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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
Engineering Manual
Approved Quality Manager:

XXX.XXX.XXX
Date

12-09-2012
Revision

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12

Approved Engineering Manager:

SUMMARY

1. 2. 3. 4.

PURPOSE ...................................................................................................................... 2 FIELDS OF APPLICATION ............................................................................................ 2 SYSTEM DESCRIPTION AND PHYSICAL CHARACTERISTICS .................................. 2 CERTIFICATION ............................................................................................................ 3
4.1. TYPE APPROVALS .............................................................................................................. 3

5.

SYSTEM COMPONENTS ............................................................................................... 3

5.1. 5.2. PIPES .................................................................................................................................... 3 FITTINGS .............................................................................................................................. 3

6.

DESIGN INSTRUCTION ................................................................................................. 6

6.1. 6.2. 6.3. 6.4. GENERAL ............................................................................................................................. 6 COUPLINGS ......................................................................................................................... 7 PENETRATIONS................................................................................................................... 8 CLAMPING ............................................................................................................................ 9

7.

INSTRUCTIONS FOR PROCESSING AND MOUNTING DETAILS ............................. 10

7.1. 7.2. 7.3. 7.4. GENERAL ........................................................................................................................... 10 PIPE CUTTING ................................................................................................................... 10 BENDING ............................................................................................................................ 10 INSTRUCTIONS FOR PROCESSING AND MOUNTING DETAILS .................................. 11

8.

RESPONSIBILITY ........................................................................................................ 12

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
Date

12-09-2012
Revision

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Engineering Manual

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12

1. PURPOSE
Purpose of this procedure is to give information about material, design, working methods, and assembly criteria for GEORG FISCHERs SeaDrain polypropylene pipes and components.

2. FIELDS OF APPLICATION
According to the limits and the requirements of Classification Societies, the SeaDrain system is applicable for the following non-essential and non-pressure systems: Black and grey water sanitary drains (internal) Scuppers and discharges (overboard) Sounding and air vent for water tanks/dry spaces The field of application of the system for the specific ship is defined in the Piping Schedule drawing issued for construction.

3. SYSTEM DESCRIPTION AND PHYSICAL CHARACTERISTICS

Pipes and fittings are made of PPFR1, polypropylene blocks homopolymer with the addition of Calcium Carbonate and Barium Sulphate fillers, of commercial production conforming to ASTM F1412 standard specifications. Material characteristics:
Mechanical Properties Density at 23C Tensile Strength at 23C (yield) Elongation at Break Flexural Strength at 23C Izod Impact at 23C Relative Hardness at 23C ASTM Cell Classification Thermodynamics Properties Coefficient of Thermal Linear Expansion per C Maximum Operating Temperature (peak) Heat Distortion Temperature at 264 PSI Flammability & Smoke Properties Flammability Flammability: Average Time of Burning Flammability: Average Extent of Burning Smoke Density : Maximum Smoke Density : Rating sec mm % % Unit Value HB ((self-extinguishing) >5 (actual 2.7) >5 (actual 1.8) 88.7 67.8 ASTM Test UL94 ASTM D635 ASTM D635 ASTM D2843 ASTM D2843 Unit m/m/C C C Value 10.98 x 10-5 100 80 ASTM Test ASTM D694 ASTM D648 Unit gr/cm3 PSI % PSI Newton Rockwell "R" Value 26.02 4500 200 200000 53.4 80 B63153 ASTM Test ASTM D792 ASTM D638 ASTM D638 ASTM D790 ASTM D256 ASTM D785 ASTM D3350

PPFR = Polypropylene Fire Retardant

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
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4. CERTIFICATION 4.1. TYPE APPROVALS

The FUSEAL SEA DRAIN system is certified by the following Classification Societies: LR n 05/60003(E1) validity: 05.10.2014 GL n 24910-05HH validity 02.02.2010 ABS n 05-HS118095A-PDA validity 14.10.2010 DNV n K-5008 validity 30.06.2016

5. SYSTEM COMPONENTS 5.1. PIPES

NOMINAL DIAMETER mm 40 50 80 100 150 EXTERNAL DIAMETER mm 48.3 60.3 88.9 114.3 168.3 THICKNESS mm 3.7 3.9 5.5 6.0 7.1 STANDARD DRAWING

375511

5.2.

