Conley Installation and Fabrication Manual

8/9/2019 Conley Installation and Fabrication Manual

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INSTALLATION &FABRICATION MANUAL

Email: [email protected]

Conley Corporation 2795 East 91st Street

Tulsa, Oklahoma USA 74137 (800) 331-5502 or (918) 299-5051

Fax (918) 299-5907

April, 2010


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IMPORTANT NOTICE

Fiberglass Reinforced Plastic Piping products have

unique characteristics and must be installed usingsound, proven procedures. To avoid serious personalinjury it is imperative that all installers / fabricatorsfamiliarize themselves thoroughly with the informationcontained in this Installation & Fabrication Manualmaterial before fabricating the product. It is imperativethat all installers / fabricators strictly follow thefabrication and testing procedures set forth in thismanual, paying particular attention to all safetywarnings, cautions and procedures. All installers /fabricators must read and thoroughly familiarize

themselves and follow all instructions, cautions andwarnings addressing heat tapes, adhesive kits or anyConley manufactured products, and on any other toolsor products used. Improper installation may causeserious injury to person and property. Follow allgeneral safety practices and procedures that includeproper use of protective clothing, cleanliness of thework area, surfaces tools, etc., and maintain properventilation.

Conley is committed to excellence and strives to offerthe finest products available. From time to time,products, literature, etc., may change. Conley reservesthe right to modify or change designs or manufacturingprocedure on any of its products and to make changesto its specifications, descriptions, literature andmaterials without incurring any obligation to furnishnotice of such changes, and without incurring anobligation to furnish or install such changes onproducts previously sold. Illustrations as shown in anyConley catalog are representations of a given size, but

do not necessarily apply to all sizes in all cases. VisitConley at www.Conleyfrp.com for the latestinformation, or contact Conley at 800-331-5502. Thisdocument is not intended to express any warranty ofany type whatsoever and shall not alter, change, or addto Conleys Terms and Conditions including Conleyswarranty and its disclaimer of implied warranties.


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TABLE OF CONTENTS

Part 1Installation & Fabrication Manual

General Guidelines .. 1 1. Unloading Pipe and Fittings 1 2. Handling Pipe and Fittings .. 1 3. Tools Required for Fabrication 2 4. Pipe and Fitting Preparation 2 5. Adhesive Mixing 3 6. Application of Adhesive and Joint Fabrication . 5 7 . Swabbing Procedure 7 8 . Adhesive Curing & Use of Heat Tapes . 8 9. Compensation for Temperature Variations .. 910. Bolting Conley Flanges 10

11. Hydrotesting .. 1112. Pipeline Repairs .... 1213. Adhesive Information 1314. Saddle Installation Procedure 1315. Conley Large Diameter (24 & 30) Pipe Field Joint Fabrication Procedure ... 1616. Conley Series 90M Fabrication Procedure ... 1617. Conley Series 90M, Lloyds & ABS Type Approved Joint Coating .. 1718. Fabricating Procedures for Conductive Product .. 1719. Conley Double Containment Piping Installation Instructions . 1920. Connecting Conley Piping to Other Products .. 20

Part 2Fabrication Training Services

1. Conley Standard Fabrication Training and Certification Program .. 232. Conley ASME B31.3 for Process Piping Training and Certification Program ... 233. Conley ABS Type Approval Bonder Training and Certification Program ... 24

Part 3Fabrication Training Services

Items required to have on hand for on-site fabrication training 26Fabrication Seminar Trainee Sign-off Sheet ... 27Conversion Factors . 29Glossary 31Index .. 34


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FIGURES

1 Typical tools required for fabricating ....... 2 2 Remove exterior glaze 1 longer than socket depth ................... 3 3 Remove Part A or 1 4

4 Remove Part B or 2 ... 4 5 Mixing both parts 4 6 Mix until color is consistent ... 4 7 Spread the adhesive thinly after mixing . 5 8 Scrub the end of the pipe . 5 9 Scrub the sanded surface of the pipe . 510 Scrub the socket of the fitting ... 511 Seal face of the fitting 612 Even coat of adhesive in the socket 613 Applying adhesive ...... 614 Connect fitting ..... 6

15 Do not twist pipe ..... 616 Checking level .... 717 Checking plumb . 718 Pulling a fillet ................................................................................................. 719 Visually inspect for the correct amount of adhesive ................... 720 A clean smooth fillet gives the joint a professional appearance ................... 721 Do not overlap heat tape ... 822 Flange bolt torque sequence 1023 Locating the saddle 1324 Drilling the branch hole .. 1425 Sanding the pipe ................... 1426 Sanding the saddle . 1427 Check fit ... 1428 Scrubbing in the pipe surface ... 1529 Sealing the branch hole ................... 1530 Scrubbing the saddle ................... 1531 Setting the saddle ... 1532 Securing the saddle and squeezing the adhesive .... 1533 Heat tape curing . 1634 Ground strap 1835 Grounding 1836 Double containment ... 1937 Interlocking union 1938 Double containment assembly ................... 1939 Double containment assembly ................... 2040 Flange joint .. 2041 Raised face flange .. 2142 Conley diaphragm valve 2143 Lug valve .. 21


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43 Wafer valve .. 2244 Lined valve .. 2245 Knife gate slurry valve ... 2246 Test specimen 25


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TABLES

1 Conley heat tape adhesive cure characteristics ...................... 82 Conley flange to Conley flange 103 Bolt torque 10

4 Adhesive information . 135 Ultimate pullout strength 136 FPC Kit table ... 17


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INSTALLATION & FABRICATION MANUALI. GENERAL GUIDELINES UPON ARRIVAL OF A SHIPMENT OF

CONLEY PIPE AND FITTINGS,IMMEDIATELY INSPECT ALL PIPE

AND FITTINGS FOR INTERNAL ANDEXTERNAL DAMAGE.

GENERALLY, SEVERE EXTERNALSHIPPING DAMAGE INDICATESINTERNAL DAMAGE.

BEFORE UNLOADING & ACCEPTINGTHE PRODUCT, VISUALLY INSPECTFOR DAMAGE. NOTE ANY DAMAGEON THE BILL OF LADING. DAMAGEDPRODUCT MUST NOT BE USED.

1 . UNLOADING PIPE AND FITTINGS

FIBERGLASS REINFORCED PLASTIC(FRP) is lightweight; normally twopeople can easily unload the pipe.

CAREFULLY LIFT and handle the pipeto prevent excessive bending. Do notdrop or impact the pipe.

STORE THE PIPE off the ground andsupport evenly to avoid point loading.

FOR SUPPORT, wooden 2x4 boardsspaced every 5 ft. will supply anadequate bearing surface. Ensure thatno sharp edges contact the pipe.

COVER THE PIPE to avoidcontamination.

WITH LIFTING EQUIPMENT, use asling rigged to two (2) points on thepipe.

DO NOT USE FORKS OR LIFT POLESIN THE END OF THE PIPE.

DO NOT USE CHAINS OR CABLES TOLIFT THE PIPE.

DO NOT DROP OR THROW PIPE ORFITTINGS

COVER THE FITTINGS to avoidcontamination and protect from falling

objects.

DO NOT POINT LOAD THE PIPE AND FITTINGS .

2. HANDLING PIPE AND FITTINGS

Cut off any damaged section of pipeBEFORE use.


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3. TOOLS REQUIRED FORFABRICATION OF CONLEYPRODUCTS

Figure 1 Typical tools required forfabricating

ACCEPTABLE CUTTING TOOLS(1). Circular saw with abrasive blade--(aluminum oxide, carbide or diamondtipped blade)(2). Band Saw / Portable or Stationary(16 to 22 teeth/inch with a speed less than600 ft/min. (Make sure the band saw isoperated dry and free of lubrication)(3). Hack saw with 22-28 teeth/inch

PREPARATION EQUIPMENT ANDSUPPLIES

(1). 4 angle grinder with rubberbacking pad and 24-60 grit disk orsegmented style(2). Emery cloth 40-60 grit(3). Flapper wheel for fittings sockets only(less than 100 grit)

MIXING OF ADHESIVE--TOOLS(1). Flat mixing board - preferable 3 ft x 3ft, any material which is clean & oil free(2). 3 stiff putty knife for mixing part A(Part 1) and part B (Part 2)(3). 1 flexible putty knife for scrub-in andapplication of adhesive(4). Wooden paint sticks to removeadhesive from containers and to applyadhesive to large diameter pipe(5). Wooden tongue depressors forscrub-in and application of adhesive tosmall diameter fittings

SAFETY EQUIPMENT IN ADDITIONTO FOLLOWING OSHA AND JOBSITESAFETY REGULATIONS

(1). Wear safety glasses or face shieldwhen cutting and grinding pipe and mixingadhesive.

