Practice Guide for the Electrofusion Jointing of Larger Diameter Polyethylene Pressure Pipes

TEPPFA Technical Guidance Document - AGU/2014/01 A Good Practice Guide for the Electrofusion Jointing of Larger Diameter Polyethylene Pressure Pipes Contents 1. Introduction 5. Saddles 2. Safe and reliable site pre-conditions 6. Typical failures and root causes 3. Quality requirements 7. Checklist for planning 4. Installation procedure for Electrofusion socket fittings 1. Introduction Polyethylene piping systems are being increasingly accepted in larger diameters (above 315 mm) as a result of their proven performance advantages and the cost eective installation techniques which can be employed. Electrofusion (EF) is an important and reliable jointing method for polyethylene pipes and a wide range of EF fittings approved to EN 12201-3/ EN 1555-3 are oered in the market. Usually EF training and certification is only applied to smaller dimensions, the common influencing factors for good installation practices and the preventive measures to avoid welding failures are often not understood. This document aims to provide general guidance only, and should be used in conjunction with more detailed information from the specific pipe, fitting and equipment supplier. 1.1. Objectives of this document The following guide provides universally valid recommendations for the safe and reliable jointing of large diameter PE pipes using electrofusion techniques with the intention of preventing installation failures. The code describes good installation practices independent of fitting design. 1.2. Scope The Electrofusion jointing of PE pipes and pipe components above dn315mm for buried Gas & Water Utilities and Sewage and Industrial Water applications. 1.3. Originators This document was created by the Teppfa Utilities Application Group 1.4. Disclaimer In the preparation of this document every eort has been made to oer the most current, and accurate information. However, to the broadest extent permitted by law, all information published or referenced in this document is provided without any representation or warranty of any kind either expressed or implied. Changes and additions to any information contained herein may be made by Teppfa without prior notification. The Voice of the European Plastic Pipes and Fittings Industry

Page 2 TEPPFA Technical Guidance Document - AGC/2014/01 2. Safe and reliable site pre-conditions The following precautionary measures should be employed to ensure a healthy and safe working environment for operatives in the trench and to generate conditions for secure and reliable jointing, Figure 2: Pipe end excavated in a suitable length which in turn safeguard a leak-free operation over the life span of the piping system. Safety aspects: Storage conditions, handling and unloading of pipes 2.1. Planning For an ecient and safe execution all necessary equipment (machines and tools) and the corresponding pipe/ fitting components have to be available on site before the fusion process is commenced. The planning stage includes ensuring that the machines, tools and components (fittings) are available, appropriate, fit for purpose and are suitable for interactive use (i.e. adapter pins of the fusion unit and the pin size of the fitting) • Additional Checklist see chapter 7. 2.2. Site surrounding Excavation pit and retaining walls The profile of the excavation or retaining walls should prevent soil/ ground movements which could harm the safety of the installer and/or disturb the later fusion process. National safety Figure 3 & 4: Safety aspects, e.g. attention is drawn regulations have to be respected! when handling floating load on site Pipe ends have to be excavated in a suitable length to enable flexibility for ease of alignment. Safety aspects: Electrical power on site The safety regulations must be complied with and attention must be paid to the safety provisions and the operational safety ordinance, particularly if any work is carried out with electrical voltage over 50 Volt. In general the fusion box shall be placed outside the trench or the electrical power source shall be GFCI equipped for outdoor use (symbol: snowflake). National safety regulations have to be Figure 1: Retaining walls respected! The Voice of the European Plastic Pipes and Fittings Industry

