seapress installation manual - viega usa

Year built:from 03/2003en_INT

Seapress

Instructions for Use

Seapress 2 from 25

Table of contents

1 About these instructions for use 4

1.1 Target groups 4

1.2 Labelling of notes 4

1.3 About this translated version 5

2 Product information 6

2.1 Standards and regulations 6

2.2 Intended use 7

2.2.1 Regulations 7

2.2.2 Areas of use 8

2.2.3 Media 9

2.3 Product description 9

2.3.1 Overview 9

2.3.2 Pipes 10

2.3.3 Press connectors 12

2.3.4 Sealing elements 13

2.4 Information for use 15

2.4.1 Corrosion 15

3 Handling 16

3.1 Transport 16

3.2 Storage 16

3.3 Assembly information 16

3.3.1 Mounting instructions 16

3.3.2 Potential equalisation 17

3.3.3 Permitted exchange of sealing elements 17

3.3.4 Space requirements and intervals 18

3.3.5 Required tools 20

3.4 Assembly 21

3.4.1 Replacing the sealing element 21

3.4.2 Bending pipes 21

3.4.3 Shortening the pipes 22

3.4.4 Deburring the pipes 22

3.4.5 Pressing the connection 23

3.4.6 Leakage test 24

3.5 Disposal 25

Table of contents

Seapress 3 from 25

1 About these instructions for useTrade mark rights exist for this document, further information can befound at viega.com/legal.

1.1 Target groupsThe information in this manual is directed at heating and sanitary pro-fessionals and trained personnel.

It is not permitted for individuals without the abovementioned training orqualification to mount, install and, if required, maintain this product. Thisrestriction does not extend to possible operating instructions.

The installation of Viega products must take place in accordance withthe general rules of engineering and the Viega instructions for use.

1.2 Labelling of notesWarning and advisory texts are set aside from the remainder of the textand are labelled with the relevant pictographs.

DANGER! This symbol warns against possible life-threatening injury.

WARNING! This symbol warns against possible serious injury.

CAUTION! This symbol warns against possible injury.

NOTICE! This symbol warns against possible damage to property.

Notes give you additional helpful tips.

About these instructions for use

Seapress 4 from 25

https://www.viega.de/de/meta/footer/legal.html

1.3 About this translated versionThis instruction for use contains important information about the choiceof product or system, assembly and commissioning as well as intendeduse and, if required, maintenance measures. The information about theproducts, their properties and application technology are based on thecurrent standards in Europe (e. g. EN) and/or in Germany(e. g. DIN/DVGW).

Some passages in the text may refer to technical codes in Europe/Germany. These should serve as recommendations in the absence ofcorresponding national regulations. The relevant national laws, stand-ards, regulations, directives and other technical provisions take priorityover the German/European directives specified in this manual: Theinformation herein is not binding for other countries and regions; as saidabove, they should be understood as a recommendation.

About these instructions for use

Seapress 5 from 25

2 Product information2.1 Standards and regulations

The following standards and regulations apply to Germany / Europe.National regulations can be found on the relevant web site of yourcountry at viega.com/standards.

Scope / Notice Regulations

Planning of pipeline installationsfor ships

DIN 86003, Part 1


Execution and manufacture ofpermitted pipes

DIN 86019

Exact calculation of the fixingpoints

DIN 86082:2008-02


Field of application of sealing ele-ments in fire extinguishing and fireprotection systems, foam andsprinkler systems, bilge and bal-last systems, sea water andcooling water systems

DIN 86003-1


DIN 86076


Herstellerangaben

Regulations from section: Regulations

Regulations from section: Pipes

Regulations from section: Sealing elements

Product information

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https://www.viega.de/normen


Corrosion of metals in sea waterand marine applications

DIN 81249-1


DIN 81249-2


DIN 81249-3


DIN 81249-4

Scope / Notice Regulations applicable in Ger-many

Leakage test in ship pipelines DIN 86001:2010-09

Leakage test in ship pipelines Standarddrucktests des ausfüh-renden Betriebs (Werft)

Leakage test in ship pipelines Anforderungen / Bestimmungender verantwortlichen Klassifizier-ungsgesellschaft(en)

2.2 Intended use

Agree the use of the system for areas of use and mediaother than those described with the Viega Service Center.

