Contents

Scope 2 Petroplas Installation

Terms & Abbreviations 2
Referenced Documents and Standards 2 Manual For
The System 3
Introduction 3 Underground
Petroplas Pipe 6
Petroplas Co-axial Pipe
Petroplas Vent & Vapor Recovery Pipe
6
7
Applications
Petroplas Pipe Markings 7
Petroplas Fittings 8 US English Version_Imperial
FRIATEC® Electro-fusion 8
PetroplasUGInstPDF_v4 00US
FRIALEN® Safety Fitting 9
Auxiliary Components 10
Petroplas Fittings Markings 10

Design Requirements 11 © 2013 Marley Pipe Systems (Pty) Ltd

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
Appendix 2: Marley Pipe Systems Contact
Backfill and Bedding 16
Information 31
Jointing Method 16
General Requirements 16 Appendix 3: Nominated Petroplas Agents Contact
Fusion Procedure Summary 17 Information 31
Detailed Fusion Procedure 17
Sub-Saharan Africa 31
Using the FRIATOOL® Scraper Tools 24
International 31
FWSGE 63 for ⅝ to 2 inch (20 to 63mm)
Appendix 4: Approved FRIALEN® Fittings 32
Applications 24
Appendix 5: Guidelines for Holding Device 33
FWSGE 225 for 3 to 9 inch (75 to 225mm)
Appendix 6: Cooling Times 34
Applications 25
Appendix 7: Petroplas Accreditation 34
Pressure Testing 26
Appendix 8: Legal Disclaimer 34
Hydrostatic Method 26
Pneumatic Method 26
Record Keeping 27
Special Tools & Equipment 28
Appendix 1: Referenced Documents & Pipe/fitting
Letter Designations 30

PETROPLAS
THE COMPLETE PIPING SYSTEM
Scope
These 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 system
• Design requirements
• Competency and training
• Storage and materials handling
• Installation
• Testing
• Record keeping
• Special tools and equipment
PETROPLAS
THE COMPLETE PIPING SYSTEM
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-fusion
• HDPE; high density polyethylene
• IP; Institute of Petroleum
• Opaque; a term describing a substance that
is impervious to light.
• PEI; Petroleum Equipment Institute
• SIPC; Shell International Procurement
Certificate
Referenced
Documents and
Standards
The 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.
US English Version_Imperial
PetroplasUGInstPDF_v4 00US 2
The System
Introduction
Petroplas 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 life
• Resistance to permeation on all susceptible
surfaces (inner and outer protection)
• Dimensional stability
• Resistance to corrosion
• Smooth bore
• Ease of installation
• Leak-tight fusion welded joints with transition
to metal systems
• 15 year warranty
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.

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 COMPLETE PIPING SYSTEM
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 5 7
6

3
9
8

2
4
1

Fig. 1: A typical forecourt installation

1-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 stack
Important 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).

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.

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THE COMPLETE PIPING SYSTEM
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 7 8

1 2 4 6 5

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 sump
Important 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
7 connection detail.
1-Petroplas primary carrier pipe,
2-Petroplas secondary containment
pipe cut away to reveal the interstitial
6 space, 3-Flanged nitrile rubber
entry boot (or electro-fused entry
boot), 4-Test boot in open position,
5-FRIALEN® Elbow (electro-fused
5 to pipe), 6-FRIALEN® Transition
to metal (electro-fused to elbow)
1 2 4 leading up to the connection of
dispenser equipment, 7-Under
3 dispenser sump
Important 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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THE COMPLETE PIPING SYSTEM
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Petroplas Pipe various organic solvents.
Petroplas pipe is • The protective layer is integrated with the
manufactured by polymer matrix.
Marley Pipe Systems, • Being a permanent chemical reaction, the
an ISO 9001 accredited protective layer is evenly distributed and
manufacturer, from may be easily measured on all batches.
a high density • Petroplas is unlike co-extruded pipe
polyethylene (HDPE). systems where the pipe substrate and
The pipe may be protective barrier are of different materials.
classified as a semi- Delamination is therefore of no concern and
rigid polymeric system the pipe may be easily recycled.
and has a protective layer integrated with the
polymer matrix that resists permeation. The The system has been rated as fit for purpose
protective layer is formed by exposing the pipe in high throughput industrial applications with
surfaces to a fluorination process, where the no layer wear off and negligible hydrocarbon
surface is modified in a chemical reaction. permeation.
• The layer offers protection against
hydrocarbons, hydrocarbon vapors and

