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Sudarshanpipes

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Sudarshan Electrofusion Fittings

Sudarshan Electrofusion Fittings are meticulously manufactured in-house to meet both national (ISO: 4427) and international standards (EN1555 part 3, EN12201 part 3). Designed with SDR 11 and SDR 13.6 ratings, these fittings ensure optimal jointing for drinking water, drainage, and gas pipelines. The Electrofusion process involves inserting pipes into the fittings, applying an electric current to seamlessly fuse the inner and outer surfaces. Each fitting is equipped with barcodes for precise heat and timing control, ensuring a secure and reliable connection every time.

JOINTING TECHNIQUE OF ELECTROFUSION

  • Clean the jointing area
  • Remove the oxidation of pipes with scrubber
  • Mark the jointing area with proper lining
  • Insert the fitting into pipe with proper clamping
  • Scan the QR code which is stuck on the fitting
  • Start the machine and wait for the jointing process to complete
  • Leave the jointing as it is for its mentioned cooling time

Technical Specifications

Electrofusion Coupler

Electrofusion Coupler

Material Grade: PE100
SDR 11 PN16
CODE
SIZE
CODE
SIZE
EFCO63
63MM
EFCO125
125MM
EFCO75
75MM
EFCO140
140MM
EFCO93
90MM
EFCO160
160MM
EFC110
110MM
EFC180
180MM
EFC125
125MM
EFC250
250MM
EFCO140
140MM
Electrofusion Elbow

Electrofusion Elbow

Material Grade: PE100
SDR 11 PN16
CODE
SIZE
CODE
SIZE
EFEL63
63MM
EFEL125
125MM
EFEL75
75MM
EFEL140
140MM
EFEL90
90MM
EFEL180
180MM
EFEL110
110MM
EFEL200
200MM
Electrofusion Tree

Electrofusion Tee

Material Grade: PE100
SDR 11 PN16
CODE
SIZE
CODE
SIZE
EFTE63
63MM
EFTE140
140MM
EFTE75
75MM
EFTE160
160MM
EFTE90
90MM
EFTE180
180MM
EFTE110
110MM
EFTE200
200MM
Electrofusion Endcap

Electrofusion Endcap

Material Grade: PE100
SDR 11 PN16
CODE
SIZE
CODE
SIZE
EFEC63
63MM
EFEC140
140MM
EFEC75
75MM
EFEC160
140MM
EFEC90
90MM
EFEC180
180MM
EFEC110
110MM
EFEC200
200MM
EFEC125
125MM
Electrofusion Fittings Tapping with bottom Saddle

Electrofusion Saddle with bottom

Material Grade: PE100
SDR 11 PN16
CODE
SIZE
CODE
SIZE
EFSA63
63MM
EFSA90
90MM
EFSA75
75MM
EFSA110
140MM
Electrofusion Reducer

Electrofusion Reducer

Material Grade: PE100
SDR 11 PN16
SIZE
75X63MM
160X90MM
180X75MM
200X110MM
90X75MM
160X75MM
180X63MM
200X90MM
90X63MM
160X63MM
200X180MM
200X75MM
90X65MM
110X75MM
180X160MM
200X63MM
110X90MM
180X110MM
200X160MM
160X110MM
180X90MM
260X140MM
Electrofusion Tree

Electrofusion Reducing Tee

Material Grade: PE100
SDR 11 PN16
SIZE
75X75X63MM
140X140X75MM
90X90X75MM
160X160X110MM
905X90X63MM
160X160X90MM
110X110X90MM
160X160X75MM
110X110X63MM
110X110X75MM
180X180X160MM
140X140X110MM
180X180X110MM
140X140X90MM
Electrofusion Tree

Electrofusion Tapping Saddle with Bottom

Material Grade: PE100
SDR 11 PN16
CODE
SIZE
CODE
SIZE
EFTS
63MM
EFTS
90MM
EFTS
75MM
EFTS
110MM
Butt Fusion Tree

Butt Fusion Tee

Material Grade: PE100
SDR 13.6 PN 10
CODE
SIZE
CODE
SIZE
BFTE63
63MM
BFTE90
90MM
BFTE75
75MM
BFTE110
110MM
Butt Fusion Elbow

Butt Fusion Elbow

Material Grade: PE100
SDR 13.6 PN 10
CODE
SIZE
CODE
SIZE
BFEL63
63MM
BFEL90
90MM
BFEL75
75MM
BFEL110
110MM
Butt Fusion Endcap

Butt Fusion Endcap

Material Grade: PE100
SDR 13.6 PN 10
CODE
SIZE
CODE
SIZE
BFEC63
63MM
BFEC90
90MM
BFEC75
75MM
BFEC110
110MM
Butt Fusion Reducer

Butt Fusion Reducer

Material Grade: PE100
SDR 13.6 PN 10
CODE
SIZE
BFRE7563/7550
75X63MM / 75X50MM
BFRE9075/9063
90X75MM / 90X63MM
BFRE11090/11075/11063
110X90MM/110X75MM/110X63MM
Butt Fusion saddle

Butt Fusion saddle

Material Grade: PE100
SDR 13.6 PN 10
CODE
SIZE
BSFA63
63MM - 20/25/32MM
BSFA75
75MM - 20/25/32MM
BSFA90
90MM - 20/25/32MM
BSFA110
110MM - 20/25/32MM
Butt Fusion Flange

Butt Fusion Flange

Material Grade: PE100
SDR 13.6 PN 10
CODE
SIZE
CODE
SIZE
BFF63
63MM
BFF110
110MM
BFF75
75MM
BFF140
140MM
BFF90
90MM
BFF160
160MM

