Gas Industry GIS/PL2-4:2014

Standard

Specification for

Polyethylene pipes and fittings for natural gas

Part 4: Fusion fittings with integral heating element(s)
 GIS/PL2-4:2014

Contents
Page

Foreword iv
Relationship with other publications iv
Mandatory and non-mandatory requirements iv
Disclaimer v
Brief history v
1 Scope 1
2 Normative references 1
3 Terms, definitions, symbols, abbreviations and units 2
3.1 Geometrical definitions 2
3.2 Material definitions 3
3.3 Material properties 3
3.4 Service conditions 4
3.5 Fitting types 5
3.6 Symbols 5
3.7 Abbreviations 5
4 Material 6
4.1 General 6
4.2 Polyethylene compound 6
4.3 Heating element material corrosion resistance 6
4.4 Elastomers 6
5 Fitting classification 6
5.1 General 6
Table 2 Fitting classes, operating pressures and connecting pipes 7
5.2 Class B fittings 7
5.3 Class C fittings 7
6 Fitting aspect, geometry and dimensions 8
6.1 General 8
6.2 Dimensions of electrofusion sockets (couplers, reducers, elbows, tees and end caps) 9
6.3 Dimensions of electrofusion saddle fittings 11
6.4 Branch saddles 14
Table 5 Flanged branch saddle outlet lengths 15
6.5 Electrofusion end cap assemblies 15
6.6 Electrofusion flange adaptors 15
7 Fitting stability 15
7.1 Dimensional stability 15
7.2 Thermal stability 16
8 Fitting electrical characteristics 16
8.1 Heating element and terminals 16
8.2 Power input 18
8.3 Jointing Time 18
9 Fusion and jointing 18
9.1 Electrofusion control boxes 18
9.2 Fusion time and pipe SDR 19
9.3 Pipe inserts 19
9.4 Fusion indicators (one per fusion zone) 19
9.5 Interface melt 19
9.6 Joint reheating 19
10 Performance of fitting/pipe assemblies 20
10.1 General 20
10.2 Conditioning and test temperature 20
Table 6 Minimum conditioning period 20

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10.3 Corrosion resistance 20

10.4 Fitting assembly force (couplers above 180 mm) 20
10.5 Pneumatic leak test (tapping tee cap) 20
10.6 Joint interface strength 20
10.7 Pressure strength 21
10.7.1 Resistance to internal pressure at 20 °C (test duration- see Table 7) 21
Table 8 Performance Requirements 22
10.8 Impact strength (tapping tee) 23
10.9 Thermal stability 23
10.10 Pressure drop 23
11 Assessment and conformity 23
11.1 General 23
11.2 Type testing 23
11.3 Batch Release Tests (BRT) 24
11.4 Process verification tests (Approved Fittings) 24
12 Marking 24
13 Protection of fittings 25
Annex A (normative) Testing and sampling requirements 26
A.1 General 26
Table A.1 Fusion conditions for test piece manufacture (type testing) a) 26
NOTE Results arising from tests conducted at conditions, which are equivalent or more
extreme than those shown in Table A.1 above, such as -10˚C and or +45˚C in the case of
temperature, shall be considered acceptable under this GIS standard. 26
A.2 Type testing 27
Table A.2 Type testing test requirements (class B and class C fittings) a) 27
A.3 Batch release tests (BRT) 29
Table A.3. Part 1 Batch release test requirements (class B and C fittings) a) 29
Table A.3. Part 2 Batch release test requirements (class B and C fittings) 30
Table A.4 Sample size code letter 32
Table A.5 Double sampling plans 32
Table A.6 Sub-batch sampling plans 33
Annex B (normative) Assessment of effect on joint integrity of fitting resistance tolerance 34
B.1 Principle 34
B.2 Apparatus 34
Table B.1 Minimum specification for resistance measuring device 34
B.3 Procedure 34
Annex C (normative) Determination of fitting cooling time 36
C.1 Principle 36
C.2 Apparatus 36
Table C.1 Minimum specification for resistance measuring device 36
C.3 Specimen 36
C.4 Procedure 36
Annex D (normative) Specification for the assessment of pipe inserts 37
D.1 Purpose of specification 37
D.2 General 37
D.3 Test requirements 37
D.3.2 Dimensions 37
Annex E (normative) Test piece components 39
E.1 General 39
E.2 Pipes 39
E.3 Socket fittings 39
E.4 Saddle fittings 39
E.5 Test piece geometry 39
Figure E.1 Test specimen assembly 40
Annex F (normative) Measurement of coupler assembly force 41
F.1 Principle 41
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F.2 Procedure 41
F.3 Performance 41
Annex G (normative) Tapping tee cap pneumatic leak test 42
G.1 Principle 42
G.2 Apparatus 42
G.3 Test piece 42
G.4 Procedure 42
G.5 Performance 42
Annex H (normative) Branch saddle pull off test (See schematic diagram below) 43
H.1 Principle 43
H.2 Apparatus 43
H.3 Test specimen 43
H.4 Procedure 43
H.5 Performance 43
Annex I (normative) Tapping tee pressure drop test 44
I.1 Principle 44
I.2 Apparatus 44
I.3 Test specimen 44
I.4 Procedure 44
I.5 Expression of results 44
Figure I.1 Layout of test rig for tapping tee pressure drop test 46
Annex J (normative) Type tests – Changes to approved fittings or tooling & Low Volume
products 47
Annex K (normative) Short term pressure test 50
Annex L (normative) Tensile test for fitting/pipe assemblies 52
Annex M Summary of and rationale for changes to document – June 07 53
Annex N Summary of and rationale for changes to document – March 2012 56

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Foreword
Gas Industry Standards (GIS) are revised, when necessary, by the issue of new editions. Users
should ensure that they are in possession of the latest edition. Contractors and other users
external to Gas Transporters should direct their requests for copies of a GIS to the department
or group responsible for the initial issue of their contract documentation.
Comments and queries regarding the technical content of this document should be directed in
the first instance to the contract department of the Gas Transporter responsible for the initial
issue of their contract documentation.
This standard calls for the use of procedures that may be injurious to health if adequate
precautions are not taken. It refers only to technical suitability and does not absolve the user
from legal obligations relating to health and safety at any stage.
Compliance with this engineering document does not confer immunity from prosecution for
breach of statutory or other legal obligations.
The UK Committee would like to emphasize that compliance with GIS/PL2-4 does not
necessarily mean that products are fit for the purpose of conveying natural gas in the UK. It is
recognised that fittings may not be fully compatible with existing UK practice in terms of
applicable pressure tiers, preferred colours for gas pipe recognition, jointing and methods of
installation and commissioning.
The requirements contained in GIS/PL2-4 are not necessarily indicative of all the performance
requirements, or the suitability of pipework for the service conditions, likely to be encountered in
the UK.

Relationship with other publications

GIS/PL2 Polyethylene pipes and fittings for natural gas consist of the following parts:
Part 1: General and polyethylene compounds for use in polyethylene pipes and fittings.
Part 2: Pipes for use at pressures up to 5.5 bar.
Part 3: Butt fusion machines and ancillary equipment.
Part 4: Fusion fittings with integral heating element(s).
Part 5: Electrofusion ancillary tooling.
Part 6: Spigot end fittings for electrofusion and/or butt fusion purposes.
Part 7: Squeeze-off tools and equipment.
Part 8: Pipes for use at pressures up to 7 bar.

Mandatory and non-mandatory requirements

For the purposes of a GIS the following auxiliary verbs have the meanings indicated:
can indicates a physical possibility;
may indicates an option that is not mandatory;
shall indicates a GIS requirement;
should indicates best practice and is the preferred option. If an alternative method is used
then a suitable and sufficient risk assessment needs to be completed to show that
the alternative method delivers the same, or better, level of protection.

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Disclaimer
This engineering document is provided for use by Gas Transporters and such of their
contractors as are obliged by the terms of their contracts to comply with this engineering
document. Where this engineering document is used by any other party, it is the responsibility
of that party to ensure that the engineering document is correctly applied.

Brief history

Edited by BSI in accordance with BS 0-3:1997 August 2006

Substantial review refer to Annex M September 2007

Change summer testing condition from +30C to +23C January 2008

Substantial review refer to Annex N March 2012

Increase size range to 800mm and associated minor November 2014

amendments

© Energy Networks Association on behalf of Cadent Gas Limited, Northern Gas

Networks, SGN and Wales & West Utilities Ltd.
This Gas Industry Standard is copyright and must not be reproduced in whole or in part
by any means without the approval in writing of Energy Networks Association.

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1 Scope
This part of GIS/PL2 specifies requirements for polyethylene (PE) fusion fittings with integral
heating elements in the nominal size range 16 mm to 800 mm inclusive. They are intended for
use with metric PE pipes conforming to GIS/PL2-2 and GIS/PL2-8 within an operating
temperature range of −20 °C to 40 °C.
It is applicable to fittings classified as class B (suitable for use at operating pressures not
exceeding 5.5 bar) and class C (suitable for use at operating pressures not exceeding 7 bar).
This Gas Industry Standard provides for the supply of fusion fittings that are capable of
connection to pipes at ambient temperature of −5 °C to 23 °C using control boxes conforming
to GIS/ECE1.
The use of alternative control boxes approved to equivalent standards (e.g. EN or ISO) may be
proposed and shall be subject to agreement with the gas transporter.

2 Normative references
The following referenced documents are indispensable for the application of this document. For
dated references, only the edition cited applies. For undated references, the latest edition of the
referenced document (including any amendments) applies.
Formal standards
BS EN 681 - 1 & 2, Elastomeric seals — Materials requirements for seals used in pipes and
fittings carrying gas and hydrocarbon fluids.
BS EN 728, Plastics piping and ducting systems — Polyolefin pipes and fittings —
Determination of oxidation induction time.
BS EN ISO 1167, Plastics piping systems — Thermoplastics pipes — Determination of
resistance to internal pressure at constant temperature.
BS EN 1555-3, Plastics piping systems for the supply of gaseous fuels — Polyethylene (PE) —
Part 3: Fittings.
BS EN 1716, Plastics piping systems — Polyethylene (PE) tapping tees — Test method for
impact resistance of an assembled tapping tee.
BS EN ISO 1043-1, Plastics — Symbols and abbreviated terms — Part 1: Basic polymers and
their special characteristics.
BS EN ISO 472, Plastics — Vocabulary.
BS EN ISO 3126, Plastics piping systems — Plastics components — Determination of
dimensions.
ISO 7005-1, Metallic flanges — Part 1: Steel flanges.
ISO 13954, Plastics pipes and fittings — Peel decohesion test for polyethylene (PE)
electrofusion assemblies of nominal outside diameter greater than or equal to 90 mm.
ISO 13955, Plastics pipes and fittings — Crushing decohesion test for polyethylene (PE)
electrofusion assemblies.
Gas Industry Standards
GIS/ECE1, Specification for electrofusion control boxes.
GIS/PL2-1, Specification for polyethylene pipes and fittings for natural gas and suitable
manufactured gas — Part 1: General and polyethylene compounds for use in polyethylene
pipes and fittings.

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GIS/PL2-2, Specification for polyethylene pipes and fittings for natural gas and suitable
manufactured gas — Part 2: Pipes for use at pressures up to 5.5 bar.
GIS/PL2-5, Specification for polyethylene pipes and fittings for natural gas and suitable
manufactured gas — Part 5: Electrofusion ancillary tooling.
GIS/PL2-6:2006, Specification for polyethylene pipes and fittings for natural gas and suitable
manufactured gas — Part 6: Spigot end fittings for electrofusion and/or butt fusion purposes.
GIS/PL2-8, Specification for polyethylene pipes and fittings for natural gas and suitable
manufactured gas — Part 8: Pipes for use at pressures up to 7 bar.
GIS/PL3:2006, Self-anchoring mechanical fittings for natural gas and suitable
manufactured gas.

3 Terms, definitions, symbols, abbreviations and units

For the purposes of this standard the following terms, definitions, symbols, abbreviations and
units apply.

3.1 Geometrical definitions

3.1.1
nominal size (DN)
numerical designation of the size of a component, other than a component designated by
thread size, which is a convenient round number, approximately equal to the manufacturing
dimension in millimetres (mm)

3.1.2
nominal size (DN/OD)
nominal size, related to the outside diameter

3.1.3
nominal outside diameter, dn
specified outside diameter, in millimetres, assigned to a nominal size DN/OD

3.1.4
mean inside diameter, ds
arithmetical mean of a number of measurements of the inside diameter of a socket through its
cross-section regularly spaced around the circumference and in the same cross section,
including the measured minimum and the measured maximum values of the inside diameter in
that cross section, rounded to the next greater 0.1 mm

3.1.5
ovality (out-of-roundness)
difference between the maximum and the minimum outside diameter in the same cross-section
of a pipe or spigot, rounded off to the nearest 0.1 mm

3.1.6
nominal wall thickness, en
numerical designation of the wall thickness of a component, which is a convenient round
number, approximately equal to the manufacturing dimension in millimetres (mm)

3.1.7
standard dimension ratio (SDR)
numerical designation of a pipe series, which is a convenient round number, approximately
equal to the dimension ratio of the nominal outside diameter, dn, and the nominal wall
thickness, en

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3.1.8
maximum penetration depth, L1
depth of penetration of the pipe or spigot fitting
NOTE In the case of a coupler without a stop it is not greater than half the total length of the fitting.

3.1.9
minimum apparent fusion length, L2
L2 is the length of the integral heating element from the 1st regular section of the element to the
end of the regular section on one side of the fitting. The dimension shall be measured from
outside edge to outside edge of wire
3.1.10
inner cold zone
unheated distance between the end of the fusion zone as declared by the manufacturer and the
end face of the insert pipe or spigot

3.1.11
fusion sealing width
minimum width of the fusion zone applicable to saddle fittings

3.2 Material definitions

3.2.1
virgin material
material in a form such as granules or powder that has not been subjected to use or processing
other than that required for its manufacture and to which no reprocessable or recyclable
materials have been added

3.2.2
Uncontaminated recyclate material (the use of yellow and orange polyethylene
compound shall only be permitted) material prepared from clean rejected unused pipes,
fittings or valves, including trimmings from the production of pipes, fittings or valves, that will be
reprocessed in a manufacturer's plant after having been previously processed by the same
manufacturer in the production of components by, for example injection moulding or extrusion

3.2.3
compound
homogenous mixture of base polymer (polyethylene) and additives, i.e. antioxidants, pigments,
UV-stabilizers and others, at a dosage level necessary for the processing and use of
components conforming to the requirements of this standard

3.2.4
batch – moulded fittings
Production off a machine, from the time it commences to produce fittings conforming to this
standard until the machine is closed down. A production batch should not exceed 170hrs
machine time or 10,000 components, whichever is the lesser.