(2). Wear dust masks for cutting andgrinding operations.(3). Wear vinyl gloves for mixing andapplying adhesive.

*SEE PRODUCTS SECTION FORFABRICATION STARTER KITS OR CALLYOUR CONLEY REPRESENTATIVEFOR MORE INFORMATION ADHESIVE POST CURE EQUIPMENT

Conley Heat Tape(1). POST CURE IS REQUIRED ON ALL

JOINTS.(2). See Conley Heat Tape AdhesiveCure Characteristics chart for curesettings and times. (TABLE 1, page 8)

*SEE PRODUCTS SECTION FORCONLEY HEAT TAPES

4. PIPE AND FITTING PREPARATION

ABRADINGSANDINGGRINDING(1). Measure the required length and cut

the pipe with hack saw, circular saw orband saw. DO NOT CRUSH THE PIPE if clamping

to hold. Particularly use caution whenusing a chain vice. Chain vices caneasily point load fiberglass pipe. Use apipe vise and protect the pipe surfacefrom point loading.

(2). Prepare the surface of the pipe withan angle grinder or sandpaper. Sandapproximately 1 longer than required bythe socket depth (see Figure 2). Sanding

removes the surface glaze and insuresproper sizing of the pipe O.D. If available,sandblasting is the best method toprepare the surface for bonding. Dust thesanded area with a clean cloth or papertowel. Do not touch the surface withhands or greasy gloves. Prepare the pipeends only on the day of fabrication.


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(3). The fitting sockets are factoryprepared and light cleaning withsandpaper is all that is normally required.IF THE FITTINGS HAVE BEEN STOREDFOR SOME TIME, EXPOSED TO ANOILY ENVIRONMENT OR TO RAIN,DUST AND DIRT, SCRUB THE

SOCKETS WITH A STRONGDEGREASING DETERGENT ANDTHOROUGHLY RINSE AND DRYBEFORE USE. Sand the face of thefitting as well as the socket.

Figure 2 Remove exterior glaze 1longer than socket depth. Conleyrecommends using the 4 grinder(illust rated). Generally, use of a 6grinder is not recommended , as over-grinding is m ore likely to occur.

CLEANINGDO NOT USEPETROLEUM BASED CLEANERS.

(1). Use only clean rags or towels.(2). Wipe down the sanded surfaces ofthe pipe and fitting with acetone ordenatured alcohol; NO EXCEPTIONS.(3). Fiberglass bonding requires amechanical bond and the cleaningprocess removes sanding dust particlesthat interfere with bonding.(4). CHECK CAREFULLY FOR OIL,DIRT OR OTHER CHEMICALCONTAMINATION ON BOTHSURFACES TO BE JOINED.STRONG DETERGENT SOAP (Tide)

AND WATER MAY BE USED WITH ASTIFF BRUSH FOR THOROUGHCLEANING, BUT JOINING SURFACESMUST BE CLEAN AND DRY.

(5). After cutting and preparing thesurface of the pipe and socket, Dry Fitthe pipe and fittingcheck for properdimensions before proceeding to mixing.

5. ADHESIVE MIXING

IMPORTANT NOTES Note 1: ADHESIVE KITS ARE PRECISION

WEIGHED TO PROVIDE ACCURATEQUANTITIES FOR MAXIMUM STRENGTH

AND OPTIMUM CHEMICAL RESISTANCE.

DO NOT ATTEMPT TO RATIO SMALLERQUANTITIES FROM THE KIT.

ALWAYS REMOVE ALL OF PART A ANDPART B OR PART 1 AND PART 2 FROM THE CONTAINERS AND PLACEONTO THE MIXING BOARD.

Note 2: IN LOW AMBIENTTEMPERATURES, WARM THE ADHESIVEBEFORE MIXING. SEE COLD WEATHERCONDITIONING. (Section 9)

Note 3 : USE THE CORRECT ADHESIVE.CHECK THE LABELS FOR ADHESIVE KITSIZE MATCH. ( Part A and Part B or Part1 and Part 2 MUST MATCH.) C-WELDFOR EPOXY PIPING, ESTERWELD FORVINYL ESTER PIPING, FUREX FORFURAN PIPING.

Note 4: REFER TO TABLE 4 SECTION 12TO MATCH THE KIT SIZE TO THENUMBER AND SIZE OF JOINTS TO BEFABRICATED.

Material Safety Data Sheets are supplied witheach shipment and are also available onrequest.

USE A FLAT SQUARE MIXING BOARD(24 to 36) placed on a firm, flatsurface. It helps to anchor the mixingboard.

EMPTY THE ENTIRE CONTENTS OFBOTH CONTAINERS (Part A and PartB or Part 1 and Part 2), onto the mixingboard (see Fig. 3, 4, & 5).


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Figure 3 Remove Part A or 1

Figure 4 Remove Part B or 2

Figure 5 Mixing both parts

MIXING TECHNIQUESUsing a 3putty knife, mix the two componentstogether using turning and spreadingmotions. Make sure all unmixedcomponents are folded into the bulk andmixed (See Figure 6).

Figure 6 Mix until color is consist ent

USE ANOTHER PUTTY KNIFE, tonguedepressor or other scraper to clean themixing knife of unmixed adhesive. Thismaterial, as well as any unblendedmaterial along the edges of the mixingboard, must be carefully mixed with themain bulk of the adhesive to insureproper ratios and complete blending.

CONLEY PART B (Part 2) is black orbrown and Part A (Part 1) is lighter incolor. CONTINUE MIXING UNTIL THE

ADHESIVE MATERIAL IS UNIFORM INCOLOR WITH NO STREAKS.

Note 1: Special color coded piping systemsmay have colored adhesive that matchesthe system. These adhesives may requireextra visual care when mixing to assure thatboth parts are mixed thoroughly.

SPREAD THE MIXED ADHESIVE overthe surface of the mixing board toremove any thick areas (See Figure 7).Bulked adhesive will create more heatand shorten the useable pot life of theadhesive.

IN WARM ENVIRONMENTS, avoidmixing adhesive in direct sunlight. Thesun can heat the exposed adhesive andshorten the pot life (working life).


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Figure 7 Spread the adhesive thin ly after

mixing

6 . APPLICATION OF ADHESIVE ANDJOINT FABRICATION

SCRUB-IN The Scrub-In procedureworks the adhesive into the abradedsurface to provide maximum adhesionwhich is critical to fabrication of a strongmechanical bond. Scrub-in maximizes

joint strength and chemical resistance.Scrub-in applies to the joint surfacesinside the fitting and outside the pipeincluding the end of the pipe and thebottom of the socket. Scrub-in alsoapplies to any cut surface including thehole for a saddle branch. (See Fig 8, 9,10 and 11)

IMPORTANT NOTE Scrub-in seals the end of the pipe or cutedges. Sealing the cut end of the pipe willprevent wicking of the fluid which could have anegative effect pipe structural integrity andability to hold fluid under pressure.

(1). Using a small amount of adhesive,spread a thin layer over all the preparedarea of the pipe, including the cut edge ofthe pipe. Using the side edge of the puttyknife, scrape the prepared area. Scrub-inis best accomplished on the pipe bymoving the knife in the direction of thelength of the pipe. (See Fig 8 & 9)

Figure 8 Scrub the end of the pipe

Figure 9 Scrub the sanded surf ace ofthe pipe

(2). The first application of adhesive tothe socket must be as a thin layer.

Adhesive must be worked into the poresof the fitting socket surface including thebevel (scrub-in). Use the edge of the stickor putty knife to scrub in the adhesive.(See Fig. 10). Seal the face of the fitting(See Fig. 11).

Figure 10 Scrub the socket of the fitting


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Figure 11 Seal face of t he fitt ing

ADHESIVE APPLICATION BUTTERING

(1). Apply a thin even coat of adhesive inthe fitting socket and on the face of thefitting (See Fig. 12).