Page 3 TEPPFA Technical Guidance Document - AGC/2014/01 Creating the appropriate working conditions Ensure dry conditions in the working pit To ensure adequate health and safety conditions In rehabilitation cases, pipelines often contain for the installers and/ or to guarantee reliable residual water, which steadily flows out at the pipe conditions for high quality jointing, sucient space ends. Preventive measures (e.g. closing valves, and dry conditions in the working pit are temporary plungers) shall be taken to stop the flow important. The application range for Electrofusion into the fusion area before the preparation process is usually -10°C to +45°C. Make sure by checking starts. For special solutions in rehabilitation please the installation manual, that installation in the consult your suppliers. intended temperature range is covered. For deviations or required additional measures, please 3. Quality requirements consult the suppliers of the pipe, fitting, tools and machines. 3.1. Quality control: Incoming goods Protection from rainfall (i.e. by using a tent) and Incoming goods shall be inspected and conform to pumping out ground water from the working pit is the relevant requirements with respect to a necessary preparation measure. dimensions, material, SDR and possible damages shall be confirmed before installation preparation. 3.2. Pipes and spigot fittings As pipes and spigot fittings are components in the jointing process their quality is as important for the fusion result as the fitting, the fusion equipment and the craftsmanship of the welder. Certification and delivery conditions Pipe deliveries should be checked for conformity to Figure 5: Protect the fusion area with a tent EN12201-2/ EN1555-2/ ISO15494, as this generates the basis for any reliable jointing. Deviations from the permissible tolerance of the outer pipe diameter and excessive ovality are not acceptable as they may significantly influence the jointing quality. Special attention is drawn to pipe bends which should be checked for local flattening and high ovality in the proposed jointing area. Geometrical deviations outside the permissible tolerance range shall not be accepted. Cutting back of bends is not Figure 6: Ground water has to be pumped out from allowed, please contact your supplier. the working pit Furthermore the pipes have to be visually checked Furthermore protection (e.g. by using an umbrella) within the proposed fusion zone for unacceptable from intense sun light especially in very hot defects such as severe toe-in (pipe end reverse), ambient conditions shall be guaranteed. flattening, scratches or damages that are not Open pipe ends should be sealed before starting eliminated during mechanical scraping. In such the installation process, to prevent contamination cases the pipe ends have to be cut or for saddles an and draft through the pipeline. unaected section of the pipe has to be selected. The Voice of the European Plastic Pipes and Fittings Industry

Page 4 TEPPFA Technical Guidance Document - AGC/2014/01 Appropriate pipe storage, transportation and In areas of high temperatures and heavy sunlight handling pipes shall be covered by a bright tarpaulin. Heat accumulation shall be prevented. Pipes shall be Use appropriate devices for handling of pipes, stored so that changes in temperature will not e.g. a crane or excavator, tie bar, belts. cause the pipes to move. Deviations from tolerances and defects may be caused by in-adequate pipe storage or transportation. Appropriate pipe storage, cautious transportation and handling – also from storage to the working pit - shall be executed in a way that no excessive ovalisation or damage (flattening, scratches, cracks) occurs, which could adversely aect the life span of the pipe or the joint quality. The ends of pipes which are intended for drinking Figure 7: Protection of pipe against direct sunlight water systems shall be closed. Allowable pipe storage times – especially for PE When several dierent wall thicknesses of pipe pipes which are not black - have to be confirmed are received, it is recommended that the pipe be by the pipe supplier. segregated into piles, each pile containing a single size and pressure rating to minimize All materials shall be carefully inspected at the sorting of the pipe at a later date. When pipe of time of delivery and any defects shall be notified dierent wall thicknesses or pressure ratings and reported immediately. Pipe shall be have to be stored in the same pile, the pipe with stockpiled adjacent to the site chosen for jointing the thickest wall shall be placed at the bottom of the pipe. If the pipe is laid directly on the ground, the pile with pipe of progressively decreasing the surface shall be level and free of stones and wall thicknesses stacked on top, providing this debris that might damage the pipe or make the matches the welding sequence. The pile shall be pipe stack unstable. constructed in a pyramidal, freestanding manner, with each successive layer having one less pipe All pipe stacks should be located on firm, flat than the layer below. The bottom layer shall be ground to evenly support the weight of the pipes braced to prevent movement under the weight and lifting equipment. Recommended ground of the pipes above. The maximum allowable conditions are level gravel, sand, snow or grass. stacking height for pipe stored in open yards, in Where such conditions do not exist or when a stacks of one nominal size, shall not exceed bed cannot be prepared, the pipe may be placed those given in Table 1. on planking. This planking shall be evenly spaced For safety and convenience of handling, the along the pipe length. Care must be taken not to stacking height for pipes shall be limited to six load the pipe in such a way that will cause flat units or not more than 2.5m, and they shall be spots. adequately wedged to prevent movement. The Voice of the European Plastic Pipes and Fittings Industry

