Proper training and certification for High Density Polyethylene (HDPE) pipe welding can be the stepping stone to a more sustainable and better quality pipeline networks
"Just as you would not let somebody drive your new Mercedes car without a driving license, you shouldn't allow someone who has not been properly trained to weld HDPE pipes." Backing the observation is over 10 years of experience in the oil & gas and water pipeline industry. But Fabian Beermann's decade plus experience with plastic pipes have taught him that the problems start with the arrival of the pipes on the site. The Division Manager for Plastic Welding Technology in BMC Gulf elaborated: "In PE piping, the entire quality chain is important. Yes, we have excellent raw material available in the GCC from suppliers such as Borouge; we also have state-of-the-art pipe manufacturers. But what about the mistakes after the site after the pipes are delivered?"
Beermann found that a common problem is damage caused to the pipes by the use of wrong storage and handling methods at the site. Further down, during the welding process issues arise due to the use of incorrect welding parameters or pressure testing of pipes. The reason: Both welders and welding supervisors lack proper knowledge of the working process. "If a quality product is installed by somebody who is not sufficiently well-trained and educated, you will face serious quality problems with your piping system," warns Beermann.
To tackle the welding issue, BMC Gulf opened the region's first training centre for PE pipe welders in June 2008. The centre, set up in partnership with the German Plastic Institute SKZ, is based in the UAE. "As a solution provider in the field of thermoplastics, from piping and lining systems made of HDPE, PP, PVDF and ECTFE to welding machines to laboratory testing equipment, it is in our interest to educate the market and develop the standards," said Beermann. "You can say the SKZ institute is the equivalent of the driving school for the plastic welder."
Why did BMC Gulf choose SKZ as its partner? Beermann pointed out that SKZ is the most experienced player in the market, operating as a non-profit organisation in the field of plastics for over 50 years. He continued, "As the market leader, SKZ is training and certifying over 4,000 HDPE pipe welders every year for the German Technical and Scientific Association for Gas & Water (DVGW). In addition, SKZ is an approved institute for third party certification, testing and site supervision."
At present, SKZ is offering two PE pipe welding training courses. 'Certified HDPE Pipe Welder GW330' is a basic training course for technicians welding the PE pipes at the site. The advanced training course titled Certified HDPE Pipe Welding Supervisor GW331 is for engineers and consultants supervising the projects. Interestingly, the welder's license issued by SKZ after successful completion of the course is valid only for one year. To extend the license, the hoder is required to attend a one-day refresher course. Beermann said, "This ensures that all holders of an SKZ Welder License are well trained and remain up-to-date. The contents and the validity of the Welder Licenses offered by SKZ are based on the established regulations of DVS and DVGW."
In the region, SKZ has instituted minimum requirements for the attendees. "In the Middle East, one has to deal with different nationalities and different levels of education," explained Beermann. A key requirement is that all participants should possess a minimum basic understanding of English because most of the installation manuals for PE fittings and the operating instructions for the welding machines are in English. "Furthermore, contractors had to understand they are not paying for the license but for the training. If the attendee does not pass the practical and theoretical examination at the end of the training period, SKZ will not issue a license to the person," he added.
Training courses apart, what about welding machine itself? Beermann said that the German Welding Society or DVS Technical Codes on Plastic Joining Technologies clearly describes the requirements on welding machines for the butt-fusion and electro-fusion process (Technical Code DVS 2208). Further it is recommended to use automatic CNC welding machines equipped with a data logger unit. These machines record the complete welding data (Traceability Welding Reports), which can be integrated in the GIS system of the network owner. "The welding equipment is a very important factor in the installation of PE piping systems," he stressed.
PE piping networks owners in the country such as ADM and ADWEA have availed of the benefits of the SKZ Training Centre. Beermann said, "Germany's water leakage rate of 7.3% is among the lowest in the world compared to over 50% for some areas of the Middle East, which implies that nearly half of the water produced through expensive desalination during the transportation stage is lost due to leaking pipes. I strongly believe that the use of PE and the professional training of the welder can help reduce these leakage rates to the levels in Germany."
Beermann also feels that need is greater for implementation of stricter installation standards. He continued, "Enforcement of standards during the installation process through well-trained inspectors employed by the authorities or their consultants is also important. If an inspector is not familiar with the PE material, he will not be able to ensure the quality meets the required standard."
Over the past two years, SKZ has trained over 250 PE pipe welders in the Middle East. Such systematic training and certification, feels Beermann, will contribute to the quality and longevity of PE pipes, increase the value of construction projects and considerably extend their service life. "The reward will be a sustainable piping system for the cities which is very important just like the veins of a human body," he concluded with an apt analogy.
© H2O 2011
