FRIATEC FRIALEN User manual

FRIALEN
®-Large Pipe Technique
for laying large pipes
and relining pipe networks
Fitting Instructions
FRIALEN
®
Large Pipe Technique
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2
1. Safety 3
2. Areas of Application 3
3. Standard publications and specifications for use 4
4. Couplers from d 250 mm 6
5. Saddle parts - Top Loading 16
6. Pipeline relining 26
7. Update of these assembly instructions 30
For further information on the processing of FRIALEN®Safety Fittings,
please contact:
FRIATEC Aktiengesellschaft
Technical Plastics Division
P.O.B. 710261 · D-68222 Mannheim
Phone [phone]
Fax [phone]
Internet: www.frialen.com
Email: [email protected]
Hotline [phone]
Contents Page
FRIALEN®Safety Fittings:
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1. Safety
1.1 Safety advice and tips
The following warning symbols are used in these assembly instructions:
DANGER!
Describes impending danger!
Non-observance of this warning may lead to serious damages to health and
objects.
WARNING!
Describes a dangerous situation!
Non-observance of this warning may cause minor injuries or damage to
objects.
IMPORTANT!
Describes advice and other useful information!
2. Areas of Application
FRIALEN®Safety Fittings are used for weld joints at pressure pipes made
of polyethylene in the dimensions SDR 17.6 to SDR 11 for use in gas and
water supply, pressure drainage, industry and landfill construction.
For processing of pipes SDR > 17.6, please call us.
When operating with other media than water and natural gas, please contact
our application engineering department.
IMPORTANT!
The information and processing instructions mentioned on the fitting or
enclosed shall apply predominantly.
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3. Standard publications and specifications for use
For detailed and up-to-date information on FRIALEN®Safety Fittings, please
see the technical datasheets available on the Internet (www.frialen.com).
Please observe the guidelines of the DVGW standard publications, and of the
DVS, BGR 500 (VBG 50), EN 1555, EN 12201, EN 13244, UVV and
respectively national regulations.
DANGER!
The described sequence of the processes is absolutely to be adhered to.
FRIALEN®Safety Fittings can be used with pipes made of PE 100,
PE 80, PE 63, PE 50 according to DIN 8074/75, EN 1555-2, EN 12201-2,
EN 13244-2, ISO 4437 and ISO 4427.
For PE pipes, a fusion flow rate MFR 190/5 in the range of 0.2 – 1.7g/10 min.
applies.
We recommend using pipes with a limited dimension tolerance range,
tolerance class B.
FRIALEN®Safety Fittings consist of PE 100 and meet the requirements
according to DIN 16963-5, -7, EN 1555-3, EN 12201-3, EN 13244-3,
ISO 8085-3 as well as the DVGW test bases. FRIALEN®Safety Fittings can
be fused with FRIAMAT®Electrofusion Units at ambient temperatures
between - 10 °C and + 45 °C. Fittings from d 710 between 0 °C and + 45 °C.
For material transition joints, the material- or system-specific standards and
installation guidelines apply in addition.
WARNING!
Fusion with other pipe materials such as e.g. PP, PVC etc. is not
possible.
WARNING!
Pipes and moulded components should have settled to a balanced
temperature level between - 10 °C and + 45 °C (Couplers UB d 710 between
0 °C and + 45 °C) when being processed.
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IMPORTANT!
FRIALEN®Safety Fittings are identified by a batch marking.
This reads from left to right:
• Production week (KW) (stamp 1+2)
• Production year (stamp 2)
• Material identification letter (stamp 3)
Example:
0
5
0
4
0
3
0
2
0
1
0
0
9
7
6
5
4
3
2
1
1
0
8
J
I
H
G
F
E
D
C
B
A
M
L
K
KW 14/01/E
The FRIALEN®Safety Fittings can be stored and processed for a long time,
provided the general storage specifications are adhered to. When properly
stored (in closed rooms or containers (boxes)) and/or not exposed to UV
radiation as well as effects of weather (humidity etc.), a storage and
processing period of more than 4 years can be assumed.
