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H E AT F U S I O N J O I N I N G P R O C E D U R E S
TA B L E O F C O N T E N T S
INTRODUCTION.............................................................................................................................................1
FEDERAL REGULATIONS...........................................................................................................................1
HEAT FUSION..................................................................................................................................................2
INCLEMENT WEATHER...............................................................................................................................3
NOTES ON FUSION CONFIDENCE..........................................................................................................3
FUSION CHECKLIST.....................................................................................................................................4
BUTT FUSION.................................................................................................................................................5 Procedure..........................................................................................................................................................6 Qualification.................................................................................................................................................. 10
SADDLE FUSION........................................................................................................................................ 15 Definitions...................................................................................................................................................... 15 Procedure....................................................................................................................................................... 17 Qualification.................................................................................................................................................. 18 SOCKET FUSION......................................................................................................................................... 22 EquipmentRequirements........................................................................................................................ 22 HeaterTemperature.................................................................................................................................... 22 Procedure....................................................................................................................................................... 23 Qualification.................................................................................................................................................. 25
APPENDIX A................................................................................................................................................. 29 HydraulicFusionMachineGaugePressure........................................................................................ 29
REFERENCES................................................................................................................................................ 30
FIGURES FIGUREI–ButtFusionBentStrapTestSpecimen............................................................................ 10 FIGUREII–SaddleFusionBentStrapTestSpecimen..................................................................... 18 FIGUREIII–SocketFusionBentStrapTestSpecimen.................................................................... 25 TABLES TABLEI–ButtFusion:ApproximateMeltBeadSize.........................................................................7 TABLEII–ButtFusion:MaximumHeaterPlateRemovalTime......................................................8 TABLEIII–ButtFusion:BeadWidthsPerWallThickness.................................................................9 TABLEIV–ButtFusion:TroubleshootingGuide............................................................................ 14 TABLEV–SaddleFusion:MaximumHeating/MinimumCoolingTimes................................ 16 TABLEVI–SaddleFusion:TroubleshootingGuide......................................................................... 21 TABLEVII–SocketFusion:TimeCycles............................................................................................... 24 TABLEVIII–SocketFusion:TroubleshootingGuide....................................................................... 28
Thestatementsandtechnicaldatagiveninthisbrochureweredevelopedonthebasisofconservativetestmeasuresandarebelievedtobeaccurate.Theinformationismeanttoserveonlyasageneralguide;andtheoperatorand/oranyindividualusermustverifythespecificparametersofeachapplicationfortheirintendeduseandspecificsystem.Duetowidevariationsinserviceconditions,installationtechniques,fieldconditions,weatherconditions,andotherfactors,NOWARRANTYORGUARANTEE,EXPRESSORIMPLIED,ISGIVENINCONJUNCTIONWITHTHEUSEOFTHESEPROCEDURES.
Inaddition,thisproceduredoesnotpurporttoaddressallofthesafetyconcerns,ifany,associatedwithitsuse.Itistheresponsibilityoftheuserofthisproceduretoestablishanyandallappropriatesafetyandhealthpracticesandtodeterminetheapplicabilityofregulatoryrequirementspriortouse.
INTRODUCTION
Anintegralpartofanypipesystemisthemethodusedtojointhesystemcomponents.Properengineeringdesignofasystemwilltakeintoconsiderationthetypeandeffectivenessofthetechniquesusedtojointhepipeandappurtenances,aswellasthedurabilityoftheresultingjoints.Theintegrityandversatilityofthejoiningtechniquesusedforpolyethylene(PE)pipeallowthedesignertotakeadvantageoftheperformancebenefitsofPEinawidevarietyofapplications.
Therearethreetypesofheatfusionjointscurrentlyusedintheindustry:butt,saddleandsocketfusion.Additionally,therearetwomethodsforproducingthesocketandsaddlefusionjoints.Inadditiontothefusion
proceduresthatfollow,electrofusionisrecognizedasanacceptablemethodofproducingsocketandsaddlefusionsbutisnotaddressedinthisdocument.Theuserofelectrofusionproductsshouldcontacttheproviderofthoseproductsfordetailsonuseinjoiningpipe.
ThefusionproceduresthatfollowhavebeenproventoconsistentlyproducesoundfusionjointsinbenchtrialswhenusedcorrectlyandarerecommendedforthejoiningofPolyPipe®products.TherecommendedproceduresforbuttandsaddlefusionsareconsistentwiththePlasticsPipeInstitute(PPI)TechnicalReports(TR)TR-33, Generic Butt Fusion Procedures and TR-41, Generic Saddle Fusion Procedures.
FEDERAL REGULATIONS
Federalregulationsrequirethatalloperatorsqualifyboththeirjoiningproceduresandthepersonnelinstallingpipe.ThePipelineSafetyRegulations,issuedbytheU.S.DepartmentofTransportation(DOT)PipelineandHazardousMaterialsSafetyAdministration,arefoundat49CFRPart192.Pursuantto49CFR192.283(a),anoperatorisrequiredtoqualifyheatfusionjoiningproceduresbeforetheprocedureisusedinthefield.Further,49CFRPart192.285requiresthatanoperatorqualifythepersonnelwhowillbemakingheatfusionjointsinthefield.AdditionalFederalregulationsmayapply,andStateregulationsthatarecorollariestothePipelineSafetyRegulationsalsoapply,asmayadditional,morestringent,stateregulations.
Theoperatorisresponsibleforensuringthatallaspectsoftheirfusionjoiningprocessesandproceduresareincompliancewiththerequirementsof49CFR,Part192andASTMstandards.
Federalregulationsrequirethatalloperatorsqualifyboththeirjoiningproceduresandthepersonnelinstallingpipe.ThePipelineSafetyRegulations,issuedbytheU.S.DepartmentofTransportation(DOT)PipelineandHazardousMaterialsSafetyAdministration,arefoundat49CFRPart192.Pursuantto49CFR192.283(a),anoperatorisrequiredtoqualifyheatfusionjoiningproceduresbeforetheprocedureisusedinthefield.Further,49CFRPart192.285requiresthatanoperatorqualifythepersonnelwhowillbemakingheatfusionjointsinthefield.AdditionalFederalregulationsmayapply,andStateregulationsthatarecorollariestothePipelineSafetyRegulationsalsoapply,asmayadditional,morestringent,stateregulations.