Note 1: Nominal adhesive thicknesses forfitting sockets is 1/16 for fittings 3 andsmaller and 1/8 for 4 through 20, and 1/4for 24 and 30.

Figure 12 Even coat of adhesive in thesocket

(2). Apply a heavy coat of adhesive onthe scrubbed area of the pipe. Any

excess will be pushed out to the end ofthe fitting where you will pull your fillet.Smooth and slightly taper the adhesive asshown in Figure 13.

Figure 13 Appl ying adhesive

Figure 14 Connect fitt ing

CONNECTION OF PIPE ANDFITTINGS

(1). Push the pipe into the fitting or thefitting onto the pipe (See Fig. 14 & 15).DO NOT withdraw pipe after insertion.DO NOT twist as you would with PVC.

Any back movement or withdrawal maydraw air into the glue line and causeleakage. Make any slight adjustments forplumb and level.

Figure 15 Do not twist pipe or fitting


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Figure 16 Checking level

Figure 17 Checking plumb

Figure 18 Pulling a fill et

(2). Scrape excess adhesive squeeze infrom the interior of the joint (usuallypossible in larger diameter piping). Insmall diameter piping a small even beadof adhesive must be visible. (See Fig. 19)

(3). Make sure you see a complete Ring(squeeze out) of adhesive at the end ofthe socket. If you do not, remove thefitting and start over, beginning with the

ADHESIVE APPLICATION BUTTERING on page 6. The inside ofthe fitting must have a small ring ofadhesive uniformly filling the bevel areabut not thick enough to cause flowrestrictions.

Figure 19 Visually inspect for the correctamount o f adhesive, a small even bead

(4). Use the excessive adhesivesqueeze out on the pipe exterior to makean attractive fillet, then remove theadditional material. (Fig. 18 & 20)

Figure 20 A clean smooth fillet gives the jo in t a pr ofess ional appearance.

7. SWABBING PROCEDURE FORCONLEY PIPE

WHEN FIELD FABRICATING SMALLDIAMETER CONLEY PIPINGSYSTEMS (1 and smaller), it may benecessary to pull a cleaning swabthrough the assembly to removeexcessive adhesive.


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INSTALL A PULL CORD DURING ASSEMBLY of the pipe and fittings toinsure a continuous length for thesegment. This length will varydepending on the complexity of thesegment, the number and type of fittingsused, and the length of the straight runs.

ONCE THE SEGMENT IS TOGETHER,tie a cleaning swab to the pull cord andpull it through before the adhesivehardens. Depending on the complexityand length, it may be necessary to pullthe cleaning swab through in onedirection; attach a new swab, and pull itback through. For this reason, it is bestto initially attach a return pull cord to thecleaning swab.

WHEN PULLING THE SWABTHROUGH, do not allow the joints tomove.

8. ADHESIVE CURING & USE OFHEAT TAPES

Proper cure of Conley Adhesivesrequires t he use of a Conley Heat Tape.

Wrap the Conley Heat Tape around thepipe and fitting at the joint. You maybegin the curing process while the jointis wet OR wait until several joints havehardened under ambient conditions anduse the heat tape to cure multiple jointsat the same time. However, if theambient temperature is below 70F,always use the heat tape to achieve B-Stage (hard to the touch) and full cure.

The following table indicates theapproximate final stage curing times atdifferent temperatures for Conleyadhesives. The initial or B Stage (hardto the touch) is accomplished either byhigh ambient temperature or with a lowtemperature setting on the heat tape.

Figure 21 Do not overlap heat tape.

TABLE 1 CONLEY HEAT TAPE ADHESIVE CURE CHARACTERISTICS Ambientdegrees

PipeSize

HeatTapeB

StageTimeSetting

HeatTape FullCure

TimeSetting

TotalCureTime

80 90F ALL 30 MinLow-Med

1 Hr -High

1 Hr-30 min

70 80F 1 to4

30 MinLow-Med

1 Hr -High

1 Hr-30 min

70 80F 6 to12.*

45 MinLow-Med

1 Hr -High

1 Hr-45 min

70 80F 14 *to30 *

1 HrLow-Med

2 Hr -High

3 Hr

Below70F

ALL See Cold WeatherFabrication Procedures

Below50F

ALL Consult Conley FieldServices [email protected]

* 12 and above will need more than one heattape for full c overage

Note 1: Temperature conditions above90F necessitate lowering of the initialsetting to avoid adhesive overheating whichcould cause air channeling and leakage.

Note 2: Exposure to direct sunlight mayshorten the setting and cure time.

Note 3: Exposure to cool or cold wind willlengthen setting and cure time.


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Note 4: While these values are a goodrepresentation of the behavior of Conleyadhesive, changes in humidity, exposure tosunlight, and exposure to wind (cooling)cause variations from these curing times.THESE APPROXIMATE CURING TIMES

ARE GIVEN AS A GUIDE ONLY. Youcannot over-cure a joint, so when in doubt

opt for a longer cure time.

9. COMPENSATION FORTEMPERATURE VARIATIONS

All thermosetting adhesives are sensitive totemperature variations, not only in theircuring time, but also in their behavior andworkability. In the temperature range of75-90F, Conley adhesive should appearas a stiff but workable paste. Although it isrecommended that all fabrication work occurwithin this temperature range, variousmeasures may be taken to effectivelycompensate for temperature variation.

COLD WEATHER CONDITIONS:Cooler temperatures, less than 75F,can cause components of the adhesiveto stiffen. This will cause extremedifficulty in mixing the adhesive andwetting the surfaces to be glued.

(1). If possible place the adhesive kits in

a warm area for approximately 8 hoursbefore use. If this is not possible gentlywarm the individual containers (of Part 1or Part A only) in an oven or with a heattape. This will lower the viscositysufficiently to permit proper mixing andapplication of the adhesive. Avoidoverheating, as this will cause theadhesive viscosity to drop excessively.Overheating will also shorten the adhesivepot life.

(2). Warm the pipe and fittings beforeapplication of the adhesive to help insurea good wet in of the surface. Warmsurfaces accept the adhesive much morereadily than cold surfaces.

(3). Do not attempt to cure a joint tooquickly. After the adhesive joint is made,

it should remain immobile until theadhesive fillet is hard to the touch.

Allow the adhesive to B Stage using aConley Heat Tape on Low setting. The

joint must be allowed to reach B Stage(hard to the touch) prior to post curing with

the heat tape. Rushing the process willresult in adhesive percolation or boilingand render the glue unstable. This willcause the joint to fail!

(4). After reaching B Stage, turn theheat tape to Max for at least 1 hours.

Note 1: For examples of common curecharacteristics at given temperatures, seeTABLE 1 Conley Heat Tapes. Fig. 21illustrates proper heat tape application.

Note 2: Although the glue on the outside ofthe fillet area may be hard, it does notnecessarily mean that the adhesive on theinside of the joint is cured. The insulatingproperties of fiberglass fittings and pipecause the glue line to cure more slowlythan the outside fillet area.

Note 3: Use the heat tape with insulation oran insulating reflective Mylar blanket(space blanket) to hold heat in coldenvironments. Wrap the heat tape edge toedge with no gaps (DO NOT OVERLAPHEAT TAPE). Cover the ends of the pipe tostop the air flow.

WARM WEATHER CONDITIONS:To extend the pot life of the adhesive inwarm weather conditions, AVOIDworking directly in the sun. If fabricationin direct sunlight is un-avoidable,remember to spread the mixed adhesivethinly on your mixing board to extendpot life. (See Fig 7, page 5).

Bulking the adhesive on your mixing boardfor any length of time will decrease the potlife.


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CONDITIONS OF EXTREMEHUMIDITY:

Avoid fabricating outdoors in rain, fog,snow, or mist. Moisture on the surface ofthe pipe and fittings will prevent the properbonding of adhesive. If fabricating isnecessary under these conditions the pipe

and fittings must be sheltered andthoroughly dried before, during, and until afully cured joint is made.

Please read and follow all safetyprocedures.

10. BOLTING CONLEY FLANGES

Conley flanges are fiberglass and willnot withstand the torque that a metalflange will take.

Use the Conley torque chart whenbolting Conley flanges (TABLE 3).

DO NOT OVER-TORQUE THEFLANGES. This will crack the flange,and the nuts and bolts will cut into theface of the flange.

