Iplex Pipelines Pty LTD

3/15/2015
IplexPipelinesPtyLtd.Copyright2009
ProductSystems
TechnicalInformation
Copyright2009IplexPipelinesPtyLtd.Allrights
reserved.
PolyethylenePipeandFittings>>ProductProperties
>>MaterialProperties
Termsfrequentlyusedtodescribethismaterialwhenusedforengineeringapplicationsarehighdensity
(HDPE),mediumdensity(MDPE)andmostrecentlyhighperformance(HPPE)polyethylene.OthersPE
types,suchaslowdensity(LDPE)andlinearlowdensity(LLDPE)aresometimesusedforirrigation
pipelines.
TheType50PEofAS1159thatwasincommonuseuntil1994,isanHDPEwithalongtermdesignstress
of5.0MPa.AS/NZS4130andAS/NZSallowforthreespecificclassificationsbymaterialstrengthsandsub
classificationsbyperformanceatelevatedtemperatures.
ThehigherstrengthPE80BandPE100compoundsaresometimesreferredtoassecondandthird
generationmaterials.Theywereintroducedintogeneralserviceinthelateseventiesandearlynineties
respectively.
POLIplexpolyethyleneisanintegratedfamilyofPEpipesproducedbyIplex,basedonPE80B,PE80C
andPE100materials.PE80Bmaterialhas50yeardesignstrengthof8MPawhilstPE100materials
minimumrequiredstrengthis10MPa.IplexPOLIplexpipesaremanufacturedtoAS/NZS4130from
polyethylenescomplyingwithAS/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,eitherblackor
colouredwithpigment,complyingwithAS/NZS4131.
Thefollowingadditives,ifused,areaddedtothePEpolymerbaseresinduringthecompoundingprocessby
therawmaterialmanufacturer.
Antioxidantsareusedtoinhibitoxidationofthepolymeratthecompoundingstageandduringsubsequent
processing.Theoxidationinductiontestisanindicatoroftheefficacyofthisadditiveandtheresidual
amountafterprocessing.
http://www.iplex.com.au/print.php?type=book&id=1
1/33
3/15/2015
CarbonblackisusedinallblackPOLIplexpipeataconcentrationof2.250.25%bymassasanultraviolet
radiationabsorber.
InnaturalandcolouredPEmaterials,chemicalultravioletabsorbersareusedinlieuofcarbonblack.
Copyright2009IplexPipelinesPtyLtd.Allrightsreserved.
2/33
3/15/2015
ProductSystems
reserved.
>>ThermalProperties
Thecoefficientofthermallinearexpansionofpolyethylenevarieswithtemperaturebutatambientliesinthe
range
1.2to2.4x104perdegreeC.Inbroadterms,thisisabouttwentytimesthatofsteel,andtherefore
unrestrainedpipewillexpandorcontractmuchmorethanthesteelstructurethatmaybesupportingit.
Shouldthepipebefullyrestrained,thestrainduetothermalchangewillgeneratestressinthematerial.
Howeverduetotherelativelylowtensiledeformationmodulus(E)ofPEandassumingatypicalambient
temperaturefluctuationoflessthan40Citcanbeassumedthatthesafeallowablestresswillnotbe
exceeded.Overthelongerterm,stressrelaxationwillincreasetheabilityofPEtoaccommodatehigh
thermalstrains.
Theconductivityofpolyethylenevarieswithtemperaturealmostlinearlyandistypically0.47W/m.Kat0C
to0.37W/m.Kat70C.
Thespecificheatofpolyethylenevarieswithtemperaturefrom1800Joules/kg.Kat0Cto2200J/kg.Kat
60C.
Attemperaturesabove25Citisnecessarytoreratepolyethylenepipesystems.Thetablebelowprovides
guidanceastothemaximumoperatingpressureofPE100pipes.
MaximumAllowableHead(m)PE100
Temp
(C)
20
25
30
35
40
45
50
55
60
80
Min
Life
(Yr)
100
100
100
50
50
35
22
15
7
1
Design
Factor
1.0
1.1
1.1
1.2
1.2
1.3
1.4
1.4
1.5
2.0
PN4
PN6.3
PN8
PN10
PN12.5
PN16
PN20
PN25
SDR41
SDR26
SDR21
SDR17
SDR13.6
SDR11
SDR9
SDR7.4
40
36
36
33
33
31
29
29
27
20
64
58
58
53
53
49
46
46
43
32
80
73
73
67
67
62
57
57
53
40
100
91
91
83
83
77
71
71
67
50
127
115
115
106
106
99
91
91
85
63
160
145
145
133
133
123
114
114
107
80
200
182
182
167
167
154
143
143
133
100
250
227
227
208
208
192
179
179
167
125
NOTE:
i. ThevaluestabledareforpipemanufacturedtoAS/NZS4130andfittingsmadefromcompounds
complyingwithAS4131.
ii. Theminimumlifeperiodsmaybeconsideredtobetheminimumpotentialservicelivesandrepresent
themaximumextrapolatedperiodspermittedbytheISO9080extrapolationrulesgiventheavailable
testdata.
iii. Maximumallowableoperatingpressureisindicatedinmetreshead(1m=9.81kPa).
3/33
3/15/2015
ProductSystems
reserved.
