AUSTRALIAN FILM AND PIPE MANUFACTURERS … Appraisal - WSAA.pdf · WSAA Product Appraisal 06/08.2...

Sydney Office: Level 11, 91 York Street, Sydney South, NSW, Australia PO Box A812, Sydney South, NSW, 1235, Australia

Telephone (02) 9290 3266, Facsimile (02) 9299 0298, Email: [email protected]

AUSTRALIAN FILM AND PIPE MANUFACTURERS HOLDINGS PTY. LTD

(AFPM)

FUSION PROVIDA

ELECTROFUSION FITTINGS

PRODUCT APPRAISAL 06/08.2

ISSUE 1

18 February 2007

This report consists of cover pages, a table of contents, 8 pages of report, a disclaimer and 3 Appendices.

WSAA Product Appraisal 06/08.2 AFPM – Fusion Provida Electrofusion fittings

18 February 2007 2 Issue 1

Note 1

This appraisal applies to the product(s) as submitted. Any changes to the product(s) either minor or major shall void this appraisal. To maintain the recommendations of this appraisal any such changes shall be detailed and notified to the Program Manager Assets for consideration and review of the appraisal report and appropriate action. Appraisals and their recommendations will be the subject of continuous review dependent upon the satisfactory performance of products. WSAA reserves the right to undertake random audits of product manufacture and installation. Where products fail to maintain appraised performance requirements the appraisal and its recommendations may be modified and reissued. Appraisal reports will be reviewed and reissued at regular intervals not exceeding five (5) years.

Note 2 Disclaimer

The Disclaimer on page 12 explains a number of very important limits on your ability to rely on the information in this Product Appraisal Report.

Please read it carefully and take it into account when considering the contents of this Product Appraisal Report.

This appraisal was carried out by Leith Forbes & Associates Pty. Ltd. on behalf of WSAA.

The report was peer reviewed by Greg Moore SA Water, Carl Radford & Yoosuf Hussian CW Water, Lance Fletcher MC Water and Grant Leslie, WSAA

Any technical inquiries regarding this report should be directed to Grant Leslie, WSAA Program Manager Assets.

Tel (02) 9290 3655 Fax (02) 9299 0298 - E-mail [email protected]



CONTENTS

1 EXECUTIVE SUMMARY 4 1.1 RECOMMENDATION 5

2 THE COMPANY 6 2.1 MANUFACTURER 6 2.2 SUPPLIER 6

3 THE PRODUCT 6

4 SCOPE OF THE APPRAISAL 7

5 APPRAISAL CRITERIA 7 5.1 QUALITY ASSURANCE REQUIREMENTS 7 5.2 PERFORMANCE REQUIREMENTS 8

6 COMPLIANCE WITH APPRAISAL CRITERIA 8 6.1 COMPLIANCE WITH QUALITY REQUIREMENTS 8 6.2 COMPLIANCE WITH APPRAISAL REQUIREMENTS 8 6.3 WSAA AGENCY NETWORK REQUESTS 8

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION 8

8 PRODUCT MARKING 9

9 PACKAGING AND DELIVERY 9

10 WATER AGENCIES EXPERIENCE / FIELD TESTING REPORT 9

11 PRODUCT WARRANTY 9

12 DISCUSSION 9

13 SUMMARY 10

14 LIFE EXPECTANCY RATING 10

15 FUTURE WORK 10

16 RECOMMENDATION 11

17 DISCLAIMER 12 17.1 ISSUE OF REPORT 12 17.2 LIMITS ON RELIANCE ON INFORMATION AND RECOMMENDATIONS 12 17.2.1 Disclaimer of liability 12 17.2.2 Need for independent assessment 12 17.2.3 No updating 12 17.2.4 No warranty 12

APPENDIX A TECHNICAL MANUAL/BROCHURES 13

APPENDIX B QUALITY ASSURANCE CERTIFICATES AND PRODUCT SCHEDULES 14

APPENDIX C SUPPLIER CONTACT DETAILS 25



1 EXECUTIVE SUMMARY

The Fusion Provida electrofusion fittings are product certified by SAI Global StandardsMark for compliance with AS/NZS 4129 – Fittings for polyethylene (PE) pipes for pressure applications.