Theoperatorisresponsibleforensuringthatallaspectsoftheirfusionjoiningprocessesandproceduresareincompliancewiththerequirementsof49CFR,Part192andASTMstandards.
POLYPIPE® PRODUCTS
GAS DISTRIBUTION/OILFIELD M&I, WATER AND SPECIALTY
PolyPipe®PolyTough1TM PolyPipe®EHMWPLUS PolyPipe®GDY20 PolyPipe®POLYPLUS PolyPipe®GDB50/GB50 PolypipE®LIGHTVIEWPLUSTM
POLYPIPE®ENVIROPIPETM
1
HEAT FUSION
Theprinciplebehindheatfusionistoheattwosurfacestoadesignatedtemperature,andthenfusethemtogetherbyapplicationoftherequiredforce.Thisappliedforcejoinsthemeltedsurfacesresultinginapermanent,monolithicfusionjoint.PolyPipe®fusionproceduresrequirespecifictoolsandequipmentforthefusiontypeandforthesizesofpipeandfittingstobejoined.
Butt Fusion –Thistechniqueconsistsofheatingthesquaredendsoftwopipes,apipeandfitting,ortwofittingsbyholdingthemagainstaheatedplate,removingtheplatewhenthepropermeltisobtained,promptlybringingtheendstogetherandallowingthejointtocoolwhilemaintainingtheappropriateappliedforce.
Saddle Fusion –Thistechniqueinvolvesmeltingtheconcavesurfaceofthebaseofasaddlefitting,whilesimultaneouslymeltingamatchingpatternonthesurfaceofthepipe,bringingthetwomeltedsurfacestogetherandallowingthejointtocoolwhilemaintainingtheappropriateappliedforce.
Socket Fusion –Thistechniqueinvolvessimultaneouslyheatingtheoutsidesurfaceofapipeendandtheinsidesurfaceofafittingsocket,whichissizedtobesmallerthanthesmallestoutsidediameterofthepipe.Afterthepropermelthasbeengeneratedateachfacetobemated,thetwocomponentsarejoinedbyinsertingthepipeintothefitting.Thefusionisformedattheinterfaceresultingfromtheinterferencefit.Themeltsfromthetwocomponentsflowtogetherandfuseasthejointcools.
ProperlyfusedPEjointsdonotleak.Ifaleakisdetectedduringpneumaticorhydrostatictesting,itispossibleforasystemfailuretooccur.Cautionshouldbeexercisedinapproachingapressurizedpipelineandanyattemptstocorrecttheleakshouldnotbemadeuntilthesystemhasbeendepressurized.
Note: PE cannot be joined by solvent bonding or threading. Extrusion welding or hot air welding is not recommended for pressure applications.
Butt Fusion
Saddle Fusion
Socket Fusion
2
INCLEMENT WEATHER
PE has reducedimpactresistanceinsub-freezingconditions.Additionalcareshouldbeexercisedwhilehandlinginsub-freezingconditions.Inaddition,PEpipewillbehardertobendand/oruncoil.
Forrecommendedguidelineswhenfusingininclementweather,refertothePlasticsPipeInstitute,PPI,TechnicalNoteTN-42: Recommended Minimum Training Guidelines for PE Pipe Butt Fusion Joining Operators for Municipal and Industrial Projects. http://plasticpipe.org/pdf/tn-42-min-training-guide-pe-butt-fusion.pdfTheseguidelinesapplytoallapplications.
AdditionalinformationconcerningcoldweatherproceduresisavailableinASTMF2620,StandardPracticeforHeatFusionJoiningofPolyolefinPipeandFittings, AnnexA1.
Theoperatorshouldensurethatitsqualifiedfusionprocedurestakeintoaccountandareadaptedforallpotentialinclementweatherconditionsinwhichtheoperatormaybefusingpolyethylenepipe.
NOTES ON FUSION CONFIDENCE
ReliablefusionjointsofPEpipingsystemscanbeaccomplishedunderreasonablelatitudeofconditions.Theoperatorshouldqualifyitsownproceduresforeveryconditionunderwhichitwillbefusingpolyethylenepipe.Additionally,theoperatorshouldqualifyallpersonnelwhowillresponsibleforperformingfusionsofpolyethylenepipe.
Thefollowingisalistingofgeneralnotestohelpensureproperequipmentandtechniquesareutilized:
1. The fusion operator must have adequate training and understanding of the equipment and tools and the fusion procedure.
Improperunderstandingoftheoperationoftheequipmentandtoolscanproduceafusionofpoorquality.Theoperatormustunderstandthoroughlyhowtousetheequipmentandtools,theirfunctionandoperation.Theoperatorshouldadheretotheequipmentmanufacturer’sinstructions.
Fusionpressuresandheating/coolingcyclesmayvarydramaticallyaccordingtopipesizeandwallthickness.Operatorsshouldnotrelyexclusivelyonautomated
fusionequipmentforjointqualification.Inaddition,visualinspectionandqualificationshouldalwaysbemade.Ifnecessary,testfusionsshouldbemadetodeterminecorrectpressuresandheat/coolcycletimes.Destructivetestmethods,suchasbendbacktests,maybenecessarytoformulatecorrectpressuresandheat/coolcycletimes(refertoQualificationProcedures).2. Pipe and fitting surfaces must be clean and properly prepared.
Anycontaminantspresentonthesurfacesorpoorpreparationofthesurfacescanproduceapoorqualityfusionjoint.Ensurethatallpipeandfittingsurfacesareclean.Ifsurfacesarereintroducedtocontaminants,theyshouldbecleanedagain.3. Heater plates must be clean, undamaged and the correct surface temperature.
Heatersurfacesareusuallycoatedwithanon-stickmaterial.Cleaningtechniquesshouldbeusedaccordingly.Ifasolventisdeemednecessary,donotusegasolineorotherpetroleumproducts.Refertotheequipmentmanufacturer’sinstructionsforpropercleaningproducts.ItisimportanttoregularlycleantheheatersurfacetoremoveanybuildupofPEmaterialthatwilldegradeduetoextendedcontactwiththeheater.
Recommendedheatingtooltemperaturesarespecifiedforeachprocedure.Thistemperatureisindicativeofthesurfacetemperature,nottheheatingtoolthermometer.Thesurfacetemperatureshouldbeverifieddailybyusingasurfacepyrometer.Ifacrayonindicator(meltstick)isused,itshouldnotbeusedinanareathatwillbeincontactwiththepipeorfitting.
