1、 Reference number ISO/TR 19480:2005(E) ISO 2005TECHNICAL REPORT ISO/TR 19480 First edition 2005-08-15 Polyethylene pipes and fittings for the supply of gaseous fuels or water Training and assessment of fusion operators Tubes et raccords en polythylne pour le transport de combustibles gazeux Formatio
2、n et valuation des oprateurs de soudage ISO/TR 19480:2005(E) PDF disclaimer This PDF file may contain embedded typefaces. In accordance with Adobes licensing policy, this file may be printed or viewed but shall not be edited unless the typefaces which are embedded are licensed to and installed on th
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5、rm the Central Secretariat at the address given below. ISO 2005 All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from e
6、ither ISO at the address below or ISOs member body in the country of the requester. ISO copyright office Case postale 56 CH-1211 Geneva 20 Tel. + 41 22 749 01 11 Fax + 41 22 749 09 47 E-mail copyrightiso.org Web www.iso.org Published in Switzerland ii ISO 2005 All rights reservedISO/TR 19480:2005(E)
7、 ISO 2005 All rights reserved iiiContents Page Foreword iv Introduction v 1 Scope . 1 2 Normative references . 1 3 Terms and definitions. 2 4 Training organization . 2 5 Training 3 6 Assessment. 7 7 Periodic operator certificate renewal 7 Annex A (normative) Examination 9 Annex B (normative) Tear te
8、st for polyethylene (PE) saddle assemblies 10 Bibliography . 13 ISO/TR 19480:2005(E) iv ISO 2005 All rights reservedForeword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standa
9、rds is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also tak
10、e part in the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2. The main task of technical committees is
11、 to prepare International Standards. Draft International Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote. In exceptional circumstances, when a
12、 technical committee has collected data of a different kind from that which is normally published as an International Standard (“state of the art”, for example), it may decide by a simple majority vote of its participating members to publish a Technical Report. A Technical Report is entirely informa
13、tive in nature and does not have to be reviewed until the data it provides are considered to be no longer valid or useful. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall not be held responsible for identifying any or al
14、l such patent rights. ISO/TR 19480 was prepared by Technical Committee ISO/TC 138, Plastics pipes, fittings and valves for the transport of fluids, Subcommittee SC 4, Plastics pipes and fittings for the supply of gaseous fuels. ISO/TR 19480:2005(E) ISO 2005 All rights reserved vIntroduction The qual
15、ity of a piping system for the supply of gaseous fuels or water is to a large extent determined by the skills of the operators involved in installing the network. When installing polyethylene (PE) pipes, the quality of the fusion joints is essential for the piping system. Since fusion joints in PE p
16、iping systems can be made using various technologies, it is important that the fusion operators are trained and competent in the fusion technology employed in constructing PE networks. Continued competence of the fusion operator is covered by periodic re-training and re-assessment. TECHNICAL REPORT
17、ISO/TR 19480:2005(E) ISO 2005 All rights reserved 1Polyethylene pipes and fittings for the supply of gaseous fuels or water Training and assessment of fusion operators 1 Scope This Technical Report gives guidance and other provisions for the training, assessment and approval of fusion operators, wit
18、h the aim of establishing and maintaining their competency in the construction of polyethylene (PE) piping systems for the supply of gaseous fuels in accordance with ISO 10839, for the supply of water, or in the construction of such systems used in other pressure applications. It covers the butt fus
19、ion, electrofusion and socket fusion jointing techniques and considers both the theoretical and practical knowledge necessary for making high-quality fusion joints. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references,
20、 only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. ISO 4427, Polyethylene (PE) pipes for water supply Specifications ISO 4437, Buried polyethylene (PE) pipes for the supply of gaseous fuels Metric series Specific
21、ations ISO 8085-1, Polyethylene fittings for use with polyethylene pipes for the supply of gaseous fuels Metric series Specifications Part 1: Fittings for socket fusion using heated tools ISO 8085-2, Polyethylene fittings for use with polyethylene pipes for the supply of gaseous fuels Metric series
22、Specifications Part 2: Spigot fittings for butt fusion, for socket fusion using heated tools and for use with electrofusion fittings ISO 8085-3, Polyethylene fittings for use with polyethylene pipes for the supply of gaseous fuels Metric series Specifications Part 3: Electrofusion fittings ISO/TS 10
23、839:2000, Polyethylene pipes and fittings for the supply of gaseous fuels Code of practice for design, handling and installation ISO 12176-1, Plastics pipes and fittings Equipment for fusion-jointing polyethylene systems Part 1: Butt fusion ISO 12176-2, Plastics pipes and fittings Equipment for fusi
24、on jointing polyethylene systems Part 2: Electrofusion ISO 13953:2001, Polyethylene (PE) pipes and fittings Determination of the tensile strength and failure mode of test pieces from a butt-fused joint ISO 13954:1997, Plastics pipes and fittings Peel decohesion test for polyethylene (PE) electrofusi
25、on assemblies of nominal outside diameter greater than or equal to 90 mm ISO 13955:1997, Plastics pipes and fittings Crushing decohesion test for polyethylene (PE) electrofusion assemblies ISO/TR 19480:2005(E) 2 ISO 2005 All rights reserved3 Terms and definitions For the purposes of this document, t
26、he following terms and definitions apply. 3.1 butt fusion cycle pressure/time diagram for a defined fusion temperature, representing the butt fusion operation 3.2 drag resistance peak drag frictional resistance due to the weight of the length of pipe fixed in the moveable clamp at the point at which
27、 movement of the moveable clamp is initiated 3.3 drag resistance dynamic drag friction occurring during movement 3.4 frictional resistance butt fusion machine force necessary to overcome friction in the whole mechanism of the machine 3.5 fusion operator person trained to carry out fusion jointing be
28、tween polyethylene (PE) pipes and/or fittings based on a fusion procedure NOTE The fusion operator is trained for one or more fusion procedures, involving the operation of manual and/or automatic fusion-jointing machines. 3.6 fusion operator certificate approval certificate issued by the examiner/as