Fusion electrofusion fittings have the following applications for Water Agencies:

• main lines (pressure water supply and gravity, pressure and vacuum sewerage)

• property service connections (water supply and sewerage)

• PE pipeline repairs

Fusion Provida automatic electrofusion fittings are manufactured using PE 80 resin for PN 12.5 fittings and PE 100 resin for PN 16 fittings. Most fittings are available in either solid blue or solid black. The complete Fusion Provida Product Guide is available on their web site at: www.fusionprovida.com

The ‘Fusion’ range in the AFPM PE System includes;

• PN 16 Electrofusion couplers, end caps, 45º & 90º elbows, 90º equal tee’s, reducers, tapping tee’s and branch saddles in sizes from DN 20 to DN 355.

• PN 12 fittings are also available.

Fusion Provida Ltd (Fusion) is one of the three largest manufacturers of electrofusion fittings in the world and is a leading developer of polyethylene pipe jointing technology. Fusion is based in Chesterfield, UK and the comprehensive range of products is available globally through the Fusion network of wholly owned companies, joint ventures, licensees and distributors.

Based on product certification to the nominated standard the Fusion Provida electrofusion fittings, have been rated ‘A’ – Life expectancy in excess of 100 years before replacement. This rating is only a general guide to life expectancy and may increase or decrease as a result of the quality of installation, system operating conditions, operating environment and other geographical and site specific factors.

The appraisal concludes that:

• The Fusion Provida electrofusion fittings are ‘fit for purpose’ and suitable for use in water supply and sewer gravity, pressure and vacuum systems.

• The Fusion Provida electrofusion fittings are suitable for use with PE pipe conforming to AS/NZS 4130.

• StandardsMark product certification of the Fusion Provida electrofusion range of fittings has been adequately addressed to the satisfaction of WSAA Appraisal Network.

Items in the AFPM PE System are appraised in the following parts:

• AFPM PE System overview (See PA 06/08.0.)

• AFPM PE Pipe – Identi-pipe. (See PA 06/08.1.)

• AFPM Fusion Provida electrofusion fittings. (PA 06/08.2 – this report)



1.1 RECOMMENDATION

It is recommended that WSAA members and associates accept/authorise the Fusion Provida electrofusion fittings supplied by AFPM as listed in Section 4 – Scope of this report and in the StandardsMark Schedule. This recommendation is subject to the pipelines / fittings being designed, installed and commissioned in accordance with Fusion Provida recommendations, appropriate WSAA Codes and nominated Standards.

It is recommended that for PE pipelines where electrofusion fittings are being used, an attentive site supervision regime be adopted using qualified, experienced supervisors until the individual installer or contractor can demonstrate competence in all aspects of installation.

It is also recommended that for the overall design, installation, pipeline testing and installer training requirements for PE pipeline systems agencies refer to the WSAA Polyethylene Pipeline Code - WSA 01 available from the bookshop at the WSAA web site www.wsaa.asn.au.



2 THE COMPANY

2.1 MANUFACTURER

Edited information from the Fusion Provida web site: www.fusionprovida.com

Fusion Provida Ltd (Fusion) is one of the three largest manufacturers of electrofusion fittings in the world and is a leading developer of polyethylene pipe jointing technology. The Fusamatic principle of electrofusion and its range of automatic butt fusion machines are at the core of their product portfolio.

Fusion is based in Chesterfield, UK and design, manufacture and supply jointing systems for polyethylene pipelines used in water and gas distribution networks and other industrial applications. The comprehensive range of products is available globally through the Fusion network of wholly owned companies, joint ventures, licensees and distributors.

2.2 SUPPLIER

AFPM is currently located in Smithfield (NSW) and forms part of the Plastics Division of (W.H. Soul) Pattinson, Cromford Pty Ltd. AFPM is in the process of establishing a new manufacturing site at Moss-vale (NSW) which will become the main pipe manufacturing facility to allow AFPM to produce PE pipe up to DN 500.

For more information see the Overview in PA 06/08.0.

