iso_dis_19480_(e)

7/25/2019 ISO_DIS_19480_(E)

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© International Organization for Standardization, 2002

DRAFT INTERNATIONAL STANDARD ISO/DIS 19480

ISO/TC 138 /SC 4 Secretariat: NEN

Voting begins on Voting terminates on2002-08-08 2003-01-08

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION • МЕЖДУНАРОДНАЯ ОРГАНИЗАЦИЯ ПО СТАНДАРТИЗАЦИИ • ORGANISATION INTERNATIONALE DE NORMALISATION

Thermoplastics pipes and fittings for the supply ofgaseous fuels — Training and assessment of fusion-machine operators

Tubes et raccords thermoplastiques pour le transport de combustibles gazeux — Formation et évaluation desopérateurs de soudage

ICS 03.100.30; 83.140.30; 91.140.40

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© ISO 2002 — All rights reserved iii

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iv © ISO 2002 — All rights reserved

ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISOmember bodies). The work of preparing International Standards is normally carried out through ISO technicalcommittees. Each member body interested in a subject for which a technical committee has been established hasthe right to be represented on that committee. International organizations, governmental and non-governmental, inliaison with ISO, also take part in the work. ISO collaborates closely with the International ElectrotechnicalCommission (IEC) on all matters of electrotechnical standardization.

International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 3.

The main task of technical committees is to prepare International Standards. Draft International Standards adoptedby the technical committees are circulated to the member bodies for voting. Publication as an International

Standard requires approval by at least 75 % of the member bodies casting a vote.

Attention is drawn to the possibility that some of the elements of this International Standard may be the subject ofpatent rights. ISO shall not be held responsible for identifying any or all such patent rights.

ISO 19480 was prepared by Technical Committee ISO/TC 138, , Subcommittee SC 4/WG Fusion Operator, .

This second/third/... edition cancels and replaces the first/second/... edition (), [clause(s) / subclause(s) / table(s) / figure(s) / annex(es)] of which [has / have] been technically revised.

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© ISO 2002 — All rights reserved v

The quality of a natural gas distribution system is to a large extent determined by the skills of the operators involvedin installing the network. When installing PE or PEX pipes, the quality of the fusion joints is essential for the system.

Since fusion joints in PE or PEX systems can be made using various technologies, it is important that the fusionoperator is trained and competent in the fusion technology employed in constructing the PE network.

Continued competence of the fusion operator is covered by periodic re-training and re-assessment.

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© ISO 2002 — All rights reserved

This International Standard provides a structure for use in the training, assessment and approval of fusionoperators in order to establish and maintain competency in construction of PE and PEX Fusion System in

accordance with ISO 10839 or ISO 14531-41) .

The fusion methods covered by this standard are: butt fusion, electrofusion and socket fusion.This international standard covers both the theoretical and practical knowledge necessary to ensure high qualityfusion joints.

The following normative documents contain provisions which, through reference in this text, constitute provisions ofthis part of ISO nnn. For dated references, subsequent amendments to, or revisions of, any of these publicationsdo not apply. However, parties to agreements based on this part of ISO nnn are encouraged to investigate thepossibility of applying the most recent editions of the normative documents indicated below. For undatedreferences, the latest edition of the normative document referred to applies. Members of ISO and IEC maintainregisters of currently valid International Standards.

ISO 4437:1997,

ISO/TS 10839:2000,

ISO 12176-1:1998,

ISO 12176-2:2000,

ISO 12176-3: 2002

ISO 13953: 2001,

ISO 13954:1997,

ISO 13955:1997

1) To be published

Thermoplastics pipes and fittings for the supply of

gaseous fuels — Training and assessment of fusion-machine operators

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ISO DIS 13956:– )

ISO 14531-1: -1) ,

ISO 14531-2: -1) .