Petroplas Co-axial Pipe

Petroplas 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

Size (Nominal Length

Product Code Description Pack * Color Code
Bore, Inches) (Feet)
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

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THE COMPLETE PIPING SYSTEM
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Petroplas Vent & Vapor Recovery Pipe
Petroplas 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

Size (Nominal Bore,

Product Code Length (Feet) Description Pack
Inches)
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
PVENT90050-6-US 3” 20’ 3” (90mm) Dia. single wall pipe Stick
PVENT110050-6-US 4” 20’ 4” (110mm) Dia. single wall pipe Stick

Petroplas Pipe Markings

Persons 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 Additional Information markings on all of the
primary pipe and secondary pipe sleeve with Petroplas pipe variants include:
identical markings. Petroplas Co-axial pipe is • Manufacturer: MARLEY
an integral primary/secondary containment • Pipe trade name: PETROPLAS SF2P
solution where the secondary pipe sleeve may • SDR Stage
not be separated from the primary pipe for • Pressure rating in imperial and metric
independent use. (for primary and secondary pipe
where Petroplas Co-axial pipe is
• UGN PS, NV AND VR PIPE FOR MV, applicable)
HB, CT AND A&M FUELS • Imperial and metric pipe dimensions
• Manufacturer batch number
Petroplas Vent & Vapor Recovery Pipe

• UGN NV AND VR PIPE FOR MV, HB,

CT AND A&M FUELS

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THE COMPLETE PIPING SYSTEM
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 All Round Fluorination
Petroplas pipe is fluorinated using the
off-line procedure on all exposed pipe
surfaces. The resultant barrier layer offers
protection on three surface areas. 1

1. Primary carrier line. 2

2. Dual containment pipelines are

protected against interstitial
deterioration in the event of a primary 3

line leakage (outer surface of the

Fig. 5 All Round Fluorination,
primary carrier line and the inner cross sectional view of Petroplas
surface of the secondary containment line). Co-axial pipe
3. Deterioration of the outer pipe surface as a result of
site spillage or contamination is not possible

Petroplas Fittings
FRIATEC® Electro-fusion
Fig. 6 Cut-away view of a
FRIALEN® Safety Fittings (electro-fusion fittings) FRIALEN® Coupler
are utilized throughout the Petroplas System in
order to join the various components
Connectors
and pipe sections. Deep sockets and
safe low voltage operation (48V) applied
Fusion indicators
through dedicated FRIAMAT® ancillary
equipment ensures maximum joint
integrity. Fusion indicators visually
confirm joint melt pressure
Exposed
while absolute security of heating coils
the weld is ensured using
the fittings bar code feature
in conjunction with the Insertion
fully automatic FRIAMAT® depth tab
Control Box Unit.

▌Cooling zones
▌Fusion zones

Chamfered
surface for
easy pipe
entry

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THE COMPLETE PIPING SYSTEM
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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 Fig 7: A selection of FRIALEN® Safety fittings
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 Fitting

FRIALEN® Safety Fittings are easily identified by the following molded markings:
• FRIALEN® logo with the words “Safety Fitting” and the metric fitting diameter .
• Fitting material
• SDR 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.

