Co-Flex™ Double Wall Pipe

Transcription

CONTACT US FOR MORE INFORMATION!
1555 Copperhill Parkway / Santa Rosa, CA 95403
Ph: (800) 688-3375 or (707) 523-2050
www.westernfg.com
Co-Flex™ Double Wall Pipe
Installation Instructions
IMPORTANT INFORMATION
FOLLOW ALL INSTRUCTIONS
INTRODUCTION:
Co-Flex piping is an environmentally compatible, double wall, flexible
piping system designed to be installed in Rockguard; our approved chase
conduit. Continuous piping runs connecting tanks and dispensers utilize
sumps to contain and protect pipe terminations.
This installation guide is to be used by trained and certified installers.
Please contact Western Fiberglass for certification information. Co-Flex
warranty is valid only if installation and testing procedures described
within this manual are followed by certified installation personnel.
COPYRIGHT 2006 BY WESTERN FIBERGLASS, INC.
ALL RIGHTS RESERVED. USE BY WRITTEN PERMISSION ONLY.
Page 1 of 12
Ph: (800) 688-3375 or (707) 523-2050
www.westernfg.com
Co-Flex piping is currently available in 3", 2", 1 1/2”, 1", 3/4", 1/2" I.D.
Pipe Diameter (ID)
3/4" Co-Flex
Swivel Fittings System
SPC-0075 SMA-7575
SFA-7575
Coax Fitting System- 1 1/2" & 2" Only
STB-0075 GTT-3836
Use w/Double Wall Only
1" Co-Flex
SPC-0100 SMA-1010 SFA-1010
STB-0100
GTT-3836
1 1/2" Co-Flex
Use w/Single Wall Only
SPC-0150 SMA-1520 SMA-1515 SCC-1515 STF-1515
SEF-1515
SCC-1520 STB-0150
CPC-1501 CPA-1520
CTF-1515
CEF-1515
GCT-3810 GTT-3836 CRA-1515 CCC-1515 CPC-1502
Use w/Double Wall Only DAF-2150
2" Co-Flex
SPC-0200 SMA-2020 SMA-2015 SCC-2020 STF-2020
CPC-2001 CPA-2020
CTF-2020
STF-2215
CRA-2020 CRA-2015
CPC-2002
SRT-2151
SRT-2152
SPC-0300 SMA-3030 SCC-3030 STF-3030
SRT-3320
Use w/Double Wall Only STB-0200
3" Co-Flex
SRT-3230
SEF-2020
SRE-2015
CEF-2020
GCT-3811 GTT-3836
STB-0300
GCT-3812 GTT-3836
Co-Flex flexible piping system installation and testing procedures are
unique. Traditional rigid metal or fiberglass piping procedures do not
apply.
Please read this manual completely prior to installation. Obey all local
regulations and requirements.
Western Fiberglass, Inc. is pleased to assist you in your site planning.
Forward a copy of your site plan to our office for a prompt, computer
generated piping layout and materials print out.
SPECIFICATIONS:
Compatibility: The Co-Flex piping system shall be UL-971 Listed to be
compatible with all current UL tested motor vehicle fuels and blends:
100% ASTM Reference Fuel No. 2
100 % ASTM Reference Fuel C
85% Reference Fuel C – 15% MTBE
70% Reference Fuel C – 30% Ethanol
85% Reference Fuel C – 15% Methanol
Piping Applications: Co-Flex double wall piping is intended for
underground use only. Co-Flex may be used for the following applications:
Page 2 of 12
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Pressure System Supply Piping
Suction System Supply Piping
Tank Vent Piping
Stage II Vapor Recovery Piping
Remote Fill Lines
Terminations: All piping terminations are to be within contained,
accessible, sump areas to facilitate testing and inspection after
installation.
Operating Pressures & Vacuums: Operating pressure should not exceed 75
psi or a vacuum of 29” Mercury.
Operating Temperatures: Operating temperatures should not exceed 150
degrees F or 66 degrees C.
Bend Radius: The listed bend radius should be followed to prevent
cracking, kinking or breaking. Any kinked sections should not be used.
Pipe Diameter (ID) Minimum Bend Radius
3"
72"
2"
36"
1 1/2"
24"
1"
18"
3/4"
18"
On site air temperature does affect the flexibility during installation, the
piping is more pliable when warm.