WARNING!
Improperly stored component parts may not be processed because
this may result in leaking fusion joints.
Traceability
An automatic component traceability is possible when using e.g. traceability-
capable FRIAMAT®Electrofusion Units with a special barcode (see Figure 9)
which contains the specific data of the fitting, e.g. manufacturer, dimension,
material, batch. These data on component traceability can be electronically
archived together with the fusion process data.
IMPORTANT!
Manual electrofusion units (without barcode reader), e.g. FWS 225, are
no longer state-of-the art. Processing of FRIALEN®Safety Fittings with
these units is thus no longer possible.
3.1 Pressure load-bearing capability
The pressure load-bearing capability of FRIALEN®Safety Fittings made of
PE 100 is expressed in SDR stages.
SDR = pipe outer diameter d
pipe wall thickness s
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The design factor C (calculation coefficient for PE components) depends on
the area of application and the specifications (min. 1.25).
The parts are identified and usable with regard to their load-bearing
capability according to the above table.
DANGER !
Fusion with escaping media is not permissible.
4. Couplers from d 250 mm
4.1 Cutting to length of pipes
Cut off the pipe in a right angle
to the pipe axis (see Figure 1). A
suitable tool is a PE pipe cutter or a
saw with toothing suitable for
plastics.
Distinctive conical oblique pipeends
must be cut off, if necessary.
DANGER!
A non-rectangular pipe cutting
may cause the heating coil
partially not being covered by the
pipe which may result in
overheating, uncontrolled melt
formation or self-ignition (see
Figure 2).
Figure 1
Figure 2
Fitting material: PE 100 Water Gas
(FRIALEN®standard)
SDR Stage maximum operating pressure maximum operating pressure
in bar for new: C = 1.25 in bar for new: C = 2
17 10 5
11 16 10
7.4 25 -
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4.2 Measure fusion zone, mark
with a FRIALEN®marker
and remove oxide layer
Fusion zone:
The length of the fusion zone
corresponds to half the length of the
coupler.
At first, remove contaminations from
the pipe. A processing allowance of
approx. + 5 mm in addition of the
insertion depth provides proof after
fusion that the oxide layer has been
removed properly. Using a manual
scraper or FRIALEN®Scraper tools
(see Figure 4 a+b+c), the oxide layer,
which formed during on the surface
of HDPE pipes and spigot fittings
during storage, has to be removed
completely directly before the
assembly.
IMPORTANT!
The Scraper tool FWSG 710 S and
FWSG 710 L have proved them-
selves for a long time in use
application and serve for the
scraping of pipes in the dimension
area d 250 to d 710.
Besides, the FWSG 710 S scrapes
only half a sleeve length, so that it
is possible to scrape spigot
fittings. With the FWSG 710 L the
whole sleeve length is scraped to
make easier the assembly as a
slide-over coupler.
The scraper tools FWSG SE 250,
280 and 315 are proper for both,
preparation of couplers-, and
saddle assembly.
Figure 3
Figure 4b
Figure 4a
Figure 4c
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Scraper Tool Estimated swarf thickness (mm) Abrasion limit (mm)
FWSG 225 0.25 - 0.35 0.4
FWSG 710 0.30 - 0.40 0.5
FWSG SE 250 - 315 0.25 - 0.35 0.4
WARNING!
If the oxide layer is not removed completely, inhomogeneous, leaking
fusion joints may result.
WARNING!
The FWSG 710 scraper tool must in all circumstances be used for fittings
from d 710.
A one-time, complete removal is sufficient (min. 0.15 mm).
Damages to the pipe surface as e.g. axial grooves or scratches may not be
located within the fusion zone.
WARNING!
An excessive swarf removal may result in an excessively large annular
gap which either cannot or only insufficiently closed by fusion (for the
remedy see item 4.8).
Please thus regularly check the condition of the blade at the manual
scraper and the wear of the scraper blade at the scraper tool. Worn blades
must be replaced (see FRIALEN®Info No. 1).