3.3 Material properties

3.3.1
lower predicted limit (LPL), σ L P L
quantity, with the dimensions of stress in megapascals (MPa), which can be considered as a
property of the material, and represents the 97.5 % lower predicted limit of the mean long term
strength at 20 °C for 50 years with internal water pressure

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3.3.2
minimum required strength (MRS)
value of σ LCL, rounded down to the next smaller value of the R10 series or of the R20 series
depending on the value of σ LCL
NOTE R10 and R20 series are the Renard number series according to ISO 3 and ISO 497.

3.3.3
overall service (design) coefficient or safety factor, C
coefficient with a value of 2.9, which takes into consideration service conditions as well as
properties of the components of a piping system other than those represented in the lower
confident limit

3.3.4
design stress, σ s
allowable stress, in megapascals (MPa) for a given application
NOTE It is derived from the MRS by dividing it by the coefficient C, i.e.:
MRS
σs =
C

3.3.5
melt-mass flow rate (MFR)
value relating to the viscosity of the molten material at a specified temperature and load,
expressed in grams per 10 min (g/10 min)

3.4 Service conditions

3.4.1
gaseous fuel
any fuel which is in gaseous state at a temperature of 15 °C, at atmospheric pressure

3.4.2
maximum operating pressure (MOP)
maximum effective pressure of the fluid in the piping system, expressed in bar, which is
allowed in continuous use. It takes into account the physical and the mechanical characteristics
of the components of a piping system
NOTE It is calculated using the following equation:
20 × MRS
MOP =
C × ( SDR − 1)

3.4.3
reference temperature
temperature for which the piping system is designed
NOTE It is used as the base for further calculation when designing a piping system or parts of a piping
system for operating temperatures different from the reference temperature.

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3.5 Fitting types

3.5.1
electrofusion socket fitting
fitting with one or more cylindrical sockets into which pipes or fitting spigots can be inserted to
form an assembly for subsequent jointing by electrofusion and the creation of an integral
pipe/fitting connection

3.5.2
electrofusion saddle fitting
fitting for placement on or around the outer surface of a pipe to form a saddle assembly for
subsequent jointing by heat fusion and the creation of an integral pipe-to-fitting connection

3.5.3
electrofusion tapping tee
saddle fitting, with various outlet configurations, containing an integral cutter designed to
perforate the wall of the pipe whilst the pipe is under pressure

3.5.4
branch saddle
saddle fitting, with various outlet configurations, with provision made for the location of a
separate tool designed to perforate the wall of the pipe whilst the pipe is under internal pressure
or in a non-pressurized state

3.5.5
flange adapter
fitting used with a seal/gasket and flange backing ring(s) for making a joint in a polyethylene
system

3.5.6
fusion compatibility
ability of two similar or dissimilar polyethylene materials to be fused together to form a joint
which conforms to the performance requirements of this standard

3.6 Symbols
C overall service (design) coefficient
dn nominal outside diameter
σs design stress
3.7 Abbreviations
DN nominal size
DN/OD nominal size outside diameter related
LPL lower predicted limit
MFR melt mass-flow rate
MOP maximum operating pressure
MRS minimum required strength
SDR standard dimension ratio

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4 Material

4.1 General
The materials used in the manufacture of the fitting shall be suitable for the conveyance of
natural gas with a composition in accordance with BS EN ISO 13686.

4.2 Polyethylene compound

The compound from which the fittings are made shall conform to GIS/PL2-1 or EN1555-1 and
shall be classified by MRS as shown in Table 1
Table 1 Classification of polyethylene compounds
Designation σLPL (20oC, 50 years, 97.5%) MRS
MPa MPa
PE80 8.00 ≤ σLPL ≤ 9.99 8.0
PE100 10.00 ≤ σLPL ≤ 12.40 10.0

The requirements shall be established and declared by the manufacturer of the compound
using the ISO 9080 extrapolation method and stated in accordance with ISO 12162. Yellow,
orange or black PE compounds may be used, but any compound used shall be supplied by the
resin manufacturer as a fully compounded material. The fittings shall be made from a single
grade of virgin material or uncontaminated yellow or orange PE compound recyclate material.
Uncomtaminated recyclate material (e.g. sprues, runners or preforms), generated from a
manufacturer's own production of fittings to this standard, may be used provided it has not left
the manufacturer's premises. Alternatively regrinding may be done outside the manufacturer's
premises provided it is under their supervision.
Rework material shall not be blended with unprocessed compound, and shall be used on its
own. Fittings produced using 100 % rework material shall be in accordance with this standard
and shall be identifiable. Rework material shall be used once only and any reclaimed material
from this run of rework shall be discarded. Fittings produced from reworked material shall be
identifiable and/or traceable throughout the manufacturer's production records.
The approval of the gas transporter shall be sought for the introduction of any changes in the
compound. The effect of the change on the ability of fittings to conform to this standard and the
need for further approval tests shall be established.

4.3 Heating element material corrosion resistance

All exposed metallic components used in the electrical terminal connections of the fitting shall
be corrosion resistant, or suitably protected against corrosion. Compliance with this
requirement shall be demonstrated by meeting the requirements specified in 10.3.

4.4 Elastomers
Elastomeric seals shall conform to BS EN 681–1 & 2.

5 Fitting classification

5.1 General
Fittings shall be classified for pressure capability as either class B or C and shall be designed
for use in gas pipe systems at operating pressures in accordance with Table 2.

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Table 2 Fitting classes, operating pressures and connecting pipes

Fitting class MOP Pipe diameter range SDR of connecting pipe

bar mm
B 5.50 a) 16 ≤ dn < 50 11 c)
50 ≤ dn < 63 11,17.6 d)
63 ≤ dn < 140 11, 17.6, 21 d) f)
140 ≤ dn < 355 b) 11,17.6, 21, 26 d) e)
355 ≤ dn ≤ 800 b) 11, 17.6, 21, 26 d)
C 7.00 16 ≤ dn ≤ 630 11
a) MOP may be selected from pressures up to and including 5.50 bar.
b) Includes non-isometric fitting sizes 213 mm, 268 mm, and 469 mm.
c) SDR 7 & 9 pipes are covered in this size group.
d) SDR17.0 pipes are recognised in these size groups.
e) SDR 26 dn ≥ 250 except 213mm & 268mm
f) For pipe sizes 63mm and 75mm, fittings shall be compatible with SDR 13.6 pipe

The performance of pipe/fitting assemblies shall be in accordance with Clause 10.

Assessment of conformity shall be carried out in accordance with Clause 11. The test schedule
shall be in accordance with Annex A.

5.2 Class B fittings

Class B fittings shall be suitable for use with pipes conforming to GIS/PL2-2 (maximum
operating pressure 5.5 bar for SDR11 pipes). Each type and size of fitting shall be suitable for
jointing to pipe with SDR values specified in Table 2.
The fittings shall be coloured yellow or black. Black fittings shall have an approved yellow label
securely affixed to indicate suitability for operation at a pressure selected from a range up to a
maximum of 5.5 bar.

5.3 Class C fittings

Class C fittings shall be suitable for use with SDR11 pipes in accordance with GIS/PL2- 8
(maximum operating pressure 7.0 bar). Each type and size of fitting shall be suitable for jointing
to pipe with SDR values specified in Table 2.
Class C fittings shall be coloured yellow, orange or black. Non orange fittings shall have an
approved orange label securely affixed to indicate suitability for 7bar operation.
Fittings approved as class C may be offered for use with pipes to GIS/PL2-2 provided that, for a
given size and type of fitting, the same fusion time is specified for each type of pipe for the SDR
range specified in Table 2.
Suitability for use with GIS/PL2-2 pipes shall be established by the conduct of joint interface
strength tests in accordance with 10.6.1 and 10.6.2 together with an 80 °C, 1000 h pressure
test (class B conditions) in accordance with 10.7.3. The fitting shall be labelled accordingly.

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6 Fitting aspect, geometry and dimensions

6.1 General
Fittings shall be designed for connection to GIS/PL2-2 and GIS/PL2-8 pipes using electrofusion
socket and saddle jointing methods and tooling in accordance with GIS/PL2-5.
The fitting manufacturer shall provide installation instructions and recommend / provide
appropriate tooling for installation and commissioning if different from that prescribed in
GIS/PL2-5.
Fittings that incorporate a spigot end(s) shall also conform to GIS/PL2-6.
Fittings shall be free from cracks, voids, blisters, holes, distortion, dents, injurious damage,
inclusions or other defects likely to impair their performance. To prevent stress concentrations,
any changes in wall thickness of the fitting body shall be gradual.
Once a fitting has been manufactured it shall be left to normalise for a minimum period of 24
hours. The fitting shall then be conditioned at 23 °C ± 2 °C for a minimum of 4 hours prior to any
measurement. Methods of measurement shall conform to BS EN ISO 3126.
A method of controlling pipe penetration within each socket shall be provided. The stops shall
be removable without interference of the socket electrical wire.
Fittings shall be designed to minimize pressure drop in accordance with 10.10.

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6.2 Dimensions of electrofusion sockets (couplers, reducers, elbows, tees and end caps)

6.2.1 Diameters and lengths of electrofusion sockets

For electrofusion sockets (see Figure 1) having a nominal diameter in Table 3, the socket
diameter and lengths shall be given by the manufacturer and should conform to Table 3 and
with L3 ≥ 5mm
Key
D1 is the mean inside diameter in the fusion zone measured in a plane parallel to the plane of
the mouth at a distance of L3 + 0,5L2 from that face;

L1 is the depth of penetration of the pipe or male end of a spigot fitting; in case of a coupling
without stop, it is not greater than half the total length of the fitting;

L2 is the length of the integral heating element from the 1st regular section of the element to the
end of the regular section on one side of the fitting. The dimension shall be measured from
outside edge to outside edge of wire;

L3 is the distance between the mouth of the fitting and the start of the fusion zone as declared by
the manufacturer to be the nominal unheated entrance length of the fitting.

L1

L2 L3

D1

L3 + 0.5 L2

Figure 1.0 Dimensions of electrofusion socket fittings

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Table 3 Dimensions of electrofusion socket fittings

Dimensions in mm
Nominal Mean internal Mean internal Penetration Minimum
diameter of diameter (D1) diameter (D1) depth nominal length
pipe Maximum Minimum L1 Max of fusion zone
dn (measured along (measured along L2 min
L2) L2)

16 16.6 16.4 41 15

20 20.6 20.4 41 16

25 25.6 25.4 41 18

32 32.9 32.5 44 18

40 41.0 40.6 49 18

50 51.1 50.7 55 20

55 56.1 55.7 63 21

63 64.1 63.7 63 23

75 76.3 75.9 70 25

90 91.5 91.1 79 28

110 111.6 111.1 82 32

125 126.7 126.2 87 35

140 141.7 141.2 92 38

160 162.1 161.4 98 42

180 182.1 181.5 105 46

200 202.1 201.4 112 46

225 227.6 226.5 120 48

250 252.6 251.7 129 50

280 282.9 281.8 139 50

315 318.3 317.1 150 50

355 164 50

400 179 50
Manufacturer shall Manufacturer shall
450 195 51
declare, shall not be declare, shall not
500 212 56
less than dn be less than dn
560 235 61

630 255 67

710 280 73

800 300 80

NOTE For Unscraped solid wall pipe compliant with PL2-2 or PL2-8 or Peelable Pipe with
sacrificial outer layer removed (PL2-2), the manufacturer shall ensure that the internal diameter of
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 GIS/PL2-4:2014

the fitting shall be sized to allow sliding assembly over misaligned and stationary pipes followed
by the subsequent fusion of a pipe to fitting joint. The manufacturer shall demonstrate this
requirement in accordance with Clause 10.4. This is a critical requirement for UK installation
practices.
In the case of a fitting having sockets of differing nominal diameters, each one shall conform to
the requirements for the nominal diameter of the corresponding component.

6.2.2 Wall thicknesses of electrofusion socket fittings en

a. The wall thickness of the body of the fitting at any point, E, shall be greater than or equal to
emin for the corresponding pipe at any part of the fitting located at a distance beyond a maximum
of 2 L1/3 from all entrance faces if the fitting and the corresponding pipe are made from a
polyethylene having the same MRS.

If the fitting is produced from a polyethylene having an MRS that is different from that of the
corresponding pipe, the relationship between the wall thickness of the fitting, E, and the pipe,
emin, shall be in accordance with Table 4.

Table 4 Relation between fitting and pipe wall thicknesses

Pipe Fitting Relation between fitting wall

thickness, E, and pipe wall
thickness, emin
PE80 PE100 E ≥ 0,8emin

PE100 PE80 E ≥ 1,25emin

b. In the case of a wall thickness design different from that according to a), fittings and
associated fusion joints shall additionally meet the performance requirements given in Clause
10.7.4.
NOTE PE80 fittings that have GIS/PL2-4:2008 approval will be exempt from testing.

6.2.3 Out-of-roundness of the bore of a fitting (at any point)

When a fitting leaves the site of the manufacturer, the out-of-roundness (ovality) of the bore of a
fitting at any point shall not exceed 0,015dn.

6.2.4 Spigots
For fittings, which contain spigot outlets (e.g. electrofusion equal tee with a spigotted branch),
the dimensions of the spigot shall conform to GIS PL2-6.

6.3 Dimensions of electrofusion saddle fittings

Outlets from tapping tees and branch saddles shall have spigots conforming to GIS/PL2-6 or an
electrofusion socket conforming to Clause 6.2.1 of this standard.

The manufacturer shall specify the overall dimensions of the fitting. These dimensions shall
include the maximum height of the saddle, H, and for tapping tees the height of the service
pipe, H1 or H2 (see Figure 2).

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GIS/PL2-4:2014

Key
H height of the saddle, which comprises the distance from the top of the main to the top of the
tapping tee or saddle
H1 height of service pipe, which comprises the distance from the axis of the main to the axis of
the service pipe
H2 height of service pipe, which comprises the distance from the top of the main pipe to the axis
of the service pipe
L width of the tapping tee, which comprises the distance between the axis of the pipe and the
plane of the mouth of the service tee

Figure 2 Dimensions of electrofusion saddle fittings

6.3.1 In-line electrofusion tees

The tee shall be configured with electrofusion sockets in longitudinal alignment for connection
to the mains pipe and a spigot outlet located perpendicular to the centreline of the sockets for
connection to the branch pipe. The nominal diameter of the branch spigot shall be equal to or
less than the nominal diameter of the fitting sockets.
The wall thickness of the branch spigot shall not be less than wall thickness of the pipe to which
connection is intended.
The fitting shall incorporate a permanent method of controlling pipe penetration within each
socket to prevent obstruction of the spigot outlet.

6.3.2Tapping tees
Tapping tees shall be designed for connection by saddle fusion, to pressurized and non-
pressurized mains pipes and by socket fusion to the outlet service pipe, using GIS/PL2-5
approved alignment and re-rounding tooling.
The fitting manufacturer shall provide installation instructions and recommend /provide
appropriate tooling if different from that prescribed in GIS/PL2-5.