Testing: Primary piping for 3”, 2”, 1 ½”, 1” and ¾” shall be capable of
maintaining 50 psi for a minimum of one (1) hour. Secondary interstitial
space for 3”, 2”, 1 ½”, 1”, ¾” shall be capable of maintaining 10 psi for a
minimum of one (1) hour. These tests may be performed after installation is
complete, but before backfill. Allowed monitoring methods are by
Pressure, Vaccum or Interstitial Liquid Level Monitoring (ILLM). Please note:
the interstitial space of Co-Flex Piping has a capacity of approx. one (1)
fluid ounce per linear foot. Care needs to be taken when pressurizing the
secondary, add pressure slowly and do not exceed 10 psi during
pressurization process. Always use safe procedures when pressure testing
piping systems. Western Fiberglass, Inc. assumes no liability or responsibility
for testing procedures.
Page 3 of 12
Ph: (800) 688-3375 or (707) 523-2050
www.westernfg.com
Assembly: Co-Flex Co-Flex double wall piping may only be installed within
Rockguard(PI4531) using Western Fiberglass tools and fittings. Failure to do
so may result in product failure and/or a void in system warranty.
Burial Requirements: Co-Flex requires proper burial procedures to ensure
product durability. Please be sure to follow all trenching, backfill materials
and burial depth requirements.
PLEASE NOTE: Co-Flex double wall piping is intended for installation in
normal soil applications.
Storage & Transit: Co-Flex double wall pipe and fittings are not intended
for storage or transport in direct sunlight or excessive temperatures.
Mishandling during transport may cause product damage or result in
leaks. Please be sure to inspect all materials prior to installation. Any
product determined to have been damaged may not be used.
Please see product technical data for additional information.
PIPING ROUTE DESIGN:
Flexible piping system routes and excavation requirements are quite
different than for traditional ridged pipe. Direction changes are made
with “sweeps” rather than 90’s or 45’s. In most installations, pipe trenching
requirements are reduced.
Series system type piping runs are continuous, with the piping originating
from one sump and passing through additional sumps until termination.
Page 4 of 12
Ph: (800) 688-3375 or (707) 523-2050
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Series routing is most desirable for pressure systems. The piping system runs
from the tank sump to each successive dispenser. All piping terminations
are to be within enclosed sump areas, not direct buried. Single and/or
dual pipe lines can be installed to accommodate any total number of
product dispensers. Note: 1 1/2” I.D. Co-Flex piping is typically suitable for
continuous operation of up to six (6) product dispenser nozzles.
Suction system routing requires direct runs where each dispenser is
connected to the tank sump via it’s own pipe line.
Co-Flex flexible piping must be installed in our approved chase conduit 4” Rockguard (PI4531). After installation of conduit, the flexible pipe is
pulled through the conduit by threading a cap with an “I” bolt to the pipe
termination and attaching a rope or cord.
PIPING TRENCHES:
Trenches should be at least twice the width of all piping and/or conduits
to be installed within. One pipe diameter spacing between each pipe run
is required.
Piping systems requiring “fall” should have a minimum of 1% or 1/8” per
linear foot from pipe run termination point back to the tank sump(s).
The recommended backfill and trench bed material is rounded pea
gravel 1/8” to 3/4” in diameter. Crushed stone, 1/8” to 3/4”, and \ or river
sand may be used if washed and it is free flowing.
A 6” bed of recommended backfill material, free from any debris, is
placed in the piping trench prior to installation.
Page 5 of 12
Ph: (800) 688-3375 or (707) 523-2050
www.westernfg.com
Co-Flex piping installed under reinforced concrete surfaces of a minimum
of 4” (100mm) thickness require a minimum cover of 6” (150 mm) of the
recommended backfill material.
Asphalt, 2” (50mm) minimum thickness, requires 6” (150mm) minimum
cover of the recommended backfill material.
Unpaved surfaces require a minimum of 14” (350mm) cover of
recommended backfill material.
After pressure testing is complete, care must be taken to insure even
distribution and packing of the backfill material around the piping during
the back fill process. Hand shovel material around and over piping to
insure correct spacing is maintained. Backfill slowly.
Additional care should be taken when initially filling the piping system to
insure that all air is removed from the product piping prior to starting any
pumps to prevent damage. Be certain that the operating pressure of the
pumping system does not exceed the maximum operating pressure of the
Co-Flex piping of 75 psi.
Periodic testing of both the primary and secondary sections of the Co-Flex
system may be performed at any time after installation.
