Contents Petroplas Installation Manual For Underground ... · THE COMPLETE PIPING SYSTEM Petroplas Installation Manual For Underground Applications ... Design requirements Competency

PETROPLASTHE COMPLETE PIPING SYSTEM

Petroplas Installation Manual For

Underground Applications

US English Version_Imperial

PetroplasUGInstPDF_v4 00US

© 2013 Marley Pipe Systems (Pty) Ltd

ContentsScope 2

Terms & Abbreviations 2

Referenced Documents and Standards 2

The System 3

Introduction 3

Petroplas Pipe 6Petroplas Co-axial Pipe 6Petroplas Vent & Vapor Recovery Pipe 7Petroplas Pipe Markings 7

Petroplas Fittings 8FRIATEC® Electro-fusion 8FRIALEN® Safety Fitting 9Auxiliary Components 10Petroplas Fittings Markings 10

Design Requirements 11

Competency & Training 11

Training 11

Storage and Materials Handling 12

Storage - Pipe 12

Storage - Fittings 12

Materials Handling - Pipe 12

Materials Handling - The Unwinding of Pipe

Coils 13

Materials Handling - Fittings 14

Installation 14

Pipe Trenches 14

Pipe Laying 15

Backfill and Bedding 16

Jointing Method 16General Requirements 16Fusion Procedure Summary 17Detailed Fusion Procedure 17

Using the FRIATOOL® Scraper Tools 24

FWSGE 63 for ⅝ to 2 inch (20 to 63mm)

Applications 24

FWSGE 225 for 3 to 9 inch (75 to 225mm)

Applications 25

Pressure Testing 26

Hydrostatic Method 26

Pneumatic Method 26

Record Keeping 27

Special Tools & Equipment 28

Appendix 1: Referenced Documents & Pipe/fitting

Letter Designations 30

Appendix 2: Marley Pipe Systems Contact

Information 31

Appendix 3: Nominated Petroplas Agents Contact

Information 31

Sub-Saharan Africa 31

International 31

Appendix 4: Approved FRIALEN® Fittings 32

Appendix 5: Guidelines for Holding Device 33

Appendix 6: Cooling Times 34

Appendix 7: Petroplas Accreditation 34

Appendix 8: Legal Disclaimer 34

PETROPLASTHE COMPLETE PIPING SYSTEM 2

US English Version_ImperialPetroplasUGInstPDF_v4 00US

ScopeThese instructions apply for the installation of non metallic underground pipelines for the transfer of fuel, where the approved electro-fusion pipe connectors, auxiliary components and Petroplas pipe must correspond to the maximum allowable working pressure applicable.

New installations or repairs to existing installations may only be undertaken by competent personnel in compliance with the latest version of these installation instructions. Failing to comply with this requirement would void the Petroplas Warranty and could result in damage and or leakage to the system or personal injury. Contractors are advised to obtain the latest version of this manual by contacting Marley Pipe Systems or any one of the Nominated Petroplas Agents. Please refer to Appendix 2 and 3 for the relevant contact information.

The following key elements are addressed in this instruction:

Introduction to the systemDesign requirementsCompetency and trainingStorage and materials handlingInstallationTestingRecord keepingSpecial tools and equipment

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Terms & Abbreviations

Accredited Petroplas Installation Personnel; a person having successfully completed the Petroplas Installation Training, including the required remedial, product revision and periodic training as may be required.EF; Electro-fusionHDPE; high density polyethyleneIP; Institute of PetroleumOpaque; a term describing a substance that is impervious to light.PEI; Petroleum Equipment InstituteSIPC; Shell International Procurement Certificate

Referenced Documents and StandardsThe standards and documents listed in Appendix 1, contain provisions and or specifications which through reference in this text, constitute provisions and or specifications of this instruction. All standards and documents are subject to revisions and since any reference thereto is deemed to be a reference to the latest edition of that standard or document, parties to agreements based on this instruction are advised to obtain the latest editions of the said standards and documents.

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The SystemIntroductionPetroplas is a high performance polyethylene pipe system designed specifically for the transfer of fuels in dispensing facilities and commercial installations. The system has been perfected to satisfy growing environmental concerns and in particular, to protect ground water against contamination often associated with corroded and leaking steel pipe systems. Petroplas offers:

A 30 year design lifeResistance to permeation on all susceptible surfaces (inner and outer protection)Dimensional stabilityResistance to corrosionSmooth boreEase of installationLeak-tight fusion welded joints with transition to metal systems15 year warranty

The system may be implemented as an integral primary/secondary containment pipe system and through a series of sumps, nitrile rubber or electro-fused entry boots and electro-fused Petroplas pipe sections, designers are able to maintain accessibility to primary carrier joints throughout installations for service and/or inspection purposes. See Fig. 1 to 4 on pages 4 and 5.

Petroplas pipe sections are joined using the FRIATEC® electro-fusion weld process ensuring safe, efficient processing and maximum joint integrity with error reporting.

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The FRIATEC® system offers a complete range of FRIALEN® Safety Fittings with transition to metal systems, dedicated FRIAMAT® ancillary fusion-weld equipment and FRIATOOL® technical equipment for the efficient preparation of all joints to be electro-fused.

For the upgrading of existing facilities and all new installations, Petroplas offers ease of handling and installation. The system is flexible and site restrictions are easily overcome without excessive joining. Petroplas pipe is supplied in coils or sticks; where coils have the added advantage of allowing the placement of pipelines with minimal joints.



Fig. 1: A typical forecourt installation1-Filler sumps, 2-Petroplas Co-axial Filler lines, 3-Tank sumps, 4-Tanks, 5-Petroplas Co-axial

dispenser lines, 6 and 7-Dispenser sumps, 8-Petroplas vent lines, 9-Vent stackImportant notice: Items 1, 3, 4, 6, 7 and 9 have been included for illustrative purposes only and are beyond the scope of this installation manual (please also see the section entitled ‘Auxillary

Components’ on page 10).

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Fig. 2: Petroplas Co-axial Pipe,with the ribbed secondary containment

pipe cut away to reveal the primary carrier pipe. The interstice (cavity) formed between the primary pipe’s outer surface and the secondary pipe’s inner surface

is suitable for the off-take of product into containment sumps in the event of a

primary line leakage.



Fig. 3: Sectional view of the dispenser sump (6) in Fig. 1 (page 4), with typical pipeline connection detail.1-Petroplas primary carrier pipe, 2-Petroplas secondary containment pipe cut away to reveal the interstitial space, 3-

Flanged nitrile rubber entry boot (or electro-fused entry boot), 4-Test boot in test position, 5-Test boot in open position, 6-FRIALEN® Tee (electro-fused to primary carrier pipe), 7-FRIALEN® Transition to metal systems (electro-fused to

tee) leading up to the connection of dispenser equipment, 8-Under dispenser sumpImportant notice: Items 3, 4, 5 and 8 have been included for illustrative purposes only and are beyond the scope of

this installation manual (please also see the section entitled ‘Auxillary Components’ on page 10).