>>ChemicalResistance
Polyethyleneisinchemicaltermsanonpolarhighmolecularweightparaffinofthehydrocarbonfamily.
Henceitisveryresistantto(nonoxidising)strongacids,strongbasesandsalts.Itismildlyaffectedby
aliphaticsolventsalthougharomaticandchlorinatedsolventswillcausesomeswelling.
Polyethyleneisattackedbystronglyoxidisingsubstancessuchashalogensandconcentratedinorganic
acidssuchasnitric,sulphuric(includingoleum),perchloricetc.
PleaseviewChemicalResistancechart.(iplex.php?page=11)
4/33
3/15/2015
ProductSystems
reserved.
>>TheTHERMAPIPEConcept
THERMAPIPEresiststheabsorptionofheatbytheuseofahighlyreflectivewhitematerialontheexternal
skinofthepipe.Thismaterialextrudedconcurrentlywiththeblackpipewall,forminganintegralpartofthe
pipe.FormulationofthewhitecoextrusionisdesignedtomatchthelongtermUVstabilityachievedby
conventionalblackPEmaterial.
Extensivetestinghasdemonstratedthatsolarradiationhaslessthanhalftheheatingeffecton
THERMAPIPEthanwasrecordedforconventionalblackPEpipesunderthesameconditions.
Inallotherrespects,THERMAPIPEmatchesorexceedstheperformancerequirementsofAS/NZS4130PE
pipes,pressureapplications.
Bylimitingtheoperatingtemperatureofabovegroundpolyethylenepipelines,athinnerwalledpipecanbe
usedthanwouldotherwiseberequiredinagivenapplication.THERMAPIPEachievesthefollowing
performanceimprovementsrelativetoblackPEpipes
Thinnerwalledpipesprovidingmoreefficientpipedesign
Lowerpipepurchasecost
Lowerpumpingcostduetogreaterhydrauliccapacity.
Reducedthermalexpansion/contraction
Lessrequirementtosnakepipelines
Extrapurchaselengthreducedto+2%toaccommodatesnaking
(Vs4%forblackPE)
THERMAPIPEreducespipemovementsontailingsdamwalls&
piperacks.
Reducedanchorageloads.
Reducedthermalstressinthepipematerial.
Higherpipestiffness
Greaterresistancetocollapseundervacuumeffect.
Easiertohandleinlonglengthsonsite.
Reducedtemperatureriseinfluid
ContentsinTHERMAPIPEremaincoolerthaninequivalentblackpipes.
RelativetoothersystemsforlimitingsolarheatingofPEpipes,whichmayincludesleeving
THERMAPIPEprovides
Factoryfinishedsystem
Nospecialinstallationstepsstandardweldingandjointingsystemsapply.
Noadditionalcostsforinstallation.
Thermalprotectionintegralwithpipestructure
Immunetowinddamageorattackbyanimals.
Maintenancecostsareminimal.
DesignForHighTemperatureService
AbovegroundPEpipecanabsorbandshedthermalenergyviaanumberofmechanisms.Incomingsolar
radiationwillheatthepipewhilstreradiation,convectionandconductiontothefluidconveyedwillacttocool
thepipe.Variationintheincomingsolarradiationintensitywithtimeofday,cloudcover,latitude,altitude,
seasonandpipelineorientationcombinetobemajordeterminantsofpipetemperature.
5/33
3/15/2015
Windvelocity,ambienttemperatureandtheflowrate,temperatureandnatureoftheconveyedfluidarealso
variablesactingtoinfluencepipewalltemperature.
Muchofthiscomplexitycanbereducedbyconsideringthatanypipedesignmustaccommodatethemost
arduousenvironmentalconditionstobeencountered.ForPE,thisrequirestheestimationoflongterm
temperatureconditionsinthepipe,especiallyduringsummer.
TestingofconventionalblackPEpipeandthewhiteTHERMAPIPEmaterialbyanindependentlaboratory
hasconfirmedlowerradiationabsorption,resultinginsubstantialreductionsintemperaturewiththismaterial.
RadiationAbsorption*
POLIplexBlackPE 96%
THERMAPIPE
42%
*Absorptance(meaning)theratiooftheamountofradiationabsorbedbyasurfacetotheamountofradiation
incidentuponit.
THERMAPIPEisabletomaintainaloweroperatingtemperatureviaboththelowerabsorptionofradiation
andbymaintainingfreeconvectionaroundtheoutsidediametertooptimisecooling.Meanpipewall
temperatureisthekeyparameterexpressedasasimpleaverageofinsideandoutsidesurfacetemperatures.
6/33
3/15/2015
ProductSystems
reserved.
>>Rural/ImperialPoly
IplexmanufacturesbothGreenlineandRedlineruralpolyethylenepipe
systems.
RedlinepolyismadetoAS2698.2dimensionsandhasamaximum
operating
pressureof900kPa.Greenline,our800kPapolypipeforrural
applications,
ismanufacturedtoIplexspecifications.BothGreenlineandRedline
pipesuse
Iplexsruralcompressionrangeoffittings.Sizesrangefrom3/4inchto
2inch.
7/33
3/15/2015
ProductSystems
reserved.