Page 5 TEPPFA Technical Guidance Document - AGC/2014/01 Each level of pipes must be supported by timber when stored as shown in the example in Figure 9. Figure 8: shows the maximum level of PE pipes permitted for each DN/OD size on flat ground or on recommended planking for loose pipe storage. Figure 9: Example of good on-site PE Pipe Packing Nominal On On Pipe Flat Recommended and Storage Size Ground Planking 3.3. EF fittings Certification and pipe compatibility 315 6 5 Each delivery of EF fittings should be checked for conformity according to EN12201-3/ EN1555-3/ 355 6 5 ISO15494, as this generates the basis for any reliable jointing. 400 6 4 Additionally the specified pressure ratings (e.g. PN10, PN16), the pipe compatibility (e.g. SDR11, SDR26) and the correct voltage (e.g. 40V, 80V) in 450 5 4 combination with the fusion unit has to be checked. The fusion bar code shall comply with ISO 13950, if 500 4 3 not declared otherwise by the manufacturer. In addition accredited quality marks, e.g. DVGW, 560 4 3 BSI, KIWA and others guarantee an independent third party inspection of the products and a 630 3 2 constant high quality level. Appropriate storage of the EF Fittings 710 3 2 Inadequate transportation and storage can harm the fusion quality, therefore the fitting should be stored in 800 2 1 its original packaging (i.e. on pallet, in carton box and PE bag) and handled in accordance with the manufacturers storage and transportation instructions Table 3.1.2.3. Number of Permitted Layers of PE (e.g. storage in an up-right orientation as elevated Pipe for Stacking and Storage ambient temperature can create fitting ovality). The Voice of the European Plastic Pipes and Fittings Industry

Page 6 TEPPFA Technical Guidance Document - AGC/2014/01 Store electrofusion fittings in closed rooms or Manufacturer’s information containers not exposed to UV radiation and eects Installation manuals and additional information of weather. The Allowable storage temperature accompanying the product must be complied with. range is 0°C to +50°C. Only remove the fitting from Technical information, e.g. data sheets, installation packaging directly before insertion. manuals for fittings and operation instructions for fusion boxes and tools are also available, via the internet. Ensure that the generator and fusion box have the required power capacity and are compatible with the fitting being used. Contact your supplier if in doubt. 3.5. Machinery and preparation tools Certification The machinery and accessories have to be designed according to country specific regulations and guidelines. Generators and cables Figure 10: Transport of EF couplers d1200, packed For the installation of Electrofusion fittings in field on individual pallets in horizontal position applications, it will be necessary to have a reliable 3.4. Welder certification and training source of AC power for the fusion processor to work properly in supplying the fitting the right Certification (where applicable) amount of energy. In some European countries a certification system The common types of generator power control are for Polyethylene Butt- and/ or Electrofusion Capacitor and Automatic Voltage Regulation welders is established. Most systems request (AVR). Better welding machine/generator frequent re-assessment of the welder skills with an performance is provided by Capacitor types as the ocial re-certification however Butt fusion and current and voltage control are synchronized. Electrofusion training/ certification is only usually Automatic Voltage Regulation is primarily designed applied on smaller dimensions. for maintaining consistent voltage supply. Training on large diameter EF jointing from fitting Generators shall manufacturer Only supply current to the fusion unit during The jointing quality in small but even in large the fusion process and not to other machinery. diameter EF jointing is heavily influenced by Be well maintained and subject to a periodic adherence to the correct installation procedure. maintenance schedule. The Utility company/ end client shall require that Provide a nominal voltage in unloaded only trained and skilled welders are specified. conditions around 230V-240V (48V, 110V, Therefore, it is the responsibility of the installation 400V). company to ensure that welders have the proper Keep the nominal voltage stable at skills for installing the specific type of fitting being 230V±15% (48V, 110V, 400V) during the used. fusion process under load. Suppliers may oer hands-on training for Remain at a stable frequency (50-60Hz) demonstrating the appropriate installation procedure. under load. The Voice of the European Plastic Pipes and Fittings Industry