Iftheheaterplateisnotinuse,itisrecommendedthatitbestoredinaninsulatedholder.Thisnotonlyprotectstheheatersurfacesfromcontaminants,butitcanalsopreventinadvertentcontact,whichcanresultinseriousinjuries.
4. Proper equipment and condition of tools and equipment for the job
Eachtypeoffusionrequiresspecialtoolsandequipment.Fusionsperformedwiththeincorrectfusionequipment,materialsortoolsand/orwithfusionequipmentthathasnotbeenproperlymaintainedcanresultinapoorfusion.Anynon-workingequipmentcomponentsshouldbereplacedorrepairedpriortofusingpipe.
3
FUSION CHECKLIST
Inspectpipelengthsandfittingsforunacceptablecuts,gouges,deepscratchesorotherdefects.Damaged
productsshouldnotbeused.RefertoPolyPipe®InfoBriefNo.2forallowablesurfacedamageaccordingtothe
PlasticsPipeInstitute(PPI)andtheAmericanGasAssociation(AGA).
Thefusioncontactareamustbefreeofanydefectsorsurfacedisruption.
Besureallrequiredtoolsandequipmentareonsiteandinproperworkingorder.
Pipeandfittingsurfaceswheretoolsandequipmentarefittedmustbecleananddry.Useclean,dry,non-
synthetic(cotton)clothsorpapertowelstoremovedirt,snow,waterandothercontaminants.Ifalcohol
isused,99%reagentgradeisopropylalcoholisrecommended.Thestandard“drugstorevariety”contains
impuritiesthatcanactasacontaminanttothefusionprocess.
Shieldand/orcoverfusionequipmentandsurfacesfrominclementweatherandwinds.Atemporaryshelter
overfusionequipmentandthefusionoperationmayberequired.
Relievetensioninthelinebeforemakingconnections.
Whenjoiningcoiledpipe,makinganS-curvebetweenpipecoilscanrelievetension.Insomecases,itmay
benecessarytoallowpipetoequalizetothetemperatureofitssurroundings.Allowpulled-inpipesto
relaxforseveralhourstorecoverfromtensilestresses.
Pipesmustbecorrectlyalignedbeforemakingconnections.
Trialfusions.
Atrialfusion,preferablyatthebeginningoftheday,canverifythefusionprocedureandequipment
settingsfortheactualjobsiteconditions.RefertoQualificationProceduresfordetailedinformationonthe
bendbacktestprocedure.
4
BUTT FUSION
Heater Surface Temperature: Minimum 400oF – Maximum 450oF
Heatingtoolsurfacesmustbetotemperaturebeforeyoubegin.Allpointsonbothheatingtoolsurfaceswheretheheatingtoolsurfaceswillcontactthepipeorfittingendsmustbewithintheprescribedminimumandmaximumtemperaturesandthemaximumtemperaturedifferencebetweenanytwopointsontheheatingtoolfusionsurfacesmustnotexceed20oFforequipmentforpipesmallerthan18”diameter,or35oFforlargerequipment.Itisagoodpracticetosettheheaterplateto425oFwhichcanhelpkeepnormalfluctuationsbetween400oFand450oF.Heatingtoolsurfacesmustbeclean.
Interfacial pressure: Minimum 60 psi – Maximum 90 psi
Interfacialpressureisusedtocalculateafusionjoininggaugepressurevalueforhydraulicbuttfusionmachinesormanualmachinesequippedwithforcereadingcapability.Theinterfacialpressureisconstantforallpipesizesandallbuttfusionmachines.However,fusionjoininggaugepressuresettingsarecalculatedforeachbuttfusionmachine,whicharedependentupontheoutsidediameter(OD)anddimensionratio(DR)andthepistonareaofthefusionmachine.
Forhydraulicmachines,theinterfacialpressure,thefusionsurfacearea,themachine’seffectivepistonareaandfrictionalresistance,andifnecessary,thepressureneededtoovercomeexternaldragresistance,areusedtocalculatehydraulicfusionjoiningpressuregaugesettings(refertoAppendixA).Theequipmentmanufacturer’sinstructionsareusedtocalculatethisvalue.Theproperamountofforceshouldbeverifiedbyvisualinspectionofthejoint.
NOTE: The interfacial pressure and the hydraulic gauge pressure are not the same.
Formanualmachineswithoutforcereadingcapability,thecorrectfusionjoiningforceistheforcerequiredtorollthemeltbeadsoveruntiltheycontactthepipesurfaceasrequiredbythejoiningprocedure.
Whenjoiningpipeswithdifferentmeltproperties,suchasbimodalMDPEtounimodalMDPE,applysufficientforcetomakethebimodalpipefusionbeadrollbackandcontactthepipesurface.BimodalMDPEhasalowermeltflowratiothanunimodalpipe.
5
PROCEDURE
1. SecureCleantheinsideandoutsideofthepipeorfitting(components)endsbywipingwithaclean,dry,lint-freeclothorpapertowel.Removeallforeignmatter.Alignthecomponentsinthemachine,placethemintheclamps,andthenclosetheclamps.Do not force pipes into alignment against open fusion clamps.Componentendsshouldprotrudepasttheclampsenoughsothatfacingwillbecomplete.Bringtheendstogetherandcheckhigh-lowalignment.Adjustalignmentasnecessarybytighteningthehighsidedown.
2. FacePlacethefacingtoolbetweenthecomponentends,andfacethemtoestablishsmooth,clean,parallelmatingsurfaces.Completefacingproducescontinuouscircumferentialshavingsfrombothends.Faceuntilthereisminimaldistancebetweenthefixedandmoveableclamps.Ifthemachineisequippedwithfacingstops,facedowntothestops.Stopthefacerbeforemovingthepipeendsawayfromthefacer.Removethefacingtool,andclearallshavingsandpipechipsfromthecomponentends.Do not touch the component ends with your hands after facing.
3. AlignBringthecomponentendstogether,checkalignmentandcheckforslippageagainstfusionpressure.Lookforcompletecontactallaroundbothendswithnodetectablegaps,andODsinhigh-lowalignment.Ifnecessary,adjustthehighsidebytighteningthehighsideclamp.Donotloosenthelowsideclampbecausecomponentsmayslipduringfusion.Re-face if high-low alignment is adjusted.
