victaulic solutions for shipbuilding and marine piping systems brochure

P I P I N G • S Y S T E M S • S O L U T I O N S

• Products tested and approved by IACS• Improve productivity and on board installation safety• Secure weight & space savings

V I C T A U L I C S O L U T I O N S F O R S H I P B U I L D I N G A N D M A R I N E

P I P I N G S Y S T E M S

2 Shipbuilding and Marine Piping Systems

Victaulic: Grooved Pipe Joining Technology

The mechanical joint, or coupling, comprises four elements: the pipe groove, a gasket, the housings and nuts and bolts. The pipe groove is cold formed or machine grooved into a pipe end. The housing, which encases the gasket and engages into the grooves, creates a unified joint. The housing fully encloses the gasket, reinforcing and securing it in position. Holding the housing section together are bolts and nuts that are tightened with hand tools. The mechanical joint creates a triple seal because of the design relationship between the pipe groove, gasket and housings. This seal is enhanced when the piping system is pressurized.

Once installed, our mechanical system is easily inspected through visual confirmation of a proper installation. Metal-to-metal bolt-pad contact confirms that the joint is properly installed and no re-work is necessary.

By specifying and installing Victaulic, ship designers, owners and shipyards conserve time and financial resources through:

Compressed project schedules Victaulic systems increase project efficiency from the start.

Lowered total installed cost over the lifetime of the system.

Safer work environment Reduced calendar days reduces exposure to on board installation accidents.

Reduced downtime during scheduled maintenance, service checks, dry docking, conversions and upgrades.

How our system works.

Coupling Assembly

Victaulic, the world leader in grooved end mechanical pipe joining systems, was founded in New York City in 1925 to market a radical new concept in the piping industry — a mechanical bolted coupling that would engage into grooves with a gasket seal.

Today our grooved mechanical piping technology - a flame-free joining method - is the most versatile, economical and reliable mechanical pipe joining system available for the shipbuilding and ship repair industry.

Shipbuilding and Marine Piping Systems 3

The heart of a mechanical coupling system is the gasket. That is why stringent quality control measures, precision engineering and exhaustive testing go into the manufacturing of a

Victaulic gasket.

Victaulic boasts the largest and most experienced team of engineers in the industry. Utilizing the most advanced nonlinear finite element analysis the research and development team predicts the performance of materials in different configurations to

understand the performance in field conditions. A proprietary compound accommodates the effects of thermal expansion, pipe end flare and pressurization. The engineered, pressure-responsive design provides increased sealing performance as internal system pressure is increased.

As the industry’s only single-source manufacturer, Victaulic uses the latest molding technology to ensure a quality product. Victaulic gaskets are subject to stringent quality control standards and Victaulic uses extensive tests, such as air and water aging, thermal cycling, compression set and tensile strength, to prove the highest product performance.

Cut Grooving Pipe Roll Grooving Pipe

Not all gaskets are the same

HOUSING

GROOVE

BOLT/NUT

GASKET

GROOVE


Unparalleled quality and innovation that provide reduced installation time, easier and safer installation and the design versatility to accommodate unique space requirements for improved shipboard efficiency.

COUPLINGSVictaulic couplings provide a simple, economical method for joining carbon steel, galvanized steel and copper nickel piping systems. Victaulic couplings provide designers with versatility not found in other pipe joining methods.

• Available to join ¾"/20 mm through 36"/915 mm piping systems. (Depending on coupling type and approvals.)

• Vic-Flange adapters are available to directly incorporate grooved components into a piping system

FITTINGSA wide range of fittings are available in sizes through 36"/915 mm for fast installation. The grooved design permits flexibility for easy alignment.

• Various styles of elbows, tees, caps and reducers are available for superior design flexibility

• Painted orange enamel with optional galvanized finish

VALVESVictaulic valves are engineered and manufactured for dependable, trouble-free performance, superior flow control and durable, long-lasting reliability.

• A full line of butterfly, check and circuit balancing valves are available

• A variety of wear-resistant materials and coatings are available for specific piping application requirements

HOLE CUT PRODUCTSVictaulic hole cut products provide a fast, easy mid-pipe outlet that does not require welding.

