TECHNICAL MANUAL

Welding and installation of polyethylene pipelines

under pressure

Definitions
Welders qualification
Standard references

Jointing systems
Transition systems
Buttfusion systems
Electrofusion systems

Inspection of welded jointings

Transport and storage

Installation of PE pipelines
Pipeline testing
The content of this manual is updated with all knowledges and existing standards at its publication
date. We decline any responsibility related to the contents which could be incorrect or not up-to-
dated.
 definitions
Definitions
This publication, making reference to the UNI, EN and ISO standards regarding
the polyethylene pipeline systems carrying fluids under pressure, uses the
following definitions relatively to the geometric characteristics of the pipes and
fittings:

d n nominal outside diameter specified outside diameter, which is a number

properly rounded-off, approximately equal to
the constructive dimension, in millimeters

en nominal wall thickness numerical designation of the wall thickness

of a component, which is a proper rounded-
off number, approximately equal to the
manufacturing dimensions in millimeters

de outside diameter dimension value of the external diameter

(at any point) through its cross section at any point of the
pipe, rounded to the next greater 0,1 mm

dem average outside diameter dimension value of the external circumference
of a pipe or spigot end of a fitting at any straight
section, divided by p (= 3,142), rounded to the
next greater 0,1 mm

SDR standard dimensional ratio numerical designation of a pipe series, which is a

proper rounded-off number, approximately equal
to the relationship between the outside nominal
diameter dn and the nominal wall thickness en

3
 polyethylene classification

The polyethylene classification, defined by the international standards is

issued depending on the parameter MRS Minimum Required Strength,
expressed in megapascal, that is considered as a characteristic of the material
and is representing the medium resistance value at long term at the reference
temperature of 20C for 50 years with internal water pressure, properly rounded.
Each MRS has a design stress value (or admittable stress) ss, derived by
MRS applying a design safety coefficient C (or called safety factor K) which
considers either the service conditions or the properties of the components of a
pipeline system.
For water distribution pipelines the total safety coefficient according to the
standard UNI EN 12201 is equal to C=1,25; while for gas distribution pipelines
the safety factor is equal to K=3,25 (according to the standard UNI 9034 and the
Decree of the Economic Development Ministry 16th April 2008).
The compounds are specified with the initials associated to the type of material
(PE) and with the value of the minimum required resistance (MRS) multiplied
by 10. The designation of the material is comprised between the information
reported on the pipes/fittings marking.

Mpa
SPECIFICATION MRS ss water ss gas
PE 80 8,0 6,3 2,5
PE 100 10,0 8,0 3,1

4
 tables

relationship between SDR, series S and pressure

class PN
The standard dimensional ratio SDR identifies the numerical designation
of a pipe series and is a proper rounded number, approximately equal to the
relationship between the outside nominal diameter dn and the nominal wall
thickness en of a pipe.
The series of the pipe S is a number used for the designation of the pipe
according to the standard ISO 4065; the relationship between the pipe series S
and the standard dimensional ratio SDR is given by the formula S = (SDR-1)/2.
The maximum real pressure of a fluid admitted at continuous use in a pipeline
system, expressed in bar, is defined as the maximum operating pressure (MOP)
and is calculated by an equation which considers the physical and mechanical
characteristics of the components:

The nominal pressure PN is a numerical designation used for reference

purpose, relative to the mechanical characteristics of the component of a
pipeline system. For pipelines systems of plastic materials for water distribution,
this is corresponding to the maximum continuous operating pressure at 20C,
based on the design safety coefficient.
The following table establishes the relation between the most common values
of the standard dimensional ratio SDR and the pipe series S with the nominal
pressure PN of the pipe, through the minimum resistance required MRS.

SDR 26 17 11 9 H 7,4

S 12,5 8 5 4 3,2

PE 80 PN 5 PN 8 PN 12,5 PN 16 PN 20

PE 100 PN 6 PN 10 PN 16 PN 20 PN 25

H excluded from the national introduction of the standard UNI EN 12201

5
 exercise pressures of PE pipelines

water distribution UNI EN 12201

The polyethylene is a material with viscoelastic characteristics: because of the

material creep, the mechanical resistance drops down by increasing of the
temperature.
When a polyethylene piping system is operating at a constant and continuous
temperature higher than 20C and up to 40C, a pressure reduction coefficient
is applicable; in the following table the operating admissible pressure values
are reported according to the exercise temperature derived from the nominal
pressure PN of the pipe applying the reduction coefficients defined in the
Appendix A of the standard UNI EN 12201-1.

ADMISSIBLE OPERATING PRESSURE ACCORDING

C TO THE EXERCISE TEMPERATURE
[bar]

20 5,0 6,0 8,0 10,0 12,5 16,0 20,0 25,0

30 4,3 5,2 7,0 8,7 10,9 13,9 17,4 21,8
40 3,7 4,4 5,9 7,4 9,3 11,8 14,8 18,5

fuel gas transport D.M. 16.04.2008

The following table reports the values of the maximum exercise pressure
according to the standard dimensional ratio SDR of the pipe and the minimum
resistance required MRS of the polyethylene, valid for fuel gas transport pipelines,
considered by applying the safety coefficient K=3,25.

dimensions allowed PE80 - pressure PE100 - pressure

SDR [mm] [bar] [bar]

17,6 63 3,0 3,7

11 16 H 5,0 5,0

H The standard UNI 9034 establihes a minimum thickness of the pipe tc equal to 3 mm

6
 pipe/fitting dimensions

UNI EN 12201 - UNI EN 1555

SDR 26 SDR 17 SDR 11 SDR 7,4

S12,5 S8 S5 S3,2

PE 80 PN 5 PN 8 PN 12,5 PN 20

PE 100 PN 6 PN 10 PN 16 PN 25

dn THICKNESS en mm THICKNESS en mm THICKNESS en mm THICKNESS en mm

16 -- -- H -- H 2,3 H
20 -- -- H 2,0 H 3,0
25 -- -- H 2,3 H 3,5
32 -- 2,0 H 3,0 4,4
40 -- 2,4 H 3,7 5,5
50 2,0 3,0 4,6 6,9
63 2,5 3,8 5,8 8,6
75 2,9 4,5 6,8 10,3
90 3,5 5,4 8,2 12,3
110 4,2 6,6 10,0 15,1
125 4,8 7,4 11,4 17,1
140 5,4 8,3 12,7 19,2
160 6,2 9,5 14,6 21,9
180 6,9 10,7 16,4 24,6
200 7,7 11,9 18,2 27,4
225 8,6 13,4 20,5 30,8
250 9,6 14,8 22,7 34,2
280 10,7 16,6 25,4 38,3
315 12,1 18,7 28,6 43,1
355 13,6 21,1 32,3 48,5
400 15,3 23,7 36,4 54,7
450 17,2 26,7 40,9 61,5
500 19,1 29,7 45,4 --

H The standard UNI 9034 establishes a minimum thickness of the pipe tc equal to 3 mm

7
 welders qualification
The experience acquired in time showed that, even if the jointing processes of
PE pipelines are today wholly supported by special equipment (welding units,
aligning clamps, scrapers, etc), frequently the correct welding procedures are
not respected, therefore compromising the positive result and reliability of
the jointings with negative effects in term of safety and economic loss. Main Welders
qualification
importance is that the welder is trained and suitably qualified.
The qualification certificate according to the standard UNI 9737 is compulsory
for the personnel employed in the welding of PE pipelines within the Decree of
the Ministry 16th April 2008 Technical rules for design, construction, testing,
operating and surveillance of the works and distribution systems and direct lines
of natural gas with density not higher than 0,8. Furthermore it is one of the
suitable requirements for issuing a correct conformity declaration according
to the D.M. n 37 dated 22nd January 2008 Direction of article 11-quaterdecies,
comma 13 letter a) Law n. 248 dated 2nd December 2005, relative to the
plant installation activities inside the buildings. Also the gas distribution and
water networks are included within this application field. With the conformity
declaration, which is issued at working end, the installation company certifies
that the network has been built-up according to the updated UNI standards.

Classification and qualification of welders for plastic materials

SALDATURE Welders by the heated tool procedure, with mechanical equipment and
by electrofusion for pipes and fittings of polyethylene for the supply of
UNI 9737
UNIPLAST
gaseous fuels, water and others fluids under pressure

SALDATURE Welding of plastic materials - Heated tool butt welding. Welding of

polyethylene pipes and/or fittings for gas, water and others pressure fluids UNI 10520
UNIPLAST pipelines

SALDATURE Welding of plastics materials - Electrofusion welding. Welding of

polyethylene pipes and/or fittings for gas, water and others pressure fluids UNI 10521
UNIPLAST pipelines

SALDATURE Field welding machines by the heated tool for polyethylene pipes and/or
fittings butt joints for gas, water and others pressure fluids pipelines. UNI 10565
UNIPLAST Functional, test and documentation characteristics

Electrofusion welding machines and auxiliary equipment for polyethylene

SALDATURE pipes and/or joints by electroweldable connections for gas, water and
others pressure fluids pipelines.
UNI 10566
UNIPLAST
Construction, test and maintenance requirements, documentation

9
 training courses

welders classification

The standard UNI 9737 identifies the method for the classification and
qualification of the personnel involved in the polyethylene pipes/fittings jointings
for the distribution of fuel gas, water and other fluids under pressure by using
buttfusion procedures with mechanical equipment and electrofusion system.
Leaving out the welding process by socket fusion jointing (pocket jointing) and
segment jointing, rarely used in the defined application field, the 2007 edition of
the standard distinguishes four different qualification classes according to the
fitting type and the welding process.
class PE-2 jointing process with buttfusion welding of pipes and/or fittings
with outside diameter less or equal to 315 mm
class PE-2-D jointing process with buttfusion welding of pipes and/or fittings
of every diameter
class PE-3 jointing process with electrofusion welding of pipes and/or
fittings with outside diameter less or equal to 225 mm using ef
sockets and ef saddles of every diameter
class PE-3-D jointing process with electrofusion welding of pipes and/or
fittings using ef sockets and ef saddles of every diameter.

technical training center Eurostandard

For each qualification class, in order to obtain the relative qualification Certificate,
the welder must pass a theoretical and practical examination. Only the Operators
who attended a suitable training course in a qualified Center are allowed for the
examination. This Center must be also approved by an accredited company
for the personnel certification on the basis of the requirements defined by the
standard UNI 9737. The teachers, having experience in the field and with the
welder certificate, must have pass a qualifying examination carried out by a
Technical Committee encharged by the accredited body.
Each course must comprise both theoretical as well as practical session.
Duration is related to the welding processes required by the type of qualification.

tYpE OF QUALIFICATION TOTAL DURATION

PE-2 16 hours
PE-2-D 18 hours
PE-3 16 hours
PE-3-D 18 hours
PE-2+PE-3 28 hours
PE-2-D+PE-3 30 hours
PE-2+PE-3-D 30 hours
PE-2-D+PE-3-D 32 hours
Upgrade D to classes PE-2 and PE-3 2 hours

10
11
 Contents of the training courses are defined by the standard UNI 9737 and
explained to the participants by the qualified teachers.
At the end of the course, every participant will be given an attendance certificate,
which in no way is a substitute of the Welder Qualification Certificate according
to the updated standard.

