Iplex Pipelines Pty Ltd

3/15/2015 IplexPipelinesPtyLtd.Copyright2009

http://www.iplex.com.au/print.php?type=book&id=1 1/33

ProductSystemsTechnicalInformationCopyright2009IplexPipelinesPtyLtd.Allrightsreserved.

PolyethylenePipeandFittings>>ProductProperties>>MaterialProperties

Termsfrequentlyusedtodescribethismaterialwhenusedforengineeringapplicationsarehighdensity(HDPE),mediumdensity(MDPE)andmostrecentlyhighperformance(HPPE)polyethylene.OthersPEtypes,suchaslowdensity(LDPE)andlinearlowdensity(LLDPE)aresometimesusedforirrigationpipelines.

TheType50PEofAS1159thatwasincommonuseuntil1994,isanHDPEwithalongtermdesignstressof5.0MPa.AS/NZS4130andAS/NZSallowforthreespecificclassificationsbymaterialstrengthsandsubclassificationsbyperformanceatelevatedtemperatures.

ThehigherstrengthPE80BandPE100compoundsaresometimesreferredtoassecondandthirdgenerationmaterials.Theywereintroducedintogeneralserviceinthelateseventiesandearlyninetiesrespectively.

POLIplexpolyethyleneisanintegratedfamilyofPEpipesproducedbyIplex,basedonPE80B,PE80CandPE100materials.PE80Bmaterialhas50yeardesignstrengthof8MPawhilstPE100materialsminimumrequiredstrengthis10MPa.IplexPOLIplexpipesaremanufacturedtoAS/NZS4130frompolyethylenescomplyingwithAS/NZS4131.

PEMaterialType PE80B PE100

MRS(50year) 8MPa 10MPa

FlexuralYieldStrength 27MPa 32MPa

CircumferentialFlexuralModulus(3minute) 700MPa 950MPa

CircumferentialFlexuralCreepModulus(50year) 200MPa 260MPa

Density 943kg/m3 955kg/m3

TensileYieldStress(50mm/min) 20MPa 25MPa

TensileYieldStrain(50mm/min) 8% 10%

TensileModulus 650MPa 900MPa

Poisson'sRatio 0.4 0.4

ThermalExpansionCoefficient 0.2mm/mK 0.18mm/mK

ThermalConductivity 0.38W/mK 0.38W/mK

MaterialComposition

ThepolyethylenecompoundsusedinPOLIplexpipesandfittingsareprecompoundedresins,eitherblackorcolouredwithpigment,complyingwithAS/NZS4131.

Thefollowingadditives,ifused,areaddedtothePEpolymerbaseresinduringthecompoundingprocessbytherawmaterialmanufacturer.

Antioxidantsareusedtoinhibitoxidationofthepolymeratthecompoundingstageandduringsubsequentprocessing.Theoxidationinductiontestisanindicatoroftheefficacyofthisadditiveandtheresidualamountafterprocessing.



CarbonblackisusedinallblackPOLIplexpipeataconcentrationof2.250.25%bymassasanultravioletradiationabsorber.

InnaturalandcolouredPEmaterials,chemicalultravioletabsorbersareusedinlieuofcarbonblack.

Copyright2009IplexPipelinesPtyLtd.Allrightsreserved.




PolyethylenePipeandFittings>>ProductProperties>>ThermalProperties

Thecoefficientofthermallinearexpansionofpolyethylenevarieswithtemperaturebutatambientliesintherange1.2to2.4x104perdegreeC.Inbroadterms,thisisabouttwentytimesthatofsteel,andthereforeunrestrainedpipewillexpandorcontractmuchmorethanthesteelstructurethatmaybesupportingit.

Shouldthepipebefullyrestrained,thestrainduetothermalchangewillgeneratestressinthematerial.Howeverduetotherelativelylowtensiledeformationmodulus(E)ofPEandassumingatypicalambienttemperaturefluctuationoflessthan40Citcanbeassumedthatthesafeallowablestresswillnotbeexceeded.Overthelongerterm,stressrelaxationwillincreasetheabilityofPEtoaccommodatehighthermalstrains.

Theconductivityofpolyethylenevarieswithtemperaturealmostlinearlyandistypically0.47W/m.Kat0Cto0.37W/m.Kat70C.

Thespecificheatofpolyethylenevarieswithtemperaturefrom1800Joules/kg.Kat0Cto2200J/kg.Kat60C.

Attemperaturesabove25Citisnecessarytoreratepolyethylenepipesystems.ThetablebelowprovidesguidanceastothemaximumoperatingpressureofPE100pipes.

MaximumAllowableHead(m)PE100

Temp(C)

MinLife(Yr)

DesignFactor

PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25SDR41 SDR26 SDR21 SDR17 SDR13.6 SDR11 SDR9 SDR7.4

20 100 1.0 40 64 80 100 127 160 200 25025 100 1.1 36 58 73 91 115 145 182 22730 100 1.1 36 58 73 91 115 145 182 22735 50 1.2 33 53 67 83 106 133 167 20840 50 1.2 33 53 67 83 106 133 167 20845 35 1.3 31 49 62 77 99 123 154 19250 22 1.4 29 46 57 71 91 114 143 17955 15 1.4 29 46 57 71 91 114 143 17960 7 1.5 27 43 53 67 85 107 133 16780 1 2.0 20 32 40 50 63 80 100 125

NOTE:

i. ThevaluestabledareforpipemanufacturedtoAS/NZS4130andfittingsmadefromcompoundscomplyingwithAS4131.

ii. TheminimumlifeperiodsmaybeconsideredtobetheminimumpotentialservicelivesandrepresentthemaximumextrapolatedperiodspermittedbytheISO9080extrapolationrulesgiventheavailabletestdata.

iii. Maximumallowableoperatingpressureisindicatedinmetreshead(1m=9.81kPa).





