iplex pipelines pty ltd
DESCRIPTION
Iplex pipelineTRANSCRIPT
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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.
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CarbonblackisusedinallblackPOLIplexpipeataconcentrationof2.250.25%bymassasanultravioletradiationabsorber.
InnaturalandcolouredPEmaterials,chemicalultravioletabsorbersareusedinlieuofcarbonblack.
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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).
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PolyethylenePipeandFittings>>ProductProperties>>ChemicalResistance
Polyethyleneisinchemicaltermsanonpolarhighmolecularweightparaffinofthehydrocarbonfamily.Henceitisveryresistantto(nonoxidising)strongacids,strongbasesandsalts.Itismildlyaffectedbyaliphaticsolventsalthougharomaticandchlorinatedsolventswillcausesomeswelling.
Polyethyleneisattackedbystronglyoxidisingsubstancessuchashalogensandconcentratedinorganicacidssuchasnitric,sulphuric(includingoleum),perchloricetc.
PleaseviewChemicalResistancechart.(iplex.php?page=11)
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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.
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Windvelocity,ambienttemperatureandtheflowrate,temperatureandnatureoftheconveyedfluidarealsovariablesactingtoinfluencepipewalltemperature.
Muchofthiscomplexitycanbereducedbyconsideringthatanypipedesignmustaccommodatethemostarduousenvironmentalconditionstobeencountered.ForPE,thisrequirestheestimationoflongtermtemperatureconditionsinthepipe,especiallyduringsummer.
TestingofconventionalblackPEpipeandthewhiteTHERMAPIPEmaterialbyanindependentlaboratoryhasconfirmedlowerradiationabsorption,resultinginsubstantialreductionsintemperaturewiththismaterial.
RadiationAbsorption*
POLIplexBlackPE 96%
THERMAPIPE 42%
*Absorptance(meaning)theratiooftheamountofradiationabsorbedbyasurfacetotheamountofradiationincidentuponit.
THERMAPIPEisabletomaintainaloweroperatingtemperatureviaboththelowerabsorptionofradiationandbymaintainingfreeconvectionaroundtheoutsidediametertooptimisecooling.Meanpipewalltemperatureisthekeyparameterexpressedasasimpleaverageofinsideandoutsidesurfacetemperatures.
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ProductSystemsTechnicalInformationCopyright2009IplexPipelinesPtyLtd.Allrightsreserved.
PolyethylenePipeandFittings>>ProductProperties>>Rural/ImperialPoly
IplexmanufacturesbothGreenlineandRedlineruralpolyethylenepipesystems.RedlinepolyismadetoAS2698.2dimensionsandhasamaximumoperatingpressureof900kPa.Greenline,our800kPapolypipeforruralapplications,ismanufacturedtoIplexspecifications.BothGreenlineandRedlinepipesuseIplexsruralcompressionrangeoffittings.Sizesrangefrom3/4inchto2inch.
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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
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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
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ProductSystemsTechnicalInformationCopyright2009IplexPipelinesPtyLtd.Allrightsreserved.
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.
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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.
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Standards
IPLEXMETRICismanufacturedtotherequirementsofAustralianStandardAS/NZS4129FittingsforPolyethylene(PE)PipesforPressureApplications.ThefittingsarecertifiedproductsholdingtheSTANDARDSMARKindicatingthattheproductshavebeenindependentlyassessedandrecognisedasqualityproductsbySAIGlobal.
IPLEXRURALismanufacturedtotherequirementsofAustralianStandardAS/NZS2698PlasticPipe&FittingsforIrrigationandRuralapplications.
Testing
TestingofIPLEXMETRICisinaccordancewiththerequirementsofAS/NZS4129.
Fittingsaresubjectedtothefollowingtests,performedasdetailedinthestandard.
DimensionaltestHydrostaticpressuretestforassembledjointsLiquidinfiltrationtestLeakproofnessunderpressurewheresubjectedtobending(upto63mm)PullouttestEffectonpotablewater
ToviewthecompleterangeofCompressionfittings,pleaseusetheproductsearchtool.