3 THE PRODUCT

The Fusion Provida electrofusion fittings are product certified by SAI Global StandardsMark and have the following applications for Water Agencies:

• main lines (pressure water supply and gravity, pressure and vacuum sewerage)

• property service connections (water supply and sewerage)

• PE pipeline repairs

Fusion Provida automatic electrofusion fittings are manufactured using PE 80 resin for PN 12.5 fittings and PE 100 resin for PN 16 fittings. Most fittings are available in either solid blue or solid black. The complete Fusion Provida Product Guide is available on their web site at: www.fusionprovida.com

The ‘Fusion’ range in the AFPM PE System includes;

• PN 16 Electrofusion couplers, end caps, 45º & 90º elbows, 90º equal tee’s, reducers, tapping tee’s and branch saddles in sizes from DN 20 to DN 355. PN 12 fittings are also available.

Fusion Provida control boxes provide computerised control and monitoring systems can supply all joint data required for a fully traceable quality system when used in conjunction with ‘Fusion’ fittings.

(Control boxes are not included in this appraisal.)

Fusion electrofusion fittings may be fused using other brands of fusion control boxes with comparable voltage; however, the automated function may not be compatible. This appraisal is based on ‘Fusion’ fittings installed using Fusion Provida control boxes.

Items in the AFPM PE System are appraised in the following parts of this appraisal:



• AFPM PE System overview (See PA 06/08.0.) • AFPM PE Pipe – Identi-pipe. (See PA 06/08.1.) • AFPM Fusion Provida electrofusion fittings. (PA 06/08.2. – this report)

4 SCOPE OF THE APPRAISAL

The Scope of this Part 2 of the AFPM PE System appraisal follows the StandardsMark Schedule and includes: (Australian common sizes in BOLD.)

• Equal couplers; 20, 25, 32, 40, 50, 63, 75, 90, 110, 125, 140, 160, 180, 200, 225, 250, 280, 315 and 355mm.

• End cap; 20, 25, 32, 40, 50, 63, 75, 90, 110, 125, 140, 160, 180, 200, 225, 250, 280, 315 and 355mm.

• 90º Elbow; 20, 25, 32, 40, 50, 63, 75, 90, 110, 125, 160 and 180mm.

• 45º Elbow; 32, 40, 50, 63, 75, 90, 110, 125, 160 and 180mm.

• 22º Elbow; 180mm.

• 90º Tee; 20, 25, 32, 40, 50, 63, 75, 90, 110, 125, 160 and 180mm.

• 90º Reducing Tee; 20mm x 20mm x 32mm, 25x25x32, 50x50x40, 63x63x40, 63x63x50, 90x90x63, 110x110x63, 110x110x90, 125x125x63, 125x125x90, 160x160x110, 180x180x125 and 180x180x90.

• Reducer; 25mm x 20mm, 32x20, 32x25, 40x32, 50x32, 50x40, 63x32, 63x40, 63x50, 90x63, 110x90, 125x90 and 180x125.

• Tapping Tee S/L 63mm x 20mm, 63x25, 63x32, 75x20, 75x25, 75x32, 90x20, 90x25, 90x32, 110x20, 110x25, 110x32, 125x20, 125x25, 125x32, 160x20, 160x25, 160x32, 180x20, 180x25, 180x32, 200x20, 200x25, 200x32, 225x20, 225x25, 225x32, 250x20, 250x25 and 250x32.

• Tapping Tee U/P 40mm x 20mm, 40x25, 40x32, 50x20, 50x25, 50x32, 63x20, 63x25, 63x32, 75x20, 75x25, 75x32, 90x20, 90x25, 90x32, 110x20, 110x25, 110x32, 125x20, 125x25, 125x32, 160x20, 160x25, 160x32, 180x20, 180x25, 180x32, 200x20, 200x25, 200x32, 225x20, 225x25 and 225x32.

• Branch Saddle U/P 40mm x 20mm, 40x25, 40x32, 50x20, 50x25, 50x32, 63x20, 63x25, 63x32, 75x20, 75x25, 75x32, 90x20, 90x25, 90x32, 110x20, 110x25, 110x32, 125x20, 125x25, 125x32, 160x20, 160x25, 160x32, 180x20, 180x25, 180x32, 200x20, 200x25, 200x32, 225x20, 225x25 and 225x32.