Fig. 4: Sectional view of the terminating dispenser sump (7) in Fig. 1 (page 4) with typical pipeline

connection detail.1-Petroplas primary carrier pipe,

2-Petroplas secondary containment pipe cut away to reveal the interstitial

space, 3-Flanged nitrile rubber entry boot (or electro-fused entry

boot), 4-Test boot in open position, 5-FRIALEN® Elbow (electro-fused to pipe), 6-FRIALEN® Transition to metal (electro-fused to elbow) leading up to the connection of dispenser equipment, 7-Under

dispenser sumpImportant notice: Items 3, 4 and 7 have been included for illustrative purposes only and are beyond the scope of this installation manual

(please also see the section entitled ‘Auxillary Components’ on page 10).

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Petroplas PipePetroplas pipe is manufactured by Marley Pipe Systems, an ISO 9001 accredited manufacturer, from a high density polyethylene (HDPE). The pipe may be classified as a semi-rigid polymeric system and has a protective layer integrated with the polymer matrix that resists permeation. The protective layer is formed by exposing the pipe surfaces to a fluorination process, where the surface is modified in a chemical reaction.

The layer offers protection against hydrocarbons, hydrocarbon vapors and

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various organic solvents.The protective layer is integrated with the polymer matrix.Being a permanent chemical reaction, the protective layer is evenly distributed and may be easily measured on all batches.Petroplas is unlike co-extruded pipe systems where the pipe substrate and protective barrier are of different materials. Delamination is therefore of no concern and the pipe may be easily recycled.

The system has been rated as fit for purpose in high throughput industrial applications with no layer wear off and negligible hydrocarbon permeation.

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Petroplas Co-axial PipePetroplas Co-axial pipe offers an integral primary/secondary containment solution conforming to progressive mandatory requirements. The system consists of a pressure rated primary pipe contained within a secondary containment pipe sleeve. Both primary and secondary pipes are fluorinated to the standard Petroplas specification.(see Table 1 below for dimensions and pack information)

Table 1: Petroplas Co-axial Pipe

Product Code Size (Nominal Bore, Inches)

Length (Feet) Description Pack * Color Code

9028/20/100MT-US ¾”- 1” 328’ ¾” (20mm) Double wall pipe Coil Y

9050/40/50MT-US 1¼” - 1½” 164’ 1¼” (40mm) Double wall pipe Coil Y with R

9063/50/8MT-US 1½” - 2” 26’ 1½” (50mm) Double wall pipe Stick Y with B

9063/50/50MT-US 1½” - 2” 164’ 1½” (50mm) Double wall pipe Coil Y with B

9075/63/8MT-US 2” - 2½” 26’ 2” (63mm) Double wall pipe Stick Y with R

9075/63/50MT-US 2” - 2½” 164’ 2” (63mm) Double wall pipe Coil Y with R

90110/90/6MT-US 3” - 4” 20’ 3” (90mm) Double wall pipe Stick Y with B

90110/90/50MT-US 3” - 4” 164’ 3” (90mm) Double wall pipe Coil Y with B

110125/90/6MT-US 4” - 5” 20’ 4” (110mm) Double wall pipe Stick Y

*Notes: Y=Yellow, R=Red stripe, B=Blue stripe



Petroplas Vent & Vapor Recovery PipePetroplas Vent and Vapor Recovery Pipe is a single wall pressure rated, natural HDPE colored pipe suitable for normal vent and vapor recovery applications. The pipe is fluorinated off-line to the standard Petroplas specification.

Table 2: Petroplas Vent & Vapor Recovery Pipe

Product Code Size (Nominal Bore, Inches) Length (Feet) Description Pack

PVENT5050-085-US 1½” 164’ 1½” (50mm) Dia. single wall pipe Coil

PVENT5050-6-US 1½” 20’ 1½” (50mm) Dia. single wall pipe Stick

PVENT63050-085-US 2” 164’ 2” (63mm) Dia. single wall pipe Coil

PVENT63050-6-US 2” 20’ 2” (63mm) Dia. single wall pipe Stick

PVENT90050-050-US 3” 164’ 3” (90mm) Dia. single wall pipe Coil



Petroplas Pipe MarkingsPersons responsible for the supervision of the construction work at installations must ensure that the correct pipe is being installed as specified on the site-plans and working drawings. The Petroplas pipe system may only be installed by competent personnel.

Petroplas Co-axial pipe is marked on both the primary pipe and secondary pipe sleeve with identical markings. Petroplas Co-axial pipe is an integral primary/secondary containment solution where the secondary pipe sleeve may not be separated from the primary pipe for independent use.

UGN PS, NV AND VR PIPE FOR MV, HB, CT AND A&M FUELS

Petroplas Vent & Vapor Recovery Pipe

UGN NV AND VR PIPE FOR MV, HB, CT AND A&M FUELS

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Additional Information markings on all of the Petroplas pipe variants include:

Manufacturer: MARLEYPipe trade name: PETROPLAS SF2PSDR StagePressure rating in imperial and metric (for primary and secondary pipe where Petroplas Co-axial pipe is applicable)Imperial and metric pipe dimensionsManufacturer batch number

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All Round FluorinationPetroplas pipe is fluorinated using the off-line procedure on all exposed pipe surfaces. The resultant barrier layer offers protection on three surface areas.

Primary carrier line.Dual containment pipelines are protected against interstitial deterioration in the event of a primary line leakage (outer surface of the primary carrier line and the inner surface of the secondary containment line).Deterioration of the outer pipe surface as a result of site spillage or contamination is not possible

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Petroplas FittingsFRIATEC® Electro-fusionFRIALEN® Safety Fittings (electro-fusion fittings) are utilized throughout the Petroplas System in order to join the various components and pipe sections. Deep sockets and safe low voltage operation (48V) applied through dedicated FRIAMAT® ancillary equipment ensures maximum joint integrity. Fusion indicators visually confirm joint melt pressure while absolute security of the weld is ensured using the fittings bar code feature in conjunction with the fully automatic FRIAMAT® Control Box Unit.

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Fusion indicators

Insertion depth tab

Exposed heating coils

Chamfered surface for easy pipe

entry

Connectors

Fig. 6 Cut-away view of a FRIALEN® Coupler

Fig. 5 All Round Fluorination, cross sectional view of Petroplas

Co-axial pipe

▌Cooling zones▌Fusion zones



Spigot flanges and NPT/BSP threaded transition fittings enable the Petroplas pipe to be directly connected to metal equipment. These fittings allow for easy dismantling for inspection access.

FRIALEN® Safety Fittings can be fused to pipes of SDR stages 17.6 to 7.4 and can be worked with at ambient temperatures between -4˚F and 122˚F (–20˚C and 50˚C).

