Embed Size (px)
Citation preview
THE MATERIALS JOINING EXPERTS
Inspection of Fusion Joints in Plastic Pipe
Delivery Reliability ProgramProject Kick-Off Meeting
Morgantown, West VirginiaDecember 16, 2003
National Energy Technology Laboratory
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
• Plastic pipe has been used successfully for 30 yrs by natural gas industry
• Butt fusion is one of the two most common processes used for joining the pipe.– It utilizes a hot plate which is inserted
between two pipes butted together and heated to temperature. The plate is removed and the pipes are forced together.
• Electro-fusion methods are typically employed for joining tees and branches.
Executive Summary - Background
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Executive Summary - Problem Statement
• Pipeline and environmental damage• Risk of fire or explosion• Risk of human personnel (user and service)• Interrupted service• Significant loss of revenue
Although infrequent, polyethylene pipe butt fusion joint failure could result in:
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Executive Summary - Technical Objective
This project will develop, demonstrate and validate an in-situ non-destructive method for butt fusion joints inspection in plastic gas distribution pipelines
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Executive Summary - Benefits
• Eliminate operator bias• Improved reliability and safety• Reduction in costly destructive QA
testing• Increased confidence in plastic pipe
use
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Executive Summary - Project Team
NYSEARCHAngelo Fabiano
EWI Connie Reichert
Project DirectorAlex Savitski
Project ManagementJohn Coffey
Accounting/ContractAntoinette Kerins
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Technical Overview
• Visual characteristic review• Initial conclusions• Initial characteristic correlation• Cross-section and surface
comparison• Demonstration unit
Technical Overview
Acceptable welds made under standard conditions
Technical Overview
Insufficient interfacial pressure – unacceptable weld
50% nominal interfacial pressure (tolerant resin) – weld acceptable
Technical Overview
Excessive interfacial pressure – good weld
Inspection of Fusion Joints in Plastic Pipe
Excessive temperature Insufficient heating
Initial Conclusions from Previous Work:
• Bond line appearance in the weld zone always correlated with the reduction of the joint’s mechanical properties
• The sensitivity of the Weld Zone Inspection Method (WZIM) was verified by industry-accepted destructive testing
• WZIM was successful in differentiating between welds made under standard and non-standard conditions
• WZIM was demonstrated to be a simple and accurate testing technique for assessing butt-fusion joint quality
Technical Overview
Conclusions (continued)
• The method is easy to use.
• No expensive testing equipment is required.
• It is less costly than common destructive testing methods (labor).
• A database of cross-sectional images representing typical standard and non-standard joints and their interpretations for selected PE pipes was developed.
Technical Overview
. Acceptable
• No visible bond line
• Proper double roll-back
• Sufficient melt
• Sufficient pressure
Technical Overview
Unacceptable
• Visible bond line
• Incomplete double roll-back (too small)
• Insufficient melt
• Sufficient pressure
Probable procedure violation – insufficient heating
Technical Overview
Technical Overview
Unacceptable
• Visible bond line
• Double roll-back (excessive)
• Excessive melt
• Disproportionately rounded outlines
Probable procedure violation – excessive temperature
Development of nondestructive procedure for PE butt-fusion joints assessment
• Transforming a destructive inspection method into a nondestructive technique was proved experimentally
• The correlation between the cross-sectional and pipe surface images (after the bead removal) was studied and analyzed
• Several “blind” tests were conducted on the joints independently prepared by gas companies
• Joints were fused under standard and non-standard conditions, and 88% were correctly assessed
Technical Overview
Driscopipe 8100 - Standard Welding Conditions
Cross-sectional image Pipe surface image
Technical Overview
Technical Overview
Cross-sectional image Pipe surface image
Driscopipe 8100 – Excessive Heating Temperature
Technical Overview
Cross-sectional image Pipe surface image
Driscopipe 8100 – Insufficient Interfacial Pressure
Demonstration unit for Weld Zone Inspection Method
Technical Overview
• EWI proprietary image recognition system
• Laser-based
• Automatically generate and interpret images
• Assign pass/fail rating
Conclusions and Recommendations
• The WZIM has the potential to become a quality-assessment field method to nondestructively identify lesser quality non-standard fusion joints.
