WSAA Product Appraisal PA 1604 1 COPYRIGHT PLASSON AUSTRALIA PRODUCT APPRAISAL REPORT PA 1604 Electrofusion Fittings for Pressure Applications AS/NZS 4129: 2008 Fittings for polyethylene (PE) pipes for pressure applications Publication Date: 8 September 2016
38
Embed
PLASSON AUSTRALIA 1… · Plasson Australia Pty Ltd, a wholly owned subsidiary of Plasson Limited, provides technical, marketing and sales support to the Plasson distributors throughout
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
WSAA Product Appraisal PA 1604 1
COPYRIGHT
PLASSON AUSTRALIA PRODUCT APPRAISAL REPORT PA 1604
Electrofusion Fittings for Pressure Applications
AS/NZS 4129: 2008 Fittings for polyethylene (PE) pipes for pressure applications
Publication Date: 8 September 2016
WSAA Product Appraisal PA 1604 2
COPYRIGHT
Document History
The following information indicates the changes made to this document.
2 THE APPLICANT ......................................................................................................................................................... 6
2.1 The Supplier and Manufacturer ............................................................................................................................. 6
3 THE PRODUCT ........................................................................................................................................................... 6
4 SCOPE OF THE APPRAISAL ..................................................................................................................................... 7
6 COMPLIANCE WITH APPRAISAL CRITERIA............................................................................................................. 8
6.1 Compliance with Quality Assurance Requirements ............................................................................................... 8
6.2 Compliance with Performance Requirements ....................................................................................................... 8
6.2.1 Effect on water ................................................................................................................................................ 8
6.2.2 Polyethylene material composition ................................................................................................................. 8
6.3 Type Testing – Geometrical and Mechanical Characteristics ................................................................................ 8
7.2.2 Product Training ........................................................................................................................................... 11
13 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW......................................................................................... 14
14 LIFE EXPECTANCY ................................................................................................................................................ 14
15 FUTURE WORKS .................................................................................................................................................... 14
16.1 Issue of Report .................................................................................................................................................. 15
16.2 Limits on Reliance on Information and Recommendations................................................................................ 15
16.2.1 Disclaimer of liability ................................................................................................................................... 15
16.2.2 Intellectual Property and other rights .......................................................................................................... 15
16.2.3 Need for independent assessment ............................................................................................................. 16
APPENDIX A - PRODUCT SCHEDULE ................................................................................................................. 17
APPENDIX B - QUALITY CERTIFICATIONS ............................................................................................................... 23
APPENDIX C - WSA PRODUCT SPECIFICATION ...................................................................................................... 26
APPENDIX D - PRODUCT INSTALLATION INSTRUCTIONS ............................................................................... 29
APPENDIX E - SUPPLIER CONTACTS ....................................................................................................................... 37
WSAA Product Appraisal PA 1604 5
COPYRIGHT
1 EXECUTIVE SUMMARY
The appraised products are nominated PLASSON polyethylene (PE) electrofusion fittings for use with PE pipes manufactured in accordance with AS/NZS 4130 Polyethylene (PE) pipes for pressure applications for the conveyance of drinking water, recycled water, and sewage in buried and above ground pressure applications.
These electrofusion fittings are supplied by Plasson Australia Pty Ltd, a well-established and long accepted Australian supplier of polyethylene pipe joining systems providing mechanical and electrofusion (heat welded) fittings and equipment systems. These are new fittings from Plasson and water agencies have requested that they be appraised by WSAA.
Plasson Australia Pty Ltd is a wholly owned subsidiary of Plasson Limited and provides technical, marketing and sales support to the Plasson distributors throughout Australia and the Pacific region. Plasson (Israel) began in 1964 using knowledge and experience to produce advanced agricultural equipment by injection moulding. They progressed to develop a range of plastic fittings for plastic pipes. These fittings are now used in industry, municipal water systems, gas conveyance systems and mines throughout the world.
Today, Plasson is an international company with over 1,200 highly skilled employees worldwide and wholly owned subsidiaries in Israel, Italy, France, Spain, UK, Germany, Poland, USA, Brazil, India, and Australia. The Plasson Group now operates more than 160 moulding/extrusion machines producing over 8,000 products. Plasson has been publicly traded in the Tel Aviv Stock Exchange, since 1997. Plasson has grown, innovated and built up a world-wide network of distributors.