PolyethylenePipeandFittings>>ProductDimensions
>>Pipe
DiametersrangefromDN16toDN2000withpressureratingsofupto
2.0MPa.PipesuptoDN110canbesuppliedincoilsinlengthsofupto
300metresinsomediameters.Largerdiametersaretypically12mlong
although15mandlongerareoccasionallymanufacturedbyarrangement.
NotethatthenominaldiameterofPEpipesreferstotheoutsidediameter
inaccordancewithinternationalpractice.
POLIplexPressurePipesDimensions
WATER&AIRSTANDARDPE80C,BLUELINEPE80B,ALLBLUEPE80B&ONEHUNDREDPE100
TOAS/NZS4130
SeeTableinPDFFormat(resources/library/polyethylene_pipe_fittings/PE100S1PressurePipeDimensionsPoly
CatalgoueCorrectedLK14082012.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
8/33
3/15/2015
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
9/33
3/15/2015
ProductSystems
reserved.
>>CompressionFittings
Iplexpipelinesofferarangeofcompressionfittingsthatdeliverstrength,securityandperformancewitha
fittingthatisinexpensiveandeasytoinstall.
IPLEXMETRICCompressionFittings
aredesignedtobeusedwithMetricPolyethylenepipemanufacturedtoAS4130.Afullrangeofsizesand
configurationsfrom20mmto110mmisavailablewiththefittingsratedPN16to63mmandPN12.5to
110mm.Thefittingutilisesleadingedgedesigncombinedwithproventechnologytodeliveranextremely
securejointwithafittingthatdoesn'tneedtobedisassembledtojoinsimplypushthepipeinandtighten
thenut.
CommonapplicationsforIPLEXMETRICcompressionfittingsinclude:
Waterdistribution,houseconnections,servicepipeetc
Ruralwaterreticulation,stockwatering,irrigation,artesianwater
etc.
Industrialapplications,watertreatmentplants,coolingwater,
aggressiveandcorrosivecircuits,sewerage,effluentsanddredging
etc.
Miningslurrytransporttailinglines,watersupplyandreturn,above
andbelowground.
IPLEXRURALCompressionFittings
aredesignedtobeusedwithimperialdimensionpipeandisamodifiedversionofIPLEXMETRIC.Afull
rangefrom"to2"isavailable.TheIPLEXRuralfittingisveryreliable,toughanddurablewitha
distinctivelycolouredgreeninsert.
IplexRuralpolyethylenepipeandfittingsarecommonlyusedinlowheadrural
applicationswherenominalpressureisbelow600kPa.
Thematerialspecificationsandcapabilitiesfortherangeareasfollows:
BodyandNutBlackpolypropylene,highgradecopolymer
Splitring(metriconly)Whiteacetal
Spacer(metriconly)Blackpolypropylene,highgradecopolymer
Insertbarb(ruralonly)Greenpolypropylene,highgradecopolymer
Oring(prelubricated)Nitrilerubber(NBR)
ChemicalResistance
IPLEXMETRICandIPLEXRURALfittingshaveexcellentchemicalresistancepropertiesandaresuitable
fortransportationofawidevarietyofchemicals,nonaromaticsolventsandoils.Adetailedlistofchemicals
andtheirsuitabilitywithspecificpipematerialscanbefoundintheIplexChemicalResistanceChart
(iplex.php?page=chemicals).TheinertnessofPolypropylenemakesitchemicallyresistanttoacidoralkali
soilshoweversealingringcomponentmaterialsmustalsobeconsidered.
OperatingTemperatures
Iplexcompressionfittingsarenotsuitableforuseinhotwaterservicesalthoughtheywithstandthesame
temperaturesaspolyethylenepipewiththesamederatingfactorsapplying.Thefittingsaresuitableforuse
atsubzerotemperatures.
10/33
3/15/2015
EffectonWater
Iplexcompressionfittingsaredesignedtocarrypotablewaterandwillnottaintthewaterorimpartany
constituentsinconcentrationsthatcouldbeharmfultohealth.
AbrasionResistanceandResistancetoImpact
IPLEXMETRICisparticularlysuitableforminingandindustrialapplications,beingusedforthe
transportationofabrasiveslurriesandeasilywithstandingtypicalconditionsfoundinurban,mining,
industrial,ruralwaterandwastewaterapplications.Iplexcompressionfittingbodiesandnutsare
manufacturedoutofahighgradePolypropyleneprovidingexcellentimpactresistance.
FeaturesandBenefits
IPLEXMETRIC
Performance
Veryeffectivesealabilitytosealonscuffedorundersizedpipe.
Toughnessofmaterialhighimpactstrength,UVresistant,long
life.
Highendloadorpulloutresistanceeg63mmfittingapproximately
1.2kilonewtons.
Fullrangeofsizesandconfigurations.
RatedPN16to63mm,PN12.5to110mm.
EaseofInstallation
Simpletousenodisassemblyrequiredorloosecomponentstolose.
Nochamferingorlubricationofpiperequired.
Smallfittings(below40mm)canbeeffectivelytightenedbyhand.
Coarsethreadswon'tclogupwithdirt.
Distinctivebluenutforeasyidentification.
Security
ManufacturedtoAS4129witha50yeardesignlifeinstandardconditions.