For further information and application, please contact:

TECHNICAL TRAINING CENTER

Eurostandard S.p.A. Course Secretary
Zona Industriale Lago
38038 TESERO (TN) - ITALY
phone +39 0462 811 211
fax +39 0462 811 200
e-mail: training@eurostandard.it

12
 standard references
The references given below are part of design, laying, management and
inspection of PE pipeline systems under pressure. The described standards and
requirements are the basic elements particularly for the designers and installers
activities.

production requirements

CEN Plastic piping systems for the supply of gaseous fuels - Polyethylene Standard
(PE) UNI EN 1555 references
UNIPLAST

CEN
Plastic piping systems for water supply - Polyethylene (PE) UNI EN 12201
UNIPLAST

CEN Plastics piping systems for industrial applications UNI EN

Polybutene (PB), polyethylene (PE) and polypropylene (PP) -
UNIPLAST Specifications for the components and the system - metric Series ISO 15494

Polyethylene-metal mixed joints for piping system for the supply

of gaseous fuels, conveyance of water and of liquid and gaseous
UNIPLAST fluids and/or polypropylene-metal mixed joints for piping systems UNI 9736
for the conveyance of water and of liquid and gaseous fluids. Types,
requirements and tests

G.U. Rules regarding the materials and the objects which can be used in the D.M. n. 174
Rep. Italiana fix plants for treatment and distribution of water for human consumption. 6 aprile 2004

G.U. Execution of EEC Directive 98/83 regarding the quality of water destined D. Lgs. n. 31
Rep. Italiana to human consumption. 2 febbraio 2001

G.U. Execution of EEC Directive 80/778 regarding the quality of water

destined to human consumption according to article 15 of the law dtd.
D.P.R. 236
Rep. Italiana 24 maggio 1988
April 16, 1987 nr. 183

Consiglio Government direction of 3 November 1998 relative to quality of water Direttiva

CEE/UE destined to human consumption 98/83/CE

13
 welder qualification and welding process

Classification and qualification of welders for plastic materials

SALDATURE Welders by the heated tool procedure, with mechanical equipment and
by electrofusion for pipes and fittings of UNI 9737
UNIPLAST polyethylene for the supply of gaseous fuels, water and others fluids
under pressure

Plastics welding personnel - Qualification testing of welders -

UNIPLAST Thermoplastics welder assemblies
UNI EN 13067

SALDATURE Welding of plastic materials - Heated tool butt welding. Welding of

polyethylene pipes and/or fittings for gas, water and others pressure UNI 10520
UNIPLAST fluids pipelines

SALDATURE Welding of plastics materials - Electrofusion welding. Welding of

polyethylene pipes and/or fittings for gas, water and others pressure UNI 10521
UNIPLAST fluids pipelines

Coordination of welding, pipe laying and test activities for polyethylene

SALDATURE transmission lines of gaseous fuels, water and other fluids under
pressure. UNI 10761
UNIPLAST Tasks and responsabilities, requirements for training, qualification and
certification of personnel

pipeline laying

Ministero Technical rules for design, construction, testing, operating and

D.M.
dello Sviluppo surveillance of the works and distribution systems
16 aprile 2008
and direct lines of natural gas with density not higher than 0,8.
Economico

Gas distribution pipelines with maximum operating pressure not

CIG exceeding 0,5 Mpa (5 bar) UNI 9034
Materials and jointing systems

Gas distribution networks. Pipeworks with maximum working operating

CIG pressure up to 5 bar UNI 9165
Design, construction, testing, operation, maintenance and rehabilitation

14
 Transport and supply of gas Pipeworks with maximum working
UNI EN
CIG operating pressure not exceeding 16 bar General functional
recommendations 12007-1

Transport and supply of gas - Pipeworks with maximum working

operating pressure not exceeding 16 bar Specific functional UNI EN
CIG recommendations for polyethylene pipelines (maximum operating 12007-2
pressure MOP not exceeeding 10 bar)

Gas service pipelines. Design, construction, testing, operation,

CIG maintenance and rehabilitation
UNI 9860

Ministero Direction of article 11-quaterdecies, comma 13 letter a) Law n. 248 dd

D.M. n. 37
dello Sviluppo 2nd December 2005 relative to the plant installation activities inside the
22 gennaio 2008
buildings.
Economico

Gas plants for domestics and similar use fed by network distribution.
CIG Design and installation
UNI 7129

Ministero
Technical standards regarding pipelines D.M.
dei Lavori Regulation of design, construction and testing 12 dicembre 1985
Pubblici

Laying and general test and inspection of polyethylene piping systems

UNIPLAST for the transport of pressure liquids
UNI 11149

Water supply - Requirements for systems and components outside

CEN buildings
UNI EN 805

Plastic pipeline systems. Water distribution and sewarage pipelines UNI ENV
UNIPLAST outside buildings
Practices for installation above and below ground. 1046

Politecnico Ed. Marzo

Polyehtylene pipelines for water supply
Milano 2005

Fire fighting equipment - Hydrant systems. Design, installation and

UNI operation
UNI 10779

15
 welding units

Field welding machines by the heated tool for polyethylene pipes and/or
SALDATURE fittings butt joints for gas, water and others
pressure fluids pipelines. Functional, test and documentation
UNI 10565
UNIPLAST
characteristics

Electrofusion welding machines and auxiliary equipment for polyethylene

SALDATURE pipes and/or joints by electroweldable connections for gas, water and
others pressure fluids pipelines
UNI 10566
UNIPLAST
Construction, test and maintenance requirements, documentation

safety

G.U. Direction of article 1 Law n. 123 dd 3rd August 2007 regarding the health D. Lgs. n. 81
Rep. Italiana and safety protection in the working sites 9 aprile 2008

16
 jointing systems

The most important jointing techniques for polyethylene pipes and fittings are
the fixed system (thermic welding) and the removable system (mechanical
welding).

fixed system
The techniques used are the electrofusion jointing, the jointing with thermic
elements by contact commonly defined buttfusion and the socket fusion jointing,
usable with polyethylene pipes and fittings according to the standards UNI EN
1555 and UNI EN 12201.
The thermic welding process allows to lay out complete-tight pipelines; infact
thanks to the molecular penetration, their elements at the end of the welding
cycle can be considered as a sole part. Jointing
systems

electrofusion jointing
Welding process of pipes and/or fittings of same nominal
diameter and equal or different SDR, joined with
electrofusion fittings which melt the surfaces thanks to the
heat developed by an integrated electric resistance.

buttfusion jointing
Welding process of pipes and/or fittings with the same
nominal diameter and same SDR where the surfaces to be
welded are at first heated by contact with an heating element
and subsequently jointed together obtaining a buttfusion
joint.

socket fusion jointing

Welding process which uses special fittings shaped to
contain the pipe end to be welded. Pipes and fittings are
heated by heating elements and specific for each diameter.
The good result of this jointing system is based on the
manual ability of the operator. For this reason it has a poor
application.

For reliable jointings it is important the use of products (pipes and fittings) of
proved quality and the employment of qualified personnel according to the
standard UNI 9737.

17
 removable system
The removable system includes all connections with stub end and backing
flange, kit antifluage as well as compression fittings (quick release joints).
These systems allow to connect different materials (PE, PVC, steel or cast-iron)
and also the connection to special products such as valves.

stub end and backing flange

The jointing with stub end, backing flange and gasket
is normally used to connect polyethylene pipes with
others of different material, or to access to valves
and branches. It can also be chosen for a temporarily
jointing of two PE pipelines.
The stub end must be welded to the PE pipe (indifferently
using buttfusion system or with electrofusion) and
forms the support base for the flange, normally made
of steel or aluminium. The connection is made by bolts,
while the tightness is guaranteed using a flat gasket,
placed between the two elements. Its composition is
suitable for the carried fluid.

kit antifluage
This jointing system similar to the above-mentioned
one, is made of a PE stub end and a polypropylene
flange charged with fiber glass; the special design
avoids the deformation of the counter-flange and
guarantees the joint tightness in the long period.

compression fitting
This is also called quick release joint or clamp joint
for its constructive characteristic which consists of
a main body screwed with two bushes. Tightness is
guaranteed by the elastomeric gasket compressed by
the mechanical elements.
This type of fitting is generally used in low pressure
pipeline systems since overpressure or hammering can
compromise the tightness, as well as the ovalization of
the pipe.

18
 transition systems
The metal/PE fittings allow the connection of a polyethylene pipe to other
pipelines, or special fittings of different material.
They can be made of:

monolithic metal/plastic coupling

with smooth or thread metal part. The polyethylene part
is overmoulded on a metallic part suitably prepared,
obtaining a fitting guaranteed to axial bursting and
internal pressure tightness.

copper/pe coupling
with smooth copper part, designed and manufactured
using the same method of the monolithic metal/plastic
coupling.
Transition
systems

assembled metal/plastic coupling

manufactured by mechanical assembling of a steel part
with a polyethylene pipe section. The metallic part is
inserted in the polyethylene pipe by mechanical forcing.
The joint clamping is made with an external nut.

metal/plastic thread long coupling

is a special application of the monolithic metal/plastic
fitting, prolonged and bended at 90 on the steel part.
It is normally used for the construction of branch
networks.

19
 electrofusion transition fitting
is made of an eletrofusion fitting arranged with brass nickel or chromate thread
insert, male or female, or with free nut. It is available in the type socket, 90 and
45 elbow.

electrofusion transition spigot saddle

the upper part of the transition saddle is supplied with
brass female thread insert which allows the direct
branch with metallic pipe. The special version with
double thread and internal/external cap allows the
insert of the shut-off equipment and the subsequent
restoration after in-line repair interventions.

