HEAT FUS ION JO IN ING PROCEDURES

TABLE OF CONTENTS

INTRODUCTION.............................................................................................................................................1

FEDERAL REGULATIONS...........................................................................................................................1

HEAT FUSION..................................................................................................................................................2

INCLEMENT WEATHER...............................................................................................................................3

NOTES ON FUSION CONFIDENCE..........................................................................................................3

FUSION CHECKLIST.....................................................................................................................................4

BUTT FUSION.................................................................................................................................................5 Procedure..........................................................................................................................................................6 Qualification.................................................................................................................................................. 10

SADDLE FUSION........................................................................................................................................ 15 Definitions...................................................................................................................................................... 15 Procedure....................................................................................................................................................... 17 Qualification.................................................................................................................................................. 18 SOCKET FUSION......................................................................................................................................... 22 EquipmentRequirements........................................................................................................................ 22 HeaterTemperature.................................................................................................................................... 22 Procedure....................................................................................................................................................... 23 Qualification.................................................................................................................................................. 25

APPENDIX A................................................................................................................................................. 29 HydraulicFusionMachineGaugePressure........................................................................................ 29

REFERENCES................................................................................................................................................ 30

FIGURES FIGUREIButtFusionBentStrapTestSpecimen............................................................................ 10 FIGUREIISaddleFusionBentStrapTestSpecimen..................................................................... 18 FIGUREIIISocketFusionBentStrapTestSpecimen.................................................................... 25 TABLES TABLEIButtFusion:ApproximateMeltBeadSize.........................................................................7 TABLEIIButtFusion:MaximumHeaterPlateRemovalTime......................................................8 TABLEIIIButtFusion:BeadWidthsPerWallThickness.................................................................9 TABLEIVButtFusion:TroubleshootingGuide............................................................................ 14 TABLEVSaddleFusion:MaximumHeating/MinimumCoolingTimes................................ 16 TABLEVISaddleFusion:TroubleshootingGuide......................................................................... 21 TABLEVIISocketFusion:TimeCycles............................................................................................... 24 TABLEVIIISocketFusion:TroubleshootingGuide....................................................................... 28

Thestatementsandtechnicaldatagiveninthisbrochureweredevelopedonthebasisofconservativetestmeasuresandarebelievedtobeaccurate.Theinformationismeanttoserveonlyasageneralguide;andtheoperatorand/oranyindividualusermustverifythespecificparametersofeachapplicationfortheirintendeduseandspecificsystem.Duetowidevariationsinserviceconditions,installationtechniques,fieldconditions,weatherconditions,andotherfactors,NOWARRANTYORGUARANTEE,EXPRESSORIMPLIED,ISGIVENINCONJUNCTIONWITHTHEUSEOFTHESEPROCEDURES.

Inaddition,thisproceduredoesnotpurporttoaddressallofthesafetyconcerns,ifany,associatedwithitsuse.Itistheresponsibilityoftheuserofthisproceduretoestablishanyandallappropriatesafetyandhealthpracticesandtodeterminetheapplicabilityofregulatoryrequirementspriortouse.

INTRODUCTION

Anintegralpartofanypipesystemisthemethodusedtojointhesystemcomponents.Properengineeringdesignofasystemwilltakeintoconsiderationthetypeandeffectivenessofthetechniquesusedtojointhepipeandappurtenances,aswellasthedurabilityoftheresultingjoints.Theintegrityandversatilityofthejoiningtechniquesusedforpolyethylene(PE)pipeallowthedesignertotakeadvantageoftheperformancebenefitsofPEinawidevarietyofapplications.

Therearethreetypesofheatfusionjointscurrentlyusedintheindustry:butt,saddleandsocketfusion.Additionally,therearetwomethodsforproducingthesocketandsaddlefusionjoints.Inadditiontothefusion

proceduresthatfollow,electrofusionisrecognizedasanacceptablemethodofproducingsocketandsaddlefusionsbutisnotaddressedinthisdocument.Theuserofelectrofusionproductsshouldcontacttheproviderofthoseproductsfordetailsonuseinjoiningpipe.

ThefusionproceduresthatfollowhavebeenproventoconsistentlyproducesoundfusionjointsinbenchtrialswhenusedcorrectlyandarerecommendedforthejoiningofPolyPipeproducts.TherecommendedproceduresforbuttandsaddlefusionsareconsistentwiththePlasticsPipeInstitute(PPI)TechnicalReports(TR)TR-33, Generic Butt Fusion Procedures and TR-41, Generic Saddle Fusion Procedures.

FEDERAL REGULATIONS

Federalregulationsrequirethatalloperatorsqualifyboththeirjoiningproceduresandthepersonnelinstallingpipe.ThePipelineSafetyRegulations,issuedbytheU.S.DepartmentofTransportation(DOT)PipelineandHazardousMaterialsSafetyAdministration,arefoundat49CFRPart192.Pursuantto49CFR192.283(a),anoperatorisrequiredtoqualifyheatfusionjoiningproceduresbeforetheprocedureisusedinthefield.Further,49CFRPart192.285requiresthatanoperatorqualifythepersonnelwhowillbemakingheatfusionjointsinthefield.AdditionalFederalregulationsmayapply,andStateregulationsthatarecorollariestothePipelineSafetyRegulationsalsoapply,asmayadditional,morestringent,stateregulations.

Theoperatorisresponsibleforensuringthatallaspectsoftheirfusionjoiningprocessesandproceduresareincompliancewiththerequirementsof49CFR,Part192andASTMstandards.

Federalregulationsrequirethatalloperatorsqualifyboththeirjoiningproceduresandthepersonnelinstallingpipe.ThePipelineSafetyRegulations,issuedbytheU.S.DepartmentofTransportation(DOT)PipelineandHazardousMaterialsSafetyAdministration,arefoundat49CFRPart192.Pursuantto49CFR192.283(a),anoperatorisrequiredtoqualifyheatfusionjoiningproceduresbeforetheprocedureisusedinthefield.Further,49CFRPart192.285requiresthatanoperatorqualifythepersonnelwhowillbemakingheatfusionjointsinthefield.AdditionalFederalregulationsmayapply,andStateregulationsthatarecorollariestothePipelineSafetyRegulationsalsoapply,asmayadditional,morestringent,stateregulations.