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 GIS/PL2-4:2014

NOTE Mains pipe sizes range in diameter from 40 mm to 630 mm Class B tees are intended for fusion
jointing to pipe conforming to GIS/PL2-2 whilst class C fittings are intended for pipes conforming to
GIS/PL2-8. Class C fittings may be attached to pipes conforming to GIS/PL2-2.
Provision for the integral location of a mains pipe cutter shall be made within the body of the
tapping tee. Tapping tees shall provide a means of cutting through the pressurized main pipe
and allowing gas to flow into the outlet pipe. Uncontrolled leakage of gas to atmosphere shall
not occur. The cutting action shall not produce swarf and the coupon shall be retained by the
cutting device. The integral cutter shall be operated with a 12 mm AF or 17 mm hexagonal key
where the depth of hexagon shall not be less than 16 mm or 17 mm respectively. A stop shall
be provided to prevent the key penetrating through the cutter.
Alternative cutter actuation mechanisms may be proposed by the contractor but shall be subject
to agreement with the gas transporter.
All fittings shall have the integral heating element clear of the path of the cutter. The design of
the tapping tee shall include provision for pressure testing, without removal of the pipe cutter
before the mains pipe is cut, of the service pipe connection and the saddle fusion joint on the
mains pipe.

6.3.2.1 Outlets
Tapping tee outlets shall be spigot type or electro-fusion type.
Spigot outlets shall have an outside diameter either 320+0.3 mm over a minimum spigot length of
46 mm, with a maximum Out of Round of 0.7mm, or 630+0.4 mm over a minimum spigot length of
70 mm, with a maximum Out of Round of 0.9mm. The spigot minimum wall thickness shall be in
accordance with GIS/PL2-6: 2009, Table 3.
Outlets that provide an electrofusion socket shall conform to the requirements of this standard
at the appropriate nominal socket diameter.
The permissible saddle base dimension, along the main, shall not be greater than 200 mm.

6.3.2.2 Installation jointing force

Tapping tees shall be capable of installation by a force between 1 kN and 1.5 kN applied from
above, with its line of action along the centre line of the tapping tee stack and the diameter line
of the mains pipe, using GIS/PL2-5 approved tooling
Alternative loading methods and tooling for fittings (e.g. temporary or permanent underclamps)
may be proposed by the contractor, provided that the resultant joint meets the performance
requirements of this standard, and shall be subject to agreement with the gas transporter.
The fitting manufacturer shall provide installation instructions and recommend /provide
appropriate tooling if different from that prescribed in GIS/PL2-5.

6.3.2.3Cutter torque requirements (Class B tapping tees)

For tees with 32 mm outlets, the cutter operating torque at -5oC shall not exceed 80 N⋅m
(applied at 5 rpm) over the range of mains pipe sizes up to and including 180 mm nominal
outside diameter. Specialist tooling (e.g. thread followers) shall not be used.
Cutter operating torque for 32 mm tees attached to mains pipe sizes greater than 180 mm
nominal outside diameter shall be limited to 130 N⋅m (applied at 5 rpm) when cutting through at
-5°C. The need for specialist tooling shall be declared by the contractor at the submission
stage. Specialist tooling shall be provided by the contractor.
For tapping tees with 63 mm outlets, the cutter operating torque shall not exceed 270 N⋅m
(applied at 5 rpm) across the mains pipe size range when cutting through at -5°C. The use of
specialist tooling shall be declared by the Contractor at the submission stage. The specialist
tooling shall be provided by the contractor.

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GIS/PL2-4:2014

6.3.2.4 Cutter torque requirements (Class C tapping tees)

For tapping tees with 32 mm outlets, the cutter operating torque shall not exceed 130 N⋅m
(applied at 5 rpm) across the mains pipe size range when cutting through at -5°C. The use of
specialist tooling shall be declared by the contractor at the submission stage. The specialist
tooling shall be provided by the contractor.
For tapping tees with 63 mm outlets, the cutter operating torque shall not exceed 270 N⋅m
(applied at 5 rpm) across the mains pipe size range when cutting through at -5°C. The use of
specialist tooling shall be declared by the Contractor at the submission stage. The specialist
tooling shall be provided by the contractor.

6.3.2.5Tapping tee cap

The tapping tee cap shall be capable of passing all tests required of the fitting without additional
fastenings or constraints to the cap. It shall not fail by cracking when a torque of 15 N⋅m is
applied at a temperature of −5 °C.
Leakage shall not occur from the cap when tested in accordance with 10.5.
Where an “O” ring is used as a seal, it shall remain in position in the cap when the cap is
removed and refitted. For alternate ‘side seal design’ the “O” ring shall sit on a purposely
moulded shoulder at the top of the stack of the body of the tapping tee.

6.4 Branch saddles

Branch saddles shall be designed for connection, by saddle fusion to pressurized and non-
pressurized mains pipes in diameters from 40 mm to 800 mm and provide a spigot or
mechanical flanged outlet for connection to the branch pipe system using GIS/PL2-5 approved
alignment and re-rounding tooling. The fitting manufacturer shall provide installation instructions
and recommend /provide appropriate tooling if different from that prescribed in GIS/PL2-5.
Heated-tool saddle fusion is not acceptable.
Class B saddles are intended for fusion jointing to pipe conforming to GIS/PL2-2 whilst class C
fittings are for pipes conforming to GIS/PL2-8.
Branches shall be of sufficient length to accommodate all aspects of the branching installation.
The branch shall be an integral part of the fitting as supplied; where necessary a pipe pup
extension may be incorporated that shall be butt fused or joined by an electrofusion coupler.
Heated-tool socket fusion shall not be permitted.
Where branches are extended by butt fusion, the joint shall have both the internal and external
beads removed and visually inspected for contamination and slit defects.
Where applicable, branch saddle off-takes involving a squeeze off operation, shall be evaluated
to ensure that the branch has an adequate resistance to squeeze off in accordance with
GIS/PL2-2 and GIS/PL2-8.

6.4.1 Outlet terminations

Class B branch terminations shall be in the form of a spigot or for outlet sizes equal to or
greater than 90 mm the branch may incorporate a polyethylene stub flange and metallic
backing ring.
Class C branch outlets shall be flanged with stub flanges with metallic backing rings.
The maximum length of the branch outlet measured from the crown of the main shall conform
to Table 5 for flanged branches, as appropriate. Flanged assemblies shall be compatible with
flanges to ISO 7005-1.

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 GIS/PL2-4:2014

Table 5 Flanged branch saddle outlet lengths

Dimension in millimetres
Offtake size Maximum dimension from flange face to crown of main
Class B/C fittings Flange size
63 180 DN 50
90 180 DN 80
125 180 DN 100
180 250 DN 150
250 250 DN 200

Fittings having flanged outlets shall be in accordance with GIS/PL3:2006, 7.6 and 7.7.
The maximum diameter of the drill that can be used with the branch saddle shall be declared by
the contractor.

6.4.2 Installation jointing force

Branch saddles having spigot outlets up to and including 63 mm shall be capable of installation
by a force between 1 kN and 1.5 kN applied perpendicular to the pipe axis on the centre-line of
the spigot using GIS/PL2-5 tooling.
Alternatively temporary or permanent under-clamps may also be used provided the resultant
joint meets the performance requirements in Clause 10.6.
The fitting manufacturer shall provide installation instructions and recommend /provide
appropriate tooling if different from that prescribed in GIS/PL2-5.
Note Alternative methods (e.g. temporary or permanent underclamps) may be proposed by the contractor
subject to agreement, provided that the resultant joint meets the performance requirements.

6.5 Electrofusion end cap assemblies

Electrofusion end cap assemblies shall consist of an approved straight coupler or in-line
reducer to 6.2 and an approved spigot cap to GIS/PL2-6, assembled and securely retained in
such a way that they do not easily separate prior to electrofusion.
NOTE Alternatively, all-in-one electrofusion end caps may be proposed by the contractor subject to
agreement by the gas transporter.

6.6 Electrofusion flange adaptors

The electrofusion portion of the flange adapter shall meet the dimensional requirements of a
straight coupler of half-length in accordance with 6.2.1. The flanged portion on flange adapters
shall be in accordance with 6.4.1.

7 Fitting stability

7.1 Dimensional stability

7.1.1 Socket fittings

All socket fitting dimensions shall conform to their specified values when the fitting has been
stored for a minimum period of 120 minutes at a temperature of 80 °C ± 2 °C. The fitting shall
then be conditioned at 23 °C ± 2 °C for a minimum of 24 hours prior to measurement.
NOTE Alternative information to demonstrate dimensional stability may be offered.

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GIS/PL2-4:2014

7.1.2 Tapping tees and branch saddles

All tapping tee and branch saddle fitting dimensions shall conform to their specified values
when the fitting has been stored for a minimum period of 120 minutes at a temperature of
80 °C ± 2 °C. The fitting shall then be conditioned at 23 °C ± 2 °C for a minimum of 24 hours
prior to measurement.
NOTE Alternative information to demonstrate dimensional stability may be offered.

7.1.3 Spigot/pup end circumferential reversion

Spigot/pup ends shall conform to GIS/PL2-6:2009, 12.5.

7.2 Thermal stability

When tested in accordance with BS EN 728, or ISO 11357, the PE material for class B fittings
and class C fittings shall have an oxidation induction time greater than 20 min at 200 °C.
NOTE The test may be carried out at 210 °C provided that there is a clear correlation with the results
at 200 °C.
In case of dispute the reference temperature shall be 200 °C.

8 Fitting electrical characteristics

8.1 Heating element and terminals

8.1.1 Resistance
For each size and type of fitting, the contractor shall declare the nominal resistance of the
heating element and specify the production tolerances.
The contractor shall demonstrate that a satisfactory joint can be made using the extremes of
these tolerances using the method specified in Annex B.

8.1.2 Short/open circuits

The heating element shall be suitably designed to prevent short circuiting or local
overheating/underheating during the fusion operation. Protective coatings applied to the heating
element shall not have a detrimental effect on the joint.
The heating element wire shall not be disturbed during assembly.
For fittings wound with parallel heating wires, the indicators (9.4) shall not operate if any wire
becomes open circuit during the first 50 % of the fusion cycle.

8.1.3 Terminal design

All fittings shall have mechanically shrouded male electrical terminals. The shroud shall be
designed so as to minimize the potential for impact damage.
Fitting terminals and shrouds should conform to either Figure 3 and 4 for 40 volt electrofusion
fittings.
80 volt electrofusion fittings terminal and shrouds should conform to Figure 5 for 80 volt
electrofusion fittings.
When hollow terminal pins are used, the hole at the top of the pin shall be less than 1 mm
diameter.
The terminal pin material shall be corrosion resistant and the surface finish shall be in
accordance with BS1134.
Fittings supplied with non-integral terminal shrouds shall be subject to 100 % inspection.

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 GIS/PL2-4:2014

All dimensions in millimetres

Key
C1 ≥ 11.8
C2 = 4.00 ± 0.1
C3 = 9.5 ± 1.0
C4 ≤ 6.0
H ≥ 12.0
H1 = 3.2 ± 0.5
H2 ≥ 7
H2 ≤ H-H1

Figure 3 Type A terminal connection for 40 volts electrofusion fittings

All dimensions in millimetres

Key Key

C1≥13,00 ± 0,5 C1 = 20.00 ± 0.2

C2 = 4.70 ± 0.1 C2 = 4.68 to 4.73
C3 = 10.0 -0.1/+0.5 C3 = 12.20 ± 0.15
h ≥ 15.5 h ≥ 18.5 ± 0.2
h1 = 4.5 ± 0.5 h1 = 6.5 ± 0.1

Figure 4 Type B terminal connection for 40 volts electrofusion fittings

All dimensions in millimetres

17
GIS/PL2-4:2014

Key Key
C1 = 20.00 ± 0.2 C1 ≥ C3 + 2.0
C2 = 5.69 to 5.74 C2 ≥ 2.0 +/- 0.1
C3 = 13.50 ± 0.1 h1: sufficient to ensure
a degree of protection
h ≥ 16.0 ± 0.2
of IP 2 X as defined in
h1 = 6.5 ± 0.1
IEC 60529
h2 ≥ 7.0

Figure 5 Type C terminal connection for 80 volts electrofusion fittings

8.2 Power input

The maximum power requirement for socket fittings up to and including 280 mm and all saddle
fittings shall be 2.5 kW at 40 V rms and the fitting voltage supply shall be 39 V to 40 V rms.
The maximum power requirement for socket fitting size 315mm to 400mm major diameters
inclusive shall be either 4 kW at 40 V rms or 80 V rms, and the fitting voltage supply shall be
either 39 V to 40 V rms or 78 V to 80 V rms.
The maximum power requirement for socket fitting sizes greater than 400 mm shall be 4.8 kW
and the fitting voltage supply shall be 78 V to 80 V rms. 40V fittings in sizes >400mm are
recognised by this GIS, provided they comply with clause 8.3.

8.3 Jointing Time

The power consumption of fittings shall not lead to excessively long fusion and cooling times.
Note When selecting the fusion time, consideration of joint cooling time before handling is necessary.
Joint cooling time is the time taken for the joint interface material to fall to 110 °C or at the discretion of
the gas transporter a lower temperature may be considered.
Based on a reference temperature of 110oC the cooling time shall be determined in accordance
with Annex C. The cooling time for fittings up to and including 180mm in diameter shall not
exceed 20 min. The jointing time (fusion plus cool time) shall not exceed 90 min for sizes
>180mm up to a maximum of 355mm.
For reference temperatures below 110oC the cooling and jointing time may be extended at the
discretion of the gas transporter.
For larger sizes jointing times may be proposed by the contractor and shall be subject to
agreement with the gas transporter.

9 Fusion and jointing

9.1 Electrofusion control boxes

Control boxes specified in GIS/ECE/1 shall be capable of routinely fusing fittings to pipes. The
fittings shall exhibit the strengths of, and fusion compatibility with, pipes in accordance with
GIS/PL2-2 and GIS/PL2-8, without correction to fusion time or voltage for ambient conditions at

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 GIS/PL2-4:2014

which fusion is initiated in the range −5 °C to 30 °C. Compliance in this respect shall be
demonstrated by the contractor by conforming to the requirements specified in Clause 10.
The use of alternative control boxes approved to equivalent standards (e.g. EN or ISO) may be
proposed and shall be subject to agreement with the gas transporter.
9.2 Fusion time and pipe SDR
Whenever possible for each type of fitting the fusion time shall be the same, irrespective of pipe
SDR. The pipe SDR details are given in Table 2 of this standard. Fittings where the fusion time
is SDR dependant shall be clearly marked with a label.
Branch saddles may be offered that are restricted in use to mains pipe with an SDR rating up to
and including SDR17.6, and shall be subject to agreement with the gas transporter.
NOTE The restriction should be displayed using a suitable label affixed to the fitting.