Use a cross torque pattern to tightenflange bolts. Snug the first bolt; snug thesecond bolt on the opposite side of theflange. Continue to snug the bolts inthis cross fashion until all bolts are snug.

Next, starting with the first bolt, torque in

5 ft-lb increments using the sequenceshown in Fig. 22 until the specifiedtorque is reached.

Figure 22 Flange Bolt Torque Sequence

On flanges 10 and above, start the bolttorque at one half the recommendedvalue and continue in 5 ft-lb incrementsusing the sequence shown in Fig. 22until the specified torque is reached.

GASKETS ARE TO BE 1/8 FULLFACE, 50-70 DUROMETER ON SHORE ASCALE.

TABLE 2 CONLEY FLANGE TO CONLEYFLANGEConley Schedule 40 Flange Bolting, 150 PSI

FlangeSize

Holes HoleSize

BoltSize

BoltLength

1 4 5/8 1/2 3 1/41 4 5/8 1/2" 3 1/4

2 4 3/4 5/8 3 7/8"2 4 3/4 5/8 4

3 4 3/4 5/8 3 7/8"4 8 3/4 5/8 4 5/8"6 8 7/8 3/4" 4 1/2"8 8 7/8 3/4" 4 3/4

10 12 1 7/8 5 1/812 12 1 7/8 614 12 1 1/8 1 6 3/416 16 1 1/8 1 7 3/818 16 1 1/4 1 1/8 7 7/820 20 1 1/4 1 1/8 8 5/824 20 1 3/8 1 1/4 9 30 Contact Conley for information

Bolts: hex head with SAE flat washers oneach sideNote1: Washers are required on all nut s and7bolts.Note2: For 3 -8 Sch 30 Flanges please referto Fittings Specification.

TABLE 3Bolt Torque* ft-lbs (lubricated threads)NomSize 1-2 2-4 6 8-20 24-30

*crosstorque 20 25 30 35 50


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11. HYDROTESTING

Testing Recommendations & Procedures

RECOMMENDATIONS

(1). Test Conley Fiberglass Piping

Systems before use to help insure that thesystem is properly installed. Al l jo in tsmust be post cured prior to linetesting.

(2). For above-ground systems, all pipesupports, guides and anchors must be inplace and secured prior to testing.

(3). Never stand in the direct flow path orin front of a pressurized joint or fitting.

(4). Buried lines should be partiallybackfilled or weighted at intervalssufficient to secure the system prior totesting. Be certain to leave joints exposedfor inspection and verification ofsoundness.

(5). Conley recommends that pipingsystems be tested in short sections duringfabrication to verify the quality ofinstallation as work proceeds.

CAUTION: WHEN TESTINGFIBERGLASS PIPING SYSTEMS,SUDDEN SURGES IN PRESSUREKNOWN AS WATER HAMMER SHOULDBE AVOIDED. SUDDEN SURGES CANCREATE VERY HIGH PRESSURES THATOFTEN EXCEED THE PRESSURERATING OF THE PIPE AND RESULT INJOINT OR COMPONENT FAILURE.

Note 1: Monitor cold weather testing closelyto prevent the possibility of freezing the liquidin the system.

WARNING: TESTING WITH AIR ORGAS IS EXTREMELY HAZARDOUS ANDSHOULD NOT BE DONE DUE TO THENATURE OF PLASTICS. A FAILUREDURING TESTING WITH AIR WILLCAUSE EXTREMELY DESTRUCTIVEWHIPPING OF THE PIPE AS WELL ASOTHER SHOCK INDUCED REACTIONS.THESE OCCURRENCES WILL LIKELYRESULT IN DAMAGE TO PROPERTY ASWELL AS INJURY OR DEATH TOPERSONNEL.

Conley will not assume any liabilityunder any warranty, contract or in tort forany damage to property or equipment orinjury to personnel that results from testingwith air or gas.

In the event testing must be conductedusing air, please contact Conley forsuggestions that will help reduce theconsiderable risk involved.Notwithstanding Conleys suggestions,testing with air is entirely at the risk of thetester and/or those responsible for thetesting.

TEST PROCEDURESNote 1: Always check local codes as they maydictate modifications to Conleys testprocedures, or may require a differentprocedure.

CONLEY RECOMMENDS FOLLOWINGTHESE PROCEDURES VERY CLOSELY INORDER TO ELIMINATE THE POSSIBILITY OFSERIOUS PERSONAL INJURY ORPROPERTY DAMAGE. FAILURE TO FOLLOWTHESE PROCEDURES WILL RESULT IN THELOSS OF THE WARRANTY. THE BUYER,INSTALLER, ANY EMPLOYEE AGENT OR

REPRESENTATIVE THEREOF ASSUMES THERISK OF ANY PERSONAL INJURY ORPROPERTY DAMAGE CAUSED BY TESTING

AND USER/TESTER, ASSUMES ALL RISKS ASSOCIATED WITH TESTING AND AGREESTO HOLD CONLEY AND ITS OFFICERS,DIRECTORS AND EMPLOYEES HARMLESSFROM ANY DAMAGES OF ANY TYPE THATRESULT FROM TESTING.


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The normal recommended testingprocedure is to perform a hydrostatictest, either cyclic or static at 1 timesthe design operating pressure. Theduration and choice of static or cyclic willbe a decision of the design engineer.

(1). FILLING THE PIPE FOR TESTING Slowly fill the system with water fromthe lowest point with the high point ventsfully opened to allow air to purge. If highpoint vents are not being used, breakloose the highest flange connection toallow for the removal of air.

Insure that all high point loops areopened so that the line is able to properlypurge.

Once water begins to escape from thehighest point, allow this process tocontinue for several minutes to clear thesystem of air. While water and air arecoming from the highest points, slowlyclose all of the vents or flangeconnections.DO NOT ALLOW PRESSURE TOBUILD AT THIS TIME.

(2). INSPECT THE LINE

Inspect the line and check for leaks atglue lines or joint connections. If a leakis discovered at a flange connection,carefully tighten the flange.

DO NOT OVER TORQUE THEFLANGE AS THIS WILL CAUSE THEFLANGE TO CRACK. LEAKS ATFLANGES ARE OFTEN THE RESULTOF A PINCHED GASKET OR DIRT ONTHE SEALING FACE OF A FLANGE.

(3). BUILDING TO TEST PRESSURE.Test pressure is usually 1.5 times theoperating pressure.

After inspection of the system, slowlyincrease the pressure in smallincrements not to exceed 25-30 PSI.Repeat this process several times until

the desired test pressure is achieved.Hydrostatic test duration is usually from1-8 hours and is designated by the enduser or specifying engineer.

12. PIPELINE REPAIRS

If a weep is discovered in the pipe wall,it is generally the result of impactdamage or inadequately sealed pipeends. Locate the source of the leak andcut out the damaged area and repairwith new pipe and couplings, be sure toseal the end of the pipe.

If no obvious crack is found, there canbe weeping caused by improper fab, notsealing the cut pipe end. The mediacan move around the corrosion barrier

and wick into the cage (structural wall).Call Conley Corp for assistance andtechnical advice.

If the leak appears in the wall of thefitting, cut it out and inspect the interiorcarefully for impact damage. Replacewith a new fitting . Do not attempt toremove pipe from the fitting socketsor attempt to reuse the fitting.

If a leak appears in the adhesive joint,

cut out the joint and repair with acoupling or fitting.

Special overwrap procedures fortemporary repair of lines are available.CONSULT WITH A FACTORYTECHNICAL REPRESENTATIVEBEFORE PERFORMING THISREPAIR. FACTORY OVERWRAP KITS

ARE AVAILABLE.

FOR ASSISTANCE PLEASE CALL

CONLEY FIELD SERVICES:[email protected]


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13. ADHESIVE INFORMATIONTABLE 4

SIZE NOTE: # OF JOINTSPER 1 CUP KIT1 14

1 102 7

2 53 44 26 1

SIZE NOTE: # OF 2 CUPKITS PER JOINT8 1

10 212 214 216 318 320 424 430 5

TABLE 5Ultimate Pullout Strengt h C-weld,Esterweld, Furex

SIZE STRENGTH1 10,900 lbs

1 15,700 lbs2 23,000 lbs

2 37,000 lbs3 44,000 lbs4 74,000 lbs6 144,000 lbs8 202,000 lbs

10 268,000 lbs12 364,000 lbs14 445,000 lbs16 569,000 lbs

18 717,000 lbs20 875,000 lbs24 1,100,000 lbs30 1,700,000 lbs

ADHESIVE PROPERTIES Tensile Shear--1100 PSI Shelf Life--2 years at room temp

Chemical Resistance: See ChemicalResistance Chart

Pot Life after Mixing at 80F: 30 Min(1/4 thick)

14. SADDLE INSTALLATIONPROCEDURE

If the line is in service, drain and ordepressurize the line prior to saddleinstallation.

