H E AT F U S I O N J O I N I N G P R O C E D U R E S

TA B L E O F C O N T E N T S

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

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

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

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

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

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

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

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

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

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

FIGURES FIGUREI–ButtFusionBentStrapTestSpecimen............................................................................ 10 FIGUREII–SaddleFusionBentStrapTestSpecimen..................................................................... 18 FIGUREIII–SocketFusionBentStrapTestSpecimen.................................................................... 25 TABLES TABLEI–ButtFusion:ApproximateMeltBeadSize.........................................................................7 TABLEII–ButtFusion:MaximumHeaterPlateRemovalTime......................................................8 TABLEIII–ButtFusion:BeadWidthsPerWallThickness.................................................................9 TABLEIV–ButtFusion:TroubleshootingGuide............................................................................ 14 TABLEV–SaddleFusion:MaximumHeating/MinimumCoolingTimes................................ 16 TABLEVI–SaddleFusion:TroubleshootingGuide......................................................................... 21 TABLEVII–SocketFusion:TimeCycles............................................................................................... 24 TABLEVIII–SocketFusion:TroubleshootingGuide....................................................................... 28

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

Inaddition,thisproceduredoesnotpurporttoaddressallofthesafetyconcerns,ifany,associatedwithitsuse.Itistheresponsibilityoftheuserofthisproceduretoestablishanyandallappropriatesafetyandhealthpracticesandtodeterminetheapplicabilityofregulatoryrequirementspriortouse.

INTRODUCTION

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

Therearethreetypesofheatfusionjointscurrentlyusedintheindustry:butt,saddleandsocketfusion.Additionally,therearetwomethodsforproducingthesocketandsaddlefusionjoints.Inadditiontothefusion

proceduresthatfollow,electrofusionisrecognizedasanacceptablemethodofproducingsocketandsaddlefusionsbutisnotaddressedinthisdocument.Theuserofelectrofusionproductsshouldcontacttheproviderofthoseproductsfordetailsonuseinjoiningpipe.

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

FEDERAL REGULATIONS

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

Theoperatorisresponsibleforensuringthatallaspectsoftheirfusionjoiningprocessesandproceduresareincompliancewiththerequirementsof49CFR,Part192andASTMstandards.

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

Theoperatorisresponsibleforensuringthatallaspectsoftheirfusionjoiningprocessesandproceduresareincompliancewiththerequirementsof49CFR,Part192andASTMstandards.

POLYPIPE® PRODUCTS

GAS DISTRIBUTION/OILFIELD M&I, WATER AND SPECIALTY

PolyPipe®PolyTough1TM PolyPipe®EHMWPLUS PolyPipe®GDY20 PolyPipe®POLYPLUS PolyPipe®GDB50/GB50 PolypipE®LIGHTVIEWPLUSTM

POLYPIPE®ENVIROPIPETM

1

HEAT FUSION

Theprinciplebehindheatfusionistoheattwosurfacestoadesignatedtemperature,andthenfusethemtogetherbyapplicationoftherequiredforce.Thisappliedforcejoinsthemeltedsurfacesresultinginapermanent,monolithicfusionjoint.PolyPipe®fusionproceduresrequirespecifictoolsandequipmentforthefusiontypeandforthesizesofpipeandfittingstobejoined.

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

Saddle Fusion –Thistechniqueinvolvesmeltingtheconcavesurfaceofthebaseofasaddlefitting,whilesimultaneouslymeltingamatchingpatternonthesurfaceofthepipe,bringingthetwomeltedsurfacestogetherandallowingthejointtocoolwhilemaintainingtheappropriateappliedforce.

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

ProperlyfusedPEjointsdonotleak.Ifaleakisdetectedduringpneumaticorhydrostatictesting,itispossibleforasystemfailuretooccur.Cautionshouldbeexercisedinapproachingapressurizedpipelineandanyattemptstocorrecttheleakshouldnotbemadeuntilthesystemhasbeendepressurized.