Theoperatorisresponsibleforensuringthatallaspectsoftheirfusionjoiningprocessesandproceduresareincompliancewiththerequirementsof49CFR,Part192andASTMstandards.

POLYPIPE PRODUCTS

GAS DISTRIBUTION/OILFIELD M&I, WATER AND SPECIALTY

PolyPipePolyTough1TM PolyPipeEHMWPLUS PolyPipeGDY20 PolyPipePOLYPLUS PolyPipeGDB50/GB50 PolypipELIGHTVIEWPLUSTM

POLYPIPEENVIROPIPETM

1

HEAT FUSION

Theprinciplebehindheatfusionistoheattwosurfacestoadesignatedtemperature,andthenfusethemtogetherbyapplicationoftherequiredforce.Thisappliedforcejoinsthemeltedsurfacesresultinginapermanent,monolithicfusionjoint.PolyPipefusionproceduresrequirespecifictoolsandequipmentforthefusiontypeandforthesizesofpipeandfittingstobejoined.

Butt Fusion Thistechniqueconsistsofheatingthesquaredendsoftwopipes,apipeandfitting,ortwofittingsbyholdingthemagainstaheatedplate,removingtheplatewhenthepropermeltisobtained,promptlybringingtheendstogetherandallowingthejointtocoolwhilemaintainingtheappropriateappliedforce.

Saddle Fusion Thistechniqueinvolvesmeltingtheconcavesurfaceofthebaseofasaddlefitting,whilesimultaneouslymeltingamatchingpatternonthesurfaceofthepipe,bringingthetwomeltedsurfacestogetherandallowingthejointtocoolwhilemaintainingtheappropriateappliedforce.

Socket Fusion Thistechniqueinvolvessimultaneouslyheatingtheoutsidesurfaceofapipeendandtheinsidesurfaceofafittingsocket,whichissizedtobesmallerthanthesmallestoutsidediameterofthepipe.Afterthepropermelthasbeengeneratedateachfacetobemated,thetwocomponentsarejoinedbyinsertingthepipeintothefitting.Thefusionisformedattheinterfaceresultingfromtheinterferencefit.Themeltsfromthetwocomponentsflowtogetherandfuseasthejointcools.

ProperlyfusedPEjointsdonotleak.Ifaleakisdetectedduringpneumaticorhydrostatictesting,itispossibleforasystemfailuretooccur.Cautionshouldbeexercisedinapproachingapressurizedpipelineandanyattemptstocorrecttheleakshouldnotbemadeuntilthesystemhasbeendepressurized.

Note: PE cannot be joined by solvent bonding or threading. Extrusion welding or hot air welding is not recommended for pressure applications.

Butt Fusion

Saddle Fusion

Socket Fusion

2

INCLEMENT WEATHER

PE has reducedimpactresistanceinsub-freezingconditions.Additionalcareshouldbeexercisedwhilehandlinginsub-freezingconditions.Inaddition,PEpipewillbehardertobendand/oruncoil.

Forrecommendedguidelineswhenfusingininclementweather,refertothePlasticsPipeInstitute,PPI,TechnicalNoteTN-42: Recommended Minimum Training Guidelines for PE Pipe Butt Fusion Joining Operators for Municipal and Industrial Projects. http://plasticpipe.org/pdf/tn-42-min-training-guide-pe-butt-fusion.pdfTheseguidelinesapplytoallapplications.

AdditionalinformationconcerningcoldweatherproceduresisavailableinASTMF2620,StandardPracticeforHeatFusionJoiningofPolyolefinPipeandFittings, AnnexA1.

Theoperatorshouldensurethatitsqualifiedfusionprocedurestakeintoaccountandareadaptedforallpotentialinclementweatherconditionsinwhichtheoperatormaybefusingpolyethylenepipe.

NOTES ON FUSION CONFIDENCE

ReliablefusionjointsofPEpipingsystemscanbeaccomplishedunderreasonablelatitudeofconditions.Theoperatorshouldqualifyitsownproceduresforeveryconditionunderwhichitwillbefusingpolyethylenepipe.Additionally,theoperatorshouldqualifyallpersonnelwhowillresponsibleforperformingfusionsofpolyethylenepipe.

Thefollowingisalistingofgeneralnotestohelpensureproperequipmentandtechniquesareutilized:

1. The fusion operator must have adequate training and understanding of the equipment and tools and the fusion procedure.

Improperunderstandingoftheoperationoftheequipmentandtoolscanproduceafusionofpoorquality.Theoperatormustunderstandthoroughlyhowtousetheequipmentandtools,theirfunctionandoperation.Theoperatorshouldadheretotheequipmentmanufacturersinstructions.

Fusionpressuresandheating/coolingcyclesmayvarydramaticallyaccordingtopipesizeandwallthickness.Operatorsshouldnotrelyexclusivelyonautomated

fusionequipmentforjointqualification.Inaddition,visualinspectionandqualificationshouldalwaysbemade.Ifnecessary,testfusionsshouldbemadetodeterminecorrectpressuresandheat/coolcycletimes.Destructivetestmethods,suchasbendbacktests,maybenecessarytoformulatecorrectpressuresandheat/coolcycletimes(refertoQualificationProcedures).2. Pipe and fitting surfaces must be clean and properly prepared.

Anycontaminantspresentonthesurfacesorpoorpreparationofthesurfacescanproduceapoorqualityfusionjoint.Ensurethatallpipeandfittingsurfacesareclean.Ifsurfacesarereintroducedtocontaminants,theyshouldbecleanedagain.3. Heater plates must be clean, undamaged and the correct surface temperature.

Heatersurfacesareusuallycoatedwithanon-stickmaterial.Cleaningtechniquesshouldbeusedaccordingly.Ifasolventisdeemednecessary,donotusegasolineorotherpetroleumproducts.Refertotheequipmentmanufacturersinstructionsforpropercleaningproducts.ItisimportanttoregularlycleantheheatersurfacetoremoveanybuildupofPEmaterialthatwilldegradeduetoextendedcontactwiththeheater.

Recommendedheatingtooltemperaturesarespecifiedforeachprocedure.Thistemperatureisindicativeofthesurfacetemperature,nottheheatingtoolthermometer.Thesurfacetemperatureshouldbeverifieddailybyusingasurfacepyrometer.Ifacrayonindicator(meltstick)isused,itshouldnotbeusedinanareathatwillbeincontactwiththepipeorfitting.