LOCATE THE SADDLE per drawing orfield location. Dry fit the saddle in thedesired location. With the saddle inplace, trace around the outside of thesaddle on the existing pipe with amarker. (Soapstone is not

recommended). Also trace the I.D. ofthe branch socket before removing thesaddle.

Figure 23 Locating the saddle

USE A DRILL MOTOR and appropriatehole saw to drill the branch hole in pipesizes up to 4. For larger diameterbranches, a reciprocating saw isrecommended. Drill several holes just

inside the drawn branch circle as thestarting point for the reciprocating saw.


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Figure 24 Drilling the branch hole

Note1: When drilling holes in FRP use ahigh quality, sharp, metal bit. Do not forcethe bit through the wall of the pipe. Let theweight of the drill motor penetrate the pipe.If the bit is forced through the wall, damage

to the inner corrosion liner could result.

AFTER DRILLING the branch hole, usea 4 angle grinder with a rubberbacking pad and 24-60 grit sanding discto abrade the exterior wall of the pipewithin the marked area and about 1beyond the line. Lightly sand theunderside of the saddle. Dry fit thesaddle to make sure the holes areproperly aligned as well as the sandedarea. If everything is acceptable,

remove the saddle and degrease theO.D. of the pipe and underside of thesaddle.

Figure 25 Sanding the pipe

Figure 26 Sanding the saddle

Figure 27 Check fit

MIX THE CORRECT TYPE ANDPROPER AMOUNT of adhesive andscrub into the prepared area of the pipeO.D. and the underside of the saddle.Remember to seal (scrub-in) the cutedge of the hole in the pipe wall.

Apply a thick layer of adhesive onboth the pipe O.D. and the saddleunderside. Press the saddle onto thepipe and use a banding tool or hoseclamps to tighten the saddle onto thepipe. Tighten the clamps to squeezeout the excess adhesive. As theadhesive is forced out, remove all butenough to form a neat fillet around theedges of the saddle. Remove theexcessive adhesive on the inside of thesaddle. Form a smooth transition fromthe pipe I.D. into the branch.


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Figure 28 Scrubbing in the pipe surface

Figure 29 Sealing (scrubbing-in) the branchhole

Figure 30 Scrubbing in the saddle Note 2: If installing saddles with female

pipe threads, closely watch the adhesive atthe branch and remove the excess adhesiveas it builds up to avoid coating the threads.

Acetone or degreaser may be used to cleanthe threads while the adhesive is soft. Bestoption is to place tape over the threads prior

to fabrication. Remove the tape after the joint is completed.

Note 3: On large diameter branches, use apiece of cardboard or plastic to catch theexcessive adhesive. Remove and discardthe excess adhesive.

Figure 31 Setting the saddle

Figure 32 Securing the saddle and squeezingthe adhesive

FINALLY, HEAT TAPE THE SADDLE,see TABLE 1, page 8. Clamps or bandsshould be left in place.


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Figure 33 Heat tape curing

15. CONLEY LARGE DIAMETER (24& 30 ) PIPE FIELD JOINTFABRICATION PROCEDURE

LARGE DIAMETER PIPE ANDFITTINGS use the same straight socket joining system as all Conley PipingProducts. The pipe and fitting jointpreparation and dry-fit procedures areexactly the same for all sizes. Due tothe volume of adhesive required, fourmixing boards and four mixers shouldbe available to mix and apply thematerial.

SHADE THE PIPE AND FITTINGS from

direct sunlight to keep the material ascool as possible. Have both the pipeand fitting in position with the necessaryequipment to push the pipe into thefitting or the fitting onto the pipe.

BEGIN MIXING the adhesive perinstructions with three mixers workingwith two 2-cup kits, and one of mixersworking with three 2-cup kits. Aftercompleting the mixing, two of thefabricators should start at the top or 12

oclock position on the fitting socket,scrubbing-in the adhesive until theymeet at the bottom or 6 oclock position.The remaining two fabricators shouldstart at the top or 12 oclock position ofthe pipe, scrubbing-in the adhesive untilthey meet at the bottom or 6 oclockposition.

ONCE SCRUBBED IN, apply theadhesive liberally to the outside of thepipe but only about in thickness tothe inside of the socket of the fitting.Use all the adhesive that is mixed.

Apply any excess to the outside of thepipe.

PUSH THE PIPE STRAIGHT INTOFITTING (or fitting straight onto pipe),without twisting. Lock the joint intoplace with pulling equipment andimmediately make a fillet or bevel.Reach inside the fitting (if possible) andremove any excess adhesive. Leavethe pulling equipment in place until theadhesive is fully cured to avoid hydraulicpush-out between the pipe and fitting.

Refer to curing times in Table 1, page 8 THE KEY TO LARGE JOINT

FABRICATION IS to move quickly andkeep any mixed adhesive spread thinlyon the mixing board before application.

16. CONLEY SERIES 90MFABRICATION PROCEDURE

Conley Series 90M materials are typicallyused for off-shore piping systems where fire

resistance is required. They can, however,be used anywhere a customer desires fireprotected pipe and fittings.

FABRICATION PROCEDURES. Thefabrication procedures differ very littlefrom standard systems. Thosedifferences are:

(1). The fire protective coating must beremoved to a distance 1 greater than thesocket depth before removing the glaze

from the exterior of the pipe. Refer toSection 4 Conley Installation & FabricationManual.

(2). The fire protective coating must beremoved from the face of the fitting. Thenlightly abrade the fitting face as stated inSection 4 Conley Installation & FabricationManual.


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(3). Once the joint is properly fabricatedusing standard fabrication methods, a fieldfire protective coating must be applied.This material is to be applied per Section17.

It is important to stress that the 90MFABRICATION PROCEDURES ARETHE SAME AS OTHER CONLEYSYSTEMS EXCEPT FOR REMOVALOF FIRE PROTECTIVE COATING priorto fabrication and the recoating of the

joints after fabrication and post curing.

17. CONLEY SERIES 90M, LLOYDS& ABS TYPE APPROVED JOINTCOATING KIT/FIELDPROCEDURES FOR FIREPROTECTION COATING (FPC)

MATERIAL PREPARATION: Surface mustbe clean and dust free for proper bonding.

THE ADHESIVE GLUE LINE must belightly sanded to ensure a good bondingsurface for the coating material.

THE SANDED AREA must be wipedclean.

JOINT COATING is to be applied to aclean and dry surface by brushing. Usethe brush supplied in the FPC Kit, or asimilar type brush. Make sure to applythe coating past the glue line and ontothe existing factory fire coating materialto maintain the fire protection integrity ofthe piping system.

COATING THICKNESS for the jointmust be a minimum of 60 mils applied intwo coats of 30 mils each. This isapproximately 1/16 of an inch.

THE COATING MUST BE ALLOWEDTO AIR CURE. Cure time will dependon weather conditions. The coatingmust be protected from the elementsuntil cured.

TABLE 6FPC Kit Table

Size

Approx.Fillet

Areasq. in. Kit Size

Approx. #Fillets

Coated1 4 2 Cup 12

1 6 2 Cup 82 8 2 Cup 63 12 2 Cup 44 15 2 Cup 36 32 1 Cup 38 41 1 Cup 2

10 51 1 Cup 212 82 1 Cup 114 95 1 Cup 116 108 1 Cup 118 120 1 Cup 120 136 2 Cup 1

Note: Kit size recommended is an approximation.This product has a relatively short pot life, and use ofexcess material is not recommended.

18. FABRICATION PROCEDURESFOR CONDUCTIVE PRODUCT

The following procedures must be followedwhen Fabricating Conductive Pipe andFittings:

FIRST, THE PIPE ENDS MUST BEGROUND to expose the conductivefilament. The conductive filament strandwill have a shiny appearance. Next,prep the end of the pipe by grinding andexposing the conductive filament string.