Please see installation instructions for DMA, dispenser mounting
assemblies, and Western Fiberglass, Inc. tank sumps for details on piping
penetrations.
Page 6 of 12
Ph: (800) 688-3375 or (707) 523-2050
www.westernfg.com
MEASURING PIPE RUNS:
Co-Flex piping is available in 250’, 500’ or 1000’ lengths. It may be ordered
by the foot if required. The greatest care is taken after manufacture to
package and ship your piping to insure against damage. Do not drag CoFlex along the ground, step or place heavy objects on top of the pipe.
Cold weather will affect the flexibility. Leaving the pipe coils in the sun
prior to installation will make them more pliable and easier to handle. In
extreme cold weather, store the piping indoors, at room temperature
before measuring and cutting. A personal type hair dryer can be inserted
into one end of the pipe coil to warm up and relax the pipe. Cut and
discard the first 12” (300mm) of pipe where any heating device has been
attached. This section may be damaged by heat exposure.
The Co-Flex termination fittings are 5” in length. 2” of pipe is inserted within
the termination. An additional 3” is added to the total pipe length at
each end of each pipe run by the installation of the terminations. For
example, if the required pipe length between the internal or “T”
connections inside two separated dispenser boxes is a total of 32’ 9”, you
must subtract 6” to account for the terminations at each end of the pipe
length. This pipe length will now be 32’ 3” before termination.
When measuring pipe lengths, use a pre-stretched line or flat tape to
calculate the distance between connection points.
Be certain to account for all sweeps and additional pipe lengths required
within containment sumps for all connections before cutting.
Co-Flex piping may be installed “lazy” within the piping trench. It does not
have to be stretched straight or tight and can be routed to
accommodate any pipe run requirements. It is important to maintain
proper fall or slope.
Piping lengths can be cut and terminated outside of the piping trench for
ease of installation.
Piping lengths may be pre-cut and terminated off-site.
CUTTING AND TERMINATION:
Co-Flex piping may be cut with any clean, sharp instrument. Be certain to
make all cuts square and even.
Page 7 of 12
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1). Cut Co-Flex pipe to proper lengths.
PLEASE NOTE: Slip Test/Crossover boot over pipe ends prior to installation
of pipe terminations.
2). Strip off final 2” (50mm) of outer containment jacket and remove. This
can be done with a razor knife. Be careful not to cut primary pipe outer
jacket.
FOR SWAGE FITTINGS:
3). The swaging machine may be manual, electric or pneumatic (See
product data). The procedure for preparation of the pipe end is the same
for all types.
4). Attach proper guide block to swage ram unit. (Not used with female
fittings.)
5). Insert draw bar through ram unit.
6). Carefully oil or grease the inside of the piping termination.
7). Insert pipe termination thread first into guide block on ram unit.
8). Screw swage mandrel onto draw bar and firmly against and partly
within the pipe termination.
9). Grease or oil swage mandrel to insure a smooth swage draw cycle.
10). Slide termination swage sleeve (silver) over termination.
Page 8 of 12
Ph: (800) 688-3375 or (707) 523-2050
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11). Insert pipe onto termination and inside swage sleeve. Must be in at
least 1 1/2” or until just visible through holes in swage sleeve.
12). Hand pump or push button to draw swage mandrel through pipe
termination.
13). Release pump pressure and remove fitting.
14). When installing swage fittings, hand-tighten the coupling onto the
Western Fiberglass fitting until snug. Using a Co-Flex wrench, tighten the
coupling nut ¼ turn more or to 200 in/lbs. without allowing the pipe to
rotate while tightening.
CAUTION: Do not over tighten. This may result in damage to the coupling
or potential leaks in the system.
CAUTION: Do not allow sealant to contact the threads of the swage fitting.
15). Remove the protective cap from the coax pipe coupling and verify
that the o-ring seals are clean and properly seated in their o-ring grooves.
Remove the plastic protective cap from the coax adapter, fitting or
connector and inspect the inside sealing surface to make sure it is smooth,
undamaged and free of dirt. Position the coax coupling to the male
threaded port of the coax fitting. This connection seals by way of static oring seals and does not require pipe sealant. Thread the coax swivel nut
onto the male threaded port by hand, until the coupling bottoms out onto
the fitting and stop. DO NOT TIGHTEN THE NUT.
CAUTION: Do not use sealant inside coax couplings or on the connection
threads. This may result in a gasket failure.
PLEASE NOTE: Use only Dow Corning 55 O-Ring Lubricant or equivalent
when cleaning or replacing coax o-rings.