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

Butt Fusion

Saddle Fusion

Socket Fusion

2

INCLEMENT WEATHER

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

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

AdditionalinformationconcerningcoldweatherproceduresisavailableinASTMF2620,StandardPracticeforHeatFusionJoiningofPolyolefinPipeandFittings, AnnexA1.

Theoperatorshouldensurethatitsqualifiedfusionprocedurestakeintoaccountandareadaptedforallpotentialinclementweatherconditionsinwhichtheoperatormaybefusingpolyethylenepipe.

NOTES ON FUSION CONFIDENCE

ReliablefusionjointsofPEpipingsystemscanbeaccomplishedunderreasonablelatitudeofconditions.Theoperatorshouldqualifyitsownproceduresforeveryconditionunderwhichitwillbefusingpolyethylenepipe.Additionally,theoperatorshouldqualifyallpersonnelwhowillresponsibleforperformingfusionsofpolyethylenepipe.

Thefollowingisalistingofgeneralnotestohelpensureproperequipmentandtechniquesareutilized:

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

Improperunderstandingoftheoperationoftheequipmentandtoolscanproduceafusionofpoorquality.Theoperatormustunderstandthoroughlyhowtousetheequipmentandtools,theirfunctionandoperation.Theoperatorshouldadheretotheequipmentmanufacturer’sinstructions.

Fusionpressuresandheating/coolingcyclesmayvarydramaticallyaccordingtopipesizeandwallthickness.Operatorsshouldnotrelyexclusivelyonautomated

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

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

Heatersurfacesareusuallycoatedwithanon-stickmaterial.Cleaningtechniquesshouldbeusedaccordingly.Ifasolventisdeemednecessary,donotusegasolineorotherpetroleumproducts.Refertotheequipmentmanufacturer’sinstructionsforpropercleaningproducts.ItisimportanttoregularlycleantheheatersurfacetoremoveanybuildupofPEmaterialthatwilldegradeduetoextendedcontactwiththeheater.

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

Iftheheaterplateisnotinuse,itisrecommendedthatitbestoredinaninsulatedholder.Thisnotonlyprotectstheheatersurfacesfromcontaminants,butitcanalsopreventinadvertentcontact,whichcanresultinseriousinjuries.

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

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

3

FUSION CHECKLIST

Inspectpipelengthsandfittingsforunacceptablecuts,gouges,deepscratchesorotherdefects.Damaged

productsshouldnotbeused.RefertoPolyPipe®InfoBriefNo.2forallowablesurfacedamageaccordingtothe

PlasticsPipeInstitute(PPI)andtheAmericanGasAssociation(AGA).

Thefusioncontactareamustbefreeofanydefectsorsurfacedisruption.

Besureallrequiredtoolsandequipmentareonsiteandinproperworkingorder.

Pipeandfittingsurfaceswheretoolsandequipmentarefittedmustbecleananddry.Useclean,dry,non-

synthetic(cotton)clothsorpapertowelstoremovedirt,snow,waterandothercontaminants.Ifalcohol

isused,99%reagentgradeisopropylalcoholisrecommended.Thestandard“drugstorevariety”contains

impuritiesthatcanactasacontaminanttothefusionprocess.

Shieldand/orcoverfusionequipmentandsurfacesfrominclementweatherandwinds.Atemporaryshelter

overfusionequipmentandthefusionoperationmayberequired.

Relievetensioninthelinebeforemakingconnections.

Whenjoiningcoiledpipe,makinganS-curvebetweenpipecoilscanrelievetension.Insomecases,itmay

benecessarytoallowpipetoequalizetothetemperatureofitssurroundings.Allowpulled-inpipesto

relaxforseveralhourstorecoverfromtensilestresses.

Pipesmustbecorrectlyalignedbeforemakingconnections.

Trialfusions.

Atrialfusion,preferablyatthebeginningoftheday,canverifythefusionprocedureandequipment

settingsfortheactualjobsiteconditions.RefertoQualificationProceduresfordetailedinformationonthe

bendbacktestprocedure.