PolyethylenePipeandFittings>>ProductProperties>>ChemicalResistance

Polyethyleneisinchemicaltermsanonpolarhighmolecularweightparaffinofthehydrocarbonfamily.Henceitisveryresistantto(nonoxidising)strongacids,strongbasesandsalts.Itismildlyaffectedbyaliphaticsolventsalthougharomaticandchlorinatedsolventswillcausesomeswelling.

Polyethyleneisattackedbystronglyoxidisingsubstancessuchashalogensandconcentratedinorganicacidssuchasnitric,sulphuric(includingoleum),perchloricetc.

PleaseviewChemicalResistancechart.(iplex.php?page=11)





PolyethylenePipeandFittings>>ProductProperties>>TheTHERMAPIPEConcept

THERMAPIPEresiststheabsorptionofheatbytheuseofahighlyreflectivewhitematerialontheexternalskinofthepipe.Thismaterialextrudedconcurrentlywiththeblackpipewall,forminganintegralpartofthepipe.FormulationofthewhitecoextrusionisdesignedtomatchthelongtermUVstabilityachievedbyconventionalblackPEmaterial.

ExtensivetestinghasdemonstratedthatsolarradiationhaslessthanhalftheheatingeffectonTHERMAPIPEthanwasrecordedforconventionalblackPEpipesunderthesameconditions.

Inallotherrespects,THERMAPIPEmatchesorexceedstheperformancerequirementsofAS/NZS4130PEpipes,pressureapplications.

Bylimitingtheoperatingtemperatureofabovegroundpolyethylenepipelines,athinnerwalledpipecanbeusedthanwouldotherwiseberequiredinagivenapplication.THERMAPIPEachievesthefollowingperformanceimprovementsrelativetoblackPEpipes

ThinnerwalledpipesprovidingmoreefficientpipedesignLowerpipepurchasecostLowerpumpingcostduetogreaterhydrauliccapacity.Reducedthermalexpansion/contractionLessrequirementtosnakepipelinesExtrapurchaselengthreducedto+2%toaccommodatesnaking(Vs4%forblackPE)THERMAPIPEreducespipemovementsontailingsdamwalls&piperacks.Reducedanchorageloads.Reducedthermalstressinthepipematerial.HigherpipestiffnessGreaterresistancetocollapseundervacuumeffect.Easiertohandleinlonglengthsonsite.ReducedtemperatureriseinfluidContentsinTHERMAPIPEremaincoolerthaninequivalentblackpipes.

RelativetoothersystemsforlimitingsolarheatingofPEpipes,whichmayincludesleeving

THERMAPIPEprovides

FactoryfinishedsystemNospecialinstallationstepsstandardweldingandjointingsystemsapply.Noadditionalcostsforinstallation.ThermalprotectionintegralwithpipestructureImmunetowinddamageorattackbyanimals.Maintenancecostsareminimal.

DesignForHighTemperatureService

AbovegroundPEpipecanabsorbandshedthermalenergyviaanumberofmechanisms.Incomingsolarradiationwillheatthepipewhilstreradiation,convectionandconductiontothefluidconveyedwillacttocoolthepipe.Variationintheincomingsolarradiationintensitywithtimeofday,cloudcover,latitude,altitude,seasonandpipelineorientationcombinetobemajordeterminantsofpipetemperature.



Windvelocity,ambienttemperatureandtheflowrate,temperatureandnatureoftheconveyedfluidarealsovariablesactingtoinfluencepipewalltemperature.

Muchofthiscomplexitycanbereducedbyconsideringthatanypipedesignmustaccommodatethemostarduousenvironmentalconditionstobeencountered.ForPE,thisrequirestheestimationoflongtermtemperatureconditionsinthepipe,especiallyduringsummer.

TestingofconventionalblackPEpipeandthewhiteTHERMAPIPEmaterialbyanindependentlaboratoryhasconfirmedlowerradiationabsorption,resultinginsubstantialreductionsintemperaturewiththismaterial.

RadiationAbsorption*

POLIplexBlackPE 96%

THERMAPIPE 42%

*Absorptance(meaning)theratiooftheamountofradiationabsorbedbyasurfacetotheamountofradiationincidentuponit.

THERMAPIPEisabletomaintainaloweroperatingtemperatureviaboththelowerabsorptionofradiationandbymaintainingfreeconvectionaroundtheoutsidediametertooptimisecooling.Meanpipewalltemperatureisthekeyparameterexpressedasasimpleaverageofinsideandoutsidesurfacetemperatures.