SuppliedandsupportedbyIplexPipelinesAustralia'sleadingplasticpipeandfittingmanufacturer.
FeaturesandBenefits
IPLEXRURAL
ReliabilityintheField
Extendedlengthofbarbreliablejointintegrityforconnectionof
Ruralpipe.
Toughnessofmaterialhighimpactstrength,UVresistant,longlife.
CaptiveOringmakesiteasiertojoinpipewithoutturningoffwatersupply.
Fullrangeofsizesandconfigurationfrom"to2".
Stainlesssteelreinforcingringonlargersizesoffemalethreadsensuresimprovedlongterm
performance.
EaseofInstallation
Fittingcanbehandtightened.
Establishedtechnologyrequiringnospecialtrainingtoinstall.
Nochamferingorlubricationofpiperequired.
Coarsethreadswon'tclogupwithdirt.
Distinctivegreenbarbforeasyidentificationforuseonruralpipe.
Security
WellestablishedandreliabletechnologyspecificallydesignedtosuitAustralianconditions.
IplexPipelinesbrandonfittingensurespieceofmind.
11/33
3/15/2015
Standards
IPLEXMETRICismanufacturedtotherequirementsofAustralianStandardAS/NZS4129Fittingsfor
Polyethylene(PE)PipesforPressureApplications.Thefittingsarecertifiedproductsholdingthe
STANDARDSMARKindicatingthattheproductshavebeenindependentlyassessedandrecognisedas
qualityproductsbySAIGlobal.
IPLEXRURALismanufacturedtotherequirementsofAustralianStandardAS/NZS2698PlasticPipe&
FittingsforIrrigationandRuralapplications.
Testing
TestingofIPLEXMETRICisinaccordancewiththerequirementsofAS/NZS4129.
Fittingsaresubjectedtothefollowingtests,performedasdetailedinthestandard.
Dimensionaltest
Hydrostaticpressuretestforassembledjoints
Liquidinfiltrationtest
Leakproofnessunderpressurewheresubjectedtobending(upto63mm)
Pullouttest
Effectonpotablewater
ToviewthecompleterangeofCompressionfittings,pleaseusetheproductsearchtool.
12/33
3/15/2015
ProductSystems
reserved.
>>ElectrofusionFittings
IplexPipelinesandGeorgFischerPipeSystemshavealongandcomplementaryassociationinthe
Australianmarketplace.
AnalternativeformofweldingPEistheelectrofusionsystemwhereheatingelementsareembeddedinPE
fittingsockets.Thesesocketsformpartofacouplingorotherfittingandrequireanelectricalinputfroma
weldingmachinetoproduceaweldedjoint.
Thewiderangeselectionofhighqualityjoiningsystems
(electrofusion
andspigotfittings),machines,toolsandaccessoriesis
representative
ofaninformedandsolutionapproachtoourcustomers
needsinthe
waterandgasutilitymarket.
TheELGEFpluselectrofusionprocedureutilisesthe
weldabilityof
POLIplexmaterialswithouttheuseoftherelatively
cumbersome
buttfusionweldingmachine.Thisisachievedbyusing
polyethylene
couplingswithembeddedcopperwirecoilsservingasheating
elements.Aportableweldingmachineconnectedtoapowersource
providesacurrentsourceofthecorrectvoltageandduration,which
isappliedtotheterminalsonthecouplingorsocket.Thiscauses
thematingsurfacesofsocketandpipetobemeltedtogiveafusedcontiguouswhole.Theelectrofusion
processunlikebuttfusioncanbeusedtojointpipesandfittingsofdifferingSDRorwallthickness.The
ELGEFplusequipmentcanbesuppliedwithabuiltindatarecordingsystemtogivefulltraceabilityof
individualwelds.
Electrofusionpermitsasafe,systematic,economicandefficientfullyweldedinstallationforbothburiedand
abovegroundPEpipingsystems.IplexsGeorgFischerelectrofusionproductsareindividuallysealedinPE
bagsandpackagedincartonstoprotectthemfromUVradiation,oxidationaswellasgeneral
contamination.AdditionallytheyaresuppliedwithaBarcodedcardthatcontainsallrelevantproduct
information,traceabilityandfusionweldingparametersrequiredforjoining.
ToviewcompleterangeofElectrofusionfittings,pleaseusetheproductsearchfunction.
FrequentlyAskedQuestions
Thefollowingisasampleofcommonlyaskedquestionspertainingtoelectrofusion.Shouldadditional
informationberequired,pleasecontactIplexPipelinesdirecton131814.
CanIplexsGeorgFischerweldingmachinesbeusedonothermanufacturerselectrofusionfittings?
Yes,butanadaptermustbeusedforconnectionpinsbiggerthan4.0mm
Onautomaticweldingmachines,willthebarcodereaderrecogniseothermanufacturersbarcode?
Yes,howeverallsettingsshouldbecheckedpriortowelding.
13/33
3/15/2015
Whatsizegeneratorisrecommendedforelectrofusionweldingmachines?
Generally5kVAgeneratorsarerecommendedforthestandardrangeoffittings.
CanIplexsGeorgFischerweldingmachinesconnectto10ampoutlets?
No.Electricalplugsareallsizedfor15amps.HoweverinlimitedcircumstancesAS/NZSapprovedadaptors
canbeutilised.
