🧿1. Main Causes of Leakage in Electric Fusion Joints

Electrofusion joints work by using a built-in resistance wire to heat the pipe and fitting, fusing them together. If leakage occurs, the root cause is the failure to form a complete, sufficiently strong fusion at the weld interface. The specific causes can be summarized as follows:

1. Improper Operation (the most common cause):

Incorrect Welding Parameters: Failure to use the welder's automatically recognized parameters, or manual input of incorrect voltage and timing, can result in insufficient heating (cold welds) or excessive heating (carbonization).

Inadequate Oxide Scraping: Failure to scrape or insufficient scraping distance can hinder effective fusion.

Inappropriate Clearance: Excessive or insufficient clearance between the pipe and fitting affects the flow and pressure buildup of the molten material.

Insecure Clamping: Pipe movement during welding can result in "false welds."

Environmental Factors: Welding in strong winds, rain, or extreme temperatures without protective measures can affect weld quality.

2. Material Issues:

Pipe/Fitting Mismatch: PE materials of different brands and materials may have melt index incompatibilities. Quality defects: Uneven distribution of resistance wires in pipe fittings, open circuits, or pipe roundness or wall thickness that exceeds tolerances.
3. Equipment issues:
Electrofusion welder malfunction: The output voltage is unstable and fails to provide the required energy.
Poor contact at the terminal: This results in insufficient voltage applied to the pipe fitting.
4. Later damage:
After the joint is completed, improper external impact, settlement, or stretching damage the weld structure.

🧿II. Troubleshooting Leaks in Electrofusion Joints

Upon discovery of a leak, first close the upstream and downstream valves and depressurize the pipeline to ensure a pressure-free operation. Then, select the following method based on the leak and site conditions:

1. Removal and Rewelding (The Most Thorough and Standard Method)

Steps: Completely remove the leaking electrofusion fitting and the affected section of pipe at each end, replace with new pipe and electrofusion fittings, and reweld.

Advantages: Completely eliminates potential hazards, maximizes reliability, and complies with regulatory requirements. Disadvantages: Long operation time, requiring large equipment and space for pipe cutting, butt welding, and high costs.

2. Using an Electric Fusion Leak Repair Clamp (the most common and effective repair method)

Steps: Clean the pipe surface around the leak, wrap a dedicated electric fusion leak repair clamp around the leak, and weld it to the main pipe to create a permanent seal.

Advantages: Fast, no need for extensive excavation, and reliable sealing (see Section 3 for details).

3. Using a Sealing Agent (Not Recommended for PE Pipes)

For pressure pipes, using sealing agents (such as steel putty and epoxy resin) is rarely effective and may contaminate water quality, so they are generally not considered.

🧿 3. Advantages of Using Leak Repair Clamps

For leaking electrofusion joints, using an electric fusion repair clamp is currently recognized as the best and most popular permanent repair solution. Its advantages are significant:

1. Permanent Repair: The leak repair clamp is an electric fusion pipe fitting that fuses to the main pipe through heat. Its strength and airtightness are equivalent to a new joint, and it is permanent, not a temporary clamp.

2. Fast Installation: No need to cut the existing pipe or perform complex joint assembly work. Simply clean the surface, install the leak repair clamp, and weld it, significantly reducing water outage time and improving emergency repair efficiency.

3. Smaller Operating Space Requirements: Compared to hot-melt welding, which requires large hydraulic equipment, electric fusion repair clamps only require excavation around the leak to accommodate the leak repair clamp and operating tools. They are particularly suitable for work in locations with limited excavation space (such as near buildings or other densely populated pipelines).
4. High Reliability: The leak repair clamp has multiple built-in sealing rings and resistance wires. It initially stops the leak mechanically, then permanently seals it with electric fusion. This double-safety design provides a high safety factor. 5. High Adaptability:
It can repair leaks at various joint angles (such as tees and elbows).
It comes in a variety of configurations, including full-wrap and sheet-type, to suit different damage scenarios.
It can be used to repair cracks and holes in the pipe itself, not just joints.
6. Standardized Operations: The installation process has clear process requirements (scraping oxide layers, installation, and welding), facilitating quality control and reducing the impact of human factors on repair quality.

The housing is typically made of metals such as ductile iron and carbon steel, which are corrosion-resistant and high-strength. It can last the same life as the original pipe, eliminating the need for frequent repairs. Baoshuo brand carbon steel half joints are available in a variety of rubber materials, including NBR, EPDM, FKM, and silicone rubber. The half joint body is available in Q235 carbon steel and 304 and 316L stainless steel.

The following are Baoshuo brand oil-resistant pipe repair clamps, high-temperature-resistant pipe repair clamps, acid- and alkali-resistant pipe repair clamps, stainless steel pipe repair clamps, high-pressure-resistant pipe repair clamps, and large-diameter pipe repair clamps.

🧿Summary and Recommendations

Cause of Leakage: Mostly due to human error. Strengthened welder training and oversight of the installation process are necessary.
Resolution: Electric fusion repair clamps offer the best balance of reliability, efficiency, and cost-effectiveness.
Key Operational Key: Regardless of the method used, thoroughly cleaning the pipe surface (scraping oxide layers) and strictly following the welding parameters specified in the product manual are crucial for a successful repair.

We recommend that you choose reliable brand leak repair clamps for emergency repairs and have them performed by licensed professionals to ensure the long-term safe and stable operation of the repaired piping system.