PolyethylenePipeandFittings>>ProductProperties>>Rural/ImperialPoly

IplexmanufacturesbothGreenlineandRedlineruralpolyethylenepipesystems.RedlinepolyismadetoAS2698.2dimensionsandhasamaximumoperatingpressureof900kPa.Greenline,our800kPapolypipeforruralapplications,ismanufacturedtoIplexspecifications.BothGreenlineandRedlinepipesuseIplexsruralcompressionrangeoffittings.Sizesrangefrom3/4inchto2inch.





PolyethylenePipeandFittings>>ProductDimensions>>Pipe

DiametersrangefromDN16toDN2000withpressureratingsofupto2.0MPa.PipesuptoDN110canbesuppliedincoilsinlengthsofupto300metresinsomediameters.Largerdiametersaretypically12mlongalthough15mandlongerareoccasionallymanufacturedbyarrangement.

NotethatthenominaldiameterofPEpipesreferstotheoutsidediameterinaccordancewithinternationalpractice.

POLIplexPressurePipesDimensions

WATER&AIRSTANDARDPE80C,BLUELINEPE80B,ALLBLUEPE80B&ONEHUNDREDPE100TOAS/NZS4130

SeeTableinPDFFormat(resources/library/polyethylene_pipe_fittings/PE100S1PressurePipeDimensionsPolyCatalgoueCorrectedLK14082012.pdf)

EconomyRuralPipe(GreenLine)

NominalIDin(mm)(inches)

ProductCode*=length

IDAve(mm)

WallAve(mm) ODAve(mm)

15(1/2) PICH15* 13.0 1.6 16.2

20(3/4) PICH20* 19.0 1.6 22.2

25(1) PICH25* 25.3 1.7 28.7

32(1) PICH32* 31.6 2.0 35.6

40(1) PICH40* 38.0 2.4 42.8

50(2) PICH50* 50.9 3.2 57.3

RedlineRuralPipetoAS2698.2

NominalIDin(mm)(inches)

ProductCode*=length

IDAve(mm)

WallAve(mm) ODAve(mm)

20(3/4) PICR20* 19.0 1.8 22.6

25(1) PICR25* 25.3 1.9 29.1

32(1) PICR32* 31.6 2.3 36.2

40(1) PICR40* 38.0 2.7 43.4

50(2) PICR50* 50.9 3.5 57.9

MicroIrrigationPipetoAS2698.1



NominalIDin(mm)(inches) ProductCode*=length IDAve(mm) WallAve(mm)

13 PICL13* 12.9 1.25

20 PICL20* 19.1 1.35

25 PICL25* 25.4 1.55

32 PICL32* 31.7 2.05





PolyethylenePipeandFittings>>ProductDimensions>>CompressionFittings

Iplexpipelinesofferarangeofcompressionfittingsthatdeliverstrength,securityandperformancewithafittingthatisinexpensiveandeasytoinstall.

IPLEXMETRICCompressionFittings

aredesignedtobeusedwithMetricPolyethylenepipemanufacturedtoAS4130.Afullrangeofsizesandconfigurationsfrom20mmto110mmisavailablewiththefittingsratedPN16to63mmandPN12.5to110mm.Thefittingutilisesleadingedgedesigncombinedwithproventechnologytodeliveranextremelysecurejointwithafittingthatdoesn'tneedtobedisassembledtojoinsimplypushthepipeinandtightenthenut.

CommonapplicationsforIPLEXMETRICcompressionfittingsinclude:

Waterdistribution,houseconnections,servicepipeetcRuralwaterreticulation,stockwatering,irrigation,artesianwateretc.Industrialapplications,watertreatmentplants,coolingwater,aggressiveandcorrosivecircuits,sewerage,effluentsanddredgingetc.Miningslurrytransporttailinglines,watersupplyandreturn,aboveandbelowground.

IPLEXRURALCompressionFittings

aredesignedtobeusedwithimperialdimensionpipeandisamodifiedversionofIPLEXMETRIC.Afullrangefrom"to2"isavailable.TheIPLEXRuralfittingisveryreliable,toughanddurablewithadistinctivelycolouredgreeninsert.

IplexRuralpolyethylenepipeandfittingsarecommonlyusedinlowheadruralapplicationswherenominalpressureisbelow600kPa.

Thematerialspecificationsandcapabilitiesfortherangeareasfollows:

BodyandNutBlackpolypropylene,highgradecopolymerSplitring(metriconly)WhiteacetalSpacer(metriconly)Blackpolypropylene,highgradecopolymerInsertbarb(ruralonly)Greenpolypropylene,highgradecopolymerOring(prelubricated)Nitrilerubber(NBR)

ChemicalResistance

IPLEXMETRICandIPLEXRURALfittingshaveexcellentchemicalresistancepropertiesandaresuitablefortransportationofawidevarietyofchemicals,nonaromaticsolventsandoils.AdetailedlistofchemicalsandtheirsuitabilitywithspecificpipematerialscanbefoundintheIplexChemicalResistanceChart(iplex.php?page=chemicals).TheinertnessofPolypropylenemakesitchemicallyresistanttoacidoralkalisoilshoweversealingringcomponentmaterialsmustalsobeconsidered.

OperatingTemperatures

Iplexcompressionfittingsarenotsuitableforuseinhotwaterservicesalthoughtheywithstandthesametemperaturesaspolyethylenepipewiththesamederatingfactorsapplying.Thefittingsaresuitableforuseatsubzerotemperatures.