FITTINGS
Fittings used in the piping system described in the present standard are specified in the following prospect. FITTING TYPE DESCRIPTION COUPLING (SxS) REPRESENTATION

STANDARD DRAWING

375551

SLEEVE COUPLING (SxS)

375554

1/4 BEND SHORT SWEEP (91.2 ELBOW) (SxS) & (SxSPG)

375521

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
Date

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FITTING TYPE DESCRIPTION 1/4 BEND LONG SWEEP (91.2 ELBOW) (SxS) 1/6 BEND (60 ELBOW) (SxS) 1/8 BEND (45 ELBOW) (SxS) & (SxSPG) 1/12 BEND (30 ELBOW) (SxS) & (SxSPG) 1/16 BEND (22.5 ELBOW) (SxS) 1/24 BEND (15 ELBOW) (SxS) & (SxSPG) 3-Way Ell (Double 91.2 Elbow) (SxSxS) REPRESENTATION

STANDARD DRAWING

NE 375525

375527

375522

375523

375530

375524

NE 375526

45 WYE (SxSxS)

375532

45 WYE DOUBLE (SxSxSxS)

375536

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
Date

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FITTING TYPE DESCRIPTION LONG TURN TEE WYE (91.2) (SxSxS) COMBO WYE (90) (SxSxS) SANITARY TEE (91.2) (SxSxS) SANITARY TEE - DOUBLE (91.2) (SxSxSxS) REPRESENTATION STANDARD DRAWING

375528

375529

375531

375535

REDUCER & INCREASER (SPGxS) (SxS)

375542

CAP (S)

375571

MALE ADAPTER (ISO) (SxMT)

375572

FEMALE ADAPTER (ISO) (SxFT)

375573

VAN-STONE FLANGE - 150 lb (S)

375581

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
Date

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FITTING TYPE DESCRIPTION VAN-STONE FLANGE - PN16 (S) REPRESENTATION STANDARD DRAWING

375580

CLEANOUT TEE w/PLUG (SxSxFT)

375513

CLEANOUT ADPATER w/PLUG (SPGxFT)

375575

Fusion

375588

6. DESIGN INSTRUCTION 6.1. GENERAL

With reference to the adoption of this system in different internal ships areas, there are no limitations thereof. According to Res. A.753(18) for the application of plastic pipes on-board ships, the SeaDrain system can be adopted passing through watertight bulkheads or decks, with the condition that the watertight integrity and strength integrity of the bulkhead or deck shall be maintained. In case the bulkhead or deck is both watertight and fire division and destruction by fire of the plastic pipes may cause the inflow of liquids from tanks, a metallic shut-off valve operable from above the freeboard deck should be fitted at the bulkhead or deck. Application in external areas subject to continuous UV radiations shall be avoided. Further technical requirements shall be fulfilled if indicated in the following documentation, issued for construction: Piping Schedule Pipe, ducts and cable runs deck/bulkhead penetrations drawings P&I diagrams (Mechanical functional diagrams)

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
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Fluid conditions for design Properties Temperature range in operating conditions Maximum admissible temperature Maximum admissible pressure Vacuum C C barg bar Unit 0-80 100 1,76 0,2 Value Peak temperature With safety factor 4 80% absolute Notes

6.2.

COUPLINGS
6.2.1. Coupling between PPFR pipes The coupling of SeaDrain system is to be carried out by means of insertion of pipe ends into sockets and automatic electrical-fusion. For assembly instructions, see par. 7. 6.2.2. Coupling between PPFR pipes and flanged fittings Flanged couplings are used for coupling of PPFR with: pipes of different material valves or other flanged fittings PPFR pipes where needed for installation requirements.

Galvanized steel loose flange (NI506211) PPFR flange adapter (NE 375574)

flanged fitting

PN6 couplings: by means of PPFR flanged adapter and galvanized steel loose flange.

Van Stone PPFR flange (NE 375574)

flanged fitting

PN16 couplings: by means of PPFR Van Stone flange.

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
Date

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6.2.3. Coupling between PPFR pipes and threaded fittings

By means of male a) or female b) PPFR threaded section end, welded to the pipe. a) 375572 b) 375573

6.3.