TESTING & ACCEPTANCE PARAMETERS OF ELECTROFUSION FITTINGS

Sl. No.
Test Description
Method of Check
Instrument to Check
Samples to Check
Ref. Standard
Requirements
1
Raw Materials
As Per BS EN 12201 3:2011 Clause 4.1
--
Once Per Lot
As Per Clause 4.1 of EN 12201 3:2011
RMTC
2
Visual Appearance
Visual
Visual Check
05 Nos. from lot
EN 12201-Part 3 
Fittings shall be free from moulding defects such as shrinkages, blow holes and damages. Surface shall be smooth and clean.
3
Dimensions
Dimension
Dial Vernier, Micrometer.
05 Nos. from lot
EN 12201-Part 3
EN 12201-Part 3 Table-1 (Thickness of Fittings Declared By Manufacturer)
4
Colour
Visual
--
05 Nos. from lot.
EN 12201-Part 3 CL-5.2
The Fittings shall be Blue or Black
5
Marking
As Per BS EN 12201 3:2003 Clause 11.2
Visual
05 Nos. from Lot
Table-7
Manufacturer Brand Name, Size, Material and SDR Ratings
6
MFR Test on fittings
Melt Flow
MFR Testing Machine.
01 No. from Lot
EN 12201-Part 3
MFR at 190°C/5 Kg shall be ±20% on the value declared by raw material manufacturer.
7
Density at 27% (Base Density)
--
Density Machine
01 No. from Lot
As per Clause 8.7 of1S 4984 - 2016 / IS 7328
940 to 960 Kg/m
8
Peel Decohesion resistance of EF Fittings ≥ 75mm.
Visual
Tensile Testing Machine
01 No. from Lot
ISO: 13954: 1997
Ductile Failure over at least 66% length
9
Crush Decohesion resistance of EF Fittings ≤ 63mm & all TT & TF.
Visual
Bench Vice
01 No. from Lot
ISO: 13955: 1997
Ductile Failure over at least 66% length
10
Hydrostatic Strength at 80°C
--
Hydraulic Pressure Testing Machine
02 Nos. from Lot
EN 12201-Part 3 Table-4
Must sustain Hydrostatic Pressure throughout the test period. Test Temp. -- 80±1°C Test Period -- 165 hrs. Test Pressure -- 5.4 MPa
11
Hydrostatic Strength at 80°C
--
Hydraulic Pressure Testing Machine
02 Nos. from Lot
EN 12201-Part 3 Table-4
Must sustain Hydrostatic Pressure throughout the test period. Test Temp. -- 80±1°C Test Period -- 1000 hrs. Test Pressure -- 5.0 MPa
12
Hydrostatic Strength at 20°C
--
Hydraulic Pressure Testing Machine
02 Nos. from Lot
EN 12201-Part 3 Table-4
Must sustain Hydrostatic Pressure throughout the test period. Test Temp. -- 20±1°C Test Period -- 100 hrs. Test Pressure -- 12.4 MPa
13
Thermal Stability
OIT Test
Differential Scanning Calorimeter
01 No. from Lot
EN 12201-Part 3
OIT Shall be ≥20min at 200°C.
14
Electrical Resistance
BS EN 12201-3:2011 03 Pcs Per MTC T W 10 Electrical Resistance Lot Clause 5.4
The Resistance of the fittings shall not exceed the following value (nominal value -+ 10%)Ohm
03 No. from Lot
--
Ohm Meter EF Welding Machine
15
Effect on Water Quality. (Applicable only for drinking water application.)
1. Taste of Water. 2. Appearance of Water. 3. Growth of Micro-organisms. 4. Cyto-toxicity. 5. Extraction of Metals
--
--
BS 6920
WRAS Approval for Testing of fitting Material by WRc-NSF, UK for the requirements of potability of water as per BS: 6920

Comparison between the two-jointing method: Butt-fusion Fittings and Electrofusion Fittings

Sl. No.
Butt-fusion
Electrofusion
1
Welding is done at the ends of the pipe & fittings
Pipes are inserted into the fittings
2
Jointing subject to min. thickness of pipe/fittings
Fusion of pipe & fittings minimum 80mm/100mm, ensuring full strength jointing
3
Jointing weakened by ovality in pipe/fitting
Fusion accommodates ovality in pipe/fitting, ensuring integrity
4
Special skill required for alignment during jointing
Machine-controlled process eliminates skill requirement
5
Jointing not possible during water supply operation
Possible with tapping saddle during water supply operation
6
Risk of sub-standard material usage
Ensures usage of high-quality materials only
7
Fittings manufactured in low thickness (PN 6/8/10/12.5)
Fittings manufactured in high thickness (PN 16)
8
Primarily used in water pipe lines
Used in both water and gas pipe lines
9
Made as per IS: 8008: 2022
Made as per EN 12201 – Part 3, ISO: 13954: 1997, ISO:13955: 1997, ISO:4427-1, 2, & 3 (2019)
10
40% cheaper compared to electrofusion
40% costlier compared to butt-fusion
11
Overall fittings cost approximately 3% of pipeline cost
Overall fittings cost approximately 4% of pipeline cost
12
Overall scheme cost approximately 0.45%
Overall scheme cost approximately 0.50%
13
Installation time almost double
Installation time almost halved
14
Lower quality workmanship
Higher quality workmanship
15
Higher water leakage due to jointing
Very low to negligible water leakage risk
16
Fitting thickness/length relatively small
Ideal fitting thickness/length
17
Discouraged by Central Govt.
Encouraged by Central Govt.
18
Not used in Developed countries
Widely used in Developed countries

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