Please note that the indicated wearing margin applies to FRIALEN®
Safety Fittings. Where appropriate please observe manufacturers’
indications.
Filing or sanding are not permitted because contaminations are
introduced.
For a control of the complete surface removal over the entire surface, we
recommend to apply marking (control) lines (see Figure 3). If during scraping of
the surface non-scraped areas occur at some points (e.g. in case of oval pipes),
these areas are to be reworked.
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The processed zone is to be protected against dirt, soap, grease, subsequently
flowing water and unfavourable effects of weather (e.g. moisture, frost formation).
Do not touch the fusion zone again after scraping.
WARNING!
FRIALEN®Safety Fittings with integrated heating coils guarantee optimal
heat transfer through their exposed heating coils and may thus not be
scraped at the inside of the fitting.
4.3 External and internal
chamfering of the cutting
edge (See Figure 5)
For this purpose, the manual scraper
is a suitable tool. A good chamfer on
the outside diameter of the face of
the pipe will make it easier to fit the
coupler. Remove swarves from
within the pipe.
4.4 Restoration of irregular /
oval pipes
Pipes, in particular bundled coils and
drums, may loose their roundness
during storage. If the pipe out-of-
roundness in the fusion zone area
exceeds 1.5% of d (outer diameter)
or is > 3.0 mm, these pipes must
be rounded in the fusion zone
area. Please use rounding clamps
for this purpose which are installed
at the end of the fusion zone (See
Figure 6).
WARNING!
For the installation of of fittings from d 710 rounding clamps for the
pipes need to be applied in all circumstances.
With UB couplers d 280 to d 450 the pipe may be adjusted to the coupler
following evaluation of the annular gap (> 1 mm) by using the pre-heating
barcode.
Figure 5
Figure 6
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WARNING!
The pre-heating barcode must be applied when using fittings from d 500.
4.5 Cleaning
The surfaces of the pipes to be fused
and the interior surfaces of the
FRIALEN®Safety Fittings must be
absolutely clean, dry and free from
any grease. These areas are to be
cleaned with a suitable cleaning
agent and exclusively with ab-
sorbent, lint-free and non-dyed
paper directly before the assembly
and after scraping (see Figure 7).
We recommend PE cleaning agents which meet the requirements of the test
basis DVGW-VP 603, e.g. AHK cleaning agents.
When cleaning, ensure that no contaminations from the unscraped pipe
surface are introduced into the fusion zone.
WARNING!
When using alcoholic cleaning agents, the alcohol percentage must be
at least 99.8% according to DVGW-VP 603.
The cleaning agent must be completely evaporated before starting the
fusion process.
Now, using the FRIALEN®marker, re-mark the line (approx. 120 °distri-
buted around the circumference) to show the width of the fusion zone on the
pipe since this will have been removed by scraping and cleaning.
The joint surfaces must be clean and dry before installing the fitting. The
cleaned fusion zone should not be touched with bare hands. Moisture in the
area of the joint area, e.g. because of dew or frost, is to be removed using
suitable aids.
The fusion fitting is to be removed from the packaging only directly before
the planned processing. The packaging protects the fittings against external
influences during transport and storage.
Figure 7
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4.6 Inserting push fit ends or pipe ends into the fitting.
When the FRIALEN®Safety Fittings and pipes are being assembled care
should be taken to ensure that the contact sockets are accessible to allow
connection of the fusion plug. Assembly can be assisted by tapping around the
face with a plastic hammer at the same time. When assembling do not tilt.
The worked insertion end must be pushed into the fitting up to the mark. If
necessary hydraulic rounding clamps should be used (see Figure 6).
Repeated scraping of the outer diameter might be necessary if the tolerance
is big. Repeated scraping may not be performed to remedy installation
problems due to out-of-roundness!
If the fitting cannot be slipped on without using force despite the above
described procedure, a repeated scraping is permitted. (see item 4.4).
A simple control of the high points is possible by installing the coupler and
evaluating the annular gap.