The appraised PE electrofusion fittings supplied by Plasson Australia Pty Ltd are:
PLASSON PN 16, SDR 11, PE 100 polyethylene (PE) Large bore branch saddles and
PLASSON PN 16, SDR 11, PE 100 polyethylene (PE) Tapping saddles and
The product descriptions are shown in Section 3 below.
The full Product Schedule is shown in Appendix A.
The PLASSON range of electrofusion fittings have ISO Type 5 Certificate of Conformity - issued by ApprovalMark Certificate No. 02018 for compliance with AS/NZS 4129:2008 Fittings for polyethylene (PE) pipes for pressure applications and compliance with AS/NZS 4020:2005 Testing of products for use in contact with drinking water.
The PLASSON range of electrofusion fittings are designed on the basis of 50 year extrapolated material test data. For correctly manufactured and installed systems, the actual life cannot be predicted, but can reasonably be expected to be in excess of 100 years before major rehabilitation is required. Polyethylene pipe and fittings life expectancy can vary with the quality of installation workmanship, system operating conditions, operating environment and other site specific factors.
The appraisal concludes that:
The PLASSON range of electrofusion fittings are ‘fit for purpose’ and suitable for
use in water supply and sewer gravity, pressure and vacuum systems.
The PLASSON range of electrofusion fittings are suitable for use with PE pipe
conforming to AS/NZS 4130.
The ApprovalMark ISO Type 5 Certification for the PLASSON range of electrofusion
fittings has been addressed to the satisfaction of WSAA.
WSAA Product Appraisal PA 1604 6
COPYRIGHT
1.1 Recommendations
It is recommended that WSAA members, subject to any specific requirements of the member,
accept or authorise the PLASSON range of electrofusion fittings as detailed in this report for
use in pressure applications including water supply, recycled water and sewerage pressure
applications provided pipeline design and installation is in accordance with relevant
conditions relating to the design, installation and acceptance testing, AS/NZS 4129:2008,
the relevant WSAA Code and the manufacturer’s requirements.
2 THE APPLICANT
Plasson Australia Pty Ltd, a wholly owned subsidiary of Plasson Limited, provides technical, marketing and sales support to the Plasson distributors throughout Australia and the Pacific region.
Plasson Ltd provides a comprehensive polyethylene pipe joining system for sizes 16 to 800 mm. Mechanical and electrofusion (heat welded) fittings and equipment systems are available. Plasson fittings and polyethylene pipe are used for fluids transmission in:
Water supply Drainage Rural and irrigation water systems Mining Communications Chemical and natural gas industries.
Plasson jointing systems have been supplied continuously throughout Australia since 1978 and Plasson products are generally well regarded by the Australian water industry as high quality and dependable products.
For more information see the Plasson website at www.plasson.com.au.
2.1 The Supplier and Manufacturer
PLASSON LTD (ISRAEL) provides a wide range of solutions for connecting PE pipe. Plasson's products can be found in municipal water distribution, gas conveyance, industrial fluids transfer and wastewater systems and mines in over 80 countries around the world. Plasson began in 1964, with a group of agriculturists modernizing to enhance labour methods. They used knowledge and experience to produce advanced agricultural equipment by injection molding. They progressed to develop a range of plastic fittings for plastic pipes. These fittings are now used in industry, municipal water systems, gas conveyance systems and mines throughout the world.
Today, Plasson is an international company with over 1,200 highly skilled employees worldwide and wholly owned subsidiaries in Israel, Italy, France, Spain, UK, Germany, Poland, USA, Brazil, India, and Australia. The Plasson Group now operates more than 160 molding/extrusion machines producing over 8,000 products. Plasson has been publicly traded in the Tel Aviv Stock Exchange, since 1997. Plasson has grown, innovated and built up a world-wide network of distributors.
3 THE PRODUCT
The PLASSON nominated range of electrofusion fittings are manufactured from PE 100 material, in SDR 11 rated PN 16 in various sizes (product depending).