Also, lightly abrade approximately 1 ofthe inner liner to ensure that the liner isclean.

Note: If fabricating 90MC product, refer toSection 16, regarding the fire protectivecoating.

THE SOCKETS OF ALL FITTINGS

must be lightly abraded to ensure agood mechanical bonding surface forthe adhesive. Also, lightly abrade thebevel area of the fitting to ensure thatthe conductive inner liner is clean.

Grounding lugs are shippedindependently (loose) from the pipe andfittings. Before beginning to fabricate,


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pre-size the appropriate ground lugs foreach joint size.

Note 1: Between each flanged joint agasket is used to prevent leakage. Thisgasket interrupts the conductivity of thepiping system which makes using thestainless steel grounding lugs a necessity.Proper use and installation of this groundinglug is shown in Fig. 34 & 35.

Note 2: Do not over-tighten the clamp.Leave a layer of adhesive between the strapand the pipe. Leave the grounding lugexposed.

Where conductive piping is required, theresistance per unit length of the pipe,fittings, elbows, tees, reducers, fabricatedspools with branch connections, etc., should

not exceed 88.4 KOhms/foot (2.9 x 105

Ohms/meter). Conductive piping notmeeting this requirement may be used onlyin non-conductive applications.

Figure 34 Ground Strap

Figure 35 Groun ding

Each side of a flange connection requires agrounding lug clamp. This permits the

continuity to pass through or around aflanged joint connection. A quali fi edelectrician should provide the groundingstrap or wire lead of suitable gauge toconnect from one grounding lug clampto t he other.

CONLEY CAN FURNISH THESTAINLESS GROUNDING LUGCLAMP with conductive adhesive forfield installation. The grounding lug is20 UNC threads.

FOR A DETAILED INSTRUCTIONMANUAL COVERING RESISTANCETESTING, CONTACT CONLEY([email protected]).


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19. CONLEY DOUBLECONTAINMENT PIPINGINSTALLATION INSTRUCTIONS

DOUBLE CONTAINMENT PIPE ANDFITTINGS (FRP carrier and FRPcontainment); use our standard straightsocket joining system. The carrier jointsshould be completed first and thecontainment pipe moved out of the way.

Figure 36 Double containment

WHERE INTERLOCKING UNIONS ARE REQUIRED, locking rings shouldbe slipped over the carrier pipe prior toassembly. One locking ring will belocated on either side of the carrier

coupling. The containment pipe shouldbe trimmed shorter than the carrier pipeby a distance equal to the thickness ofthe locking ring plus one half the carriercoupling length. This step should bedone on both ends of the containmentpipe to allow the bridge coupling to fitwith the correct overlap.

Figure 37 Interlock ing Union

GLUE THE CARRIER COUPLING ontothe carrier pipe, making sure it trapsthe locking ring between the end of thecontainment pipe and the end of thecoupling.

SLIP THE REMAINING LOCKING RINGover the connecting carrier pipe beforeapplying adhesive. Glue the couplingonto the connecting pipe making sure itrests against the locking ring and trapsit between the containment pipe and theend of the coupling. Since the lockingrings are not bonded to the carrier pipeany leakage or seepage can still bedetected during hydrotesting. Do notassemble the outer section or bridgecoupling over the locking rings until the

carrier system has passed hydrotest.

Figure 38 Double Containment Assem bl y

WHEN ALL THE CARRIER JOINTS in asection or area have completely cured,the piping should be hydro-tested to 1.5times the working pressure or ratedpressure, whichever is lower. Test thecarrier according to the Conleyhydrotest joint procedure in Section 11.


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Figure 39 Double Containment As sem bl y

AFTER THE CARRIER PIPE ISTESTED and all the joints areexamined, the containment pipe jointsmay be completed. The bridge

couplings may now be used to close thecontainment system. The containmentpipe may also be tested for jointintegrity. This is usually done with 5 to10 psi vacuum.

CAUTION: DO NOT EXCEED THEMAXIMUM VACUUM RATING FOR THESIZE AND SCHEDULE PIPE BEINGTESTED See PRODUCTS Section forvacuum ratings.

20. CONNECTING CONLEY PIPINGTO OTHER PRODUCTS

Follow the recommended gasketing andbolting requirements in Section 10, Fig. 22,Table 2 & Table 3.

FLANGED CONNECTIONS--Flangedconnections including flat face, raisedface, etc.

Flange bolt connections must be tightenough to slightly compress the gasketand make a good seal without bending oradding excessive stress on the flanges.Maximum allowable misalignment in anydirection is 1/8. Maximum angularallowable misalignment is 1/16. Suitablewashers must be used between the bolthead/nut and flange surface. Bolts must

be tightened with a torque wrench insuitable increments and in alternatingsequence. Use lubricated bolts andrecommended bolt torques from Table 3in Section 10. Do not exceed therecommended flange bolt t orque .

Flange alignment must be achieved priorto tightening the bolts. Any att emp t todraw together or fix misalignment bytightening the bolts may result incracking of the flange and hub.

(1). Flat face flanges : Conley fiberglassflanges can be bolted directly to anymatching flat face flange. Conley flangesshould never be pulled into alignmentand never allowed to be pulledtogether, to close a gap. Follow the

recommended gasketing and boltingrequirements in Section 10, Fig. 22, Table2 & Table 3.

Figure 40 Flange Join t

(2). Raised face flanges : If a raised faceflange cannot be machined flat, a spacerring must be added to achieve a flat face.Do not exceed the recommendedflange bolt torqu e in Section 10 . Followthe recommended gasketing and bolting

requirements in Section 10, Fig. 22, Table2 & Table 3. Steel backing rings may beused with Conley flanges to increase theflange stiffness.


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Figure 41 Raised Face Flange

(3). Valves and other components

a. Do not allow fiberglass pipe tosupport the weight of the valve orcomponent.

b. Flanged valves: Do not exceed therecommended flange bolt torque. .Follow the recommended gasketingand bolting requirements in Section10, Fig. 22, Table 2 & 3. Steelbacking rings may be used withConley flanges to increase theflange stiffness.

c. Wafer body design and lug stylevalves: Refer to Figure 43 and 44

Do not exceed the recommendedflange bolt torque . Follow therecommended gasketing and boltingrequirements in Section 10, Fig. 22,Table 2 & Table 3.

Figure 42 Conley diaphragm valve

Figure 43 Lug Valve


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Figure 44 Wafer Valve

d. Threaded joints require special

attention. The pipe or fitting shouldbe threaded together hand tight.Using a strap wrench only, tightenthe joint an additional to 1- turnspast hand tight. Tightening beyondthis point may cause excessivestress that may result in joint failure.

(4). Lined valves and pipi ngconnections

a. Special consideration is required forconnecting to FRP flanges. Pleaseconsult the valve manufacturer foradditional information.

b. Do not exceed the recommendedflange bolt torque in Section 10 .Follow the recommended gasketingand bolting requirements in Section10, Fig. 22, Table 2 & Table 3.

Figure 45 Lined Valve

Figure 46 Knif e Gate Slurry Valve


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II. FABRICATION TRAINING SERVICESProper fabrication is critical to a successfulinstallation. Conley Training Services aredesigned to provide the installation crewwith the knowledge, skill and confidence toproperly install and test Conley Materials.

Conley Training options available are:1. Conley Standard Fabrication Training

and Certification Program2. Conley ASME B31.3 Training and

Certification Program3. Conley ABS Type Approval Bonder

Training and Certification Program

Note: The ABS Program is designed to satisfythe fabrication / training requirements forOffshore Projects where ABS, DNV, Lloyds arethe surveyors of record.

1. Conley Standard FabricationTraining and Certif ication Program

This Training Program includes a classroomsecession where the trainees review theConley Installation & Fabrication Manual for

All Type Approved Products And ConleyStandard Products.

The classroom session is followed by afabrication demonstration by a ConleyCertified Trainer. Once each Trainee hasdemonstrated the proper fabricationtechniques and completed the fabricationchecklist, he or she will receive aCertification Card and Certificate.

2. Conley ASME B31.3 for ProcessPiping Training and Certif icationProgram

This training program includes a classroomformat where the trainees review the Conley

Installation & Fabrication Manual for AllType Approved Products and ConleyStandard Products.