• Gaskets are molded to conform to the O.D. of the pipe and are of a pressure responsive design

• Hole cut products are mounted to the pipe using a locating collar and provide a smooth flow area

• Victaulic offers a line of easy to operate hole cutting tools

PIPE PREPARATION TOOLSVictaulic is the leader in the development of roll and cut grooving tools. In addition to our extensive lines of grooving tools, Victaulic offers hole cutting tools and cut-off tools.

• Tools are available for use in the field, fabrication shop or groove-in-place

• Patented enhanced tracking rolls provide for hands free grooving

• Tools available for rental or purchase

Products are available for the following pipe materials: carbon steel, galvanized steel and copper nickel.

Products


Within the shipbuilding industry, Victaulic systems and components are tested, approved and accepted by IACS for use on various applications and vessels.

FPSO/Drillships

Tankers/LPG/LNGCargo ships

Passenger ships

Container ships

Workboats

Applications & Approvals


SEA WATER

• Ballast

• Bilge

• Cooling

• Fire Main

• Non-essential Lines

• Scuppers and Discharge

• Water Spray/Foam/Sprinkler Systems

FLAMMABLE FLUIDS

• Fuel Oil Transfer

• Hydraulic Oil

• Lubricating Oil

• Vent Lines

Container Ships

Systems

FRESH WATER

• Condensate Returns

• Cooling Water

• Deck Drains

• Fire Systems

• Non-essential lines

• Potable Water

• Sanitary Drains

• Sanitary


• Sounding and Venting

• Vents and Overflows

• Water Tanks/Dry Spaces

INERT GAS

• C02

• Main and Distribution Lines

• Scrubber Effluent

• Water Seal

MISCELLANEOUS

• Air Conditioning

• Air Piping

• Brine

• Deck Scupper

• Domestic Fresh Water

• Domestic Sanitary Drains

• Fire and Deck Wash Lines

• Heating and Air Conditioning

• Non-Essential

• Service Air (non-essential)


SEA WATER

• Ballast

• Bilge

• Cooling

• Fire Main




FLAMMABLE FLUIDS


• Hydraulic Oil

• Lubricating Oil

• Vent Lines

Cargo Ships

Systems

FRESH WATER


• Cooling Water

• Deck Drains

• Fire Systems


• Potable Water

• Sanitary Drains

• Sanitary





INERT GAS

• C02



• Water Seal

MISCELLANEOUS


• Air Piping

• Brine

• Deck Scupper





• Non-Essential



SEA WATER

• Ballast

• Bilge

• Cooling

• Fire Main



• Tank cleaning


FLAMMABLE FLUIDS

• Cargo Oil

• Crude Oil

• Crude Oil Washing


• Hydraulic Oil

• Lubricating Oil

• Thermal Oil Lines

• Vent Lines

Tankers/LPG/LNG

FRESH WATER


• Cooling Water

• Deck Drains

• Fire Systems


• Potable Water

• Sanitary Drains

• Sanitary





INERT GAS

• C02



• Water Seal

MISCELLANEOUS


• Air Piping

• Brine

• Deck Scupper





• Non-Essential


Systems


SEA WATER

• Ballast

• Bilge

• Cooling

• Fire Main




FLAMMABLE FLUIDS


• Hydraulic Oil

• Lubricating Oil

• Vent Lines

Passenger Ships

Systems

FRESH WATER


• Cooling Water

• Deck Drains

• Fire Systems


• Potable Water

• Sanitary Drains

• Sanitary





INERT GAS

• C02



• Water Seal

MISCELLANEOUS


• Air Piping

• Brine

• Deck Scupper





• Non-Essential



Workboats

SEA WATER

• Ballast

• Bilge

• Cooling

• Fire Main




FLAMMABLE FLUIDS


• Hydraulic Oil

• Lubricating Oil

• Vent Lines

FRESH WATER


• Cooling Water

• Deck Drains

• Fire Systems


• Potable Water

• Sanitary Drains

• Sanitary





INERT GAS

• C02



• Water Seal

MISCELLANEOUS


• Air Piping

• Brine

• Deck Scupper





• Non-Essential


Systems


SEA WATER

• Ballast

• Bilge

• Cooling

• Fire Main




FLAMMABLE FLUIDS


• Hydraulic Oil

• Lubricating Oil

• Vent Lines

FPSO/Drillships

Systems

FRESH WATER


• Cooling Water

• Deck Drains

• Fire Systems


• Potable Water

• Sanitary Drains

• Sanitary





INERT GAS

• C02



• Water Seal

MISCELLANEOUS


• Air Piping

• Brine

• Deck Scupper





• Non-Essential



At the root of all the benefits that Victaulic solutions bring to a project – such as on board installation productivity, safety, design flexibility, high performance, and quality – are the unique features of Victaulic products.