4

BUTT FUSION

Heater Surface Temperature: Minimum 400oF – Maximum 450oF

Heatingtoolsurfacesmustbetotemperaturebeforeyoubegin.Allpointsonbothheatingtoolsurfaceswheretheheatingtoolsurfaceswillcontactthepipeorfittingendsmustbewithintheprescribedminimumandmaximumtemperaturesandthemaximumtemperaturedifferencebetweenanytwopointsontheheatingtoolfusionsurfacesmustnotexceed20oFforequipmentforpipesmallerthan18”diameter,or35oFforlargerequipment.Itisagoodpracticetosettheheaterplateto425oFwhichcanhelpkeepnormalfluctuationsbetween400oFand450oF.Heatingtoolsurfacesmustbeclean.

Interfacial pressure: Minimum 60 psi – Maximum 90 psi

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

Forhydraulicmachines,theinterfacialpressure,thefusionsurfacearea,themachine’seffectivepistonareaandfrictionalresistance,andifnecessary,thepressureneededtoovercomeexternaldragresistance,areusedtocalculatehydraulicfusionjoiningpressuregaugesettings(refertoAppendixA).Theequipmentmanufacturer’sinstructionsareusedtocalculatethisvalue.Theproperamountofforceshouldbeverifiedbyvisualinspectionofthejoint.

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

Formanualmachineswithoutforcereadingcapability,thecorrectfusionjoiningforceistheforcerequiredtorollthemeltbeadsoveruntiltheycontactthepipesurfaceasrequiredbythejoiningprocedure.

Whenjoiningpipeswithdifferentmeltproperties,suchasbimodalMDPEtounimodalMDPE,applysufficientforcetomakethebimodalpipefusionbeadrollbackandcontactthepipesurface.BimodalMDPEhasalowermeltflowratiothanunimodalpipe.

5

PROCEDURE

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

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

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

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

6

heatingtool.Theproperbeadsizeisdependentuponthesizeofthecomponent.ApproximatevaluesareshowninTableI.

Duringheating,themeltbeadwillexpandoutflushtotheheatingtoolsurface,ormaycurlslightlyawayfromthesurface.Ifthemeltbeadcurlssignificantlyawayfromtheheatingtoolsurface,unacceptablepressureduringheatingmayhaveoccurred.

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

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

ThemaximumrecommendedtimeallowedforheaterplateremovalisindicatedinTableII.

TABLE IAPPROXIMATE MELT BEAD SIZE

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

≤0.15 1/32”–1/16” 0.15–0.30 1/16” Above0.30–0.75 1/8”–3/16” Above0.75–1.15 3/16”–1/4” Above1.15–1.60 1/4”–5/16” Above1.60–2.20 5/16”–7/16” Above2.20–3.00 7/16”–9/16”

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

7

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

Avoidpulling,installation,pressuretestingandroughhandlingforatleastanadditional30minutes.

Forambienttemperaturesabove100oF,longercoolingtimesmayberequired.

7. InspectionOnbothsides,thedoublebeadshouldberolledovertothesurface,andbeuniformlyroundedandconsistentinsizeallaroundthejoint.

1.Thegap(A)betweenthetwosinglebeadsmustnotbebelowthefusionsurfacethroughouttheentirecircumferenceofthebuttjoint.

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

3.RefertoTableIIIforgeneralguidelinesforbeadwidth,B,foreachrespectivewallthickness.

TABLE IIMAXIMUM HEATER PLATE REMOVAL TIMES

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

8

4.Thesizedifferential(Smax–Smin)betweentwosinglebeadsshallnotexceedX%ofthecombinedbeadwidth(B).

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

Minimum Wall

Thickness, in.

Approximate Bead Width (B), in.

Approximate Bead Width (B), in.

Minimum Wall Thickness, in.

