DN-27 Service jointing, electrofusion

• Site conducted

• Conducted on

  Date

• Prepared by

• Location
  Address

• Operative being assessed

  Yes

  No

  N/A

• - Checks size (i.e. outside diameter and SDR of pipe and fitting are compatible)

  Yes

  No

  N/A

• - Checks fusion heating time and the power requirements for larger fittings

  Yes

  No

  N/A

• - Checks cooling time

  Yes

  No

  N/A

• Question - Below what level of percentage LEL must an electrofusion box not be taken into a gaseous atmosphere?

• Answer - 20% LEL The Electrofusion control box must not be taken into any excavation or gaseous atmosphere

• Checks for a location that is flat and dry to carry out the operation

  Yes

  No

  N/A

• Question - What action must be taken if there is likely to be a problem with airborne contamination or wind chill?

• Answer - An appropriate shelter must be used

• - Checks the fitting is sealed within its protective bag, free from contamination and ensures it remains protected until immediately prior to its use

  Yes

  No

  N/A

• Question - Is it acceptable to scrape any surface containing a heating element and what action must be taken if the fusion cycle stops mid process?

• Answer - There should be no damage to the heating element and if the fusion cycle fails then the fitting is to be allowed to cool, cut off / out the fitting and start the process again. No fitting should be re-fused

• Checks the voltage of the fusion box is compatible with the fitting i.e. 39.5, 48 or 80 volts and the <br>generator is the correct voltage / power output. Ensure that the generator has sufficient fuel to <br>complete the electrofusion cycle

  Yes

  No

  N/A

• Checks the pipe ends are square and cuts if necessary

  Yes

  No

  N/A

• Checks the pipe for roundness and uses a re-rounding clamp where necessary

  Yes

  No

  N/A

• Prepares suitable restraining clamp for use, fitting adaptor shells if required

  Yes

  No

  N/A

• Checks there is sufficient clearance around the pipe to fit the restraining clamp

  Yes

  No

  N/A

• Cleans the jointing area of the pipe with a clean, damp non-synthetic cloth or paper towelling. If <br>using soapy water this must be cleaned off with clean water and the joint area dried

  Yes

  No

  N/A

• With the fitting still in its protective bag, places the fitting against the pipe and with a felt tip <br>marker pen, marks half the length of the fitting plus 25mm and roughly marks a spiral lune around <br>the pipe. Repeats on the other pipe(s) to be joined

  Yes

  No

  N/A

• Question - Why is it necessary to mark a spiral mark, or similar around the pipe?

• This clearly shows the area to be scraped and will also aid visual indication of areas not scrapped

• Uses an approved scraping tool to thoroughly scrape the whole area marked

  Yes

  No

  N/A

• Removes fitting from its protective bag taking care not to handle or contaminate the surface of the <br>fitting containing the heating coil or section of scraped pipe

  Yes

  No

  N/A

• Places the fitting onto the end of the pipes, ensuring it touches the stop within the fitting. Marks <br>the penetration depth on the side of the pipe at either end of the fitting

  Yes

  No

  N/A

• Question - Why is it necessary to mark the penetration depth on the pipe?

• Answer - This is to provide a visual warning if the fitting moves in relation to the mark prior to, or during
  fusion taking place and provides a visual indication of correct alignment

• Question - What needs to be done to a coupler so as it can be slipped over both ends of the pipe when carrying out a cut-out operation?

• Answer - The central stop register inside the coupler needs to be removed

• Assembles the restraining clamp onto the pipe, checks the penetration depth markings and <br>visually checks pipe alignment in all planes. Rotates the fitting to ensure no excessive forces are <br>present

  Yes

  No

  N/A

• Starts the generator and connects the control box to the generator

  Yes

  No

  N/A

• Connects the terminal leads from the control box to the electrofusion fitting

  Yes

  No

  N/A

• Sets the control box timer to the fusion time marked on the fitting and starts process. Ensures all <br>personnel are aware that electrofusion is in progress and they do nothing to disrupt the procedure

  Yes

  No

  N/A

• Stands clear of the fitting when fusion is in progress and does not adjust the restraining clamp <br>during the fusion process

  Yes

  No

  N/A

• Checks the control box has completed its full cycle, disconnects the terminal leads from the fitting <br>and allows the joint to cool for the required cooling time prior to removing the restraining clamp

  Yes

  No

  N/A

• Checks that the fusion indicators have risen and that no melted material or wire has extruded from <br>the ends of the fitting

  Yes

  No

  N/A

• Checks the penetration markings to confirm that the pipe has not moved during fusion / cooling <br>time

  Yes

  No

  N/A

• Checks joint result using print facility or electronic data retrieval from control box, if available

  Yes

  No

  N/A

Sign off

• Name of assessor

  Yes

  No

  N/A

• Pass or refer for additional training

  Pass

  Fail

  N/A