9.3 Pipe inserts

Where electrofusion socket fittings are supplied for connection to pipes, produced in
accordance with GIS/PL2-2 and/or GIS/PL2-8, followed by an additional solid state shape
forming process (e.g. swagelining) and where the use of pipe inserts are necessary to reform
the pipe, the fitting and pipe insert shall be tested and supplied as a package. The fitting should
be labelled to indicate suitability for use with the appropriate type of processed pipe.
NOTE Alternative forms of labelling may be offered.
Where applicable the use of pipe inserts in association with thin walled pipes (e.g. SDR26 or
greater) shall also be tested and supplied as a complete package and labelled accordingly.
Inserts (metal or plastic) shall be sized such that when installed, the outside diameter of the
polyethylene pipe is in accordance with the relevant size from GIS/PL2-2, Table 1 or
GIS/PL2-8.
Pipe insert packages shall conform to Annex D.
The design of the inserts shall be such that they do not cause an undue restriction to gas flow.

9.4 Fusion indicators (one per fusion zone)

A permanent and obvious means of showing that the joint has been subjected to the fusion
cycle shall be provided on the external surface of the fitting. It shall be shown to be reproducible
and shall be demonstrated during batch release testing, see Table A.3.

9.5 Interface melt

With the exception of fusion indicators, melt from the fusion operation shall not exude outside
the confines of the fitting or into the inner cold zone(s) of the fitting beyond the end of the
inserted pipe.
The fusion process shall not create significant voids on the fusion interface or promote pipe
collapse on the adjoining pipe(s). After the fusion cycle, where any moulding preform is used,
there shall be no delamination between the moulding preform and the coated wires over the
fusion areas during the performance testing of the fitting.
NOTE Voids are classed as “un-fused areas”, and will be accounted for in the de-cohesion calculation.

9.6 Joint reheating

Each fitting designed for use on SDR11 and SDR17.6 pipe shall be capable of one reheat or
fusion at the specified time plus 50% under assembly conditions for the full fusion cycle time
without deterioration of the fusion joint. The fitting shall be allowed to cool to 23 °C ± 2 °C prior
to the reheating cycle.

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GIS/PL2-4:2014

The joint shall be assembled and tested in accordance with Table A.2 (stress crack resistance
and tensile strength of couplers tests).

10 Performance of fitting/pipe assemblies

10.1 General
Jointed pipe and fitting assemblies, prepared in accordance with Annex A (Table A.1) and
Annex E, shall conform to 10.3 to 10.10 inclusive.

10.2 Conditioning and test temperature

During type testing, or in any case of disagreement between the gas transporter and the
contractor, assemblies shall be conditioned prior to test in accordance with Table 6.
Table 6 Minimum conditioning period
Minimum wall thickness Minimum conditioning period
mm h
In air In liquid at In liquid at In liquid at
20°C (± 1˚C) 80°(± 2˚C) 80°C (± 2˚C) a)
23 °C ± 2 °C.
≤12 6 1 6 3 a)
>12 and ≤25 10 2 10 5 a)
>25 and <60 24 3 24 12 a)
≥60 48 4 48 24 a)
a) These conditioning times in liquid at 80 °C shall apply only if the assembly, instead of being cold-filled
with liquid, is initially pre-filled with liquid at the same temperature as the hot tank.

Tests, other than those involving liquid immersion or otherwise specified, shall be conducted at
a laboratory temperature of 23 °C ± 2 °C.

10.3 Corrosion resistance

The corrosion resistance of metallic parts shall be assessed by immersing the fitting for a
minimum of 170 hrs in an aqueous sodium chloride solution (30 g/l) at 23 °C ± 2 °C. On
completion of the test period there shall be no evidence of rust spots and corrosion of exposed
metal.

10.4 Fitting assembly force (couplers above 180 mm)

When the coupler is assembled to pipe in accordance with Annex F, the measured assembly
force shall not exceed 500 N. The assembly shall be fused and then subjected to a peel test in
accordance with 10.6.1.

10.5 Pneumatic leak test (tapping tee cap)

When tested in accordance with Annex G no leakage shall be detected.

10.6 Joint interface strength

10.6.1 Peel strength (sockets)

The peel strength of electrofusion socket fittings equal to or greater than 90 mm shall be
assessed in accordance with ISO 13954. Interface tearing along the fusion length shall be
ductile over a minimum length of 66 % of the apparent fusion length.

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 GIS/PL2-4:2014

NOTE Socket fittings less than 90 mm may be tested using the peel test. A suitable test method may be
proposed.

10.6.2 Crush strength (sockets and saddles)

The interface strength of saddle fusion joints incorporated in tapping tee and branch fittings less
than 90 mm diameter shall be assessed using the crush strength test specified in ISO 13955.
No cracking shall occur at the fusion interface during the test period of 10 min. End effects over
the first two complete turns of wire shall be ignored.
Fittings equal to or greater than 90 mm in diameter shall be tested by crushing in accordance
with ISO 13955 unless the branch saddle is so large that it becomes impractical to crush.
In this case the contractor may propose an alternative test method, such as a peel test and this
shall be subject to agreement with the gas transporter.

10.6.3 Tensile strength and leak-tightness at 80 °C (AREL) (16 mm to 75mm)

A socket joint assembly shall be tested in accordance with and meet the requirements of
GIS/PL3: 2006, 8.7.

10.6.4 Tensile strength (branch saddles)

A branch saddle joint assembly shall not fail when tested in accordance with Annex H, unless
the branch saddle is so large that the test becomes impractical.
Where it becomes impractical to conduct a pull off test on large branch saddles in accordance
with Annex H, then the contractor may propose an alternative test and this shall be subject to
agreement with the gas transporter.

10.7 Pressure strength

10.7.1 Resistance to internal pressure at 20 °C (test duration- see Table 7)

Class B and class C fitting/pipe assemblies shall be pressure tested at 20 °C in accordance
with BS EN ISO1167 and the relevant test criteria given in Table 7. The fitting shall not fail at
the following applicable circumferential pipe hoop stress:
— class B fittings: 10.00 MPa;
— class C fittings: 12.00 MPa.
The fitting/pipe assembly shall be sectioned and suitably prepared after testing for visual
examination. There shall be no evidence of cracking or pipe collapse when the joint is
examined using dye penetrant or other equivalent methods.

Table 7 Test Criteria

Supplier Band Test Duration
Existing mature / approved UK suppliers 100 hours
At the gas transporters discretion new
suppliers using European approved resins
with a proven track record (at the discretion of
the GT) of supply to gas transporters within
the European Commission
*Approved European resins to include those
manufactured outside of Europe
New suppliers/materials 5000 hours
NOTE the manufacturer shall seek clarification of banding from the Certification Body.
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GIS/PL2-4:2014

10.7.2 Resistance to internal pressure at 80 °C (165 h)

A fitting/joint assembly shall be pressure tested at 80 °C in accordance with BS EN ISO1167.
for 165 h without failure at the following applicable circumferential pipe hoop stress:
— class B fittings: 4.5 MPa;
— class C fittings: 5.4 MPa.
The fitting/joint assembly shall be sectioned and suitably prepared after testing. There shall be
no evidence of cracking or pipe collapse when the joint is examined using dye penetrant or
other equivalent methods.

10.7.3 Resistance to internal pressure at 80 °C (1000 h)

A fitting/joint assembly shall be pressure tested in accordance with BS EN ISO1167 for 1000 h
at 80 °C without failure at the following applicable circumferential pipe hoop stress:
— class B fittings: 4.0 MPa;
— class C fittings: 5.0 MPa.
The test shall be conducted at the minimum and maximum SDR ratings for which the fitting is
claimed to be suitable in accordance with Table 1.
The fitting/joint assembly shall be sectioned and suitably prepared after testing. There shall be
no evidence of cracking or pipe collapse when the joint is examined using dye penetrant or
other equivalent methods.

10.7.4 Performance Requirements – electrofusion socket fittings

Where 6.2.2 b) applies, electrofusion socket fittings shall, additionally, be in accordance with
Table 8.

Table 8 Performance Requirements

Short-term Requirement Test Parameter Test Value Test
internal Method
pressure
resistance
Short-term Failure pressure End caps Type A of EN ISO Annex K
internal shall be > 1167-1:2006
pressure pressure Orientation Free
resistance equivalent Conditioning time 12 h
of 2 × MRS Type of test Water-in-water
calculated Minimum pressure:
for thickest-walled PE 80 pipe, SDR 11 32 bar
pipe for which PE 100 pipe, SDR 11 40 bar
fitting Pressure increase rate 5 bar/min
has been Test temperature 20 °C
designed
Resistance to No leakage or Test temperature 23 °C Annex L
tensile load failure
of the fusion joint
after 25% pipe
elongation
1 bar = 0,1 MPa = 105 Pa; 1 MPa = 1 N/mm2

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 GIS/PL2-4:2014

10.8 Impact strength (tapping tee)

A tapping tee, when tested in accordance with BS EN 1716, shall withstand an impact energy
of 100 J without failure.

10.9Thermal stability
When tested in accordance with BS EN 728 or ISO 11357, class B fittings and class C fittings
shall have an oxidation induction time greater than 20 min at 200 °C.

10.10 Pressure drop

10.10.1 Tapping tees

When class B applications only are tested in accordance with Annex I, the pressure drop shall
not exceed the velocity head values specified in Table 9, for the appropriate natural gas flow at
a working pressure of 25 mbar.
At the discretion of the gas transporter BS EN 12117 may be considered for calculation of
pressure drop as an alternate to GIS PL2-4 Annex I. Equivalency in respect of calculated
values shall be demonstrated.
Table 9 Tapping tee pressure drop a)

Outlet size Mains pipe size Flow rate of methane Maximum pressure drop in
service pipe velocity heads a)
mm mm m3[st]/h
32 All 4.3 4
63 63 to 75 18 10
63 Greater than 75 18 4
a) Tapping tee includes approved electrofusion fitting fused to spigot outlet.

11 Assessment and conformity

11.1 General
Type testing and batch release testing shall be carried out in accordance with 11.2 and 11.3.
Process verification shall be carried out in accordance with 11.4.
Testing and sampling shall be carried out in accordance with Annex A. Type tests (TT) and
batch release tests (BRT) shall be conducted on fittings to pipe test assemblies that incorporate
pipes with the smallest SDR rating (largest wall thickness) for which the fitting was designed
(see Table 2). Additionally, assemblies for the 80 °C type testing pressure test shall include
pipes covering the minimum and maximum SDR ratings for which the fitting is claimed to be
suitable, in accordance with Table 2.
A range of previously approved fittings produced in a new material may gain approval from a
reduced number of test samples. Tests shall be performed on the smallest and largest size in
the contractor’s range, and on one intermediate size. Different fitting types may be used to
demonstrate conformity. Once these three sizes have gained approval, approval shall be
granted to any other sizes between the smallest and largest pipe size tested.

11.2 Type testing

Type testing of each type and size of fitting shall be carried out in accordance with A.1 and A.2
before a particular fitting shall be considered suitable for supply to the gas transporter.

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GIS/PL2-4:2014

NOTE Sample test assemblies shall take account of manufacturing and assembly tolerances
based on process control data of upper and lower variance ranges.
11.2.1 Type testing – Modifications to approved Fittings and Low Volume Products.
Refer to Appendix J of this standard for details of the Type Approval Tests, which shall be
performed in respect of modifications to approved fittings and low volume products.

11.3 Batch Release Tests (BRT)

Batch release tests shall be carried out in accordance with A.1 and A.3 in order to demonstrate
a continuing satisfactory level of product quality in day-to-day production.
Batch release tests on fittings shall be carried out using approved pipe in accordance with
GIS/PL2-2 (class B fittings) or GIS/PL2-8 (class C fittings), and GIS/PL2-5 tooling.
The fitting manufacturer shall provide installation instructions and recommend / provide
appropriate tooling if different from that prescribed in GIS/PL2-5.

11.4 Process verification tests (Approved Fittings)

Every two years after gaining Type Approval, one fitting per size group (rotating sizes), shall
meet the requirements of clause 10.7.3 of this standard. The subsequent fitting test assemblies
shall feature the minimum and maximum pipe SDR, and be fused at the minimum and
maximum jointing conditions as shown in Table A.1 of this standard.
Size Groups: (I) 16- 63mm; (II) 75-225mm; (III) 250-800mm.

12 Marking
All fittings supplied in accordance with this standard shall be marked using characters of 3 mm
dimension, where practical. Alternatives may be offered subject to agreement with the gas
transporter.
Products conforming to GIS/PL2-4:2014 shall be permanently marked with the following
information as a minimum:
a) The name or trademark of the manufacturer or their appointed agent.
b) The size of the fitting in mm.
c) The date of manufacture (a code may be used for this, subject to agreement)
d) The fusion time in seconds (preferably visible from above in installed position)
e) The cooling time in minutes (preferably visible from above in installed position)
f) SDR rating of fitting or MOP in bar.
NOTE Requirements d) and e) should be repeated on a label firmly fixed to the fitting packaging or on an
individual bag.
Alternatively embossed or indented tags maybe attached to the fitting if agreed by the gas
transporter. Any tag shall remain attached to the fitting in normal back fill conditions.
The information shall be embossed or indented on the fitting to a minimum depth of 0.15 mm
In addition to the above an orange label shall be securely affixed to each yellow or black Class
C fitting to indicate the MOP of 7Bar.
Packaging: Minimum information required on a label securely attached to the fitting packaging:
a) The mass of the fitting in kg for fittings of mass greater than 10 kg;
b) For branch saddles, the maximum drill diameter that can be used.
Additional information, which may also be shown on the label:

24
 GIS/PL2-4:2014

a) The number and date of this standard, i.e. GIS/PL2-4: 2014 (See Note )
b) Where authorized, the product conformity mark of a third party certification body,
e.g. BSI Kite-mark
c) The manufacturers contact details.
d) The SDR ratings of pipe that the fitting is approved for use with.
NOTE Marking GIS/PL2- 4:2014 on or in relation to a product represents a manufacturer’s declaration
of conformity, i.e. a claim by or on behalf of the manufacturer that the product meets the requirements of
the specification. The accuracy of the claim is therefore solely the responsibility of the person making the
claim. Such a declaration is not to be confused with third party certification of conformity, which may also
be desirable.
All marking shall remain legible under normal handling, storage and installation procedures.
The method of marking shall not prevent the fitting from meeting the requirements of this
standard.

13 Protection of fittings
Fittings shall be individually sealed in transparent polyethylene bags of at least 300 gauge
thickness (75 μm thick) to ensure seal integrity is not compromised during storage, transit and
handling in the field.

The outer pack shall be suitable for stacked storage and be marked with the information
specified in GIS/PL2-4 Clause 12 b and f together with the fitting type and quantity in the pack.

Constituents of fitting packaging shall not create contamination which can prevent normal
jointing.

The packaging or fitting design shall ensure protection of heating elements.

NOTE Fittings should be stored in their original packing. They should only be removed before installation
in order to avoid contamination.