The PLASSON nominated range of electrofusion fittings are suitable for use with polyethylene (PE) pipes manufactured in accordance with AS/NZS 4130 Polyethylene (PE) pipes for pressure applications for the conveyance of drinking water, recycled water, and sewage in buried and above ground pressure applications.
The PLASSON nominated range of electrofusion fittings are listed as ISO Type 5 product certified by ApprovalMark Certification No. 02018 for compliance with AS/NZS 4129:2008 Fittings for polyethylene (PE) pipes for pressure applications.
The PLASSON appraised range of electrofusion fittings are manufactured from INEOS ELTEX TUB 121 N6000 PE 100 material as listed by PIPA’s POP004A list.
PLASSON Adjustable elbows: used to provide a stress free electrofusion installation
(PIPA requirement) when pipes are slightly misaligned in a trench. The fittings are
available as single sided or double sided and can adjust 12º per side (up to 24º for the
two sided elbow) in any direction. Once fused, it becomes a fixed joint.
The sizes include DN 90, 110, 125, 160, 180, 200, 225 & 250.
Plasson also provide an electrofusion Flex Restraint (Product Code 49009999) used to restrain thrust and can replace traditional more expensive methods. Each unit restrains 3100 kg of axial force and multiple units can be used around the pipe surface to multiply the amount of thrust which can be restrained. This product is not included in the appraisal due to its unique design and no particular standard to enable product certification to be achieved. Information about this product is available at the Plasson website www.plasson.com.
The Plasson electrofusion control boxes and other electrofusion tooling are not included in this appraisal. For more information refer to Plasson or the Plasson website www.plasson.com.
The Schedule of appraised products is shown in Appendix A as included in the Schedule for Certificate No. AMI 02018.
4 SCOPE OF THE APPRAISAL
The scope of the appraisal applies to the range of electrofusion fittings described in Section 3 above and as listed Product Schedule is shown in Appendix A.
The Schedule to ApprovalMark Certification Licence No. 02018 includes the appraised products and provides product listing including model identification, model name and product description including size.
5 APPRAISAL CRITERIA
5.1 Quality Assurance Requirements
The WSAA Product Appraisal Technical Advisory Group accepts polyethylene electrofusion
fittings suitable for pressure applications manufactured in compliance with AS/NZS
4129:2008 Fittings for polyethylene (PE) pipes for pressure applications and duly certified
by means of an ISO Type 5 product certification scheme undertaken by a JAS-ANZ
accredited Conformity Assessment Body (CAB) or by an international accreditation system
recognised by JAS-ANZ.
The manufacturer is generally expected to have a production management and control
system that has been duly accredited in accordance with AS/NZS ISO 9001 as a prerequisite
to undergoing a product certification audit.
5.2 Performance Requirements
The PLASSON electrofusion fittings have been appraised for compliance with AS/NZS 4129:2008 Fittings for polyethylene (PE) pipes for pressure applications.
Appraisal criteria is also determined by the WSAA Product Appraisal Technical Advisory Group and regularly reviewed to ensure that the criteria reflect the requirements of WSAA members.
The following Product Specifications are also relevant to this application.
WSA PS–207 Polyethylene (PE) Pipe for Pressure Applications - Water Supply and Sewerage
WSA PS–208 Polyethylene (PE) Moulded Pressure Fittings for Pressure Applications - Water Supply and Sewerage
Copies of the above Product Specifications can be found in Appendix C or downloaded from
the WSAA website.
6 COMPLIANCE WITH APPRAISAL CRITERIA
6.1 Compliance with Quality Assurance Requirements
PLASSON LTD (ISRAEL) has a Quality Management System complying with SI ISO 9001:2008 Certified by The Standards Institution of Israel Licence No 55311 for ‘Manufacture of Injection Moulded Plastic Products’. This certificate was originally issued on 5 May 1993 and is currently valid until 4 January 2018.
PLASSON LTD (ISRAEL) has been issued with Certificate of Conformity No AMI 02018 by
ApprovalMark International for electrofusion fittings complying with AS/NZS 4129:2008 -
Fittings for polyethylene (PE) pipes for pressure applications. This certificate was originally
issued on 5 March 2015 and is currently valid until 5 March 2020. The Schedule to this
Licence contains the products listed in Section 3 above.