EffectonWater

Iplexcompressionfittingsaredesignedtocarrypotablewaterandwillnottaintthewaterorimpartanyconstituentsinconcentrationsthatcouldbeharmfultohealth.

AbrasionResistanceandResistancetoImpact

IPLEXMETRICisparticularlysuitableforminingandindustrialapplications,beingusedforthetransportationofabrasiveslurriesandeasilywithstandingtypicalconditionsfoundinurban,mining,industrial,ruralwaterandwastewaterapplications.IplexcompressionfittingbodiesandnutsaremanufacturedoutofahighgradePolypropyleneprovidingexcellentimpactresistance.

FeaturesandBenefits

IPLEXMETRIC

Performance

Veryeffectivesealabilitytosealonscuffedorundersizedpipe.Toughnessofmaterialhighimpactstrength,UVresistant,longlife.Highendloadorpulloutresistanceeg63mmfittingapproximately1.2kilonewtons.Fullrangeofsizesandconfigurations.RatedPN16to63mm,PN12.5to110mm.

EaseofInstallation

Simpletousenodisassemblyrequiredorloosecomponentstolose.Nochamferingorlubricationofpiperequired.Smallfittings(below40mm)canbeeffectivelytightenedbyhand.Coarsethreadswon'tclogupwithdirt.Distinctivebluenutforeasyidentification.

Security

ManufacturedtoAS4129witha50yeardesignlifeinstandardconditions.SuppliedandsupportedbyIplexPipelinesAustralia'sleadingplasticpipeandfittingmanufacturer.

FeaturesandBenefits

IPLEXRURAL

ReliabilityintheField

ExtendedlengthofbarbreliablejointintegrityforconnectionofRuralpipe.Toughnessofmaterialhighimpactstrength,UVresistant,longlife.CaptiveOringmakesiteasiertojoinpipewithoutturningoffwatersupply.Fullrangeofsizesandconfigurationfrom"to2".Stainlesssteelreinforcingringonlargersizesoffemalethreadsensuresimprovedlongtermperformance.

EaseofInstallation

Fittingcanbehandtightened.Establishedtechnologyrequiringnospecialtrainingtoinstall.Nochamferingorlubricationofpiperequired.Coarsethreadswon'tclogupwithdirt.Distinctivegreenbarbforeasyidentificationforuseonruralpipe.

Security

WellestablishedandreliabletechnologyspecificallydesignedtosuitAustralianconditions.IplexPipelinesbrandonfittingensurespieceofmind.



Standards

IPLEXMETRICismanufacturedtotherequirementsofAustralianStandardAS/NZS4129FittingsforPolyethylene(PE)PipesforPressureApplications.ThefittingsarecertifiedproductsholdingtheSTANDARDSMARKindicatingthattheproductshavebeenindependentlyassessedandrecognisedasqualityproductsbySAIGlobal.

IPLEXRURALismanufacturedtotherequirementsofAustralianStandardAS/NZS2698PlasticPipe&FittingsforIrrigationandRuralapplications.

Testing

TestingofIPLEXMETRICisinaccordancewiththerequirementsofAS/NZS4129.

Fittingsaresubjectedtothefollowingtests,performedasdetailedinthestandard.

DimensionaltestHydrostaticpressuretestforassembledjointsLiquidinfiltrationtestLeakproofnessunderpressurewheresubjectedtobending(upto63mm)PullouttestEffectonpotablewater

ToviewthecompleterangeofCompressionfittings,pleaseusetheproductsearchtool.





PolyethylenePipeandFittings>>ProductDimensions>>ElectrofusionFittings

IplexPipelinesandGeorgFischerPipeSystemshavealongandcomplementaryassociationintheAustralianmarketplace.

AnalternativeformofweldingPEistheelectrofusionsystemwhereheatingelementsareembeddedinPEfittingsockets.Thesesocketsformpartofacouplingorotherfittingandrequireanelectricalinputfromaweldingmachinetoproduceaweldedjoint.

Thewiderangeselectionofhighqualityjoiningsystems(electrofusionandspigotfittings),machines,toolsandaccessoriesisrepresentativeofaninformedandsolutionapproachtoourcustomersneedsinthewaterandgasutilitymarket.TheELGEFpluselectrofusionprocedureutilisestheweldabilityofPOLIplexmaterialswithouttheuseoftherelativelycumbersomebuttfusionweldingmachine.Thisisachievedbyusingpolyethylenecouplingswithembeddedcopperwirecoilsservingasheatingelements.Aportableweldingmachineconnectedtoapowersourceprovidesacurrentsourceofthecorrectvoltageandduration,whichisappliedtotheterminalsonthecouplingorsocket.Thiscausesthematingsurfacesofsocketandpipetobemeltedtogiveafusedcontiguouswhole.TheelectrofusionprocessunlikebuttfusioncanbeusedtojointpipesandfittingsofdifferingSDRorwallthickness.TheELGEFplusequipmentcanbesuppliedwithabuiltindatarecordingsystemtogivefulltraceabilityofindividualwelds.

Electrofusionpermitsasafe,systematic,economicandefficientfullyweldedinstallationforbothburiedandabovegroundPEpipingsystems.IplexsGeorgFischerelectrofusionproductsareindividuallysealedinPEbagsandpackagedincartonstoprotectthemfromUVradiation,oxidationaswellasgeneralcontamination.AdditionallytheyaresuppliedwithaBarcodedcardthatcontainsallrelevantproductinformation,traceabilityandfusionweldingparametersrequiredforjoining.