Page 7 TEPPFA Technical Guidance Document - AGC/2014/01 Provide the required power considering the temperature range (-10°C to +45°C). It should be following circumstances: requirements of the noted that fusion boxes and fittings with automatic connected fitting, power eciency of the temperature compensation are available. welding unit, use of extension cables, altitude and ambient temperature and Fusion box cooling times others (e.g. ≥ 6kVA). Fusion boxes may require cooling times when fittings with high power consumption are used or The length of extension cables shall not exceed during high ambient temperatures on site. The use of 50m, they should be rolled out completely and a second fusion box allows a continuous work flow. have a cross section of at least 2.5 mm2. Recommended types of Generators may be found Tools on a positive list, ask your supplier. Generally tools shall be applied only for their intended use as shown in the instruction manual of the tool Fusion units manufacturer. For all tools the following requirements Fusion units according to ISO12176-2 should be must be guaranteed for a proper jointing and to used to comply with the fusion data recognition respect the health and safety regulations: and to comply with the necessary health & safety regulations. Preferably data retrieval units should be Tools should be inspected for any external used allowing the storage of the actual fusion data damage or defects and any necessary and permitting a read-out of the data. Ensure that repairs eected before use. adapter plugs, e.g. 4.7 mm are available, if required. Fusion units shall be calibrated in a regular time. No tools shall damage or contaminate the fusion areas. Visual inspection Regular monitoring of the fusion cable is necessary. After use the tools must be cleaned from Damaged cables must be replaced. Worn contacts dirt, mud and other debris and checked for can become hot during the fusion process and damage and defects and stored safely in should be replaced. their transportation boxes. Technical inspection approval Cutting tools According to the information from the Powered cutting tools are commercially available, manufacturer the fusion equipment must be but the following requirements shall be respected: regularly inspected in accordance with the manufacturer’s recommendations by an expert • Only plastic saws or other cutting tools approved by the manufacturer concerned. suitable for PE should be used. Appropriate power consumption When chain saws are used contamination Special requirements for the energy output given from oil/ lubricants must be avoided. by the fitting manufacturer must be adhered to (e.g. 90A @ 40V). Ensure a square cut is achieved either by the design of the cutting tool or with an Temperature compensation adequate, circumferential marking on the Equipment shall cover the full intended pipe. The Voice of the European Plastic Pipes and Fittings Industry

Page 8 TEPPFA Technical Guidance Document - AGC/2014/01 Tools for Scraping As the removal of the oxide layer of the pipe is a critical factor for the fusion quality special attention has to be given to this process. To provide reliable and consistent scraping results mechanical rotary/ window scraping tools shall be used, whenever possible. Mechanical scraping tools shall Be well maintained and subject to a periodic maintenance schedule, especially with regards to the wear of the blade Figure 11: Electrical cutting tool Tools for Re-Rounding before mechanical Provide a min. swarf removal of >= 0.2mm scraping/ fusion The condition and the wear of the scraper blade should be regularly checked, e.g. the swarf thickness with a Mechanical or hydraulic re-rounding tools/ clamps vernier caliper. Worn blades must be replaced are commercially available and the following Pipe Estimated Abrasion requirements must be considered: dimension swarf thickness limit (mm) (mm) (mm) • When re-rounding tools/ clamps are used damage to the pipe surface and any ≥ d315 0.20 - 0.40 ≤ 0.40 contamination of the fusion zone have to be avoided. ≥ d800 0.40 - 0.60 ≤ 0.80 Re-rounding tools shall be suitable to Table 2: Swarf thickness and abrasion limits reduce the ovality in the fusion zone <3mm. Abrasives, grinding wheels, or other devices that do not cleanly remove the oxide layer in an appropriate way should not be used! Figure 12: Re-Rounding tool Figure 13: Example of mechanical scraping tool The Voice of the European Plastic Pipes and Fittings Industry

Page 9 TEPPFA Technical Guidance Document - AGC/2014/01 Measurement tools (Pi Tape, yard stick) 4.2. Prevent escaping media Pi Tapes are used to check the compliance of the Fusion with escaping media will negatively influ- pipe or spigot fitting with the diameter tolerance in ence the jointing quality and is therefore not the standard (EN12201-2, EN1555-2, ISO15494). permissible! Clean, state of the art yardsticks are used to mark the insertion depth of the pipe into the fitting. 4.3. Pre-cleaning of pipes and components Remove dirt, mud and other debris from the pipe and other components to reduce the wear on the mechanical scrapers and cutting tools. Do not use clothes or rags which may contain oily or greasy substances. Clean water can be used, but the pipe components Figure 14: Example of mechanical scraping tool must be dry and clean before starting the installa- tion process. Use a handscraper to deburr the pipe edge. Figure 17: Checking the outer diameter of the pipe PE cleaner and tissues where applicable Use only an appropriate cleaner (e.g. Ethyl-Alcohol >99.8%) and colourless, lint-free, absorbent, non-dyed and clean paper towel. Check on a hand mirror that the cleaning solvent completely evapo- rates without residues, to guarantee the quality of Figure 15: Deburr the pipe edge cleaning solvents. Alignment clamps PE-Marker Alignment tools are commercially available, either Use recommended markers only which do not as a stand-alone clamp or combined with aect the pipe material. re-rounding clamps. Functional test of the aligning result is recommended before use Pipe support Pipe supports are used for a simple and 4. Installation procedure for damage-free movement of pipes. They help to Electrofusion socket fittings improve pipe alignment and pipe movement with lower forces to achieve a stress-free installation. 4.1 Prepare working space Prepare necessary machines, tools and components for the installation (See checklist in appendix, incl. SDR compatibility etc.). Ensure sucient clearance and cleanliness around Figure 16: Pipe support the pipe in the working area. The Voice of the European Plastic Pipes and Fittings Industry