25
GIS/PL2-4:2014

Annex A (normative)
Testing and sampling requirements

A.1 General
Test pieces for type testing, with the exception of those intended for tests to determine
corrosion resistance, dimensional stability, thermal stability, MFR and electrical resistance, shall
be assembled and fused in accordance with the manufacturer’s procedure and under the
conditions specified in Table A.1.
For batch release and batch release testing, fusion joints shall be constructed with the pipes
and fittings at ambient temperature using a control box that conforms to GIS/ECE1. Ancillary
equipment shall conform to GIS/PL2-5.
The fitting manufacturer shall provide installation instructions and recommend / provide
appropriate tooling if different from that prescribed in GIS/PL2-5.

Table A.1 Fusion conditions for test piece manufacture (type testing) a)

Condition Pipe and fitting temperatures b) Applied fitting Saddle fitting

voltage c) assembly force
e)

°C V N
Pipe Pipe SDR Fitting
I −5 11 d) −5 Minimum 1 000
II −5 11 d) 23 Minimum 1 000
III −5 11 d) 23 Maximum 1 500
IV 23 17.6 d) 23 Maximum 1 500
a) Test piece component requirements are specified in Annex E.
b) Pipes and fittings shall be conditioned for at least 8h at – 5 °C ± 2 °C or 23°C ± 2 °C as
applicable. Where the pipe is conditioned at –5 °C the test piece shall be fused at this
temperature with assembly and start of fusion completed within 2 min.
c) Jointsshall be fused for the necessary time period using an adjustable output voltage
control box in accordance with GIS/ECE/1. The output voltage shall be adjusted in
accordance with Annex B to create minimum and maximum power conditions.
d)Fitting manufacturers shall ensure that their fittings have been tested for use with the pipe
SDR’s intended e.g. SDR21 or 26. See Clause 5.1, Table 2 of this standard, which gives
details of recognised pipe SDR’s.
e) The values indicated are applicable to mains sizes up to and including 250mm.

Alternative values may be proposed by the contractor, for larger size saddles, and shall be
subject to agreement with the gas transporter”.

NOTE Results arising from tests conducted at conditions, which are equivalent or more extreme than
those shown in Table A.1 above, such as -10˚C and or +45˚C in the case of temperature, shall be
considered acceptable under this GIS standard.

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 GIS/PL2-4:2014

A.2 Type testing

Each size and type of fitting (class B and class C fittings) shall have been tested in accordance
with A.3 or A.4 and shall be tested in accordance with Table A.2.

Table A.2 Type testing test requirements (class B and class C fittings) a)

Property Requirement Test method No. of Fitting/pipe No. of

clause fittings assembly test
parameters pieces
Cooling time 8.3 Annex C 1 per size Condition IV 1 per
per type fitting
Corrosion 4.3.2 10.3 1 b) Not applicable 1 per
resistance fitting
Coupler 10.4 Annex F 1 per size c) Assembly at 23 °C 4 per
assembly force 10.6.1 ISO 13954 followed by socket
(off-set pipes) jointing at
minimum power
(J.3.2)
Cutting torque 6.3.2.3 6.3.2.3 2 per outlet Condition I 1 per
(tapping tee) 6.3.2.4 6.3.2.4 size d) fitting
Dimensional 7.1.1 7.1.1 1 per size Not applicable 1 per
stability 7.1.2 7.1.2 per type fitting
Impact strength 10.8 BS EN 1716 1 per outlet Condition I 1 per
(tapping tees) size fitting
Joint interface 10.6.1 ISO 13954 1 per size Condition I 4 per
peel strength per type socket
Joint interface 10.6.2 ISO 13955 1 per size Condition I 2 per
crush strength per type socket
1 per
saddle
Pneumatic leak 10.5 Annex G 1 per outlet Any Temperature 1 per
test (tapping size Condition fitting
tee cap) e)
Pressure drop 10.10.2 BS EN 12117 1 per size Any Temperature 1 per
(equal tees, 10.10.3 per type Condition fitting
elbows,
reducers) 10.10.4

Table A.2 Type testing test requirements (class B and class C fittings) a) (continued)

Property Requirement Test method No. of Fitting/pipe No. of

clause fittings assembly test
parameters pieces
Pressure drop 10.10.1 Annex I 1 per Condition IV 1 per
(tapping tee) e) outlet size fitting
Resistance to 10.7.1 BS EN 4 per type Conditions I, II, III, 1 fitting
internal ISO1167 per size IV per
pressure at condition
20 °C (100, or
27
GIS/PL2-4:2014

5000(i) hours) –
see Table 7
Resistance to 10.7.3 BS EN 4 per type Conditions I, II, III, 1 fitting
internal ISO1167 per size IV f) per
pressure at condition
80 °C, 1 000 h
(stress crack
resistance)
Resistance to 6.2.2 b & Annex K 4 per type Conditions I, II, III, 1 fitting
short term 10.7.4 per size IV f) per
internal condition
pressure
Resistance to 6.2.2 b & Annex L 4 per type Conditions I, II, III, 1 fitting
tensile load 10.7.4 per size IV f) per
condition
Spigot end 7.1.3 GIS/PL2-6, 1 per type Not applicable 1 per
reversion Clause 12.5 per size fitting
Tensile strength 10.6.4 Annex H 2 per Joint conditions I 1 fitting
of branch outlet size and IV per
saddles condition
Tensile strength 10.6.3 GIS/PL3:2006, 1 per Conditions I, II, III, 1 fitting
of couplers 8.7 size h) IV f) per
(AREL) g) condition
a) Class
B fittings shall be tested with pipes in accordance to GIS/PL2-2 and class C fittings with pipes in
accordance to GIS/PL2-8.
b) Whereseveral combinations of metallic materials are used in a range of fittings one fitting for each
combination shall be tested.
c) For coupler sizes greater than 180 mm.
d) One
pipe shall be cut with the assembly at 23 °C and the other with the assembly at –5 °C. Each
assembly shall be conditioned at the appropriate temperature for 1 h prior to the pipe being cut.
e) Forclass B tapping tees only; requirements for class C tapping tees shall be determined in consultation
with the gas transporter.
f) Joints
made under condition IV shall be allowed to cool to ambient temperature (23 °C) and then re-
energized for the manufacturer’s stated fusion time.
g) Flange adaptors shall be tested in accordance with GIS/PL3:2006, 9.
h) The test applies up to and including 75mm size.
i)
A BSI Certification Report may be issued upon completion of 2500hrs. The report will clearly state that
the test has been witnessed and verified, and that the intended purpose is to complete 5000hrs,in order
for the products to be covered on the relevant Kitemark Licence. The report will also include a
termination date (the completion date for the full 5000hr test) from which the report will no longer be
valid.

28
 GIS/PL2-4:2014

A.3 Batch release tests (BRT)

Checks shall be carried out in accordance with Table A.3.
Table A.3. Part 1 Batch release test requirements (class B and C fittings) a)
Initially for a period of no less than 6 months, the checks given in Table A.3.Part 1 shall be
carried out at the stated frequency on production from each injection-moulding machine or
manufacturing process. When the contractor has shown by consistently good results that it is
not necessary for him to check at this frequency, Table A.3.Part 2 shall be operated by formal
agreement with the gas transporter and or BSI.
Note: Table A.3. Part 1 shall also be operated following a change of raw material compound / a
fundamental change to the fitting outside the scope of Appendix J.

Property Requirement Test method Initial No. of Fitting/pipe No. of

clause fittings/test assembly test
frequency parameters pieces
Joint interface 10.6.2 ISO 13955 1 per type per A.1 2 per
crush strength size socket
Every 24 h 1 per
rotating cavities saddle
as applicable b)
Joint interface 10.6.1 ISO 13954 1 per type per A.1 4 per
peel strength size socket
Every 24 h
rotating cavities
as applicable b)
Measurement 6.1 c) Measure to 1 per type per Not applicable 1 per
of dimensions agreed size fitting
procedure Every 2 h b)
giving an
appropriate
degree of
accuracy d)
Melt flow rate GIS/PL2-1 ISO 1133 Daily b) Not applicable 1 per
fitting
Operation of 9.4 Visual 1 per type per A.1 1 per
fusion examination size fitting
indicators to agreed Every 24 h
limits rotating cavities
as applicable b)
Resistance of 8.1.1 Measure Every fitting Not applicable 1 per
heating resistance of fitting
element fitting at
23 °C
excluding
terminal pin
contact
resistance

29
GIS/PL2-4:2014

Table A.3 Part 1 Batch release test requirements (class B and C fittings) a) (continued)

Property Requirement Test No. of Fitting/pipe No. of test

clause method fittings /test assembly pieces
frequency parameters

Resistance to 10.7.3 BS EN 1 fitting from A.1 1 per fitting

internal ISO1167 the Start &
pressure at End of each
80 °C, 165 h Batch
(stress crack (rotating
resistance) cavities as
applicable)
Spigot end GIS/PL2-6 GIS/PL2-6 1 per batch Not 1 per fitting
reversion applicable
Thermal 7.2 BS EN 728 1 every 7 Not 1 per fitting
Stability OIT or ISO production applicable
11357, days
a) Valid for fitting sizes up to and including 400 mm; schedules for sizes greater than 400 mm shall be

subject to agreement by the gas transporter and or BSI.

b) Or every 50th component whichever is least frequent.
c) All
dimensions (specified and non specified) may be subject to measurement the extent of which
shall be subject to agreement.
d) Dimensions of injection moulded fittings shall be checked on start up for cavity effects; thereafter on
basis of fitting diameter. Frequency and method of checking machined and/or fabricated fittings shall
be declared by the contractor at the submission stage.

Table A.3. Part 2 Batch release test requirements (class B and C fittings)
Size Groups (I)16mm to 63mm (II) 75mm to 225mm, (III) 250mm to 800mm
The authorisation to operate BRT tests as per Table A.3. Part 2 may be withdrawn by the
Gas Transporter or BSI at any time, if adverse change occurs in the relationship between
the recorded results and the requirements of this Specification.

Property Requirement Test method Reduced Fitting/pipe

clause Frequency / No of assembly
Test Pieces parameters
Joint interface 10.6.2 ISO 13955 2 sockets & 2 saddle A.1
crush strength fittings, per size
Sizes <90mm group, per week (if
manufactured).
(See Note 1)
Joint interface 10.6.1 ISO 13954 2 sockets & 2 saddle A.1
peel strength fittings, per size
Sizes 90mm and group, per week (if
above. manufactured)
(See Note 1)

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 GIS/PL2-4:2014

Table A.3. Part 2 continued

Property Requirement Test method Reduced Frequency Fitting/pipe

clause assembly
No of Test Pieces
parameters
Measurement 6.1 Measure to In Process check Not applicable
of dimensions agreed (Minimum of 1 fitting
procedure every 4hrs).
giving an .
appropriate
degree of
accuracy.
Melt flow rate GIS/PL2-1 ISO 1133 1 socket & 1 saddle Not applicable
On Fittings fitting, per size group,
per week (if
manufactured)
(See Note 1)
Operation of 9.4 Visual 2 sockets & 2 saddle A.1
Fusion examination fittings, per size group,
Indicators per week (if
manufactured)
(See Note 1)
Resistance of 8.1.1 Measure 100% Continuity check Not applicable
heating resistance of of every fitting during
element fitting at manufacture and
23 °C Recorded resistance
excluding values a minimum of
terminal pin every 4hrs.
contact
resistance .
Resistance to 10.7.3 BS EN 1 socket & 1 saddle A.1
internal ISO1167 fitting, per size group,
pressure at per week (if
80 °C, 165 h manufactured)
(stress crack (See Note 1)
resistance)
Spigot End GIS/PL2-6 GIS/PL2-6 1 socket & 1 saddle Not Applicable
Reversion fitting, per size group,
per week (if
manufactured)
(See Note 1)
Thermal 7.2 BS EN728 or 1 socket & 1 saddle Not Applicable
Stability OIT ISO 11357, fitting, per size group,
On Fittings per (if manufactured)
(See Note 1)
Note 1: The contractor shall rotate the type and size of socket & saddle fittings to be tested
within each size group.

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GIS/PL2-4:2014

A.4 Batch release testing

Batch acceptance tests on fully normalized fittings shall be carried out if batch release tests by
the contractor have been shown to be inadequate. For moulded fittings, a batch shall be
defined as the production of a machine, from the time it commences to produce fittings
conforming to this standard until the machine is closed down. A production batch should not
exceed 170 h machine time.
For machined and/or fabricated fittings, the batch definition shall be agreed with the gas
transporter.
When batch acceptance is carried out, the sampling plans specified in Table A.4 and Table A.5
shall be used. Samples shall be taken one each from batches preferably bearing different
dates.
NOTE Rejected batches may be split into sub-batches based on the date of production.
Each sub-batch shall be tested for those aspects which were failed, to one of the sampling
plans specified in Table A.6. All defective items shall be rejected.

Table A.4 Sample size code letter

Batch Dimensional Destructive tests Other tests
size tests
Short term Stress crack Joint Thermal Melt
pressure and resistance strength stability flow
operation of and end rate
fusion indicators reversion
Less C B B B A A
than 150
150 to D C C C A A
500
501 to E D D D A A
2 500
2 501 to F E E E E E
10 000

Table A.5 Double sampling plans

Sample Sample sizes Action to be taken on number of rejects

size
1st 2nd Total 1st sample Total of both
code
samples
Accept Reject Take 2nd Accept Reject
batch batch sample batch sample
A 1 3 4 0 ≥2 1 1 ≥2
B 2 6 8 0 ≥2 1 1 ≥2
C 3 9 12 0 ≥2 1 1 ≥2
D 5 15 20 0 ≥2 1 1 ≥2
E 8 24 32 0 ≥2 1 1 ≥2
F 13 39 52 0 ≥2 1 1 ≥2

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 GIS/PL2-4:2014

Table A.6 Sub-batch sampling plans

Sub-batch size Sample size Action to be taken on number of rejects

Accept sub-batch Reject sub-batch
Less than 500 5 0 1
500 and over 15 0 1

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GIS/PL2-4:2014

Annex B (normative)
Assessment of effect on joint integrity of fitting resistance tolerance

B.1 Principle
Variation in fitting resistance has a significant effect on the applied fusion energy and joint
integrity. The method is used to assess this effect.

B.2 Apparatus

B.2.1 Four-wire resistance bridge, or alternative resistance measuring device, with the
specification specified in Table B.1 as a minimum.

B.2.2 A true rms voltmeter, with an accuracy of at least ±0.1 % and a resolution of 10 mV in the
0 V to 100 V range.

B.2.3 Temperature controlled air space, which can be maintained at −5 °C ±2 °C and 23 °±2 °C

B.2.4 Adjustable output voltage control box, in accordance with GIS/ECE1.