DoIneedcurrentregulatorprotectiononthegenerator?
MSA250plusmachineshaveaninbuiltvoltageregulatorwhereasMSA210aremoresusceptibletovoltage
spikes.WerecommendanAVR(AutomaticVoltageControlRegulator)unitshouldbeusedwiththe
generator.
DoIneedqualificationsforelectrofusionwelding?
Competentandexperiencedproceduraltrainingcanbesufficient,butinmostcasescertificationfroma
recognisedtrainingorganisationisrequired.Detailsforcertifiedtrainingorganisationscanbeprovided.
WhydoIneedtoscrapethepipe?
PEpipeformsanoxidisedlayerwhenexposedtoUVradiation.Thislayermustberemovedfromthejoining
surfacespriortowelding.
Cananytypeofcleaningwipe/fluidbeusedonthepreparedsurface?
No.OnlycommerciallyavailablePEsolventcleanersarepermitted,withaminimumalcoholcontentof
90%.Cleaningagentswithadditiveslikemoisturizesorsimilaradditivesarenottobeused.
AreSDRandPNratingsthesame?
No.PNratingsrefertointernalpressuresandSDRratingsrefertopipewallthickness.
CandifferingSDRratedpipebeelectrofused?
Yes.IplexsGeorgFischerfittingsareratedeitherSDR11(PN16)orSDR17(PN10).Thefittingscanbe
usedonPN100piperangingfromSDR9(PN20)uptoSDR26(PN6.3)ratingshowevertheSDRofthe
fittingswilldeterminethefinalratingoftheinstallation.InallnonstandardcasespleasecontactIplexto
checkforsuitability.
AreclampsrequiredforElectrofusionjoining?
Yes.Alljointsmustbemovementandstressfreethroughouttheweldingandcoolingprocess.
Isitnecessarytoreroundpipe?
Pipecanbecomeovalinshapeduetostorageorcoiling.Reroundingisonlynecessaryforinstallationof
fittingsifpipeisoutofround.
Whatisthefunctionofasqueezeofftool?
Oncertainpipesizes,squeezeofftoolsareusedtocompressPEpipewherenoisolationvalvesare
installed.Oncompletionoftherepairorcutin,thetoolisreleasedandthepipereturnstooriginalshape.
14/33
3/15/2015
HowdoIstoreelectrofusionfittings?
Fittingsshouldbestoredoutofthedirectsunlightandintheoriginalpackinguntilimmediatelybefore
use.Couplersshouldbestoredontheirflatends.
DoIneedtoscrapefittingspriortouse?
No,aslongasfittingshavebeencorrectlystoredintheoriginalpackaging.PEcleanershouldstillbeused
onallpreparedsurfaces.
Whatarecooldowntimes?
Theweldingprocessinvolvestwophasesfusion(heating)andcooling.Cooldowntimesonthebarcode
cardsorthemachinedisplaymustbeobserved.
Whydopipeendsneedtobesquare?
Theweldingprocessreliesonpressureaswellastemperature.Pipeendsneedtobesquaretoensure
alignmentwithinthefittingandcontainmentofmeltflows.
Canweldingbecarriedoutininclementweather?
Yes.Howevertheelectrofusionjointmustbeprotectedfromallweatherinfluences.Allpreparedjoining
surfacesmustbecleananddrypriortoinstallation.Safetyprecautionsmustbefollowedwhenusing
electricalequipmentinallconditions.
15/33
3/15/2015
ProductSystems
reserved.
>>PEFabricatedandMouldedFittings
PolyFabricatedandMouldedfittingsaregenerallymadefromPE100materialandcanbeusedinbutt
weldingorelectrofusionapplications.Thesefittingsincludeitemssuchastees,elbows,flangesand
reducers,andaregenerallyusedinlargerdiameterpipelines.
Fabricatingfittingsinvolvesthecuttingandweldingofpipeintoavarietyofshapesandsizesforarangeof
applicationsintheminingandwaterindustries.Detaileddrawingsareusuallyrequiredforthefabrication
departmenttomanufacturethesefittings.
ToviewcompleterangeofFabricatedandMouldedfittings,pleaseusetheproductsearchfunction.
16/33
3/15/2015
ProductSystems
reserved.
PolyethylenePipeandFittings>>StandardsandApprovals
>>StandardsandTesting
POLIplexpolyethyleneisanintegratedfamilyofPEpipesproducedbyIplex,basedonPE80BandPE100
materials.POLIplexpipesaremanufacturedtoAS/NZS4130frompolyethylenescomplyingwithAS/NZS
4131.IplexPOLIplexpipesareStandardsMarklicensedtoAS/NZS4130bySAIGlobal.
17/33
3/15/2015
ProductSystems
reserved.
PolyethylenePipeandFittings>>PipelineDesign
>>HydraulicDesign
SelectionofPipediameterandclass
Thechoiceofpipediameterandpressureclasswill
dependonthefollowingfactors.
Therequiredflowrateincludinganyplannedfuture
increases.
Thefrictionlossescausedbythepipesand
fittings.
Thelongitudinalsectionoftheproposedpipeline
route.
Inthecaseofpressurisedgravitysystems,the
availableheaddifferential.