Page 10 TEPPFA Technical Guidance Document - AGC/2014/01 4.2. Prevent escaping media Toe-in of pipe end: Cut-back required if longer than Fusion with escaping media will negatively influ- inner cold zone of the fitting ence the jointing quality and is therefore not Check pipe diameters with a Pi tape before and permissible! after mechanical scraping. Check compliance with the tolerance specified in the standard (EN12201-2, 4.3. Pre-cleaning of pipes and components EN1555-2, ISO15494). Remove dirt, mud and other debris from the pipe and other components to reduce the wear on the mechanical scrapers and cutting tools. 4.5. Re-Rounding Do not use clothes or rags which may contain oily Pre-check the ovality with fitting insertion test up or greasy substances. to 1cm of the cold zone to verify if the assembly is Clean water can be used, but the pipe components feasible. must be dry and clean before starting the installa- If not, check ovality of the pipes with a yardstick. tion process. Pipe ovality (dmax-dmin) in the area of fitting positioning shall be ≤ 3,0 mm, unless specified dierently by the fitting manufacturer. Do not over-scrape to remove high sides of oval pipes! If required apply re-rounding tool/ place re-round- ing clamp on the pipes immediately outside of the proposed fitting position. Re-check out of round- ness of the pipes and reposition the tool, if required. Figure 18: Pre-cleaning the pipe 4.4. Pipe cutting and check of pipe diameter The pipe surfaces have to be visually checked within the fusion zone for unacceptable defects like severe toe-in (pipe end reverse), flattening, scratch- es or damage that will not be eliminated during mechanical scraping. Where damage is apparent Figure 23: Mechanical Re-Rounding / Figure 24: the pipe ends should be cut at right angles with Hydraulic Re-Rounding appropriate pipe cutter and if necessary edges 4.6. Peeling of Multi-Layer Pipes, if applicable have to be deburred. Consult your pipe supplier about the tools and The cutting surfaces of the pipe ends shall be procedure for removal of the peelable skin and then smooth and flat. continue with the procedure. 4.1 Prepare working space 4.7. Mechanical Scraping Prepare necessary machines, tools and components Measure lengths which must be mechanically for the installation (See checklist in appendix, incl. scraped (insertion length plus 2 cm or complete SDR compatibility etc.). Fig. 19 Fig. 20 Fig. 21 Fig. 22 fitting length for slide over installation) with a Ensure sucient clearance and cleanliness around Toe-in of pipe ends, Marking the cutting position, yardstick on the pipes / components and mark the the pipe in the working area. Cutting the pipe end / Deburr the pipe end area with a permanent marker. The Voice of the European Plastic Pipes and Fittings Industry

Page 11 TEPPFA Technical Guidance Document - AGC/2014/01 Figure 25: Marking the length for peeling Figure 27: Checking the pipe diameter Scrape the pipes with rotary scraping tool until the 4.8. Cleaning outer surfaces of the pipes have been removed to The Electrofusion fitting should only be removed expose a clean, virgin pipe material. Inspect the from its packaging directly before the planned entire circumference of the scraped areas to ensure jointing process. Avoid touching the fusion zone. total scraping coverage. Clean pipes only in the scraped area and fittings internally with an appropriate cleaner (e.g. Ethyl-Alcohol >99.8%) and colourless, lint-free, absorbent, non-dyed and clean paper towel. Use several new paper towels for larger areas and for each component. Avoid cross-contamination of the pipes from outside of the scraped zone. Let the cleaner evaporate. Avoid possible recontamination of the prepared Figure 26: Peeling the pipe end surfaces (these should not be touched with bare Repeated scraping may be necessary, depending hands due to body oils), as this could aect the on actual pipe diameter. Min. chip removal of jointing quality! approx. 0.2 mm has to beachieved. Ensure the min. Make sure that any possible moisture, dew or frost allowable pipe diameter given in the table below is is removed. maintained or consult the fitting manufacturer. Pipe Pipe Pipe dn dn, min dn, min s1 355 355,0 354,2 400 400,0 399,2 450 450,0 449,2 500 500,0 499,2 560 560,0 559,2 630 630,0 629,2 Figure 28: Cleaning of the fusion zone / Figure 29: 710 710,0 709,2 Cleaning of the EF coupler 800 800,0 798,4 900 900,0 898,4 4.9. Marking of Insertion depth 1000 1000,0 998,4 Pipe-Pipe-Installation 1200 1200,0 1198,4 1400 1400,0 1399,0 Measure the insertion depths (half-length of the 1600 1600,0 1599,0 fitting) with a yardstick and mark with a permanent 2000 2000,0 1999,0 pen in multiple positions around the circumferences dn, dn,min according to EN1555, EN12201 1) Min pipe diameter after scraping: dn, minS = dn,min – 2 x chip (according to Table 2) of both pipe ends. The Voice of the European Plastic Pipes and Fittings Industry