Iftheheaterplateisnotinuse,itisrecommendedthatitbestoredinaninsulatedholder.Thisnotonlyprotectstheheatersurfacesfromcontaminants,butitcanalsopreventinadvertentcontact,whichcanresultinseriousinjuries.

4. Proper equipment and condition of tools and equipment for the job

Eachtypeoffusionrequiresspecialtoolsandequipment.Fusionsperformedwiththeincorrectfusionequipment,materialsortoolsand/orwithfusionequipmentthathasnotbeenproperlymaintainedcanresultinapoorfusion.Anynon-workingequipmentcomponentsshouldbereplacedorrepairedpriortofusingpipe.

3

FUSION CHECKLIST

Inspectpipelengthsandfittingsforunacceptablecuts,gouges,deepscratchesorotherdefects.Damaged

productsshouldnotbeused.RefertoPolyPipeInfoBriefNo.2forallowablesurfacedamageaccordingtothe

PlasticsPipeInstitute(PPI)andtheAmericanGasAssociation(AGA).

Thefusioncontactareamustbefreeofanydefectsorsurfacedisruption.

Besureallrequiredtoolsandequipmentareonsiteandinproperworkingorder.

Pipeandfittingsurfaceswheretoolsandequipmentarefittedmustbecleananddry.Useclean,dry,non-synthetic(cotton)clothsorpapertowelstoremovedirt,snow,waterandothercontaminants.Ifalcohol

isused,99%reagentgradeisopropylalcoholisrecommended.Thestandarddrugstorevarietycontains

impuritiesthatcanactasacontaminanttothefusionprocess.

Shieldand/orcoverfusionequipmentandsurfacesfrominclementweatherandwinds.Atemporaryshelter

overfusionequipmentandthefusionoperationmayberequired.

Relievetensioninthelinebeforemakingconnections.

Whenjoiningcoiledpipe,makinganS-curvebetweenpipecoilscanrelievetension.Insomecases,itmay

benecessarytoallowpipetoequalizetothetemperatureofitssurroundings.Allowpulled-inpipesto

relaxforseveralhourstorecoverfromtensilestresses.

Pipesmustbecorrectlyalignedbeforemakingconnections.

Trialfusions.

Atrialfusion,preferablyatthebeginningoftheday,canverifythefusionprocedureandequipment

settingsfortheactualjobsiteconditions.RefertoQualificationProceduresfordetailedinformationonthe

bendbacktestprocedure.

4

BUTT FUSION

Heater Surface Temperature: Minimum 400oF Maximum 450oF

Heatingtoolsurfacesmustbetotemperaturebeforeyoubegin.Allpointsonbothheatingtoolsurfaceswheretheheatingtoolsurfaceswillcontactthepipeorfittingendsmustbewithintheprescribedminimumandmaximumtemperaturesandthemaximumtemperaturedifferencebetweenanytwopointsontheheatingtoolfusionsurfacesmustnotexceed20oFforequipmentforpipesmallerthan18diameter,or35oFforlargerequipment.Itisagoodpracticetosettheheaterplateto425oFwhichcanhelpkeepnormalfluctuationsbetween400oFand450oF.Heatingtoolsurfacesmustbeclean.

Interfacial pressure: Minimum 60 psi Maximum 90 psi

Interfacialpressureisusedtocalculateafusionjoininggaugepressurevalueforhydraulicbuttfusionmachinesormanualmachinesequippedwithforcereadingcapability.Theinterfacialpressureisconstantforallpipesizesandallbuttfusionmachines.However,fusionjoininggaugepressuresettingsarecalculatedforeachbuttfusionmachine,whicharedependentupontheoutsidediameter(OD)anddimensionratio(DR)andthepistonareaofthefusionmachine.

Forhydraulicmachines,theinterfacialpressure,thefusionsurfacearea,themachineseffectivepistonareaandfrictionalresistance,andifnecessary,thepressureneededtoovercomeexternaldragresistance,areusedtocalculatehydraulicfusionjoiningpressuregaugesettings(refertoAppendixA).Theequipmentmanufacturersinstructionsareusedtocalculatethisvalue.Theproperamountofforceshouldbeverifiedbyvisualinspectionofthejoint.

NOTE: The interfacial pressure and the hydraulic gauge pressure are not the same.

Formanualmachineswithoutforcereadingcapability,thecorrectfusionjoiningforceistheforcerequiredtorollthemeltbeadsoveruntiltheycontactthepipesurfaceasrequiredbythejoiningprocedure.

Whenjoiningpipeswithdifferentmeltproperties,suchasbimodalMDPEtounimodalMDPE,applysufficientforcetomakethebimodalpipefusionbeadrollbackandcontactthepipesurface.BimodalMDPEhasalowermeltflowratiothanunimodalpipe.

5

PROCEDURE

1. SecureCleantheinsideandoutsideofthepipeorfitting(components)endsbywipingwithaclean,dry,lint-freeclothorpapertowel.Removeallforeignmatter.Alignthecomponentsinthemachine,placethemintheclamps,andthenclosetheclamps.Do not force pipes into alignment against open fusion clamps.Componentendsshouldprotrudepasttheclampsenoughsothatfacingwillbecomplete.Bringtheendstogetherandcheckhigh-lowalignment.Adjustalignmentasnecessarybytighteningthehighsidedown.

2. FacePlacethefacingtoolbetweenthecomponentends,andfacethemtoestablishsmooth,clean,parallelmatingsurfaces.Completefacingproducescontinuouscircumferentialshavingsfrombothends.Faceuntilthereisminimaldistancebetweenthefixedandmoveableclamps.Ifthemachineisequippedwithfacingstops,facedowntothestops.Stopthefacerbeforemovingthepipeendsawayfromthefacer.Removethefacingtool,andclearallshavingsandpipechipsfromthecomponentends.Do not touch the component ends with your hands after facing.

3. AlignBringthecomponentendstogether,checkalignmentandcheckforslippageagainstfusionpressure.Lookforcompletecontactallaroundbothendswithnodetectablegaps,andODsinhigh-lowalignment.Ifnecessary,adjustthehighsidebytighteningthehighsideclamp.Donotloosenthelowsideclampbecausecomponentsmayslipduringfusion.Re-face if high-low alignment is adjusted.

