FRIATEC FRIALEN, Fitting Instructions Manual

Page 1: ...FRIALEN Large Pipe Technique for laying large pipes and relining pipe networks Fitting Instructions FRIALEN Large Pipe Technique ...

Page 2: ...6 7 Update of these assembly instructions 30 For further information on the processing of FRIALEN Safety Fittings please contact FRIATEC Aktiengesellschaft Technical Plastics Division P O B 710261 D 68222 Mannheim Phone 49 621 486 1486 Fax 49 621 479196 Internet www frialen com Email info frialen friatec de Hotline 49 621 486 1486 Contents Page FRIALEN Safety Fittings ...

Page 3: ...scribes advice and other useful information 2 Areas of Application FRIALEN Safety Fittings are used for weld joints at pressure pipes made of polyethylene in the dimensions SDR 17 6 to SDR 11 for use in gas and water supply pressure drainage industry and landfill construction For processing of pipes SDR 17 6 please call us When operating with other media than water and natural gas please contact o...

Page 4: ... MFR 190 5 in the range of 0 2 1 7g 10 min applies We recommend using pipes with a limited dimension tolerance range tolerance class B FRIALEN Safety Fittings consist of PE 100 and meet the requirements according to DIN 16963 5 7 EN 1555 3 EN 12201 3 EN 13244 3 ISO 8085 3 as well as the DVGW test bases FRIALEN Safety Fittings can be fused with FRIAMAT Electrofusion Units at ambient temperatures be...

Page 5: ...erly stored component parts may not be processed because this may result in leaking fusion joints Traceability An automatic component traceability is possible when using e g traceability capable FRIAMAT Electrofusion Units with a special barcode see Figure 9 which contains the specific data of the fitting e g manufacturer dimension material batch These data on component traceability can be electro...

Page 6: ...t angle to the pipe axis see Figure 1 A suitable tool is a PE pipe cutter or a saw with toothing suitable for plastics Distinctive conical oblique pipeends must be cut off if necessary DANGER A non rectangular pipe cutting may cause the heating coil partially not being covered by the pipe which may result in overheating uncontrolled melt formation or self ignition see Figure 2 Figure 1 Figure 2 Fi...

Page 7: ...n the surface of HDPE pipes and spigot fittings during storage has to be removed completely directly before the assembly IMPORTANT The Scraper tool FWSG 710 S and FWSG 710 L have proved them selves for a long time in use application and serve for the scraping of pipes in the dimension area d 250 to d 710 Besides the FWSG 710 S scrapes only half a sleeve length so that it is possible to scrape spig...

Page 8: ...rge annular gap which either cannot or only insufficiently closed by fusion for the remedy see item 4 8 Please thus regularly check the condition of the blade at the manual scraper and the wear of the scraper blade at the scraper tool Worn blades must be replaced see FRIALEN Info No 1 Please note that the indicated wearing margin applies to FRIALEN Safety Fittings Where appropriate please observe ...

Page 9: ...e of the pipe will make it easier to fit the coupler Remove swarves from within the pipe 4 4 Restoration of irregular oval pipes Pipes in particular bundled coils and drums may loose their roundness during storage If the pipe out of roundness in the fusion zone area exceeds 1 5 of d outer diameter or is 3 0 mm these pipes must be rounded in the fusion zone area Please use rounding clamps for this ...

Page 10: ...on zone WARNING When using alcoholic cleaning agents the alcohol percentage must be at least 99 8 according to DVGW VP 603 The cleaning agent must be completely evaporated before starting the fusion process Now using the FRIALEN marker re mark the line approx 120 distri buted around the circumference to show the width of the fusion zone on the pipe since this will have been removed by scraping and...

Page 11: ... permitted see item 4 4 A simple control of the high points is possible by installing the coupler and evaluating the annular gap 4 7 Ensuring a tension free assembly of the components All joints prepared for fusion must be tension free Pipes may not be positioned in the FRIALEN Safety Fitting under bending stress or self load After the installation on the pipe ends it must still be possible to mov...

Page 12: ...joining area has also a positive effect on the fusion result Procedure 1 Preparation of the joining area corresponding to the FRIALEN installation instructions for large pipes and pipe network relining 2 Centre the coupler on the pipe such that the ring gap across the circumference is as equal as possible If required support the coupler 3 Close the ring gap with adhesive tape to prevent heat losse...

Page 13: ... Use FRIAMAT fusion units only for FRIALEN UB d 710 For the fusion of the coupler d 800 please observe our FRIALEN Info No 42 The fusion parameters are contained in the main barcode affixed to the FRIALEN Safety Fitting When using fully automatic fusion units e g FRIAMAT the parameters are entered into the fusion unit using the reader After reading of the barcode see Figure 9a the fitting data are...

Page 14: ...ely For fittings with continuous coil both fitting sides are to be fused simulta neously see Figure 11 FRIALEN Safety Fittings are equipp ed with a swell indicator this only gives an indication that fusion has taken place This swell indicator signalises the fusion process by changing its colour red and by increase of volume The proper progress of the fusion process however is only shown by the fus...

Page 15: ...otline 4 10 Cooling times The cooling time is a the time which is required to cool down the component to the temperature which facilitates the movement of the joint This time is also listed on the barcode and is identified by CT b the time which is required to cool down the component to the temperature which facilitates the application of the full test or operating pressure This is classified into...