Therelativecostofdifferentpipediametersand
classes.
Financialparameterssuchasexpectedinterestrateandrepaymentterm.
Forpumpedsystemsthecostofpowerandanticipatedinflationrateforenergycosts.
Estimatedwaterhammerandsurgescausedduringnormaloperationandduetopowerfailure.
Specifiedfieldandtestpressures.
Toassistinyourdesign,pleaseuseourHydraulicDesignTool.(iplex.php?page=13)
18/33
3/15/2015
ProductSystems
reserved.
PolyethylenePipeandFittings>>PipelineDesign
>>StructuralDesign
Inengineeringterms,POLIplexPEpipesareconsideredtobeflexiblewhenburiedwithrespectto
surroundingembedmentmaterials.Asgroundloadsresultinstressesinaburiedpressurepipelineadditional
tothoseduetointernalhydraulicloadings,itisimportanttocarryoutacombinedloadingdesigncheck.Non
pressureaswellaspressurepipesrequiredesigncheckswithregardtopredicteddiametraldeflection,
circumferentialwallbendingstrainandsafetywithregardtobucklingstability.
Toassistinyourdesign,pleaseuseourStructuralDesignTool.(http://www.iplex.com.au/iplex.php?page=104)
19/33
3/15/2015
ProductSystems
reserved.
PolyethylenePipeandFittings>>InstallationandFieldTesting
>>HandlingandStorage
Storage
Storageareasshouldbesmoothandlevel.Foreaseofhandlingandtoavoiddamage,pipepacksshouldbe
placedontimberbearersatapproximately2metercentresthatmatchtheframespacingofthepacks.The
tendencyforPOLIplextocreepunderloadrequiresthatattentionbepaidtolimitinglongtermstacking
heightsforbundlesforstraightpipeswithouttimberframingto2metres.(or3timesdiameterifgreater.)
Wheretimberframepacksarestackeditisimportanttokeepframesofpacksstackedverticallyclose
togetheralternatingevenly.Packswithwidelydifferingframespacingshouldnotbestacked.Havingthe
timberbearersclosetogether,sidebyside,effectivelyincreasesthebearingareafortheloadsbetween
stacksandreducesthepointloadings.Itisneitherpracticablenordesirableforbearerstobealigned
verticallyasthesestacksarethenunstableagainstlongitudinalslidingwhenbeingtransported.Furthermore
theoverallheightofthestackwillbeincreasedsignificantly.Providedproperregardisgiventosideways
stability(eg:windforces),packswhichareusually1.2meterswidemaybestackedupto3metersinheight.
Coilsareusuallytransportedandstoredinthenearverticalplanealthoughthismaybegovernedbythe
availabilityofasupport,whichwillsafelyholdleaningcoils.Ifstackedhorizontallytheyshouldbeplacedon
palletsforconvenientliftingorslinging.Coilsstackedinthiswayshouldalsobelimitedto1.0meterin
height.
Blackorwhitepigmentedpolyethylenehasextremelygoodultravioletradiationresistance.Howeverblue,
orangeandyellowpigmentedpipewillexhibitfadingifstoredindirectsunlightformorethensixmonthsand
thereforeshouldbecoveredwhereanextendedperiodofstorageisenvisaged.Pipeswhichexhibit
significantfadingshouldnotbeusedinhighlystressedapplications.Undernocircumstancesshallpipesbe
coveredinopenareaswithblackplasticsheeting.
LiftingandUnloading
Metalhooks,chainsorslingsmustnotbeusedwithoutpadding
forliftingcoilsorpacks.Webbedfabricslingsarethepreferred
option.Becauseoftheflexibilityofpacksofsmallerdiameterpipe
in12meterorgreaterlength,twoliftingpointsorspreaderbars
betweenslingsshouldbeusedtoreducedrooping.Ifthisisnot
donepacksmaybedifficulttoliftcleanlyoffthegroundcausing
scuffedpipeends.
20/33
3/15/2015
ProductSystems
reserved.
>>JoiningInstructionsMetricCompressionFittings
1.Preinstallation
Makesurefittingisinopenpositionwithatleast3or4threadsshowing
Cutthepipetorequiredlengthanddeburrtheend.Thepipedoesnotneedto
bechamfered.
2.MarkthePipe
ThepipehastobepushedpasttheOringforthefittingtoseal.Toensure
thatyouinsertthepipetothecorrectdepthitishelpfultomarkthepipe.Use
thismarkorworkoffthemiddleofthebodyofthefitting.
Forsizes75mmandaboveonlyinsertpipetothepointofinitialresistance.
Don'tpushallthewayhome.
3.Insertthepipe
Pushthepipeintothefittingtothecorrectdepth.Youwillfeelresistanceas
thepipepushespasttheOring,howeverthisshouldnotrequiremuchforce.
Ifdifficultyisencounteredthenlubricatingtheendofthepipemayhelp.
Forsizes75mmandabovethepipeshouldn'ttobepushedpasttheOring,
simplyinsertthepipeuntilthefirstpointofresistanceismet.
4.Tightenthenut
Forsizes32mmandbelowthiscannormallybeaccomplishedbyhand,for
othersizesuseanappropriatetool.