Persons responsible for the supervision of the construction work at installations must ensure that only the approved FRIALEN® Safety Fittings, as specified on the site-plans and working drawings, are being used. Appendix 4 on page 32 lists all FRIALEN® Safety Fittings approved for use FRIALEN® Safety Fittings may be easily identified by molded and printed markings as described in the following subsection entitled “FRIALEN® Safety Fitting”.

FRIALEN® Safety FittingFRIALEN® Safety Fittings are easily identified by the following molded markings:

FRIALEN® logo with the words “Safety Fitting” and the metric fitting diameter .Fitting materialSDR stage; the pressure loading capacity of FRIALEN® Safety Fittings are printed in SDR stages, taking into account the new design factor where C = 1.25 (calculation coefficient for components made of PE).

SDR (Standard Dimension Ratio) = the ratio of pipe outside diameter / pipe wall thickness.

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Fig 7: A selection of FRIALEN® Safety fittings

Fig 8: FRIALEN® Safety Ftting identification by molded markings



The unique barcode label on all FRIALEN® Safety Fittings has the following information for identification and processing purposes:

Fitting information barcode; scanned into fusion unit before welding and supplier’s fitting type, welding time and resistance.Fitting type and size.Pipe SDR range where the fitting is safe to use.The cooling times given in the bar code, and identified by the additional letters “C.T.”, are the times in minutes during which the fused joint should not be moved. Cooling times required before pressurization can be found in Appendix 6 on page 34.Fitting traceability barcode; when using the FRIAMAT® Prime or Memo fusion units, components can be automatically traced back to source via a special barcode containing specific fittings data such as manufacturer dimension, raw material and batch. The tracing data can be electronically archived together with the fusion processing data.Emergency barcode information for manual input.

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Auxiliary ComponentsAll pipeline components, other than the Petroplas pipe and the listed FRIALEN® Safety Fittings (Appendix 4), as may be required in an installation, are to be approved as fit for purpose by the relevant manufacturer. Installation personnel are required to be trained and competent with the use of such components and must follow the relevant manufacturer’s installation instructions.

Petroplas Fittings MarkingsPersons responsible for the supervision of the construction work at installations must ensure that the correct fittings are being used as specified on the site-plans and working drawings. The Petroplas pipe system may only be installed by competent personnel.

All FRIALEN® Safety Fittings will carry the following markings on the packaging. The letter designations are listed on page 30 in Appendix 1, Table 4. UGN FITTING FOR MV, HB, CT, AND A&M

FUELS.The approved FRIALEN® Safety Fittings have their own unique barcode label which has been accepted for identification purposes.

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Fig 9: FRIALEN® Safety Fitting barcode

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Design RequirementsWhen selecting the Petroplas System for an installation, designers must refer to the Petroplas Pipe & Component Specifications in order to satisfy themselves that the pipe system meets or exceeds the minimum design requirements.Designers must take into consideration the criteria used to specify the minimum performance required of the pipe system on installation. Where necessary, the criteria may be redefined in order to meet a specific design requirement, provided the manufacturer is consulted in this process in order to meet the non-standard requirement.

Competency & TrainingIt is imperative that personnel responsible for the storage, handling and installation of the Petroplas System, or components thereof, be fully qualified and competent therein. To satisfy this requirement, the specified Petroplas Installation Training must be duly completed by such personnel before any work on new or existing installations may be commenced. Failure to comply with this requirement will void the Petroplas Manufacturer’s Warranty on the applicable installation and could result in damage or leakage of the system.

TrainingPetroplas Installation Training should be arranged through the nominated Petroplas Agents (Appendix 3).

Numbered and dated competency certificates are issued by the Manufacturer or nominated Petroplas Agents to persons having successfully completed the Petroplas Installation Training program. Consequently

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such persons will be referred to as Accredited Petroplas Installation Personnel.The training program includes;

Electro-fusion machine certificationTheory with a written examination.Practical; minimum of one supervised installation.

Certificate holders may from time to time be required to successfully complete product revision or remedial training, as determined by the manufacturer or nominated Petroplas Agents, in order to maintain Petroplas competency certification.Currently contractors are required to be retrained every 18 to 24 months.It is important to note that a competency certificate may be revoked at the sole discretion of the Manufacturer or nominated Petroplas Agent, should the certificate holder be found to be acting in gross negligence in so far as the requirements of this instruction or the aforementioned training.

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Storage and Materials HandlingThe Petroplas product range is resilient, lightweight and easy to handle, however care should be taken so as to avoid personal injury or product damage prior to installation. Installers are also required to familiarize themselves with the product, safety and chemical data sheets for any cleaning solvents used.

Storage - PipeKeep protective packaging intact until the Petroplas pipe is ready for use.Petroplas pipe should be stored away from direct sunlight. For an extended storage period (more than 3 months), Petroplas pipe should be completely covered with an opaque UV resistant material.Keep Petroplas pipe away from excessive heat.The storage area must be flat and level, with no sharp objects or projections and able to support the complete plan area and weight of the pipe being stored.Pipe sticks should be stored in a bundled beehive configuration not exceeding 3ft (915mm) in height. See dimension A in Fig. 10.Pipe sticks should be supported along the pipe length at spans not exceeding 3.28ft (1m). See dimension B in Fig. 10.Stacked coils may not exceed a height of 6ft (1.830m). See dimension A in Fig. 11.

Storage - FittingsFittings are to be stored in cool dry conditions under cover.Fittings should be stored inside their individual plastic bags and boxes.Keep the protective packaging intact until fittings are ready for use.

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Materials Handling - PipePipes should be transported by a suitable vehicle, having a flat and level load bed with no sharp objects or projections and able to support the complete plan area and weight of the pipe being transported.During transport, pipe sticks should be supported along the pipe length at spans not exceeding 3.28ft (1m).Coils may be transported on edge provided,

The coils are secured against a support suitably protected so as to prevent chaffing of the pipe surface.The coils remain in this position for only a limited period of time during transport.

During transport, all loads should be securely anchored with suitable ratchet webbing loadstraps so as to prevent

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Fig. 10: Storage of pipe sticks

Fig. 11: Storage of pipe coils

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movement and chaffing of the pipe.The loading and unloading of pipe should be under trained and experienced supervision.Wide band slings of a non-metallic material should be used when lifting pipe bundles by crane. Do not use hooks, chains or hawsers.Pipe lengths of 20 and 26 foot (6 and 8m) and coils may be loaded or off loaded using a forklift, provided the fork edges are suitably covered so as to prevent any damage to the pipe.

Fork edges may be protected using lengths of HDPE pipe which have been slit open along the length, enabling a single pipe section to be pushed over the entire fork length. The slit along the pipe should be positioned so as to face down.