4.7 Ensuring a tension-free assembly of the components
All joints prepared for fusion must be tension-free. Pipes may not be positioned
in the FRIALEN®Safety Fitting under bending stress or self-load. After the
installation on the pipe ends, it must still be possible to move the couplers by
hand.
If required, the piping or the fitting is to be supported or suitable fixing
facilities are to be used. The tension-free fixing of the joint is to be maintained
until the cooling time stated on the barcode and in the table is reached. (see
item 4.9).
Before starting the fusion process, check again based on the markings
whether the position of the pipe insertion end in the FRIALEN®Safety Fitting
has shifted (correct, if required).
WARNING!
A non-tension-free or shifted joint
may result in an impermissible melt
flow and a defective joint during
fusion (see Figure 8).
Figure 8
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4.8 Pre-heating for reducing the annular gap between coupler and
pipe.
WARNING!
Only use fusion units which have been approved by the manufacturer
with regard to their function for the processing of FRIALEN®Safety
Fittings. See DVS 2207-1.
Use FRIAMAT®fusion units only for FRIALEN®UB d 710!
Preheating barcode (see also instruction leaflet enclosed with the
component part)
The ring gap between the coupler and the pipe can be compensated for
to a certain extent by using a specifically matched preheating barcode
(Figure 9). The maximum bridgeable distance between the coupler and the
pipe may not exceed 3 mm across the entire circumference. For the coupler
mounted and centred at the pipe,
this means: Δd ≤6 mm.
For relining slide-over couplers REM
d110/DN100 and d160/DN150, a
maximum gap of 2 mm applies. The
thermal reduction of tensions in the
joining area has also a positive
effect on the fusion result.
Procedure:
1. Preparation of the joining area corresponding to the FRIALEN®installation
instructions for large pipes and pipe network relining.
2. Centre the coupler on the pipe such that the ring gap across the
circumference is as equal as possible. If required, support the coupler.
3. Close the ring gap with adhesive tape to prevent heat losses.
4. Close open pipe ends (chimney effect).
5. Standard processing:
I. Preheating of first coupler side, record yellow barcode with FRIAMAT®
electrofusion unit and start the process; then
II. preheating of second coupler side, record yellow barcode with
FRIAMAT®electrofusion unit and start the process; then
III. first coupler side: check the ring gap: if it is still too large, the
preheating can be repeated 2 x maximum. If ok: Start fusion of first
coupler side, (white barcode), then
IV. second coupler side: check the ring gap: if it is still too large, the
preheating can be repeated 2 x maximum. If ok: Start fusion of
second coupler side, (white barcode)
Figure 9
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WARNING!
Between preheating and fusion, a waiting time is always required to
ensure heating through of the component parts. This waiting time
corresponds approximately to the preheating or fusion time, depending
on the dimension approx. 15-30 minutes. If only one coupler side is to
be processed, the waiting time between preheating and fusion is to be
observed.
If the waiting time is exceeded by more than the double time, the
described process is to be repeated.
4.9 Carrying out the fusion
WARNING!
Only use fusion units which have
been approved by the manufac-
turer with regard to their function
for the processing of FRIALEN®
Safety Fittings. See DVS 2207-1.
Use FRIAMAT®fusion units only
for FRIALEN®UB d 710!
For the fusion of the coupler d 800
please observe our FRIALEN®Info
No. 42.
The fusion parameters are contained in the main barcode affixed to the
FRIALEN®Safety Fitting. When using fully automatic fusion units (e.g.
FRIAMAT®), the parameters are entered into the fusion unit using the reader.
After reading of the barcode (see Figure 9a), the fitting data are to be
compared with the data shown on the unit’s display.
The subordinated barcode contains the data for component traceability (see
information). This barcode is only to be read if the component traceability
function is to be used. This requires suitable fusion units.
The fusable pipe series are listed in the SDR labelling on the label.
The fusion units automatically monitor the fusion process and control the
supplied energy in determined limits.