Plasson has submitted an ApprovalMark International (AMI) initial Factory Audit Report of the Plasson factory at Menashe Israel dated 20 April 2015 relating to products complying with AS/NZS 4129:2008. There were some minor criticisms noted but no Corrective actions or Recommendations recorded.
Refer to Appendix B for copies of the certificates.
6.2 Compliance with Performance Requirements
6.2.1 Effect on water
Ref: AS/NZS 4129:2008 Clause 1.12
Plasson Australia has referred to PIPA Industry Guidelines POP004A Issue 1.7 dated 10 May 2016 - Supplementary list – Materials specific to electrofusion and moulded fittings noting INEOS Polyolefins, Lillo, Belguim ELTEX TUB 121 N6000 was certified for compliance with AS/NZS 4020 in August 2015.
Plasson Ltd Hydraulic Laboratory has Accreditation Certificate No. 292 demonstrating accreditation to ISO/IEC 17025:2005 in accordance with the requirements of ISO/IEC 17011:2004.
WSAA Product Appraisal PA 1604 9
COPYRIGHT
6.3.1 PLASSON Adjustable elbows
Plasson has provided Inspection Certificate Report Number: QAIC120012016 dated 20 January 2016 for product Electrofusion Adjustable Elbow one sided / two sided pressure rating PN 16 SDR 11.
The products tested were one sided and two sided in sizes DN 90, 110, 125, 160, 180, 200, 225, & 250.
The tests included:
AS/NZS 4129:2008 Clause 1.11
AS/NZS 4129:2008 Clause 1.15
EN 1555-3:2010 Clause 5.2 (Colour)
AS/NZS 4129:2008 Table 3.1
EN 1555-3:2010 Clause 5.5 (Electrical characteristics)
The report demonstrated compliance with all the above tests.
The report concluded: This is to certify that to the best of our understanding and belief the above tests have been performed according to the requirements of the Australian standard AS/NZS 4129:2008 and the European Standard EN 1555-3:2010.
6.3.2 PLASSON Tapping Saddles
Plasson has provided five (5) Inspection Certificates with Report Numbers / sizes:
All reports are dated 5 January 2016 for Electrofusion Tapping Saddle pressure rating PN 16 SDR 11. Plasson Ltd Hydraulic Laboratory has Accreditation Certificate No. 292 demonstrating accreditation to ISO/IEC 17025:2005 in accordance with the requirements of ISO/IEC 17011:2004.
The tests included:
AS/NZS 4129:2008 Clause 1.11
AS/NZS 4129:2008 Clause 1.15
EN 1555-3:2010 Clause 5.2 (Colour)
AS/NZS 4129:2008 Table 3.1
EN 1555-3:2010 Clause 5.5 (Electrical characteristics)
The report demonstrated compliance with all the above tests.
WSAA Product Appraisal PA 1604 10
COPYRIGHT
The report concluded: This is to certify that to the best of our understanding and belief the above tests have been performed according to the requirements of the Australian standard AS/NZS 4129:2008 and the European Standard EN 1555-3:2010.
6.3.3 PLASSON Large Bore Saddles
Plasson has provided four (4) Inspection Certificates with Report Numbers / sizes:
All reports are dated 13 December 2015 for Electrofusion Branch Saddle pressure rating PN 16 SDR 11. The Plasson Inspection Certificate states the testing is in accordance with BS EN 10204-3.1.
The report demonstrated compliance with all the above tests.
The report concluded: This is to certify that to the best of our understanding and belief the above tests have been performed according to the requirements of the Australian standard AS/NZS 4129:2008.
Note: Reference to AS/NZS 4129:2008 Clause 3.4.2.2.2 and further reference to Clause 3.5.2 and Table 3.4 has been considered and deemed unnecessary testing as the appraised fittings are manufactured from PE100 material and therefore compatible with PE100 pipe that is now in common use.
7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION
7.1 Product Use:
Plasson has provided the following general information:
Tapping Saddles are typically used to make meter connections to polyethylene lines. A cutting mechanism is used with a wrench to cut a hole in the polyethylene pipe. A spigot outlet is used with a compression or electrofusion fitting to make the connection to the meter.