20
 buttfusion jointing

Welding with heated elements by contact, commonly named buttfusion jointing

is defined as the jointing proceeding of two elements (pipes and/or fittings) where
the surfaces to be welded are at first heated by contact with an heating element
and subsequently, after the removal of the heating plate, are joined together with
pressure in order to obtain the welding. The process is defined by the standard
UNI 10520.
The welder must be qualified according to the standard UNI 9737 for the classes
PE-2 or PE-2-D.

compatibility
The buttfusion jointing is applicable to PE 80 and PE 100 pipes and fittings
with the same nominal diameter (preferably higher than 50 mm), equal SDR
(therefore, same nominal thickness) and melt flow index MFR comprised in the
range:

0,2 1,4 g / 10 min (190C / 5 kg)

ambient conditions
Welding must take place in a dry site and ambient temperature field comprised
between: Buttfusion
jointing

-5C +40C

When necessary, suitable protection measures must be taken to protect the

welding operation from adverse ambient conditions such as portable tents,
equipped boxes or others. It is absolutely forbidden the use of gas torch or flame
burners in order to increase the temperature surfaces to be welded.

preliminary controls
The Operator must arrange himself in order to have the complete visual control
on the different operations and must have the necessary space to work without
constraints, in a dry place and whatsoever possible on a level surface.
The components must be collected from storage according to the updated
standards and must be checked before the start of the welding operations;
particularly, it is necessary to verify that the inside and outside surfaces of
the pipes and/or fittings, near to the ends to be welded, are free of cuts and
abrasions that can compromise the correct welding and that the tolerances
relative to thickness, to medium external diameter and to maximum ovalization
allowed by the product standards are respected.
Furthermore, before starting all welding operations it is necessary to evaluate

21
 the efficiency of the equipment which will be used, with reference to the
requirements of the standard UNI 10565.
The preparation of the surfaces to be welded are of main importance for the
guarantee of the jointing quality and must be carried out following the next
operations:

cleaning and facing

Before positioning of the elements to be welded, it is necessary to clean their
internal and external surfaces in order to remove traces of dust, grease, earth
residuals or mud and others. The operation is made by using a wet strong soft
cloth drenched with proper detergent; avoid the use of water detergents.
Following the same procedure, proceed by cleaning the facer tool and the
heating plate.
The pipes/fittings must be closed in the welding unit jaws in the way to
guarantee the possibility of axial movement without relevant frictions, by using
special rollers where let the pipes slide. When possible, work by rotating the two
elements up to the most favorable connection condition, or work on the fixing
system of the jaws taking care to apply a correct clamping strength (if excessive,
it can damage the surfaces of the elements to be welded).
The facing operation must be carried out by moving both parts close to the
rotating facer, only after starting up the tool and working a gradual pressure,
in order to avoid an excessive heating of the contact surfaces or causing the
tool stop. If the facing operation is correctly done, the shavings are continuous
on both ends to be welded. The facer tool must be switched-off only after the
moving away of the ends. The facer cutters must be sharpened or substituted
whenever there are any problem or anomaly during the facing phase.
When facing is completed, the inside and outside shavings must be removed
from the welding area using a clean cloth or brush. The faced ends cannot be
touched any more with hands or get dirty; on the contrary, it is necessary to
repeat the cleaning cycle.

22
 controls
At end of the operation, remove the facer tool, put into contact the surfaces to
be welded in order to verify that:
the maximum mismatch, measured on each point of the circumference, is
not bigger than 10% of the thickness of the elements to be welded, with a
maximum of 2 mm. On the contrary, it is necessary to repeat the aligning and
facing cycle;
the possible detachment between the contact ends is lower than the values
stated in the above table; on the contrary, the aligning and facing operations
must be repeated.
external nominal diameter maximum detachment
[dn] [mm]
up to 250 0,3
over 250 and up to 400 0,5
over 400 and up to 630 1,0
over 630 2/1000 dn

heating plate temperature

The heating plate used to heat the parts must guarantee a constant temperature
over the whole surface within 20 minutes; after this time, on each point of both
surfaces the temperature, read on the thermostat, must be comprised in a
tolerance of 10C of the value set on the thermostat.
Indipendently from the material type (PE80 or PE100) and from the dimensions
of the pipes/fittings to be welded (diameter and thickness), the heating plate
temperature must be:

T = (215+1
-5
0
) C

cautions
The operator must check that during the welding phase, no external agents can
occur to the correct performance of the jointing. Frequently, it can happen that
the heating plate is cooled because of the air chanelled inside the pipelines: in
this case, take out the protection caps, normally inserted on the pipes only at
end of the welding phase, or anyway close the pipe ends.
The heating plate must be always placed in its special support to avoid damages
to the superficial anti-adherent coating, which needs periodical reconditioning,
according to the frequency use. Whenever traces of grease, dust or PE residuals
are present, it is necessary to clean it at cold with proper detergent.

23
 welding pressure
The welding pressure required by the polyethylene must be like that the surfaces
at contact is equal to:

(0,15 0,02) N/mm2

This pressure is calculated through the proper formula, knowing the total
pressure section of the oleodinamic cylinders of the welding buttfusion machine.
In general, the values are reported on proper tables supplied by the manufacturer
according to the weldable diameters and thicknesses. The drag pressure Pt must
be always added to these values.
The pressure, monitored by the pressure gauge, is adjusted using the specific
device.

drag pressure
The drag pressure Pt is the minimum pressure value necessary in order to win
the friction of the movable jaws of the welding machine (loaded with the pipe/
fitting), which depends on the weight of the gear and of the pipes/fittings to be
welded, from the oil temperature in the hydraulic circuit and the jaws clamping
force. Its value has always to be traced experimentally every time we proceed
with a welding process and then added to the pre-heating (P1) and welding (P5)
pressures given in the tables. Never exceed to this value.

24
 welding cycle at single pressure

Y 1 2 3 4 (P5 + Pt) 5 6
(P1 + Pt)

(P2 )
t6

t1 t2 t3 t4 t5 X

The welding operations must immediately follow the ends preparation phase. On
trench site, if within the time between the planing phase and the welding starting
operation dust traces, grease or dirty are settled on the ends to be welded, it is
necessary to repeat the cleaning.

The welding parameters used for the jointing operation must be recorded in a
proper report.

25
 phase 1
hauling and pre-heating

The two surfaces to be welded are put in contact with the heating plate, taking
care to insert it correctly in order to guarantee its steadiness. Afterwards, draw
near both ends to the heating plate and apply the pressure:

P1 + Pt

where P1 is deduced from the tables supplied by the machine manufacturer and
then summed to the drag pressure Pt.
The pre-heating phase ends after a time t1 sufficient as long as it forms on both
welding ends a ring of fused material whose width is equal to:

A = 0,5 + (0,1 x en) [millimeters]

where en is the nominal thickness of the pipe and/or fitting to be welded.

26
 phase 2
heating

In a relative short time it forms a melted plastic ring which shows that the material
has started the fusion process. At this step, the pressure at contact of the
ends with the heating plate must be released avoiding the push-out of the PE
material from the welding zone, which is necessary for a good quality jointing
obtaining only a cold welding, which is extremely fragile.
Pressure is then released to its initial value P1 + Pt (Phase 1) up to a P2 value
which guarantees the ends contact and the heating plate during the whole
heating time and which satisfies:

P2 0,02 N/mm2

Whenever P2 is not specified in the table supplied with the machine, in the
operative practice it is advisable to set the pressure gauge on a value next to
zero but never higher than the Pt. If the operation is correct, the surface heating
continues without increasing the overthickness of the ring.

In this phase, the ends must be in contact with the heating plate for a time
equal to:

t2 = 12 en [seconds]

where en is the nominal thickness of the pipe and/or fitting to be welded.

A tolerance of (+8%, -0%) is admitted on the t2 value.

27
 phase 3
removal of the heating plate

At the expiring of the time t2, the ends are separated to allow the heating plate
removal (take care to avoid the damage of the ends to be welded) and then
brought together for jointing.
This phase is extremely critical and its correct performance is essential for
a successful welding. The removal of the heating plate has to be as fast as
possible in order to avoid the excessive cooling of the ends; at the same
time it is necessary to reduce the closing speed for putting into contacts the two
ends, in order to obtain a jointing that does not take to an abrupt out-coming of
the melted material. This allows to the two parts to correctly melt and avoid the
formation of cold areas inside the joint.
The entire operation must be anyway completed within a time shorter then:

t3 = 4 + (0,3 en) [seconds]

where en is the nominal thickness of the pipe and/or fitting to be welded.

28
 phase 4
build-up welding pressure

Put into contact the ends by increasing pressure in a progressive way and
anyway to avoid a harsh and excessive coming-out of the melted material from
both surfaces, up to the value of:

P5 + Pt

where P5 (equal to P1) is deducted from the tables supplied by the machine
manufacturer and then summed to the drag pressure Pt.
The reaching of this pressure must be within a time equal to:

t4 = 4 + (0,4 en) [seconds]

where en is the nominal thickness of the pipe and/or fitting to be welded.

29
 phase 5
welding

Maintain the ends into contact with pressure (P5 + Pt) for a time equal to:

t5 = 3 + en [minutes]

where en is the nominal thickness of the pipe and/or fitting to be welded.

A tolerance of (+10%, -0%) is admitted on the t5 value.

P5 + Pt P5 + Pt

phase 6
cooling

At the expiring of the time t5, the pressure is released to zero and the welded
joint can be removed from the clamps. The joint must not be stressed until the
complete cooling at touch, because it is possible the formation of cracks and
slackenings in the cut area. The cooling must be carried out naturally, avoid any
quick cooling with water, compressed air and other methods.

The cooling time must not be shorter than:

t6 = 1,5 en [minutes]

where en is the nominal thickness of the pipe and/or fitting to be welded.

30
 synoptic table
phases and parameters of the welding cycle
AT SINGLE PRESSURE

contact time
phase notes
pressure [seconds]

Time t1 which allows to form a

hauling and
1 0,15 N/mm + Pt 2
- ring of fused material with width:
pre-heating
A=0,5 + (0,1 x en) [mm]

Release pressure and maintain

2 heating 0,02 N/mm 2
12 x en the ends into contact with the
heating plate.

removal of the Remove the heating plate

3 - < 4 + (0,3 x en)
heating plate avoiding to damage both ends.

Put into contact the ends avoiding

build-up of the
4 0-> 0,15 N/mm + Pt 2
4 + (0,4 x en) an excessive coming-out of
welding pressure
melted material.

5 welding 0,15 N/mm2 + Pt (3 + en) x 60 Maintain the ends into contact.

The joint cannot be subjected to

6 cooling - 1,5 x en x 60
stresses.

N.B. Within the formula, en shows the nominal thickness of the pipe/fitting

31
 welding cycle at double pressure
When pipes and/or fittings have wall thicknesses higher or equal to 20 mm,
the standard UNI 10520 foresees that it is possible to use alternatively to the
standard cycle (with single pressure), also a welding cycle at double pressure,
here below described.