Figure 9a
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Information:
The fusion parameters are encoded on the barcode label in the form
of a 24-digit figure (top), the data for component traceability in the
form of a 26-digit column of numbers (bottom), and can also be
entered manually into the FRIAMAT®fusion unit using the emergency
entry mode.
Information:
Fusion units FRIAMAT®L and
FRIAMAT®LE are not suitable for
the fusion of large couplers.
For fittings with separate coils (see
Figure 10), each fitting side is to be
fused separately.
For fittings with continuous coil, both
fitting sides are to be fused simulta-
neously (see Figure 11).
FRIALEN®Safety Fittings are equipp-
ed with a swell indicator, this only
gives an indication that fusion has
taken place. This swell indicator
signalises the fusion process, by
changing its colour (red) and by
increase of volume. The proper
progress of the fusion process,
however, is only shown by the
fusion unit.
After reading of the barcode, the
fitting data are to be compared with
the data shown on the unit’s display.
If they are identical, start fusion.
Please observe the operating in-
struction of the FRIAMAT®fusion
unit.
Avoid stress on the connecting spot.
Figure 10
Figure 11
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WARNING!
Keep a distance of one meter to the fusion site during the fusion
process for general safety reasons.
The obtained actual fusion time is
to be compared with the target
fusion time on the unit and to be
noted on the pipe or the FRIALEN®
Safety Fitting (See Figure 12).
With this identification it is ensured
that no fusion point is overlooked.
In case of doubt, a fusion can be
repeated. But the joint surfaces
must be cooled down to ambient
temperature before each renewed fusion. Please contact for this purpose
your local FRIALEN®sales engineer by phone or the FRIALEN®Hotline.
4.10 Cooling times.
The cooling time is
a) the time which is required to cool down the component to the temperature
which facilitates the movement of the joint. This time is also listed on the
barcode and is identified by CT.
b) the time which is required to cool down the component to the temperature
which facilitates the application of the full test or operating pressure. This is
classified into pressure volumes of up to 8 bar and > 8 bar.
WARNING!
When inserting piping (e.g. relining) it is the cooling time before pres-
surising which is important.
Figure 12
Diameter Cooling time in minutes for FRIALEN®
in mm couplers and fittings
CT Up to pressurising Up to pressurising
until the joint at up to 8 bar at > 8 bar
may be moved
250 – 355 30 75 100
400 – 710 40 95 120
800 90 200 240
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Information:
A piping may only be commissioned after successful pressure test (see
EN 805, EN 12007 and DVGW G 469, W 400). The guidelines of the
DVGW leaflets for pressure tests, the European standards or the
country-specific regulations are to be observed.
Information:
The detachment of the outer armouring wire during the cooling down
stage is caused by the thermal expansion characteristics of the fused
joint and does not present a problem.
5. Saddle parts - Top Loading
FRIALEN®TL saddle parts are used with pipes from SDR 17 to SDR 11
from d 250 mm. The processing occurs with the FRIATOP Clamping Unit
(Figure 15b).
5.1 DAA-TL Pressure Tapping Tees - Top Loading, d 250 - 315 (400)
FRIALEN®DAA-TL Pressure Tapping Tees Top-Loading are suitable for
fitting as branch connectors onto unpressurised or pressurised pipelines.
WARNING!
FRIALEN®pressure tapping valves
≥d 355 mm may be processed
using only SDR 17 and SDR 17,6
pipes due to tapping technique.
Processing temperature: between
0 °C and 45 °C.
Figure 13
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5.1.1 Measuring of fusion zone of
the pipes (and the lateral
outlet spigot), marking and
removing oxide layer
The fusion zone: is the area of pipe
covered by the saddle; for a side outlet
it is the insertion depth on the smooth
pipe spigot. The oxide layer in the
area of the fusion zone, which has
formed on the surface of the HDPE
pipes during storage, must be totally
removed with a hand scraper or a
scraper tool (e.g. FWSG SE) imme-
diately beforeassembly (See Figure
14).