Also, this program is built upon the ASMErule that the trainee is not only learning thewritten manual but must complete andwitness a test of a spool they haveindependently fabricated.

The following information is listed in the ASME Code B31.3, Chapter VII,Nonmetallic Piping, para. A328 Bonding ofPlastics.

ASME B31.3 requires a formal process ofdeveloping, documenting and qualifyingbonding procedures and personnelperforming the bonding.

The first step is to have a documentedbonding procedure specification (BPS). Thespecification must document the proceduresfor making the joint, as set forth in para.

A328 as follows:

BONDING RESPONSIBILITYEach employer is responsible for thebonding performed by his personnel andshall conduct the required performancequalification tests to qualify bondingprocedure specifications (BPS), andbonders or bonding operators.

Note 1: The information listed abovecan be found in ASME B31.3, para.

A328.

Note 2: The Conley Field FabricationCertified Trainer will be responsible forcompleting the Training/Certification perthe BPS. The Conley Bonding


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Procedures (BPS) consist of the ConleyInstallation & Fabrication Manual.

BPS REQUIRED SPECIFICATIONSThe BPS is required to specify at least thefollowing:

All materials and supplies (includingstorage requirements)

Tools and fixtures (including propercare and handling)

Environmental requirements (e.g.temperature, humidity and method ofmeasurement)

Joint preparation Dimensional requirements and

tolerances Cure time Protection of work Tests and examinations other than

those required by ASME B31.3 para. A328.

Acceptance criteria for the completedtest assembly

SIZE REQUIREMENTSTo qualify the BPS, at least one of each

joint type covered by the BPS must beincluded in the test(s). With respect to size,if the largest joint is NPS 4 (100mm) or

smaller, the test assembly is required to bethe largest size to be joined. If the largestpipe to be joined is greater than NPS 4(100mm), the size must be NPS 4 (100mm)or 25% of the largest pipe to be joined,whichever is greater.

QUALIFICATION RECORDSThe bonding procedure must be qualified bytest to be used by the organization for whichthe bonder works. The BPS and records ofthe BPS qualifications must be maintained

by the employer and be available for reviewby the Owner or Owners agents and theinspector.

QUALIFICATION TEST The qualification test is the same for thebonding procedure and the bonder. Thebonder must fabricate an assembly andpressure test it. Testing shall be inaccordance with para. A328.

General Notes from Conley: Note 1: Production joints shall be made

only by qualified bonders or bondingoperators who have appropriate training andexperience in the use of the applicable BPSand have satisfactorily passed aperformance qualification test that wasperformed in accordance with a qualifiedBPS.

Note 2: Each qualified bonder and bondingoperator shall be assigned an identificationsymbol. Each pressure containing bond oradjacent area shall be stenciled or otherwisesuitably marked with the identificationsymbol of the bonder or bonding operator.

Note 3: Please note that this is a summaryonly of the ASME Code requirements forB31.3, para. A328, Bonding of Plastics.Conley will follow the requirements of theproject specification as it relates to thecurrent edition of the code which must be inforce and applicable.

3. CONLEY ABS TYPE APPROVALBONDER TRAINING ANDCERTIFICATION PROGRAM

This training program includes a classroomsession to assist reviewing the ConleyInstallation & Fabrication Manual for AllType Approved Products and ConleyStandard Products.

This program also is built upon the ABS rulethat the trainee is not only learning thewritten manual but must complete andwitness a test of a spool they haveindependently fabricated.Typically, an ABS Surveyor whose time andscheduling are the responsibility of thecontractor will be present to witness, at aminimum, the test of each individuals spool.


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BONDING OPERATORQUALIFICATION

Each bonder and each bonding operator areto make up test assemblies, the size andnumber of which are to be as requiredbelow.

TEST ASSEMBLY A test assembly (spool) is to be fabricated inaccordance with the Conley Qualified JointBonding Procedure for Type ApprovedProducts and it is to consist of at least onepipe-to-pipe joint and one pipe-to-fitting

joint.

When the test assembly (spool) has beencured, it is to be subjected to a hydrostatictest pressure at a safety factor of 2.5 timesthe design pressure for not less than onehour. No leakage or separation of joints isallowed. The test is to be conducted so thatthe joint is loaded in both the longitudinaland circumferential direction.

PIPE SIZESelection of the pipe used for the testassembly must be in accordance with thefollowing:

When the largest pipe size to be joined is 8in. (200 mm) nominal outside diameter, thesize of the test assembly (spool) is to beeither 8 in. or 25% of the largest piping sizeto be joined, whichever is greater. ForConley Type Approved Products through 20in. diameter, the test assembly (spool) pipesize is to be 8 in. and fabricated in

accordance with the drawing ABS 8 TESTSPOOL DIMENSIONS.

Figure 47 Test Specimen

To schedule on-sight fabrication training foryour project contact:



Tulsa, Oklahoma USA 74137 (800) 331-5502 or (918) 299-5051

Fax (918) 299-5907


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III. FABRICATION TRAINING SERVICES:

Items required for on-site fabrication training

Items to have available for on-site training: Clean work table (example: 4 x 8 sheet of plywood on sturdy sawhorses, etc.). 2 ft x 2ft piece of clean plywood, particle board, or like material to be used for

mixing adhesive. 3 Stiff putty knife. 1 Flexible putty knife. 4 angle grinder. 4 rubber backing pad and sanding discs (24 to 60 grit). OR 4 one piece flapper style sanding pads (24 to 60 grit). Drill Motor. 60 grit sanding drum to fit in drill motor. Clean Rags. One gallon of Acetone or Denatured Alcohol. 60 to 80 grit sand cloth. Other standard pipe fitting equipment (level, square, pipe stands, etc.) XL latex surgical style rubber gloves. Power supply, extension cord, etc. Dust Masks.

Cold Weather (below 60 degrees F)1. Portable forced air heater.2. Heat tent.3. Heated area to keep fittings and adhesive warm.

Hot Weather (above 80 degrees F)1. Shaded area for mixing adhesive.2. Cool area for storing adhesive.

To schedule on-sight training for your project contact:Email: [email protected]


Tulsa, Oklahoma USA 74137 (800)-331-5502(918) 299-5051

Fax (918) 299-5907


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CONLEY CORPORATIONFABRICATION SEMINAR TRAINEE SIGN-OFF SHEET

INITIAL FOR PREPARATION OF

CONLEY PIPE & FITTINGS ______ 1. Proper cutting of Conley Pipe.

______ 2. Glaze must be removed beforecementing to a distance 1greater than the socket depth.

______ 3. Use a 24-60 grit abrasivesanding disc on a 4 anglegrinder with rubber backing pad.

______ 4. Clean the fitting sockets withemery cloth (sand cloth) or aflapper wheel to abrade thesurface of the socket andremove any potentialcontamination. (Grit must be 100or less)

______ 5. Surface must be cleaned using Acetone or Denatured Alcohol.Surface must be clean, dry andfree of contamination.

______ 6. Both pipe and fitting surfacesneed to be clean and dry. Theymust also be dust, dirt, grease,and glaze free for a goodadhesive bond.

INITIAL FOR MIXING PROCEDURE

______ 1. Empty the entire contents ofadhesive and hardner onto athrow-away cardboard surface ora permanent mixing stationwhich is cleaned after each mix.

______ 2. The two components must bemixed thoroughly. All colorstreaks must disappear. Takeextra care when mixing colorcoded adhesive.

______ 3. Unmixed portions will causeuncured spots that will causeleakage.

______ 4. Using partial adhesive kits forany joint is strictly prohibited.

INITIAL FOR ADHESIVE BONDING OFCONLEY PIPE

______ 1. A thin layer of adhesive must bescrubbed into the socket of thefitting.

______ 2. Apply an even layer of adhesiveto the fitting socket. Do notoverload the socket It will causeexcessive push in. Appropriatethickness is 1/16 for fittings 3and smaller, and 1/8 for 4 andlarger.

______ 3. Seal the cut end of the pipe witha coating of adhesive.

______ 4. Apply a thin coating of adhesiveto the exterior of the pipe. Scrubthe adhesive into the surface ofthe pipe.

______ 5. Apply a generous coat ofadhesive to the scrubbed area ofthe pipe. This layer should be aMINIMUM of 3/8 thick andshould exceed the tolerancebetween the pipe and fitting.