2.2.1 RegulationsWhen planning pipeline installations, the regulations applicable for therespective type of vessel must be observed.

Observe for instance the requirements defined by:

n Classification societiesn IMOn SOLASn Marpoln The respective flag state,

for instance the See-Berufsgenossenschaftn Standardsn Equipment manufacturersn Building regulations

Regulations from section: Corrosion

Regulations from section: Leakage test

Product information

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n Pressure equipment directivesn UVV Seen US Coast Guardn Regulations for the Suez Canaln Regulations for the Panama Canal

See also Ä „Regulations from section: Regulations“ on page 6

2.2.2 Areas of useSeapress cannot only be used with aggressive media (e. g. sea water),but also in aggressive surroundings (e. g. on ships or in marine engi-neering systems).

In accordance with the classification criteria and the rating of the classIII of the IACS, the equipment can be used amongst others in the fol-lowing areas:

n Fire extinguishing and fire protection systemsn Foam and sprinkler unitsn Bilge and ballast systemsn Saltwater cooling systemsn Saltwater desalination systemsn Low-pressure steam systems (only with FKM sealing element)n Condensation removaln Deck and sanitary drainage pipelines (internal)n Scupper pipes and drainpipesn Compressed air pipelines (operating air, no starting or control air)

Product information

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2.2.3 MediaThe system is suitable for the following media, amongst others:

n Saltwatern All types of process watern Compressed air (operating air) in acc. with the specification of the

sealing element used– EPDM at oil concentration < 25 mg/m3

– FKM at oil concentration ≥ 25 mg/m3

n Fuelsn Lubricantsn Hydraulic fluidsn Steam in low-pressure steam systems (only with FKM sealing ele-

ment)n Spring and ballast watern Distilled water

NOTICE! Before installation, refer to the relevant valid certificate forverification of suitability and approval, or contact the appro-priate certification body.

2.3 Product description2.3.1 Overview

The piping system consists of press connectors for CuNiFe pipes andthe corresponding press tools.

Product information

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Fig. 1: Seapress – Overview

The system components are available in the following dimensions:d 15 / 22 / 28 / 35 / 42 / 54.

2.3.2 PipesOnly use CuNiFe pipes, see Ä „Regulations from section: Pipes“on page 6.

The pipes must also be made of a corrosion proof copper nickelwrought alloy, which has the material number 2.1972.11 or 2.1972.22.

Only use pipes produced in compliance with the Standards, i.e. pipeswith the following technical data:

Nominal width[DN]

d x s [mm] Volume permetre of pipe

[l/m]

Pipe weight[kg/m]

Mass per unitlength [8.9

kg/dm3]

12 15 x 1.0 0.133 0.39

20 22 x 1.0 0.314 0.59

25 28 x 1.5 0.491 1.11

Product information

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Nominal width[DN]

d x s [mm] Volume permetre of pipe

[l/m]

Pipe weight[kg/m]

Mass per unitlength [8.9

kg/dm3]

32 35 x 1.5 0.804 1.41

40 42 x 1.5 1.195 1.70

50 54 x 1.5 2.043 2.21

Requirements for fixing intervals should restrict the number of fixingpoints to a technically justifiable amount, on the other hand, they shouldprevent intervals being so large as to cause damage due to vibrations.

The intervals for the fixing pipelines contained in following table are rec-ommended for the fixing of pipelines:

Interval between the pipe clamps

d [mm] Fixing interval between the pipeclamps [m]

15.0 1.20

22.0 1.20

28.0 1.20

35.0 2.20

42.0 2.20

54.0 2.20

Information on the accurate calculation of the fixing pointsis comprised in the Standard, see Ä „Regulations from sec-tion: Pipes“ on page 6.

Pipelines expand with heat. Heat expansion is dependent on the mate-rial. Changes in length lead to tension within the installation. These ten-sions must be equalised with suitable measures.