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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.
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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.
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HowdoIstoreelectrofusionfittings?Fittingsshouldbestoredoutofthedirectsunlightandintheoriginalpackinguntilimmediatelybeforeuse.Couplersshouldbestoredontheirflatends.
DoIneedtoscrapefittingspriortouse?No,aslongasfittingshavebeencorrectlystoredintheoriginalpackaging.PEcleanershouldstillbeusedonallpreparedsurfaces.
Whatarecooldowntimes?Theweldingprocessinvolvestwophasesfusion(heating)andcooling.Cooldowntimesonthebarcodecardsorthemachinedisplaymustbeobserved.
Whydopipeendsneedtobesquare?Theweldingprocessreliesonpressureaswellastemperature.Pipeendsneedtobesquaretoensurealignmentwithinthefittingandcontainmentofmeltflows.
Canweldingbecarriedoutininclementweather?Yes.Howevertheelectrofusionjointmustbeprotectedfromallweatherinfluences.Allpreparedjoiningsurfacesmustbecleananddrypriortoinstallation.Safetyprecautionsmustbefollowedwhenusingelectricalequipmentinallconditions.
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PolyethylenePipeandFittings>>ProductDimensions>>PEFabricatedandMouldedFittings
PolyFabricatedandMouldedfittingsaregenerallymadefromPE100materialandcanbeusedinbuttweldingorelectrofusionapplications.Thesefittingsincludeitemssuchastees,elbows,flangesandreducers,andaregenerallyusedinlargerdiameterpipelines.
Fabricatingfittingsinvolvesthecuttingandweldingofpipeintoavarietyofshapesandsizesforarangeofapplicationsintheminingandwaterindustries.Detaileddrawingsareusuallyrequiredforthefabricationdepartmenttomanufacturethesefittings.
ToviewcompleterangeofFabricatedandMouldedfittings,pleaseusetheproductsearchfunction.
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PolyethylenePipeandFittings>>StandardsandApprovals>>StandardsandTesting
POLIplexpolyethyleneisanintegratedfamilyofPEpipesproducedbyIplex,basedonPE80BandPE100materials.POLIplexpipesaremanufacturedtoAS/NZS4130frompolyethylenescomplyingwithAS/NZS4131.IplexPOLIplexpipesareStandardsMarklicensedtoAS/NZS4130bySAIGlobal.
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PolyethylenePipeandFittings>>PipelineDesign>>HydraulicDesign
SelectionofPipediameterandclass
Thechoiceofpipediameterandpressureclasswilldependonthefollowingfactors.
Therequiredflowrateincludinganyplannedfutureincreases.Thefrictionlossescausedbythepipesandfittings.Thelongitudinalsectionoftheproposedpipelineroute.Inthecaseofpressurisedgravitysystems,theavailableheaddifferential.Therelativecostofdifferentpipediametersandclasses.Financialparameterssuchasexpectedinterestrateandrepaymentterm.Forpumpedsystemsthecostofpowerandanticipatedinflationrateforenergycosts.Estimatedwaterhammerandsurgescausedduringnormaloperationandduetopowerfailure.
Specifiedfieldandtestpressures.
Toassistinyourdesign,pleaseuseourHydraulicDesignTool.(iplex.php?page=13)
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PolyethylenePipeandFittings>>PipelineDesign>>StructuralDesign
Inengineeringterms,POLIplexPEpipesareconsideredtobeflexiblewhenburiedwithrespecttosurroundingembedmentmaterials.Asgroundloadsresultinstressesinaburiedpressurepipelineadditionaltothoseduetointernalhydraulicloadings,itisimportanttocarryoutacombinedloadingdesigncheck.Nonpressureaswellaspressurepipesrequiredesigncheckswithregardtopredicteddiametraldeflection,circumferentialwallbendingstrainandsafetywithregardtobucklingstability.
Toassistinyourdesign,pleaseuseourStructuralDesignTool.(http://www.iplex.com.au/iplex.php?page=104)
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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.
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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.