Value-added Engineering

ALIGNMENT EASEThe grooved system allows full rotation of the pipe and system components before tightening so that proper alignment can be achieved eliminating mate-up problems and field rework, which makes this system the ideal solution for deck or wall penetrations.

Since 1925, Innovative Design From the Originator of the Grooved Mechanical CouplingRIGIDITYRigidity is achieved with standard couplings. The unique angled pad design of Zero-Flex® and other Victaulic couplings provides positive clamping of the pipe to resist torsional and flexural loads.

FLEXIBILITYThe Victaulic grooved end solution accommodates expansion/contraction/deflection and enables designing that takes advantage of these built-in system features.

Contraction

De�ection

Deflection CapabilitiesRigidity & Flexibility


A UNION AT EVERY JOINTRemoval of two couplings permits removal of a pipe section for replacement, cleaning or servicing.

Exaggerated for clarity

NOISE AND VIBRATION ATTENUATIONExessive vibration and noise continue to be two of the main challenges in the shipbuilding industry. Not only do they decrease the lifetime of the system but they are also key elements in the comfort of the passengers.

Noise attenuation characteristics are inherent in the design of the grooved system. The unique coupling construction enables the gasket to seal against the pipe, while the ductile iron housing provides both space for the elastomeric material to flex and containment to prevent overstretching. The ductile iron also possesses vibration dampening qualities to absorb sound.

IMPROVE PRODUCTIVITY THROUGH PREFABRICATIONAND LEAN CONSTRUCTION TECHNIQUESVictaulic lean construction and prefabrication concepts improve shop fabrication by 20 times,reduce material handling and dramatically improve field constructability, eliminate rework and drive overall productivity improvement.

Prefabrication

MAINTAINABILITY Maintenance plans are a critical element for every ship owner. By using Victaulic mechanical piping systems, changing out or servicing equipment is as easy as loosening two bolts and two nuts. There is no risk and no time required to cut out sections of pipe and re-weld, enabling system maintenance on board and even at open sea.

Victaulic systems provide easy accessibility when conducting preventative systems maintenance, resulting in a continued high level of energy efficiency and little-to-no maintenance time required in the dry dock.

Exaggerated for clarityExaggerated for clarity Exaggerated for clarity


S/77 Coupling

PN10 Slip-On Flange

10

0m

m /

4”

30

0m

m /

12

”

50

0m

m /

20

”

WE

IGH

T IN

KG

.

PIPE SIZE

(Comparison based on one coupling & two flanges)

3.2

15.5

41.4

9.6

33.7

105

20

40

60

80

100

120

Total Weight InstalledVictaulic Coupling versus Flanges

One of the unique benefits of installing Victaulic products in the shipbuilding industry, is that it provides you considerable weight and space savings compared to flanged systems.

Valve assemblies are typically constructed with flanged components, but this joining method can add unnecessary weight to a piping system compared to our grooved assembly:

Example given:

• Flanged valve assembly (6"/152,4mm) consists of:

1 Lug butterfly valve

2 weld-neck flanges

8 bolts and nuts

Approximate weight: 86 pounds/39 kg

• Grooved valve assembly (6"/152,4mm) consists of:

1 grooved end butterfly valve

2 couplings with 2 bolts and nuts each

Approximate weight: 36 pounds/16,3 kg

Result:

Transport More Bulk Instead Of Heavy Equipment

A weight reduction of 58% compared to the flanged assembly.

With only 2 bolts and nuts to tighten on each coupling, 2 pieces of pipe to groove and no need to weld, installing victaulic couplings is much faster compared to welding the flanges to the pipe and tightening the 8 bolts and nuts.


Green Shipbuilding is an inevitable trend in the industry. Victaulic will help you to minimize the negative effects on the environment and maximize the efficient use of raw materials and energy.

