Comparison of Procedures PPI TR-33 and ASTM F2620

AGA Operations ConferenceMay 20, 2015

Jim Johnston

Chief Innovation Officer

Standardization

The process of developing and implementing technical standards. Standardization can help to maximize compatibility, interoperability, safety,repeatability, or quality.

• PE is a very forgiving material with a wide window of acceptable fusion.

• Globally, procedures range from interfacial pressures 21.7 psi up to 150 psi

• Butt Fusion Heater Surface temperatures range from 400 - 500° F

PPI TR-33

• SECTION I – GENERIC BUTT FUSION PROCEDURE TESTING FOR FIELD JOINING OF ASTM D2513 GAS PIPING MATERIALS

• SECTION II – GENERIC BUTT FUSION PROCEDURE TESTING FOR FIELD JOINING OF ASTM F714, ASTM D3035, AWWA C-901, AWWA C-906 AND PE PIPING FOR OTHER APPLICATIONS

• SECTION III – BUTT FUSION PROCEDURE TESTING FOR FIELD BUTT FUSION OF PE 4710 PIPE FOR ALL APPLICATIONS.

• APPENDIX A - Generic Butt Fusion Joining Procedure for Field Joining PE (Polyethylene) Pipe

PPI TR-33

• 1994 US DOT contacted the Plastic Pipe Institute® (PPI)

– Proliferation of similar but varying procedures from pipe procedures.

– Difficult for operators to qualify personnel

Source: PPI TR-33

PPI TR-33

• PPI established a task group including:– Performance Pipe

– PolyPipe Central Plastics US Poly

– Charter Plastics

– BP Solvay

– Total Petrochemicals

– KWH Pipe

– McElroy Manufacturing

– Connectra Fusion Technologies, LLC Source: PPI TR-33

PPI TR-33

• October 1999 PPI Published Section I: Generic Butt Fusion Procedure Testing for Field Joining of ASTM D2513 Gas Piping Materials

– All testing done using procedure in Appendix A

Heater Surface temperature 400 - 450° F

Interfacial Pressure 60-90 psi

ASTM F2620

• 2006 ASTM F2620 was published using the testing in TR-33 as its technical basis.

PPI TR-33

• 2006 PPI Published Section II: Generic Butt Fusion Procedure Testing for Field Joining Of ASTM F714, ASTM D3035, AWWA C-901, AWWA C-906 and PE Piping for Other Applications.

– All testing done using procedure in Appendix A

– Introduced holding the pipe under pressure until indication of melt is seen.

PPI TR-33

• 2012 PPI Published Section III: Butt Fusion Procedure Testing For Field Butt Fusion Of PE 4710 Pipe For All Applications.

– All testing done per F2620

– Added min soak time for 14” and larger

– Established Maximum open/close (dwell) time

– Changed cooling time basis to wall thickness

Fusion Process

• Secure

• Face

• Align

• Melt (Heat)

• Join (Fuse)

• Hold (Cool)

• Inspect

Fusion Process

• Secure

• Face

• Align

• Melt (Heat)

• Join (Fuse)

• Hold (cool)

• Inspect

MeltMinimum Bead Size

Pipe Size (IPS) TR33 F2620

1 ¼” and smaller 1/32” – 1/16” --

< 2" -- 1/32"

Above 1 ¼” through 3” About 1/16” --

>2" through 3" -- 1/16"

Above 3” through 8” 1/8”-3/16” 3/16"

Above 8” through 12” 3/16”-1/4” 1/4"

Above 12” through 24” 1/4”-7/16” 3/8"

Above 24” through 36” About 7/16” 7/16"

Above 36” through 63” About 9/16” 9/16"

MeltMinimum Soak Time

Pipe Size (IPS) TR33 F2620

less than 14” IPS None None

14”IPS and larger - 4.5 minutes / inch wall thickness

Fusion Process

• Secure

• Face

• Align

• Melt (Heat)

• Join (Fuse)

• Hold (cool)

• Inspect

Hold (Cool)Minimum Cool Time

TR-33 The fusion force should be held between the pipe ends for approximately 30-90 seconds per inch of pipe diameter or until the surface of the melt bead is cool to the touch.

F2620 Maintain fusion pressure against the piping component ends for a minimum of 11 minutes per inch (25.4mm) of pipe wall.

Source: ASTM F2620-13, PPI TR-33

Hold (Cool)Minimum Cool Time

IPS Pipe

size OD 30s 60s 90s

DR11

Cooling

Time

2 2.37 0:01:11 0:02:22 0:03:33 0:02:22

4 4.5 0:02:15 0:04:30 0:06:45 0:04:30

6 6.63 0:03:18 0:06:37 0:09:56 0:06:37

8 8.63 0:04:18 0:08:37 0:12:56 0:08:37

10 10.75 0:05:22 0:10:44 0:16:07 0:10:45

12 12.75 0:06:22 0:12:45 0:19:07 0:12:45

14 14 0:07:00 0:14:00 0:21:00 0:14:00

16 16 0:08:00 0:16:00 0:24:00 0:16:00

18 18 0:09:00 0:18:00 0:27:00 0:18:00

20 20 0:10:00 0:20:00 0:30:00 0:20:00

TR33 Cooling F2620

Hold (Cool)Minimum Cool Time

IPS Pipe

size OD 30s 60s 90s

DR7

Cooling

Time

DR7.3

Cooling

Time

DR9

Cooling

Time

DR9.3

Cooling

Time

DR11

Cooling

Time

DR13.5

Cooling

Time

2 2.37 0:01:11 0:02:22 0:03:33 0:03:43 0:03:34 0:02:53 0:02:48 0:02:22 0:01:55

4 4.5 0:02:15 0:04:30 0:06:45 0:07:04 0:06:46 0:05:30 0:05:19 0:04:30 0:03:40

6 6.63 0:03:18 0:06:37 0:09:56 0:10:25 0:09:59 0:08:06 0:07:50 0:06:37 0:05:24

8 8.63 0:04:18 0:08:37 0:12:56 0:13:33 0:13:00 0:10:32 0:10:12 0:08:37 0:07:01

10 10.75 0:05:22 0:10:44 0:16:07 0:16:53 0:16:11 0:13:08 0:12:42 0:10:45 0:08:45

12 12.75 0:06:22 0:12:45 0:19:07 0:20:02 0:19:12 0:15:35 0:15:04 0:12:45 0:10:23

14 14 0:07:00 0:14:00 0:21:00 0:22:00 0:21:05 0:17:06 0:16:33 0:14:00 0:11:24

16 16 0:08:00 0:16:00 0:24:00 0:25:08 0:24:06 0:19:33 0:18:55 0:16:00 0:13:02

18 18 0:09:00 0:18:00 0:27:00 0:28:17 0:27:07 0:22:00 0:21:17 0:18:00 0:14:40

20 20 0:10:00 0:20:00 0:30:00 0:31:25 0:30:08 0:24:26 0:23:39 0:20:00 0:16:17

TR33 Cooling F2620

Fusion Process

• Secure

• Face

• Align

• Melt (Heat)

• Join (Fuse)

• Hold (cool)

• Inspect

Inspect

• Material differences

– Unimodal/bimodal

– Medium density/high density/legacy materials

• Bead appearance (shape) is changing

• Inspection procedures?

Source: PPI TR-33

Inspect

TR-33

Inspect

F2620

Source: ASTM F2620-13

Inspect

F2620

Source: ASTM F2620-13

Conclusions

• Polyethylene is a very forgiving material and many standards exist for safe and effective fusion.

• Harmonization of standards used will help with training continuity.

• PE materials continue to improve and processes should adapt to those changes.

Questions?