ISO/TR 19480:2005
(Main)Polyethylene pipes and fittings for the supply of gaseous fuels or water — Training and assessment of fusion operators
Polyethylene pipes and fittings for the supply of gaseous fuels or water — Training and assessment of fusion operators
ISO/TR 19480:2005 gives guidance and other provisions for the training, assessment and approval of fusion operators, with the aim of establishing and maintaining their competency in the construction of polyethylene (PE) piping systems for the supply of gaseous fuels in accordance with ISO 10839, for the supply of water, or in the construction of such systems used in other pressure applications. It covers the butt fusion, electrofusion and socket fusion jointing techniques and considers both the theoretical and practical knowledge necessary to enable high-quality fusion joints to be produced.
Tubes et raccords en polyéthylène pour le transport de combustibles gazeux — Formation et évaluation des opérateurs de soudage
General Information
Standards Content (Sample)
TECHNICAL ISO/TR
REPORT 19480
First edition
2005-08-15
Polyethylene pipes and fittings for the
supply of gaseous fuels or water —
Training and assessment of fusion
operators
Tubes et raccords en polyéthylène pour le transport de combustibles
gazeux — Formation et évaluation des opérateurs de soudage
Reference number
ISO/TR 19480:2005(E)
©
ISO 2005
---------------------- Page: 1 ----------------------
ISO/TR 19480:2005(E)
PDF disclaimer
This PDF file may contain embedded typefaces. In accordance with Adobe's licensing policy, this file may be printed or viewed but
shall not be edited unless the typefaces which are embedded are licensed to and installed on the computer performing the editing. In
downloading this file, parties accept therein the responsibility of not infringing Adobe's licensing policy. The ISO Central Secretariat
accepts no liability in this area.
Adobe is a trademark of Adobe Systems Incorporated.
Details of the software products used to create this PDF file can be found in the General Info relative to the file; the PDF-creation
parameters were optimized for printing. Every care has been taken to ensure that the file is suitable for use by ISO member bodies. In
the unlikely event that a problem relating to it is found, please inform the Central Secretariat at the address given below.
© ISO 2005
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form or by any means,
electronic or mechanical, including photocopying and microfilm, without permission in writing from either ISO at the address below or
ISO's member body in the country of the requester.
ISO copyright office
Case postale 56 • CH-1211 Geneva 20
Tel. + 41 22 749 01 11
Fax + 41 22 749 09 47
E-mail copyright@iso.org
Web www.iso.org
Published in Switzerland
ii © ISO 2005 – All rights reserved
---------------------- Page: 2 ----------------------
ISO/TR 19480:2005(E)
Contents Page
Foreword. iv
Introduction . v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions. 2
4 Training organization . 2
5 Training. 3
6 Assessment. 7
7 Periodic operator certificate renewal. 7
Annex A (normative) Examination. 9
Annex B (normative) Tear test for polyethylene (PE) saddle assemblies. 10
Bibliography . 13
© ISO 2005 – All rights reserved iii
---------------------- Page: 3 ----------------------
ISO/TR 19480:2005(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
In exceptional circumstances, when a technical committee has collected data of a different kind from that
which is normally published as an International Standard (“state of the art”, for example), it may decide by a
simple majority vote of its participating members to publish a Technical Report. A Technical Report is entirely
informative in nature and does not have to be reviewed until the data it provides are considered to be no
longer valid or useful.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO/TR 19480 was prepared by Technical Committee ISO/TC 138, Plastics pipes, fittings and valves for the
transport of fluids, Subcommittee SC 4, Plastics pipes and fittings for the supply of gaseous fuels.
iv © ISO 2005 – All rights reserved
---------------------- Page: 4 ----------------------
ISO/TR 19480:2005(E)
Introduction
The quality of a piping system for the supply of gaseous fuels or water is to a large extent determined by the
skills of the operators involved in installing the network. When installing polyethylene (PE) pipes, the quality of
the fusion joints is essential for the piping system.
Since fusion joints in PE piping systems can be made using various technologies, it is important that the
fusion operators are trained and competent in the fusion technology employed in constructing PE networks.
Continued competence of the fusion operator is covered by periodic re-training and re-assessment.