Table B.1 Minimum specification for resistance measuring device

Range Resolution Accuracy

Ω
0 to 1 100 µΩ ±0.25 % of reading
0 to 10 1 mΩ
0 to 100 10 mΩ

B.3 Procedure

B.3.1 Minimum tolerance value (maximum voltage)

Pipe shall conform to GIS/PL2-2 (class B fittings) or to GIS/PL2-8 (class C fittings), and shall be
of the largest SDR for which the fitting is designed.
Condition the pipe and fitting at 23 C ± 2 °C.
Measure the resistance of the fitting under test (R23).
Calculate the applied fitting voltage from:

R23
applied voltage = V (B.1)
Rmin
where:
Rmin is the manufacturer's declared minimum fitting resistance;
V is 40 V or 80 V as applicable.
Using a resistive load on the output of the control box, set the control box output voltage to the
voltage calculated in the equation above.
Assemble the pipe(s) and fitting and fuse for the specified time.
When the joint has cooled, section the sample and check for signs of pipe collapse or creasing
of the pipe bore.

34
 GIS/PL2-4:2014

Subject the sectioned samples to the joint strength test specified in 10.6.1 or 10.6.2 as
appropriate.

B.3.2 Maximum tolerance value (minimum voltage)

Pipe shall conform to GIS/PL2-2 (class B fittings) or to GIS/PL2-8 (class C fittings), and shall be
of the smallest SDR for which the fitting is designed.
Measure the resistance of the fitting under test (R 23 ) at 23 °C ± 2 °C.

Condition the pipe and fitting at −5 °C ± 2 °C.

Calculate the applied fitting voltage from:

R23
applied voltage = V (B.2)
Rmax
where:
V is 39 V or 78 V as applicable;
Rmax is the manufacturer's declared maximum fitting resistance.
Using a resistive load on the output of the control box, set the control box output voltage to the
voltage calculated in the equation above.
Assemble the pipe(s) and fitting and fuse for the specified time.
When the pipe has cooled, section the sample and subject it to the joint strength test specified
in 10.6.1 or 10.6.2, as appropriate.

35
GIS/PL2-4:2014

Annex C (normative)
Determination of fitting cooling time

C.1 Principle
Pipe/fitting assemblies with thermocouples attached to the pipes in the area of the fusion joint
are conditioned at 23°C and fused at maximum power. The temperature within the joint is
continuously recorded and the fitting cooling time is determined.

C.2 Apparatus

C.2.1 Four-wire resistance bridge, or alternative resistance measuring device, with the
specification specified in Table C.1 as a minimum.

C.2.2 A true rms voltmeter, with an accuracy of at least ±0.1 % and a resolution of 10 mV in the
0 V to 100 V range.

C.2.3 Thermocouples, suitable for operation up to 400 °C connected to a temperature recording

device.

C.2.4 Adjustable output voltage control box, in accordance with GIS/ECE1.

Table C.1 Minimum specification for resistance measuring device
Range Resolution Accuracy
Ω
0 to 1 100 µΩ ±0.25 % of reading
0 to 10 1 mΩ
0 to 100 10 mΩ

C.3 Specimen
Pipes shall be in accordance with GIS/PL2-2 (class B fittings) or GIS/PL2-8 (class C fittings).

C.4 Procedure

C.4.1 Condition pipes and fittings at a temperature of 23°C ± 2 °C for at least 8 h. For socket
fittings, position two thermocouples diametrically opposite each other with the thermocouple's
tip on the outside surface of the pipe. Position the thermocouples in the centre of the resulting
fusion joint. One thermocouple shall be on the top of the pipe during the fusion operation. For
reducing couplers, the cooling time of both ends shall be determined.
For saddle fittings, position two thermocouples on the crown of the pipe, one either side of the
outlet stack, at a position in the centre of the resulting fusion joint.

C.4.2 Measure the resistance of the fitting under test. Adjust the voltage of the control box to
simulate maximum power input into the fitting.
NOTE This can be calculated from:

actual fitting resistance

Applied voltage, V = (C.1)
minimum fitting resistance specified by manufacture

where V = 40 V or 80 V as applicable.
Energize the fitting for the required fusion time. Record the temperatures.
On switching off the power, record the time for the thermocouples to reach 110 °C.
The cooling time shall be the mean time for the thermocouples at one end to reach 110 °C. For
reducing couplers, the higher of the two cooling times shall be taken as the fitting cooling time.
36
 GIS/PL2-4:2014

Annex D (normative)
Specification for the assessment of pipe inserts

D.1 Purpose of specification

NOTE 1 National Grid utilizes a number of techniques for the installation of polyethylene pipes. Most
techniques do not involve any change in the properties of the polyethylene pipe and can therefore use
electrofusion fittings, approved to GIS/PL2-4, to make joints between pipes.
NOTE 2 Some techniques, such as swagelining, involve a change in the dimensions of the pipe and
historically this has been addressed by the provision of pipe inserts to return the pipe to its original
specified dimensions. Guidance is given in the method statements, for example T/SP/DIS 5.11.1 but
such guidance does not provide information on sizing of the inserts to match a given pipe/fitting
combination.
NOTE 3 Historically the specifications have not permitted the use of plastic inserts, of any form, to be
specified for pipes of SDR 26 or thinner wall section. With improvements in the types and grades of
plastics materials available, this standard has been prepared to enable approval of such material
variants. It is desirable to have plastic alternatives to provide lightweight fittings for compliance with
manual handling regulations, and to enable the inserts to be packaged with electrofusion couplers
without risk of contamination due to machining fluids or corrosion products.
Inserts produced in accordance with this standard shall only be supplied as part of a package
with a matched electrofusion coupler. Such packages shall also include documented
instructions on the method of assembly to be used.

D.2 General
Electrofusion fittings for use with inserts made to this standard shall be in accordance with
GIS/PL2-4 and shall have type testing approval.
Pipe suitable for use with inserts made to this standard shall be in accordance with
GIS/PL2-2:2006, with dimensions in accordance with Table 3.
The contractor shall propose a design for the insert comprising material selection and product
profile/dimensions.
The contractor shall declare the material grade as part of the type testing approval process.
The contractor shall propose the method of installation of the inserts and make available a
written method statement to enable field installations to be made where pipe is in the
temperature range −5 °C to +23 °C.
Any specialist tools required for assembly of the inserts shall be supplied by the contractor.

D.3 Test requirements

D.3.1 Principle
Dimensions of the insert component are monitored by the tests specified in D.3.2, D.3.3,
and D.3.4 to assess the effect of storage time and temperature on dimensional stability. The
ability of the insert to provide support to the pipe during the welding process with an
electrofusion fitting is determined by D.3.5.

D.3.2 Dimensions

D.3.2.1 Procedure
Condition insert components for a period of 12 h at ambient temperature (23 °C).

D.3.2.2 Performance

After conditioning:
a) outside diameter shall be within the specified tolerance of the manufacturer’s drawing;

37
GIS/PL2-4:2014

b) length shall be within the specified tolerance of the manufacturer’s drawing.

D.3.3 Long-term dimensional stability

D.3.3.1 Procedure
Condition inserts to a temperature of 23 °C for a period of 12 months.

D.3.3.2 Performance
On completion of the conditioning period, the inserts shall still be within the dimensional
tolerances as specified by the manufacturer.

D.3.4 Assembly dimensional stability

D.3.4.1 Apparatus

D.3.4.1.1 Coupler, of maximum internal diameter, in accordance with GIS/PL2-4.

D.3.4.2 Procedure

D.3.4.2.1 Fit an insert to polyethylene pipe which has previously been deformed using the
swagelining process. The assembly shall comprise a coupler (D.3.4.1.1), and a pipe section of
minimum outer diameter in accordance with GIS/PL2-2. The insert shall be fitted in accordance
with the manufacturer’s instructions and at an ambient temperature of 23 °C.

D.3.4.2.2 On completion of the manufacturer’s specified relaxation period measure the

dimensions of the assembly (outside diameter and ovality).

D.3.4.2.3 The assembly shall be measured at 24 h intervals for a further period of 5 days when
stored at 23 °C.

D.3.4.2.4 Measurements taken in D.3.4.2.2 and D.3.4.2.3 shall conform to GIS/PL2-2 for pipe
of the nominal diameter and SDR.
Measurements of diameter and ovality shall conform to GIS/PL2-2 for pipe of the nominal
diameter and SDR.

D.3.5 Electrofusion compatibility tests

D.3.5.1 Procedure

D.3.5.1.1 Condition pipe, insert and coupler for a period of 12 h at ambient temperature (23 °C).
Assemble the components in accordance with the contractor’s method statement and weld the
electrofusion fitting at maximum voltage (as specified in this standard). Allow the assembly to
cool to ambient temperature and then apply a second fusion cycle. Make two fittings at this
condition, evaluate in accordance with D.3.4.2.2.

D.3.5.1.2 Subject samples to a hydrostatic pressure test at 80 °C, at a test stress of 4 MPa, for
a period of 1 000 h.

D.3.5.2 Performance
There shall be no failure of the sample.
When samples are sectioned and joints subjected to the electrofusion peel decohesion test in
accordance with GIS/PL2-4, samples shall conform to 6.2.2 for minimum ductile fusion length.

38
 GIS/PL2-4:2014

Annex E (normative)
Test piece components

E.1 General
The preparation and assembly of test pieces shall be carried out using the tooling specified in
GIS/PL2-5,except for approval testing of tapping tees and branch saddles, which shall be
assembled as shown in Figure E.1 where the force is reacted through the stack of the fitting.
NOTE The fitting manufacturer shall provide installation instructions and recommend / provide
appropriate tooling if different from that prescribed in GIS/PL2-5.
NOTE For fittings where the force is not reacted through the stack, alternative assembly techniques
should be employed.

E.2 Pipes
For approval testing, pipe shall conform to GIS/PL2-2 (class B fittings) or to GIS/PL2-8 (class C
fittings). Pipe from coils shall be used in sizes equal to or less than 180 mm.
For batch release testing, pipe shall conform to GIS/PL2-2 (class B fittings) or to GIS/PL2-8
(class C fittings) but need not be coiled.

E.3 Socket fittings

Socket fittings shall be assembled to pipe to provide a gap between the pipe ends and the pipe
penetration stop(s) of at least 0.05 times the pipe outside diameter. For approval test samples
only, the pipe and fitting shall be measured to identify the maximum and minimum diameters.
Assemblies shall give maximum clearance at one point, and minimum clearance at another.
For coupler sizes greater than 180 mm, the pipes shall be held in a clamping arrangement to
restrain pipe movement. The clamps shall be arranged to produce a 1.5° offset between the
pipes across the coupler.

E.4 Saddle fittings

Where saddle fittings are fused to coiled pipe, the fittings fused with a stack load of 1 000 N
shall be positioned perpendicular to the minimum diameter of the pipe. Fittings fused with a
stack load of 1 500 N shall be positioned perpendicular to the maximum diameter of the pipe.
The pipe shall be removed from the coil immediately prior to conditioning, and the first 5 m from
the coil shall not be used.
Where assemblies contain saddle fittings with integral cutters, the main shall be cut and the
cutter retracted into the body of the fitting before testing.
Where assemblies contain saddle fittings with a separate cutter, the main pipe shall be cut
and the cutter removed before testing. Tapping tee caps shall be tightened in accordance
with 6.3.2.5.

E.5 Test piece geometry

If assemblies contain more than one fitting the free length of pipe between fittings of any type
shall not be less than three times the pipe outside diameter for sizes not greater than 250mm,
or twice the pipe outside diameter for sizes greater than 250mm. For tapping tee fitting
assemblies, the free length of pipe between fittings shall not be less than twice the pipe outside
diameter for all sizes, provided adjacent fittings are rotated relative to each other by not less
than 90°.
Specimens for pressure test shall be closed with pressure tight end-load bearing end caps,
plugs or flanges which shall be provided with connections for the entry of water and release
of air.
NOTE Spigots may be closed without the use of electrofusion fittings.

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GIS/PL2-4:2014

Figure E.1 Test specimen assembly

40
 GIS/PL2-4:2014

Annex F (normative)
Measurement of coupler assembly force

F.1 Principle
The test is designed to simulate in a tie-in situation, the assembly and fusion jointing of rigidly
fixed and misaligned pipes using electrofusion socket couplers. The assembly force is
measured and the strength of the joint is determined.

F.2 Procedure
Pipe shall conform to GIS/PL2-2 (class B fittings) or to GIS/PL2-8 (class C fittings). The pipes
and fitting shall be at a temperature of 23 °C ± 2 °C.
Offset the pipes to be joined 1.5° and rigidly clamp to restrain pipe movement. The clamps shall
be 2.5 times the nominal pipe diameter apart. Position the pipes centrally within the clamps.
Cut the pipe ends square and the maximum pipe end-to-end clearance shall be 10 mm.
Mark a distance equal to one half of the coupler overall length from the end of each pipe.
Slide the coupler, for its full length, on to one pipe. Measure the force required to position the
fitting centrally between the marks on the pipe.

F.3 Performance

F.3.1 The fitting shall be capable of being slid from one pipe on to an adjoining pipe, offset
at 1.5°, with a force of not greater than 500 N. There shall be no dislodgement of the heating
element wire.

F.3.2 The assembled joint shall be fused at minimum power input (see B.3.2).
The assembly shall conform to 10.6.1.

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Annex G (normative)
Tapping tee cap pneumatic leak test

G.1 Principle
The tapping tee is internally pressurized using air as the pressurizing medium to assess the
leaktightness of the fitting closure cap.

G.2 Apparatus

G.2.1 Water bath or air chamber, capable of maintaining the required temperature to within
±1 °C and subjecting the specimen to the specified pressure to an accuracy of ±2 %.

G.2.2 Air, which shall be used as the pressurizing medium.

G.2.3 Torque wrench, or other approved method, to tighten the tapping tee cap to the specified
torque to an accuracy of ±5 %.

G.3 Test piece

The test piece shall be prepared in accordance with Annex A, Tables A.1 and A.2, except
that the main shall not be cut, and pressurization shall be effected through the outlet of the
tapping tee.

G.4 Procedure
Appropriate precautions shall be taken to provide protection to personnel should a specimen
fail under test.
NOTE This standard calls for the use of procedures that may be injurious to health if adequate
precautions are not taken. It refers only to technical suitability and does not absolve the user from legal
obligations relating to health and safety at any stage.
Tighten the tapping tee cap to a maximum torque of 4 N⋅m.
Maintain the specimen at a temperature of 23 °C ± 3 °C throughout the test.
Pressurize the specimen to 4 bar, and maintain this pressure within a range of ±2 % for a
period of 2 500 h.
Leak detect by immersing the pressurized specimen, at a depth not exceeding 250 mm, in a
bath of clean water.

G.5 Performance
There shall be no leakage.

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 GIS/PL2-4:2014

Annex H (normative)
Branch saddle pull off test (See schematic diagram below)

H.1 Principle
A fused assembly consisting of a branch saddle fused to a mains pipe and branch offtake is
subjected to a tensile load until failure occurs.

H.2 Apparatus

H.2.1 Tensometer, capable of applying a tensile load through the axis of the outlet pipe.

H.3 Test specimen

The test specimen shall consist of a branch saddle fitting fused in accordance with Annex A
to a length of polyethylene pipe conforming to GIS/PL2-2 (class B fittings) or GIS/PL2-8
(class C fittings).
A length of polyethylene pipe conforming to GIS/PL2-2 (class B fittings) or GIS/PL2-8 (class C
fittings) shall be fused in accordance with Annex A to the spigot outlet of the saddle fitting. The
length of the pipe shall be four times the nominal spigot outlet diameter.