Victaulic can greatly improve work efficiency and secure operations at sea as our products and the way they are installed have a low ecological footprint.

Transport More Bulk Instead Of Heavy Equipment

PRODUCTION METHODGrooved products use recycled steel and the products are manufactured using the natural elements of water, fire, sand and air. The manufacture of grooved products also requires the use of sand molds and 98% of the sand molds can be re-used. Dust emissions are far lower than the relevant national environmental standards. Unlike spray painting, grooved products are painted by using a dip coating application to create less wasted paint. Moreover, Victaulic’s products make use of water-soluble paint, which is more environmental friendly and ensures the health and security of the installation crew.

FLAME FREE INSTALLATIONBy-products of weld and solder fumes can contain leadoxide, carbon monoxide, VOCs and hydrochloric acidin addition to many other harmful particles and gases.Reducing the particulate matter preserves indoor and-outdoor air quality leading to a safe and healthyenvironment. Victaulic no-weld pipe joining methodeliminates these harmful airborne pollutants normallyemitted into the environment during the welding process.

VISUAL CONFIRMATION OF A PROPER INSTALLATIONOnce installed, mechanical systems are easily inspected. Our grooved systems provide for quality control through visual confirmation of proper installation. Metal-to-metal bolt pad contact confirms that the joint is properly installed and no re-work is necessary. This eliminates the need of harmfull X-rays.

REDUCING WEIGHTInstalling Victaulic couplings and valves instead of flanged assemblies leads to weight savings, thus also resulting in considerable fuel savings.

REDUCING NOISE POLLUTIONThe elastomeric gasket used to seal pipe couplings also creates discontinuity in the piping system. This reduces noise and vibration transmitted through piping from pumps, chillers and other components.

PROTECTING THE MARINE ENVIRONMENTGrooved products can be used on various applications, such as ballast and bilge water treatment, exhaust emission reduction and system retrofit, to effectively manage the environmental impact of maritime operations.

Please refer to PB-303 "Designing for Sustainability," the brochure which highlights all the solutions offered by Victaulic that support sustainability standards.

Click here to read the brochure.

Sustainable Solutions

Green Shipbuilding


Meet or Beat Finite Project Schedules

3

1

2

6

5

4

9

10

11

8

7

12

MAN

HOU

RS P

ER J

OIN

T

PIPE SIZE

Victaulic Grooved

Welded

Flanged

2" 4" 6" 8" 10" 12"

Quicker, easier installations3 TO 5 TIMES FASTER TO INSTALL

Victaulic will work with you in each phase of the project life cycle. Our services allow you to build, commission, test and turnover your project to meet or beat project schedules.

Victaulic benefits that save you time and valuable resources:

IMPROVED SAFETYNo flame joining method

LABOR SAVINGSEasier maintenance and reduced downtime

When reviewing the design for your piping system, consider:

• Welded systems demand 45% more man-hours on average.

• Hexavalent Chromium, produced by welding stainless steel, is highly toxic.

• Grooved-end valves have a smaller profile and provide you with space-saving advantages over flanged valves.

• Victaulic couplings require only two nuts and bolts compared to flanged systems, and grooved products significantly weigh less, easing handling in the shop and on board.

Please refer to the PB-306 "Worksite Safety" the brochure which highlights how Victaulic can help you to manage safety-related costs.

Click here to read the brochure.


Victaulic will increase project efficiencies and reduce on board installation man-hours from start to finish with value added services.

NU

MBE

R OF

MEN

INST

ALLI

NG

MECHANICAL CONSTRUCTION WEEKS

Shift Maximum Manpower Line

Meet or Beat Project Schedule

Victaulic Peak Man-Power

Welded Peak Man-Power

VICTAULIC SERVICES INCLUDE:

• Estimating

• Pre-Planning and Project Management

• On Board Installation Training

• Software Solutions

• Construction Drawings

•Pad equipment and pump layouts

• Piping layouts

• Fabrication spools

• Laydown coordination

Our Services

Click here for additional information or to download our CAD files.


A broad variety of vessels and rigs all over the world have already taken advantage of the benefits that come along with employing Victaulic products in a wide range of applications.