(P5 + Pt)

Y 1 2 3 4 5 6 7
(P1 + Pt)

(P6 )

(P2 )

t1 t2 t3 t4 t5 t6 t7
X

In this case, the heating plate temperature, the pressures P1 (Phase 1) and P5
(Phase 5) and the pressure P2 (Phase 2) remain unchanged with respect to the
standard cycle, so as unchanged are the ambient conditions, the buttfusion
machines characteristics, the preliminary controls and the welding preparation.
Also in this case, to pressures P1 (Phase 1) e P5 (Phase 5) it is necessary to add
the drag pressure Pt pointed out as in the standard cycle. This is not valid for
pressure P6 (Phase 6), where the surfaces at contact must be subjected to a
pressure equal to:

(0,05 0,01) N/mm2

The welding parameters used for the jointing operation must be recorded in a
proper report.

32
 phase 1
hauling and pre-heating

Position the heating plate in the buttfusion machine, taking care to insert it
correctly on the way to guarantee its stability. Successively, put in contact the
pipe/fitting ends with the heating plate and apply pressure:

P1 + Pt

The pre-heating phase ends after a time t1 sufficient to allow to form on both
welding ends a ring (melted material ring) whose width A is equal to:

A = 0,5 + (0,1 en) [millimeters]

where en is the nominal thickness of the pipe and/or fitting to be welded.

phase 2
heating

Release contact pressure of the ends from the heating plate from initial value
P1 + Pt (Phase 1) up to value P2 and maintain into contact with the heating plate
for a time equal to:

t2 = (10 en) + 60 [seconds]

where en is the nominal thickness of the pipe and/or fitting to be welded.

A tolerance of (+8%, -0%) is admitted on a t2 value.

phase 3
removal of the heating plate
Remove the heating plate, taking care to avoid the damage of the ends to be
welded. Separation speed must be as fast as possible to avoid cooling of the
ends. The time between the removal of the heating plate and the contact of the
ends (Phase 4) must be:

t3 10 [seconds] for dn 630 mm

t3 15 [seconds] for dn > 630 mm

33
 phase 4
build-up of the welding pressure

Put into contact the ends by increasing the pressure in a progressive way and
anyway avoid a harsh and eccessive coming-out of the melted material from
both surfaces, up to a value of:

P5 + Pt

This pressure will be reached within a time of:

t4 10 [seconds]

phase 5
welding

Mantain the ends into contact with pressure (P5 + Pt) for a time equal to:

t5 = 10 [seconds]

phase 6
welding

Release pressure from value (P5 + Pt) up to value P6 and maintain into contact
both ends for a time equal to:

t6 = 3 + en [minutes]

where en is the nominal thickness of the pipe and/or fitting to be welded.

phase 7
cooling

At expiring of the time t6, pressure is released to zero and the welded joint can be
removed from the clamps. The joint must not be stressed until the complete
cooling at touch, because it is possible the formation of cracks and slackenings
in the cut area. The cooling must be carried out naturally, avoiding any quick
cooling with water, compressed air and other methods.
This cooling time must not be shorter than

t7 = 1,5 en [minutes]

where en is the nominal thickness of the pipe and/or fitting to be welded.

34
 synoptic table
phases and parameters of the welding cycle
AT DOUBLE PRESSURE

contact time
phase notes
pressure [seconds]

Time t1 which allows to form a

hauling and
1 0,15 N/mm + Pt 2
- ring of fused material with width:
pre-heating
A=0,5 + (0,1 x en) [mm]

Release pressure and maintain

2 heating 0,02 N/mm 2
(10 x en) + 60 the ends into contact with the
heating plate.

10
removal of the (dn 630 mm) Remove the heating plate
3 -
heating plate 15 avoiding to damage both ends.
(dn > 630 mm)

Put into contact the ends avoiding

build-up of
4 0-> 0,15 N/mm + Pt 2
10 an excessive coming-out of
welding pressure
melted material.

5 welding 0,15 N/mm2 + Pt 10 Maintain the ends into contact.

Release pressure and maintain

6 welding 0,05 N/mm2 (3 + en) x 60
both ends into contact.

The joint cannot be subjected to

7 cooling - 1,5 x en x 60
stresses.

N.B. Within the formula, en shows the nominal thickness of the pipe/fitting

welding tables
All typical parameters (times and pressures) of the buttfusion welding process
are reported in the specific tables supplied by the machine manufacturer
according to weldable diameters and thicknesses. As, the calculated pressure
values depend from the total pressure section of the oleodinamic cylinders of
the buttfusion machine, consequently these tables are specific for each type of
machine; THEREFORE THEY ARE NOT INTERCHANGEABLE.
The welding tables must be always available whenever the welding machine is
used; therefore a copy should be filed in a safe place.

35
 manual buttfusion machines
The site buttfusion machines used for the welding
of polyethylene pipes and/or fittings for transport of
fuel gas, water and other fluids under pressure must
be manufactured in accordance to the standard UNI
10565, provided with CE marking and they are also
guaranteed to give:
a perfect axial adjustment of the pipes through
the clamps;
a proper and true preparation of the pipes/fittings
ends through the facer tool;
an accurate control of the welding pressure and
of the temperature of the heating plate;
the conformity to the safety standard regulations.
The machines consist of a base-body made of
a supporting frame, two guide elements and two
carriages, one fixed and the other movable. The
movable carriages and the welding force are moved
by the thrust cylinders.
On each carriage there are at least two jaws, which
can tighten the pipes/fittings to be welded and are
arranged to fit the necessary reducing inserts for
the welding of the elements with nominal diameter
lower than the maximum operative diameter of the
machine.
The machines are also provided with hydraulic unit with manual control, heating
plate and facer tool; particularly the hydraulic unit must permit the continuous
regulation of the pressure. The facer tool must at the same time work on both
element ends and at straight angle with respect to the axis of the pipes/fittings
to be welded; the shaving is taken out of the pipe/fitting, in the way that the
operator can check its continuity.
The heating plate must guarantee uniform temperature on its whole surface
and must be covered with anti-
adherent material to improve the
easy separation of the elements
to be welded.
It must be also supplied with
a system that shows the
temperature and is independent
from each control equipment and/
or regulation of the temperature
itself.

The machine, together with all separated accessories, must be submitted

to overhaul each two years by the manufacturer or in an authorized center.
During this service the inspection testings are carried out according to the
standard UNI 10565 and a proper document will be issued declaring the
conformity to the requirements.

36
 automatic buttfusion machines
The standard UNI 10565 also defines the automatic buttfusion machines,
which states the additional requirements.
These machines are equipped with electronic device able to perform and
control the specific phases of the welding cycle and stop the process when any
error occurs. The control unit is equipped with a keyboard for the data insert, a
display and a system for the data memory and the welding data transfer.
The electronic control unit regulates and checks the temperature of the heating
plate during the use phases, the pressures and the welding times; it can also define
the drag pressure and carry out the measurement of the ambient temperature. If
there is any error during the welding cycle, the process is automatically stopped.

welding recorders
The standard UNI 10565 also foresees the welding recorders, which are electronic
devices that, connected to a manual buttfusion machine, allow to record the
carried-out welding cycle and compare it with the applied standard references.
They are also supplied with a system for the welding data memory and transfer,
for issuing a proper protocol.

accessories
The use of special rollers is suggested in order to let the pipelines slide and
reduce any friction with the soil.

37
 electrofusion jointing

The electrofusion welding system is the jointing process of pipes and/or

fittings of the same connection diameter, and is carried out by fusion of the
contact surfaces through an electrical resistance inserted in the electrofusion
fitting. Today it is considered the most developed and safe method for realizing
polyethylene jointings. Thanks to its versatility, can weld together pipes and/or
fittings with different thickness and made with different polyethylene materials.
The electrofusion welding process is defined by the standard UNI 10521; the
welder in charge of the jointings must be adequately trained and have the
qualification certificate for class PE-3 or PE-3-D according to UNI 9737 standard.

electrofusion sockets and integrated fittings

The jointing quality directly depends on strictly compliance with the following
instructions.

preparation

The jointing process must be carried out in a dry and protect place. In case
of adverse ambient conditions (humidity, rain, snow, blast, excessive solar
irradiance), suitable measures must be taken to protect the working zone.

The ambient temperature must

be always between -5C and +40C.

Critical element for the jointing reliability is the preparation of the pipe surface
where the electrofusion fitting will be welded, through the removal of the oxidized Electrofusion
iointing
layer and the accurate cleaning of the whole contact area with the fitting itself.
The above described procedure, also if always referred to pipes, is anyway
equally applied if instead of a pipe, a buttfusion spigot fitting is inserted.

1. electrofusion fitting
2. aligning clamp
3. manual or mechanical scraper 2
5
4. pipe cutter
5. detergent
6. cleaned cloth or strong soft paper 4 6
7. indelible marker pen or wax pencil

1 3

39
 Visually check that the pipes are free
of cuts and abrasions (the maximum
depth admitted is equal to 10% of the wall
thickness). Eventual anomalies must be
taken out by cutting the interested pipe
section.

The pipes ends to be welded must be cut

at right angle preferably using proper pipe
cutters.
Avoid to use excessive ovalized pipes.
In any case, the ovalization cannot exceed
1,5% calculated as follows:

de max - de min
OV= x 100
dn

de = external diameter at any point

dn = nominal diameter

Ovalization and bending are reduced by using special re-rounders. The coiled
pipes must be unrolled at least 24 hours before its use. Avoid the use of heat
sources to recover possible ovalizations or to reduce the pipe bending.

40
 scraping

Clean the pipes ends from dust, dum, grease

and dirt.
Mark the scraping area with an indelible
marker pen or wax pencil, the pipe length
interested to scraping must be larger than
the insertion depth of the ef fitting for at
least 10 mm.
The electrofusion fitting MUST NOT be
scraped.

Remove the oxidized surface of the pipe by

scraping it.
The operation must be done using a manual
scraper supplied with the control unit, or
using the special mechanical pipe scrapers.
A uniform layer of material must be removed
for a depth of approximately 0,1 mm for
pipe diameters up to 63 mm and of approx.
0,2 mm for diameters bigger than 63 mm.
Using the manual scraper, consider the
procedure as correct, when an uniform PE
shaving is attached to the pipe end. Then
remove it by slightly rounding off at 45 angle
the pipe/fitting end.
AVOID the use of abrasive paper, rasp, emery
wheels, saw blades or other equipment.

41
 cleaning

Just before the jointing with the electrofusion

fitting, clean all scraped surfaces using a
strong soft paper slightly drenched with a
suitable detergent (i.e. isopropyl alcohol or
methylene chloride) to remove any trace of
dust and grease.
Do not use products such as
thrichloroethylene, denaturated alcohol,
gasoline, acetone or paint diluent.

Clean in the same way the inner surface of

the electrofusion fitting, which has to be
removed from its protective wrapping only at
the moment of use.
Do not touch with hands the just cleaned
surfaces; on the contrary, repeat cleaning.