ToviewcompleterangeofElectrofusionfittings,pleaseusetheproductsearchfunction.

FrequentlyAskedQuestions

Thefollowingisasampleofcommonlyaskedquestionspertainingtoelectrofusion.Shouldadditionalinformationberequired,pleasecontactIplexPipelinesdirecton131814.CanIplexsGeorgFischerweldingmachinesbeusedonothermanufacturerselectrofusionfittings?Yes,butanadaptermustbeusedforconnectionpinsbiggerthan4.0mm

Onautomaticweldingmachines,willthebarcodereaderrecogniseothermanufacturersbarcode?Yes,howeverallsettingsshouldbecheckedpriortowelding.



Whatsizegeneratorisrecommendedforelectrofusionweldingmachines?Generally5kVAgeneratorsarerecommendedforthestandardrangeoffittings.

CanIplexsGeorgFischerweldingmachinesconnectto10ampoutlets?No.Electricalplugsareallsizedfor15amps.HoweverinlimitedcircumstancesAS/NZSapprovedadaptorscanbeutilised.

DoIneedcurrentregulatorprotectiononthegenerator?MSA250plusmachineshaveaninbuiltvoltageregulatorwhereasMSA210aremoresusceptibletovoltagespikes.WerecommendanAVR(AutomaticVoltageControlRegulator)unitshouldbeusedwiththegenerator.

DoIneedqualificationsforelectrofusionwelding?Competentandexperiencedproceduraltrainingcanbesufficient,butinmostcasescertificationfromarecognisedtrainingorganisationisrequired.Detailsforcertifiedtrainingorganisationscanbeprovided.

WhydoIneedtoscrapethepipe?PEpipeformsanoxidisedlayerwhenexposedtoUVradiation.Thislayermustberemovedfromthejoiningsurfacespriortowelding.

Cananytypeofcleaningwipe/fluidbeusedonthepreparedsurface?No.OnlycommerciallyavailablePEsolventcleanersarepermitted,withaminimumalcoholcontentof90%.Cleaningagentswithadditiveslikemoisturizesorsimilaradditivesarenottobeused.

AreSDRandPNratingsthesame?No.PNratingsrefertointernalpressuresandSDRratingsrefertopipewallthickness.

CandifferingSDRratedpipebeelectrofused?Yes.IplexsGeorgFischerfittingsareratedeitherSDR11(PN16)orSDR17(PN10).ThefittingscanbeusedonPN100piperangingfromSDR9(PN20)uptoSDR26(PN6.3)ratingshowevertheSDRofthefittingswilldeterminethefinalratingoftheinstallation.InallnonstandardcasespleasecontactIplextocheckforsuitability.

AreclampsrequiredforElectrofusionjoining?Yes.Alljointsmustbemovementandstressfreethroughouttheweldingandcoolingprocess.

Isitnecessarytoreroundpipe?Pipecanbecomeovalinshapeduetostorageorcoiling.Reroundingisonlynecessaryforinstallationoffittingsifpipeisoutofround.

Whatisthefunctionofasqueezeofftool?Oncertainpipesizes,squeezeofftoolsareusedtocompressPEpipewherenoisolationvalvesareinstalled.Oncompletionoftherepairorcutin,thetoolisreleasedandthepipereturnstooriginalshape.



HowdoIstoreelectrofusionfittings?Fittingsshouldbestoredoutofthedirectsunlightandintheoriginalpackinguntilimmediatelybeforeuse.Couplersshouldbestoredontheirflatends.

DoIneedtoscrapefittingspriortouse?No,aslongasfittingshavebeencorrectlystoredintheoriginalpackaging.PEcleanershouldstillbeusedonallpreparedsurfaces.

Whatarecooldowntimes?Theweldingprocessinvolvestwophasesfusion(heating)andcooling.Cooldowntimesonthebarcodecardsorthemachinedisplaymustbeobserved.

Whydopipeendsneedtobesquare?Theweldingprocessreliesonpressureaswellastemperature.Pipeendsneedtobesquaretoensurealignmentwithinthefittingandcontainmentofmeltflows.

Canweldingbecarriedoutininclementweather?Yes.Howevertheelectrofusionjointmustbeprotectedfromallweatherinfluences.Allpreparedjoiningsurfacesmustbecleananddrypriortoinstallation.Safetyprecautionsmustbefollowedwhenusingelectricalequipmentinallconditions.





PolyethylenePipeandFittings>>ProductDimensions>>PEFabricatedandMouldedFittings

PolyFabricatedandMouldedfittingsaregenerallymadefromPE100materialandcanbeusedinbuttweldingorelectrofusionapplications.Thesefittingsincludeitemssuchastees,elbows,flangesandreducers,andaregenerallyusedinlargerdiameterpipelines.

Fabricatingfittingsinvolvesthecuttingandweldingofpipeintoavarietyofshapesandsizesforarangeofapplicationsintheminingandwaterindustries.Detaileddrawingsareusuallyrequiredforthefabricationdepartmenttomanufacturethesefittings.

