1、 Generic Butt Fusion Joining Procedure for Field Joining of Polyethylene Pipe TR-33 2012 105 Decker Court, Suite 825, Irving, TX 75062 Phone: 469-499-1044 Fax: 469-499-1063 www.plasticpipe.org ii Contents Foreword . iv SECTION I Generic Butt Fusion Procedure Testing for Field Joining of ASTM D2513 G
2、as Piping Materials 1 1.0 INTRODUCTION 1 2.0 SCOPE . 1 3.0 TESTING PROGRAM TO EVALUATE USE OF GENERIC JOINING PROCEDURE WITH POLYETHYLENE GAS PIPING PRODUCTS . 2 Part 1 - Pipe Fusion and Testing - 2“ IPS DR 11 (Like Materials) 3 Part 2 - Pipe Fusion and Testing -2“ IPS DR11 (Unlike Materials) . 4 Pa
3、rt 3 - Pipe Fusion and Testing - 8“ IPS DR11 (Unlike Materials) 5 4.0 CONCLUSIONS AND RECOMMENDATIONS 6 5.0 ACKNOWLEDGEMENTS 6 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. 8 1.0 SCOPE . 8 2.0
4、 TESTING PROGRAM TO EVALUATE USE OF GENERIC BUTT JOINING PROCEDURE FOR FIELD JOINING OF POLYETHYLENE PIPING PRODUCTS 9 Part 1 Pipe Fusion and Testing (5) different pipe manufacturers pipe samples with various wall thickness. . 10 Part 2 Pipe Fusion and Testing Compare tensile test results using diff
5、erent interfacial pressures. 11 3.0 CONCLUSIONS AND RECOMMENDATIONS 12 Other Acceptable Fusion Procedures . 12 SECTION III Butt Fusion Procedure Testing for Field Butt Fusion of PE 4710 pipe for all applications. . 13 1.0 SCOPE . 13 2.0 TESTING PROGRAM TO EVALUATE THE USE OF ASTM F2620-11 BUTT JOINI
6、NG PROCEDURES FOR FIELD JOINING OF PE 4710 POLYETHYLENE PIPING PRODUCTS 13 Phase I - Pipe Fusion and Testing 2” IPS pipe size 14 Phase II - Pipe Fusion and Testing 8” IPS pipe size . 15 Phase III - Pipe Fusion and Testing Variety of pipe sizes from 6” to 36” and up to 4” wall thickness 16 3.0 CONCLU
7、SIONS AND RECOMMENDATIONS 18 APPENDIX A . 19 Generic Butt Fusion Joining Procedure for Field Joining PE (Polyethylene) Pipe 19 1.0 SECURE 20 2.0 FACE 20 3.0 ALIGN . 20 4.0 MELT 20 5.0 JOINING . 21 6.0 HOLD . 22 7.0 VISUAL INSPECTION . 22 APPENDIX B . 25 iii LETTERS OF COMPLIANCE FROM PPI MEMBER COMP
8、ANIES FOR 49 CFR 192.283 FOR PIPE INTENDED FOR GAS DISTRIBUTION APPLICATIONS 25 APPENDIX C . 26 Municipal and Industrial Applications 26 APPENDIX D . 28 ILLUSTRATION OF A PROPERLY MADE BUTT FUSION JOINT. 28 iv FOREWORD GENERIC BUTT FUSION JOINING PROCEDURE FOR FIELD JOINING OF POLYETHYLENE PIPE This
9、 report was developed and published with the technical help and financial support of the members of the PPI (Plastics Pipe Institute, Inc.). The members have shown their interest in quality products by assisting independent standards-making and user organizations in the development of standards, and
10、 also by developing reports on an industry-wide basis to help engineers, code officials, specifying groups, and users. The purpose of this technical report is to provide important information available to PPI on a particular aspect of polyethylene pipe butt fusion to engineers, users, contractors, c
11、ode officials, and other interested parties. More detailed information on its purpose and use is provided in the document itself. This report has been prepared by PPI as a service of the industry. The information in this report is offered in good faith and believed to be accurate at the time of its
12、preparation, but is offered without any warranty, expressed or implied, including WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Consult the manufacturer for more detailed information about the particular joining procedures to be used with its piping products. Any reference to o
13、r testing of a particular proprietary product should not be construed as an endorsement by PPI, which does not endorse the proprietary products or processes of any manufacturer. The information in this report is offered for consideration by industry members in fulfilling their own compliance respons
14、ibilities. PPI assumes no responsibility for compliance with applicable laws and regulations. PPI intends to revise this report from time to time, in response to comments and suggestions from users of the report. Please send suggestions of improvements to the address below. Information on other publ
15、ications can be obtained by contacting PPI directly or visiting the web site. The Plastics Pipe Institute, Inc. www.plasticpipe.org This Technical Report, TR-33, was first issued in October 1999, and was revised in 2006, and in June 2012. 1 SECTION I GENERIC BUTT FUSION PROCEDURE TESTING FOR FIELD J
16、OINING OF ASTM D2513 GAS PIPING MATERIALS11.0 INTRODUCTION In 1994, representatives of the U.S. DOT (Department of Transportation), Office of Pipeline Safety requested that the Plastics Pipe Institute (PPI) assist in promoting greater uniformity in the joining procedures utilized by gas utilities in
17、 the butt fusion of polyethylene (PE) gas piping products. DOT reported that it had encountered a proliferation of similar but slightly varying joining procedures from individual PE pipe producers. The slight differences in the various procedures made it more difficult for pipeline operators to qual