ISO 14531-4: -1) ,

ISO/IEC 17025: 1999

EN 45004: 1995

EN 45013: 1989

For the purposes of this part of ISO 19480, the following terms and definitions apply

pressure/time diagram for a defined fusion temperature, representing the butt fusion operation

frictional resistance due to the weight of the length of pipe fixed in the moveable clamp at the point at which

movement of the moveable clamp is initiated (peak drag) or the friction occurring during movement (dynamic drag)

force necessary to overcome friction in the whole mechanism of the butt fusion machine

person trained to carry out fusion jointing between polyethylene (PE) pipes and/or fittings based on a writtenprocedure agreed by the pipeline operator. The fusion operator is trained for one or more fusion–jointingprocedures, involving the operation of manual and/or automatic fusion-jointing machines.

approval certificate issued by the examiner/assessor stating the knowledge and the skill of the fusion operator toproduce fusion joints following a given fusion procedure.

document providing in detail the required variables and its values for a specific fusion process to assurerepeatability, e.g. butt fusion procedure, electrofusion procedure

private or public organisation authorised to design, construct and/or operate and maintain the gas supply system

establishment for training of fusion operators

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A trainee fusion operator for underground PE or PEX systems for distribution of natural gas shall follow a trainingcourse at a training centre, in order to obtain a fusion operator certificate for PE or PEX pipes. The training centreshall provide the training courses under the conditions described in this standard. The training centre shall be asrequired by national authorities. The courses will be delivered by a competent trainer with the required experienceof fusion processes and who has mastered the fusion technique involved. The trainer shall have a qualification asrequired by national requirements.

The training centre shall have a range of fusion machines representative of the equipment encountered onworksites for installing gas pipes, in order for the trainee fusion operator to become acquainted with the fusionequipment commonly used. The trainee fusion operator may be trained on one of these fusion machines or on a

machine from his own company if accepted by the training centre. The fusion machine shall comply with therelevant ISO standards: ISO 12176-1 for butt fusion machines and ISO 12176-2 for electrofusion machines.

Preferably a training centre should not carry out activities related to contracting, supervision of construction work, orinspection of fusion joints.

A trainee fusion operator who has followed a training course as described above shall then pass a theoretical andpractical assessment in order to be qualified as a fusion operator for PE and PEX systems.

The assessor shall not be the trainer and shall have appropriate assessment qualifications.

NOTE The assessor can be a body accepted by the contracting parties or an accredited body e.g. EN 45004 or a

certification body e.g. EN 45013.

A qualified fusion operator shall renew his operator certificate every two year. For this purpose he shall pass apractical examination with an assessor body as specified in 7.

The training course should comprise of any combination of fusion packages based on the requirements of thepipeline operators. These packages may be given as individual modules or combined to suit requirements.

During the training, attention shall also be paid to safety. The course related to safety shall deal with safety relatedto the fusion process as indicated in Annex A.

An instructor who at least meets the requirements described in 4.1 above shall provide training.

All consumables and tools necessary for the training package shall be available during the training session.

The pipes and fittings used shall be conform to ISO 4437, ISO 8085 parts 1 to 3, ISO/FDIS 14531-1 and ISO/FDIS14531-2 and corresponding to what is normally used locally for building gas systems.

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The lessons should be designed so that the trainee fusion operator learns to master the fusion technique and alsolearns to master the materials and practical problems involved in laying a pipe in a trench, with or withoutobstacles. In connection with the latter aspect, the trainee fusion operator shall construct at least one three-dimensional configuration (connection between two pipes laid in different axes).

The trainee fusion operator shall receive a written manual covering all the elements dealt with in the training. Thecourse shall be drawn up in one of the national languages.

The theoretical course shall deal with general information in connection with raw materials, pipes and fittings, andalso with theoretical knowledge about joining components, including details of the different fusion techniques,namely electrofusion, butt fusion or socket fusion, different materials (e.g. PEX 80, PEX 100, PEX 125, PE 80, PE100), different SDR series and correct and incorrect parameters.

The safety course shall include information concerning the fusion process, such as protective clothing, generalsafety regulations for electrical equipment, handling heater plates. The content of the course shall comply with atleast the outline laid down in annex A of this standard.

The trainee shall be made familiar with the electrofusion technique and procedure by making a sufficient number ofelectrofusion joints.

The fusion procedure shall be carried out in accordance with the instructions supplied by the manufacturer of theelectrofusion fitting or as written in a national specification. The fusion parameters are laid down by themanufacturer, and are normally implemented automatically by the fusion machine itself (by reading in a bar code orsuchlike).

The trainee shall begin by realising an assembly with an electrofusion socket between two pipes, and shall then be

taught to make joints with more specific electrofusion fittings such as T-fittings, reductions, saddles and tappingtees. Consideration shall also be given to the cleanliness of the pipe, fitting and fusion equipment.