4. MeltVerifythatthecontactsurfaceoftheheatingtoolismaintainingthecorrecttemperature.Placetheheatingtoolbetweenthecomponentends,andmovetheendsagainsttheheatingtool.Bringthecomponentendstogetherunderpressuretoensurefullcontact.Theinitialcontactpressureshouldbeheldverybrieflyandreleasedwithoutbreakingcontact.Pressureshouldbereducedwhenevidenceofmeltappearsonthecircumferenceofthepipe.Holdtheendsagainsttheheatingtoolwithout force(dragforcemaybenecessarytoensurecontact).BeadsofmeltedPEwillformagainsttheheatingtoolatthecomponentends.Whenthepropermeltbeadsizeisformed,quicklyseparatetheendsandremovethe
6
heatingtool.Theproperbeadsizeisdependentuponthesizeofthecomponent.ApproximatevaluesareshowninTableI.
Duringheating,themeltbeadwillexpandoutflushtotheheatingtoolsurface,ormaycurlslightlyawayfromthesurface.Ifthemeltbeadcurlssignificantlyawayfromtheheatingtoolsurface,unacceptablepressureduringheatingmayhaveoccurred.
5. JoinImmediatelyaftertheheatingtoolisremoved,quicklyinspectthemeltedends,whichshouldbeflat,smoothandcompletelymelted.Ifthemeltsurfacesareacceptable,immediatelyandinacontinuousmotion,bringtheendstogetherandapplythecorrectjoiningforce(orfusionpressure).Thecorrectfusionpressurewillformadoublebeadthatisrolledoverandcontactsthepipesurface.thesurfaceonbothends.
A concave melt surface is unacceptable; it indicates pressure during heating. Do not continue. Allow the component ends to cool and start over with Step 1.
ThemaximumrecommendedtimeallowedforheaterplateremovalisindicatedinTableII.
TABLE IAPPROXIMATE MELT BEAD SIZE
Approximate Wall Thickness, inches Melt Bead Size* (Approximate)
≤0.15 1/32”–1/16” 0.15–0.30 1/16” Above0.30–0.75 1/8”–3/16” Above0.75–1.15 3/16”–1/4” Above1.15–1.60 1/4”–5/16” Above1.60–2.20 5/16”–7/16” Above2.20–3.00 7/16”–9/16”
*The appearance of the melt swell zone may vary depending on the pipe material. The melt bead width is to be determined by measuring the distance from the heater plate to the melt swell origin.
7
6. HoldMaintainfusiongaugepressureuntilthejointiscool.Thejointiscoolenoughforgentlehandlingwhenthedoublebeadiscooltothetouch.Coolforaminimumof11minutesperinchofpipewall.Donottrytodecreasethecoolingtimebyapplyingwater,ice,wetclothsorthelike.
Avoidpulling,installation,pressuretestingandroughhandlingforatleastanadditional30minutes.
Forambienttemperaturesabove100oF,longercoolingtimesmayberequired.
7. InspectionOnbothsides,thedoublebeadshouldberolledovertothesurface,andbeuniformlyroundedandconsistentinsizeallaroundthejoint.
1.Thegap(A)betweenthetwosinglebeadsmustnotbebelowthefusionsurfacethroughouttheentirecircumferenceofthebuttjoint.
2.Thedisplacement(V)betweenthefusedendsmustnotexceed10%ofthepipe/fittingminimumwallthickness.
3.RefertoTableIIIforgeneralguidelinesforbeadwidth,B,foreachrespectivewallthickness.
TABLE IIMAXIMUM HEATER PLATE REMOVAL TIMES
Pipe Wall Thickness, in Max. Heater Removal Time, sec 0.20to0.36 8 >0.36to0.55 10 >0.55to1.18 15 >1.18to2.5 20 >2.5to4.5 25
8
4.Thesizedifferential(Smax–Smin)betweentwosinglebeadsshallnotexceedX%ofthecombinedbeadwidth(B).
Where:X =Percentdifferenceofbeadwidth,% Pipetopipe,maximumX=10% Pipetofitting,maximumX=20% Fittingtofitting,maximumX=20% ∆S =Smax-Smin,inchesB =Combinedwidthofbothfusionbeads,inches
Minimum Wall
Thickness, in.
Approximate Bead Width (B), in.
Approximate Bead Width (B), in.
Minimum Wall Thickness, in.
TABLE IIIBEAD WIDTHS PER WALL THICKNESS
Minimum Maximum Minimum Maximum .118 5/32 1/4 1.06 19/32 25/32 .157 5/32 9/32 1.18 5/8 13/16 .197 3/16 5/16 1.34 21/32 7/8 .246 1/4 11/32 1.57 11/16 29/32 .315 9/32 3/8 1.77 25/32 1 .354 5/16 7/16 1.97 7/8 1-1/16 .433 11/32 1/2 2.16 15/16 1-3/16 .512 3/8 9/16 2.36 1 1-1/4 .630 7/16 19/32 2.56 1-1/8 1-7/16 .710 1/2 5/8 2.76 1-3/16 1-1/2 .750 1/2 11/16 2.95 1-1/4 1-9/16 .870 1/2 11/16 3.15 1-5/16 1-11/16 .940 9/16 3/4 3.35 1-3/8 1-3/4 3.54 1-1/2 1-13/16
Instructions: Determine the wall thickness of the pipe/fitting. Find the wall thickness above. If the exact wall thickness is not shown, use the next lowest wall thickness for determination of bead width.
NOTE: 1. Whenbuttfusingpipetomoldedfittings,thefittingsidebeadmayhaveanirregularappearance. Thedifferentmanufacturingprocessesused(extrusionvsmolding)willcausethebeadappearancetobe differentwhenitrollsback.Thisisacceptable,providedthepipesidebeadiscorrect.(SeeImages1&2.) 2. WhenfusingunimodalMDPEpipetobimodalMDPEpipeorHDPEpipe,theunimodalMDPEpipebeadmay beslightlylargerthanthebimodalMDPEorHDPEpipebead.Thisoccursbecauseofthedifferentmelt propertiesoftheresins.(SeeImages3&4) 3. PolyPipePolyTough1™hasbeensuccessfullyfusedtoavarietyofpipesthatmaybeinuseinexistinggaspipe systems.Photosofthesefusionsareprovidedforvisualreference.(SeeImages5thru16)
9
QUALIFICATION
The following summarizes the ASTM methods to which the operator and/or user should refer for specific qualification requirements
1.Prepareasamplejoint.Samplelengthsshouldbeatleast6”or15timestheminimumwallthickness(seeFigureI).