© ISO 2005 – All rights reserved v
---------------------- Page: 5 ----------------------
TECHNICAL REPORT ISO/TR 19480:2005(E)
Polyethylene pipes and fittings for the supply of gaseous fuels
or water — Training and assessment of fusion operators
1 Scope
This Technical Report gives guidance and other provisions for the training, assessment and approval of fusion
operators, with the aim of establishing and maintaining their competency in the construction of polyethylene
(PE) piping systems for the supply of gaseous fuels in accordance with ISO 10839, for the supply of water, or
in the construction of such systems used in other pressure applications. It covers the butt fusion, electrofusion
and socket fusion jointing techniques and considers both the theoretical and practical knowledge necessary
for making high-quality fusion joints.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
ISO 4427, Polyethylene (PE) pipes for water supply — Specifications
ISO 4437, Buried polyethylene (PE) pipes for the supply of gaseous fuels —Metric series — Specifications
ISO 8085-1, Polyethylene fittings for use with polyethylene pipes for the supply of gaseous fuels — Metric
series — Specifications — Part 1: Fittings for socket fusion using heated tools
ISO 8085-2, Polyethylene fittings for use with polyethylene pipes for the supply of gaseous fuels — Metric
series — Specifications — Part 2: Spigot fittings for butt fusion, for socket fusion using heated tools and for
use with electrofusion fittings
ISO 8085-3, Polyethylene fittings for use with polyethylene pipes for the supply of gaseous fuels — Metric
series — Specifications — Part 3: Electrofusion fittings
ISO/TS 10839:2000, Polyethylene pipes and fittings for the supply of gaseous fuels — Code of practice for
design, handling and installation
ISO 12176-1, Plastics pipes and fittings — Equipment for fusion-jointing polyethylene systems — Part 1: Butt
fusion
ISO 12176-2, Plastics pipes and fittings — Equipment for fusion jointing polyethylene systems — Part 2:
Electrofusion
ISO 13953:2001, Polyethylene (PE) pipes and fittings — Determination of the tensile strength and failure
mode of test pieces from a butt-fused joint
ISO 13954:1997, Plastics pipes and fittings — Peel decohesion test for polyethylene (PE) electrofusion
assemblies of nominal outside diameter greater than or equal to 90 mm
ISO 13955:1997, Plastics pipes and fittings — Crushing decohesion test for polyethylene (PE) electrofusion
assemblies
© ISO 2005 – All rights reserved 1
---------------------- Page: 6 ----------------------
ISO/TR 19480:2005(E)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
butt fusion cycle
pressure/time diagram for a defined fusion temperature, representing the butt fusion operation
3.2
drag resistance
〈peak drag〉 frictional resistance due to the weight of the length of pipe fixed in the moveable clamp at the
point at which movement of the moveable clamp is initiated
3.3
drag resistance
〈dynamic drag〉 friction occurring during movement
3.4
frictional resistance
〈butt fusion machine〉 force necessary to overcome friction in the whole mechanism of the machine
3.5
fusion operator
person trained to carry out fusion jointing between polyethylene (PE) pipes and/or fittings based on a fusion
procedure
NOTE The fusion operator is trained for one or more fusion procedures, involving the operation of manual and/or
automatic fusion-jointing machines.
3.6
fusion operator certificate
approval certificate issued by the examiner/assessor stating that the knowledge and skill of the fusion operator
is sufficient to produce fusion joints following a given fusion procedure
3.7
fusion procedure
document agreed by the pipeline operator providing in detail the required variables and values for a specific
fusion process, in order to ensure repeatability
EXAMPLE Butt fusion procedure, electrofusion procedure.
3.8
pipeline operator
private or public organization authorized to design, construct and/or operate and maintain the supply system
3.9
training centre
establishment for training of fusion operators
4 Training organization
4.1 Training course
A trainee fusion operator for underground PE systems should follow a training course at a training centre, in
order to obtain a fusion operator certificate for PE pipes. The training centre should provide the training
courses under the conditions described in this Technical Report.
2 © ISO 2005 – All rights reserved
---------------------- Page: 7 ----------------------
ISO/TR 19480:2005(E)
Where applicable, the training centre shall be as required by national authorities.
The courses should be delivered by a competent trainer having the required experience of fusion processes
and mastery of the fusion technique involved.
