in Australia.

The role of proper training for safe electrofusion installations

The recent incident in Australia is a clear indicator that the safe use of electrofusion technology is not just about having the right equipment; it’s about having the right skills and knowledge. Proper training is paramount to ensure that operators understand the critical steps of the installation process and the potential hazards of incorrect practices.

Training should cover the following aspects:

• Understanding the equipment: Operators must be familiar with the specific electrofusion units they are using, including how to set and verify the correct parameters for different types of fittings and pipes.

• Step-by-step installation procedures: Detailed guidance on each step of the process helps installers avoid common mistakes and reinforces the importance of following protocols meticulously.

• Recognition of faults: Installers should be trained to recognize signs of improper fusion, such as fitting deformation, liquid PE squeeze-out and understanding of the welding indicators (two pins coming out after successful pressure buildup) or a loose fitting after welding and cooling time and understand how to troubleshoot these issues before completing an installation. The installer/welder also needs to check the feedback of the welding unit. If the machine or the protocol indicates that the fusion was incomplete the installer needs to cut it out and replace it.

• Safety protocols: Emphasizing safety measures, including the correct use of personal protective equipment (PPE) and emergency procedures, is essential to mitigate risks. Additionally, there are several testing methods to find out the quality of a weld: destructive testing, or ultrasonic non-destructive testing.

• Ongoing assessment and certification: Regular assessments and certifications ensure that installers maintain high standards of proficiency and are updated on the latest industry practices and standards.

Conclusion: Commitment to training as a safety imperative
It's important to note GF Piping Systems’ ELGEF Plus fittings should not be sold as a commodity. Electrofusion fittings are highly engineered products they require trained and skilled workers to operate. Having the correct tools including sharp mechanical peelers, clamps and calibrated machines is essential to insure a long-term leak free joint.

The safe use of electrofusion technology is critical in ensuring the integrity of piping systems in a wide range of applications. The recent incident in Australia serves as a reminder that proper installation cannot be taken for granted. Errors in the fusion process can lead to severe consequences, putting lives, property, and the environment at risk.

Investment in comprehensive training programs is not just a best practice—it is a necessary commitment to safety and quality. By equipping installers with the knowledge and skills they need, the industry can prevent incidents like the one in Australia and ensure that electrofusion joints continue to deliver the reliability and performance that make them a preferred choice for modern piping systems.

Through proper training, adherence to standards, and a commitment to continuous improvement, the safe use of electrofusion technology can be upheld, protecting both people and infrastructure.

Book your training with us in our Global Academy.

About the authors:

Bruce Dyne is the Business Development Manager for GF Piping Systems in Australia, bringing over 30 years of experience in the piping industry. Trained by GF since 1998 and starting with GF Australia at just 25, Bruce transitioned from the building and irrigation piping sector to specialize in the installation of PE pipelines using advanced jointing technologies. With 26 years of hands-on expertise in butt fusion, electrofusion, and infrared welding, Bruce is dedicated to ensuring the long-term reliability of piping systems through proper training and failure prevention strategies.

Torben Schulz, born in Germany's picturesque Black Forest, holds a degree in Industrial Engineering with a focus on Marketing and Sales from HFU University in Furtwangen. He began his career with Georg Fischer in 2013, where he gained comprehensive experience through roles in product management, sales, and training, each expanding his expertise across various business functions. Now a Customer Success Manager, Torben leverages his strategic acumen and hands-on knowledge to drive outstanding customer satisfaction and long-term success.

Business contact:

Bruce Dyne
Business Development Manager Utility – GF Australia
Bruce.Dyne@georgfischer.com

Torben Schulz
Customer Success Manager
Torben.Schulz@georgfischer.com

Media contact:
Constanze Werdermann, Global PR Manager
constanze.werdermann@georgfischer.com
+41 76 33 99 218

GF Piping Systems
As the leading flow solutions provider for the safe and sustainable transport of fluids, GF Piping Systems creates connections for life. The division focuses on industry-leading leak-free piping solutions for numerous demanding end-market segments. Its strong focus on customer-centricity and innovation is reflected by its global sales, service, and manufacturing footprint and its award-winning portfolio, including fittings, valves, pipes, automation, fabrication, and jointing technologies.

GF Piping Systems has its own sales companies in 33 countries, which means it is always by its customers' side. Production sites in 40 locations in America, Europe, and Asia ensure sufficient availability and quick, reliable delivery. In 2023, GF Piping Systems generated sales of CHF 2'1 bn and employed 8'798 people. GF Piping Systems is a division of Georg Fischer AG, founded in 1802 and headquartered in Schaffhausen, Switzerland.
www.gfps.com
 

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