Fig 8: FRIALEN® Safety Ftting

identification by molded markings

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THE COMPLETE PIPING SYSTEM
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The unique barcode label on all FRIALEN® Auxiliary Components
Safety Fittings has the following information for All pipeline components, other than the
identification and processing purposes: Petroplas pipe and the listed FRIALEN® Safety
Fittings (Appendix 4), as may be required
in an installation, are to be approved as fit
6 for purpose by the relevant manufacturer.
2 Installation personnel are required to be
1
3 trained and competent with the use of such
5 components and must follow the relevant
4 manufacturer’s installation instructions.
6
Fig 9: FRIALEN® Safety Fitting barcode
Petroplas Fittings Markings
Persons responsible for the supervision of
1. Fitting information barcode; scanned into the construction work at installations must
fusion unit before welding and supplier’s ensure that the correct fittings are being used
fitting type, welding time and resistance. as specified on the site-plans and working
2. Fitting type and size. drawings. The Petroplas pipe system may only
3. Pipe SDR range where the fitting is safe to be installed by competent personnel.
use.
4. The cooling times given in the bar code, and All FRIALEN® Safety Fittings will
identified by the additional letters “C.T.”, are carry the following markings on the packaging.
the times in minutes during which the fused The letter designations are listed on page 30 in
joint should not be moved. Cooling times Appendix 1, Table 4.
required before pressurization can be found • UGN FITTING FOR MV, HB, CT, AND A&M
in Appendix 6 on page 34. FUELS.
5. Fitting traceability barcode; when using • The approved FRIALEN® Safety Fittings
the FRIAMAT® Prime or Memo fusion have their own unique barcode label which
units, components can be automatically has been accepted for identification
traced back to source via a special barcode purposes.
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.
6. Emergency barcode information for manual
input.

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THE COMPLETE PIPING SYSTEM
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Design Requirements
• When 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 &
Training
It 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.
such persons will be referred to as
Accredited Petroplas Installation Personnel.
• The training program includes;
• Electro-fusion machine certification
• Theory 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.

Training
Petroplas 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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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 11
Storage and Materials
Handling
The 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 A
are also required to familiarize themselves with
the product, safety and chemical data sheets for
B
any cleaning solvents used.
Fig. 10: Storage of pipe sticks
Storage - Pipe
• Keep 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
A
pipe should be completely covered with an
opaque UV resistant material.
• Keep Petroplas pipe away from excessive
heat.
Fig. 11: Storage of pipe coils
• The storage area must be flat and level, with
no sharp objects or projections and able to
support the complete plan area and weight Materials Handling - Pipe
of the pipe being stored. • Pipes should be transported by a suitable
• Pipe sticks should be stored in a bundled vehicle, having a flat and level load bed with
beehive configuration not exceeding 3ft no sharp objects or projections and able to
(915mm) in height. See dimension A in Fig. support the complete plan area and weight
10. of the pipe being transported.
• Pipe sticks should be supported along the • During transport, pipe sticks should be
pipe length at spans not exceeding 3.28ft supported along the pipe length at spans not
(1m). See dimension B in Fig. 10. exceeding 3.28ft (1m).
• Stacked coils may not exceed a height of 6ft • Coils may be transported on edge provided,
(1.830m). See dimension A in Fig. 11. • The coils are secured against a
support suitably protected so as to
Storage - Fittings prevent chaffing of the pipe surface.
• Fittings are to be stored in cool dry • The coils remain in this position for
conditions under cover. only a limited period of time during
• Fittings should be stored inside their transport.
individual plastic bags and boxes. • During transport, all loads should be
• Keep the protective packaging intact until securely anchored with suitable ratchet
fittings are ready for use. webbing loadstraps so as to prevent

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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 12
 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.
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.
Secure
outside Uncoil direction
pipe end

Fig. 12: Unwinding of pipe coils

Materials Handling - The
Unwinding of Pipe Coils
In 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.