4. MeltVerifythatthecontactsurfaceoftheheatingtoolismaintainingthecorrecttemperature.Placetheheatingtoolbetweenthecomponentends,andmovetheendsagainsttheheatingtool.Bringthecomponentendstogetherunderpressuretoensurefullcontact.Theinitialcontactpressureshouldbeheldverybrieflyandreleasedwithoutbreakingcontact.Pressureshouldbereducedwhenevidenceofmeltappearsonthecircumferenceofthepipe.Holdtheendsagainsttheheatingtoolwithout force(dragforcemaybenecessarytoensurecontact).BeadsofmeltedPEwillformagainsttheheatingtoolatthecomponentends.Whenthepropermeltbeadsizeisformed,quicklyseparatetheendsandremovethe

6

heatingtool.Theproperbeadsizeisdependentuponthesizeofthecomponent.ApproximatevaluesareshowninTableI.

Duringheating,themeltbeadwillexpandoutflushtotheheatingtoolsurface,ormaycurlslightlyawayfromthesurface.Ifthemeltbeadcurlssignificantlyawayfromtheheatingtoolsurface,unacceptablepressureduringheatingmayhaveoccurred.

5. JoinImmediatelyaftertheheatingtoolisremoved,quicklyinspectthemeltedends,whichshouldbeflat,smoothandcompletelymelted.Ifthemeltsurfacesareacceptable,immediatelyandinacontinuousmotion,bringtheendstogetherandapplythecorrectjoiningforce(orfusionpressure).Thecorrectfusionpressurewillformadoublebeadthatisrolledoverandcontactsthepipesurface.thesurfaceonbothends.

A concave melt surface is unacceptable; it indicates pressure during heating. Do not continue. Allow the component ends to cool and start over with Step 1.

ThemaximumrecommendedtimeallowedforheaterplateremovalisindicatedinTableII.

TABLE IAPPROXIMATE MELT BEAD SIZE

Approximate Wall Thickness, inches Melt Bead Size* (Approximate)

0.15 1/321/16 0.150.30 1/16 Above0.300.75 1/83/16 Above0.751.15 3/161/4 Above1.151.60 1/45/16 Above1.602.20 5/167/16 Above2.203.00 7/169/16

*The appearance of the melt swell zone may vary depending on the pipe material. The melt bead width is to be determined by measuring the distance from the heater plate to the melt swell origin.

7

6. HoldMaintainfusiongaugepressureuntilthejointiscool.Thejointiscoolenoughforgentlehandlingwhenthedoublebeadiscooltothetouch.Coolforaminimumof11minutesperinchofpipewall.Donottrytodecreasethecoolingtimebyapplyingwater,ice,wetclothsorthelike.

Avoidpulling,installation,pressuretestingandroughhandlingforatleastanadditional30minutes.

Forambienttemperaturesabove100oF,longercoolingtimesmayberequired.

7. InspectionOnbothsides,thedoublebeadshouldberolledovertothesurface,andbeuniformlyroundedandconsistentinsizeallaroundthejoint.

1.Thegap(A)betweenthetwosinglebeadsmustnotbebelowthefusionsurfacethroughouttheentirecircumferenceofthebuttjoint.

2.Thedisplacement(V)betweenthefusedendsmustnotexceed10%ofthepipe/fittingminimumwallthickness.

3.RefertoTableIIIforgeneralguidelinesforbeadwidth,B,foreachrespectivewallthickness.

TABLE IIMAXIMUM HEATER PLATE REMOVAL TIMES

Pipe Wall Thickness, in Max. Heater Removal Time, sec 0.20to0.36 8 >0.36to0.55 10 >0.55to1.18 15 >1.18to2.5 20 >2.5to4.5 25

8

4.Thesizedifferential(SmaxSmin)betweentwosinglebeadsshallnotexceedX%ofthecombinedbeadwidth(B).

Where:X =Percentdifferenceofbeadwidth,% Pipetopipe,maximumX=10% Pipetofitting,maximumX=20% Fittingtofitting,maximumX=20% S =Smax-Smin,inchesB =Combinedwidthofbothfusionbeads,inches

Minimum Wall

Thickness, in.

Approximate Bead Width (B), in.

Approximate Bead Width (B), in.

Minimum Wall Thickness, in.

TABLE IIIBEAD WIDTHS PER WALL THICKNESS

Minimum Maximum Minimum Maximum .118 5/32 1/4 1.06 19/32 25/32 .157 5/32 9/32 1.18 5/8 13/16 .197 3/16 5/16 1.34 21/32 7/8 .246 1/4 11/32 1.57 11/16 29/32 .315 9/32 3/8 1.77 25/32 1 .354 5/16 7/16 1.97 7/8 1-1/16 .433 11/32 1/2 2.16 15/16 1-3/16 .512 3/8 9/16 2.36 1 1-1/4 .630 7/16 19/32 2.56 1-1/8 1-7/16 .710 1/2 5/8 2.76 1-3/16 1-1/2 .750 1/2 11/16 2.95 1-1/4 1-9/16 .870 1/2 11/16 3.15 1-5/16 1-11/16 .940 9/16 3/4 3.35 1-3/8 1-3/4 3.54 1-1/2 1-13/16

Instructions: Determine the wall thickness of the pipe/fitting. Find the wall thickness above. If the exact wall thickness is not shown, use the next lowest wall thickness for determination of bead width.

NOTE: 1. Whenbuttfusingpipetomoldedfittings,thefittingsidebeadmayhaveanirregularappearance. Thedifferentmanufacturingprocessesused(extrusionvsmolding)willcausethebeadappearancetobe differentwhenitrollsback.Thisisacceptable,providedthepipesidebeadiscorrect.(SeeImages1&2.) 2. WhenfusingunimodalMDPEpipetobimodalMDPEpipeorHDPEpipe,theunimodalMDPEpipebeadmay beslightlylargerthanthebimodalMDPEorHDPEpipebead.Thisoccursbecauseofthedifferentmelt propertiesoftheresins.(SeeImages3&4) 3. PolyPipePolyTough1hasbeensuccessfullyfusedtoavarietyofpipesthatmaybeinuseinexistinggaspipe systems.Photosofthesefusionsareprovidedforvisualreference.(SeeImages5thru16)

9

QUALIFICATION

The following summarizes the ASTM methods to which the operator and/or user should refer for specific qualification requirements

1.Prepareasamplejoint.Samplelengthsshouldbeatleast6or15timestheminimumwallthickness(seeFigureI).