All the above fittings are PN 16 and there are additional StandardMarked fittings in PN 12.5. See the StandardsMark Schedule in Appendix ‘B’.

NOTE: The use of PN 12.5 fittings with PN 16 pipe requires the system to be downgraded to PN 12.5.

5 APPRAISAL CRITERIA

5.1 QUALITY ASSURANCE REQUIREMENTS

The WSAA product appraisal network accepts system (ISO 9001) and product certification by a Certification Body at the manufacturing site of strategic products to appropriate Australian or



internationally recognized standards. The Certification Body shall have relevant accreditation by the Joint Accreditation System of Australia and New Zealand (JAS-ANZ) or by an equivalent international accreditation system recognized by JAS-ANZ.

NOTE: Refer to the quality assurance requirements appended to the “Products and Materials” sections of WSA 02-2002 or WSA 03-2002 and WSA 06-2004 for further information.

5.2 PERFORMANCE REQUIREMENTS

Fusion Provida electrofusion fittings have been appraised for compliance with AS/NZS 4129 – Fittings for polyethylene (PE) pipes for pressure applications.

6 COMPLIANCE WITH APPRAISAL CRITERIA

6.1 COMPLIANCE WITH QUALITY REQUIREMENTS

Fusion Provida electrofusion fittings are product certified by SAI Global, StandardsMark Licence No. SMKP20303. A copy of the Licence and Schedule are shown in Appendix ‘B’. The Licence and Schedule may also be viewed on the SAI Global web site at: http://register.sai-global.com/SuppliersDetails.asp?Regisno=SMKP20303

Fusion Provida Ltd. operates a BSI certified quality management system in compliance with BS EN ISO 9001:2000, BSI Certificate No. FM 28179.

6.2 COMPLIANCE WITH PERFORMANCE REQUIREMENTS

StandardsMark Product Certification provides some confidence that the product is manufactured for compliance with the requirements of the nominated Standard (AS/NZS 4129).

6.3 WSAA AGENCY NETWORK REQUESTS

The Network made no specific requests with respect to the Fusion Provida electrofusion fittings beyond compliance with AS/NZS 4129.

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION

The Fusion Provida Product Guide is available on their web site at: www.fusionprovida.com which includes complete assembly and operating instructions including:

• Electrofusion preparation and process requirements,

• Assembly instructions for sockets, fittings and adaptors,

• Assembly instructions for saddles and tapping valves and

• Assembly instructions for strengthening saddles.

WSAA has published the Polyethylene Pipeline Code - WSA 01 with significant input and peer review of the Plastics Industry Pipe Association of Australia (PIPA) on PE pipeline systems design, installation, testing and installer training requirements.

Satisfactory completion of a recognised PE pipeline installation training program is a recommended pre-requisite for all PE pipeline installers and supervisors.

WSAA also recommended that for the overall design, installation, pipeline testing and installer training requirements for PE pipeline systems agencies refer to the WSAA Polyethylene Pipeline Code - WSA 01 available from the bookshop at the WSAA web site www.wsaa.asn.au.



8 PRODUCT MARKING

StandardsMark product certification ensures that marking complies with the requirements of AS/NZS 4129 and includes:

• Manufacturers name or registered trademark;

• Dezincification resistance of copper alloy components marked with “DR”

• Date or batch code;

• Nominal size – “DN”;

• Abbreviated material identification;

• Class “PN”

• Standard No. – AS/NZS 4129

9 PACKAGING AND DELIVERY

Individual electrofusion fittings are packed in transparent protective bags and contained in carton boxes. Each carton or protective package clearly indicates its contents. All fittings are packaged to allow use on site without additional cleaning.

Where only one type of product is packaged in a bag or carton box, a label showing the manufacturer identification, the description of the product, a drawing of the product, the relevant size and the quantity is on each package.

10 WATER AGENCIES EXPERIENCE / FIELD TESTING REPORT

While electrofusion fittings are a mature widely installed product, the Australian water industry has had varied experience with the performance of these fittings. They are approved by many Water Agencies simply based on product certification and the knowledge that they are capable of performing well provided the installation is carried out correctly by competent well-trained installers.