Fig. 13: Unwinding mechanism

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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
Outlet
for
used
hot air
Inlet is shielded so as to prevent
Inlet for
hot air direct heating of coil(s)
Fig. 14: Plan view of coil heating box
aspect is addressed in the following section
entitled “Installation”, within the “Pipe Laying”
subsection.
Materials Handling - Fittings
• Fittings 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.
PETROPLAS
THE COMPLETE PIPING SYSTEM
Installation
The 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 joining
process and backfill.
Pipe Trenches
Pipe 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.
US English Version_Imperial
PetroplasUGInstPDF_v4 00US 14
• 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
PETROPLAS
THE COMPLETE PIPING SYSTEM
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.
A
H
B
G C C G
D
F
E
Fig. 15: Trench dimensions and pipe separation
Pipe Laying
• The 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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PetroplasUGInstPDF_v4 00US 15
 greater than 25 times the pipe diameter.
Backfill and Bedding
All 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%
PETROPLAS
THE COMPLETE PIPING SYSTEM
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 Requirements
The 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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PetroplasUGInstPDF_v4 00US 16
 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).
Fusion Procedure Summary
An in-depth description of the steps below
has been given in the following section.
1. Clean pipe/spigot ends, cut pipe ends
square and deburr.
2. Mark insertion depth and fluorination
removal check lines on pipe/spigot ends.
3. Completely remove the fluorination layer,
remove swarf and chamfer the pipe/spigot
ends.
4. Clean pipe/spigot ends with
recommended cleaner and remark
insertion depth mark.
5. Apply rounding clamps on pipe/spigot
ends.
6. Insert pipe/spigot ends into fitting and
remove rounding clamps thereafter.
7. Stabilize the joint using a holding clamp.
8. Connect fusion unit, weld and disconnect.
9. Using the recommended marker, note all
of the required information on the fitting or
pipe.
10. Allow the joint to cool for the
recommended cooling time.
11. Remove the holding clamp.
PETROPLAS
THE COMPLETE PIPING SYSTEM
Detailed Fusion Procedure
WARNING; 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.
Fig. 16: Cut pipe ends square
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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 Fig. 17: Remove fitting from packaging
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). Fig. 18: Measuring the fusion zone
• 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 Fig. 19: Checking lines
of the surface is sufficient, removing
a minimum of 0.4 point (0.15mm)
material.

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PETROPLAS
THE COMPLETE PIPING SYSTEM
18
• 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,
Fig. 20: Removal of oxide layer
always commence scraping from
behind the fusion depth mark,
ensuring that the stroke extends
over the pipe or spigot end. See
Fig. 21: Chamfer pipe end
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
Fig. 21: Complete removal of oxide layer
can leave a large annular gap which
from fusion zone
cannot be closed, or completely
closed, during fusion.
• After scraping do not touch the fusion
zones again.

Fig. 22: Using the hand scraper

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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 19
• 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. Fig. 23: Chamfer pipe/ spigot ends
• 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, Fig. 24: Protected pipe/ spigot ends after working
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 Fig. 25: Cleaning the fitting fusion zone

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- Fig. 26: Clean worked pipe/ spigot ends with suitable
colored paper towel (Fig. 26). Dispose the cleaner

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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 20
• 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 Fig. 29: Connect & scan

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
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.
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.

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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 22
• 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 number
• Initials 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 Fig. 29a: Weld markings

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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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 23
Using the FRIATOOL®
Scraper Tools
FWSGE 63 for ⅝ to 2 inch (20
4