42
 positioning

It is compulsory the use of the aligning clamp,

for all diameters to be welded, which:
removes the jointing stresses during the
fusion of material and the subsequent
cooling time;
allows to revise possible off-centering
between the elements to be welded;
allows to recover the out-of-round of parts, if
ovalized.
In order to set the aligning clamp to the different
diameters, it is necessary to insert the reducing
inserts and in case adjust the internal distance
between the movable jaws.
In case of electrofusion fittings installation such as 90 and 45 elbows, suitable
aligning clamps are available with adjustable joint.

By using a colored pen or wax pencil sign on

at least one third of the pipe circumference, in
correspondence to the ends to be welded, the
insertion depth in the electrofusion fitting. This
operation must be carried out also in case of
fittings with central stop.
This mark, beyond helping the positioning of
the fitting on the pipe, will permit the control at
welding end that there are no movements of the
jointing.

Insert the electrofusion fitting on the end of the

first pipe up to the location mark.
Fasten the pipe into the aligning clamp.

Insert the second pipe into the fitting up to its

location mark and fasten it into the aligning
clamp.

43
 welding

Connect the plugs of the control unit to the

terminals of the fitting and proceed with the
set-up of the welding parameters according
to the instructions of the welding unit.
N.B.: If there is an accidental interruption of
the welding cycle, the operation can only
be repeated after the electrofusion joint
has been totally cooled.

When the fusion cycle is completed, verify

the fusion indicators coming out.
WARNING: the coming out of the fusion
indicators cannot be the guarantee of good
success of the welding. This is exclusively
indication of the material fusion.

cooling

Generally the cooling time of the jointing can vary, according to the diameter
and fitting type, from 10 up to 30 minutes and anyway it is always shown by
the fitting manufacturer. During this time, the joint cannot be either moved,
or removed from the aligning clamp, or stressed. At fusion cycle end, it is
advisable to write with a colored pen or wax pencil the time when the jointing
will be completely cooled.
It is absolutely forbidden the use of external cooling methods (water, compressed
air, etc) to speed up the cooling.
In any case, the pipeline can be put into pressure not before 2 hours from the
last fitting welding.

The welding parameters used for the jointing of each fitting must be recorded in
a proper report.

44
 electrofusion tapping and spigot saddles
The jointing quality directly depends on strictly compliance with the following
instructions.

preparation

The jointing process must be carried out in a dry and protect place. In case
of adverse ambient conditions (humidity, rain, snow, blast, excessive solar
irradiance), suitable measures must be taken to protect the working zone

The ambient temperature

must be always between -5 C and +40 C.

Critical element for the jointing reliability is the preparation of the pipe surface
where the electrofusion fitting will be welded, through the removal of the oxidized
layer and the accurate cleaning of the whole contact area with the fitting itself.

Check and prepare all the materials

necessary for the welding process:
- EF control unit
1. upper saddle
2. blank saddle
5
3. bolts kit
4. manual scraper 1
5. detergent 6
6. cleaned cloth or strong soft paper 2
7. manual or pneumatic screwdriver for 4
the bolts tightening 8
8. manual hexagonal key for the cutter 7
screw 3 9
9. indelible marker pen or wax pencil

Visually check that the pipes are free of defects such as cuts and abrasions
(the maximum admitted depth is equal to 10% of the wall thickness). Eventual
anomalies must be taken out by cutting the interested pipe section.
Avoid to use excessive ovalized pipes. In any case, the ovalization cannot
exceed 1,5% calculated as follows:

de max - de min
OV= x 100
dn

de = external diameter at any point

dn = nominal diameter

Ovalization and bending are reduced by using special re-rounders. The coiled
pipes must be unrolled at least 24 hours before its use. Avoid the use of heat
sources to recover possible ovalizations or to reduce the pipe bending.

45
 scraping

Clean the pipe from dust, dirt and grease.

Place the upper saddle on the pipe and mark the
scraping area with a colored pen or wax pencil.

Remove the oxidized surface layer by scraping

the external pipe surface for at least 10 mm over
the previous marked area.
The operation must be done by using the manual
scraper supplied with the EF control unit.
Remove an uniform surface layer of material for a
depth of approximately 0,1 mm for diameters
up to 63 mm and of approx. 0,2 mm for
diameters greater than 63 mm.
AVOID the use of abrasive paper, rasp, emery
wheels, saw blades or other equipment.

cleaning

Just before positioning the saddle on the pipe,

clean the scraped surface with a clean cloth or
strong soft paper slightly drenched with suitable
detergent (i.e. isopropyl alcohol or methylene
chloride) to remove any trace of dust and grease.
Do not use products such as thrichloroethylene,
denaturated alcohol, gasoline, acetone or paint
diluent.

Clean in the same way the inner surface of the

upper saddle, which has to be removed from its
protective wrapping only at the moment of use.

Do not touch with hands the just cleaned

surfaces; on the contrary, repeat cleaning.

46
 saddle positioning on the pipe

Insert the hexagonal nuts in the seats on the

blank saddle and the bolts complete with
washers in the upper saddle.
Position the upper saddle on the pipe,
centering it on the scraped surface.

Clamp the saddle on the pipe by tightening the

four connection bolts: proceed alternatively,
in a criss-cross way using a screwdriver or
wrench according to the type of bolt.
Proceed by tightening the bolts until the saddle
is fully blocked on the pipe.

welding

Connect the plugs of the control unit to the

terminals of the fitting and proceed with the
set-up of the welding parameters, strictly
following the instructions of the welding unit.
N.B.: If there is an accidental interruption of
the welding cycle, the operation can only be
repeated after the electrofusion joint has
been totally cooled.

When fusion cycle is completed, verify the

fusion indicators coming out.

WARNING: the coming out of the fusion

indicators cannot be the guarantee of good
success of the welding. This is exclusively
indication of the material fusion.

47
 cooling

The cooling time of the jointing is always

shown by the fitting manufacturer; during
this time, the joint cannot be either moved or
stressed. At fusion cycle end, it is advisable
to write with a colored pen or wax pencil the
time when the jointing will be completely
cooled.
It is absolutely forbidden the use of external
cooling methods (water, compressed air, etc)
to speed up the cooling.
In any case, the pipeline can be put into
pressure not before 2 hours from the last
fitting welding.

The welding parameters used for the jointing of each fitting must be recorded in
a proper report.

boring

The saddle boring must be carried out only after a complete cooling of the
welded joint, independently from the type of saddle, and anyway not before 20
minutes from the cooling shown on the fitting.

code 21.30: ef tapping saddle

Unscrew the outlet cap of the saddle.
Insert the manual hexagonal key into the
built-in cutter. Avoid the use of pneumatic or
electric screwers, which due to the excessive
rotation speed can damage the cutter thread.
Screw clockwise until the pipe perforation,
this is evidenced by a great decrease in the
screwing force. Do not continue in order to
avoid any damage in the cutter thread.

Screw anticlockwise and retract the

cutter back to its original position.
Remove the hexagonal key and strongly
screw the cap checking the presence of the
internal O-ring gasket.

48
code 21.20: ef spigot saddle
The saddle boring is carried out by
using a normal hole-saw, whose external
diameter is a little bit smaller than the
internal branch diameter see the next
table. Pay attention avoiding damages
on the branch internal walls.
WARNING: pipe boring is not allowed
before the welding operation, this can
seriously damage the jointing quality.

maximum external diameter hole-saw

for spigot saddles (code 21.20)

dn branch saddle external diameter

[mm] hole-saw [mm]
20 13
25 17
32 25
40 32
50 38
63 48
90 72
110 88

accessories
EF tapping saddles of the series EURO (code 21.31) with automatic gas
safety system called Gas-Stop are available. This device is made of a safety
valve with automatic working usable on gas branch installations, and particularly
on the polyethylene buried connections. This device has been designed to move
automatically in the close position within very short times (in a split second) due
to the pressure loss, whenever an accidental service pipeline break will happen
afterwards the device. Breaks of this type can be caused by impacts with
mechanical machines during works/digs carried out close to the network after
the laying or by sysmic phenomena. In these cases the valve, by closing, will
cut off the flow and therefore avoid all risks connected to possible gas leakages
up to the pipeline restoration. After repair intervention, the relay of the valve can
occur spontaneously, depending from the model, or applying a counter-pressure
or using an external source.

49
 automatic reading systems
of the welding parameters

bar code

The bar code is an universally recognized system to store up information and

to allow their reading by proper devices using the format type INTERLEAVED
2-in-5 with 24 digits with control character according to standard ISO 13950.
The information stored in the code allow the control unit to automatically
understand the characteristics of the fitting to be welded and to consequently
work, therefore avoiding any error of manual set-up.
The code stores all data identified by the manufacturer and necessary for the
electrofusion cycle: manufacturer code, type of fitting, diameter, welding time,
ohmic resistance value and its adjustment according to ambient temperature,
output voltage, cooling time. The guarantee of correct code reading is defined by
the control character. Possible differences between the fitting connected to the
control unit and the code reading are shown on the machine by error signalling
which does not proceed with the welding cycle.
The Operator must only acquire, with the scanner or the optical pen supplied
with the control unit, the data stored in the bar code label on the fitting and then
manually confirm the correctness of the reading.
For a correct data acquisition, we recommend to use the scanner at several
centimeters distance from the label and work by means of the proper button
and directing the ray towards the bar code. By using the optical pen, pass it
over the bar code label with an approx. 45 inclination, moving it straight and
continuously at constant speed from left to right side or from right to left, without
excessive pressure.
Several fitting manufacturers also apply, besides the bar code with the welding
parameters, a second bar code, containing the traceability data of the
products such as the batch number and the raw material number, according to
the standard ISO 12176-4. This second code can be read and recorded using
qualified control units.

magnetic card

Alternative system to the bar code; it foresees the use of a magnetic card
supplied by the fitting manufacturer where all welding parameters are codified.
The magnetic card is inserted by the Operator in the special reader of the proper
control unit.
The magnetic card can also contain the recording of the welding data, when
required to ensure the traceability of the jointings.

50
 ef units and accessories

monovalent ef unit

The monovalent electrofusion control units are designed and built-up to only
work with electrofusion fittings from a single manufacturer. No guaranteed
results can be given for any use with other fittings.
The units type EURO S1 and type EURO S1 LIGHT are
monovalent units which allow the Operator to work at
a welding safety voltage lower than 50 Volt. They are
manufactured according to the standards UNI 10566 and
ISO 12176-2, are furnished with CE mark and use the
switching technology which permit to be light and compact.
The heating power is automatically fixed according to
the type and diameter of the ef fitting, to the SDR of the
pipe (or buttfusion fitting) to be welded and to the ambient
temperature.
They can be used only on the fittings range of the series
EURO manufactured by Eurostandard.
An alfanumeric display guides the Operator when setting
the parameters:
type of fitting to be welded - nominal diameter - SDR and
consequently shows the following welding parameters:
ambient temperature
voltage
welding time
progressive number of welding operations
alarm or malfunctioning messages.
Both models are designed to store the operator code, the
work site, the date and time of electrofusion and welding
parameters. The memorized data can be subsequently
transferred using the USB or the serial port through the DBManager software
supplied with the unit. Alternatively it is also possible to print out all information.