Lifting points along pipe lengths or pipe bundles are to be evenly spaced.The dragging of pipe along the ground should be avoided.Scratches or striations deeper than 10% of the pipe wall thickness would void the pressure rating of the pipe and the use of such damaged pipe is not permitted.The use of a pipe section that has been kinked is not permitted except where an electro-fused reinforcing coupler has been used to repair the kink.

Materials Handling - The

Unwinding of Pipe CoilsIn order to avoid accidental injury when unwinding pipes from drums or coils, it is essential to ensure that the pipe end does not spring outwards when loosening the fastening, as considerable forces are released, particularly from larger diameter pipes.

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Pipes with a diameter (nominal bore) up to 3 inches (90mm) can be unwound from the coil, where the coil is held in an upright position whilst securing the outside pipe end on the ground and releasing coil restraints one at a time. Petroplas pipe coils have multiple fasteners that should only be loosened as pipe is unwound from the coil. See Fig. 12.

For larger diameter pipe, the use of an unwinding mechanism is recommended. The coil can be laid flat on a rotating wooden or steel cross and be unwound from the outside end. Coil fasteners should only be loosened as pipe is unwound from the coil. See Fig 13.

Pipes must be unwound in such a way so as to avoid any buckling. Spiral unwinding must be avoided as this will cause the pipe to buckle.

Fig. 12: Unwinding of pipe coils

Secure outside

pipe endUncoil direction

Fig. 13: Unwinding mechanism



The flexibility of HDPE pipe is subject to the ambient temperature. For cold conditions (up to -40˚F (-40˚C)), a Salamander Indirect oil fired heater may be connected to a specially fabricated box or trailer able to contain the pipe. See Fig. 14. The pipe may be heated until more flexible, taking care not to exceed the maximum temperature of 140˚F (60˚C). Under no circumstances may exhaust gas emissions be used to heat the pipe.

Temperature changes cause alterations in pipe length and this must be taken into account when cutting and installing pipelines. This

aspect is addressed in the following section entitled “Installation”, within the “Pipe Laying” subsection.

Materials Handling - FittingsFittings should not be thrown.Under no circumstances should the electro-fusion surface be touched.Fittings are to remain in their original packaging until ready for use.Electro-fusion fittings should have their bar code on them.

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InstallationThe Petroplas System must be installed in accordance with the latest version of these instructions as published by Marley Pipe Systems, the NFPA 30A standard, prevailing government regulations or codes and customer specifications. The manufacturer should be consulted where any standard, specification or regulatory code is in conflict with the Petroplas installation instructions.

All Petroplas pipelines are either single lengths of pipe or formed from short lengths of pipe electro-fused together to form a single homogenous pipeline. The following subsections will describe in detail trench requirements, the laying of pipe, the joiningprocess and backfill.

Pipe TrenchesPipe trenches must enable installation of pipelines at a depth sufficient to prevent damage imposed by earth and/or traffic loads.

The minimum cover depth for normal road traffic loads is 1ft (300mm) above the crest of the largest diameter pipe. See dimension ‘A’ in Fig. 15 on page 15.Excavation of all trenches must be at least 6” (150mm) deeper than the required depth. The trench is then brought back to the correct depth by placing a number 10 to 5 sieve size (ASTM E-11), stone free aggregate of either river sand or pea shingle. See dimension ‘B’ in Fig. 15 on page 15.The trench bottom should be evenly finished so as to provide consistent support throughout the entire pipeline.

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Fig. 14: Plan view of coil heating box

Outlet for

used hot air

Inlet for hot air

Inlet is shielded so as to prevent direct heating of coil(s)



Where two or more pipelines are laid along the same trench, the distance separating the pipelines (dimension ‘C’ in Fig. 15) must be equal to the largest pipe diameter (dimension ‘D’ in Fig. 15) being used in the trench. Short pieces of pipe from the larger diameter pipe may be cut for use as temporary spacers between adjacent pipe sections.Referring to Fig. 15, minimum trench widths may be calculated as follows:

TW=AP+2(CL) where:TW= Minimum trench width (dimension E).AP=Aggregate dimension of all the pipes laid in the trench, including the minimum pipe separation dimensions (dimension ‘F’).CL=The clearance required on each side of the pipeline (dimensions ‘G’), determined by applying a factor of 2 to the largest pipe diameter being used in the trench (dimension ‘D’).

Petroplas pipe runs should be laid in a pattern incorporating directional changes in order to compensate for pipeline movement within the prescribed granular bed.

Referring to Fig. 15, trenches should be widened in areas having to accommodate directional changes on the outside of the radius or bend in order to meet this requirement (dimension ‘G’). A factor of 4 (instead of 2) may be applied to the largest diameter pipe being used in the trench (dimension ‘D’) to meet this additional requirement. Pipe lines should be laid accordingly.

Pipelines must be laid with a continuous fall back to the nearest drainage point, with a

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minimum gradient not less than 1 in 200 but preferably 1 in 100. Changes in gradient are permitted but pipeline sagging is not acceptable.Changes in geological structure resulting in differential load bearing capacities of the trench base must be compensated for by suitable measures by referring to the design engineer in order to prevent super imposed stresses along the pipeline.

Pipe LayingThe laying of pipe from a coil is best done during the warmest part of the day as this will facilitate the unwinding process. Care should however, be taken when cutting pipe, as shrinkage could take place when the pipe cools down.Designers and contractors should be aware of the differential rates of expansion and contraction between primary carrier and secondary containment sleeves where Petroplas Co-axial pipe is being placed.The primary carrier line should be free to move within the secondary containment sleeve and be terminated with flexible hosing on either end.Pipe bends should be at a radius equal to or

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Fig. 15: Trench dimensions and pipe separation

A

C

B

DC

E

F

G

H

G



greater than 25 times the pipe diameter.

Backfill and BeddingAll pipelines must be installed with adequate protection against mechanical damage, where the protection is to remain effective throughout the operational lifetime of the installation. The prescribed bedding and backfill will ensure that pipelines remain adequately protected.

High water tables may require the placement of a geotextile membrane to prevent migration of the granular material in trenches.When pipes are to be installed in steep areas, appropriate precautionary measures should be taken so as to avoid the pipe’s embedding being washed away.All temporary levelling supports and spacers must be removed prior to the commencement of backfilling.Petroplas pipe is laid on a 6 inch (150mm) bed of a number 10 to 5 sieve size (ASTM E-11), stone free aggregate of either river sand or pea shingle.Thereafter the pipe is finally covered with another 6 inch (150mm) of the same granular material. See dimension ‘H’ in Fig. 15 on page 15.Where the temperature of the pipe line is expected to exceed that of the trench due to direct sunlight, the pipeline should be left to stand covered by the river sand or pea shingle prior to final filling and consolidation, for a time sufficient to allow the pipe to cool down.Final filling must be carried out according to PEI RP100 (Installation of Underground Liquid Storage Systems). Mechanical devices may be used, provided that the permissible filling height is observed. Final compaction on top of trench should be equivalent to ASTM D-1557 95%

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Jointing Method Petroplas pipe sections and HDPE spigot ends are joined using the FRIATEC® Electro-fusion weld process, ensuring safe efficient processing and maximum joint integrity with error reporting. The FRIATEC® system offers a complete range of FRIALEN® Safety Fittings with transition to metal systems, dedicated FRIAMAT® ancillary fusion-weld equipment and FRIATOOL® technical equipment for the efficient preparation of all joints to be electro-fused.