29、sessor stating that the knowledge and skill of the fusion operator is sufficient to produce fusion joints following a given fusion procedure 3.7 fusion procedure document agreed by the pipeline operator providing in detail the required variables and values for a specific fusion process, in order to
30、ensure repeatability EXAMPLE Butt fusion procedure, electrofusion procedure. 3.8 pipeline operator private or public organization authorized to design, construct and/or operate and maintain the supply system 3.9 training centre establishment for training of fusion operators 4 Training organization 4
31、.1 Training course A trainee fusion operator for underground PE systems should follow a training course at a training centre, in order to obtain a fusion operator certificate for PE pipes. The training centre should provide the training courses under the conditions described in this Technical Report
32、. ISO/TR 19480:2005(E) ISO 2005 All rights reserved 3Where applicable, the training centre shall be as required by national authorities. The courses should be delivered by a competent trainer having the required experience of fusion processes and mastery of the fusion technique involved. Where appli
33、cable, the trainer shall have a level of qualification as required by national authorities. The training centre should have a range of fusion machines representative of the equipment encountered on worksites for installing pipes, in order for the trainee fusion operator to become acquainted with the
34、 fusion equipment commonly used. The trainee fusion operator may be trained on one of these fusion machines or on a machine from his or her own company if accepted by the training centre. The fusion equipment shall comply with ISO 12176-1 for butt fusion equipment and ISO 12176-2 for electrofusion e
35、quipment. Preferably, a training centre should not carry out activities related to contracting, supervision of construction work, or inspection of fusion joints. 4.2 Operator assessment A trainee fusion operator who has followed a training course as described above should then pass a theoretical and
36、 practical assessment in order to be qualified as a fusion operator for PE systems. The assessor should not be the trainer and should have appropriate assessment qualifications. NOTE The assessor is a person accepted by the contracting parties or an accredited body, e.g. EN 45004 1or a certification
37、 body e.g. EN 45013 2 . 5 Training 5.1 Training curriculum The training course should consist of any combination of fusion packages based on the requirements of the pipeline operators. These packages may be given as individual modules or combined to suit requirements. During the training, attention
38、should also be drawn to safety. The course related to safety should deal with safety related to the fusion process. 5.2 Course 5.2.1 General The training should be provided by a trainer having the qualification according to 4.1. All consumables and tools necessary for the training package should be
39、available during the training session. The pipes and fittings to be used shall be those in accordance with ISO 4437, ISO 8085-1, ISO 8085-2 and ISO 8085-3 for the supply of gaseous fuels, and ISO 4427 for the supply of water, and corresponding to what is normally used locally for the construction of
40、 PE piping systems. The lessons should be designed so that the trainee fusion operator learns to master the fusion technique and also to master the materials and practical problems involved in laying a pipe in a trench, with or without obstacles. In connection with the latter aspect, the trainee fus
41、ion operator should construct at least one three- dimensional configuration (connection between two pipes laid in different axes). The trainee fusion operator should receive a written manual covering all the elements dealt with in the training. The course should be drawn up in one of the national la
42、nguages. 5.2.2 Theoretical course on general information The theoretical course should deal with general information in connection with raw materials, pipes and fittings, but also with theoretical knowledge on preparation, tools and devices and joining components. It should ISO/TR 19480:2005(E) 4 IS
43、O 2005 All rights reservedinclude details of the different fusion techniques namely electrofusion, butt fusion or socket fusion of materials (e.g. PE 80, PE 100) and SDR series, as well as on correct and incorrect parameters. The safety course should include information concerning the fusion process
44、, such as protective clothing, general safety regulations for electrical equipment, and the handling of heater plates. The main features are given in Table 1. Table 1 Theoretical course on general information Characteristics of PE compounds Typical properties of thermoplastics, PE 80, PE 100, UV beh
45、aviour and typical colours Physical and mechanical behaviour of PE compounds: temperature effects, strain/stress, creep, elongation/shrinkage, stress cracking, etc. Manufacturing of pipes and fittings Extrusion of pipes Overview of the manufacturing process, packaging and marking Transport, handling
46、 and storage of pipes Injection moulding of fittings Overview of the manufacturing process, packaging and marking Standardization of PE piping systems Dimensional data: nominal outside diameter and wall thickness (SDR), out of roundness Maximum allowed pressure, standards for pipes, fittings and acc
47、essories (valves) Overview of relevant test methods with this document Fusion operator certificate Identification number, time period validity, skill Health and safety considerations General Principle of risk management Clothing, shoes, hard hat, gloves Risks related to cleaning fluids, handling and
48、 storage of pipes Use of fire extinguishers Working in trenches, lifting equipments References to national regulations related to working on piping systems with pressure Butt fusion Electricity safety, use of generators, heating plates Electrofusion Electricity safety, use of generators Socket fusio
49、n Electricity safety, use of generators, heating tools Environmental aspects Use of cleaning fluid Disposal of packaging materials 5.2.3 Theoretical and practical course on fusion jointing techniques 5.2.3.1 Electrofusion jointing The trainee should become familiar with the electrofusion jointing technique and the associated fusion procedure by making a sufficient number of electrofusion joints. ISO/TR 19480:2005(E) ISO 2005 All rights reserved 5The fusion procedure shall be carried
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