Where applicable, the trainer shall have a level of qualification as required by national authorities.
The training centre should have a range of fusion machines representative of the equipment encountered on
worksites for installing pipes, in order for the trainee fusion operator to become acquainted with the fusion
equipment commonly used. The trainee fusion operator may be trained on one of these fusion machines or on
a machine from his or her own company if accepted by the training centre. The fusion equipment shall comply
with ISO 12176-1 for butt fusion equipment and ISO 12176-2 for electrofusion equipment.
Preferably, a training centre should not carry out activities related to contracting, supervision of construction
work, or inspection of fusion joints.
4.2 Operator assessment
A trainee fusion operator who has followed a training course as described above should then pass a
theoretical and practical assessment in order to be qualified as a fusion operator for PE systems.
The assessor should not be the trainer and should have appropriate assessment qualifications.
[1]
NOTE The assessor is a person accepted by the contracting parties or an accredited body, e.g. EN 45004 or a
[2]
certification body e.g. EN 45013 .
5 Training
5.1 Training curriculum
The training course should consist of any combination of fusion packages based on the requirements of the
pipeline operators. These packages may be given as individual modules or combined to suit requirements.
During the training, attention should also be drawn to safety. The course related to safety should deal with
safety related to the fusion process.
5.2 Course
5.2.1 General
The training should be provided by a trainer having the qualification according to 4.1.
All consumables and tools necessary for the training package should be available during the training session.
The pipes and fittings to be used shall be those in accordance with ISO 4437, ISO 8085-1, ISO 8085-2 and
ISO 8085-3 for the supply of gaseous fuels, and ISO 4427 for the supply of water, and corresponding to what
is normally used locally for the construction of PE piping systems.
The lessons should be designed so that the trainee fusion operator learns to master the fusion technique and
also to master the materials and practical problems involved in laying a pipe in a trench, with or without
obstacles. In connection with the latter aspect, the trainee fusion operator should construct at least one three-
dimensional configuration (connection between two pipes laid in different axes).
The trainee fusion operator should receive a written manual covering all the elements dealt with in the training.
The course should be drawn up in one of the national languages.
5.2.2 Theoretical course on general information
The theoretical course should deal with general information in connection with raw materials, pipes and fittings,
but also with theoretical knowledge on preparation, tools and devices and joining components. It should
© ISO 2005 – All rights reserved 3
---------------------- Page: 8 ----------------------
ISO/TR 19480:2005(E)
include details of the different fusion techniques — namely electrofusion, butt fusion or socket fusion — of
materials (e.g. PE 80, PE 100) and SDR series, as well as on correct and incorrect parameters.
The safety course should include information concerning the fusion process, such as protective clothing,
general safety regulations for electrical equipment, and the handling of heater plates. The main features are
given in Table 1.
Table 1 — Theoretical course on general information
Characteristics of PE compounds
Typical properties of thermoplastics, PE 80, PE 100, UV behaviour and typical colours
Physical and mechanical behaviour of PE compounds: temperature effects, strain/stress, creep, elongation/shrinkage,
stress cracking, etc.
Manufacturing of pipes and fittings
Extrusion of pipes Overview of the manufacturing process, packaging and marking
Transport, handling and storage of pipes
Injection moulding of fittings Overview of the manufacturing process, packaging and marking
Standardization of PE piping systems
Dimensional data: nominal outside diameter and wall thickness (SDR), out of roundness
Maximum allowed pressure, standards for pipes, fittings and accessories (valves)
Overview of relevant test methods with this document
Fusion operator certificate
Identification number, time period validity, skill
Health and safety considerations
General Principle of risk management
Clothing, shoes, hard hat, gloves
Risks related to cleaning fluids, handling and storage of pipes
Use of fire extinguishers
Working in trenches, lifting equipments
References to national regulations related to working on piping systems with pressure
Butt fusion Electricity safety, use of generators, heating plates
Electrofusion Electricity safety, use of generators
Socket fusion Electricity safety, use of generators, heating tools
Environmental aspects
Use of cleaning fluid
Disposal of packaging materials
5.2.3 Theoretical and practical course on fusion jointi
...
Questions, Comments and Discussion
Ask us and Technical Secretary will try to provide an answer. You can facilitate discussion about the standard in here.