For the purpose of this instruction, the correct assembly of couplers, elbows, reducers, tees and transition fittings from the FRIALEN® Safety Fittings range has been detailed. Electro-fusion for large bore applications and other specialist fittings available from the FRIALEN® Safety Fittings range is beyond the scope of this instruction manual. For such applications, the Manufacturer should be consulted as to the suitability of the specific fitting and for the appropriate training.

General RequirementsThe integrity of any single joint affects the integrity of the entire system. It is essential that all of the required joint preparations and instructions are followed meticulously.

Use of the dedicated FWA315, FRIAMAT® Prime or FRIAMAT® Memo fusion units is compulsory.

Installation personnel are required to be competent with the use of the fusion unit selected for use.The particular fusion unit’s operating instructions are to be observed at all times.When using the FRIAMAT® PRIME or MEMO fusion units with traceability function, EF fittings can be traced back to source via a special barcode. This tracing data may be

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Detailed Fusion ProcedureWARNING; the sequence of working operations described below must always be adhered to.

Select the correct FRIALEN® Safety Fitting for the application (see Appendix 4).Carefully clean the pipe or HDPE spigot ends.Cut the pipe end(s) to length. Cuts are to be executed perpendicular to the pipe axis with the aid of a suitable pipe cutter (Fig. 16). Deburr the outer and inner cut edges on the pipe or spigot ends using a hand scraper tool.

A pipe which has not been cut off square may lead to the heating coil not being fully covered by the pipe or spigot end and this can cause overheating, uncontrolled melting or spontaneous ignition.Distinctive conical oblique pipe ends or any other pipe damage must be cut off.There may not be any surface damage such as grooves or scratches within the fusion zone.

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electronically archived together with the fusion processing data.Fusion units are to be kept in good working condition and serviced.

Fusion whilst the medium is leaking out is not permitted. Under such conditions fusion may only be performed provided;

The line has been inerted with nitrogen,A FRIALEN® repair sleeve has been installed and the joint is not leaking.

Prior to fusion, pipes and fittings should have settled to a balanced temperature level between -4˚F and 122˚F (–20˚C and 50˚C).

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Fig. 16: Cut pipe ends square

Fusion Procedure SummaryAn in-depth description of the steps below has been given in the following section.

Clean pipe/spigot ends, cut pipe ends square and deburr.Mark insertion depth and fluorination removal check lines on pipe/spigot ends.Completely remove the fluorination layer, remove swarf and chamfer the pipe/spigot ends.Clean pipe/spigot ends with recommended cleaner and remark insertion depth mark.Apply rounding clamps on pipe/spigot ends.Insert pipe/spigot ends into fitting and remove rounding clamps thereafter.Stabilize the joint using a holding clamp.Connect fusion unit, weld and disconnect.Using the recommended marker, note all of the required information on the fitting or pipe.Allow the joint to cool for the recommended cooling time.Remove the holding clamp.

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Carefully remove the FRIALEN® Safety Fitting to be used from the original packaging (Fig. 17). Inspect the fitting for any visible damage and ensure that the barcode label is attached. The fitting should be kept clean, avoiding accidental contact with the fusion-weld surface.Measure off the fusion zone on the pipe and/or HDPE spigot ends, marking it with a FRIALEN® marker or any other permanent metallic silver marker for the removal of the fluorination layer (Fig. 18 and 19).

The fusion zone may be determined by measuring from the insertion depth tab (see Fig. 6 on page 8) to the fitting’s edge. An allowance of 1/5 inch (5mm) in addition to the insertion depth will ensure that the fluorination layer was correctly removed.As a check that the removal of material from the pipe/ spigot surface is unbroken and covers the full area, we recommend the marking of checking lines (Fig. 19).

Before joint assembly, the Teflon® like layer which has formed on the surface of pipes and HDPE spigot ends due to oxidation and fluorination must be completely removed using either a hand scraper tool or the appropriate FRIALEN® Scraper tool. Only material in the fusion zone needs to be removed.

All fusion area markings, including the fusion depth mark, need to be completely removed (Fig. 20 and 21, page 19).A one-off complete scraping process of the surface is sufficient, removing a minimum of 0.4 point (0.15mm) material.

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Fig. 18: Measuring the fusion zone

Fig. 19: Checking lines

Fig. 17: Remove fitting from packaging

PETROPLASTHE COMPLETE PIPING SYSTEM



Failing to completely remove the Teflon® like layer may lead to a fused joint which is not homogeneous and which may leak.The condition of the manual scraper blade and the scraper tool blade should be checked regularly and replaced if found to be worn.If during the scraping process, localized areas of the surface are not scraped, these must be redone.When using the hand scraper tool, always commence scraping from behind the fusion depth mark, ensuring that the stroke extends over the pipe or spigot end. See Fig 22. Even when localized areas of the surface are not scrapped, the correcting strokes are to be from behind the fusion depth mark, scraping towards the pipe or spigot end.The use of filling or emery cloth in order to remove the oxide layer is not acceptable, as this can lead to impurities being embedded in the surface.Warning: the removal of an excessively large amount of shaving can leave a large annular gap which cannot be closed, or completely closed, during fusion.After scraping do not touch the fusion zones again.

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Fig. 21: Chamfer pipe end

Fig. 20: Removal of oxide layer

Fig. 21: Complete removal of oxide layerfrom fusion zone

Fig. 22: Using the hand scraper



Using a hand scraper tool, chamfer the outside surface of the cut pipe or spigot end, making it easier to fit the coupler (Fig. 23).Remove all resulting swarf from all surfaces, including the inside surface.There may not be any pipe or spigot end surface damage such as grooves or scratches within the fusion zone.For quick reference, a list of suitable FRIATOOL® Scraper Tools is included in the chapter entitled “Special Tools and Equipment”.The operating instructions for the FRIATOOL® Scraper Tools FWSG 63 and FWSG 225 have also been included in the following section entitled “Using the FRIATOOL® Scraper Tools”.Protect the worked zone from dirt, soap, grease, water running back and environmental elements (e.g. from effects of moisture or the formation of frost). This may be done by placing clean plastic bags, fastened with tape or zip ties over pipe or spigot ends (Fig. 24).Worked pipe or spigot ends need to be fused within 4 hours of the scraping process.FRIALEN® Safety Fittings with integral heating coils ensure optimal heat transfer due to their exposed coils and because of this, the inside of the fitting must not be scraped.The surfaces of the pipe or spigot ends being fused and the internal fusion surfaces of the FRIALEN® Safety Fitting(s) (Fig. 25) must be absolutely clean, dry and free from grease.Immediately before assembly and after scraping, clean these surfaces using IPA (isopropyl alcohol), acetone, MEK, ether, white spirits or non colored denatured alcohol with an absorbent, lint free, non-colored paper towel (Fig. 26). Dispose the