A processing allowance of several
millimetres in addition to the covered
area provides proof after fusion that
the oxide layer has been properly
removed from the pipe.
WARNING!
If the oxide layer is not removed
completely, leaking fusion joints
may result.
Worn blades of the scraper tool and manual scraper must be replaced.
A one-time, complete removal is sufficient (min. 0.15 mm). A uniform surface
without flattening and material grates at the pipe diameter should be the
result.
WARNING!
Filing or sanding of the pipe is not permitted because contaminations
are introduced.
Figure 14
Figure 14 a
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For a control of the complete surface removal over the entire surface, we
recommend to apply marking (control) lines (see Figure 13). If during scraping
of the surface non-scraped areas occur at some points, these areas are to
be reworked.
The processed zone is to be protected against dirt, soap, grease,
subsequently flowing water and unfavourable effects of weather (e.g.
moisture, frost formation).
5.1.2 Cleaning
The surfaces of the pipes to be fused and the interior surfaces of the
FRIALEN®DAA-TL Pressure Tapping Tees Top-Loading must be
absolutely clean, dry and free from any grease. These areas are to be
cleaned with a suitable cleaning agent and exclusively with absorbent,
lint-free and non-dyed paper directly before the assembly and after
scraping.
We recommend PE cleaning agents which meet the requirements of the test
basis DVGW-VP 603, e.g. AHK cleaning agents.
When cleaning, ensure that no contaminations from the unscraped pipe
surface are introduced into the fusion zone.
WARNING!
When using alcoholic cleaning agents, the alcohol percentage must be
at least 99.8% according to DVGW-VP 603.
The cleaning agent must be completely evaporated before starting the
fusion process.
Subsequently, re-apply marking line for the fusion zone width with the
FRIALEN®marker because this line was removed during scraping and
cleaning. The joint surfaces must be clean and dry before installing the
fitting. The cleaned fusion zone should not be touched with bare hands.
Moisture in the area of the joint area, e.g. because of dew or frost, is to be
removed using suitable aids.
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The fusion fitting is to be removed
from the packaging only directly
before the planned processing. The
packaging protects the fittings
against external influences during
transport and storage.
5.1.3 Assembly
- Place the saddle onto the prepared
surface of the pipe.
- Fit the adapter of the FRIATOP
clamping device (Figure 15a).
- Fit the clamping device as directed
in the Operating Instructions (Figure
15b).
WARNING!
For pressure tapping tees and
pressure tapping valves, the
factory drill setting may not be
changed before starting the fusion
process.
5.1.4 Carrying out of fusion
When fusing Pressure Tapping
Tees to media-carrying pipings, the
following operating pressures may
not be exceeded until the pipe has
cooled down completely:
Figure 15a
Figure 15b
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WARNING!
Only use fusion units which are authorised by their manufacturer to
process FRIALEN®Safety Fittings as part of their function. See DVS
2207-1.
The fusion parameters are contained in the main barcode affixed to the
FRIALEN®Safety Fitting. When using fully automatic fusion units (e.g.
FRIAMAT®), the parameters are entered into the fusion unit using the reader.
After reading of the barcode, the fitting data are to be compared with the
data shown on the unit’s display. If they are identical, start fusion. Please
observe the operating instruction of the FRIAMAT®fusion unit.
The fusion units automatically monitor the fusion process and control the
supplied voltage in determined limits.
The swell indicator only indicates to the performed fusion process. The
proper fusion process is, however, only indicated by the fusion unit!
WARNING!
Keep a distance of one meter to the fusion site during the fusion
process for general safety reasons.
The obtained ACTUAL fusion time is to be compared with the target
fusion time on the unit and to be noted on the pipe or the FRIALEN®
Safety Fittings.
With this identification it is ensured that no fusion point is overlooked.
After the fusion process has finished always maintain the jointing
pressure for a 10 minute cooling period!
Pipe material PE 80 PE 100
SDR 17 11 17 11
Maximum permissible working pressure in bar
Gas pipe 2 5 5 10
Water pipe 8 12.5 10 16
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