The following are effective:

n Fixed and gliding pointsn Expansion equalisation joints (expansion bends)

Laying and fixing pipes

Length expansion

Product information

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Heat expansion co-efficients CuNiFe

Material Heat expansion co-effi-cient ⍺

[mm/mK]

Example:

Length expansion withpipe lengths = 20 m and

ΔT = 50 K [mm]

CuNiFe 0.017 17.0

Fig. 2: Length expansion of CuNiFe pipes

1 - Length expansion ⃗ ΔI [mm]2 - Pipe length ⃗ l0 [m]3 - Temperature difference → Δϑ [K]

2.3.3 Press connectorsPress connectors are available in a number of shapes. An overview ofthe press connectors suitable for the system can be found in the cata-logue.

The press connectors in the Seapress system are made of the alloyCuNi10Fe1.6Mn, a copper-nickel-iron alloy. This alloy fulfils the specialrequirements for saltwater applications.

Product information

Seapress 12 from 25

Fig. 3: Press connectors

The press connectors have a circumferential bead in which the sealingelement lies. The connector is deformed upstream and downstream ofthe bead and permanently connected to the pipe during pressing. Thesealing element is not deformed during pressing.

2.3.4 Sealing elementsThe press connectors are factory-fitted with EPDM sealing elements.For areas of use with higher thermal resistance, such as e. g. in the caseof low-pressure steam systems, the press connectors must beequipped with FKM sealing elements.

The sealing elements can be distinguished as follows:

n EPDM sealing elements are polished black.n FKM sealing elements are matt black.

Product information

Seapress 13 from 25

Area of use

Fire extin-guishing andfire protectionsystems

Foam andsprinkler units

Bilge and bal-last systems

Saltwater andcooling watersystems

Compressed airpipelines (operatingair)

Area of use all pipeline sec-tions 1)

all pipeline sec-tions 1)

all pipeline sec-tions 1)

e. g. vaporisersupply pipe 1)

Sanitaryprocess andwastewater 1)

Tank cleaning 1)

all pipeline sections2)

Operating tem-perature [Tmax.]

110 °C 110 °C 110 °C 110 °C 110 °C

Operating pres-sure [Pmax]

1.6 MPa(16 bar)

1.6 MPa(16 bar)

1.6 MPa(16 bar)

1.6 MPa(16 bar)

1.6 MPa (16 bar)

Comments Use is to becoordinated inacc. with theclassification

criteria and therating of the

general rules ofengineering.3)

Use is to becoordinated inacc. with theclassificationcriteria and therating of thegeneral rules ofengineering.3)

Use is to becoordinated inacc. with theclassificationcriteria and therating of thegeneral rules ofengineering.3)

Use is to becoordinated inacc. with theclassification

criteria and therating of the

general rules ofengineering.3)

Oil content< 25 mg / m3

1) only fire-tested types are permitted in category A machine rooms

2) no starting or control air

3) see Ä „Regulations from section: Sealing elements“ on page 6

Area of use Compressed air Low-pressure steam sys-tems

Use all pipeline sec-tions

all pipeline sections 1)

Operating temper-ature [Tmax.]

60 °C 120 °C

Operating pres-sure [Pmax]

1.6 MPa (16 bar) 0.1 MPa (1 bar)

Commentsdry, oil content≥ 25 mg /m3 —

1)Harmonize the use with the classification criteria and the rating pur-suant to the general directives, Ä „Regulations from section: Sealingelements“ on page 6.

Area of use of the EPDM sealing element

Area of use of the FKM sealing element

Product information

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2.4 Information for use2.4.1 Corrosion

The corrosion resistance against seawater is due to the phenomenonthat a CuNiFe alloy forms a thin protective layer on the surface if itcomes into contact with clean seawater.

The wrought iron alloy CuNiFe 1.6 Mn is very resistant to corrosion afterthe protective coating has formed. Especially with saltwater and otheraggressive waters such as e.g. brackish and bilge water and their sur-rounding area.

For notes on corrosion of metals in saltwater and marine atmosphere,see the applicable regulations, Ä „Regulations from section: Corro-sion“ on page 7.