ToviewcompleterangeofFabricatedandMouldedfittings,pleaseusetheproductsearchfunction.





PolyethylenePipeandFittings>>StandardsandApprovals>>StandardsandTesting

POLIplexpolyethyleneisanintegratedfamilyofPEpipesproducedbyIplex,basedonPE80BandPE100materials.POLIplexpipesaremanufacturedtoAS/NZS4130frompolyethylenescomplyingwithAS/NZS4131.IplexPOLIplexpipesareStandardsMarklicensedtoAS/NZS4130bySAIGlobal.





PolyethylenePipeandFittings>>PipelineDesign>>HydraulicDesign

SelectionofPipediameterandclass

Thechoiceofpipediameterandpressureclasswilldependonthefollowingfactors.

Therequiredflowrateincludinganyplannedfutureincreases.Thefrictionlossescausedbythepipesandfittings.Thelongitudinalsectionoftheproposedpipelineroute.Inthecaseofpressurisedgravitysystems,theavailableheaddifferential.Therelativecostofdifferentpipediametersandclasses.Financialparameterssuchasexpectedinterestrateandrepaymentterm.Forpumpedsystemsthecostofpowerandanticipatedinflationrateforenergycosts.Estimatedwaterhammerandsurgescausedduringnormaloperationandduetopowerfailure.

Specifiedfieldandtestpressures.

Toassistinyourdesign,pleaseuseourHydraulicDesignTool.(iplex.php?page=13)





PolyethylenePipeandFittings>>PipelineDesign>>StructuralDesign

Inengineeringterms,POLIplexPEpipesareconsideredtobeflexiblewhenburiedwithrespecttosurroundingembedmentmaterials.Asgroundloadsresultinstressesinaburiedpressurepipelineadditionaltothoseduetointernalhydraulicloadings,itisimportanttocarryoutacombinedloadingdesigncheck.Nonpressureaswellaspressurepipesrequiredesigncheckswithregardtopredicteddiametraldeflection,circumferentialwallbendingstrainandsafetywithregardtobucklingstability.

Toassistinyourdesign,pleaseuseourStructuralDesignTool.(http://www.iplex.com.au/iplex.php?page=104)





PolyethylenePipeandFittings>>InstallationandFieldTesting>>HandlingandStorage

Storage

Storageareasshouldbesmoothandlevel.Foreaseofhandlingandtoavoiddamage,pipepacksshouldbeplacedontimberbearersatapproximately2metercentresthatmatchtheframespacingofthepacks.ThetendencyforPOLIplextocreepunderloadrequiresthatattentionbepaidtolimitinglongtermstackingheightsforbundlesforstraightpipeswithouttimberframingto2metres.(or3timesdiameterifgreater.)Wheretimberframepacksarestackeditisimportanttokeepframesofpacksstackedverticallyclosetogetheralternatingevenly.Packswithwidelydifferingframespacingshouldnotbestacked.Havingthetimberbearersclosetogether,sidebyside,effectivelyincreasesthebearingareafortheloadsbetweenstacksandreducesthepointloadings.Itisneitherpracticablenordesirableforbearerstobealignedverticallyasthesestacksarethenunstableagainstlongitudinalslidingwhenbeingtransported.Furthermoretheoverallheightofthestackwillbeincreasedsignificantly.Providedproperregardisgiventosidewaysstability(eg:windforces),packswhichareusually1.2meterswidemaybestackedupto3metersinheight.

Coilsareusuallytransportedandstoredinthenearverticalplanealthoughthismaybegovernedbytheavailabilityofasupport,whichwillsafelyholdleaningcoils.Ifstackedhorizontallytheyshouldbeplacedonpalletsforconvenientliftingorslinging.Coilsstackedinthiswayshouldalsobelimitedto1.0meterinheight.

Blackorwhitepigmentedpolyethylenehasextremelygoodultravioletradiationresistance.Howeverblue,orangeandyellowpigmentedpipewillexhibitfadingifstoredindirectsunlightformorethensixmonthsandthereforeshouldbecoveredwhereanextendedperiodofstorageisenvisaged.Pipeswhichexhibitsignificantfadingshouldnotbeusedinhighlystressedapplications.Undernocircumstancesshallpipesbecoveredinopenareaswithblackplasticsheeting.

LiftingandUnloading

Metalhooks,chainsorslingsmustnotbeusedwithoutpaddingforliftingcoilsorpacks.Webbedfabricslingsarethepreferredoption.Becauseoftheflexibilityofpacksofsmallerdiameterpipein12meterorgreaterlength,twoliftingpointsorspreaderbarsbetweenslingsshouldbeusedtoreducedrooping.Ifthisisnotdonepacksmaybedifficulttoliftcleanlyoffthegroundcausingscuffedpipeends.





PolyethylenePipeandFittings>>InstallationandFieldTesting>>JoiningInstructionsMetricCompressionFittings

1.Preinstallation

Makesurefittingisinopenpositionwithatleast3or4threadsshowingCutthepipetorequiredlengthanddeburrtheend.Thepipedoesnotneedtobechamfered.

2.MarkthePipe

ThepipehastobepushedpasttheOringforthefittingtoseal.Toensurethatyouinsertthepipetothecorrectdepthitishelpfultomarkthepipe.Usethismarkorworkoffthemiddleofthebodyofthefitting.Forsizes75mmandaboveonlyinsertpipetothepointofinitialresistance.Don'tpushallthewayhome.

