Russel Brown-Module 4 2020

Module 4
PE Welding on site
Russel Brown
P.E. Coils
2
Preparation
 Risk Assessment
 Ensure all hazards are controlled with appropriate measures
 All PPE to be worn and available when required
 Goggles must be worn whilst carrying out electro-fusion
 Work to be carried out in accordance with other procedures i.e.

"Safe Control of Operations"
3
Restrictions
• Temperatures below ground exceed 20ºC.
• Above ground positions and other positions reached by daylight unless protective
sleeving or other suitable protection is used.
• Where solvents and harmful chemicals are present.
• On in-filled demolition sites, unless suitable backfill is available.
4
Handling of Material
 Delivery
 Inspection - reject if damaged
 Storage
 Unbanded coils
 Stacking no more than 2 high
 Lowering - operators must be competent when using slings and chains

i.e. Lifting operators procedures.
5
Coil Pipe Sizes
Diameter 25 m 50 m 100 m 150 m
25 mm 855 880 930 955
Dimensions
are max 32 mm 876 908 972 1004
external
diameter in 50 mm 1400 1450 1550 1650
mm
63 mm 1436 1489 1562 1625
90 mm 2900 3000
125 mm 3720
180 mm 4000
Addition Information
Weight in KG
Diameter
Length
SDR
Off loading of Coiled pipe
9
Coils - safe off loading
• Ensure the correct equipment is available and in good working order.
• Ensure compliance with site safety rules
• Agree “responsible” person
• Prepare a storage area

Safety precautions - off loading
• Coiled pipe holds an enormous amount of energy and

should be handled with care.
• Particular care should be taken not to damage the

restraining straps.
• In wet conditions PE pipe can become very slippy and

extra care should be taken in these conditions.
• It is unsafe to lift coils over the side of caged vehicles.
• Coils should not be dropped or thrown from vehicles.
• Coils should be off loaded with wide webbing slings or a fork lift truck
fitted with a protected boom.
• Palletised coils should only be handled by a fork lift truck.
• Individual small coils (32 mm diameter and below) can be easily man
handled.
Lifting Coils
Correct
Incorrect
Storage of Coiled pipe
Coils stored flat
maximum height 2.5m.
Storage
of Coils
2.5m
Timber battens
should be used to
allow access.
If coils are stored upright a suitable cage should be

used.
Wrong
17
Coils per stack
If the coils are stored flat the max / stack:
• 5 coils for 32 mm
• 1 coil for 110 mm
Coil stacks
Picture
63mm coils
50 m in Length
Question?
Correctly or Incorrectly Stacked
Remove steel Remove Bands from
the outside first -
security working inwards
bands at A & E.
Ensure the coil in

Never cut all the
properly held in a trailer
bands at once
before cutting bands
Coil Jointing
6 January 2005 FTS/CPH/1

Coil Jointing
Great care is required when welding coils due to
the stored energy retained by coiled pipe
Specific equipment is available to aid the jointing of
coils. This includes:
❑Double ring clamp
❑Coil jointers
Materials Used
• Medium Density Polyethylene PE 80

• (MDPE) – Yellow
• High Density Polyethylene PE 100
• (HDPE) - Orange
23
Standard Dimension Ratio (SDR)
SDR = Specific Outside Diameter of Pipe

Minimum Specified Wall Thickness
• Pipe should not be used/or replaced if any

damage exceeds 10% of the wall thickness of
the pipe.
24
To Calculate Wall Thickness
 SDR 17.6 Wall Thickness - 125 / 17.6 = 7.1 mm

 SDR 11 Wall Thickness - 125 / 11.0 = 11.4 mm
 SDR 17.6 Wall Thickness - 180 / 17.6 = 10.2 mm

 SDR 11 Wall Thickness - 180 / 11.0 = 16.4 mm
25
Bending Limits
Size of Pipe Minimum Bend

Radius
20mm 0.3m
32mm 0.5m
63mm 1.0m
90mm 1.4m
125mm 1.9m
180mm 2.7m
No joints allowed on bends
26
Surface Damage to PE Pipes
10%
90%
Wall Thickness in mm =
Unacceptable deep scoring

Pipe diameter in mm
(defect extends to 10% or
more of wall thickness) SDR
10%
90%
Acceptable surface scratching

(defect less than 10% of wall
thickness)
27
Preparatory Work
Equipment shall not be taken into gaseous atmospheres
or potentially gaseous atmospheres.
 The fusion plates do not have any gouges or dents,
 The non-stick coating is not damaged,
 The temperature indicator is not damaged,
 Electrical cables are not damaged and have no loose connections

29
Electro-fusion: Heat and pressure
Critical Fusion Factors
▪ End pipe
preparation
Terminal pin
▪ Cut square
▪ Cleaning
▪ Centre
registration
Cold Cold Cold

Alignment
Zone Zone Zone
▪ Ovality
▪ Restraining
Coil
30
Electro-fusion Equipment
Wires connected to fitting