2.Observethefusionprocessandverifytherecommendedprocedureforbuttfusionisbeingfollowed.
3.Visuallyinspectthesamplejointforquality.
4.Allowthejointtocoolcompletely.
5.PreparethesampleasshowninFigureI.Thesampleshouldbecutlengthwiseintoatleastthreelongitudinalstrapswithaminimumof1”or1.5timesthewallthicknessinwidth.Itisrecommendedthatfourequallyspacedstripsbecut,onefromeachquadrantofthepipe.
6.Visuallyinspectthecutjointforanyindicationsofvoids,gaps,misalignmentorsurfacesthathavenotbeenproperlybonded.
7.Bendeachsampleattheweldwiththeinsideofthepipefacingoutuntiltheendstouch.Theinsidebendradiusshouldbelessthantheminimumwallthicknessofthepipe.Inordertosuccessfullycompletethebendback,avisemaybeneeded.Forthick(>1”)wallpipe,contactPolyPipe®Engineeringforrecommendedproceduresandtestapparatus.
8.Thesamplemustbefreeofcracksandseparationswithintheweldlocation.Iffailuredoesoccurattheweldinanyofthesamples,cutanothersampleadjacenttothepositionthefailedsamplecamefromandretest.Ifthesecondsamplefails,thenthefusionprocedureshouldbereviewedandcorrected.Aftercorrection,anothersamplefusionshouldbemadeperthenewprocedureandre-tested.
Figure IButt Fusion Bent Strap Test Specimen
(Reference ASTM F2620)
BEND BACK TESTING - NO GAPS OR VOIDS(SeeFigure1)
10
ACCEPTABLE FUSIONS
BUTT FUSION
PROPER ALIGNMENT AND DOUBLE ROLL-BACK BEAD
Unimodal HDPE fused to molded fitting
Unimodal MDPE fused to PolyTough1TM bimodal MDPE
Unimodal MDPE fused to HDPE
PolyTough1TM fused to molded fitting
11
PolyTough1tm BIMODAL MDPE JOINED TO VINTAGE AND CURRENT MATERIALS
Unimodal MDPE fused to PolyTough1TM PolyTough1TM fused to PolyTough1TM
PolyTough1TM fused to PLEXCO PE2306 PolyTough1TM fused to PE3408
PE4710 fused to PolyTough1TM DRISCO M8000 fused to PolyTough1TM
DUPONT ALDYL A PE2306 fused to PolyTough1TM
12
UNACCEPTABLE FUSIONS
BUTT FUSION
Meltbeadtoosmallduetoinsufficientheattime Meltbeadtoolargeduetoexcessiveheatingand/oroverpressurizationofjoint
Misalignment IncompleteFacing
Pressurefluctuation,misalignmentoverpressurization13
TABLE IVBUTT FUSION TROUBLESHOOTING GUIDE
Observed Condition Possible Cause
•Excessivedoublebeadwidth •Overheating •Excessivejoiningforce •Doublebeadv-groovetoodeep •Excessivejoiningforce •Insufficientheating •Pressureduringheating •Flattoponbead •Excessivejoiningforce •Overheating •Non-uniformbeadsizearoundpipe •Misalignment •Defectiveheatingtool •Wornequipment •Incompletefacing •Onebeadlargerthantheother •Misalignment •Componentslippedinclamp •Wornequipment •Heatingirondoesnotmovefreelyinthe axialdirection •Defectiveheatingtool •Incompletefacing •Alsopossiblewhenfusingbimodalpipesto unimodalpipes
•Beadstoosmall •Insufficientheating •Insufficientjoiningforce
•Beadnotrolledovertosurface •Shallowv-groove–Insufficientheating& insufficientjoiningforce •Deepv-groove–Insufficientheating& excessivejoiningforce •Beadonbimodalpipemayhaveslightgap tothepipesurface
•Beadstoolarge •Excessiveheatingtime
•Squaretypeouterbeadedge •Pressureduringheating •Rough,sandpaper-like,bubbly, •Hydrocarbon(gasolinevapors,spray orpockmarkedmeltbeadsurface paintfumes,etc.)contamination
14
SADDLE FUSION
Heater Surface Temperature:500oF ± 10oF(Minimum490oF-Maximum510oF)
Heatertoolsurfacesmustbeuptotemperaturebeforeyoubegin.Allpointsonbothheatingtoolsurfaceswheretheheatingtoolsurfaceswillcontactthepipeandfittingmustbewithintheprescribedminimumandmaximumtemperatures.Heatertoolsurfacesmustbeclean.
DEFINITIONS
Initial Heat (Bead-up)Theheatingstepusedtodevelopameltbeadonthepipe.
Initial Heat Force (Bead-up Force)Theforce(pounds)appliedtoestablishameltpatternonthepipe.TheInitialheatforceisdeterminedbymultiplyingthefittingbasearea(in2)bytheinitialheatinterfacialpressure(psi).
Heat Soak ForceTheforce(pounds)appliedafteraninitialmeltpatternisestablishedonthepipe.Theheatsoakforceistheminimumforce(essentiallyzero)thatensuresthefitting,heaterandpipestayincontactwitheachother.
Fusion ForceTheforce(pounds)appliedtoestablishthefusionbondbetweenthefittingandthepipe.Thefusionforceisdeterminedbymultiplyingthefittingbasearea(in2)bythefusioninterfacialpressure(psi).
Interface Pressure:Minimum54psi–Maximum66psi
Total Heat TimeAtimethatbeginswhentheheaterisplacedonthepipeandinitialheatforceisappliedandstopswhentheheaterisremoved.MaximumheatingtimesareshowninTableIVforbothpressure(hottapping)andnon-pressurefusionapplications.Cool TimeThetimerequiredtocoolthejointtoapproximately120oF±10oF.TheFusionForcemustbemaintainedfor5minuteson1-1/4”IPSor10minutesforallotherpipesizes,afterwhichthesaddlefusionequipmentcanberemoved.Thejointmustbeallowedtocoolforanadditional30minutesbeforetappingthepipeorjoiningtothebranchoutlet.RecommendedminimumcoolingtimesareshowninTableIV.
15
INTERFACIAL AREA
Rectangularbasefittings
Themajorwidthtimesthemajorlengthofthesaddlebase,withouttakingintoaccountthecurvatureofthebaseorsides,minustheareaofholeinthecenterofthebase.