18、ify persons with appropriate training and experience in the use of these procedures. It was even more difficult for DOT to enforce the joining requirements in 192.283 (Plastic pipe, qualifying joining procedures) of the C.F.R. (Code of Federal Regulations) Title 49. In response to DOTs request, PPI
19、established a task group to examine the differences among the varying joining procedures, to identify similarities in those procedures, and to determine whether there were a sufficient number of common elements to provide a basis for a more uniform, or “generic” joining procedure that could be quali
20、fied by pipeline operators for most applications. A more uniform joining procedure would bring greater consistency to this aspect of gas pipeline installation, facilitate the pipeline operators efforts to qualify the procedure, reduce costs, and simplify DOTs enforcement duties. 2.0 SCOPE The progra
21、m undertaken by the PPI Task Group for the testing of representative materials under a generic set of conditions was designed to reflect the fusion conditions and parameters specified in most joining procedures recommended by pipe producers and qualified by pipeline operators. It was intended to pro
22、vide a technical basis for the development of a generic butt fusion procedure (see Appendix A) that can be offered to the industry for use with selected PE (polyethylene) piping products. The procedure would be available for use by pipeline operators who would determine whether the procedure is appr
23、opriate for use with the PE piping products it employs. Pipeline operators could consider the recommendations and testing performed by others in their effort to comply with the fusion procedure qualification requirements of 49 C.F.R. 192.283 (Plastic pipe, qualifying joining procedures). It is impor
24、tant to emphasize that the testing performed by the PPI Task Group was intended only to establish a technical basis for developing and proposing a more generic fusion joining procedure that would offer the maximum opportunity to be qualified and used by pipeline operators with a broad range of polye
25、thylene piping products. The testing was not intended to qualify the 1Dupont Aldyl A MDPE, Uponor Aldyl A MDPE and Phillips Driscopipe 7000 and 8000 HDPE are not included in this procedure. 2 procedure for use with any particular pipe product, and PPI offers no opinion on whether the procedure is pr
26、operly qualified for use with any particular PE pipe product. PE pipe producers remain solely responsible for any representations that they may make about the use of this generic procedure or any other joining procedure with their proprietary PE piping products, and pipeline operators remain solely
27、responsible for compliance with the requirements of 49 C.F.R. 192.283 (Plastic pipe, qualifying joining procedures) when qualifying any procedure for use with the products it selects for its pipelines. PPI member pipe manufacturers have endorsed this generic procedure for joining their product to it
28、self and to other commercially available pipe materials. Pipe producer compliance letters are in Appendix B for gas pipe applications and Appendix D for all other applications. A typical illustration of a properly made butt fusion joint is in Appendix D. PPI hopes that the inherent value of greater
29、uniformity will provide all the incentive necessary for companies to evaluate the generic procedure in Appendix A as a first option for butt fusion joining of its PE piping products. Use of this procedure is obviously not mandatory, and every PE pipe producer and pipeline operator retains the option
30、 of developing different procedures for its particular products and pipelines. However, PPI believes that its work in developing this generic procedure as a candidate for widespread acceptance throughout the industry will lead to greater efficiency, simplicity, and understanding in this area and pro
31、mote the use of effective, qualified procedures for butt fusion joining of PE pipe. 3.0 TESTING PROGRAM TO EVALUATE USE OF GENERIC JOINING PROCEDURE WITH POLYETHYLENE GAS PIPING PRODUCTS The Task Group collected and examined a large number of diverse procedures now in use by gas pipeline operators o
32、r recommended by pipe producers for specific PE piping products. It then identified those conditions and fusion parameters that were common to the majority of those procedures. The Task Group proposed the following fusion parameters as representative of the conditions in the individual procedures th
33、at they reviewed: Heater Surface temperature 400 - 450 F (204-232C) Interfacial Pressure 60-90 psi (4.14-6.21 bar) From its review of the different procedures collected from PE gas pipe producers, the Task Group further developed the generic joining procedure set out in Appendix A, based on its asse
