Pipe and Fitting Manufacturer’s Implementation Tracking and Traceability Heath Casteel Sr. Technical Engineer, Performance Pipe Division of Chevron Phillips Chemical company LP

Purpose of Presentation Information The Problem to be Solved Current Solutions Quality and Scanning Lessons Learned to Date Future Steps

What the codes look like ASTM F2897 Base 62 Manufacturer Code Unique Lot # to ID Resin and Mfg Information Date Material Type of product Size Skip this if someone else has covered it. Otherwise, Touch on the information that is captured, that its capture in a base 62 format including upper case, lower case and numbers….. and point to the example of what it looks like. Just set the stage.

The Problem to be Solved The problems include: A change in date isnt a simple index from 1 to 2 to 3, or Jan to Feb. Instead the date change becomes more complex – show example. Additionally it is difficult to tell the difference between lower case ‘L’ and number ‘1’, between upper case ‘O’ and zero. For us to provide reliability in our production, we can’t rely on our operators to manually load the characters. The 1D bar code is a code 128. the 2D bar code is a QR code. Additionally, we need to provide a method where the end user can also capture the number and avoid errors, so it needs to be presented as a bar code. -- see example.

The Problem to be Solved The previous method of permanent print is not suitable Explain how the indent print wheel worked --- manually loading the print slugs, and manually indexing the counter blocks. Reiterate that it isnt well suited due to the operator intervention, Unable to have the counters developed, and unable to generate a bar code.

The Problem to be Solved Ink is often used to print bar codes Ink doesn’t stick to polyethylene Surface treatment methods have limitations of effectiveness and reliability. Ink jet printing is not permanent. The technologies used to improve ink adhesion on PE films don’t transfer as well to pipe (heavier wall and shape). Flames can be used to improve adhesion, but the proximity of flame and ink thinners prevented it from being used. Plasma treaters provide a method of improving the adhesion of inks to PE pipes. There are limitations to the speed that they can handle, and they are subject to mechanical reliability issues. These are still used, but are most effective only on pipe sizes. Blown arc air plasma treater

The Problem to be Solved Laser printing/etching is used to print bar codes. Significant Expense Reliable even at high speeds Reduced Contrast Permanent

The Problem to be Solved Labels are an effective method to place bar codes on fittings Fittings can be very small Moved to a 2D/QR bar code

Current Solution Encode the 16 character from a central location Push the 16 character code to the production locations for printing Print labels for each fitting and box Laserjet print smaller diameter sizes (in process) Inkjet print and indent print larger diameter sizes Verify that the bar code is legible on line QA to verify that the 16 character code is correct.

Current Solution – Pipe BEFORE ENCODING CURRENT

Matrix of Pipe Print Methods Function Cost Reliability Safety Permanence Indent Printing Low High Medium Yes Ink Jet Printing with Surface Treatment High ≥3” No Laser Printing High, focus on ≤2”

Ink Jet Pipe With Verification Print Head Verifier Indent print is at 90 degrees to the inkjet print Surface treatment is upstream from the print head. The corona arc is inside the plastic covering of the print heat Read dot on the printline is the verifier Leave this out of the packet given to AGA

Pipe Quality Tests Weatherability (ASTM D2513-14) simulated 3 years (6600 hrs) in Florida sunlight/rain samples pulled at 3300 hrs and 6600 hrs No effect of weathering Fusion (49 CFR 192.283) Butt fusion: all joints passed Saddle and Socket fusion: all joints passed Of course also did 80C sustained pressure.

Barcode Scanning Quality Barcode Graded “A” RJS 4000 grading scanner Lower contrast between print and pipe on Laserprinting requires capable scanner cell phone not recommended however; Cortex Scan (iOS) is the best available app

Barcode Scanning Suggested Scanners Cognex Honeywell Dataman 9500 (discontinued) Dataman 8600 Honeywell Granit i1910 (corded) Granit i1911 (Bluetooth) Matt has these two scanners if you want to borrow them for show and tell.

Lessons Learned You’ll need to print extra labels due to packaging obscuring the pipe print.

Lessons Learned Where there are two print lines (inkjet and indent) Inkjet changes dates automatically Indent dates are changed manually Procedures to get the dates to agree.

Lessons Learned Assemblies have Multiple Dates Date Assembled Date Body Molded Date Cap Molded Date of Cutter Internal system tracks component information Users need track only the final date shown on label.

Lessons Learned Verification of bar code readability is critical Good Code Read The difference can be just in the distance of the print head from the pipe. Bad Code Read

Lessons Learned If the size is not in the ASTM F2897 tables, some decoders may err the whole 16characters, some decoders may bring a zero for the missing value. Example: 1” CTS x .125 wall is not in chart Asim is going to develop one (its on his list) In the meantime I have an excel spreadsheet that covers most of our products.

Lessons Learned Readers don’t necessarily decode You will want some access to a decoder Result of a Reader: PE3k8j9uXB811bT0 Result of a Reader/Decoder: Manufacturer Performance Pipe Lot Code 792379 Production Date December 31, 2015 Material PE2708 Type Tapping Tee Saddles heat Fusion by Butt fusion Outlet Size Large 4” IPS SDR 11 Size Small 1” CTS .101 Wall 0ther 0 Asim is going to develop one (its on his list) In the meantime I have an excel spreadsheet that covers most of our products.

Future Steps Continue to update with new Products. Complete installation throughout all plants and all extrusion lines. Look forward to newer technologies RFID If there is technology available for RFID or other methods, we will be active in considering.

FAQ

Thank you. Heath Casteel Sr. Technical Engineer, Performance Pipe Division of Chevron Phillips Chemical company LP