Roundbasefittings
Theradiusofthesaddlebasesquaredtimesπ(3.1416),withouttakingintoaccountthecurvatureofthebaseorsides,minustheareaoftheholeinthecenterofthebase.
TABLE VMAXIMUM HEATING/MINIMUM COOLING TIMES
Pipe Size Maximum Heating Time Minimum Cooling Time 1-1/4”IPS 1/16”meltpatternvisiblearoundthebaseofthefitting. 5min+30min Do not exceed 15 seconds when hot tapping. 2”IPS 1/16”meltpatternvisiblearoundthebaseofthefitting. 10min+30min Do not exceed 35 seconds when hot tapping. 3”IPS&larger 1/16”meltpatternvisiblearoundthebaseofthefitting. 10min+30min
FITTING LABELS
Theinitialheatforce,heatsoakforceandfusionforcewillbelistedinthelowerright-handcornerofthefittinglabelforthemajorityofsaddlefusionfittings.Thiseliminatestheneedtocalculatetheinformationinthefield.Forexample,80/0/40representstheinitialheatforce,heatsoakforceandfusionforce,respectively.Ifthisinformationisnotlocatedonthefitting,pleasecontactthefittingmanufacturerforthecorrectfusionparameters.
16
PROCEDURE
1. Preparation
Thisprocedurerequirestheuseofasaddlefusiontool.Thistoolmustbecapableofholdingandsupportingthepipe,roundingthepipeforproperalignmentbetweenthepipeandfitting,holdingthefitting,andapplyingandindicatingtheproperforceduringthefusionprocess.
A.Installthesaddlefusiontoolonthepipeaccordingtothemanufacturer’sinstructions.Thetoolshouldbecenteredoveraclean,drylocationwherethefittingwillbefused.Securethetooltothepipe.Asupportisrecommendedunderthepipeon6”IPSandsmallerpipesizes.
B.Abradethesurfaceofthepipe,wherethefittingwillbejoined,witha50–60gritutilityclothuntilathinlayerofmaterialisremovedfromthepipesurface.Theabradedareamustbelargerthantheareacoveredbythefittingbase.Afterabrading,cleantheresidueawaywithaclean,drycloth.
C.Abradethefusionsurfaceofthefittingwith50-60gritutilitycloth.Removealldustandresiduewithaclean,drycloth.Insertthefittinginthesaddlefusiontoolloosely.Usingthesaddlefusiontool,movethefittingbaseagainstthepipeandapplyabout100pounds-forcetoseatthefitting.Securethefittinginthesaddlefusiontool.
2. Heating
Theheatingandfusingprocessmustbeperformedwithaccuracyandefficiency,especiallywhenfusingtoapressurizedmainpipe.
WARNING: Overheatingorexcessivetimebetweenthesetwoprocessescanhavedetrimentaleffects,includingpipelinerupture.
Theheatermustbefittedwiththecorrectheateradapters.
Theheateradapterfusionsurfacemustbebetween490oFto510oF.
Ensuretheheatingsurfacesareclean.
Determinethesaddlefusionforcefromthefittinglabelorbycalculation.
A.Placetheheatingtoolonthepipecenteredbeneaththefittingbase.Immediatelymovethefittingagainsttheheaterfaces,applytheinitialheatforce(seefittinglabel)andstarttheheattime.Applytheinitialheatforceuntilmeltisfirstobservedonthecrownofthepipemain.“Initialheat”isthetermusedtodescribetheinitialheating(bead-up)steptodevelopameltbeadonthepipeandisusually3-5seconds,andthenreducetheforcetotheheatsoakforce(bead-upforce)(seefittinglabel).Maintaintheheatsoakforceuntilthetotalheattimeiscomplete.
B.Attheendofthetotalheattime,removethefittingfromtheheaterandtheheaterfromthepipewithaquick,snappingaction.Quicklycheckforanevenmeltpatternonthepipeandheatedfittingsurfaces(nounheatedareas).Thetotalheattimeendswhenoneofthefollowingconditionsaremet:
i. Totalheattimeexpiresforapressurized 1-1/4”IPSor2”IPSpipe,or
ii.Ameltbeadofapproximately1/16”isvisible aroundthefittingbasefora11/4”IPSor2”IPS non-pressurizedpipe,oralargerpressurizedor non-pressurizedpipe.
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3. Fusion and Cooling
Pressthefittingontothepipe(within3seconds)afterremovingtheheaterandapplytheFusionForce(seethefittinglabel).Maintainthefusionforceontheassemblyfor5minuteson1-1/4”IPSandfor10minutesforlargersizes.Whenthisinitialcoolingtimehasexpired,thesaddlefusionequipmentmayberemoved.Allowtheassemblytocoolforanadditional30minutesbeforehandlingorTapping.
Ifthemeltpatternwasnotsatisfactoryorifthefusionbeadisunacceptable,cutoffthesaddlefittingabovethebasetopreventuse,relocatetoanewsectionofmain,andmakeanewsaddlefusionusinganewfitting.
NOTE: The fusion force may need to be adjusted during the initial cooling period; however, the fusion force should never be reduced.
4. Inspection
Visuallyinspectthefusionbeadaroundtheentirebaseofthefittingatthepipe.Thefusionbeadshouldbeofuniformsize.Thefusionshouldhavea“three-bead”shape,whichischaracteristicofthistypeoffusion.Thefirstbeadisthefittingbasemeltbead.Thesecondoroutermostbeadistheresultoftheheatertoolfaceonthepipe.Thethirdbead,orcenterbead,isthepipemeltbead.Allbeadsshouldbeofuniformsizewiththefirstandthirdbeadsapproximately1/8”andthesecondbeadbeinggenerallysmaller.
QUALIFICATION
The following summarizes the ASTM methods to which the operator and/or user should refer for specific qualification requirements
1.Prepareatleasttwosamplejoints.Thepipelengthshouldbeaminimumof2’orseventimesthemaximumsaddlefittingbasedimension,whicheverisgreater.
2.Observethefusionprocessandverifytherecommendedprocedureforsaddlefusionisbeingfollowed.
3.Visuallyinspectthesamplejointforquality.
4.Allowthejointtocoolcompletely(minimumofonehour).Thepipesampleshouldnotbetappedforthisqualificationprocess.