to 63mm) Applications
• Referring to Fig. 30; 3
• Release the roller handle (1).
• Set the guide rollers (2) according to the
pipe size being scraped by releasing the 1
guide clamp (3) in a counter-clockwise
direction. There are two positions indicated 2
on the unit. Tighten after setting.
5
• 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. Fig. 30: FWSGE 4 Scraper tool
• Turn the twist grip knob counter-clockwise
until the scraper tool is able to fit over result. If the marking lines are not completely
the pipe end. The pipe should be nested removed, the scraping process should be
between the smooth and knurled rollers. repeated.
• For pipes of diameter ⅝ to 1¼ inch (20 • Tighten the twist grip knob (4) until fully
to 40mm), place the scraper blade on the seated and collapse the handle (1) to the
fusion depth mark as indicated on the pipe storage position by gently pulling whilst
section. Scraping will be from the fusion simultaneously folding.
depth mark toward the pipe end. • The scraper tool must be kept clean and dry
• For pipes of diameter 1½ to 2 inch (50 to and always stored in its transport case.
63mm), place the scraper blade on the pipe • Keep the blade covered (5) in order to
end. Scrapping will be from the pipe end prevent accidental injury.
towards the fusion depth mark. • The condition of the tool blade should be
• Tighten the twist grip knob firmly. checked regularly and replaced if found to
• Using the roller handle, continuously rotate be worn.
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

PETROPLAS US English Version_Imperial

THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 24
FWSGE 225 for 3 to 9 inch (75 1

to 225mm) Applications
• Referring to Fig. 31; 2
• Fully open the clamping carriage by turning
the twist grip knob (1) anti-clockwise.
• Hold the scraper tool by the roller handle
4
(2) and point it towards the floor. Turn the
tool anti-clockwise with twisting movements 3

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.
Fig. 31: FWSGE 3 Scraper tool
• Remove the protective cap (3) from the
scraper blade.
• Guide the tool over the pipe end so that and always stored in its transport case.
the clamping carriage (4) is inside the pipe • The condition of the tool blade should be
and the scraper blade is on the outside checked regularly and replaced if found to
surface of the pipe. Turn the twist grip knob be worn.
(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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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 25

Pressure Testing
Petroplas 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 Method
• The 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.
PETROPLAS
THE COMPLETE PIPING SYSTEM
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 Method
• Either 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 that
there will be a pressure variance (positive or
negative) on the gauge.
• Small leaks are more difficult to detect using
the pneumatic method.
US English Version_Imperial
PetroplasUGInstPDF_v4 00US 26
• The secondary containment system should
be tested using the same procedure with all
interstitial spaces connected as described in
the Hydrostatic test method.
Record Keeping
Contractors 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 contractor
• Site name, site number and location
• Date site-work commenced
• Date when installation was completed
• Accredited Petroplas Installation Personnel
PETROPLAS
THE COMPLETE PIPING SYSTEM
used and the designated initials as marked
on all electro-fusion welds.
• Petroplas pipe used in the installation with
batch numbers
• Number of electro-fusion welds completed
on the site
• Site inspector
• Appointed 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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PetroplasUGInstPDF_v4 00US 27
Special Tools & Equipment
Description/ Detail Article Code
Electro-fusion Units
Friamat Eco Prime 613092

Friamat Eco Basic 613090

Friamat 110V 613217

Scraper Tools
FWSG 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.

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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 28
 Hand Scraper
FWZ Hand Hand Scraper 613300
Scraper

Blades 613270

Rounding Clamps
FWXR Manual FWXR-S1 32-63mm 613416
Rounding
Clamps

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

picture.

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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 29
Appendix 1: Referenced Documents
& Pipe/fitting Letter Designations

Referenced Documents/ Standards Availability

Abstract (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 Available from the IHS online standards store
GARAGES (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 Available from the IHS online standards store
Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3)) (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

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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 30
Appendix 2: Marley Pipe Systems Contact
Information
Marley Pipe Systems (Pty.) Ltd.
Reg. No. 1991/003365/07
Address: 3 Platinum Close, Tsessebe Crescent, Midrand, Johannesburg
Postal address: P.O. Box 67, Nigel, 1490, South Africa
Tel: 0861 - MARLEY
Fax: +27 11 314 9022
www.marleypipesystems.co.za