Page 12 TEPPFA Technical Guidance Document - AGC/2014/01 Integration and Repair fitting length is required on the first pipe, to For sliding cases, on the first pipe end measure full prevent contamination of the fitting during sliding fitting length and insertion depth with a yardstick over. Push the fitting completely onto the first pipe and mark both with a permanent pen in multiple (full fitting length) until the marking is reached. positions around the circumference. On the second Then install second pipe face to face with first pipe pipe end measure the half-length of the fitting with without a gap and slide fitting backwards until the a yardstick and mark with a permanent pen in end aligns with the marking on the second pipe multiple positions around the circumference. (half-length of the fitting). Check that the distance between fitting and marking on the first pipe is equal to half fitting length, to ensure that no gap has been created between the pipe ends during insertion. Figure 30: Measuring the coupler length Figure 32: Sliding over of the coupler 4.11. Clamping and alignment All joints prepared for fusion must be stress-free (no bending, self-loading or misalignment stresses)! Figure 31: Marking the insertion depth If required use alignment tools or similar measures, 4.10. Pipe insertion to guarantee a stress-free installation. Insert pipe or spigot end into the Electrofusion fitting. Leave plastic bag over the other fitting end 4.12. Fusion to prevent contamination and debris from entering Check compatibility before starting the fusion the open end. Assembly can be assisted by tapping (Diameter, SDR) around the face with a plastic hammer at the same Start the fusion process – using a preheating phase, time. Care should be taken for a low stress if applicable – in accordance with the user manual installation and do not tilt. Secure pipe and fitting supplied by the specific manufacturers of the fitting against dislocation. Check that full insertion has and fusion unit. been achieved up to the markings. Repeat process Fusion parameters are given by a bar code label on on second pipe end. Check the correct end position the fitting and are automatically converted by the of the fitting between the marks on both pipe ends. reader wand or scanner of the fusion box. It is Additional information for Integration and Repair: recommended to use automatic fusion process Sucient scraping and cleaning for the entire documentation and traceability function, which The Voice of the European Plastic Pipes and Fittings Industry

Page 13 TEPPFA Technical Guidance Document - AGC/2014/01 have to be activated at the fusion box. 4.14. Mark fusion parameters Keep a distance of one meter to the fusion site Mark the relevant fusion parameters (date, joint during the fusion process for general safety reasons number, fusion time, cooling time and welder and control and supervise the fusion process. (See name) on the fitting / pipe and in the job site next chapter “Cooling and quality control of documentation. fusion”) Electronically processed documentation and In case of interruption during the fusion process traceability via fusion box is recommended. (generator, fusion unit break-down), consult the fitting manufacturer’s installation manual for 5. Saddles re-heating process. 5.1. Prepare workspace Prepare all necessary machines, tools and components for the installation (See checklist in appendix, incl. SDR compatibility etc.). Ensure there is sucient clearance and cleanliness around the pipe in the working area. 5.2. Prevent escaping media Fusion with escaping media will negatively influence the jointing quality and is therefore not permissible! 5.3. Pre-cleaning of pipe Clean the pipes initially by hand to remove dirt, mud Figure 34: Scanning the fusion bar code and other debris to reduce the wear on the mechanical scrapers and cutting tools. Clean water can be used, but the pipe components 4.13. Cooling and quality control of fusion must be dry and clean before starting the installation During and after the fusion process check the process. following: 5.4. Re-Rounding / Scratches • No error message on the fusion unit As flattening, excessive ovality and scratches may • No melt exudation outside the fitting confines have a negative influence on the fusion quality, select an appropriate area for the saddle placement. • No unusual deformations of pipe or fitting The shape of the pipe in the related fusion zone • Fusion indicators show correct result must comply with the requirements of the fitting • Fitting remains stress-free and avoid manufacturer. Check shape of the pipe with fitting curvature or dislocation until complete cooling time has elapsed similar gauges and compare with the required Comply with the specific cooling times given by the tolerance given by the fitting manufacturer. fitting manufacturer, before conducting any If required apply re-rounding tool/ place re-rounding operations which could cause joint movement e.g clamp on the pipe immediately outside of the removal of clamps, pressurising the system or proposed fitting position. Re-check out of roundness carrying out pressure tests. of the pipe and reposition tool, if required. The Voice of the European Plastic Pipes and Fittings Industry