Heater
31
Procedure for Straight Coupler
Step 1 Step 2
32
Step 3 Step 4
33
Step 5 Step 6
34
Step 1 Step 2
35
Step 3 Step 4
36
Step 5 Step 6
37
Step 7 Step 8
38
Step 9 Step 10
39
Step 11 Step 12
40
Step 13 Step 14
41
Step 15 Step 16
42
Step 17 Step 18
43
Procedure for Tapping Tee
Step 1 Step 2
44
Step 3 Step 4
45
Step 5 Step 6
46
Step 7 Step 8
47
Step 9 Step 10
48
Step 11 Step 12
49
Site Audits for faults
50
51
52
53
54
55
56
57
Hydro Testing
Safety Planning / Site Specific Requirements
• Develop a site-specific test plan including descriptions of safety
procedures and requirements
• Review the test specifications
• Suspend the test if equipment is not in working order
• Potential weather extremes should be considered
• Review the piping set up plan
• All temp piping should be connected with welded/flanged/ threaded
joints
• Anchors should be used upstream and downstream of all fittings
Safety Planning / Site Specific Requirements
• Verify all pressure ratings. Place all mainline valves in the open
position and all others in the closed position
• Calculate the back pressure for the injecting water/ running pigs
• Input supply pressure should be below 150psig
• Fill up pig location
• Inspect test heads to confirm all in good condition
Test Sequence
• Confirm barriers and signage in place
• Personnel to patrol all areas of pipe
• Raise the test pressure slowly and smoothly MAOP and hold for 30
mins
• Raise slowly again to 75% test pressure and hold for 30 mins
• Allow to stabilise then raise at a uniform rate not to exceed
10psi/minute
• Upon completion of test use caution when releasing the water
Commissioning services not greater
than 63 mm diameter.
▪ Services greater than 63mm should be treated as

mains.
▪ Services not greater than 63mm should be direct

purged.
▪ A flexible purge hose with a flame trap should be

connected to mcv and hose outlet positioned safely
outside premises.
-ENM- Commissioning etc.: 62

Commissioning
Commissioning pipelines or mains
by direct purging
▪ Commissioning of mains by the removal of bags, or

by the use of an ejector, is forbidden.
▪ Sections of pipelines and mains, up to and including

2”/63mm diameter, may be commissioned by the
controlled release of a squeeze-off or by the
controlled release of a valve or service tee.

by direct purging
•At the discretion of the A.P., sections of pipelines and

mains above 2”/ 63mm diameter, may be
commissioned, by direct purging only, by the controlled
release of a squeeze-off, if the release of the squeeze-
off can be controlled to a position corresponding to the
required rider size for achieving the min. purge velocity.

by direct purging
•At the discretion of the A.P. sections of pipelines and

mains above 2”/ 63mm diameter up to and including 10”/
250mm may be commissioned by the controlled opening
of a valve, using direct purging only.

by direct purging
• Communication and monitoring of upstream

pressure are essential when carrying out the
above operations.

by direct purging
Rider N2
(note 1)
N2
Vent
Pressure Sample
P1 P2 point
Flow
NOTES Physical
1. Rider may be omitted at the discretion of the engineer Isolation
2. Isolation alternative: an approved stop-off method may be used if nitrogen injection (Note 2)
pressure is limited to 1/3 of the pressure in the live pieline and the minimum velocity
can be achieved

Slug purging
▪ More economic than complete displacement
▪ May be used on pipelines and mains greater

than 250m in length.
▪ Limited to pipes of nom. diameter 600mm

and below.
▪ Slug volume of inert gas must be at least 10%

of pipe volume.

Russel Brown-Module 4 2020

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Russel Brown-Module 4 2020

Uploaded by

Copyright:

Available Formats

Module 4

 Ensure all hazards are controlled with appropriate measures

 All PPE to be worn and available when required

 Goggles must be worn whilst carrying out electro-fusion

 Work to be carried out in accordance with other procedures i.e.

• Temperatures below ground exceed 20ºC.

• Where solvents and harmful chemicals are present.

• On in-filled demolition sites, unless suitable backfill is available.

 Inspection - reject if damaged

 Stacking no more than 2 high

 Lowering - operators must be competent when using slings and chains

• Ensure the correct equipment is available and in good working order.

• Ensure compliance with site safety rules

• Agree “responsible” person

• Prepare a storage area

• Coiled pipe holds an enormous amount of energy and

• Particular care should be taken not to damage the

• In wet conditions PE pipe can become very slippy and

• It is unsafe to lift coils over the side of caged vehicles.

• Coils should not be dropped or thrown from vehicles.

• Palletised coils should only be handled by a fork lift truck.

If coils are stored upright a suitable cage should be

Ensure the coil in

6 January 2005 FTS/CPH/1

• Medium Density Polyethylene PE 80

SDR = Specific Outside Diameter of Pipe

• Pipe should not be used/or replaced if any

 SDR 17.6 Wall Thickness - 125 / 17.6 = 7.1 mm

 SDR 17.6 Wall Thickness - 180 / 17.6 = 10.2 mm

Size of Pipe Minimum Bend

No joints allowed on bends

Unacceptable deep scoring

Acceptable surface scratching

Equipment shall not be taken into gaseous atmospheres

or potentially gaseous atmospheres.

 The fusion plates do not have any gouges or dents,

 The non-stick coating is not damaged,

 The temperature indicator is not damaged,

 Electrical cables are not damaged and have no loose connections

Cold Cold Cold

Wires connected to fitting

▪ Services greater than 63mm should be treated as

▪ Services not greater than 63mm should be direct

▪ A flexible purge hose with a flame trap should be

-ENM- Commissioning etc.: 62

▪ Commissioning of mains by the removal of bags, or

▪ Sections of pipelines and mains, up to and including

-ENM- Commissioning etc.: 64

•At the discretion of the A.P., sections of pipelines and

-ENM- Commissioning etc.: 65

•At the discretion of the A.P. sections of pipelines and

-ENM- Commissioning etc.: 66

• Communication and monitoring of upstream

-ENM- Commissioning etc.: 67

-ENM- Commissioning etc.: 68

▪ More economic than complete displacement

▪ May be used on pipelines and mains greater

▪ Limited to pipes of nom. diameter 600mm

▪ Slug volume of inert gas must be at least 10%

-ENM- Commissioning etc.: 69

You might also like