Page 16: ...he fused joint and does not present a problem 5 Saddle parts Top Loading FRIALEN TL saddle parts are used with pipes from SDR 17 to SDR 11 from d 250 mm The processing occurs with the FRIATOP Clamping Unit Figure 15b 5 1 DAA TL Pressure Tapping Tees Top Loading d 250 315 400 FRIALEN DAA TL Pressure Tapping Tees Top Loading are suitable for fitting as branch connectors onto unpressurised or pressur...

Page 17: ...e diately before assembly See Figure 14 A processing allowance of several millimetres in addition to the covered area provides proof after fusion that the oxide layer has been properly removed from the pipe WARNING If the oxide layer is not removed completely leaking fusion joints may result Worn blades of the scraper tool and manual scraper must be replaced A one time complete removal is sufficie...

Page 18: ...free and non dyed paper directly before the assembly and after scraping We recommend PE cleaning agents which meet the requirements of the test basis DVGW VP 603 e g AHK cleaning agents When cleaning ensure that no contaminations from the unscraped pipe surface are introduced into the fusion zone WARNING When using alcoholic cleaning agents the alcohol percentage must be at least 99 8 according to...

Page 19: ...adapter of the FRIATOP clamping device Figure 15a Fit the clamping device as directed in the Operating Instructions Figure 15b WARNING For pressure tapping tees and pressure tapping valves the factory drill setting may not be changed before starting the fusion process 5 1 4 Carrying out of fusion When fusing Pressure Tapping Tees to media carrying pipings the following operating pressures may not ...

Page 20: ...matically monitor the fusion process and control the supplied voltage in determined limits The swell indicator only indicates to the performed fusion process The proper fusion process is however only indicated by the fusion unit WARNING Keep a distance of one meter to the fusion site during the fusion process for general safety reasons The obtained ACTUAL fusion time is to be compared with the tar...

Page 21: ...ressure Tapping Tees Remove blanking plug Turn the drill down up to the lower stop using the matching FRIALEN activating key SW 19 See Figure 16 Turn the drill backwards up to the upper stop Position the blanking plug and turn down the FRIALEN activating key until the collar of the plug slightly touches the front face of the drill spigot Subsequently turn back the plug half a turn to relieve the O...

Page 22: ...n turn back approx half a rotation The metal end points for the open shut positions of the valve lead to a distinctly noticeable increase in the activating force As sealing takes place in the closed position using a radially injected O ring it is not necessary to apply a great deal of pressure when closing the valve Install the FRIALEN Installation Kit EBS on the 14 mm square of the DAV TL and sec...

Page 23: ...r fitted with a valve in accordance with the relevant Fitting Instructions from the different valve manufacturers The preparation and conduct of the pressure test are carried out in accordance with the details given by the valve manufacturer The threaded components fitted at the factory must be secured with a spanner to prevent them from twisting Care should be taken to ensure that the insulation ...

Page 24: ... the O ring must seal in the dome The required torque of approx 150 Nm can be achieved through a lever A visual control takes place Figure 20 A torque screwdriver is not necessary After fitting the brass plug either the plastic nut must be screwed on or a FRIALEN cap for Shut off Sadd les must be fused on ensuring that the usual scraping and cleaning work is carried out see Figure 21 5 4 SA TL Spi...

Page 25: ...e to be observed 5 5 VSC TL Repair Saddle Top Loading d 250 560 5 5 1 Assembly For localised damage to the pipe at a single point the damaged spot can be sealed off with a plug and then fused with the repair Saddle Top Loading The preparation of the installation and the fusion process of the individual half shells is made analogue to the FRIALEN Pressure Tapping Tee see 5 1 1 5 1 5 WARNING Care mu...

Page 26: ...as saddle component analogue to the FRIALEN Pressure Tapping Tee see items 5 1 1 5 1 5 INFORMATION For a leakage free tapping of pressurised pipings we recommend the tapping unit of the company of Hütz Baumgarten Remscheid www huetz baumgarten de Please ask our Application Engineering Department The telescopic FRIALEN actuation key BS is particularly designed for the technical and geometrical requ...

Page 27: ... matched to the dimensions of the pipes used for this process The other end corres ponds to the standard pipe size This allows renovated sections of pipeline to be connected using fitted pieces of standard pipe The fittings are used like slide over couplers 6 3 Fitting and fusion 6 3 1 Relining using HDPE standard pipes When joining standard pipes the appropriate FRIALEN Safety Fittings are used T...

Page 28: ...f the support sleeve is dependent on the medium flowing the material and the pipe size The fitting of coupler and sleeve will be made easier if the pipe tolerances are taken into account when deciding on the size The use of preheating in accordance with item 6 3 3 will then be essential 6 3 5 Use of a pipe expander tool as a temporary support sleeve If a support sleeve is not wanted the coupler ca...

Page 29: ...ameter range d of the moulded component being used If necessary the saddle must be brought into line either axially or radially The assembly of the saddle components occurs according to items 5 1 1 to 5 1 6 Before the renovation the old pipe should be cut away at the point where a moulded saddle component is to be fused to the inner liner pipe The pipe diameter will be brought to size at the propo...

Page 30: ...RIATOP Clamping Unit FWFIT Clamping and Tapping Tool These technical statements are regularly revised to be up to date The date of the last revision is stated on the document For an updated version of the operating instructions please visit our website www frialen com on the Internet You will find the Download page on the navigation bar This page contains our updated operating instructions as pdf ...

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Page 32: ...FRIATEC Aktiengesellschaft Technical Plastics Division P O Box 71 02 61 D 68222 Mannheim Phone 49 621 486 1486 Fax 49 621 479196 E Mail info frialen friatec de www frialen com 2104 8e II 08 Update 26 02 08 ...