Many Water Agencies are cautious about the use of electrofusion fittings due to the lack of confidence in the installers. Because of the history of erratic installation quality it is imperative that satisfactory completion of a recognised PE pipeline installation training program be a minimum pre-requisite for all PE pipeline installers. In addition it is recommended that for PE pipelines where electrofusion fittings are being used, an attentive site supervision regime be adopted using qualified, experienced supervisors until the individual installer or contractor can demonstrate competence in all aspects of installation.

Field testing of these products should be required as they seem to be new to Australia. AFPM should request independent product endorsements from ‘Fusion’. (See future work)

11 PRODUCT WARRANTY

The products are covered by the normal commercial and legal requirements of The Trade Practices Act 1974, which covers manufacture to the relevant Standard.

12 DISCUSSION

The Fusion Provida web site provides lists of approvals from all over Europe including the following:

• Dutch KIWA Approval



• Belgium - PE100 Water approval

• Italian Institute Of Plastics Certificate of Conformity

• Poland - Oil & Gas Institute Certificate

• Latvia Approval

• WRAS Document

• KITEMARK

This is in addition to the WSAA requirement for Type 5 Product certification documented in this report. The ‘Fusion’ products meet all the requirements for a WSAA recommendation as ‘fit for purpose’ products. At this time all that could be added to this report is a report on a ‘field trial’ or a suitable independent product endorsement.

13 SUMMARY

Electrofusion jointing of PE pipelines offers a permanently sealed and jointed system provided the process is carried out correctly. The electrofusion jointed PE pipeline has the potential to have life expectancy equal to and, in some cases well beyond other pipeline materials and jointing systems. The PE material is corrosion resistant and correctly made joints are permanently fused and provide a high level of joint integrity to leakage and/or infiltration over the long-term. Similar to other plastic pipe systems, PE is susceptible to fatigue from cyclic pressure changes and additional design considerations must be made if used in a pumped pipeline. Refer to WSAA Technical Note TN4, plus design material available from Fusion Provida and AFPM.

PE pipelines are susceptible to permeation of specific organic chemicals (as are other pipeline systems) and care must be exercised if designing for installation in contaminated ground and/or brownfield sites. Seek further advice from Fusion Provida and AFPM regarding such installations.

The appraisal concludes that:

• The Fusion Provida electrofusion fittings are ‘fit for purpose’ and suitable for use in water supply and sewer gravity, pressure and vacuum systems.

• The Fusion Provida electrofusion fittings are suitable for use with PE pipe conforming to AS/NZS 4130.

• StandardsMark product certification of the Fusion Provida electrofusion range of fittings has been adequately addressed to the satisfaction of WSAA Appraisal Network.

14 LIFE EXPECTANCY RATING

Based on product certification to the nominated standard the Fusion Provida electrofusion fittings, jointed with Fusion Provida control boxes have been rated ‘A’ – Life expectancy in excess of 100 years before replacement. This rating is only a general guide to life expectancy and may increase or decrease as a result of the quality of installation, system operating conditions, operating environment and other geographical and site specific factors.

15 FUTURE WORK

It is required that AFPM arrange field testing of the ‘Fusion’ fittings in conjunction with a WSAA member water agency and a report be provided by the agency to the WSAA Program Manager Assets for inclusion in updates of this report before 1 October 2008.

It is required that AFPM obtain copies of independent product endorsements from ‘Fusion’ and these endorsements be available for addition to this report before 31 June 2008.



16 RECOMMENDATION

It is recommended that WSAA members and associates accept/authorise the Fusion Provida electrofusion fittings supplied by AFPM as listed in Section 4 – Scope of this report and in the StandardsMark Schedule. This recommendation is subject to the pipelines / fittings being designed, installed and commissioned in accordance with Fusion Provida recommendations, appropriate WSAA Codes and nominated Standards.

It is recommended that for PE pipelines where electrofusion fittings are being used, an attentive site supervision regime be adopted using qualified, experienced supervisors until the individual installer or contractor can demonstrate competence in all aspects of installation.

It is also recommended that for the overall design, installation, pipeline testing and installer training requirements for PE pipeline systems Agencies refer to the WSAA Polyethylene Pipeline Code - WSA 01 available from the bookshop at the WSAA web site www.wsaa.asn.au.