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Fig. 25: Cleaning the fitting fusion zone

Fig. 23: Chamfer pipe/ spigot ends

Fig. 24: Protected pipe/ spigot ends after working

Fig. 26: Clean worked pipe/ spigot ends with suitable cleaner



Connect the fusion plugs to the contact sockets and power on the fusion unit (Fig. 29).Fusion parameters are contained in the fitting information barcode on the FRIALEN® Safety Fitting (see annotation 1, Fig. 9, page 10). With the FRIAMAT® Memo or Prime fusion units, the parameters are entered into the fusion unit using the barcode wand. Hold the wand at an angle and scan the barcode using an even stroke. The barcode may be scanned from any direction (Fig. 29).After entering the barcode, the fitting and pipe to be fused should be compared to the data being displayed on the fusion unit. If all of the information (fitting and pipe SDR stage) is correct, confirm the fusion unit’s prompt and proceed.The secondary barcode contains the data for component traceability. This barcode must be entered only if component traceability is to be used.Always replace the barcode wand in the pouch when scanning is complete.Fusion parameters and traceability data is coded on the barcode sticker of all FRIALEN® Safety Fittings using a 24 and 26 digit code respectively. Both codes may be entered manually into the FRIAMAT® fusion unit via the emergency programming mode in the case of a barcode failure.After scanning the fusion parameters and traceability code, the unit prompts users to confirm that the joint has been suitably prepared and stabilized. Confirming this prompt will start the fusion process.

For the sake of general safety always maintain a distance of 39 inches (1m) from the fusion point during the fusion process.Should there be an interruption, for example a power failure, fusion may be repeated after the particular

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FRIALEN® Safety Fittings are equipped with fusion indicators that increase in volume giving indication that fusion has taken place. However, the proper progress of the fusion process may only be confirmed by the fusion unit on completion.

fitting’s cooling time (CT) has elapsed.For fittings with separate windings, each end of the fitting has to be fused separately. For fittings with a continuous winding, the two ends of the fitting are fused simultaneously.The fusion unit automatically monitors the progress of the fusion process and regulates the electrical energy supplied to specified limits. The unit will beep when fusion is complete.The fusion plugs may be removed.

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Fig. 29: Connect & scan



Carefully note on the fitting or on the pipe immediately adjacent to the fitting using a FRIALEN® Marker or other permanent metallic silver marker (Fig. 29a)

Weld numberInitials of the person performing the weld.Date on which the weld was completed.The actual fusion time achieved. This time should be compared with the target fusion time on the FRIAMAT® unit.

These markings will ensure that no fusion point is overlooked.The cooling down time is the time which is needed to allow the component to cool down to a temperature which permits movement of the joint. This time is also indicated on the fitting barcode by the letters “CT”.Cooling times required before test and full pressurization can be found in Appendix 6 on page 34.A pipeline must not be put into operation until it has passed a pressure test as described in the chapter entitled “Pressure Testing”.

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Fig. 29a: Weld markings

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Using the FRIATOOL® Scraper ToolsFWSGE 63 for ⅝ to 2 inch (20

to 63mm) ApplicationsReferring to Fig. 30;Release the roller handle (1).Set the guide rollers (2) according to the pipe size being scraped by releasing the guide clamp (3) in a counter-clockwise direction. There are two positions indicated on the unit. Tighten after setting.

For pipes of diameter ⅝ to 1¼ inch (20 to 40mm)For pipes of diameter 1½ to 2 inch (50 to 63mm)

Remove the protective cap from the scraper blade.Turn the twist grip knob counter-clockwise until the scraper tool is able to fit over the pipe end. The pipe should be nested between the smooth and knurled rollers.For pipes of diameter ⅝ to 1¼ inch (20 to 40mm), place the scraper blade on the fusion depth mark as indicated on the pipe section. Scraping will be from the fusion depth mark toward the pipe end.For pipes of diameter 1½ to 2 inch (50 to 63mm), place the scraper blade on the pipe end. Scrapping will be from the pipe end towards the fusion depth mark.Tighten the twist grip knob firmly.Using the roller handle, continuously rotate the scraper tool around the pipe axis in a clockwise direction until the oxide layer is completely removed to the indicated fusion depth mark or to the pipe end.Loosen the twist grip knob (4) and remove the scraper tool from the pipe end.Remove the swarf and inspect the scraping

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result. If the marking lines are not completely removed, the scraping process should be repeated.Tighten the twist grip knob (4) until fully seated and collapse the handle (1) to the storage position by gently pulling whilst simultaneously folding.The scraper tool must be kept clean and dry and always stored in its transport case.Keep the blade covered (5) in order to prevent accidental injury.The condition of the tool blade should be checked regularly and replaced if found to be worn.

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Fig. 30: FWSGE 4 Scraper tool

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FWSGE 225 for 3 to 9 inch (75

to 225mm) ApplicationsReferring to Fig. 31;Fully open the clamping carriage by turning the twist grip knob (1) anti-clockwise.Hold the scraper tool by the roller handle (2) and point it towards the floor. Turn the tool anti-clockwise with twisting movements until it reaches the mark for the required scraping dimension.

Check every 5 to 10 turns to see if the mark has been reached.The line to the right of the nominal pipe diameter must be flush with the housing.

Remove the protective cap (3) from the scraper blade.Guide the tool over the pipe end so that the clamping carriage (4) is inside the pipe and the scraper blade is on the outside surface of the pipe. Turn the twist grip knob (1) clockwise until all four guide rollers are pressed firmly against the pipe.Continuously rotate the tool clockwise around the pipe axis, scraping up to the pipe end. Note that the tool should be pressed against the pipe end while scrapping in order to avoid tilting of the tool in an axial direction. Release the twist grip knob (1) by turning it anti-clockwise. The scraper tool may now be withdrawn from the pipe.Remove the swarf and inspect the scraping result. If the marking lines are not completely removed, the scraping process should be repeated.Replace the blade cover (3).Hold the scraper tool by the roller handle (2) and point it towards the floor. Turn the tool clockwise with twisting movements until it reaches the initial position for storage.The scraper tool must be kept clean and dry

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and always stored in its transport case.The condition of the tool blade should be checked regularly and replaced if found to be worn.