3.Insertthepipe

Pushthepipeintothefittingtothecorrectdepth.YouwillfeelresistanceasthepipepushespasttheOring,howeverthisshouldnotrequiremuchforce.Ifdifficultyisencounteredthenlubricatingtheendofthepipemayhelp.Forsizes75mmandabovethepipeshouldn'ttobepushedpasttheOring,simplyinsertthepipeuntilthefirstpointofresistanceismet.

4.Tightenthenut

Forsizes32mmandbelowthiscannormallybeaccomplishedbyhand,forothersizesuseanappropriatetool.Forsizes75mmandabovetighteningthenutfullyshouldpullthepipethroughthesealtothelinemarkedonthebodyofthefittingandlabelledSTOP.

5.Fullyinstalled

Itisnotnecessarytotightenthenutuntilitbuttsagainsttheflangeofthebody.Thefittingisfullyinstalledwhenthenutcannotbetightenedanyfurther,normallyatleastonethreadisexposed.Forsizes75mmandaboveitisnecessarytotightenthenutuntilitbuttsagainsttheflangeofthebody.

ForDisassemblysimplyunscrewthenutandpullpipefromfitting.




PolyethylenePipeandFittings>>InstallationandFieldTesting>>JoiningInstructionsRuralCompressionFittings

1.Cutthepipesquareandremoveexcessburrs.Disassemblethefittingandidentifythecentralbody,nutsplitringandinsertcomponents.Slidenutontopipe,followedbythesplitring.

2. Nutthreadshouldbefacingtowardsthecentralbodywiththetaperededgeofthesplitringfacingthenut.

3. Pushthebarbedinsertfullyintotheendofthepipe,untilthemouldedflangeisbuttedagainstthepipe.

4. Pushthepipe/insertintothecentralbodyofthefitting,andpushuntiltheflangebuttsontothecentralbody.

5. Slidethesplitringandnuttowardsthecentralbodyandscrewthenutontothebodyuntilthefittingisfirmlytightened.

NOTE:

Itmaybenecessarytogentlyknocktheinsertintothepipeusingawoodenorrubbermallet.EnsurethattheOringsealisnotdislodgedfromtheinsertduring



assembly.Forlargersizesitmaybenecessarytouseawrenchorspannertofullytightenthenut.DisassemblyUnscrewnutandslideawayfromcentralbodyontothepipe.Thenremovepipe/insertfromcentralbody





PolyethylenePipeandFittings>>InstallationandFieldTesting>>JoiningInstructionsElectrofusionFittings

GeneraltipsforpreparationandassemblyofIplexsGeorgeFischerfittings:

Carefulpreparationofthefusionsurfaceistheabsoluteprerequisiteandshouldnotbenegotiated.Fusionzonesshouldbewellprotectedfrommoistureduringinclementweather(rain,snowfalletc.).IplexsGeorgeFischerfittingsaresuppliedwiththeappropriateBarcodedcardsinapolythenebag.Fittingsintheiroriginalpackagingdonotrequirescrapingorpeelinghowever,itisrecommendedtoalwaysusePEcleaneronfittingspriortoassembly.Atanystageduringassembly,ifthefusionzonesaretouchedbyhand,thefittingmustberecleanedwiththePEcleaner.Thepipeshouldbewiped,scrapedandfinallycleanedwiththePEcleaner.Werecommendscrapingtoolsshouldbeusedforevenandtimesavingpipepreparation,ratherthanhandscrapers.

AssemblyandoperatinginstructionsforIplexsGeorgFischerELGEFPluselectrofusionfittings.

OverviewofElectrofusionWeldingProcedures:

1. Roughlycleanpipe(s).Cutatrightanglesandtrimedges.

2. Remove(scrapeorpeel)oxidefilmoffpipe(s)usingcorrecttooling.

3. Cleanpipe(s)infusionzonewithPEcleaner(Tangitorequivalent).



4. Marktheinsertiondepthonthepipe.

5. Removefitting(s)fromthepackagingwithouttouchingthefusionsurfaceswithcleaner.

6. PushinthePEpipeuptocentrestopormarking.

7. Firmlyfastenintegratedbracket.

8. Mountandfixassemblyclamps.

9. Slideinsecondpipeuptocentrestopormarking

10. Firmlyfastenintegratedclamps



11. Mountandfixassemblyattached

12. Fusioninaccordancewithoperatinginstructionsoftheweldingmachine(manualorbarcodescannerunit)

13. Afterfusioncompletedcheckmachinedisplayforerrormessagethenvisuallycheckallpartsofthefittingandfusionindicators.

14. Removeanyexternalclamps.

15. Waitmaximumcoolingtimebeforepressuretest.

OverviewofElectrofusionSaddleWeldingProcedures:



1. Cleanpipeinfusionarea,removeoxidefilmofpipeusinghandscraperorpeelingtool.

2. CleanpipefusionareausingPEcleaner(Tangitorequilivalent).

3.4.

Removesaddlefrompackagingwithouttouching,hanglowerpartonitshinge.Placesaddleonpipeandequallytightenwithpremountedbolts.