The welding units must be submitted to periodic overhaul (biennal) by the

manufacturer according to standard UNI 10566.

EF UNIT CHARACTERISTICS EURO S1 EURO S1 LIGHT

supply voltage 230V AC 15%
frequency 50 Hz 15%
output voltage < 50V
max power consumption 4500 W 3000 W
operating temperature from -10C up +45C
port connections USB serial / RS-232
protection IP 54
welding cycle memory capacity 1600 n. 800 n.
dimensions LxPxH 36x21x31 cm 35x19x30 cm
electrofusion sockets and fitting
the complete electrofusion d. 20-160 EUROSTANDARD
weldable diameters
EUROSTANDARD range ef saddles d. 40x - 250x
EUROSTANDARD
weight 14,2 kg 8,0 kg

51
 polyvalent ef unit
The electrofusion control units type universal are designed
and built-up to work with all types of electrofusion fittings
using the bar code or magnetic card for the acquisition of
the welding parameters.
The unit type EURO SP1 is an universal machine which
allow the Operator to work at a welding safety voltage lower
than 50 Volt. It is manufactured according to the standards
UNI 10566 and ISO 12176-2, is furnished with CE mark
and use the switching technology which permit to be light
and compact. The scanner device allows the maximum
operative easiness in all different site conditions.
The unit can work automatically with the scanner by reading
of the welding and traceability bar-codes, or manually by
set up of voltage and welding time or numerical sequence
of all digits which form the bar code. The display and the four buttons guide the
Operator in all operations.
The unit can be used for the welding of all electrofusion fittings of any
manufacturer, provided with the foreseen requirements.
The unit is designed to store the operator code, the work site, the date and time
of electrofusion and welding parameters, as well as the traceability data of the
products used. The memorized data can be subsequently transferred using the
USB or the serial port through the DBManager software supplied with the unit.
Alternatively it is also possible to print out all information.

The welding units must be submitted to periodic overhaul (biennal) by the

manufacturer according to standard UNI 10566.

EF UNIT CHARACTERISTICS EURO SP1

supply voltage 230V AC 15%
frequency 50 Hz 15%
output voltage 8 48V
max output current 110 Amp
60% output current 80 Amp
max power consumption 4500 W
operating temperature -10C +45C
port connections USB - serial / RS-232
protection IP 54
working range 20 710 mm
working modes bar code reading and manual setting
bar codes for ef welding according to ISO
ef welding Interleaved 2.5/24 digit
13950
operator - Interleaved 2.5/30 digit traceability -
bar code traceability ISO 12176/3/4
128/26/40 digit
bar code reading system scanner
setting: time and voltage or 24 digit sequence
manual system
of bar code
welding cycle memory capacity n. 1600
connectors 4.0 mm
ancillary connectors 4.7 mm
dimensions LxPxH 32x26x31 cm
weight kg 14,0
ancillary equipment on request GPS

52
welding unit supply using power generators
To avoid risks of damages of the electrofusion units, use power generator as
supply source in accordance to the following requirements:
1. POWER not lower than 3,0 kVA effective in order to weld fittings up to dn140
and not lower than 5,5 kVA for bigger dimensions.
2. SUPPLY FREQUENCY 50 Hz 10%.
Attention: some generators supply a frequency of 60 Hz. Avoid this type of
generator.
3. MONOPHASIC VOLTAGE only alternating 230 V at frequency 50 Hz.
Absolutely avoid direct or rectified current
(present on some generators).
4. EXTENSION CABLES with section size cable
2,5 mm2 in case of lengths up to 10 m and 4,0
mm2 in case of lengths up to 30 m.
5. HARMONIC DISTORSIONS of the generator
must be within 20%.

53
 ancillary equipment
aligning clamp

It prevents that, either during the fusion

cycle or the subsequent cooling, the
jointing can be submitted by axial
stresses and bending moments.
It allows to revise possible off-centering
between both ends to be welded.
It allows to recover the our-of-round of
the ovalized pipes.
The aligning clamp is auxiliary to the
welding control unit, its use is essential
for the successful electrofusion jointing.
It consists of a support frame with four
jaws and reducing inserts to adapt the unit
to the various diameters used; the central
adjustable joint allows the use also with integrated electrofusion fittings such as
90 and 45 elbows.
Simultaneous use of multiple aligning clamps will positively affect the speed of
installation.

re-rounder

It is similar to the aligning clamp, but has wider jaws designed to exercise a
mechanical force on the pipe wall in order to correct ovalization without damaging
its integrity.
It corrects ovalizations higher than 1,5% within the limits foreseen by the
standard UNI 10521, in order to allow a correct jointing; normally it is used up
to dn 110 which corresponds to the maximum nominal diameter recommended
for coiled pipes.
It can be manually driven or using hydraulic devices.

54
 pipecutter

A square cut of the pipe to be welded is carried

by using a pipe cutter. It is available the type
with roller or tool with blade at fix guide and
for the correct choice between the models, it is
important to consider the wall thickness of the
pipe to be cut.
The use of electrical equipment with high cutting
speed, like disk grinders or similars, is not
recommended as the heat can compromise the
material characteristics.

mechanical scraper

The oxidized layer on pipes and buttfusion fittings of small diameter (up to dn 63)
is removed by using manual scrapers with straight interchangeable blade.

Mechanical pipe scrapers are available for bigger

diameters which are fastened on the pipe/fitting
end. In this case, the removal of the oxidized layer
is done using a special tool manually moved.
The use of these tools requires the perfect cut
of the pipe end by using the pipe cutter and the
periodic overhaul of the cutting tool.

55
 inspection of welded
jointings
Either for the buttfusion jointing or for the electrofusion process, by end of the
cooling time the joint quality must be checked according to the standards UNI
10520 and UNI 10521, through:
non destructive controls: mainly consist on the visual control and on the
dimensional control of the ring;
destructive controls: consist in the mechanical resistance identification of the
jointing through testings carried out according to the reference standards.

non destructive testings

buttfusion welding UNI 10520
visual control

The visual control is relative to the following checks:

the carving by the center of the ring must be above the external diameter
of the welded elements, as too deep carvings trace back to temperature or
welding pressure values lower than those foreseen;
on the external surface of the ring there cannot be porosity, dust inclusions
or other contaminations, as these are indicative of unsuitable cleaning of the
elements to be welded;
after cooling, the external surface of the ring cannot be excessively bright, as
this is index of overheating of the welded material.

dimensional control of the bead

The dimensional control of the bead foresees the following checks:

the width B of the bead must be uniform on the whole area of the welding. Inspection
At any point of the welding, the width B of the bead cannot vary more than of welded
10% with respect to the average value Bm: jointings

Bm = ( Bmin + Bmax ) / 2

where Bmin e Bmax respectively are the minimum and maximum measured value;
at any point of the welding, the maximum difference between the two beads
which form the ring must be lower than 10% of the width B of the bead in
case of pipe-pipe joint and 20% in case of pipe-fitting and fitting-fitting joint;
the maximum misalignment of the two welded elements must be lower then
10% of their thickness;
at any point of the welding, the width B of the bead must be comprised in the
value shown in the next table:

57
 thickness of width of the thickness of width of the
welded elements bead B welded elements bead B
[mm] [mm] [mm] [mm]
3 4-6 29 15 - 21
4 4-7 30 15 - 21
5 5-8 31 15 - 21
6 6-9 32 15 - 22
7 7 - 10 33 16 - 22
8 7 - 10 34 16 - 22
9 8 - 11 35 16 - 22
10 8 - 12 36 16 - 23
11 9 - 13 37 17 - 23
12 9 - 13 38 17 - 23
13 10 - 14 39 17 - 23
14 10 - 15 40 17 - 24
15 10 - 15 41 18 - 24
16 11 - 16 42 18 - 24
17 11 - 16 43 18 - 25
18 12 - 17 44 19 - 25
19 12 - 17 45 19 - 25
20 12 - 18 46 19 - 25
21 13 - 18 47 20 - 26
22 13 - 18 48 20 - 26
23 13 - 19 49 20 - 26
24 13 - 19 50 21 - 27
25 14 - 20 55 23 - 29
26 14 - 20 60 26 - 32
27 14 - 20 65 29 - 36
28 14 - 21

non perfectly connected bead

If the bead is not perfectly connected to the plain surface of the pipe, the welding
is anyway considered acceptable.
In case of welding of pipes and/or fittings with thickness lower or equal to 10 mm,
if the bead is not connected with the typical form at gull wings, the welding
cycle must be modified working on the phase 3 and 4 in the following way:
phase 3: the time t3 cannot be higher than 4 seconds;
phase 4: the time t4 cannot be higher than 6 seconds.

non perfectly connected bead bead at gull wings

58
 electrofusion welding UNI 10521
visual control

The visual control is relative to the following checks:

if fusion indicators (proof of the correct fusion cycle) are present on the fitting,
they must fulfil the direction of the fitting manufacturer (usually, come out of
their cavities);
the welded elements must be correctly aligned;
there cannot be fusion lacks between the welded elements;
the scraped area must be clearly visible on the whole circumference of the
welded elements;
the insertion deep previously marked on the elements to be welded must be
respected;
no protrusion of melted material and damages on the outside surface of the
welded elements are shown.
Take also care of the possible error messages on the display of the electrofusion
control unit used for the jointing operation.

59
 welding errors
The following pictures report several jointings performed without respecting the
welding instructions defined by the standards UNI 10520 and UNI 10521.
The experience developed in the years on trench sites, in the testing laboratories
and at the Technical Training Center allowed the characterization and filing of the
most common welding error types:

irregular welding bead buttfusion off-centering of the elements

uncomplete insertion of the pipes wrong centering of the pipes

off-centering of the pipe on the left side

off-centering of the pipe on the left side and wrong welding parameters setting

60
 uncorrect pipe cut
uncorrect pipe cut and uncomplete insertion

irregular scraping
(carried out with unproper tool) lack of scraping

pipe boring before cooling wrong welding parameters setting

61
 destructive testings
The evaluation on the welding conformity by destructive testings must be carried
out exclusively at specialized laboratories and by qualified personnel. The
results on the jointing tests must be filed in a proper document which certify the
occurred control.
The testings which can be carried out are shown on the following table:

TESTING TYPE TEST METHOD

resistance to internal pressure UNI EN ISO 1167

tensile resistance on buttfusion weldings ISO 13953

peel decohesion on electrofusion joints ISO 13954

crushing decohesion on electrofusion joints ISO 13955

peel test crush test

determination of the resistance to tensile resistance test

internal pressure

62
 transport and storage
The guidelines for the loading, transport, handling and piling-up of the pipes and
for the storage of the fittings and special joints are reported in the Ministerial
Decree dated 12/12/1985 and by the standard UNI EN 12007-2 and UNI 11149.

transport
For pipes transportation the truck supports must be without any harshness; the
pipes must be aligned to avoid any damage.
Coiled pipes must be preferably positioned horizontally.
The loading clamp can be slinged using cables or hemp/nylon ropes or of similar
materials, taking care that the pipes are not damaged.