2.Observethefusionprocessandverifytherecommendedprocedureforbuttfusionisbeingfollowed.

3.Visuallyinspectthesamplejointforquality.

4.Allowthejointtocoolcompletely.

5.PreparethesampleasshowninFigureI.Thesampleshouldbecutlengthwiseintoatleastthreelongitudinalstrapswithaminimumof1or1.5timesthewallthicknessinwidth.Itisrecommendedthatfourequallyspacedstripsbecut,onefromeachquadrantofthepipe.

6.Visuallyinspectthecutjointforanyindicationsofvoids,gaps,misalignmentorsurfacesthathavenotbeenproperlybonded.

7.Bendeachsampleattheweldwiththeinsideofthepipefacingoutuntiltheendstouch.Theinsidebendradiusshouldbelessthantheminimumwallthicknessofthepipe.Inordertosuccessfullycompletethebendback,avisemaybeneeded.Forthick(>1)wallpipe,contactPolyPipeEngineeringforrecommendedproceduresandtestapparatus.

8.Thesamplemustbefreeofcracksandseparationswithintheweldlocation.Iffailuredoesoccurattheweldinanyofthesamples,cutanothersampleadjacenttothepositionthefailedsamplecamefromandretest.Ifthesecondsamplefails,thenthefusionprocedureshouldbereviewedandcorrected.Aftercorrection,anothersamplefusionshouldbemadeperthenewprocedureandre-tested.

Figure IButt Fusion Bent Strap Test Specimen

(Reference ASTM F2620)

BEND BACK TESTING - NO GAPS OR VOIDS(SeeFigure1)

10

ACCEPTABLE FUSIONS

BUTT FUSION

PROPER ALIGNMENT AND DOUBLE ROLL-BACK BEAD

Unimodal HDPE fused to molded fitting

Unimodal MDPE fused to PolyTough1TM bimodal MDPE

Unimodal MDPE fused to HDPE

PolyTough1TM fused to molded fitting

11

PolyTough1tm BIMODAL MDPE JOINED TO VINTAGE AND CURRENT MATERIALS

Unimodal MDPE fused to PolyTough1TM PolyTough1TM fused to PolyTough1TM

PolyTough1TM fused to PLEXCO PE2306 PolyTough1TM fused to PE3408

PE4710 fused to PolyTough1TM DRISCO M8000 fused to PolyTough1TM

DUPONT ALDYL A PE2306 fused to PolyTough1TM

12

UNACCEPTABLE FUSIONS

BUTT FUSION

Meltbeadtoosmallduetoinsufficientheattime Meltbeadtoolargeduetoexcessiveheatingand/oroverpressurizationofjoint

Misalignment IncompleteFacing

Pressurefluctuation,misalignmentoverpressurization13

TABLE IVBUTT FUSION TROUBLESHOOTING GUIDE

Observed Condition Possible Cause

Excessivedoublebeadwidth Overheating Excessivejoiningforce Doublebeadv-groovetoodeep Excessivejoiningforce Insufficientheating Pressureduringheating Flattoponbead Excessivejoiningforce Overheating Non-uniformbeadsizearoundpipe Misalignment Defectiveheatingtool Wornequipment Incompletefacing Onebeadlargerthantheother Misalignment Componentslippedinclamp Wornequipment Heatingirondoesnotmovefreelyinthe axialdirection Defectiveheatingtool Incompletefacing Alsopossiblewhenfusingbimodalpipesto unimodalpipes

Beadstoosmall Insufficientheating Insufficientjoiningforce

Beadnotrolledovertosurface Shallowv-grooveInsufficientheating& insufficientjoiningforce Deepv-grooveInsufficientheating& excessivejoiningforce Beadonbimodalpipemayhaveslightgap tothepipesurface

Beadstoolarge Excessiveheatingtime

Squaretypeouterbeadedge Pressureduringheating Rough,sandpaper-like,bubbly, Hydrocarbon(gasolinevapors,spray orpockmarkedmeltbeadsurface paintfumes,etc.)contamination

14

SADDLE FUSION

Heater Surface Temperature:500oF 10oF(Minimum490oF-Maximum510oF)

Heatertoolsurfacesmustbeuptotemperaturebeforeyoubegin.Allpointsonbothheatingtoolsurfaceswheretheheatingtoolsurfaceswillcontactthepipeandfittingmustbewithintheprescribedminimumandmaximumtemperatures.Heatertoolsurfacesmustbeclean.

DEFINITIONS

Initial Heat (Bead-up)Theheatingstepusedtodevelopameltbeadonthepipe.

Initial Heat Force (Bead-up Force)Theforce(pounds)appliedtoestablishameltpatternonthepipe.TheInitialheatforceisdeterminedbymultiplyingthefittingbasearea(in2)bytheinitialheatinterfacialpressure(psi).

Heat Soak ForceTheforce(pounds)appliedafteraninitialmeltpatternisestablishedonthepipe.Theheatsoakforceistheminimumforce(essentiallyzero)thatensuresthefitting,heaterandpipestayincontactwitheachother.

Fusion ForceTheforce(pounds)appliedtoestablishthefusionbondbetweenthefittingandthepipe.Thefusionforceisdeterminedbymultiplyingthefittingbasearea(in2)bythefusioninterfacialpressure(psi).

Interface Pressure:Minimum54psiMaximum66psi

Total Heat TimeAtimethatbeginswhentheheaterisplacedonthepipeandinitialheatforceisappliedandstopswhentheheaterisremoved.MaximumheatingtimesareshowninTableIVforbothpressure(hottapping)andnon-pressurefusionapplications.Cool TimeThetimerequiredtocoolthejointtoapproximately120oF10oF.TheFusionForcemustbemaintainedfor5minuteson1-1/4IPSor10minutesforallotherpipesizes,afterwhichthesaddlefusionequipmentcanberemoved.Thejointmustbeallowedtocoolforanadditional30minutesbeforetappingthepipeorjoiningtothebranchoutlet.RecommendedminimumcoolingtimesareshowninTableIV.