16). The ¾” and 1” Co-Flex pipe couplings are fixed male NPT fittings and
are assembled as rigid steel pipe. After installing the appropriate test
boot, apply a liberal amount of thread sealant or Teflon tape to the
threads of the coupling and tighten to 20 ft/lbs.
17). The jacket of double wall Co-Flex piping must be tested to ensure
liquid tightness. Connect all test and connector tubes into the test boot or
coax fittings. Tighten all band clamps to 30 in/lbs. For coax fittings, use only
Page 9 of 12
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CTT-3836 test tubes with Teflon tape. DO NOT USE METALLIC FITTINGS IN
COAX TEST PORTS – THIS WILL RESULT IN DAMAGE TO THE COAX FITTING.
CAUTION: Swaging must be done in one complete action, do not stop
once you have started.
PLEASE NOTE: Use only Western Fiberglass approved terminations.
DIRECT CONNECTION™ FITTINGS:
Direct Connection fittings use (2) band clamps per fitting. Install with bolts
in opposing directions (see details).
18). Clamps are to be placed no more than ¼” apart. First clamps is to be
no more than ¼” from pipe end nearest to termination fitting.
19). LUBRICATE clamp bolt threads and clamp tongue with WD-40 or light
machine oil. Do not lubricate inside of pipe or outside barbed section of
termination fittings!
20). For 1.5” fittings, initial band clamp torque set is 12 foot pounds. For 2”
fittings, initial band clamp torque set is 20 foot pounds.
21). Tighten clamp nearest pipe termination fitting first. Prior to testing and
after all clamps have been torqued, re-check all torque settings.
CAUTION: Keep all fittings and pipe ends clean!
PLEASE NOTE: Use only Western Fiberglass approved terminations.
INSTALLING PIPE LENGTHS:
After test/crossover boots, and if required crossover supports, have been
installed and pipe termination has been swaged on, insert pipe through
pipe penetration boots one side at time. Remove penetration hose clamp
or loosen first for ease of installation.
Page 10 of 12
Ph: (800) 688-3375 or (707) 523-2050
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Prepare coupling fitting and attach Co-Flex termination fitting (male or
female) to connector within sump area/s. Tighten.
Position pipe within trench. Lay out piping runs while maintaining
separation between pipe lengths and at crossover points.
TEST & CROSSOVER BOOT/TUBING INSTALLATION:
The Test/Crossover Assembly Boots are attached to the Co-Flex Piping
ends to provide a sealed access and test point for the
interstitial/secondary space within the pipe. The Test/Crossover Boots
utilizes two (2) #28 stainless steel hose clamps which when tightened
around the termination fitting swage sleeve and the Co-Flex outer jacket
isolate the interstitial space. An air valve stem is installed in the boot on
the bottom for an outlet opening for connecting the crossover and/or test
tubes. These tubes are used for the testing of and the interconnection of
the interstitial space from pipe section to pipe section. Crossover tube
assemblies are used for junctions within dispenser sumps, pipe to pipe in
line connections, piping run termination points, tank sump connection
points and any piping manifold connection points.
Test/Crossover Boots and tubes are fitted and tightened in place after the
piping terminations and their connections have been made.
After installation and tightening of all test and crossover boots and tubes
pressure testing may be done. (See Above).
Page 11 of 12
Ph: (800) 688-3375 or (707) 523-2050
www.westernfg.com
INITIAL PIPE SYSTEM FILLING:
Upon completion of connection and testing of your Co-Flex system, initial
filling of the system may begin. Be careful to provide a venting point or
place that will allow any air within the piping to escape during this initial
filling. Do not operate any pumping devices until all air has been purged
from piping system. Small bubbles trapped within the system will be
purged under normal operating conditions. Do not exceed the safe
operating pressure of the Co-Flex piping of 75 psi.
MAINTENANCE AND INSPECTION:
Monthly inspections are recommended inside all containment sumps. All
sumps must be kept free of fuel, water and debris. While changing fuel
filters, be sure to clean any excess fuel that may spill into the containment
sump. Any fuel leaks must be reported and investigated by the site owner.
If any leaks or damage to the piping system are detected, immediately
notify Western Fiberglass at (800) 688-3375 or (707) 523-2050.
CAUTION: Ignoring or disabling leak detection alarms can lead to further
damage and possible system failure.
Page 12 of 12

Co-Flex™ Double Wall Pipe

Transcription

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