Transport
and storage

63
 loading, unloading and handling
If the loading and unloading from the truck and generally the handling are done
using a crane or the arm of a digging machine, the pipes must be lifted in the
center with a special equipment.
If these operations are carried out manually, the pipes cannot be dragged on the
edges of the truck or anyway on tough and sharp objects.

piling-up
During piling-up, the support plane must be flat, free of harshness and sharpened
stones.
The piling-up for the pipes in bars cannot be higher than 1,5 m for every diameter
and thickness. The coiled pipes must be horizontally laid; the piling-up canno be
higher than 2 m.
Only for pipes bigger than 500 mm, it is advisable to internally reinforce their
ends in order to avoid excessive ovalizations.
After piling-up, check that the protection caps are positioned on the relative pipe
ends in order to prevent that leaves, dust or small animals can enter the pipes.

64
 buttfusion fittings
These items are generally supplied inside proper packings. If loose, it is necessary
to avoid a confused piling-up during transport and storage in order to keep off
damages due to impacts.

electrofusion fittings
The electrofusion fittings must be always supplied inside proper packings of
resistant material, in order to protect them from dust, humidity, salt, UV ray, etc.
They must be stored in warehouses on shelves or anyway over the ground.
On trench sites, it is necessary to protect the electrofusion fittings from adverse
agents or avoid heat sources. They must be stored inside their original packing
up to final use.

65
 installation
of PE pipelines
The polyethylene differs from traditional materials used for pipelines carrying fuel gas
and fluids under pressure for its particular physical and mechanical characteristics
of high flexibility and ductility. If in the past these characteristics were considered
a performance limit the same are now an advantage allowing the laid pipelines to
support the ground stress. If the laying and covering conditions are controlled,
especially for the ground compressing, the use of PE pipes allow a greater
network safety in case of ground settlings, landslides or earthquakes. Furthermore
the PE pipelines flexibility allow the use of innovative laying technologies with
important reduction in times and laying network costs. The PE lightweight and the
easy weldability give advantages in terms of speed of the laying operations.

gas pipelines
gas pipeline classification

The Decree of the Economic Development Ministry 16th April 2008 classifies the
pipelines relative to the natural gas distribution with density not higher than 0,8
within seven different types, characterized from decreasing values of the maximum
working pressure (MOP) from 1st up to 7th type. For the materials and the products
to be used in the construction of the distribution systems, the Decree refers to the
standard UNI 9034, which allows the use of polyethylene pipes, fittings and special
joints for pipelines with maximum working pressure lower or equal to 5 bar:

type maximum working pressure (MOP)

4th 1,5 bar < MOP 5 bar
5 th
0,5 bar < MOP 1,5 bar
6 th
0,04 bar < MOP 0,5 bar
7 th
MOP 0,04 bar

excavation

The polyethylene pipes for the gas distribution must be normally used for
underground pipelines. The minimum buried depth defined by the standard
UNI 9165, calculated from the upper generatrix of the pipe at ground level, is
according to the pipeline type, to the laying area and to the laying conditions, as
detailed in the following table.

pipeline type
laying area notes
4th and 5th 6th and 7th
Roadway 0,90 m 0,60 m

Areas without vehicle traffic Only if the pipeline is laid at least 0,50 m from
0,40 m 0,40 m Installation
(i.e. flowerbeds, pavements, traffic islands, city green areas) roadway border
of PE
A buried depth with minimum of 0,50 m is
Country lands 0,90 m 0,60 m allowed near to undulations, drainage ditch,
pipelines
bumps and similars fro short distances
Rocky soils 0,40 m 0,40 m

67
 The laying of polyethylene pipes out of ground is generally forbidden; anyway
for underground connections, the standard UNI 9860 allows the pipes laying
outside ground only for the end part of branch line, if it is suitably protected from
UV ray, mechanical damages, and fire.
The trench is done at fix section, with minimum width on the bottom, at least 20
cm bigger than the pipe diameter to be laid.

building distance

The safety distance from buildings vary according to the pipeline type, gas type,
laying area and laying conditions as detailed in the following table:

safety distance
laying category
pipeline type
4th and 5th
Cat. area and laying conditions gas with gas with 6th and 7th
density 0,8 density > 0,8
Branch lines laid in the ground with pavings in asphalt, stone
and cement slabs and any other similar natural or artificial
A covering. In this category it is also considered those soils 2m 2m
without the above-mentioned pavings, but where there is a
higher permeability than the superficial layers.

Branch lines laid on the ground without pavings as shown in

the category A, or only if such condition exists for at least a
B strip of 2 meters and is coaxial to the pipeline. In this category 1m 2m
no
it is also considered those soils where in depth there is a lower
prescription1)
permeability or practically equivalent to the superficial layers.

Branch lines of the category A in which it is provided the

drainage of gas according to the foreseen procedures. This
C 1m -
drainage system is irrelevant for fuel gas with density >0,8 and
therefore not adopted.

Branch lines where all protection works are done following the
D no prescription1)
foreseen procedures.

1) Except that shown in the article 889 Civil Code, which foresees a distance 1 m.

cross-service interferences

underground services
In case of parallel routes, overpasses and underpasses with another existing
pipeline, the distance measured between the two surfaces:
if the other pipeline is under pressure, (i.e. water pipeline, the other gas
pipeline) maintenance intervention must be allowed on both networks;
if in the other pipeline there is no pressure (i.e. electrical or phone cables
shaft, drainage) it must be:

pipeline type minimum distance between the surfaces

4th 0,50 m
5 th
0,50 m
6 th
enough to allow possible maintenances on both
7th underground services

68
If one pipeline is made in polyethylene and the other pipeline has an outside
temperature higher than 30C, the distance must be higher or equal to 1 meter.
If, for installation needs, the minimum requested distances between one pipeline
and the other cannot be observed or, in case of intervention on both works there
can be damages, it will be necessary to proceed with a protection work such
as pipes or other items. In case of crossing, these protection works must be
extended from one side to the other of the crossover for at least:
1 m in the overpasses and 3 m in the underpasses for gas with density 0,8.
1 m in the underpasses and 3 m in the overpasses for gas with density >0,8.
In case of parallelism between pipelines for transport of gas with density < 1 kg/m3
(i.e. methane) with sewerage systems, the first must be laid at a superior level in the
way so that the lower generatrix of the gas pipeline will be laid at the same level of the
upper generatrix of the sewerage pipe, but on a different vertical position.
Opposite are the regulation for parallelism between pipelines for transport of gas

SEWERAGE
PIPE SEWERAGE
PIPE

GAS PIPE GAS PIPE

Gas pipeline (methan) with r < 1 kg/m3 Gas pipeline (LPG) with r > 1 kg/m3

heavier than air (i.e. LPG) with sewerage systems. For parallelism longer than
150 meters it is necessary to provide compensators and breather devices.

city tramway lines

In case of parallel routes to urban tramlines the minimum distance horizontally
measured between the external pipeline surface and the nearest rail must be
higher or equal to 0,50 m.
In case of underpass of city tramway lines the distance measured between the
upper generatrix of the pipe and the rail track, must be higher or equal to 1 meter;
the pipelines of 4th and 5th type must be fitted in a protected pipe extended for at
least 1 meter with respect to the external rails. For pipelines of 6th and 7th type it
is possible a minor distance, up to a minimum of 0,50 meter, only if the pipeline
is positioned within a protected pipe and prolonged from one side to the other
crossover for at least 1 meter with respect to the external rails.

railway lines
In case of parallelism and crossings of railway lines (or suburban tramway) the
special updated regulations issued by the Transport Ministry are applied.

pipes bending

In case of polyethylene pipes, direction changes are allowed taking advantage of

the flexibility characteristics of the pipe, only if the bending radius is at least 20
times the external diameter of the pipe itself. In case of smaller bending radii, it
is necessary to use injection moulded elbows or segment bends.

69
 water pipelines
The reference standard for the laying of polyethylene pipeline systems for the
transport of fluids under pressure is the UNI 11149. This standard is applied to
water networks, irrigation systems, drainage systems, fire-fighting and waste
water networks, underpressure dumps included.

excavation

The trench is done at fix section; the minimum width on the bottom must be 20
cm bigger than the pipe diameter to be laid.
The minimum buried depth h must be of 1 meter measured from the upper
generatrix of the pipe or 1,2 meter if subjected to raiway or air traffic, and anyway
it must be evaluated according to the traffic loads and ice danger. If the minimum
value of requested depth cannot be respected, the pipeline must be protected
with tubular coating, cement products or equivalent materials.

The width B of the trench, measured in correspondence to the upper surface

of pipe, vary according to the pipe dimensions and must respect the minimum
measures defined in the following table:

pipe diameter trench width B

[mm] [mm]

de 315 de + 400
315 < de 900 de + 600
900 < de 1600 de + 800
de > 1600 de + 1200

If no personnel must work inside the trench, its dimensions can be reduced.
The pipeline must be laid, if possible, in correspondence to the center line of the
trench.
If the trench must contain two or more pipeline systems, these must be laid at
a distance bigger than at least 150 mm with respect to the width of the used
compressing equipment.

70
 parallelism and crossing

For parallel routes to urban railway lines, the minimum distance measured
horizontally between the external surface of the pipeline and the closer rail
cannot be lower than 0,50 meter.
For the crossing of railway lines the laying depth of pipelines cannot be lower than
1 meter measured between the upper generatrix of the pipeline and the railway
level. Furthermore, the pipeline must be inserted in a prolonged protection pipe,
at both crossing sides for at least 1 meter, measured from the external rail.
For the water crossing and for the overcoming of slopes, the use of preexisting
workings (bridges, underpasses, ecc) are allowed.
In case of overpasses or underpasses with other pipelines, the distance between
the surfaces must allow maintenance interventions on both services.

bending of pipes

As for gas pipelines, direction changes are allowed also for the polyethylene
pipes for water distribution. They take advantage in the flexibility characteristics
of the pipe. Anyway, in order to avoid any excessive stress on the material, it is
necessary to respect the minimum bending radii shown in the following table,
valid for temperature of 20C:

SDR pipe bending radius

from 7,4 to 17 25 de
from 21 to 26 35 de
33 40 de

If the requested bending radii are lower, it is necessary to use injection moulded
elbows or segment bends.