17 DISCLAIMER

17.1 ISSUE OF REPORT

This Product Appraisal Report (Report) has been published and/or prepared by the Water Services Association of Australia, Inc and nominated Project Manager and peer group of technical specialists (the Publishers).

The Report has been prepared for use within Australia only by technical specialists that have expertise in the function of products such as those appraised in the Report (the Recipients).

By accepting this Report, the Recipient acknowledges and represents to the Publisher[s] and each person involved in the preparation of the Report that the Recipient has understood and accepted the terms of this Disclaimer.

17.2 LIMITS ON RELIANCE ON INFORMATION AND RECOMMENDATIONS

17.2.1 Disclaimer of liability

Neither the Publisher[s] nor any person involved in the preparation of the Report accept[s] any liability for any loss or damage suffered by any person however caused (including negligence or the omission by any person to do any thing) relating in any way to the Report or the product appraisal criteria underlying it. This includes (without limitation) any liability for any recommendation or information in the Report or any errors or omissions.

17.2.2 Need for independent assessment

The information and any recommendation contained (expressly or by implication) in this Report are provided in good faith. However, you should treat the information as indicative only. You should not rely on that information or any such recommendation except to the extent that you reach an agreement to the contrary with the Publisher[s].

This Report does not contain all information that a person might require for the purposes of assessing any product discussed or appraised within it (Product). The product appraisal critieria used in preparing this Report may not address all relevant aspects of the Product. Recipients should seek independent evidence of any matter which is material to their decisions in connection with an assessment of the Product and consult their own advisers for any technical information required. Any decision to use the Product should take into account the reliability of that independent evidence obtained by the Recipient regarding the Product. Recipients should also independently verify and assess the appropriateness of any recommendation in the Report, especially given that any recommendation will not take into account a Recipient's particular needs or circumstances.

17.2.3 No updating

Neither the Publisher[s] nor any person involved in the preparation of this Report [has][have] any obligation to notify you of any change in the information contained in this Report or of any new information concerning the Publisher[s] or the Product or any other matter.

17.2.4 No warranty

The Publisher[s] do[es] not, in any way, warrant that steps have been taken to verify or audit the accuracy or completeness of the information in this Report, or the accuracy, completeness or reasonableness of any recommendation in this Report.



APPENDIX A TECHNICAL MANUAL/BROCHURES

Technical manuals and Product Guide for this appraisal are available at the Fusion Provida web site at;

www.fusionprovida.com

Also refer to AFPM for copies of their various manuals and brochures or see the AFPM web site at: www.afpm.com.au

AFPM advise that their web site is expected to be completed by April 2008.



APPENDIX B QUALITY ASSURANCE

CERTIFICATES AND PRODUCT SCHEDULES Includes:

• Fusion Provida Ltd. BSI certified quality management system Certificate No. FM 28179 for compliance with BS EN ISO 9001:2000. (1 Page)

• Fusion Provida Ltd electrofusion fittings StandardsMark Licence No. SMKP20303 certified by SAI Global for compliance with AS/NZS 4129. (1 page)

• Fusion Provida Ltd electrofusion fittings StandardsMark Schedule for Licence No. SMKP20303. (8 pages)



APPENDIX C SUPPLIER CONTACT DETAILS

NSW

Promains 5 Yulong Close Moorebank,NSW 2170 P. 02 9602 0528 F. 02 9602 0732 Kenkar Plastics 13/11-12 Boden Rd Seven Hills NSW 2147 P. 02 9620 8458 F. 02 9620 8468 Adroit Piping Systems 67 Atkins Rd. Ermington NSW 2115 P. 029684 4266 F. 02 9698 9498

Victoria

Promains 43-45 Capital link Drive Campbellfield Vic 3061 P. 03 9357 8787 F. 03 9357 8785

Queensland

Allmain Fittings 16 Andrew Campbell Drive Narangba, Qld 4504 P. 07 3888 5100 F. 07 3888 5300

South Australia

Promains Building ‘C’ 13 Naweena St. SA 5010 P. 08 8340 4977 F. 08 8340 4988

AUSTRALIAN FILM AND PIPE MANUFACTURERS … Appraisal - WSAA.pdf · WSAA Product Appraisal 06/08.2...

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