TABLE IIIBEAD WIDTHS PER WALL THICKNESS

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

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

NOTE: 1. Whenbuttfusingpipetomoldedfittings,thefittingsidebeadmayhaveanirregularappearance. Thedifferentmanufacturingprocessesused(extrusionvsmolding)willcausethebeadappearancetobe differentwhenitrollsback.Thisisacceptable,providedthepipesidebeadiscorrect.(SeeImages1&2.) 2. WhenfusingunimodalMDPEpipetobimodalMDPEpipeorHDPEpipe,theunimodalMDPEpipebeadmay beslightlylargerthanthebimodalMDPEorHDPEpipebead.Thisoccursbecauseofthedifferentmelt propertiesoftheresins.(SeeImages3&4) 3. PolyPipePolyTough1™hasbeensuccessfullyfusedtoavarietyofpipesthatmaybeinuseinexistinggaspipe systems.Photosofthesefusionsareprovidedforvisualreference.(SeeImages5thru16)

9

QUALIFICATION

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

1.Prepareasamplejoint.Samplelengthsshouldbeatleast6”or15timestheminimumwallthickness(seeFigureI).

2.Observethefusionprocessandverifytherecommendedprocedureforbuttfusionisbeingfollowed.

3.Visuallyinspectthesamplejointforquality.

4.Allowthejointtocoolcompletely.

5.PreparethesampleasshowninFigureI.Thesampleshouldbecutlengthwiseintoatleastthreelongitudinalstrapswithaminimumof1”or1.5timesthewallthicknessinwidth.Itisrecommendedthatfourequallyspacedstripsbecut,onefromeachquadrantofthepipe.

6.Visuallyinspectthecutjointforanyindicationsofvoids,gaps,misalignmentorsurfacesthathavenotbeenproperlybonded.

7.Bendeachsampleattheweldwiththeinsideofthepipefacingoutuntiltheendstouch.Theinsidebendradiusshouldbelessthantheminimumwallthicknessofthepipe.Inordertosuccessfullycompletethebendback,avisemaybeneeded.Forthick(>1”)wallpipe,contactPolyPipe®Engineeringforrecommendedproceduresandtestapparatus.

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

Figure IButt Fusion Bent Strap Test Specimen

(Reference ASTM F2620)

BEND BACK TESTING - NO GAPS OR VOIDS(SeeFigure1)

10

ACCEPTABLE FUSIONS

BUTT FUSION

PROPER ALIGNMENT AND DOUBLE ROLL-BACK BEAD

Unimodal HDPE fused to molded fitting

Unimodal MDPE fused to PolyTough1TM bimodal MDPE

Unimodal MDPE fused to HDPE

PolyTough1TM fused to molded fitting

11

PolyTough1tm BIMODAL MDPE JOINED TO VINTAGE AND CURRENT MATERIALS

Unimodal MDPE fused to PolyTough1TM PolyTough1TM fused to PolyTough1TM

PolyTough1TM fused to PLEXCO PE2306 PolyTough1TM fused to PE3408

PE4710 fused to PolyTough1TM DRISCO M8000 fused to PolyTough1TM

DUPONT ALDYL A PE2306 fused to PolyTough1TM

12

UNACCEPTABLE FUSIONS

BUTT FUSION

Meltbeadtoosmallduetoinsufficientheattime Meltbeadtoolargeduetoexcessiveheatingand/oroverpressurizationofjoint

Misalignment IncompleteFacing

Pressurefluctuation,misalignmentoverpressurization13

TABLE IVBUTT FUSION TROUBLESHOOTING GUIDE

Observed Condition Possible Cause

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

•Beadstoosmall •Insufficientheating •Insufficientjoiningforce

•Beadnotrolledovertosurface •Shallowv-groove–Insufficientheating& insufficientjoiningforce •Deepv-groove–Insufficientheating& excessivejoiningforce •Beadonbimodalpipemayhaveslightgap tothepipesurface

•Beadstoolarge •Excessiveheatingtime

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

14

SADDLE FUSION

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

Heatertoolsurfacesmustbeuptotemperaturebeforeyoubegin.Allpointsonbothheatingtoolsurfaceswheretheheatingtoolsurfaceswillcontactthepipeandfittingmustbewithintheprescribedminimumandmaximumtemperatures.Heatertoolsurfacesmustbeclean.

DEFINITIONS

Initial Heat (Bead-up)Theheatingstepusedtodevelopameltbeadonthepipe.