15

INTERFACIAL AREA

Rectangularbasefittings

Themajorwidthtimesthemajorlengthofthesaddlebase,withouttakingintoaccountthecurvatureofthebaseorsides,minustheareaofholeinthecenterofthebase.

Roundbasefittings

Theradiusofthesaddlebasesquaredtimes(3.1416),withouttakingintoaccountthecurvatureofthebaseorsides,minustheareaoftheholeinthecenterofthebase.

TABLE VMAXIMUM HEATING/MINIMUM COOLING TIMES

Pipe Size Maximum Heating Time Minimum Cooling Time 1-1/4IPS 1/16meltpatternvisiblearoundthebaseofthefitting. 5min+30min Do not exceed 15 seconds when hot tapping. 2IPS 1/16meltpatternvisiblearoundthebaseofthefitting. 10min+30min Do not exceed 35 seconds when hot tapping. 3IPS&larger 1/16meltpatternvisiblearoundthebaseofthefitting. 10min+30min

FITTING LABELS

Theinitialheatforce,heatsoakforceandfusionforcewillbelistedinthelowerright-handcornerofthefittinglabelforthemajorityofsaddlefusionfittings.Thiseliminatestheneedtocalculatetheinformationinthefield.Forexample,80/0/40representstheinitialheatforce,heatsoakforceandfusionforce,respectively.Ifthisinformationisnotlocatedonthefitting,pleasecontactthefittingmanufacturerforthecorrectfusionparameters.

16

PROCEDURE

1. Preparation

Thisprocedurerequirestheuseofasaddlefusiontool.Thistoolmustbecapableofholdingandsupportingthepipe,roundingthepipeforproperalignmentbetweenthepipeandfitting,holdingthefitting,andapplyingandindicatingtheproperforceduringthefusionprocess.

A.Installthesaddlefusiontoolonthepipeaccordingtothemanufacturersinstructions.Thetoolshouldbecenteredoveraclean,drylocationwherethefittingwillbefused.Securethetooltothepipe.Asupportisrecommendedunderthepipeon6IPSandsmallerpipesizes.

B.Abradethesurfaceofthepipe,wherethefittingwillbejoined,witha5060gritutilityclothuntilathinlayerofmaterialisremovedfromthepipesurface.Theabradedareamustbelargerthantheareacoveredbythefittingbase.Afterabrading,cleantheresidueawaywithaclean,drycloth.

C.Abradethefusionsurfaceofthefittingwith50-60gritutilitycloth.Removealldustandresiduewithaclean,drycloth.Insertthefittinginthesaddlefusiontoolloosely.Usingthesaddlefusiontool,movethefittingbaseagainstthepipeandapplyabout100pounds-forcetoseatthefitting.Securethefittinginthesaddlefusiontool.

2. Heating

Theheatingandfusingprocessmustbeperformedwithaccuracyandefficiency,especiallywhenfusingtoapressurizedmainpipe.

WARNING: Overheatingorexcessivetimebetweenthesetwoprocessescanhavedetrimentaleffects,includingpipelinerupture.

Theheatermustbefittedwiththecorrectheateradapters.

Theheateradapterfusionsurfacemustbebetween490oFto510oF.

Ensuretheheatingsurfacesareclean.

Determinethesaddlefusionforcefromthefittinglabelorbycalculation.

A.Placetheheatingtoolonthepipecenteredbeneaththefittingbase.Immediatelymovethefittingagainsttheheaterfaces,applytheinitialheatforce(seefittinglabel)andstarttheheattime.Applytheinitialheatforceuntilmeltisfirstobservedonthecrownofthepipemain.Initialheatisthetermusedtodescribetheinitialheating(bead-up)steptodevelopameltbeadonthepipeandisusually3-5seconds,andthenreducetheforcetotheheatsoakforce(bead-upforce)(seefittinglabel).Maintaintheheatsoakforceuntilthetotalheattimeiscomplete.

B.Attheendofthetotalheattime,removethefittingfromtheheaterandtheheaterfromthepipewithaquick,snappingaction.Quicklycheckforanevenmeltpatternonthepipeandheatedfittingsurfaces(nounheatedareas).Thetotalheattimeendswhenoneofthefollowingconditionsaremet:

i. Totalheattimeexpiresforapressurized 1-1/4IPSor2IPSpipe,or

ii.Ameltbeadofapproximately1/16isvisible aroundthefittingbasefora11/4IPSor2IPS non-pressurizedpipe,oralargerpressurizedor non-pressurizedpipe.

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3. Fusion and Cooling

Pressthefittingontothepipe(within3seconds)afterremovingtheheaterandapplytheFusionForce(seethefittinglabel).Maintainthefusionforceontheassemblyfor5minuteson1-1/4IPSandfor10minutesforlargersizes.Whenthisinitialcoolingtimehasexpired,thesaddlefusionequipmentmayberemoved.Allowtheassemblytocoolforanadditional30minutesbeforehandlingorTapping.

Ifthemeltpatternwasnotsatisfactoryorifthefusionbeadisunacceptable,cutoffthesaddlefittingabovethebasetopreventuse,relocatetoanewsectionofmain,andmakeanewsaddlefusionusinganewfitting.

NOTE: The fusion force may need to be adjusted during the initial cooling period; however, the fusion force should never be reduced.

4. Inspection

Visuallyinspectthefusionbeadaroundtheentirebaseofthefittingatthepipe.Thefusionbeadshouldbeofuniformsize.Thefusionshouldhaveathree-beadshape,whichischaracteristicofthistypeoffusion.Thefirstbeadisthefittingbasemeltbead.Thesecondoroutermostbeadistheresultoftheheatertoolfaceonthepipe.Thethirdbead,orcenterbead,isthepipemeltbead.Allbeadsshouldbeofuniformsizewiththefirstandthirdbeadsapproximately1/8andthesecondbeadbeinggenerallysmaller.

QUALIFICATION

The following summarizes the ASTM methods to which the operator and/or user should refer for specific qualification requirements

1.Prepareatleasttwosamplejoints.Thepipelengthshouldbeaminimumof2orseventimesthemaximumsaddlefittingbasedimension,whicheverisgreater.

2.Observethefusionprocessandverifytherecommendedprocedureforsaddlefusionisbeingfollowed.

3.Visuallyinspectthesamplejointforquality.

4.Allowthejointtocoolcompletely(minimumofonehour).Thepipesampleshouldnotbetappedforthisqualificationprocess.