71
 gas and water pipeline laying
The installation procedures must be carried out by expert operators.
The pipes must be laid either altimetrically or planimetrically in the exact position
as shown in the project drawings, unless otherwise suggested by the Works
Direction.
The single pipelines made outside the excavation must be laid inside the trench
using ropes or hemp/nylon or similar materials bands, avoiding possible scraping
on the soil or on the trench edge. The pipe sections with external surface cuts
with depth exceeding 10% of their thickness must be cutted off.
Control devices such as valves and gate valves which can stress the pipes due
to their weight must be hold by independent supports avoiding any stress on the
pipeline and on the jointings.

laying bed and filling up

The pipelines laid on the bottom of the excavation must have stable support on
the bottom of it along the whole lower generatrix and along its whole length. To
achieve this the trench base must be flat, made by an uniform material in order
to avoid possible mechanical stresses to the pipe.
If on rocky, gravelly or with filling material soils, the trench bottom must be leveled
with sand or other material with similar granulometric characteristics. Anyway
the polyethylene pipelines must be always laid on a proper bed made of sand or
riddled soil with thickness higher than 10 cm. The pipeline must be protected on
its whole circumference with the same material suitably compressed.
When the pipeline is finally laid in the trench, it must be covered with a layer of
sand not lower than 10 cm, measured from the upper generatrix of the pipe.
The compacting of the layer till about 2/3 of the pipe must be particularly cared,
made manually avoiding any movement of the pipe. The compressed sand must
be of good consistency and uniformity, covering the pipe on each side.

72
 covering

Considering that the pipe, if blocked on the ends before the trench covering,
can be subjected to significant stresses because of its high thermal expansion
coefficient, it is necessary to proceed as follows:
the covering must be carried out on the whole pipeline within the same
conditions of external temperature and, if possible, during the less hot hours
of the day;
always proceed by sections of 20-30 meters working on one direction,
possibly up-hill;
it is suitable to work simultaneously on three consecutive pipeline sections
for a maximum total length of 90 m;
on the three sections proceed by covering up to the top of the pipe;
the first two sections that come before the final one are covered with further
15-20 cm of material without stones;
in the first section (next to the already laid pipeline part) the covering is carried
out together with partial filling up to a height of 50 cm covering the pipe;
afterwards the covering operation of the second section will be done and
then the third section.

73
 signals

It is necessary to lay over the pipeline at a distance of 30 cm from the upper

generatrix of the pipe and during the filling up of the excavation a continuous
colored strip indicating the pipe presence for future excavation works.
For polyethylene pipelines for gas distribution, the strip will be yellow colored
with the message Attention Gas Pipe; the strip is not compulsory when the
pipeline is covered with protection systems.
For water transport pipelines, the strip will be blue colored with the message
Attention Water Pipe.
The strip may contain a metal filament which allows the pipelines to be traced
with proper equipment. It is also possible to lay an isolated copper wire along
the PE pipeline, which if necessary can be electrically provided and located with
suitable tools which traces magnetic fields. There are special devices available
called ball-markers: they are plastic spheres with diameters of about 10-15
cm, containing small electronic equipment which put at established distances
(each 30-50 m) and at every direction change and on each outlet branch, allow
the tracking of the pipeline through specified electronic tools or via satellite.

74
 pipeline testing
Even if not clearly required by the contract terms or from customer, before
starting the final filling-up of the pipeline it is always advisable to carry out a
tightness jointing inspection and pressure test of the complete network.
Generally the testings are performed by sectioning parts of suitable length which
must be closed by special systems, such as blank flanges with connection to
pressure gauges, pumps and possible breathers.

gas pipelines
The pressure testings foreseen for the gas distribution pipelines and relative
branch connections are stated by the standards UNI 9165 and UNI 9860 and
the Decree of the Economic Development Ministry 16th April 2008, and define the
following operative directions:
according to network extension, to diameters, to testing pressure and used
fluid, the testing can be carried out on sections of different length or on the
complete pipeline. In the first case it will be also necessary a final testing of
the whole pipeline. The sections must buried except their ends, which must
be uncovered for the testing control. It is suitable to leave also the jointings
uncovered in the way to facilitate the research of possible losses if the testing
is negative;
for branch connections, the testing must be carried out before boring operation
and with the integrated detecting device in open position. Furthermore the
branch connection cannot be covered.
for new distribution networks, it is possible to check simultaneously the
distribution pipeline and the branch connection once the pipe boring and
filling-up have been done;
the testing can be either of pneumatic type (by using air or inert gas) or
of hydraulic type. The second alternative is only possible with distribution
pipelines and not for branch connections, it is necessary to remove the water
inside the pipelines;
the pipeline is tested at a pressure equal at least:

type testing pressure

4 th
1,5 times the maximum working pressure
5th
6th
1,0 bar
7th
7th (aereal connections) 0,1 bar

the testing result is positive if there are no pressure drops caused by leakages
after stabilization of testing conditions and for at least 24 hours except the
variations due to temperature effect. For branch connections, it is foreseen
the possibility to reduce the period of the testing up to 4 hours or 30 minutes
if the pipeline respects the stated requirements;
a report must be drawn up for each test containing the test registration
diagram.

Pipeline
75 testing
 gas installation for domestic use
supplied from main distribution network
The standard UNI 7129 states the procedure for carrying out the tightness
testing on domestic installations and similars for the use of fuel gas supplied
from the distribution network. In this case:
the testing will be carried out before the setting up of the internal installation,
the connection to the gas meter, the connection to the devices and the
pipeline covering, using air or inert gas introduced by the proper pressure
outlet positioned downstream of the starting point;
the testing pressure must be comprised between 100 mbar and 150 mbar,
after pressurization it will be necessary to wait for stabilization for at least 15
minutes;
the first pressure reading is performed by using a pressure gauge with
sensitivity not lower than 0,1 mbar. A second reading will be done after 15
minutes from the first one;
the testing result is positive if both readings do not show any pressure drop;
if there are leakages, these must be investigated and removed. It will be
necessary to repeat a new tightness testing of the network.

76
 water pipelines

The hydraulic testing of pipeline systems for water distribution is carried out
after installation in order to ensure the integrity of pipes, joints, fittings and other
components of the pipeline. If the accessories/devices cannot support the test
pressure, they must be isolated using detection disks.
The Decree of Public Works Ministry dated 12th December 1985 states that the
pressure tests are carried out according to the Contract Terms.
For polyethylene pipelines, the testing procedure applied is defined by the
standard UNI 11149 which, with respect to the direction described by D.M.
12/12/1985, takes into consideration the viscoelastic behaviour of the material.
The testing is based on the evaluation of the volume variation which occurs
inside the pipeline due to the applied pressure variations.

preparation of section to be tested

The length of the pipeline section to be tested cannot be longer than 800 meters.
The relative section ends must be closed with blank flanges or welded caps. It is
necessary to insert breather devices in the highest points of the pipeline in order
to allow ejection of residual air.
The water pumping point must be placed in the lowest pipeline point. At this
same point the following equipment must be installed:
a pressure gauge,
a pressure and time parameter recorder,
a volumetric meter.
The pipeline must be anchored to avoid movement of the pressurized pipes.
For this reason it is recommended to proceed with almost total trench covering
leaving the sole jointings uncovered for further inspection. This allows to uniform
the pipe temperature, avoiding sudden changes of temperature during the
different hours of day and night. It also permits great accuracy in the calculation
of water quantity added during test cycle.

filling-up

The pipeline section to be tested must be filled-up with water of good quality
avoiding any contamination of the network or of the water carried during the
subsequent pipeline working. The water is filled at a speed lower than 1 m/s with
open valves to allow the coming out of air.
Once the pipeline is completely filled-up and air discharged, proceed by closing
the breather devices.
The complete filled-up pipeline must stabilized for at least 3 hours. The testing is
preferably carried out after 24 hours from its filling-up.

77
 testing procedure

The testing procedure starts after the stabilization phase.

Pressurization: the pipeline is progressively pressurized up to the testing
pressure (STP) calculated according to the maximum operative pressure of the
system defined by the designer:

STP = 1,5 x MOP

In any case STP cannot be lower than 6 bar.

Maintenance: keep this pressure for 30 minutes, restoring it by subsequent
pumpings in order to balance the volume addition due to the pipeline expansion.
The system inspection must be carried out for identifying possible leakages.
Pressure decrease: after the above 30 minutes quickly discharge the water
from the system up to a pressure of 3 bar.
Contraction: due to the viscoelastic behaviour of the polyethylene, the pipeline
shrinks causing therefore a pressure increase. For the successively 90 minutes
the pressure values must be recorded with the following intervals:

minutes minutes
reading reading
after starting after starting
1st 2 9th 30

2 nd
4 10 th
40

3rd 6 11th 50

4th 8 12th 60

5 th
10 13 th
70

6 th
15 14 th
80

7th 20 15th 90

8th 25

final operations

Testing is positively passed if the pressure values filed on the test diagram show
an increasing or stable progress in reply to the viscolelastic behaviour of the
polyethylene. A pressure value reduction shows the presence of a leakage in the
system; in this case it is advisable to check all mechanical joints and then those
welded. Testing must be repeated after the removal of leakage.
The diagram with the pressure graph must be enclosed to the testing report.

78
 example of testing diagram

16
Maintenance for 30 minutes
15

Fast pressure drop to value

of 3 bar

10
Pressure [bar]

Diagram with increasing pressure,

showing a pipeline without leakages
Testing pressure
6 achievement

4
3
Diagram with decreasing pressure, showing
2 a leakaging pipeline

-30 0 10 20 30 40 50 60 70 80 90
Time [min]

testing report

The testing report must detail all parameters and testing results. The document
must comprise:
data;
place and location of the pipeline;
drawing plan;
installation company and encharged operators;
supervision of works;
material used for pipeline installation;
reference standards;
outside diameter, thickness and length of the pipe;
maximum project pressure (nominal pressure);
stabilization time;
testing pressure;
water temperature;
time/pressure diagram;
testing results.

79
Edition September 2010
 ph. Nadia Baldo - Pierluigi Orler orlerimages.com - Realizzazione e stampa Esperia Srl - Lavis (TN)

PE/PP fittings for pressure pipes for gas and water

Zona Industriale Lago - 38038 Tesero (Trento) Italy

Phone ++39 0462 811 211 - Fax ++39 0462 811 200
E-mail: info@eurostandard.it - Website: www.eurostandard.it