PENETRATIONS
6.3.1. Fire Class and watertight divisions Penetrations through Fire Class divisions (A, B divisions) and through watertight divisions are detailed in the Pipe, ducts and cable deck/bulkhead penetrations drawing, issued for construction. 6.3.2. Decks/bulkheads without fire class or watertight prescriptions Penetrations through decks or bulkheads without fire class or water-tight division prescriptions are carried out without special measures (see figures 1 and 2). A securing PVC tape shall be arranged on the portion of pipe crossing the deck/bulkhead, in order to prevent damages to the PPFR pipe due to possible contact with the hole steel edges. A coaming shall be arranged on decks in humid areas, where water leakages might occur.
bulkhead deck coaming

PVC tape

Fig. 1

Fig. 2

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
Date

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6.4.

CLAMPING
6.4.1. Anchoring points The fixed mounting is guaranteed by the manufacturer, with a maximum spacing allowable between anchoring points as defined in the following table.
Pipe O.D. [mm] Distance between clamps for horizontal pipes Distance between clamps for vertical pipes 48.26 60.32 88.9 114.3 168.28

1300

1400

1700

1800

2200

1600

1700

2000

2200

2600

Note: It is recommended to guarantee the defined span and not to support the system in correspondence of each welded coupling or bend. 6.4.2. Clamps To support the pipes, the clamps shown are in two halves with the insertion of PVC tape to avoid damages, shall be adopted (see fig. 3).
PVC tape

Fig. 3

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7. INSTRUCTIONS FOR PROCESSING AND MOUNTING DETAILS 7.1. GENERAL

To maintain optimum long-term performance of the SeaDrain PPFR pipes the following indications have to be fulfilled.

Avoid untidy transport if the pipes have been removed from their original packaging.

To avoid deformations as time goes by, the maximum stacking height must not exceed 2 metres, whatever the diameter. Outdoor storage must be limited to a maximum of six months and the pipe should be covered with a light covered tarp to help preventing UV attack. The pipes must be laid on smooth flat surfaces.

Avoid dragging them on the ground or rubbing against the sides of the vehicle.

7.2.

PIPE CUTTING
Pipes to be cut at right angle by means of mitre saws or plastic pipe wheel cutters only, NO SHEAR cutters are allowed. An internal deburring can be carried out if necessary. Pipe ends to be then bevelled to facilitate joining.

7.3.

BENDING
To be exclusively carried out by moulded fittings (see par. 5.2).

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
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Therefore, pipes shall not be bent.

7.4.

INSTRUCTIONS FOR PROCESSING AND MOUNTING DETAILS

Jointing of +GF+ SeaDrain system are made by electro-fusion as described in the following guidelines2.

Cut pipe end square and bevel the pipe end.

Clean the surface & fusion collar (socket) with a lint-free tissue and a GF approved cleaner.

Mark the socket insert depth on the pipe end.

Insert the pipe into the fitting and push it up to the pipe stop. The pipe must be fully inserted into the fitting socket to the pipe stop. Rotate the collar in way that the socket depth mark is visible when looking at the duplex receptacle. Verify the continuity of the collar by using the continuity tester provided on the bar code set.

Tighten the clamp. Proper clamp tightness will result when the fitting cannot be rotated by hand on the pipe (minimum 2 clicks). Verify the material setup on the MSA250 Multi to read PP. Install the welding cable plug into the duplex connector on the fusion collar.

Scan the bar code for the fusion parameters, verifying that we are welding and scanning the correct pipe diameter.

For further information, refer to +GF+ SeaDrain (1 6) Installation and training manual.

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INSTRUCTIONS FOR THE DESIGN AND ASSEMBLY OF +GF+ SeaDrain SYSTEM PPFR POLYPROPYLENE PIPING
Date

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Revision

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Verify the time on the MSA250 with the bar code card. Remember, the MSA250 has an internal temperature sensor and will adjust the fusion time to compensate for higher or lower ambient temperatures. Start the fusion cycle by pressing the Green start button on the MSA250 Multi, the countdown starts and an audible alarm sounds when the welding is done.

Allow the joint to cool for at least 10 min before disturbing

8. RESPONSIBILITY
This information is provided as a reference only document and +GF+ is not responsible for any errors found or misuse of the information provided. Please review and understand all installation documents for the referenced piping system and each installer must attend a training class and successfully pass an understanding exam every 12 months. Please review and understand all technical documents available for the referenced piping system. These can be found at www.gfpiping.com