Forsizes75mmandabovetighteningthenutfullyshouldpullthepipe
throughthesealtothelinemarkedonthebodyofthefittingandlabelled
STOP.
5.Fullyinstalled
Itisnotnecessarytotightenthenutuntilitbuttsagainsttheflangeofthe
body.Thefittingisfullyinstalledwhenthenutcannotbetightenedany
further,normallyatleastonethreadisexposed.
Forsizes75mmandaboveitisnecessarytotightenthenutuntilitbutts
againsttheflangeofthebody.
ForDisassemblysimplyunscrewthenutandpullpipefromfitting.
21/33
3/15/2015
22/33
3/15/2015
ProductSystems
reserved.
>>JoiningInstructionsRuralCompressionFittings
1.
Cutthepipesquareandremoveexcessburrs.
Disassemblethefittingandidentifythecentralbody,nutsplitringandinsert
components.
Slidenutontopipe,followedbythesplitring.
2. Nutthreadshouldbefacingtowardsthecentralbodywiththetaperededgeof
thesplitringfacingthenut.
3. Pushthebarbedinsertfullyintotheendofthepipe,untilthemouldedflangeis
buttedagainstthepipe.
4. Pushthepipe/insertintothecentralbodyofthefitting,andpushuntiltheflange
buttsontothecentralbody.
5. Slidethesplitringandnuttowardsthecentralbodyandscrewthenutontothe
bodyuntilthefittingisfirmlytightened.
NOTE:
Itmaybenecessarytogentlyknocktheinsertintothepipeusinga
woodenorrubbermallet.
EnsurethattheOringsealisnotdislodgedfromtheinsertduring
23/33
3/15/2015
assembly.
Forlargersizesitmaybenecessarytouseawrenchorspannertofully
tightenthenut.
DisassemblyUnscrewnutandslideawayfromcentralbodyontothe
pipe.Thenremovepipe/insertfromcentralbody
24/33
3/15/2015
ProductSystems
reserved.
>>JoiningInstructionsElectrofusionFittings
GeneraltipsforpreparationandassemblyofIplexsGeorgeFischerfittings:
Carefulpreparationofthefusionsurfaceistheabsoluteprerequisiteandshouldnotbenegotiated.
Fusionzonesshouldbewellprotectedfrommoistureduringinclementweather(rain,snowfalletc.).
IplexsGeorgeFischerfittingsaresuppliedwiththeappropriateBarcodedcardsinapolythenebag.
Fittingsintheiroriginalpackagingdonotrequirescrapingorpeelinghowever,itisrecommendedto
alwaysusePEcleaneronfittingspriortoassembly.
Atanystageduringassembly,ifthefusionzonesaretouchedbyhand,thefittingmustberecleaned
withthePEcleaner.
Thepipeshouldbewiped,scrapedandfinallycleanedwiththePEcleaner.
Werecommendscrapingtoolsshouldbeusedforevenandtimesavingpipepreparation,ratherthan
handscrapers.
AssemblyandoperatinginstructionsforIplexsGeorgFischerELGEFPluselectrofusion
fittings.
OverviewofElectrofusionWeldingProcedures:
1.
Roughlycleanpipe(s).Cutatrightanglesandtrimedges.
2.
Remove(scrapeorpeel)oxidefilmoffpipe(s)usingcorrecttooling.
3.
Cleanpipe(s)infusionzonewithPEcleaner(Tangitorequivalent).
25/33
3/15/2015
4.
Marktheinsertiondepthonthepipe.
5.
Removefitting(s)fromthepackagingwithouttouchingthefusion
surfaceswithcleaner.
6.
PushinthePEpipeuptocentrestopormarking.
7.
Firmlyfastenintegratedbracket.
8.
Mountandfixassemblyclamps.
9.
Slideinsecondpipeuptocentrestopormarking
10. Firmlyfastenintegratedclamps
26/33
3/15/2015
11. Mountandfixassemblyattached
12. Fusioninaccordancewithoperatinginstructionsofthewelding
machine(manualorbarcodescannerunit)
13. Afterfusioncompletedcheckmachinedisplayforerrormessage
thenvisuallycheckallpartsofthefittingandfusionindicators.
14. Removeanyexternalclamps.
15. Waitmaximumcoolingtimebeforepressuretest.
OverviewofElectrofusionSaddleWeldingProcedures:
27/33
3/15/2015
1.
Cleanpipeinfusionarea,removeoxidefilmofpipeusing
handscraperorpeelingtool.
2.
CleanpipefusionareausingPEcleaner(Tangitor
equilivalent).
3.
4.
Removesaddlefrompackagingwithouttouching,hang
lowerpartonitshinge.
Placesaddleonpipeandequallytightenwithpremounted
bolts.
5.
Removesaddlecomponentfromthepackagingand
assemble(withouttouchingfusionsurface)
6.
Placesaddleonpipeandassemblewithtoploadtool
(detailedassemblyinstructions)ifrequired.
28/33
3/15/2015
7.
Alignoutletandfirmlyfastenintegratedbracketofsaddle
outlet.
8.
Weldinaccordancewithoperatinginstructionsofwelding
machine(manualorbarcodescannerunit).
9.
Afterfusion:Checkfusionindicator,checkfusionunit
display,andthenremoveleads.