Page 14 TEPPFA Technical Guidance Document - AGC/2014/01 5.5. Peeling of Multi-Layer Pipes, if applicable due to body oils), as this could aect the jointing Consult the specific pipe supplier regarding the quality! tools and procedure for removal of the peelable Make sure that any possible moisture, dew or frost skin and then continue with procedure. is removed. 5.6. Mechanical Scraping Measure area which must be mechanically scraped (fitting area, length and with plus 2 cm) with a yardstick on the pipe and mark with a permanent pen. Scrape the pipe with rotary or window scraping tool or with a hand scraper. Scrape the pipe surface until the outer “skin” of the pipe has been removed to expose a clean, virgin pipe material. Inspect the entire fusion area to ensure total scraping coverage. Min. swarf removal of 0.2 mm has to be fulfilled. Figure 39: Cleaning of the scraped area Fig. 1 Fig. 3 5.8. Clamping of the saddle The installation manual supplied by the specific saddle manufacturer should be strictly complied with as the requirements for clamping/ top-loading of the saddles and the clamping techniques and Fig. 3 Fig. 4 procedures for each brand of saddle can vary significantly. Place saddle in the correct position and within the prepared pipe area. After clamping check to confirm that the gaps between saddle and pipe are within recommended levels. Figure 35 & 36: Marking the area for scraping Figure 37: Window scraping tool / Figure 38: Rotary scraping tool 5.7. Cleaning The Electrofusion saddle fitting should only be removed from its packaging immediately before the planned jointing process and without touching the fusion zone. Figure 40: Mechanically clamped system Clean pipes only in the scraped area with Figure 41: Vacuum system Ethyl-Alcohol (>99.8%) and saddle fusion zone with colourless, lint-free, absorbent, non-dyed and clean paper towel. Use several new paper towels for 5.9. Fusion larger areas and for each component. Avoid Check compatibility before starting the fusion cross-contamination of the pipes from outside of (dimensions, SDR). the scraped zone. Let the cleaner evaporate. Start the fusion process in accordance with the user Avoid all possible recontaminations of the prepared manual supplied by the specific manufacturer of surfaces (should not be touched with bare hands the fitting and fusion unit. The Voice of the European Plastic Pipes and Fittings Industry

Page 15 TEPPFA Technical Guidance Document - AGC/2014/01 Keep a distance of at least one meter away from 6. Typical failures and root causes the fusion site during the fusion process for general safety reasons and in order to control and 6.1. Misaligned pipes supervise the fusion process. (See next chapter Due to high stresses on the joints, moving wires “Cooling and quality control of fusion”) result in overheating and melt flow at the inner or In case of interruption during the fusion process outer cold zone. Overheating can cause voids or (generator, fusion unit break-down), consult the pipe/ fitting deformation. fitting manufacturer’s installation manual for the recommended re-heating process. 5.10. Quality control of fusion During and after the fusion process check the following: • No error message on the fusion unit • No melt exudation outside the saddle confines Figure 42: Misalignment • No unusual deformations of pipe or saddle • Fusion indicators show correct result • Fitting remains stress-free and avoid • Use alignment clamps to avoid dislocation until complete cooling time has misalignment elapsed 6.2. Pipe joint not centred 5.11. Mark fusion parameters If the pipe is not centered, not properly cut or not Mark the relevant fusion parameters (date, joint fully inserted into the fitting, melt and wires can number, fusion time, cooling time and welder cause uncontrolled flow into the pipe gap. name) on the fitting and in the job site Overheating can cause voids or pipe/ fitting documentation. Electronically processed deformation. documentation and traceability is recommended. • Mark insertion depth and control 5.12. Cooling penetration to avoid Consider different cooling times for • Use alignment clamp to avoid pipe leak-tightness-test and tapping. movement 5.13. Leak tightness test Following the welding of saddles a leak-tightness-test through the outlet before tapping the outlet is recommended. 5.14. Tapping Equipment / Tapping under pressure If separate tapping equipment is used the installation procedures have to be followed. Special attention is drawn to tapping of pipes under pressure. Figure 43: Insucient insertion The Voice of the European Plastic Pipes and Fittings Industry