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PolyethylenePipeandFittings>>InstallationandFieldTesting>>JoiningInstructionsRuralCompressionFittings
1.Cutthepipesquareandremoveexcessburrs.Disassemblethefittingandidentifythecentralbody,nutsplitringandinsertcomponents.Slidenutontopipe,followedbythesplitring.
2. Nutthreadshouldbefacingtowardsthecentralbodywiththetaperededgeofthesplitringfacingthenut.
3. Pushthebarbedinsertfullyintotheendofthepipe,untilthemouldedflangeisbuttedagainstthepipe.
4. Pushthepipe/insertintothecentralbodyofthefitting,andpushuntiltheflangebuttsontothecentralbody.
5. Slidethesplitringandnuttowardsthecentralbodyandscrewthenutontothebodyuntilthefittingisfirmlytightened.
NOTE:
Itmaybenecessarytogentlyknocktheinsertintothepipeusingawoodenorrubbermallet.EnsurethattheOringsealisnotdislodgedfromtheinsertduring
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assembly.Forlargersizesitmaybenecessarytouseawrenchorspannertofullytightenthenut.DisassemblyUnscrewnutandslideawayfromcentralbodyontothepipe.Thenremovepipe/insertfromcentralbody
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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).
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4. Marktheinsertiondepthonthepipe.
5. Removefitting(s)fromthepackagingwithouttouchingthefusionsurfaceswithcleaner.
6. PushinthePEpipeuptocentrestopormarking.
7. Firmlyfastenintegratedbracket.
8. Mountandfixassemblyclamps.
9. Slideinsecondpipeuptocentrestopormarking
10. Firmlyfastenintegratedclamps
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11. Mountandfixassemblyattached
12. Fusioninaccordancewithoperatinginstructionsoftheweldingmachine(manualorbarcodescannerunit)
13. Afterfusioncompletedcheckmachinedisplayforerrormessagethenvisuallycheckallpartsofthefittingandfusionindicators.
14. Removeanyexternalclamps.
15. Waitmaximumcoolingtimebeforepressuretest.
OverviewofElectrofusionSaddleWeldingProcedures:
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1. Cleanpipeinfusionarea,removeoxidefilmofpipeusinghandscraperorpeelingtool.
2. CleanpipefusionareausingPEcleaner(Tangitorequilivalent).
3.4.
Removesaddlefrompackagingwithouttouching,hanglowerpartonitshinge.Placesaddleonpipeandequallytightenwithpremountedbolts.
5. Removesaddlecomponentfromthepackagingandassemble(withouttouchingfusionsurface)
6. Placesaddleonpipeandassemblewithtoploadtool(detailedassemblyinstructions)ifrequired.
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7. Alignoutletandfirmlyfastenintegratedbracketofsaddleoutlet.
8. Weldinaccordancewithoperatinginstructionsofweldingmachine(manualorbarcodescannerunit).
9. Afterfusion:Checkfusionindicator,checkfusionunitdisplay,andthenremoveleads.
10. Waitforminimumcoolingtimebeforepressuretestingifrequired.
11. Removescrewandorfusioncap.
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12. Fortappingsaddlesinserthextoolingandscrew(tap)clockwiseuntilpipepenetrationisachieved.Seedetailedassemblyinstructionsinpackaging.
13. Withdrawcutteruptotopstop.
14. Fastenscrewcapbyhandorfitfusioncap.
15. Weldinaccordancewithoperatinginstructionsofunit.
Note:Theseinstructionsareintendedasaguideonly.Electrofusionweldingshouldonlybeundertakenbysuitablytrainedandexperiencedoperators.
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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.
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Ifthepipetemperatureisnotuniform,suchasforexamplecanoccurwhenweldingiscarriedoutindirectsunlight,anunevenpipewalltemperaturewillexistwhichcouldaffecttheuniformityoftheweld.Thistemperaturedifferencemustbeequalisedbyshieldingtheweldzonewellinadvanceofmakingthejoin.Coversontheendsofpipesremotefromtheweldwillpreventcoolingairpassingthroughthepipeinteriorandassistinkeepingweldzonetemperaturesuniform.
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