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Fig. 31: FWSGE 3 Scraper tool

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Pressure TestingPetroplas installations are to be tested in one of two ways before the trenches are closed. The consulting engineer or project manager may specify that the tests be used independently or in conjunction with each other.

For primary carrier pipes the test pressure must correspond to the pipe’s rated pressure.For secondary containment testing, the test pressure must correspond to the lesser of the pipe’s or test boot’s rated pressure.

Hydrostatic MethodThe pipeline is filled with water from the highest point of the installation.All air is removed from the system, by opening all valves until the water level reaches the top of the valve at which point the valve is shut.Once all the air has been removed from the system and the pipe is completely filled to the highest point, the pipe is connected watertight to a pressure pump using the required metal fittings.The water in the pipe is pressurized to test pressure.As water is not compressible, leaks will show up immediately if the pressure gauge does not maintain its static pressure reading. Note that due to pipe elasticity, some time must be allowed for the pressure to stabilize.The test is successful once full pressure has been attained and maintained for a period of 1 hour.The secondary containment system should be tested using the same procedure following the setup detailed below:

All test boots along the pipeline are fitted and secured over the terminated secondary containment pipe ends.

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The primary pipe clamps on the test boots are also secured.All terminated secondary containment sections are connected with jumper pipes having a higher pressure rating than the test pressure.All interstitial spaces are now interconnected for test purposes.

Pneumatic MethodEither air or nitrogen is pressurized in the line to the rated pipe pressures.Air may only be used in new installations.Nitrogen should be used as the pressurizing gas where hydrocarbons have been introduced in the pipe system, including new lines connected to existing installations.The gas in the pipe is pressurized to test pressure.Once the lines have been pressurized, a soap and water test should be performed on each fitting of the pressurized line.

A soap and water solution is mixed and applied at the pipe to fitting interface.Observe for the formation of any bubbles, in which case a leak is present.

The test is successful once full pressure has been attained and maintained for a period of at least 4 hours but preferably 24 hours.The most ideal situation would be leaving the pipeline under pressure for 24 hours where the pressure is preferably checked at the same time of day.As gas is very susceptible to temperature change, and expands and contracts proportionally, it is important to note thatthere will be a pressure variance (positive or negative) on the gauge.Small leaks are more difficult to detect using the pneumatic method.

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The secondary containment system should be tested using the same procedure with all interstitial spaces connected as described in the Hydrostatic test method.

Record KeepingContractors are required to submit via email, an electronic warranty card containing the details of completed or repaired installations. The cards, in PDF format, are available from either Marley Pipe Systems or the Nominated Petroplas Agents and should be returned to the designated email recipient no later than 30 days after an installation or repair has been completed in order to validate the warranty.

The following information will be required on the warranty cards:

Responsible contractorSite name, site number and locationDate site-work commencedDate when installation was completedAccredited Petroplas Installation Personnel

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used and the designated initials as marked on all electro-fusion welds.Petroplas pipe used in the installation with batch numbersNumber of electro-fusion welds completed on the siteSite inspectorAppointed engineer

Contractors may also be required upon request, to furnish for any installation or repair:

The original FRIAMAT® Memo slips or records where possible.The approved site plans and working drawings.The dated and signed Quality Control inspection sheet.

It is important to emphasize that the information noted on joints where electro-fusion has been completed (described on page 22 of the Fusion Procedure), form an integral part of the record keeping requirements.

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Special Tools & EquipmentDescription/ Detail Article Code

Electro-fusion UnitsFriamat Eco Prime 613092

Friamat Eco Basic 613090

Friamat 110V 613217

Scraper ToolsFWSG 63 Scraper Tool 20-63mm 613305

FWSG 225 Scraper Tool 75-225mm 613311

FWSG 20/225 * Scraper Tool 20-225 613316 *FWSG 63 and FWSG 225 supplied as a kit.



Hand ScraperFWZ Hand Scraper

Hand Scraper 613300

Blades 613270

Rounding ClampsFWXR Manual Rounding Clamps

FWXR-S1 32-63mm 613416

FWXR-S2 90-110mm 613431 Note: 90 mm Insert not shown in picture.



Appendix 1: Referenced Documents & Pipe/fitting Letter Designations

Referenced Documents/ Standards AvailabilityAbstract (where applicable)1. FRIALEN® Safety Fittings Catalogue Marley Pipe Systems and Nominated Petroplas Agents

2. FRIAMAT® Fusion Units Operating Instructions Marley Pipe Systems and Nominated Petroplas Agents

3. Petroplas Pipe & Component Specifications Marley Pipe Systems and Nominated Petroplas Agents (www.innovativepetroleum.com)

4. NFPA 30A, CODE FOR MOTOR FUEL DISPENSING FACILITIES AND REPAIR GARAGES

Available from the IHS online standards store(www.ihs.com) or NFPA home page (www.nfpa.org)

4.1 This code shall apply to motor fuel dispensing facilities; marine/motor fuel dispensing facilities; and motor fuel dispensing facilities located inside buildings, at fleet vehicle motor fuel facilities, and at farms and isolated construction sites. This code shall also apply to motor vehicle repair garages.

4.2 This code shall not apply to those motor fuel dispensing facilities where only liquefied petroleum gas (LP-Gas), liquefied natural gas (LNG) , or compressed natural gas (CNG) is dispensed as motor fuel.

4.3 The mission of the international nonprofit NFPA is to reduce the worldwide burden of fire and other hazards on the quality of life by providing and advocating consensus codes and standards, research, training, and education. NFPA membership totals more than 81,000 individuals from around the world and more than 80 national trade and professional organizations.

5. ISO 9001, Quality Management Systems Available from the IHS online standards store(www.ihs.com)

5.1 Quality Systems Model for Quality Assurance in Design, Development, Production, Installation and Servicing (ISO 9001 : 1994)

6. PEI RP100 (Installation of Underground Liquid Storage Systems) Available from the PEI online standards store(www.pei.org)

7. ASTM D-1557, Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3))

Available from the IHS online standards store(www.ihs.com)

8. ASTM E-11, Standard Specification for Wire Cloth and Sieves for Testing Purposes Available from the ANSI online standards store (www.webstore.ansi.org)

Table 3: Pipe Markings Letter Designations

PS Integral Primary/Secondary

NV Nonmetallic Normal Vent Pipe

VR Nonmetallic Vapor Recovery Pipe

MV Motor Vehicle Fuels

HB High Blend Fuels

CT Concentrated Fuels

A&M Aviation & Marine Fuels

Table 4: Fitting Markings Letter Designations

UGN Underground

MV Motor Vehicle Fuels

HB High Blend Fuels

CT Concentrated Fuels

A&M Aviation & Marine Fuels



Appendix 2: Marley Pipe Systems Contact InformationMarley Pipe Systems (Pty.) Ltd.Reg. No. 1991/003365/07Address: 3 Platinum Close, Tsessebe Crescent, Midrand, JohannesburgPostal address: P.O. Box 67, Nigel, 1490, South AfricaTel: 0861 - MARLEYFax: +27 11 314 9022www.marleypipesystems.co.za

Appendix 3: Nominated Petroplas Agents Contact InformationSub Saharan AfricaTBJ AfricaTel: +27 11 894 5219 | +27 11 894 5222Fax: +27 86 554 3453E-mail: [email protected]



paper towel after cleaning and use a new towel for each joint.When cleaning, take special care to avoid dirt from the unscraped pipe surface being introduced into the fusion zone (Fig. 27).