Large Bore Saddles are used to save time and cost of installation on large polyethylene
lines typically DN 250 and above.
The large bore saddle is significantly easier and faster to install than an equal or reducing
spigot tee which is the product it typically replaces.
Adjustable elbows are used to provide a stress free electrofusion installation (PIPA requirement) when pipes are slightly misaligned in a trench. The fitting can adjust 12 0 per side (up to 240 for the two sided elbow) in any direction. Once fused, it becomes a fixed joint.
The Flex restraint (not appraised) is used to restrain thrust and can replace traditional more expensive methods. Each unit restrains 3100 kg of axial force and multiple units can be used around the pipe surface to multiply the amount of thrust which can be restrained.
WSAA Product Appraisal PA 1604 11
COPYRIGHT
7.2 Product Installation
No special tools are needed when using tapping saddles. Bolts are done up with a wrench and the electrofusion process is conducted as normal.
No special tools are needed when using adjustable elbows. The electrofusion process is conducted as normal.
A set of tools is required to install a large bore saddle including a clamp and ratchet set to enable the electrofusion process and a drill and core cutter to cut out the coupon. All are readily available from Plasson Australia.
A set of straps are needed to install the Flex Restraint. Readily available from Plasson Australia.
The following videos of installation are available at the below link and have been included with the appraisal submission;
Schematic installation video – Tapping saddles
Schematic installation video – Large Tapping saddles
Schematic installation video – Adjustable elbow
http://plasson.com/content/page/Video-Library
7.2.1 Product Repair
Repair is not possible with these products.
The Large Bore Saddle has an inbuilt test spigot to enable testing of the welding prior to the removal of the coupon.
7.2.2 Product Training
For Large Bore Saddles and Flex Restraints, it is suggested that Plasson Australia aid with the installation of the product for new contractors and provide training.
No special training is required for tapping saddles or adjustable elbows.
Plasson has provided the following extensive PDF fitting instructions available in Appendix D:
Product description – Saddles for large diameter PE pipes.
Installation instructions - Saddles for large diameter PE pipes.
Product description – Adjustable elbow.
For further product information, PE pipeline design and other installation instructions review the Plasson web site at www.plasson.com.au.
For specification for PE pressure pipelines and PE gravity pipelines refer to the WSAA Polyethylene Pipeline Code - WSA 01 available at the WSAA Codeshop www.wsaa.asn.au or AS/NZS 2033:2008 Installation of polyethylene pipe systems.
Electrofusion welding and butt fusion may be used for joining pipe-to-pipe or fitting to-pipe. All welding shall be performed by welders who have successfully completed training by a Registered Training Organisation, endorsed by the Plastics Industry Pipe Association for the relevant welding method(s).
The Plastics Industry Pipe Association (PIPA) provides technical guidelines for electrofusion welding in the following documents.
POP001 Electrofusion Jointing of Pipe and fittings for Pressure Applications and
POP003 Butt Fusion Jointing of PE Pipes and Fittings – Recommended Parameters.
POP001 contains recommendations for equipment required, for jointing, maintenance, servicing and calibration procedures, records to be kept and the training program to be respected to produce good fusion joints in polyethylene pipes.
POP003 is a guide to the butt fusion of polyethylene pipe using AS/NZS 4130 material as a basis, recommending the butt fusion procedures and parameters as specified in ISO 21307.
Copies of these documents can be downloaded from the PIPA website http://www.pipa.com.au.
7.2.3 Product Availability
All products are readily available through Plasson’s regular national distribution
8 PRODUCT MARKING
Products are marked in accordance with Clause 1.15 of AS/NZS 4129:2008 “Fittings for polyethylene (PE) pipes for pressure applications”. Products are marked with the following information:
These markings are provided on the body of the fitting –
Manufacturer’s name;
Nominal size;
Pressure class;
Material type;
Date or batch code;
Standard number;
Certification Mark
Bar code for fusion
FIGURE 1 PRODUCT MARKING WITH BAR CODE
These markings are provided on the packaging – Plasson boxed fittings packaging is labelled with the following information:
Manufacturer’s name (PLASSON);
Fitting name and diagram
Date, batch code and bar code;
Nominal size (450-710X160)
The number of fittings in the box The bar code can reveal more complete information.