Figure IISaddle Fusion Bent Strap Test Specimen

18

5.PrepareteststrapsasshowninFigureII.Cutthejointlengthwisealongthemainpipeandthroughthesaddlefitting.

6.Visuallyinspectthejointforanyvoids,gaps,misalignmentorsurfacesthathavenotbeenproperlybonded.

7.Bendeachteststrap180owiththeinsidefacingout.

8.Thefusionjointmustbefreeofcracks,voids,gapsandseparations.

9.Testtheothersamplejointbyimpactagainstthesaddlefitting.Thefailuremustoccurbyeithertearingthefitting,bendingthefittingatleast45oorbyremovingasectionofthepipe.Failureatthefusionisnotacceptable.ThistestisaFederalrequirementforqualificationoffusionprocedures.

10.Iffailuredoesoccurattheweldinanyofthesamples,thenthefusionprocedureshouldbereviewedandcorrected.Aftercorrection,anothersamplefusionshouldbemadeperthenewprocedureandretested.

ACCEPTABLE FUSIONS

ProperAlignment,MeltandForce

BendBackTesting-NoGapsorVoids(SeeFigureII)

Areawherelikelygapsandvoidsmightoccur

Areawherelikelygapsandvoidsmightoccur

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UNACCEPTABLE FUSIONS

ExcessiveHeatingand/orOverpressurizationofjoint

ExcessiveForce

FittingMisalignmentonpipe

InsufficientMelt

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TABLE VISADDLE FUSION TROUBLESHOOTING GUIDE

Observed Condition Possible Cause

Non-uniformbeadsizearoundfittingbase Misalignment Defectiveheatingtool Fittingnotsecuredinheatingtool Heatingtemperaturenotwithinspecifiedrange Onebeadlargerthantheother Misalignment Heatingtemperaturenotwithinspecifiedrange Fittingslippedinclamp Defectiveorwornequipment Beadstoosmall Insufficientheating Insufficientjoiningforce Beadstoolarge Excessiveheatingtime Excessivejoiningforce Absenceofthirdbead,orthirdbead Incorrectpipemainheatingtool widelyseparatedfromcenterbead Insufficientjoiningforce Pressurizedmainblowout Excessiveheating (besidebaseorthroughfittingbase) Heatingtemperaturenotwithinspecifiedrange Incorrectheatingtoolfaces Excessivetimetostartheatingorinjoiningthe fittingtothemainpipeafterheatingtimecycle Rough,sandpaper-like,bubbly, Hydrocarbon(gasolinevapors,spraypaint orpockmarkedmeltbeadsurface fumes,etc.)contamination

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SOCKET FUSION

Equipment Requirements

Inordertoproduceaqualitysocketfusion,thefollowingequipmentisrequiredforthisprocedure:

Apparatus SocketfusiontoolsmanufacturedinaccordancewithASTMF1056.

Heating tool faces Consistingoftwoparts,amaleendfortheinteriorsocketsurfaceandafemaleendfortheexteriorpipesurface.

Rounding clamps (cold ring) -Devicetomaintaintheroundnessofthepipeandcontrolthedepthofpipeinsertionintothesocketduringthejoiningoperation.

Depth gauge Properpositioningoftheroundingclamp.

Chamfering tool Devicetobeveltheendofthepipe.Thedepthgaugeandchamferingtoolmaybecombinedintoasingletool.

Holding tools Recommendedforsocketfusionof2IPSandlargerpipeandfittings.

Heater Temperature

Heater Surface Temperature:Minimum490oFMaximum510oF

Inordertoobtainapropermelt,auniformtemperaturemustbemaintainedacrosstheheatingsurface.Allpointsonbothheatingsurfaceswheretheheatingsurfaceswillcontactthepipeandfittingmustbewithintheprescribedminimumandmaximumtemperatures.Heatingtoolsurfacesmustbeclean.

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Procedure

1. Preparation

A.Verifyheatingtemperatureiswithinthespecifiedtemperaturerange(490oF510oF).

B.Cutthepipeendsquarely,andcleanthepipeendandfitting,bothinsideandoutwithaclean,dry,lint-freecloth.Donottouchcleanedsurfaceswithyourhands.

C.Chamfertheoutsideedgeofthepipeendslightly.Thepipeshouldbefreeofdebrisandburrs.

D.PlacethecoldringonthepipeasdeterminedbythedepthgaugePlacethedepthgaugeoverthechamferedendofthepipe.Clampthecoldringimmediatelybehindthedepthgauge.

2. Heating

A.ReviewtherecommendedheatingtimesinTableVI.TheheatingtimebeginsafterStepChasbeencompleted.

B.Insertthefittingontothemaleheatingface.Thefittingshouldbeheldagainstthebacksurfaceofthemaleheaterface.

C.Insertthepipeintothefemaleheatingface.Thefemalesocketheatingfaceshouldbeagainstthecoldringclamp.

D.HoldthepipeandfittinginplaceagainsttheheaterfacesfortherecommendedheatingtimeasshowninTableVI.

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3. Fusion and Cooling

A.Attheendoftheheatingtime,simultaneouslyremovethepipeandfittingstraightoutfromthetoolusingasnapaction.Donottorqueortwistthepipeorfittingduringremoval.

B.AQUICKinspectionshouldbemadeofthemeltpatternonthepipeendandfittingsocket.Ifthereisevidenceofanincompletemeltpattern,donotcontinuewiththefusionprocedure.C.Immediatelyinsertthepipestraightintothesocketofthefittingsothatthecoldringisflushagainsttheendofthefittingsocket.Whilecooling,pressureshouldbemaintainedonthefusionpertherecommendedcoolingtimeshowninTableVI.

TABLE VIISOCKET FUSION TIME CYCLES

PE2708 PE4710 PolyPipe GDY20 & PolyTough1 & PolyPipe Pipe Size fusedtounimodalMDPEfittings PolyTough1 PE27081 fusedtoHDPEfittings

Heating Time Cooling Time Heating Time Cooling Time seconds seconds seconds seconds

1/2CTS 56 30 810 30 3/4CTS 78 30 1012 30 1CTS 910 30 1214 30 1/2IPS 56 30 810 30 3/4IPS 810 30 1214 30 1IPS 1012 30 1416 30 1-1/4IPS 1214 45 1820 60 1-1/2IPS 1214 45 1820 60 2IPS 1620 45 2226 60 3IPS 2025 60 2530 75 4IPS 2530 60 30-35 75

Notes: If an incomplete bead rollout is noticed when joining PolyTough1 to unimodal socket fittings, PolyPipe recommends the use of bimodal MDPE fittings HDPE fittings or other means of joining the pipe.

