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Pipe Fusion: Selecting the Right MachineThe fusing of thermoplastic pipe results in a leak­free and corrosive­resistant system that is becoming the preferredchoice for replacing conventional piping systems that are failing across the country.

McElroy is the worldwide leader in the science of joining thermoplastic pipe in a growing number of infrastructures. Acrucial part of any new installation is the selection of a fusion machine that will cater to your jobsite’s specific needs.

Here’s a few tips on McElroy machine selection:

Pipe SizeWhat size range of pipe and wall thickness will you be working with? This determines which size carriage and orcombination of carriages you may need. McElroy fusion machines are available for pipe as small as 16mm and aslarge as 2m (½’’ CTS to 78” OD).

The pipe size range, dimensional ratio (DR) and the particular fusion standard being followed will dictate whether alow­, medium­ or high­force fusion machine should be used on your job. Typically, when fusing pipe with highinterfacial pressures, a medium­ or high­force cylinder is required.

Magnitude of the JobHow much fusing will you be doing and where will you be doing it? If you are fusing smaller diameter pipe in theconfines of a ditch, a manual Pit Bull® butt fusion machine may be all you need. These compact machines will fit intight work spaces more easily. They are lightweight and can be physically carried from joint to joint yet they are ruggedenough to perform fusions all day long.

But if you are fusing a very long pipeline with medium­ and large­diameter pipe, you will want to consider theportability of the machine and how much accompanying equipment — such as generators and hydraulic power units(HPUs) — you are willing to haul around.

McElroy’s Rolling fusion machines and the flagship TracStar® machine line are good options because they allow forgreater mobility whether on wheels or a track system.

The Rolling machines are towed with another piece of equipment to the fusion area and remain stationary as sticks ofpipe are fused and pulled through. Many are self­contained as well, generating their own electricity and hydraulicpower, so you don’t have to transport those items separately.

The TracStars are not only self­contained, but they are self­propelled which offers greater freedom of movement evenacross rugged terrain. They can remain stationary at your fusion site or easily move between fusion locations.Whether a Rolling machine or a TracStar, the fusion unit can be easily removed for in­ditch fusion. In tight installations,the outer fixed jaw and skid can be removed for an even more compact fusion unit.

If there are many fusions on schedule for the day, opting for the hydraulic clamping feature should be stronglyconsidered. Operators using manual fusion machines rely on their own strength to apply fusion pressure and canbecome fatigued. A lot of time and effort can be saved when the necessary muscle is hydraulically­powered. On theother hand, the most powerful machine may not make sense if only a few fusions are being done. A more lightweightand economical machine in the line of fusion products may be a better option.

DeadlinesWhat is your deadline? Time is of the essence on most jobsites. Taking advantage of productivity tools to expedite yourfusion process can help you turn out long runs of fused pipe each day saving time and money.

McElroy’s PolyHorse® and MegaMc® PolyHorse®, powered pipe­handling systems, can hold a day’s worth of pipe atthe jobsite. They feature a series of adjustable racks that lift and feed pipe into the fusion machine which increasesproductivity by 150 percent and eliminates costs for the extra manpower and heavy machinery that would be neededotherwise.

The MegaMc Pipe Stands hold the fused pipe lengths level with the machine which helps maintain the alignment forongoing fusion processes. Low Profile Rollers pull long lengths of fused pipe long distances and minimize pipe drag.These kinds of productivity tools allow the fusion to be staged in one area.

Installing coiled pipe is also performed more quickly with the LineTamer® which was designed to straighten and re­round an entire coil of pipe with a minimum of two fusion joints.

Data Collection RequirementsThe advantage of choosing machines with hydraulic power, even for pipe as small as 2”, is the built­in data loggingcapability which keeps a record of each fusion joint.

The McElroy DataLogger® is used to record and document the key parameters of the fusion process with easy­tointerpret graphics of the heat and cool times and fusion pressures. A consistent routine of data collection can provideassurance that fusion joints are safe and sound before they go in the ground, potentially avoiding costly expenses toextricate and repair questionable joints.

This is especially important to contractors, pipeline owners and engineers as new regulations continue to emerge thatrequire better record keeping and increased accountability for those creating and managing pipeline infrastructures.

Data logging tools are becoming more and more advanced in an effort to capture information in a variety of ways. Keyfeatures of the latest model DataLogger 5 include GPS tagging targeting fusion locations, built­in 5MP cameras tocapture fusion alignment, and barcode scanning to input data from pipe and fittings.

The DataLogger 3, 4 and 5 generate joint reports for in­field review or transfer to the DataLogger Vault™, a free onlineapplication that provides secure storage and analysis in the cloud that can be accessed from multiple locations with aninternet connection.

Maintenance and Operator TrainingIn addition to machine selection, two other factors must be strongly considered for a successful fusion operation:maintenance of fusion equipment and well­trained operators. Both are achieved by taking advantage of on­the­job,hands­on and classroom training that is available through McElroy University which helps promote efficiency,productivity and safety.

TradeshowsMcElroy will have products on display at several trade shows over the next few months. We’d love to see you at ourbooth!

INDOWATERMay 27­29JakartaBooth # E40

World GasConferenceJune 1­5Paris, FranceBooth # P35

AWWA ACE15June 7­10 Anaheim, CA Booth # 2522

Sign Up Now For Spring 2015 Classesat McElroy University

Whether it's machine operation, troubleshooting and maintenance or fusion inspection, our classes are designed togive you the skills and knowledge you need to be successful in your field. Plan ahead by signing up for one of ourclasses taught by McElroy Certified Instructors. Classes are a mix of classroom and hands­on learning. They fill upquickly, so be sure and register soon!

Here’s a few upcoming classes:

Large Diameter Troubleshooting and Rebuild, March 23­26; May 18­21

Fusion Inspector Training & Qualification, April 7­9; June 2­4

Small Diameter Operator Qualification, April 27­29

Medium Diameter Operator Qualification, April 29­May 1

Large Diameter Operator Qualification, May 4­7

Small Diameter Troubleshooting & Rebuild, May 11­13

Medium Diameter Troubleshooting & Rebuild, May 13­15

Tech Bulletin: Fusion PressureCalculatorIf you received a piece of McElroy equipment that was shipped after Jan. 1, 2015, the Fusion Pressure Calculator thatwas enclosed contained a typographical error.

The misprint is for the 14.5 psi indicator on the Imperial Units side of the calculator. The corrected calculator will beincluded with upcoming fusion machine orders. If you would like a replacement Fusion Pressure Calculator, please fillout this Request Form.

Fusion pressure can always be calculated using the McCalc App on your smartphone or tablet, or the online Fusion

Pressure Calculator on our website.

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