Page 16 TEPPFA Technical Guidance Document - AGC/2014/01 Figure 44: Pipe not centered Figure 46: Pipe toe-in 6.4. Insucient peeling The oxidized surface is not suciently removed by mechanical scraping. This will result in insucient bonding and leakage may occur. • Use mechanical scraping tool and control chip removal frequently to create a consistent and reliable scraping result. Figure 45: Pipe not cut properly 6.3. Excessive pipe toe in, pipe scratches, flattenings Excessive pipe toe-in may result in melt exudation into the pipe gap. Pipe scratches (even minor ones) that are not peeled o during mechanical scraping, can result in Figure 47: Insucient peeling poor bonding, as the surface in the scratch is not prepared (scraped). This can result in the formation of a leak path. 6.5. Insucient cleaning/ cross contamination Flattened sections on the pipe locally can increase A contaminating layer prevents the pipe surface the gap excessively. Flattened pipes do not comply from bonding with the fitting. This may be caused with the specification and cannot be re-rounded! by body oils, other lubricants or trench contaminations. • Cut away the pipe toe-in • Avoid positions with scratches or flattened • Avoid touching, contaminating fusion areas sections or apply a second mechanical after peeling scraping, providing the pipe will remain • Clean pipe surfaces and fittings in the within the dimensional specification. appropriate way The Voice of the European Plastic Pipes and Fittings Industry

Page 17 TEPPFA Technical Guidance Document - AGC/2014/01 Notes Figure 48: Insucient cleaning 6.6. Intended use and operation Gas and Water according to EN1555, EN12201, ISO4427, ISO4437 and Industrial applications according to ISO 15494. 6.7. Pressure test Pressure test of the piping system should be conducted in accordance with the national regulations. Typically a 1.1 x PN test pressure is applied with medium drinking water. A conditioning time of minimum 12 hours and a conditioning pressure of minimum the nominal pressure should be carried out when filling and conditioning with water. Make sure that the pipe section is completely free from air before testing. Registered Ofce: Avenue de Cortenbergh 71 1000 Brussels Belgium tel: +32 2 736 24 06 fax: +32 2 736 58 82 e-mail: info@teppfa.eu www.teppfa.eu All rights including the copyright, on the materials described in this document rest with The European Plastics Pipes and Fittings Association (“TEPPFA”), Avenue de Cortenbergh, 71, B-1000 Brussels (Belgium). This document may not be reproduced or brought into circulation without the prior written consent of TEPPFA. Without prior permission in writing from TEPPFA this document may not be used, in whole or in part, for the lodging of claims, for conducting proceedings, for publicity and/or for the benefit or acquisition in a more general sense. Every eort has been made to ensure the accuracy of the information contained in this document but it is provided for information purposes only and compliance with the recommendations does not imply or guarantee performance. The Voice of the European Plastic Pipes and Fittings Industry

Page 18 TEPPFA Technical Guidance Document - AGC/2014/01 7. Checklist for planning Availability Criteria Check Documents • welder pass • certificates • instructions Generator • in working order Fusion Box • suitable for the job Ext. cables • application range Scraper Tool • valid calibration (EF box, scraper tool) Cutting Tool • check generator fuel tank is full Specic installation tools • manuals available Re-Rounding tool • application range Clamps • application range Rollers • application range Cleaning Solvent • sufficient cleaner (e.g. highly pure Ethyl-Alcohol (>99.8%)) Lint free cloth Marker pen Yardstick, Pi tape Handling device • safety on site Pipes • correct dimensions Fittings • compatibility, application range, colour • pressure class, SDR • Socket • visual aspects • Saddle • quality aspects Site installation conditions • clean • dry • free from grease The Voice of the European Plastic Pipes and Fittings Industry