D.Allowthejointtocoolanadditionalfive(5)minutesbeforeremovingthecoldring.Anadditional10minutesofcoolingtimeisrecommendedbeforeexposingthejointtoanytypeofstresses(i.e.,burialortesting).

4. Inspection

Visuallyinspecttheweld.Acompleteimpressionoftheroundingclampshouldbevisibleinthemeltpatternattheendofthesocket.Thereshouldbenogaps,voidsorunbondedareas.

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Qualification

The following summarizes the ASTM methods to which the operator and/or user should refer for specific qualification requirements

1.Prepareasamplejointsuchasacouplingwithpipesocketfusedtobothends.Thepipeshouldbeatleast6or15timesthewallthicknessinlength.

2.Observethefusionprocessandverifytherecommendedprocedureforsocketfusionisbeingfollowed.

3.Visuallyinspectthesamplejointsforquality.

4.Allowthesampletocoolcompletely(minimumofonehour).

Figure IIISocket Fusion Bent Strap Test Specimen

6.Visuallyinspectthecutjointforanyindicationsofvoids,gaps,misalignmentorsurfacesthathavenotbeenfused.

7.Bendeachteststrap180owiththeinsideofthepipefacingout.

8.Thefusionjointmustbefreeofcracks,voids,gapsandseparations.Iffailuredoesoccurattheweldinanyofthesamples,thenthefusionprocedureshouldbereviewedandcorrected.Aftercorrection,anothersampleweldshouldbemadeperthenewprocedureandretested.

5.PrepareteststrapsasshowninFigureIII.Cutthejointslengthwiseintoatleastthreelongitudinalstrapswithaminimumof1or1.5timesthewallthicknessinwidth.

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ACCEPTABLE FUSIONS

ProperAlignmentandStabDepthMeltBeadFlattenedDuetoColdRing-Nogapsorvoids

BendBackTesting-NoGapsorVoids(SeeFigureIII)

SOCKET FUSION

Areawherelikelygapsandvoidsmightoccur

Areawherelikelygapsandvoidsmightoccur

26

SocketFusion

ExcessiveStabDepthCausedbyFailuretoUseaColdRing

ShortStabDepthCausedbyFailuretoUseaDepthGauge

UNACCEPTABLE FUSIONS

SOCKET FUSION

27

TABLE VIIISOCKET FUSION TROUBLESHOOTING GUIDE

Observed Condition Possible Cause Noevidenceofcold-ringimpression Insufficientheatingtime insocketfittingmeltbead Depthgaugenotused Coldringnotused Coldringsetatincorrectdepth Gapsorvoidsaroundthepipeat Pipeorfittingnotremovedstraight thesocketfittingedge fromheaterface Componentsnotjoinedtogetherstraight whenfusing Coldringnotused Coldringsetatincorrectdepth Wrinkledorcollapsedpipeend Coldringnotutilized Coldringsetatincorrectdepth Incorrectheatingsequence Voidsinfusionbondarea Pipeorfittingnotremovedstraightfromheaterface Componentsnotjoinedtogetherstraight whenfusing Coldringnotused Coldringsetatincorrectdepth Unbondedareaonpipeatendofpipe Coldringnotused Coldringsettoodeep Socketmeltextendspastendofpipe Coldringsettooshallow Rough,sandpaper-like,bubbly,or Hydrocarbon(gasolinevapors,spraypaint pockmarkedmeltbeadsurface fumes,etc.)contamination

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APPENDIX A

HYDRAULIC FUSION MACHINE GAUGE PRESSURE

ThemanufacturerofthefusionmachineshouldbeconsultedforguidanceindeterminingtheproperconversionofPolyPipesrecommendedinterfacialpressuretothegaugepressure.Theeffectivehydraulicpistonareamustbeavailableinordertocalculatetherequiredhydraulicgaugepressure.Thecalculationforhydraulicgaugepressureisasfollows:

Where PG = Hydraulicgaugepressure,psi OD = Pipeoutsidediameter,inches ID = Pipeinsidediameter,inches PI = Requiredinterfacialpressure,psi AP = Totalhydraulicpistonarea,in

2 DF = Hydraulicfusionpressurerequiredtomovethecarriageholdingthepipe (generallyacceptedminimumis30psi).

*Thedragfactorisanimportantparametereasilyoverlooked.Iftwolongpiecesofpipearebeingfused,thedragfactorcaneasilyreachseveralhundredpoundspersquareinch(psi).

ExampleCalculations

FusionMachine:McElroyManufacturing28HighForceMachine Hydraulicpistonareaisprovidedbythefusionequipmentmanufacturer. Totalhydraulicpistonareaforthismachineis4.71in2

DesiredInterfacialPressure:75psi

For2IPSSDR11:

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REFERENCES

1. PlasticsPipeInstituteTechnicalReport-33.GenericButtFusionJoiningProcedureforPolyethyleneGasPipe,2006. www.plasticpipe.org

2. PlasticsPipeInstituteTechnicalReport-41.GenericSaddleFusionJoiningProcedureforPolyethyleneGasPiping, 2002.www.plasticpipe.org

3. PlasticsPipeInstituteTechnicalNote42.RecommendedMinimumTrainingGuidelinesforPEPipeButtFusionJ oiningOperatorsforMunicipalandIndustrialProjects,2009.www.plasticpipe.org

4. ASTMF2620-11.StandardPracticeforHeatFusionJoiningofPolyolefinPipeandFittings.www.astm.org

5. ASTMF1056-11.StandardSpecificationforSocketFusionToolsforUseinSocketFusionJoiningPolyethylenePipe orTubingandFittings.www.astm.org

6. PipelineSafetyRegulations.U.S.DepartmentofTransportation.CFR49.Washington,June2011.http://ecfr. gpoaccess.gov/cgi/t/text/text-idx?c=ecfr&tpl=/ecfrbrowse/Title49/49cfr192_main_02.tpl

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NOTES

NOTES NOTES

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(Revised04/30/2012)