Appendix 3: Nominated Petroplas Agents

Contact Information
Sub Saharan Africa
TBJ Africa
Tel: +27 11 894 5219 | +27 11 894 5222
Fax: +27 86 554 3453
E-mail: orders@tbjafrica.com
www.tbjafrica.com

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THE COMPLETE PIPING SYSTEM
PetroplasUGInstPDF_v4 00US 31
 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). Fig. 27: Do not introduce dirt from the unscraped
pipe end
• 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.
Fig. 28: Recheck insertion depth
• All joints assembled for fusion must be free
of stress.
• Pipe or spigot ends may not be the joint must be maintained until the
inserted into any FRIALEN® Safety cooling time given on the bar code of
Fitting under a bending stress or the fitting has elapsed.
under a load from their own weight. • A joint which is not free of stress or which is
• Pipe or spigot ends must be displaced can lead to an unacceptable flow
supported by a suitable holding of molten material during the fusion process
device. Appendix 5 on page 33 and this can lead to a defective joint.
details general guidelines for the • Before fusing, check once again by means
holding device. of the fusion line marks that the pipe or
• After completion of the fusion spigot ends in the FRIALEN® Safety Fitting
process, the stress-free support of have not moved. If necessary, correct this.

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 Appendix 4: Approved FRIALEN® Fittings
Size (Metric) Size (ID, Pack Description
Imperial)
Electro-fusion Couplers
25mm 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
90mm OD Coupler 3” Single FRIALEN® Electro-fusion Coupler
110mm OD Coupler 4” Single FRIALEN® Electro-fusion Coupler
Electro-fusion Reducing Couplers
63/50 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
110/90 Reducing Couplers 4-3” Single FRIALEN® Electro-fusion Reducing Coupler
110/90 Reducing Couplers 4-3” Single FRIALEN® Electro-fusion Reducing Coupler
125/90 Reducing Couplers 5-3” Single FRIALEN® Electro-fusion Reducing Coupler
125/90 Reducing Couplers 5-3” Single FRIALEN® Electro-fusion Reducing Coupler
160/110 Reducing Couplers 6-4” Single FRIALEN® Electro-fusion Reducing Coupler
Electro-fusion Tees
25mm 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
90mm Tee 3” Single FRIALEN® Electro-fusion Tee
110mm Tee 4” Single FRIALEN® Electro-fusion Tee
Electro-fusion Elbows
50mm Elbows 1.½” Single FRIALEN® Electro-fusion Elbows
63mm Elbows 2” Single FRIALEN® Electro-fusion Elbows
90mm Elbows 3” Single FRIALEN® Electro-fusion Elbows
110mm Elbows 4” Single FRIALEN® Electro-fusion Elbows
Electro-fusion Spigot Transition Fittings
50x1½” 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
90x3” Transition Male 3” Single FRIALEN® 90-3” Transition Male
90x2½” Transition Female 3” Single FRIALEN® 90-2½” Transition Female
110x4” Transition Male 4” Single FRIALEN® 110-4” Transition Male
110x3” Transition Female 4” Single FRIALEN® 110-3” Transition Female
Electro-fusion Transition Fittings
20x1/2” Transition Male ½” Single FRIALEN® 20-½” Transition Male
25x½” Transition Male ¾” Single FRIALEN® 25-¾” Transition Male
32x1” Transition Male 1” Single FRIALEN® 32-1” 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

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Appendix 5: Guidelines for Holding Device
5
2
2
4

2
2

A
1

Fig. 32: Holding device

1- 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.

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Appendix 6: Cooling Times
FRIALEN® Cooling Times Test Pressure Max. Pressure
Fitting diameter
in mm Cooling time before joint can be moved, Cooling time in Minutes Cooling time in Minutes
also indicated on FRIALEN® fitting for testing at 87 psi before full pressure
barcode
20 – 32 5 8 10
40 – 63 7 15 25
75 – 110 10 30 40

Appendix 7: Petroplas Accreditation

Approvals as of 2007-08
California 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 Disclaimer

Whilst 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.

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