Figure IISaddle Fusion Bent Strap Test Specimen
18
5.PrepareteststrapsasshowninFigureII.Cutthejointlengthwisealongthemainpipeandthroughthesaddlefitting.
6.Visuallyinspectthejointforanyvoids,gaps,misalignmentorsurfacesthathavenotbeenproperlybonded.
7.Bendeachteststrap180owiththeinsidefacingout.
8.Thefusionjointmustbefreeofcracks,voids,gapsandseparations.
9.Testtheothersamplejointbyimpactagainstthesaddlefitting.Thefailuremustoccurbyeithertearingthefitting,bendingthefittingatleast45oorbyremovingasectionofthepipe.Failureatthefusionisnotacceptable.ThistestisaFederalrequirementforqualificationoffusionprocedures.
10.Iffailuredoesoccurattheweldinanyofthesamples,thenthefusionprocedureshouldbereviewedandcorrected.Aftercorrection,anothersamplefusionshouldbemadeperthenewprocedureandretested.
ACCEPTABLE FUSIONS
ProperAlignment,MeltandForce
BendBackTesting-NoGapsorVoids(SeeFigureII)
Areawherelikelygapsandvoids
mightoccur
Areawherelikelygapsandvoids
mightoccur
19
UNACCEPTABLE FUSIONS
ExcessiveHeatingand/orOverpressurizationofjoint
ExcessiveForce
FittingMisalignmentonpipe
InsufficientMelt
20
TABLE VISADDLE FUSION TROUBLESHOOTING GUIDE
Observed Condition Possible Cause
•Non-uniformbeadsizearoundfittingbase •Misalignment •Defectiveheatingtool •Fittingnotsecuredinheatingtool •Heatingtemperaturenotwithinspecifiedrange •Onebeadlargerthantheother •Misalignment •Heatingtemperaturenotwithinspecifiedrange •Fittingslippedinclamp •Defectiveorwornequipment •Beadstoosmall •Insufficientheating •Insufficientjoiningforce •Beadstoolarge •Excessiveheatingtime •Excessivejoiningforce •Absenceofthirdbead,orthirdbead •Incorrectpipemainheatingtool widelyseparatedfromcenterbead Insufficientjoiningforce •Pressurizedmainblowout •Excessiveheating (besidebaseorthroughfittingbase) •Heatingtemperaturenotwithinspecifiedrange •Incorrectheatingtoolfaces •Excessivetimetostartheatingorinjoiningthe fittingtothemainpipeafterheatingtimecycle •Rough,sandpaper-like,bubbly, •Hydrocarbon(gasolinevapors,spraypaint orpockmarkedmeltbeadsurface fumes,etc.)contamination
21
SOCKET FUSION
Equipment Requirements
Inordertoproduceaqualitysocketfusion,thefollowingequipmentisrequiredforthisprocedure:
Apparatus –SocketfusiontoolsmanufacturedinaccordancewithASTMF1056.
Heating tool faces –Consistingoftwoparts,amaleendfortheinteriorsocketsurfaceandafemaleendfortheexteriorpipesurface.
Rounding clamps (cold ring) -Devicetomaintaintheroundnessofthepipeandcontrolthedepthofpipeinsertionintothesocketduringthejoiningoperation.
Depth gauge –Properpositioningoftheroundingclamp.
Chamfering tool –Devicetobeveltheendofthepipe.Thedepthgaugeandchamferingtoolmaybecombinedintoasingletool.
Holding tools –Recommendedforsocketfusionof2”IPSandlargerpipeandfittings.
Heater Temperature
Heater Surface Temperature:Minimum490oF–Maximum510oF
Inordertoobtainapropermelt,auniformtemperaturemustbemaintainedacrosstheheatingsurface.Allpointsonbothheatingsurfaceswheretheheatingsurfaceswillcontactthepipeandfittingmustbewithintheprescribedminimumandmaximumtemperatures.Heatingtoolsurfacesmustbeclean.
22
Procedure
1. Preparation
A.Verifyheatingtemperatureiswithinthespecifiedtemperaturerange(490oF–510oF).
B.Cutthepipeendsquarely,andcleanthepipeendandfitting,bothinsideandoutwithaclean,dry,lint-freecloth.Donottouchcleanedsurfaceswithyourhands.
C.Chamfertheoutsideedgeofthepipeendslightly.Thepipeshouldbefreeofdebrisandburrs.
D.Placethecoldringonthepipeasdeterminedbythedepthgauge–Placethedepthgaugeoverthechamferedendofthepipe.Clampthecoldringimmediatelybehindthedepthgauge.
2. Heating
A.ReviewtherecommendedheatingtimesinTableVI.TheheatingtimebeginsafterStepChasbeencompleted.
B.Insertthefittingontothemaleheatingface.Thefittingshouldbeheldagainstthebacksurfaceofthemaleheaterface.
C.Insertthepipeintothefemaleheatingface.Thefemalesocketheatingfaceshouldbeagainstthecoldringclamp.
D.HoldthepipeandfittinginplaceagainsttheheaterfacesfortherecommendedheatingtimeasshowninTableVI.
23
3. Fusion and Cooling
A.Attheendoftheheatingtime,simultaneouslyremovethepipeandfittingstraightoutfromthetoolusinga“snap”action.Donottorqueortwistthepipeorfittingduringremoval.
B.AQUICKinspectionshouldbemadeofthemeltpatternonthepipeendandfittingsocket.Ifthereisevidenceofanincompletemeltpattern,donotcontinuewiththefusionprocedure.C.Immediatelyinsertthepipestraightintothesocketofthefittingsothatthecoldringisflushagainsttheendofthefittingsocket.Whilecooling,pressureshouldbemaintainedonthefusionpertherecommendedcoolingtimeshowninTableVI.
TABLE VIISOCKET FUSION TIME CYCLES
PE2708 PE4710 PolyPipe® GDY20 & PolyTough1™ & PolyPipe® Pipe Size fusedtounimodalMDPEfittings PolyTough1™ PE27081 fusedtoHDPEfittings
Heating Time Cooling Time Heating Time Cooling Time seconds seconds seconds seconds
1/2”CTS 5–6 30 8–10 30 3/4”CTS 7–8 30 10–12 30 1”CTS 9–10 30 12–14 30 1/2”IPS 5–6 30 8–10 30 3/4”IPS 8–10 30 12–14 30 1”IPS 10–12 30 14–16 30 1-1/4”IPS 12–14 45 18–20 60 1-1/2”IPS 12–14 45 18–20 60 2”IPS 16–20 45 22–26 60 3”IPS 20–25 60 25–30 75 4”IPS 25–30 60 30-35 75
Notes: If an incomplete bead rollout is noticed when joining PolyTough1 to unimodal socket fittings, PolyPipe® recommends the use of bimodal MDPE fittings HDPE fittings or other means of joining the pipe.