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

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

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

Interface Pressure:Minimum54psi–Maximum66psi

Total Heat TimeAtimethatbeginswhentheheaterisplacedonthepipeandinitialheatforceisappliedandstopswhentheheaterisremoved.MaximumheatingtimesareshowninTableIVforbothpressure(hottapping)andnon-pressurefusionapplications.Cool TimeThetimerequiredtocoolthejointtoapproximately120oF±10oF.TheFusionForcemustbemaintainedfor5minuteson1-1/4”IPSor10minutesforallotherpipesizes,afterwhichthesaddlefusionequipmentcanberemoved.Thejointmustbeallowedtocoolforanadditional30minutesbeforetappingthepipeorjoiningtothebranchoutlet.RecommendedminimumcoolingtimesareshowninTableIV.

15

INTERFACIAL AREA

Rectangularbasefittings

Themajorwidthtimesthemajorlengthofthesaddlebase,withouttakingintoaccountthecurvatureofthebaseorsides,minustheareaofholeinthecenterofthebase.

Roundbasefittings

Theradiusofthesaddlebasesquaredtimesπ(3.1416),withouttakingintoaccountthecurvatureofthebaseorsides,minustheareaoftheholeinthecenterofthebase.

TABLE VMAXIMUM HEATING/MINIMUM COOLING TIMES

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

FITTING LABELS

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

16

PROCEDURE

1. Preparation

Thisprocedurerequirestheuseofasaddlefusiontool.Thistoolmustbecapableofholdingandsupportingthepipe,roundingthepipeforproperalignmentbetweenthepipeandfitting,holdingthefitting,andapplyingandindicatingtheproperforceduringthefusionprocess.

A.Installthesaddlefusiontoolonthepipeaccordingtothemanufacturer’sinstructions.Thetoolshouldbecenteredoveraclean,drylocationwherethefittingwillbefused.Securethetooltothepipe.Asupportisrecommendedunderthepipeon6”IPSandsmallerpipesizes.

B.Abradethesurfaceofthepipe,wherethefittingwillbejoined,witha50–60gritutilityclothuntilathinlayerofmaterialisremovedfromthepipesurface.Theabradedareamustbelargerthantheareacoveredbythefittingbase.Afterabrading,cleantheresidueawaywithaclean,drycloth.

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

2. Heating

Theheatingandfusingprocessmustbeperformedwithaccuracyandefficiency,especiallywhenfusingtoapressurizedmainpipe.

WARNING: Overheatingorexcessivetimebetweenthesetwoprocessescanhavedetrimentaleffects,includingpipelinerupture.

Theheatermustbefittedwiththecorrectheateradapters.

Theheateradapterfusionsurfacemustbebetween490oFto510oF.

Ensuretheheatingsurfacesareclean.

Determinethesaddlefusionforcefromthefittinglabelorbycalculation.

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

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

i. Totalheattimeexpiresforapressurized 1-1/4”IPSor2”IPSpipe,or

ii.Ameltbeadofapproximately1/16”isvisible aroundthefittingbasefora11/4”IPSor2”IPS non-pressurizedpipe,oralargerpressurizedor non-pressurizedpipe.

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3. Fusion and Cooling

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

Ifthemeltpatternwasnotsatisfactoryorifthefusionbeadisunacceptable,cutoffthesaddlefittingabovethebasetopreventuse,relocatetoanewsectionofmain,andmakeanewsaddlefusionusinganewfitting.

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

4. Inspection

Visuallyinspectthefusionbeadaroundtheentirebaseofthefittingatthepipe.Thefusionbeadshouldbeofuniformsize.Thefusionshouldhavea“three-bead”shape,whichischaracteristicofthistypeoffusion.Thefirstbeadisthefittingbasemeltbead.Thesecondoroutermostbeadistheresultoftheheatertoolfaceonthepipe.Thethirdbead,orcenterbead,isthepipemeltbead.Allbeadsshouldbeofuniformsizewiththefirstandthirdbeadsapproximately1/8”andthesecondbeadbeinggenerallysmaller.

QUALIFICATION

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

1.Prepareatleasttwosamplejoints.Thepipelengthshouldbeaminimumof2’orseventimesthemaximumsaddlefittingbasedimension,whicheverisgreater.