All Plasson moulded PE electrofusion fittings are supplied individually in sealed plastic bags and packed in cardboard cartons to protect the fittings during transport and handling.
Fittings should be stored in a cool, dry area, out of direct sunlight and transported in their cardboard cartons.
Steps should be taken to prevent:
• damage to the sealed plastic bags;
• large temperature fluctuations which may result in the build-up of moisture within the bags;
and
• prolonged exposure to sunlight which may result in degradation of the plastic bags.
10 PRODUCT WARRANTY
The products are covered by the normal commercial and legal requirements of the
Competition and Consumer Act 2010 (Cth), which covers manufacture to the relevant
standard, and details of Plasson warranty is included in their terms and conditions of sale.
11 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING
REPORT
Plasson has provided the following and contact details can be provided by Plasson on request.
SADDLES
APLNG: 1000 successful installations for gas and water applications
SA Water: Marion Road Trunk Main Renewal 45x 110x450-800 saddles installed on DN560 main
Yarra Valley Water: Highlands Stage 153 – Newbury Bvd, Craigieburn. 1 x saddle for live tapping.
Shoalhaven Water: Matron Porter Drive, Mollymook. 2 x saddles. North Bendalong. 3 x Saddles
Aroona Project (Qld) DN710 Rising main. 6x saddles for air valves
WSAA Product Appraisal PA 1604 14
COPYRIGHT
QGC(Qld): DN 450 Main. 6 x saddles for air valves Legacy Way Tunnel (Brisbane) 10 x saddles on DN 250 mains for air vents.
TAPPING SADDLES
Used extensively in mechanical versions by Sydney Water as an approved product.
ADJUSTABLE ELBOW
No known approvals – Future Work requirement, see Clause 15 below.
FLEX RESTRAINT
Approved by SA Water. Product not appraised.
12 DISCUSSION
The PLASSON nominated range of electrofusion fittings provide connection to PE pipelines
using Electrofusion jointing which offers a permanently sealed and jointed system provided
the electrofusion process is carried out correctly. The electrofusion jointed PE pipeline has
the potential to have life expectancy equal to and in some cases well beyond other pipeline
materials and jointing systems. The PE material is corrosion resistant and correctly made
joints are permanently fused to provide a high level of joint integrity against leakage and/or
infiltration over the long-term. Similar to other plastic pipe systems, PE is susceptible to
fatigue from cyclic pressure changes and additional design considerations must be made if
used in a pumped pipeline. Refer to WSAA Technical Note TN4, plus design material
available from Plasson.
PE pipelines are susceptible to permeation of specific organic chemicals (as are other
pipeline systems) and care must be exercised if designing for installation in contaminated
ground and/or brownfield sites. Seek further advice from Plasson regarding such
installations.
The appraisal concludes that:
• The PLASSON nominated range of electrofusion fittings are ‘fit for purpose’ and
suitable for use in water supply and sewer gravity, pressure and vacuum systems.
• The PLASSON nominated range of electrofusion fittings are suitable for use with PE
pipe conforming to AS/NZS 4130.
• The ISO Type 5 product certification for the PLASSON nominated range of
electrofusion fittings has been addressed to the satisfaction of WSAA Appraisal
Network
13 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW
There are no issues to address.
14 LIFE EXPECTANCY
The PLASSON range of electrofusion fittings are designed on the basis of 50 year extrapolated material test data. For correctly manufactured and installed systems, the actual life cannot be predicted, but can reasonably be expected to be in excess of 100 years before major rehabilitation is required. Polyethylene pipe and fittings life expectancy can vary with the quality of installation workmanship, system operating conditions, operating environment and other site specific factors.
15 FUTURE WORKS
Plasson is required to provide a report prepared or signed by a representative of a WSAA
member water agency to demonstrate the successful installation of an Adjustable Elbow(s)
complete with photo record of the installation. This report should be submitted to Carl
Radford, Program Manager Asset Creation at [email protected] before 1 July 2017.