H.4 Procedure
Insert plain metal plugs in the ends of the polyethylene pipes to support the pipe under the
action of the loading grips. Alternative methods of holding the pipe may be proposed by the
contractor and shall be subject to agreement with the gas transporter. Rigidly hold the mains
pipe of the test specimen in a clamp with the outlet pipe vertical. The distance between the
clamp inside faces shall be saddle fitting width plus 30 mm.
Assemble the test specimen and clamp in a tensometer. Apply the tensile load at an extension
speed of (25 ± 1) mm/min, until the specimen fails. Subject the outlet pipe of a branch saddle
fitting to a tensile load. Increase the tensile load until the outlet pipe fails by 'necking' or the
mains pipe fails.

H.5 Performance
There shall be no failure in the saddle joint fusion area, spigot outlet and pipe/fitting interface or
saddle fitting body.

Force F

Flat solid surface

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Annex I (normative)
Tapping tee pressure drop test

I.1 Principle
Measurements are made of tapping tee pressure drop and its corresponding flow rate. The
equivalent flow rate of natural gas and the velocity head lost in the fitting is determined.

I.2 Apparatus

I.2.1 Pressure controller (A), capable of giving a steady output of 25 mbar

I.2.2 Flow meter (B), positive displacement or turbine meter type accurate to ±5 %.

I.2.3 Inclined manometer, for mains pressure.

I.2.4 Inclined manometer, for differential pressure.

I.2.5 Outlet valve.

I.3 Test specimen

The configuration of the specimen tee shall be in accordance with Figure I.1.

I.4 Procedure

I.4.1 Connect the inclined manometer across the tee and partially open the outlet valve (E).
Open the inlet valve so that gas starts to flow and check that gas flows from the outlet
valve only.
By means of pressure controller (A), regulate the mains pressure (C) to 25 mbar and measure
and record the flow rate, Q, on flow meter (B) and the pressure drop, ∆P, on manometer (D).

I.4.2 Open the outlet valve (E) sufficiently to reduce the mains pressure, C, by approximately
5 mbar. Increase the flow rate until the mains pressure (C) returns to 25 mbar and measure and
record the flow rate, Q, and the pressure drop, ∆P.

I.4.3 Repeat I.4.2 until the outlet valve (E) is fully open.

I.5 Expression of results

NOTE 1 The procedure specified in I.4 gives a number of pressure drop values and the corresponding
flow rate for each.
From the relationship:
∆P =FQ 2 (I.1)
where:
∆P is the pressure drop, expressed in mbar;
F is a factor;
Q is the flow rate, expressed in m3/h.
The factor F shall be calculated for each set of readings and the average value determined.
Using the average value, the pressure drop, ∆P, shall be determined for a gas flow rate, Q
appropriate to the size of service fitting (see Table 7).

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If air or nitrogen is used for this test, the flow rates shall be corrected using the following
relationship:

Q nat = Q med ρ med / ρ nat (I.2)

where:
Qnat is the flow rate using natural gas, expressed in m3/h;
Qmed is the flow rate using other gas (air or nitrogen), expressed in m3/h;
ρ med is the density of other gas (air or nitrogen), expressed in kg/m3;

ρ nat is the density of natural gas, expressed in kg/m3.

The number of velocity heads lost across the fitting shall be calculated from:

 ∆P  200  V12 
K=   2 +  2 − 1 (I.3)
 ρ  V2  V2 
where:
K is the velocity head lost in the fitting based on the velocity in the service pipe;
∆P is the measured pressure drop, expressed in mbar;
ρ is the density of natural gas = 0.71 kg/m3;
V1 is the velocity in main = Qnat/A1 = m/s;
where:
A1 is the bore area of the main;
V2 is the velocity in service pipe = Qnat/A2 expressed in m/s;
where:
A2 is the bore area of service pipe under test.
NOTE 2 The equation assumes the density effects due to velocity are negligible.

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NOTE 1 Pressure tappings should be at least 2d (d = relevant pipe diameter) from any fitting or valve
and, in the case of the tee, diametrically opposite it and upstream of it.
NOTE 2 The flow meter should be installed in accordance with the requirements of the device
selected.

Figure I.1 Layout of test rig for tapping tee pressure drop test

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 GIS/PL2-4:2014

Annex J (normative)
Type tests – Changes to approved fittings or tooling & Low Volume products

Change No.1 - Electrical Design (no change to Polymer or Mechanical Design)

Shall include Wire change / Resistance change / Fuse time change / Fusion length change i.e.
number of wire turns.
Tests, which shall be performed
Property Requirement Test Method No. of fittings Fitting/pipe
Clause Assembly
parameters
Joint Interface 10.6.1 ISO13955 1 per size per Conditions I & IV
type per
Peel Strength Table A.1
condition
(See Note 1)
Joint Interface 10.6.2 ISO13954 1 per size per Conditions I & IV
type per
Crush Strength Table A.1
condition
(See Note 1)
Resistance to internal 10.7.3 ISO1167 2 per size per Condition I
pressure at 80ºC, type per
Table A.1
1000hrs (stress crack condition
resistance)
Note 1: Fuse and Cool Time to be determined whilst carrying out Joint Interface Strength tests.

Change No. 2 – New Product from existing Tooling/Cavities by “thickening” the fitting.
Tests, which shall be performed
Property Requirement Test Method No. of fittings Fitting/pipe
Clause Assembly
parameters
Joint Interface 10.6.1 ISO13955 1 per size per Conditions I & IV
type per
Peel Strength Table A.1
condition
(See Note 1)
Joint Interface 10.6.2 ISO13954 1 per size per Conditions I & IV
type per
Crush Strength Table A.1
condition
(See Note 1)
Resistance to internal 10.7.3 ISO1167 2 per size per Condition I
pressure at 80ºC, type per
Table A.1
1000hrs (stress crack condition
resistance)
Resistance to internal 10.7.1 ISO1167 2 per size per Condition I
pressure at 20 °C for type per Table A.1
100hrs
condition

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Property Requirement Test Method No. of fittings Fitting/pipe

Clause Assembly
parameters
Thermal Stability OIT 7.2 BS EN 728 1 per size per Not applicable
or ISO type
11357,
Note 1: Fuse and Cool Time to be determined whilst carrying out Joint Interface Strength tests.

Change No.3 - Changes to dimensions of the PE body (approved fittings)

Wall thickness of the fitting is not reduced or increased by more than 5%, including
Socket Bore dimensions & Tapping Tee Saddle base radius.
Tests, which shall be performed
Property Requirement Test Method No. of fittings Fitting/pipe
Clause Assembly
parameters
Joint Interface 10.6.1 ISO13955 1 per size per Conditions I, II,
type III & IV
Peel Strength
per condition Table A.1
(See Note 1)
Joint Interface 10.6.2 ISO13954 1 per size per Conditions I, II,
type III & IV
Crush Strength
per condition Table A.1
(See Note 1)
Resistance to internal 10.7.3 ISO1167 2 per size per Conditions I, II,
pressure at 80ºC, type III, & IV
1000hrs (stress crack
per condition Table A.1
resistance)
Resistance to internal 10.7.1 ISO1167 2 per size per Condition I, II,
pressure at 20 °C for type III & IV
100hrs Table A.1
per condition

Note 1: Fuse and Cool Time to be determined whilst carrying out Joint Interface Strength tests.

Note: If a “range” of existing PL2-4 approved fittings undergo one of the modifications shown in
Annex J, the smallest, largest, and an intermediate size representative of the range will be
tested, consistent with Clause 11.1 of this standard.

Change 4 – Qualifying a different pipe SDR, in PE80 or PE100 Material (approved fitting)

The tests, which shall be performed are as per those detailed for Change No.1.

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Low Sales Volume requirement – Electro-fusion Fittings 16mm to 560mm (<250pcs per
annum)

The tests, which shall be performed are as per those for Change 3 above, with the following
amendments.

The Resistance to Internal Pressure test at 20ºC for 100hrs shall be performed on Conditions I,
and IV only. In addition, the Impact Test shall be performed on Saddle Fittings, with 1 sample
being fused at each of the four Conditions shown in Table A.1.

Low Sales Volume requirement – Electro-fusion Fittings 630mm to 800mm (<250pcs per
annum)
The annual requirements for fittings in the size range 630mm to 800mm may often be so small
that the number of test samples required for type approval is often greater than the number of
fittings sold. The reduced type testing detailed in Table J1 may therefore be adopted for fittings
in this size range.

Table J.1 Type Testing of Low Volume Fittings (630-800 mm)

Mechanical properties References No. of test No. of Fitting/pipe

pieces a) fittings Assembly
parameters

Resistance to internal pressure at 20°C 10.7.1 1 1 per size Condition I

(100h or 5000h) per type Table A.1

Resistance to internal pressure at 80ºC, 10.7.2 1 1 per size Condition I

(stress crack resistance) (165h) per type Table A.1

Joint Interface Peel Strength 10.6.1 ISO13955 1 per size Condition I,

per type
(See Note 1) Table A.1
a) The number of test pieces given in the table shall be the minimum.

Note 1: Fuse and Cool Time to be determined whilst carrying out Joint Interface Strength
tests.

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Annex K (normative) Short term pressure test

K.1 Principle
A test piece, consisting of an electrofusion fitting assembled with one or more PE pipes having
reduced free length sufficient to suppress pipe failure and create preferential failure in the fitting
or in the connecting pipe-to-fitting joint, is placed in a controlled-temperature environment and
subjected to an essentially continually increasing internal hydraulic pressure until failure occurs.
The method is designed to establish the short-term failure pressure of the fitting/pipe assembly.
K.2 Apparatus
K.2.1 Constant-temperature water bath, in accordance with BS EN ISO 1167-1, capable of
being maintained at (20 ± 2) °C.
K.2.2 Pressure test equipment, in accordance with BS EN ISO 1167-1, capable of applying a
continuously increasing internal hydraulic pressure at a rate of (5 ± 1) bar/min 3) until the test
piece fails.
K.2.3 Pressure gauge, having an accuracy of not less than 1 % of full-scale deflection and with
a hand which indicates the maximum pressure reached.
A gauge shall be used that will indicate the failure pressure at approximately mid-scale. The
gauge should preferably be equipped with a surge protection device. The gauge shall be
located in a position within the pressure system such that it will indicate the internal pressure of
the test piece without being affected by pressure transients within the pressure supply lines,
etc.
K.3 Test piece
The test piece shall be an assembly of one or more electrofusion fittings connected to PE
pipes, with a minimum free pipe length between fittings of any type not exceeding dn. The pipes
used shall be the thickest-walled pipe for which the fitting has been designed. The test piece
shall be closed with type A end caps in accordance with EN ISO 1167-1:2006.
K.4 Procedure
Attach the end caps to the test piece and fill it with water at ambient temperature.
Connect the test piece to the pressure source, ensuring that no air is trapped in the test
assembly.
Immerse the test piece in the constant-temperature bath and condition it at (20 ± 2) °C for at
least as long as the period defined in EN ISO 1167-1 for the appropriate pipe wall thickness.
Increase the pressure uniformly at a rate of (5 ± 1) bar/min until failure of the test piece occurs.
Record the pressure at failure.
After testing, inspect the test piece and record the location and mode of failure.
K.5 Test report
The test report shall include the following information:
a) Reference to GIS/PL2-4 Addendum;
b) All details necessary for complete identification of the pipes and socket fusion fittings used,
including manufacturer, type of material and size of fitting and pipe;
c) Details of the fusion-jointing procedure used to assemble the test piece;
d) Pressure at failure;
e) Time to failure;
f) Failure location;

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g) Mode of failure, e.g. ductile in fitting, brittle along fusion interface;

h) Any factor that could have affected the results, such as any incidents or operating details not
specified in this annex;
i) Date of test.

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Annex L (normative) Tensile test for fitting/pipe assemblies

L.1 Principle
A test piece consisting of an electrofusion fitting and two connecting PE pipes is subjected to an
increasing tensile load at a constant pulling rate until ductile pipe failure occurs. The test is
conducted at a constant temperature and is intended to simulate the creation of longitudinal
tensile loading along a pipeline as a consequence of external mechanical interference. Rupture
of the fitting or the connecting fusion joints is not an acceptable failure mode.
L.2 Apparatus
This shall be in accordance with ISO 13951:2001, with the additional requirement that the
tensile-testing machine shall be capable of accommodating a test piece elongation of 25 % and
of sustaining a constant test speed of (5 ± 1,25) mm/min.
L.3 Test piece
The test piece shall be in accordance with ISO 13951:2001.
In cases where dn ≥ 180 mm and where the conduct of tensile tests on fitting/pipe assemblies
is beyond the Limits of the available test equipment, the testing of joint segments may be
appropriate. Testing of segment test pieces shall not be undertaken, however, unless a
correlation with testing of complete pipe/joint assemblies has been established.
L.4 Procedure
This shall be in accordance with ISO 13951:2001, but without that International Standard’s
requirement for the load to be constant. The pulling rate shall be 5 mm/min ± 25 %, sustained
until a test piece elongation of 25 % is reached.
L.5 Test report
The test report shall include the following information:
a) Reference to GIS/PL2-4 Addendum;
b) All details necessary for complete identification of the pipes and electrofusion fittings used,
including manufacturer, type of material and size of fitting and pipe;
c) Details of the fusion-jointing procedure used to assemble the test piece;
d) Test temperature;
e) Leaktightness and integrity of the fitting and fusion joint after 25 % elongation of the test
piece;
f) Any factor that could have affected the results, such as an incident or operating detail not
specified in this annex;
g) Date of test.