• Evaluated results can be recorded, stored and documented for QA auditing and process mapping
Technical Overview
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Area I and II Tasks
• Task 1: Research Management Plan• Summary of technical objectives and technical
approach
• Task 2: Technology Status Assessment• Describe current state-of-the-art of plastic pipe
inspection
• Task 3: Validation of Inspection Method and Testing Procedure Optimization
• Correlation between the WZIM joint image and mechanical joint strength by using short-term destructive mechanical tests
Project Plan
Area I and II Tasks ( continued)
• Task 4: Method Verification using Long Term Destructive Testing
• Determine if a detrimental affect occurs on a quality weld by performing local reheating
• Task 5: Specification of User Requirements• Define requirements for assigning pass/fail rating
• Task 6: Development of Image Recognition Inspection System
• Develop hardware
• Refine software
• Integrate and calibrate components
Project Plan
Area III Tasks
• Task 7: Development of Field Test Program• Test matrix of conditions, type, materials and sizes
to be tested during field operations
• Task 8: Field Test Preparation• Inspection parameters will be optimized based on
Task 7 test matrix
• Operator training
• Task 9: Field Testing• Cover a representative range of materials and sizes
Project Plan
Area III Tasks (continued)
• Task 10: Data Analysis, Specification Optimization and Inspection Guidelines
• Next step towards technology commercialization
• Task 11: Reporting• Final technical report
• Comprehensive operation and maintenance manual
Project Plan
• Overall Project Budget• $373,005 (includes $93,000 cost match)
• Area I and II (Task 1 – 6) $243,330• DOE funding $170,330
• Cost share $73,000
• Area III (Task 7-11) $129,675• DOE funding $109,675
• Cost share $20,000
Note: Decision point will not be reached based on DOE obligated funds of $132,000.
Project Plan - Funding
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Project Schedule
ID % Complete Task Name Start Finish
1 5% Inspection of Fusion Joints in Plastic Pipe 10/1/03 9/29/05
2 6% Area I and II 10/1/03 9/2/04
3 100% Task 1.0 Research Management Plan 10/8/03 11/28/03
7 100% Task 2.0 Technology StatusAssessment
10/27/03 1/16/04
15 0% Task 3.0 Validation of InspectionMethod and Optimization of Testing
10/1/03 5/3/04
22 0% Task 4.0 Method Verification usingLong Term Destructive Testing
10/1/03 5/3/04
26 0% Task 5.0 Specification of UserRequirements for Prototype Image
11/17/03 12/26/03
29 0% Task 6.0 Development of ImageRecognition Inspection System
10/8/03 9/2/04
34
35 0% Decision Point 9/2/04 9/2/04
36
37 0% Area III 10/1/03 9/29/05
38 0% Task 7.0 Development of Field TestProgram
9/3/04 9/30/04
40 0% Task 8.0 Field Test Preparation 10/1/03 2/17/05
44 0% Task 9.0 Prototype Field Testing 2/18/05 5/12/05
46 0% Task 10.0 Field Data Analysis,Development of NDT SystemSpecifications and Inspection
5/13/05 8/4/05
49 0% Task 11.0 Final Reporting 8/5/05 9/29/05
9/2
Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 12003 2004 2005 2006
Executive Summary– Background– Problem Statement– Technical Objective– Benefits– Project Team
Technical Overview
Project Plan
Schedule
Milestones
Milestone Responsibility Milestone DescriptionApproximate
Submission Date
M1 EWI Hazardous Substance Plan 10/31/2003
M2 EWI Research Management Plan - Draft 10/31/2003
M3 NETLDOE Input Received for Research
Management Plan 11/20/2003
M4 EWITechnology Status Assessment
Report - Draft 11/30/2003
M5 NETL
DOE Input Received for Technology Status Assessment Report 12/19/2003
M6 EWI User Requirements Defined 12/26/2003
M7 EWILaser Based Inspection Hardware
Developed 5/4/2004
M8 EWILaser Based Inspection Software
Developed 5/4/2004
M9 EWI Integrated Inspection System 9/2/2004
M10 NETLWritten approval from DOE COR to
proceed beyond Task 6 9/2/2004
Project Schedule – Phase I
Milestone Responsibility Milestone DescriptionApproximate
Submission Date
M11 EWI Developed Field Test Matrix 9/30/2004
M12 EWI
One Day Training Course on the Fundamentals of WZIM Inspection System 2/17/2005
M13 NETL Final Technical Report 10/28/2005
M14 EWIComprehensive Operation and
Maintenance Manual Developed 10/28/2005
M15 EWI Hazardous Waste Report 10/1/2005
M16 EWIReport of Termination or Completion
Inventory 10/1/2005
M17 EWI Semi-Annual Report 1 4/30/2004
M18 EWI Semi-Annual Report 2 10/31/2004
M19 EWI Semi-Annual Report 3 4/30/2005
Project Schedule – Phase II