NOTE For practical reasons and if accepted by the pipeline operator, the assembly can be limited to the complete jointing procedure

without starting the final fusion cycle.

The trainee shall learn about typical fusion faults, how they can be detected and how to avoid them.

Finally, the trainee shall learn how to assess the quality of an electrofusion joint, and what the available testmethods are.

ISO standard TS 10839 may be used as a guide for a general electrofusion procedure; this standard also providesinformation about quality control for electrofusion joints.

The trainee fusion operator shall be made familiar with the butt fusion technique and procedure by making asufficient number of butt fusion joints.

The butt fusion procedure used shall be a procedure recommended by the pipeline operator.

NOTE In some cases the butt fusion cycle may vary according to the diameter, e.g. with double fusion pressure being usedfor larger diameters. In such a case, the fusion operator shall also be made familiar with this technique.

Attention shall also be paid to the differences between automatic and manual fusion machines, as regards amongother things drag resistance and frictional resistance in the butt fusion machine.

The trainee shall start by making a butt joint between two pipes, and shall then learn to make butt fusion joints withpipes and fittings such as tees, reductions etc. The trainee shall learn about typical fusion faults, how they can bedetected and how to avoid them.

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Finally, the trainee shall learn how to assess the quality of a butt fusion joint, and what the available test methodsare.

ISO standard TS 10839 may be used as a guide for a general butt fusion procedure; this standard also providesinformation about quality control for butt fusion joints.

The trainee fusion operator shall be made familiar with the socket fusion technique and procedure by making asufficient number of socket fusion joints.

The procedure shall be carried out in accordance with the instructions supplied by the manufacturer of the socketfusion fitting. The fusion operator shall be made familiar with type A and B fittings, and with the fact that these twosystems are not compatible with each other. The fusion parameters shall be as laid down by the manufacturer ofthe socket fusion fitting.

The trainee shall start by making a socket fusion joint between two pipes, and shall then learn to make joints withmore specific socket fusion fittings. The trainee shall learn about typical fusion faults, how they can be detected and

how to avoid them.Finally, the trainee shall learn how to assess the quality of a socket fusion joint, and what the available testmethods are.

ISO standard TS 10839 may be used as a guide for the general socket fusion jointing procedure; this standard alsoprovides information about quality control for socket fusion joints.

The fusion training shall end with a theoretical and practical examination (test piece). The content of theexamination is laid down in Appendix B of this standard, and shall be taken with an assessor based on theassessment to be obtained as specified in 4.2 above.

The assessor shall visually observe the making of test pieces and any failure to comply with the jointingspecification shall constitute a failure of the practical test. The assessor may select test pieces for the followingdestructive tests :

ISO 13953 (tensile test) for butt fusion joint: the test piece shall present a ductile failure;

ISO 13954 (peel decohesion) for electrofusion joint or socket fusion joint with a diameter equal or greater then90: the test piece shall not present a brittle failure zone longer then 33 % of the fusion zone in the longitudinal

axis.

ISO 13955 (crushing decohesion) for electrofusion joint or socket fusion joint with a diameter smaller then 90:the test piece shall not present a brittle failure zone longer then 33 % of the fusion zone in the longitudinal axis.

ISO DIS 13956 (tear test) for fusion saddles: the test piece shall not present a brittle failure surface longer then25 % of the fusion zone in the longitudinal axis.

Where the test piece fails to meet the requirements of the test this shall constitute failure of the practical test.

The testing of test pieces shall be performed in a laboratory chosen by the assessor.

NOTE To avoid cases of dispute, accredited laboratories following ISO 17025 are recommended.

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Trainee fusion operators who pass the theoretical and practical examination shall receive a fusion operatorcertificate bearing the logo of the assessment centre awarding the approval.

The fusion operator certificate shall state the technique or techniques for which the operator is qualified:electrofusion, manual and/or automatic butt fusion or socket fusion. The fusion operator certificate shall be drawnup in one of the national languages.

NOTE A qualified fusion operator may be issued with a certificate that meets the requirements of ISO 12176-3.

If the trainee fails one of the examinations, he shall retake it after a period not shorter than one week.

If the result is negative once more, the trainee shall repeat the training the course.