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Annex K Summary of and rationale for changes to document – June 07

GIS/PL2-4 Comment & Rationale Proposer Action Required

Clause (if applicable)
Foreword Review period, Wording on frequency Declan Change policy document
currently shown in Draft GIS/PL2-4 to be Robinson advocated by NG & BSI
removed governing the suite of GIS’s.
Topic referred to TSF for
discussion/action as appropriate.
4.2 Polyethylene Compound, RCP Trevor To submit alternative wording
Nicholson ideally for inclusion in the notes
accompanying Table 2 –
“Properties of the compound in
the form of pipe, GIS/PL2-1”
based on the response from
Dr Martyn Greig.
6.2 Table 2. Socket dimensions, if pipe is Bill Rose & Working Group Members
Table 2. manufactured with high OD then it will not Michael reluctant to support a change to
fit into the socket dimensions proposed by Gressman Table 2 of specification, hence
GF. Minimum values below those specified Table to remain as is.
in GIS:PL2:4.
GF on smaller diameters have a shorter
apparent fusion length (based on BS EN
1555 dimensions).
The longer the fusion zone the perceived
greater resistance to joint abuse.
6.3.2 Overall length of reducers Bill Rose & As 6.2 above Working Group
Table 3 200, 225 & 250mm GF reducer extended Michael Members reluctant to support a
length, concern over tooling and placing the Gressman change to Table 3 of
fitting within the clamp, will not fit within specification, hence
the limits set in Figure 6.Changing the Table to remain as is.
specification will render clamps in the field
redundant.
6.6.1 6.6.1 Tapping tees, request made to add Bill Rose & GF request to include 17mm
17mm hexagonal key to engage tapping Michael hexagonal key not supported by
tee cutter Gressman Working Group, on the basis that
additional tooling would need to
be carried in the field. A major
re-tooling would be required to
progress this request.
6.6.2 Tapping tee outlets, dimensional tolerances Various WG Agreement reached to retain
0.7 OOR 32mm Members document as is, but add the OOR
0.9 OOR 63mm values.
6.6.2 20 & 25mm outlets, Customers other than Paul Kimplas have a 20mm outlet
NG, would like to have included these Thompson tapping tee approved by
diameters. Advantica which is currently
BSI commented that customers may use outside the scope of this
this product based on their own risk specification.
assessment. To be considered in future
update

6.6.2 Saddle base dimensions, GF dimension 165, Bill Rose & As per comments reference 6.2 &
specification requirement 120mm. Michael 6.3.2.
Requirement for smaller dimension to Gressman NG & BSI stated that GF product
minimise distance between fittings. differences were “outside” the
Terms of Reference for the
Working Group.
GF advised to submit request to
TSF as per previous comments.
6.7.2 Class C, branch saddle outlets, PE100 stub Dave DC has raised a question with
flange as opposed to PECat. Transition to Clayton the TSF in advance of TSF
7bar via PECat. meeting 14.7.07.
8.1.3 Terminal design, request made to include a Bill Rose & As 6.6.2, GF to submit request to
sketch of the 4mm terminal pin shroud Michael the TSF for review, as request
design, and to change the wording to Gressman outside the Terms of Reference
reflect that an adaptor would “not” for the Working Group.
necessarily be supplied with every fitting.
Requests triggered concerns over tooling / GIS/PL2-4 Draft Specification
adaptor requirements. Uponor spoke about wording to revert to that pre the
its “poor” experience with 4mm pin fittings Working Group meeting 25.4.07.
supplied in the UK some years ago. This (3rd paragraph of clause to be
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was further supported by Kimplas with PT removed).

commenting that he has discussed this with
contractors who have requested not to
proceed with the 4mm pin.
7.1.2 120min to be preceded by minimum as per Noel Taylor
7.1.1
Figure 3 Terminal shroud Agreement reached on C1 of
20mm +/- 2
9.5 Voids classed as an un-fused area and will Wording in 9.5 to be amended
go into the de-cohesion calculation. to reflect statement regarding
unfused area.
10.7.2 Noel Taylor Agreed with content
10.10.1 Pressure drop, tapping tees, request made Bill Rose & Should GF or Kimplas wish to
to include BS EN 12117 as an alternative Paul request that BS EN 12117 be
method for determination of pressure drop. Thompson included as an alternative
standard/test method, then a
National Foreword in BS EN12117 states submission should be made to
that “since it does not determine the TSF evidencing the case for this
velocity head loss, it is not technically standards inclusion.
equivalent to either appendix E or F in
BS7336: 1990”. Given that BS7336 was a
straight copy of British Gas PL2/Part 4:
circa 1990, its equivalence to GIS: PL2:
Part 4 has YET to be demonstrated.
11.1 General, Small medium and large fitting to T Peach Agreement reached, it is possible
be tested, is this for every type of fitting to test small medium and large
design or alternatively is it possible to test fittings of alternative fitting
different fittings, i.e. couplers, elbows, design.
reducers of alternative diameters
12 Marking All
Items a-f (Agreed) TP to update Marking Section
Character dimensions (3.0mm) based on comments made
Packaging rather than ‘Poly bag’.

12.Note 1 Marking date, not 2006. Trevor

Nicholson
Annex A Tests conducted at –10C & +45C Bill Rose Accepted, only if the testing is
equivalent or more extreme.
Wording introduced to reflect
this.
Table A.2, i BSI Certification report 2,500 hours Accepted
Table A.3 Batch Release 20˚C 100hr test proposal All Agreement reached to remove
Part 1 seen as not relevant as a BRT on the this test
grounds that it relates to material strength.
Original 1hr test has produced no failure in
two decades of testing so no value.
Table A.3 Start & end of batch (what if only one TP To modify wording
Part 1 fitting to be manufactured)
Table A.3 Batch Release Test 20 degree C All Agreement reached to remove
Part 2 requirement – As per Table A.3 Part 1 this test.
E.5 Delete word ‘is’ TP
Annex H Include sketch of branch saddle pull off test TP
Annex I 20 degree C test removed Declared Obsolete/Remove from
Draft Standard
Annex I Already discussed above
Annex J Modifications - Request received to reduce Bill Rose & Statement added to Appendix K
the number of tests to be performed e.g. Paul stating that if a range of existing
Test one size only per type if already Thompson PL2-4 fittings undergo the same
approved to PL2-4/BS EN1555. modification, then the smallest,
largest, and an intermediate size
shall be tested, which aligns with
the wording in Clause 11.1 of
this standard
Does not apply to fittings already
approved to BS EN1555.
Low sales <250 pieces per annum’ All
volume After some discussion concept of Acceptance reached on the 250
“large gap” necessitating “some action” in piece value.
terms of Low Sales Volume Fittings, could
not be readily substantiated.
Clause 3.2.4 Greater detail required with regard to batch TP
definition

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GIS/PL2-4:2014

Annex L Summary of and rationale for changes to document – March 2012

Comment & Rationale Proposer Action

GIS/PL2-4 Required
Clause (if applicable)

Title Page Title modification: Polyethylene pipes and GDN’S, GL Noble

fittings for natural gas Denton

The standard is specific for natural gas

only. Supporting evidence is required to
show that the product is compatible with
other gas media.

Foreword Statement: GL NOBLE DENTON

The UK Committee would like to emphasize
that compliance with GIS/PL2-4 does not
necessarily mean that products are fit for
the purpose of conveying natural gas in the
UK. It is recognised that fittings may not be
fully compatible with existing UK practice in
terms of applicable pressure tiers, preferred
colours for gas pipe recognition, jointing
and installation methods.
The requirements contained in GIS/PL2-4
are not necessarily indicative of all the
performance requirements, or the
suitability of pipework for the service
conditions, likely to be encountered in the
UK.
GDN’S need to be aware that this standard
assesses fitness for purpose in terms of
functionality. Field testing will be critical to
ensure compatibility with working practices.

Clause 3.3.2 & 4.2 New requirement - only allow rework of GPS
yellow and orange PE compound. Black
compound easily hides such contamination,
allowing unscrupulous suppliers to produce
fittings made from “less than perfect”
material.

Clause 4.2 Prescriptive requirement of compliance with GL NOBLE DENTON

GIS/PL2-1 removed. Polyethylene
compliant with EN1555-1 permitted.
Provision of further detail in respect to
polyethylene characteristics – adopting
Table and text from BS ISO 8085-1

Clause 5.1 Table removed from Clause 5.3 and GL NOBLE DENTON
incorporated within Clause 5.1.
Table placement was considered in
appropriate.

Clause 5.3 Class C Table removed and incorporated into Radius Systems
fittings Table 2 Clause 5.1. Table placement was
considered in appropriate.
SDR26 addition to the SDR options shown
for 355≤ dn ≤630
SGN are looking to use SDR26 in
preference to SDR21 for general
application.
Maximum threshold SDR26 dn ≥ 250

Clause 6.1 New Statement; The fitting manufacturer GL NOBLE DENTON

shall provide installation instructions and
recommend / provide appropriate tooling if

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 GIS/PL2-4:2014

different from that prescribed in GIS/PL2-5.

This will remove prescriptive tooling
requirements barring entry of fittings with
different design configuration which are not
compatible with GIS/PL2-4.
New Statement: The stops shall be
removable without interference of the
socket electrical wire. This should help
negate the possibility of contamination /
damage in the field.
The following statement has been deleted
to remove the prescriptive nature and align
with EN1555-3:
Fitting sockets shall be provided with a
lead-in to ease joint assembly, see
Figure 1.
For socket sizes equal to or greater than
250 mm, means shall be provided to
facilitate site handling and to protect fusion
surfaces from handling damage.

Clause 6.2 The ‘shall’ requirement replaced by ‘should’ GL NOBLE DENTON

in respect to coupler diameter and fusion
zone requirements.
An option to use tooling other than that of
GIS/PL2-5
The GNO’s realise that the loss of the
prescriptive design requirements designed
specifically for the UK industry means that
they will have to adopt a performance
based methodology in terms of product
selection and use. This will ensure that they
aligned with the operating practices of
polyethylene pipeline assets owners
globally. The robust testing regime of
GIS/PL2-4 has been retained in order to
ensure only high quality fittings
demonstrating equivalence in terms of
functionality to existing products enter the
UK. Thereafter stringent performance
testing will ensure compatibility with UK
working practices.

Clause 6.3.2.2 Addition to accommodate European design George Fischer

- Alternatively temporary or permanent
under-clamps may also used.

Clause 6.3.2.3 Torques increased to accommodate George Fischer

European design.

Clause 6.3.2.4 Torques increased to accommodate George Fischer

European design.

Clause 6.3.2.5 Accommodation of alternate ‘side seal Radius Systems

design’.

Clause 6.4.2 Addition to accommodate European design George Fischer

- Alternatively temporary or permanent
under-clamps may also used.
Deletion of text: For outlet sizes greater
than 63 mm, and for all class C branch
saddles. Aim to accommodate European
variable design.

Clause 7.2 Introduction of ISO 11357 as an alternate George Fischer

thermal stability test method.
Test method is considered equivalent.

Clause 8.1.3 Clause changed to accommodate EN1555-3 GL NOBLE DENTON

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terminal designs.

Clause 8.3 The jointing time (fusion plus cool time) for Plasson , George
sizes >180mm up to a maximum of Fischer
355mm increased to 90 minutes to
accommodate variable European design –
this does affect performance other than
fusion productivity
Statement which allows lower reference
temperature for joint cooling time and
longer fusion times. Lower temperature
beneficial in terms of giving increased joint
strength. Possible impact on productivity. George Fischer
This change is removing prescriptive
requirements to align with EN1555-3.
George Fischer
Accommodation of European design
variability by removal of statement: Fittings
up to and including 400mm nominal size
incorporating two electrofusion sockets
shall have both sockets fused in a single
operation.
Clause 10.7.1 & Annex The 20oC 5000 hour test duration for UK GL NOBLE DENTON
A, Table A2 and European manufactured fittings with
proven history of supply to the gas industry PLASSON
has been reduced to 100 hours. Note the FUSION
stress levels have been increased so that
the test is aligned with EN1555-3. GEORGE FISCHER
Steve Beech - Steve
The test is considered by Fusion, Plasson, is involved in Sub-
George Fisher and Steve Beech to be no Committees and all
more than a structural integrity test Working Groups for
which also assesses ductility across the polyolefin pressure
fusion zone. It gives a preliminary pipes and fittings in
assessment of structural strength which both ISO/TC 138 and
can actually be achieved within 100 hours. CEN/TC 155. He is
The material performance in terms of Convenor of several
ductility is considered to be tested more at Working Groups and
80oC at 1000 hours. notably TC
GL Noble Denton is in agreement with 155/WG12 which has
these parties that at a temperature of 20oC been revising the
the long term slow crack failure European system
mechanisms are not likely to manifest standards for PE gas
within 5000 hours at such high stress levels and water systems.
unless there is fundamental problem with
the polymer. Due to the time, temperature
dependency of plastics it is considered that
the 80oC tests at lower stress will give a
more accurate prediction of long term
performance and would identify issues with
material quality.
The 5000 hour test has been retained for
non European grades with very little history
of use in Europe as a precautionary
measure. We would like to assess
performance at high stress in order to
assess material behaviour.

Clause 10.7 & Table A2 New Clause providing performance testing

& Annex K, L guidance for couplers which do not comply
with Part b of Clause 6.2.2 Wall thicknesses
of electrofusion socket fittings.
Test requirement aligned with EN1555-3.

Clause 10.9 & Annex A Introduction of ISO 11357 as an alternate George Fischer
Tables A3 part 1 and thermal stability test method.
part 2, Annex J Change
No. 3 Table Test method is considered equivalent.

Clause 10.10.1 New Statement: At the discretion of the GL NOBLE DENTON

gas transporter BS EN 12117 may be

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 GIS/PL2-4:2014

considered for calculation of pressure drop

as an alternate to GIS PL2-4 Annex I.
Equivalency in respect of calculated values
shall be demonstrated.
Alignment with EN1555-3.

Clause 11.2 New statement: Sample test assemblies GL NOBLE DENTON

shall take account of manufacturing and
assembly tolerances based on process
control data of upper and lower variance
ranges.
The fitting manufacture must ensure that
they have strict control of process
parameters and that all possible
combinations of product i.e. upper and
lower tolerance range are compliant.

Clause 11.3 New Statement; The fitting manufacturer GL NOBLE DENTON

shall provide installation instructions and
recommend / provide appropriate tooling if
different from that prescribed in GIS/PL2-5.
This will remove prescriptive tooling
requirements.

Clause 12 An addition to Note: Requirements d) and GL NOBLE DENTON

e) may be repeated on a label firmly fixed
to the fitting packaging or on an
individual bag.

Alignment with marking practices in Europe

Clause 13 More comprehensive guidance in respect to GL NOBLE DENTON

the requirements of packaging in order to
ensure protection of fittings when released
into the field. This is an issue which needs
addressing. Field experience shows that
polyethylene packaging is not tolerant and
is susceptible to damage.

Annex A, Table 1 Additional note e) The values indicated are GPS

applicable to mains sizes up to and
including 250mm. Alternative values may
be proposed by the contractor, for larger
size saddles, and shall be subject to
agreement with the gas transporter”.
Annex A, Table 2 ISO1133 quoted as a standard for MFR Radius Systems
testing in place of GIS/PL2-1

Annex A4 Amended to 170 hours machine time only. Radius Systems

A production batch should not exceed

170hrs machine time or 10,000
components, whichever is the lesser" is a
dated statement. Whilst Radius support the
170hrs, the advent of robotic technology
managing moulding machines, means that
10,000 components can be achieved within
3 days, if you are manufacturing fittings
such as 20mm Couplers. The figure of
10,000 components needs re-visiting
(30,000pcs) would be better, or deleting
completely so that the focus is firmly on
170hrs.

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GIS/PL2-4:2014

Bibliography
Formal standards
BS EN ISO 13686, Natural gas — Quality designation.
ISO 3, Preferred numbers – Series of referred numbers.
ISO 497, Guide to the choice of series of preferred numbers and of series containing more
rounded values of preferred numbers.
National Grid standards
T/SP/DIS 5.11.1, Close fit PE lining of pipe.

60