D.Allowthejointtocoolanadditionalfive(5)minutesbeforeremovingthecoldring.Anadditional10minutesofcoolingtimeisrecommendedbeforeexposingthejointtoanytypeofstresses(i.e.,burialortesting).
4. Inspection
Visuallyinspecttheweld.Acompleteimpressionoftheroundingclampshouldbevisibleinthemeltpatternattheendofthesocket.Thereshouldbenogaps,voidsorunbondedareas.
24
Qualification
The following summarizes the ASTM methods to which the operator and/or user should refer for specific qualification requirements
1.Prepareasamplejointsuchasacouplingwithpipesocketfusedtobothends.Thepipeshouldbeatleast6”or15timesthewallthicknessinlength.
2.Observethefusionprocessandverifytherecommendedprocedureforsocketfusionisbeingfollowed.
3.Visuallyinspectthesamplejointsforquality.
4.Allowthesampletocoolcompletely(minimumofonehour).
Figure IIISocket Fusion Bent Strap Test Specimen
6.Visuallyinspectthecutjointforanyindicationsofvoids,gaps,misalignmentorsurfacesthathavenotbeenfused.
7.Bendeachteststrap180owiththeinsideofthepipefacingout.
8.Thefusionjointmustbefreeofcracks,voids,gapsandseparations.Iffailuredoesoccurattheweldinanyofthesamples,thenthefusionprocedureshouldbereviewedandcorrected.Aftercorrection,anothersampleweldshouldbemadeperthenewprocedureandretested.
5.PrepareteststrapsasshowninFigureIII.Cutthejointslengthwiseintoatleastthreelongitudinalstrapswithaminimumof1”or1.5timesthewallthicknessinwidth.
25
ACCEPTABLE FUSIONS
ProperAlignmentandStabDepthMeltBeadFlattenedDuetoColdRing-Nogapsorvoids
BendBackTesting-NoGapsorVoids(SeeFigureIII)
SOCKET FUSION
Areawherelikelygapsandvoids
mightoccur
Areawherelikelygapsandvoids
mightoccur
26
SocketFusion
ExcessiveStabDepthCausedbyFailuretoUseaColdRing
ShortStabDepthCausedbyFailuretoUseaDepthGauge
UNACCEPTABLE FUSIONS
SOCKET FUSION
27
TABLE VIIISOCKET FUSION TROUBLESHOOTING GUIDE
Observed Condition Possible Cause •Noevidenceofcold-ringimpression •Insufficientheatingtime insocketfittingmeltbead •Depthgaugenotused •Coldringnotused •Coldringsetatincorrectdepth •Gapsorvoidsaroundthepipeat •Pipeorfittingnotremovedstraight thesocketfittingedge fromheaterface •Componentsnotjoinedtogetherstraight whenfusing •Coldringnotused •Coldringsetatincorrectdepth •Wrinkledorcollapsedpipeend •Coldringnotutilized •Coldringsetatincorrectdepth •Incorrectheatingsequence •Voidsinfusionbondarea •Pipeorfittingnotremovedstraightfromheaterface •Componentsnotjoinedtogetherstraight whenfusing •Coldringnotused •Coldringsetatincorrectdepth •Unbondedareaonpipeatendofpipe •Coldringnotused •Coldringsettoodeep •Socketmeltextendspastendofpipe •Coldringsettooshallow •Rough,sandpaper-like,bubbly,or •Hydrocarbon(gasolinevapors,spraypaint pockmarkedmeltbeadsurface fumes,etc.)contamination
28
APPENDIX A
HYDRAULIC FUSION MACHINE GAUGE PRESSURE
ThemanufacturerofthefusionmachineshouldbeconsultedforguidanceindeterminingtheproperconversionofPolyPipe®’srecommendedinterfacialpressuretothegaugepressure.Theeffectivehydraulicpistonareamustbeavailableinordertocalculatetherequiredhydraulicgaugepressure.Thecalculationforhydraulicgaugepressureisasfollows:
Where PG = Hydraulicgaugepressure,psi OD = Pipeoutsidediameter,inches ID = Pipeinsidediameter,inches PI = Requiredinterfacialpressure,psi AP = Totalhydraulicpistonarea,in2 DF = Hydraulicfusionpressurerequiredtomovethecarriageholdingthepipe (generallyacceptedminimumis30psi).
*Thedragfactorisanimportantparametereasilyoverlooked.Iftwolongpiecesofpipearebeingfused,thedragfactorcaneasilyreachseveralhundredpoundspersquareinch(psi).
ExampleCalculations
FusionMachine:McElroyManufacturing28HighForceMachine Hydraulicpistonareaisprovidedbythefusionequipmentmanufacturer. Totalhydraulicpistonareaforthismachineis4.71in2
DesiredInterfacialPressure:75psi
For2”IPSSDR11:
29
REFERENCES
1. PlasticsPipeInstituteTechnicalReport-33.GenericButtFusionJoiningProcedureforPolyethyleneGasPipe,2006. www.plasticpipe.org
2. PlasticsPipeInstituteTechnicalReport-41.GenericSaddleFusionJoiningProcedureforPolyethyleneGasPiping, 2002.www.plasticpipe.org
3. PlasticsPipeInstituteTechnicalNote–42.RecommendedMinimumTrainingGuidelinesforPEPipeButtFusionJ oiningOperatorsforMunicipalandIndustrialProjects,2009.www.plasticpipe.org
4. ASTMF2620-11.StandardPracticeforHeatFusionJoiningofPolyolefinPipeandFittings.www.astm.org
5. ASTMF1056-11.StandardSpecificationforSocketFusionToolsforUseinSocketFusionJoiningPolyethylenePipe orTubingandFittings.www.astm.org
6. PipelineSafetyRegulations.U.S.DepartmentofTransportation.CFR49.Washington,June2011.http://ecfr. gpoaccess.gov/cgi/t/text/text-idx?c=ecfr&tpl=/ecfrbrowse/Title49/49cfr192_main_02.tpl
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NOTES
NOTES NOTES
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