2.Observethefusionprocessandverifytherecommendedprocedureforsaddlefusionisbeingfollowed.

3.Visuallyinspectthesamplejointforquality.

4.Allowthejointtocoolcompletely(minimumofonehour).Thepipesampleshouldnotbetappedforthisqualificationprocess.

Figure IISaddle Fusion Bent Strap Test Specimen

18

5.PrepareteststrapsasshowninFigureII.Cutthejointlengthwisealongthemainpipeandthroughthesaddlefitting.

6.Visuallyinspectthejointforanyvoids,gaps,misalignmentorsurfacesthathavenotbeenproperlybonded.

7.Bendeachteststrap180owiththeinsidefacingout.

8.Thefusionjointmustbefreeofcracks,voids,gapsandseparations.

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

10.Iffailuredoesoccurattheweldinanyofthesamples,thenthefusionprocedureshouldbereviewedandcorrected.Aftercorrection,anothersamplefusionshouldbemadeperthenewprocedureandretested.

ACCEPTABLE FUSIONS

ProperAlignment,MeltandForce

BendBackTesting-NoGapsorVoids(SeeFigureII)

Areawherelikelygapsandvoids

mightoccur

Areawherelikelygapsandvoids

mightoccur

19

UNACCEPTABLE FUSIONS

ExcessiveHeatingand/orOverpressurizationofjoint

ExcessiveForce

FittingMisalignmentonpipe

InsufficientMelt

20

TABLE VISADDLE FUSION TROUBLESHOOTING GUIDE

Observed Condition Possible Cause

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

21

SOCKET FUSION

Equipment Requirements

Inordertoproduceaqualitysocketfusion,thefollowingequipmentisrequiredforthisprocedure:

Apparatus –SocketfusiontoolsmanufacturedinaccordancewithASTMF1056.

Heating tool faces –Consistingoftwoparts,amaleendfortheinteriorsocketsurfaceandafemaleendfortheexteriorpipesurface.

Rounding clamps (cold ring) -Devicetomaintaintheroundnessofthepipeandcontrolthedepthofpipeinsertionintothesocketduringthejoiningoperation.

Depth gauge –Properpositioningoftheroundingclamp.

Chamfering tool –Devicetobeveltheendofthepipe.Thedepthgaugeandchamferingtoolmaybecombinedintoasingletool.

Holding tools –Recommendedforsocketfusionof2”IPSandlargerpipeandfittings.

Heater Temperature

Heater Surface Temperature:Minimum490oF–Maximum510oF

Inordertoobtainapropermelt,auniformtemperaturemustbemaintainedacrosstheheatingsurface.Allpointsonbothheatingsurfaceswheretheheatingsurfaceswillcontactthepipeandfittingmustbewithintheprescribedminimumandmaximumtemperatures.Heatingtoolsurfacesmustbeclean.

22

Procedure

1. Preparation

A.Verifyheatingtemperatureiswithinthespecifiedtemperaturerange(490oF–510oF).

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

C.Chamfertheoutsideedgeofthepipeendslightly.Thepipeshouldbefreeofdebrisandburrs.

D.Placethecoldringonthepipeasdeterminedbythedepthgauge–Placethedepthgaugeoverthechamferedendofthepipe.Clampthecoldringimmediatelybehindthedepthgauge.

2. Heating

A.ReviewtherecommendedheatingtimesinTableVI.TheheatingtimebeginsafterStepChasbeencompleted.

B.Insertthefittingontothemaleheatingface.Thefittingshouldbeheldagainstthebacksurfaceofthemaleheaterface.

C.Insertthepipeintothefemaleheatingface.Thefemalesocketheatingfaceshouldbeagainstthecoldringclamp.

D.HoldthepipeandfittinginplaceagainsttheheaterfacesfortherecommendedheatingtimeasshowninTableVI.

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3. Fusion and Cooling

A.Attheendoftheheatingtime,simultaneouslyremovethepipeandfittingstraightoutfromthetoolusinga“snap”action.Donottorqueortwistthepipeorfittingduringremoval.