Product information

Seapress 15 from 25

3 Handling3.1 Transport

Observe the following when transporting pipes:

n Do not pull the pipes over the sill. The surface could be damaged.n Secure pipes during transportation. Pipes may become bent due to

shifting.n Do not damage the protective caps on the pipe ends and do not

remove them until immediately before mounting. Damaged pipeends may not be pressed.

In addition, observe the instructions provided by the pipemanufacturer.

3.2 StorageObserve the following when storing pipes and press connectors:

n Store components in a clean and dry place.n Do not store the components directly on the floor.n Provide at least three points of support for the storage of pipes.n Where possible, store different sizes separately.

Store small sizes on top of larger sizes if separate storage is not pos-sible.

n To prevent contact corrosion, store pipes of different materials sepa-rately.

In addition, observe the instructions provided by the pipemanufacturer.

3.3 Assembly information3.3.1 Mounting instructions

System components may, in some cases, become damaged throughtransportation and storage.

n Check all parts.n Replace damaged components.n Do not repair damaged components.n Contaminated components may not be installed.

Checking system components

Handling

Seapress 16 from 25

3.3.2 Potential equalisation

DANGER! Danger due to electrical currentAn electric shock can lead to burns and serious injury andeven death.

Because all metallic piping systems conduct electricity,unintentional contact with a live part can lead to the wholepiping system and components connected to it (e. g. radia-tors) becoming energised.

– Only allow electrical work to be carried out by qualifiedelectricians.

– Always integrate the metallic piping system into thepotential equalisation.

It is the fitter of the electrical system who is responsible forensuring that the potential equalisation is tested andsecured.

3.3.3 Permitted exchange of sealing elements

Important instructionWith their material-specific qualities, sealing elements inpress connectors are adapted for use with the corre-sponding media and/or the areas of use of the piping sys-tems and are generally only certified for them.

The exchange of a sealing element is generally permitted.The sealing element must be exchanged for a designatedspare part for the intended application Ä Chapter 2.3.4„Sealing elements“ on page 13. The use of other sealingelements is not permitted.

Exchanging a sealing element is permitted in the following situations:

n if the sealing element in the press connector is obviously damagedand should be exchanged for a Viega replacement sealing elementmade of the same material

n if an EPDM sealing element should be exchanged for an FKM sealingelement (due to higher thermal resistance on ships)

Handling

Seapress 17 from 25

3.3.4 Space requirements and intervals

Space requirement PT1, Type 2 (PT2), PT3-EH, PT3-AH, Pressgun 4B,4E, 5

d 15 22 28 35 42 54

a [mm] 20 25 25 30 45 50

b [mm] 50 60 70 85 100 115

Space requirement Picco, Pressgun Picco

d 15 22 28 35

a [mm] 25 25 25 25

b [mm] 60 65 65 65

Space requirement press ring

d 15 22 28 35 42 54

a [mm] 40 45 50 55 60 65

b [mm] 50 60 70 75 85 90

Space requirement PT1, Type 2 (PT2), PT3-EH, PT3-AH, Pressgun 4B,4E, 5

d 15 22 28 35 42 54

a [mm] 25 30 30 50 50 55

b [mm] 65 80 85 95 115 140

c [mm] 40 40 50 50 70 80

Space requirement Picco, Pressgun Picco

d 15 22 28 35

a [mm] 30 30 30 30

b [mm] 70 75 80 80

c [mm] 40 40 40 40

Pressing between pipelines

Pressing between pipe and wall

Handling

Seapress 18 from 25

Space requirement press ring

d 15 22 28 35 42 54

a [mm] 40 45 50 55 60 65

b [mm] 50 60 70 75 85 90

c [mm] 35 40 45 50 55 65

Assess the completion of wall and shutter lead-ins on anindividual basis and in agreement as well as in acc. with thecorresponding certification body.

Minimum interval with d 15–54

Press machine amin [mm]

PT1 45

Type 2 (PT2)

50

Type PT3-EH

Type PT3-AH

Pressgun 4E / 4B

Pressgun 5

Picco / Pressgun Picco 35

NOTICE! Leaky press connections due to pipes being too short!If two press connectors are to be mounted onto a pipewithout an interval, the pipe must not be too short. If thepipe is not inserted up to the prescribed insertion depth inthe press connector during pressing, the connection maybecome leaky.