10. Waitforminimumcoolingtimebeforepressuretestingif
required.
11. Removescrewandorfusioncap.
29/33
3/15/2015
12. Fortappingsaddlesinserthextoolingandscrew(tap)
clockwiseuntilpipepenetrationisachieved.Seedetailed
assemblyinstructionsinpackaging.
13. Withdrawcutteruptotopstop.
14. Fastenscrewcapbyhandorfitfusioncap.
15. Weldinaccordancewithoperatinginstructionsofunit.
Note:Theseinstructionsareintendedasaguideonly.
Electrofusionweldingshouldonlybeundertakenby
suitablytrainedandexperiencedoperators.
30/33
3/15/2015
ProductSystems
reserved.
>>JoiningInstructionsButtWeldJoint
Thisprocedureutilisestheexceptionalweldabilityofthevariouspolyethylenematerialsandresultsina
pipelinewithanaxialstrengthclosetothatoftheparentmaterial.Beforeundertakingtheinstallationofa
weldedPEpipeline,considerationmustbegiventothefollowing.
ChoiceofEquipment
Therangeofavailablebuttfusionweldingmachineshasexpandedrapidlyinrecentyears.Thecostof
machinesforlargerpipesishighandtheuseofspecialistweldingsubcontractorsisnormalpractice.
Machineoperatingcharacteristicsvarywithage,withearliermodelsrequiringmanualoperationandthelatest
beingequippedwithfullyautomaticcontroltotheextentthataprintedrecordofallweldparameterscanbe
producedforeachjoiningoperation.
Aweldingmachineisinfactcomprisedofanumberofcomponentsmountedonasinglebaseframeor
chassis.Theseincludepipeclampsforeachsideofthejoint(i.e.fullcirclevices)specificallytosuitthepipe
diametersbeingjoined,ahydraulicpump,hydraulicramstoprovidethejointingforces,anelectricallathe
withdoublesidedcutterfortrimmingoperations,anelectricallyheatedtwinsidedweldingplate(withnon
sticksurface)sometimescalledamirror,pressuregagesforthehydraulicsystemand(weldingplate)
temperaturesenses.Ifthemachineissemiorfullyautomated,therewillusuallybeacomputer/printerunit
aswell.
Apowersourcesuchasaportablegeneratororcompatibleelectricmainsconnectionisalsonecessary.
Piperollerstoreducedragfrictiontogetherwithliftingequipmentwillbeneededforlargerpipes.Temporary
shelterforthisequipmentduringtheweldingoperationsuchasatentisimportant,asitwillassistinkeeping
thepipebeingweldedatauniformandstabletemperaturefreeofmoistureanddust.Sunlightandwindcan
createunevenambientpipetemperaturesaffectingtheweldquality.
OperatorTraining
Aswithallweldingcarriedoutonanymaterialusedforengineering
purposes,polyethyleneweldingisaskilledoperationrequiringtheuseof
properlyqualifiedoperators.Formalcourses,whichprovideaccreditation
tosuitablyskilledpersonnel,areavailable.Theuseofunqualified
operatorsisunacceptable.
WeldingPrincipals
Pipestobejoinedmustbeofthesamewallthickness(i.e.SDR)andthe
endsmustbecutsquare,i.e.perpendiculartothepipeaxis.Unmatched
wallthicknesseswillrequireamachiningorchamferingoperationofthe
greaterthicknessatanangleoffifteendegrees(1:4)orlesstogivethe
samefacethicknessonbothsidesofthejoint.Thesuccessofeachweld
inextremelydependantoncleanliness,temperaturecontrolandgood
equipment,whichhasbeenproperlymaintained.Thepipeendsmustbe
properlyalignedbeforemachiningandheating.Theyshouldbedryand
freeofdustcontamination.Matingsurfacesmustbeplannedimmediately
beforeweldingtoremovesurfacematerialaspolyethyleneoxidiseson
exposuretotheair.Ifthesepreparedsurfacesaretouchedaftermachining
thereisariskofcontaminationthatmaybenotbevisibletothenakedeye.
Thetimingoftheweldingsequenceismostimportantifconsistentweldqualityistobeobtained.Timesfor
thesimultaneousheatingofthepipeendsagainstthehotplateorthemirror,mirrorremoval,thepressingof
themeltedpipeendstogethertogivetherequiredamountandshapeofbeadmaterial,andfinallythecooling
timewhilstmaintainingpressure,areallofcriticalimportance.
31/33
3/15/2015
Ifthepipetemperatureisnotuniform,suchasforexamplecanoccurwhenweldingiscarriedoutindirect
sunlight,anunevenpipewalltemperaturewillexistwhichcouldaffecttheuniformityoftheweld.This
temperaturedifferencemustbeequalisedbyshieldingtheweldzonewellinadvanceofmakingthejoin.
Coversontheendsofpipesremotefromtheweldwillpreventcoolingairpassingthroughthepipeinterior
andassistinkeepingweldzonetemperaturesuniform.
32/33
3/15/2015
33/33

Iplex Pipelines Pty LTD

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Iplex Pipelines Pty LTD

Enviado por

Direitos autorais:

Formatos disponíveis

3/15/2015

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

Você também pode gostar