After cleaning with the solvent, do not touch the fusion zones again.The cleaner must have evaporated completely before fusing.

Using the FRIALEN® marker (or other permanent metallic silver marker), re-mark the line (using approximately a 120° distribution around the circumference) to show the width of the fusion zone on the pipe or spigot end, since this mark will have been removed by scraping (Fig. 28).Ensure that the fusion zones remain clean and untouched. If necessary, repeat cleaning with the solvent.Insert the pipe or spigot ends into the fitting, taking care that the contact sockets remain accessible for connection of the fusion plug.

For out of round pipe, apply the rounding clamps over the pipe or spigot ends, about ½” (13mm) deeper than the fusion depth mark.The worked pipe or spigot end must be pushed into the fitting up to the fusion zone mark. Rounding clamps may now be removed.

All joints assembled for fusion must be free of stress.

Pipe or spigot ends may not be inserted into any FRIALEN® Safety Fitting under a bending stress or under a load from their own weight.Pipe or spigot ends must be supported by a suitable holding device. Appendix 5 on page 33 details general guidelines for the holding device. After completion of the fusion process, the stress-free support of

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the joint must be maintained until the cooling time given on the bar code of the fitting has elapsed.A joint which is not free of stress or which is displaced can lead to an unacceptable flow of molten material during the fusion process and this can lead to a defective joint.Before fusing, check once again by means of the fusion line marks that the pipe or spigot ends in the FRIALEN® Safety Fitting have not moved. If necessary, correct this.

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Fig. 28: Recheck insertion depth

Fig. 27: Do not introduce dirt from the unscraped pipe end



Appendix 4: Approved FRIALEN® FittingsSize (Metric) Size (ID,

Imperial)Pack Description

Electro-fusion Couplers25mm OD Coupler ¾” Single FRIALEN® Electro-fusion Coupler

40mm OD Coupler 1¼” Single FRIALEN® Electro-fusion Coupler

50mm OD Coupler 1½” Single FRIALEN® Electro-fusion Coupler

63mm OD Coupler 2” Single FRIALEN® Electro-fusion Coupler

75mm OD Coupler 2.5” Single FRIALEN® Electro-fusion Coupler



Electro-fusion Reducing Couplers63/50 Reducing Couplers 2-1.½” Single FRIALEN® Electro-fusion Reducing Coupler

75/63 Reducing Couplers 2.½-2” Single FRIALEN® Electro-fusion Reducing Coupler

75/63 Reducing Couplers TP 2.½-2 Single FRIALEN® Electro-fusion Reducing Coupler

90/63 Reducing Couplers 3-2” Single FRIALEN® Electro-fusion Reducing Coupler






Electro-fusion Tees25mm Tee ¾” Single FRIALEN® Electro-fusion Tee

40mm Tee Single FRIALEN® Electro-fusion Tee

50mm Tee 1.½” Single FRIALEN® Electro-fusion Tee

63mm Tee 2” Single FRIALEN® Electro-fusion Tee



Electro-fusion Elbows50mm Elbows 1.½” Single FRIALEN® Electro-fusion Elbows

63mm Elbows 2” Single FRIALEN® Electro-fusion Elbows



Electro-fusion Spigot Transition Fittings50x1½” Transition Male 1½” Single FRIALEN® 50-1.1/2” Transition Male

63x2” Transition Male 2” Single FRIALEN® 63-2” Transition Male

63x1½” Transition Female 2” Single FRIALEN® 63-1.1/2” Transition Female


90x2½” Transition Female 3” Single FRIALEN® 90-2½” Transition Female


110x3” Transition Female 4” Single FRIALEN® 110-3” Transition Female

Electro-fusion Transition Fittings20x1/2” Transition Male ½” Single FRIALEN® 20-½” Transition Male

25x½” Transition Male ¾” Single FRIALEN® 25-¾” Transition Male


40x1½” Transition Female 1¼” Single FRIALEN® 40-1½” Transition male

50x1½” Transition Male 1½” Single FRIALEN® 50-1½” Transition Male

63x2” Transition Female 2” Single FRIALEN® 63-2” Transition Female



Appendix 5: Guidelines for Holding Device

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Fig. 32: Holding device1- U-channel of steel or aluminum with dimensions enabling the pipe to be nested on top,

supported by the two channel flanges, 2- Ratchet webbing loadstraps, placed as close to the fitting and channel ends as possible, 3- Petroplas pipe, 4- FRIALEN® Safety Fitting, 5- Part of U-channel milled away so as to prevent channel from interfering with the fitting. Dimension ‘A’

should be at least the fitting length plus the pipe diameter multiplied by a factor of 6.

Alternatively, a more elaborate mechanism may be constructed where multiple rounding clamps are aligned on a rail or series of parallel rails able to support the joint. Dimension

‘A’ would still however be applicable to the design, as would the positioning of the rounding clamps replacing the ratchet webbing loadstraps.

34PETROPLASTHE COMPLETE PIPING SYSTEM


Appendix 6: Cooling TimesFRIALEN®

Fitting diameter in mm

Cooling Times Test Pressure Max. PressureCooling time before joint can be moved,

also indicated on FRIALEN® fitting barcode

Cooling time in Minutes for testing at 87 psi

20 – 32 5 8 10

40 – 63 7 15 25

75 – 110 10 30 40

Appendix 7: Petroplas AccreditationApprovals as of 2007-08California State Fire Marshall; Vapor Recovery Certification

California Department of Industrial Relations; Occupational Safety & Health Approval

CARB; California Air Regulation Board

Florida Department of Environmental protection EQ 683

Institute of Petroleum Specification for Underground Pipework Systems at Petrol Filling Stations (ERA Report 1998-1010)

Institute of Petroleum Specification for Underground Pipework Systems at Petrol Filling Stations (ERA Report 2000-0115)

Michigan Department of Environmental Quality (Rule 9)

SIPC 1998

SIPC 2000

Appendix 8: Legal DisclaimerWhilst every care has been taken in the preparation of this instruction manual, neither Marley Pipe Systems nor any of their agencies can be held liable for any errors printed in this publication. It should also be noted that this manual is intended for reference only. Due consultation is required when designing for particular applications, and no liability will be entertained in this regard.

Cooling time in Minutes before full pressure