With pipes with a diameter of d 15–28, the length of thepipe must be at least as long as the total insertion depth ofboth press connectors.

Distance to walls

Interval between the pressings

Handling

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Minimum interval with press jaws d 15–54

d amin [mm]

15 0

22 0

28 0

35 10

42 15

54 25

For the Z dimensions, refer to the respective product page in the onlinecatalogue.

3.3.5 Required toolsThe following tools are required for production of a press connection:

n pipe cutter or a fine-toothed hacksawn deburrer and coloured pen for markingn press machine with constant pressing forcen press jaw or press ring with corresponding adapter jaw, suitable for

the pipe diameter and suitable profile

Fig. 4: Press jaws

Recommended Viega press machines:

n Pressgun 5n Pressgun Piccon Pressgun 4E / 4Bn Piccon Type PT3-AHn Type PT3-H / EHn Type 2 (PT2)

Z dimensions

Handling

Seapress 20 from 25

3.4 Assembly3.4.1 Replacing the sealing element

Do not use pointed or sharp-edged objects to remove thesealing element. These could damage the sealing elementor bead.

Remove the sealing element from the bead.

Insert a new, undamaged sealing element into the bead.

Ensure that the complete sealing element is in the bead.

3.4.2 Bending pipes

CuNiFe pipes in the sizes d 15, 22 and 28 can be bent cold with com-mercially available bending equipment (radius at least 3.5 x d).

Removing the sealing element

Inserting the sealing element

Handling

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The pipe ends (a) must be at least 50 mm long so that the press con-nectors can be mounted properly.

3.4.3 Shortening the pipes

NOTICE! Leaky press connections due to damaged material!Press connections can become leaky due to damagedpipes or sealing elements.

Observe the following instructions to avoid damage to pipesand sealing elements:

– Do not use cutting discs (angle grinders) or flame cutterswhen cutting to length.

– Do not use grease or oils (e. g. cutting oil).

For information about tools, also see Ä Chapter 3.3.5 „Requiredtools“ on page 20.

Cut the pipe properly using a pipe cutter or fine-toothed hacksaw.

Avoid grooves on the pipe surface.

3.4.4 Deburring the pipesDeburring prevents the sealing element being damaged or the that thepress connector cants when mounted. Use of a deburrer (model 2292.2)is recommended.

NOTICE! Damage due to the wrong tool!Do not use sanding disks or similar tools when deburring.The pipes could be damaged by these.

Handling

Seapress 22 from 25

Deburr the inside and outside of the pipe.

3.4.5 Pressing the connection

Requirements:

n The pipe end is not bent or damaged.n The pipe is deburred.n The correct sealing element is in the press connector.

EPDM = polished blackFKM = matt black

n The sealing element is undamaged.n The complete sealing element is in the bead.

Push the press connector onto the pipe as far as it will go.

Handling

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Mark the insertion depth.

Place the press jaw onto the press machine and push the retainingbolt in until it clicks into place.

INFO! Observe the press tool instruction manual.

Open the press jaw and place at a right-angle onto the connector.

Check the insertion depth using the marking.

Ensure that the press jaw is placed centrally on the bead of thepress connector.

Carry out the pressing process.

Open and remove the press jaw.

ð Connection is pressed.

3.4.6 Leakage test

The installer must perform a leakage test before commissioning.

Handling

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Carry out this test on a system that is finished but not yet covered.

Observe the applicable regulations, see Ä „Regulations from section:Leakage test“ on page 7.

The leakage test pursuant to the applicable regulations must also becarried out for non-drinking water installations, see Ä „Regulations fromsection: Leakage test“ on page 7.

Document the result.

3.5 DisposalSeparate the product and packaging materials (e. g. paper, metal,plastic or non-ferrous metals) and dispose of in accordance with validnational legal requirements.

Handling

Seapress 25 from 25

seapress installation manual - viega usa

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