City Wismar & Cape MolliniSTX Europe, formerly Aker Yards, is an international shipbuilding company based in Norway. As the largest shipbuilding company in Europe and the fourth-largest firm in the world, STX requires that all vessels meet the highest of global industry standards. In 2006, construction was completed on two containerships - Cape Mollini and City Wismar. Because Victaulic products meet stringent global approval standards, the Victaulic grooved pipe joining method was specified and installed on the ship’s galvanized carbon steel drinking water, sea cooling water and fire protection lines.

La SuperbaOne of the world’s largest and fastest luxury cruise ferries, La Superba can house 2,920 passengers and 1,000 vehicles. The owners of the ferry cruise needed a world class piping solution. Noise and vibration attenu-ation, as well as ease of installation and maintenance, made Victaulic a natural choice.

Bohai Shi JiBOHAI SHI JI, a DNV classed Floating Production Storage Offloading (FPSO) vessel is located in the QHD32-6 field development in Bohai Bay China, in a water depth of 20m. The mooring system is designed to produce a total of 270,000 Barrels Per Day (BPD) of combined fluids including 80,000 BPD of crude oil.

Victaulic Style 07 rigid couplings and Style 77 flexible couplings are installed to connect six pipeline systems on FPSO. The contractor, Dalian Shipyard Offshore Co., Ltd., reported substantial time savings on installing Victaulic grooved couplings as compared to flanged products. Furthermore, the installation of Victaulic products provided a reliable and high quality solution for this vessel's 32"/813 mm seawater cooling system.

References


Celebrity EclipseWhen one of the most luxurious cruise ships in the world, the Celebrity Eclipse, operated by Celebrity Cruises, needed a quick upgrade in the Port of Malaga, the contractor, Servyman del Estrecho S.L., and system provider, Mahle – Industrial Filtration, relied on Victaulic piping solutions to meet the operator’s demanding time schedule.

With only a scheduled stop-over of 6 hours to install a new oil/water filter between two containers, Mahle went looking for a solution that was easy and quick to install and enabled Servyman del Estrecho S.L. to prefabricate part of the installation before the ship arrived at the port. To work in the most efficient and cost effective way, Mahle chose to install Victaulic products and to rely on the experience of the Victaulic Construction Piping Services (CPS) division. By employing Victaulic couplings and fittings they were reassured of a smooth and fast installation and the detailed system drawings, made by the CPS division, were used by Servyman del Estrecho S.L. as a blueprint to cut pipes to the exact required length and to prefabricate considerable segments of the installation in their workshop.

Once boarded, Servyman del Estrecho S.L., finished the whole installation in three hours, which included cutting and grooving some pipes on board, resulting in plenty of time left to test the entire system. Installing Victaulic couplings and fittings proved to be the ideal solution to meet and even beat the deadline and allowed the Celebrity Eclipse to continue its journey on the Mediterranean Sea with no delays, resulting in elaborate cost savings for Celebrity Cruises.

• Click here for more references.

www.victaulic.com

The Victaulic website is an information resource that can help you with your piping projects. Among the many resources available at the site:

•Fullysearchableproductandprojectdatabases

•Freeproductsubmittals

•Freeproductliterature

•Pipingsoftwaredemos,modulesanddownloads

• Informationonnewproductinnovations

•Supportservices,andmore...

VICTAULIC IS A REGISTERED TRADEMARK OF VICTAULIC COMPANY. © 2012 VICTAULIC COMPANY. ALL RIGHTS RESERVED.

VICTAULIC GLOBAL CONTACT INFORMATION

US & WORLD HEADQUARTERS

P.O. Box 31Easton, PA 18044-0031 USA

4901 Kesslersville RoadEaston, PA 18040 USA

Sales: David Gibbons+1 610 559 [email protected]

CANADA

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Sales:Scott McDonald+1 800 387 [email protected]

www.victaulic.com

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Sales: Didier Vassal+32 479 20 11 [email protected]

MIDDLE EAST

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ASIA

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Sales:China: Peter Jiang+86 21 6170 [email protected]

Singapore: HP Chan+65 9388 [email protected]

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Sales:Elan Avichzer+61 411 222 [email protected]

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Sales:Ravindra Deshpande+91 9922 423 [email protected]

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Sales:South: Shaun Hughes+44 7867 515 [email protected]

North: David Brownlie+44 7789 640 [email protected]

MB-560 0748 Rev E

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