The fusion operator certificate shall be valid for a limited period, typically lasting two year from the date of issueunless another period is laid down at national level.

Approved fusion operators should therefore be re-assessed every two-year (by the assessor body mentioned in4.2) to renew their fusion operator certificate (periodic re-assessment).

If the operator succeeds in making a test joint, the validity of the fusion certificate shall be extended.

The test joint shall consist of making a fusion joint and shall then be tested according to the relevant ISO-methode.g. ISO 13954 (peel test) for electrofusion joint and/or ISO 13953 (tensile test) for butt fusion joint and/or ISO13955 (crush test) for electrofusion or heated tool socket fusion joint and/or ISO 13955 (crush test) for electrofusionand heated tool socket fusion joints and /or ISO 13956 (tear test) for saddles. The test criteria are laid down insection 6.1.

A fusion operator shall be re-approved after any 12-month period without producing any fusion joint following theprocedure mentioned on its operator certificate or when the tests on joints made by the fusion operator are foundunacceptable. For this purpose a fusion operator shall be subjected to spot checks in order to verify the quality ofthe fusion joints made by him.

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Polyethylene compound:

Typical properties of thermoplastics, PE 80, PE 100, PEX 80, PEX 100, PEX 125, UV behaviouand typical colours;

Physical and mechanical behaviour of PE compound: temperature effects, strain/stress, creep,elongation/shrinkage, stress cracking, etc.

Extrusion of pipes:

Overview of the production process, packaging and marking

Transport, handling and storage of pipes

Injection moulding of fittings:

Overview of the production process, packaging and marking

Dimensions:

Nominal diameter and wall thickness (SDR), out of roundness

Maximum allowed pressure, standards for pipes and fittings and other accessories (valves), , etc.

Overview of relevant test methods associated with this standard.

Identification number, validity, skill.

Principles of risk management

Clothing, shoes, hard hat, gloves, ..

Risks related to cleaning fluid, risks related to pipe handling and pipe storage,

Use of fire extinguishers

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Working in trenches, lifting objects

Reference to national regulations regarding working under pressure

Electrical safety, use of generators, heating plate,

Electrical safety, use of generators

Electrical safety, use of generators, heating tool

Fusion machines, tools (scrapers, clamps, rollers, shelters, cleaning fluid, ..), installationinstructions (aligning, scraping, clamping, etc.), the use and installation of mechanical joints etc.

Maintenance and servicing of equipment

Overview of code of practice for installation ISO 10839

Principle

Scope: straight/coiled pipes, service lines, main lines, etc.

Components: pipes, spigot fittings, other fittings

Butt fusion equipment: manual and automatic machines

Joint preparation: scraping, re-rounding, alignment, cleaning

Butt fusion cycle: pressure, time and temperature diagram

Failure reasons: understanding and avoiding possible deficiencies

Test methods: visual inspection, tensile test, bending test, hydrostatic test, etc.

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Principle

Scope: straight/coiled pipes, service lines, main lines

Components: pipes, electrofusion fittings, other fittings,

Electrofusion equipment: retrieval of fusion parameters, traceability data


Fusion parameters


Test methods: visual inspection, peel test, crush test, hydrostatic test, etc.

Principle

Scope: service lines, main lines

Components: pipes, socket fittings, other fittings

Socket fusion equipment


Fusion parameters


Test methods: visual inspection, hydrostatic test, etc.

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The theoretical examination shall consist of a list of multiple-choice questions that have to be answered by thetrainee fusion operator within a set time.

The questions shall cover the entire field of the theoretical course. The number of questions shall be minimum 20.

There shall be a sufficiently wide range of questions, so that the same questions do not constantly recur insuccessive training cycles.

The fusion operator shall be able to answer at least 80 % of the questions correctly.

The practical examination shall consist of a test joint on a PE pipe with a diameter representative of the intendedfield. According to the required skill, two or three electrofusion joints, butt fusion joints and/or socket fusion jointsmay be made.

The test pieces shall then be visually inspected. If a failure is observed the test piece shall be refused. Otherwiseone of the test pieces of each fusion method shall be tested according to ISO 13953 (tensile test) and/or ISO13954 (peel test) and/or ISO 13955(crush test) and/or ISO 13956 (tear test). The test criteria are described in 6.1.

If the fusion operator does not pass the practical examination, the examination report shall state the reason.

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