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

TABLE VIISOCKET FUSION TIME CYCLES

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

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

1/2”CTS 5–6 30 8–10 30 3/4”CTS 7–8 30 10–12 30 1”CTS 9–10 30 12–14 30 1/2”IPS 5–6 30 8–10 30 3/4”IPS 8–10 30 12–14 30 1”IPS 10–12 30 14–16 30 1-1/4”IPS 12–14 45 18–20 60 1-1/2”IPS 12–14 45 18–20 60 2”IPS 16–20 45 22–26 60 3”IPS 20–25 60 25–30 75 4”IPS 25–30 60 30-35 75

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

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

4. Inspection

Visuallyinspecttheweld.Acompleteimpressionoftheroundingclampshouldbevisibleinthemeltpatternattheendofthesocket.Thereshouldbenogaps,voidsorunbondedareas.

24

Qualification

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

1.Prepareasamplejointsuchasacouplingwithpipesocketfusedtobothends.Thepipeshouldbeatleast6”or15timesthewallthicknessinlength.

2.Observethefusionprocessandverifytherecommendedprocedureforsocketfusionisbeingfollowed.

3.Visuallyinspectthesamplejointsforquality.

4.Allowthesampletocoolcompletely(minimumofonehour).

Figure IIISocket Fusion Bent Strap Test Specimen

6.Visuallyinspectthecutjointforanyindicationsofvoids,gaps,misalignmentorsurfacesthathavenotbeenfused.

7.Bendeachteststrap180owiththeinsideofthepipefacingout.

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

5.PrepareteststrapsasshowninFigureIII.Cutthejointslengthwiseintoatleastthreelongitudinalstrapswithaminimumof1”or1.5timesthewallthicknessinwidth.

25

ACCEPTABLE FUSIONS

ProperAlignmentandStabDepthMeltBeadFlattenedDuetoColdRing-Nogapsorvoids

BendBackTesting-NoGapsorVoids(SeeFigureIII)

SOCKET FUSION

Areawherelikelygapsandvoids

mightoccur

Areawherelikelygapsandvoids

mightoccur

26

SocketFusion

ExcessiveStabDepthCausedbyFailuretoUseaColdRing

ShortStabDepthCausedbyFailuretoUseaDepthGauge

UNACCEPTABLE FUSIONS

SOCKET FUSION

27

TABLE VIIISOCKET FUSION TROUBLESHOOTING GUIDE

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

28

APPENDIX A

HYDRAULIC FUSION MACHINE GAUGE PRESSURE

ThemanufacturerofthefusionmachineshouldbeconsultedforguidanceindeterminingtheproperconversionofPolyPipe®’srecommendedinterfacialpressuretothegaugepressure.Theeffectivehydraulicpistonareamustbeavailableinordertocalculatetherequiredhydraulicgaugepressure.Thecalculationforhydraulicgaugepressureisasfollows:

Where PG = Hydraulicgaugepressure,psi OD = Pipeoutsidediameter,inches ID = Pipeinsidediameter,inches PI = Requiredinterfacialpressure,psi AP = Totalhydraulicpistonarea,in2 DF = Hydraulicfusionpressurerequiredtomovethecarriageholdingthepipe (generallyacceptedminimumis30psi).

*Thedragfactorisanimportantparametereasilyoverlooked.Iftwolongpiecesofpipearebeingfused,thedragfactorcaneasilyreachseveralhundredpoundspersquareinch(psi).

ExampleCalculations

FusionMachine:McElroyManufacturing28HighForceMachine Hydraulicpistonareaisprovidedbythefusionequipmentmanufacturer. Totalhydraulicpistonareaforthismachineis4.71in2

DesiredInterfacialPressure:75psi

For2”IPSSDR11:

29

REFERENCES

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

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

3. PlasticsPipeInstituteTechnicalNote–42.RecommendedMinimumTrainingGuidelinesforPEPipeButtFusionJ oiningOperatorsforMunicipalandIndustrialProjects,2009.www.plasticpipe.org

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

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

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

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NOTES

NOTES NOTES

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(Revised04/30/2012)