34、ssment of the common elements in the individual procedures. It was agreed that proprietary products such as Uponor Aldyl A MDPE products and Phillips Driscopipe 8000 HDPE piping products were sufficiently different from the remainder of the materials being discussed that they were not included in th
35、e test program.22Uponor Aldyl-A and Phillips Driscopipe 8000 are no longer manufactured. The manufacturers should be contacted for more information on particular joining procedures for those 3 products. Only current commercially available products from PPI member companies were included in this test
36、 program. For information on older or other products, please contact the manufacturer of those products. Using these parameter ranges and procedures, the Task Group initiated a 3-part test program to evaluate whether a representative cross-section of marketed PE gas piping products would qualify und
37、er the qualification requirements of Part 192 when joined in accordance with this generic joining procedure. The evaluation was conducted using pipe from MDPE and HDPE materials deemed suitable for fuel gas applications per ASTM D2513. These materials have a grade designation, in accordance with AST
38、M D3350, of PE24 and PE34, respectively. Grade Density Melt Index Pipe (Grams/cc) (Grams/10min.) Marking _ PE 24 .926 - .940 .15 to .40 PE 2406 PE 34 .941 - .955 .05 to .15 PE 3408 After fusion of the samples, tensile and quick-burst tests were conducted in accordance with the requirements of 49 C.F
39、.R. 192.283 (Plastic pipe, qualifying joining procedures). Non-destructive ultrasonic inspections and high speed tensile impact testing were also conducted on each fusion combination. Additional testing conducted only on 8” pipe samples, included 176 F (80C), 1,000-hour long-term hydrostatic testing
40、 at 580 psi (40 bar) hoop stress. The results of the test program are described in the following sections. PPIs Conclusions and Recommendations, based on the Task Groups work, are found at the end of this section. Test data are maintained at PPI headquarters. Part 1 - Pipe Fusion and Testing - 2“ IP
41、S DR 11 (Like Materials) Part 1 of this project was to evaluate the generic procedure for use in fusing a PE pipe producers product to itself (e.g., Phillips MDPE to Phillips MDPE). The Task Group members supplied 2“ SDR 11 pipe samples for fusion joining. A total of 24 sample fusions, like material
42、 to like material, were made for each MDPE and HDPE pipe product. The total number of sample pieces was 72 and the total number of fusion joints made was 290. To evaluate the fusion parameters initially selected by the Task Group, all combinations of min/max heater surface temperatures 400 - 450F (2
43、04 -232C) and min/max interfacial pressures 6090 psi (4.14-6.21 bar) were used in this testing. In addition, sample fusions at heater face temperatures (375F and 475F) (191C and 246C) and interfacial pressures (50 and 100 psi) (3.45 and 6.90 bar) were made and tested to examine conditions for fusion
44、 outside the initially generic parameters. The Task Group agreed to use these same fusion parameters for both the MDPE and HDPE. The results of testing these fusion samples were 100% positive. All of the fusion joints (including those made under the extended parameters) passed every test 4 conducted
45、. As noted above, these tests included tensile testing, quick burst testing, high speed tensile impact testing and 100% ultrasonic inspection. Part 2 - Pipe Fusion and Testing -2“ IPS DR11 (Unlike Materials) Part 2 of this project was to evaluate the generic procedure, the fusion temperature range,
46、and the interfacial pressure range for cross fusions of unlike materials (e.g., Phillips MDPE to PLEXCO MDPE or Uponor MDPE to KWH Pipe HDPE). Again 2“ IPS SDR11 PE pipe was chosen. The Task Group members reviewed the information presented in Table 1. Overview of Polyethylene Plastic Gas Pipe Materi
47、als and decided that the cross fusion program could be simplified by selecting representative materials only. For MDPE materials it was decided that two materials could be selected to represent the two main families of MDPE materials (chromium oxide/slurry loop produced MDPE and Unipol Gas Phase MDP
48、E). The two specific materials selected were Phillips Marlex TR-418 and Union Carbide DGDA 2400. The testing of these two materials would help to assess the appropriateness of the generic conditions for cross fusion of all MDPE plastic pipe gas compounds commonly being used today. The Task Group dec
49、ided to use the same joining parameters as in Part 1 in these tests, based on the view that successful fusions under these conditions would cover all the other materials under the generic ranges. The chosen combinations of joining parameters were (1) 475F/100 psi (246C/6.90 bar) and (2) 375F/50 psi (191C/3.45 bar). The remainder of the fusion procedures remained the same as Part 1. Fusion joints between Phillips TR-418 and Union Carbide DGDA 2400 were prepared. There
