Safe and correct installation in electrofusion: Lessons from the recent incident in Australia - GF Piping Systems

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:

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.

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:

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:

Conclusion: Commitment to training as a safety imperativeIt'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 DyneBusiness Development Manager Utility – GF [email protected]

Torben SchulzCustomer Success [email protected]

Media contact:Constanze Werdermann, Global PR Manager[email protected]+41 76 33 99 218

GF Piping SystemsAs 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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