5. Removesaddlecomponentfromthepackagingandassemble(withouttouchingfusionsurface)

6. Placesaddleonpipeandassemblewithtoploadtool(detailedassemblyinstructions)ifrequired.



7. Alignoutletandfirmlyfastenintegratedbracketofsaddleoutlet.

8. Weldinaccordancewithoperatinginstructionsofweldingmachine(manualorbarcodescannerunit).

9. Afterfusion:Checkfusionindicator,checkfusionunitdisplay,andthenremoveleads.

10. Waitforminimumcoolingtimebeforepressuretestingifrequired.

11. Removescrewandorfusioncap.



12. Fortappingsaddlesinserthextoolingandscrew(tap)clockwiseuntilpipepenetrationisachieved.Seedetailedassemblyinstructionsinpackaging.

13. Withdrawcutteruptotopstop.

14. Fastenscrewcapbyhandorfitfusioncap.

15. Weldinaccordancewithoperatinginstructionsofunit.

Note:Theseinstructionsareintendedasaguideonly.Electrofusionweldingshouldonlybeundertakenbysuitablytrainedandexperiencedoperators.





PolyethylenePipeandFittings>>InstallationandFieldTesting>>JoiningInstructionsButtWeldJoint

Thisprocedureutilisestheexceptionalweldabilityofthevariouspolyethylenematerialsandresultsinapipelinewithanaxialstrengthclosetothatoftheparentmaterial.BeforeundertakingtheinstallationofaweldedPEpipeline,considerationmustbegiventothefollowing.

ChoiceofEquipment

Therangeofavailablebuttfusionweldingmachineshasexpandedrapidlyinrecentyears.Thecostofmachinesforlargerpipesishighandtheuseofspecialistweldingsubcontractorsisnormalpractice.Machineoperatingcharacteristicsvarywithage,withearliermodelsrequiringmanualoperationandthelatestbeingequippedwithfullyautomaticcontroltotheextentthataprintedrecordofallweldparameterscanbeproducedforeachjoiningoperation.

Aweldingmachineisinfactcomprisedofanumberofcomponentsmountedonasinglebaseframeorchassis.Theseincludepipeclampsforeachsideofthejoint(i.e.fullcirclevices)specificallytosuitthepipediametersbeingjoined,ahydraulicpump,hydraulicramstoprovidethejointingforces,anelectricallathewithdoublesidedcutterfortrimmingoperations,anelectricallyheatedtwinsidedweldingplate(withnonsticksurface)sometimescalledamirror,pressuregagesforthehydraulicsystemand(weldingplate)temperaturesenses.Ifthemachineissemiorfullyautomated,therewillusuallybeacomputer/printerunitaswell.

Apowersourcesuchasaportablegeneratororcompatibleelectricmainsconnectionisalsonecessary.Piperollerstoreducedragfrictiontogetherwithliftingequipmentwillbeneededforlargerpipes.Temporaryshelterforthisequipmentduringtheweldingoperationsuchasatentisimportant,asitwillassistinkeepingthepipebeingweldedatauniformandstabletemperaturefreeofmoistureanddust.Sunlightandwindcancreateunevenambientpipetemperaturesaffectingtheweldquality.

OperatorTraining

Aswithallweldingcarriedoutonanymaterialusedforengineeringpurposes,polyethyleneweldingisaskilledoperationrequiringtheuseofproperlyqualifiedoperators.Formalcourses,whichprovideaccreditationtosuitablyskilledpersonnel,areavailable.Theuseofunqualifiedoperatorsisunacceptable.

WeldingPrincipals

Pipestobejoinedmustbeofthesamewallthickness(i.e.SDR)andtheendsmustbecutsquare,i.e.perpendiculartothepipeaxis.Unmatchedwallthicknesseswillrequireamachiningorchamferingoperationofthegreaterthicknessatanangleoffifteendegrees(1:4)orlesstogivethesamefacethicknessonbothsidesofthejoint.Thesuccessofeachweldinextremelydependantoncleanliness,temperaturecontrolandgoodequipment,whichhasbeenproperlymaintained.Thepipeendsmustbeproperlyalignedbeforemachiningandheating.Theyshouldbedryandfreeofdustcontamination.Matingsurfacesmustbeplannedimmediatelybeforeweldingtoremovesurfacematerialaspolyethyleneoxidisesonexposuretotheair.Ifthesepreparedsurfacesaretouchedaftermachiningthereisariskofcontaminationthatmaybenotbevisibletothenakedeye.

Thetimingoftheweldingsequenceismostimportantifconsistentweldqualityistobeobtained.Timesforthesimultaneousheatingofthepipeendsagainstthehotplateorthemirror,mirrorremoval,thepressingofthemeltedpipeendstogethertogivetherequiredamountandshapeofbeadmaterial,andfinallythecoolingtimewhilstmaintainingpressure,areallofcriticalimportance.



Ifthepipetemperatureisnotuniform,suchasforexamplecanoccurwhenweldingiscarriedoutindirectsunlight,anunevenpipewalltemperaturewillexistwhichcouldaffecttheuniformityoftheweld.Thistemperaturedifferencemustbeequalisedbyshieldingtheweldzonewellinadvanceofmakingthejoin.Coversontheendsofpipesremotefromtheweldwillpreventcoolingairpassingthroughthepipeinteriorandassistinkeepingweldzonetemperaturesuniform.


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