______ 6. Lack of adhesive can causetrapped air in the socket that willcause leakage. While pushingthe parts together, make surethere is a complete ring ofsqueeze out around the end ofthe fitting.


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______ 7. If possible, remove excessadhesive from the interior of pipeand fitting.

______ 8. Use excess adhesive on theexterior surface to form anattractive filet.

______ 9. Do not move the joint until theadhesive has hardened.

______ 10. Heat tapes must be used on ALL joints.

INITIAL FOR WEATHER CONDITIONS

______ 1. Cooler temperatures can causeadhesive to stiffen causingdifficulty in mixing.

______ 2. In cooler weather, if possible,place adhesive in a warm roomfor eight (8) hours before use.

______ 3. Do not overheat the adhesive.

______ 4. Do not attempt to cure the jointtoo quickly

______ 5. Spread the adhesive thinly aftermixing

______ 6. Do not fabricate outdoors in therain, fog, snow or mist.

INITIAL FOR BOLT-UP AND TORQUE

______ 1. Do not over-torque the bolts, thiswill cause the flange to crack.

______ 2. Do not torque to maximum untilflanges are drawn together.

______ 3. Use a cross torque technique

______ 4. Use washers on all nuts andbolts. SAE work best due totheir small O.D.

______ 5. Gasket materials need to be 1/8full face and have a durometer of

50-70 Shore A. Teflon gasketsare not recommended due to thehigh seating stress andexcessive bolt torque required.

______ 6. When bolting a Conley flange toa valve or pump with a raisedface, a spacer ring must be usedto fill the gap; if not used,cracking of the flange and orglue line can occur.

______ 7. Threaded lug body and waferbody valves may require specialconsiderations for use withConley flanges such as spacersand backing rings and theallowable bolt torque for Conleyflanges should not be exceeded.

______ 8. Consult Conley Engineering forassistance with information onspacers and backing rings.Conley does not manufactureflange spacers or backing rings.

Conley Trainer _________________

Job __________________

Date __________________

Customer _________________

Employee Train ed ________________

Customer Superv isor ________________

VOID


35/41 - 29 -

CONLEY ENGINEERING DESIGN MANUALCONVERSION FACTORS

To Convert To Multiply byLengthinches millimeters 25.4inches centimeters 2.54inches feet 0.0833feet inches 12feet centimeters 30.48feet meters 0.3048millimeters inches 0.03937centimeters inches 0.3937centimeters feet 0.0328meters inches 39.37meters feet 3.281mils inches 0.001mils microns 25.4

To Convert To Multiply by

Areasquare inches squarecentimeters

6.452

square inches square feet 0.006944square feet square inches 144square feet square

centimeters929.034

square feet square meters 0.09290squarecentimeters

square inches 0.15499

squarecentimeters

square feet 1.0764 x 10 -

square meters square inches 1550

square meters square feet 10.76

To Convert To Multiply byVolumecubic inches cubic

centimeters16.39

cubic inches ounces 0.55441cubic inches cubic feet 0.0005787cubic feet cubic inches 1728cubic feet cubic

centimeters28317.016

cubic feet cubic meters 0.02832cubic feet U.S. gallons 7.481cubic feet liters 28.31625cubiccentimeters

cubic feet 3.5314 x 10 -5

cubiccentimeters

ounces 0.03381

cubiccentimeters

U.S. gallons 2.6417 x 10 -

cubic meters cubic feet 35.31liters quarts 1.057quarts liters 0.9463U.S. gallons cubic feet 0.1337

To Convert To Multiply byWeightounces grams 28.35pounds grams 453.6pounds kilograms 0.4536pounds short tons 0.0005pounds long tons 0.0004464pounds metric tons 0.0004536tons (short) pounds 2000tons (long) pounds 2240tons (metric) pounds 2205grams ounces 0.03527grams pounds 2.205 x 10 - kilograms ounces 35.27kilograms pounds 2.205kilograms short tons 1.102 x 10 - kilograms long tons 9.839 x 10 - tonnes (metrictons)

kilograms 1000

To Convert To Multiply byDensitypounds percubic foot

grams percubiccentimeter

0.01602


pounds percubic foot

62.42

grams percubic

centimeter

kilograms percubic meter

1000

kilograms percubic meter


0.001

To Convert To Multiply byPressurepsia atmospheres 0.0680psia inches of

water27.67

psi kilopascals 6.8948inches ofwater

psia 0.03614

feet of water kilopascals 2.989atmospheres psia 14.70bar kilograms per

squarecentimeter

1.020

bar atmospheres 0.9869kilograms persquarecentimeter

psia 14.22

kilopascals psi 0.14505kilopascals feet of water 0.33456


36/41

- 30 -

To Convert To Multiply byFlowcubic feet persecond

U.S. gallonsper minute

448.9

cubic feet persecond

cubic metersper second

0.028317



0.002228


liters perminute

3.7854

liters perminute


0.26417

cubic metersper second


35.315

To Convert To Multiply byVelocityfeet persecond

meters persecond

0.3048

meters persecond

feet persecond

3.2808

To Convert To Multiply byLiqu id Measure and Weightpound ofwater

U.S. gallon 0.11995

pound ofwater

cubic inch 27.708

pound ofwater

cubic foot 0.016035

pound ofwater

liter 0.45404

pound ofwater

cubic meter 0.000454

U.S. gallon pound ofwater

8.337

U.S. gallon cubic inch 231.0U.S. gallon cubic foot 0.13368U.S. gallon liter 3.785U.S. gallon cubic meter 0.003785cubic inch U.S. gallon 0.004329cubic inch pound of

water0.3609

cubic inch cubic foot 0.000578

cubic inch liter 0.016387cubic inch cubic meter 0.0000164cubic foot U.S. gallon 7.4805cubic foot pound of

water62.365

cubic foot cubic inch 1728.0cubic foot liter 28.316cubic foot cubic meter 0.028314liter U.S. gallon 0.26418liter pound of 2.202

waterliter cubic foot 0.035315liter cubic inch 61.025liter cubic meter 0.0010cubic meter U.S. gallon 264.2cubic meter pound of

water

2202.6

cubic meter cubic foot 35.3183cubic meter cubic inch 61030.0cubic meter liter 999.97

To Convert To Multiply byPressure and Headpsi kilogram per

square

centimeter

0.070307

psi inch water 27.726psi feet water 2.3106psi bar 0.06895kilogram persquarecentimeter

psi 14.2233

kilogram persquarecentimeter

inch water 394.27


feet water 32.864


bar 0.9807

inch water psi 0.03607inch water kilogram per

squarecentimeter

0.00254

inch water feet water 0.08333inch water bar 0.00249feet water psi 0.43278feet water kilogram per

squarecentimeter

0.03043

feet water inch water 12.0feet water bar 0.02984bar psi 14.5038bar kilogram per

squarecentimeter

1.0197

bar inch water 402.1bar feet water 33.51


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GLOSSARY

adhesive a two-part material, one part is resin, one is hardener, used to join pipe tofittings.

adhesive jointB-stage the degree to which a thermoset resin has crosslinked. Three stages, inorder of increasing crosslinking include A-stage, wet; B-stage, gelled or hard to thetouch; and C-stage is fully cured.

buttering applying a layer of adhesive and the action of working or scrubbing theadhesive into the prepared surface to be joined by adhesive bonding.

cage structural wall.

conductive having the ability to conduct electricity as in conductive pipe, fittings, oradhesive.

cure the hardening of a thermoset resin system by addition of a hardener and thechemical reaction, completed with heat (post-curing).

FRP fiberglass reinforced plastic

fillet the tapering or angle of excess adhesive on the outside of an adhesive bonded joint normally to create an attractive appearance.

hardener chemicals added to thermoset resin systems which are required for thecuring process to occur, also known as cross-linking.

heat tape an electric strip or tape used to heat a fabricated joint to full cure(crosslinking), C-stage.

hydrostatic test a pressure test of the completed fabrication section to confirmintegrity of the piping system.

jo in ing a method for connecting two separate components of a piping systemtogether including straight socket, bell and spigot, threaded, flanged, coupled, etc.

jo in t a term used to describe and individual length of pipe or the actual joining of apipe to fitting, adhesive bonded, threaded, flanged, coupled, etc.

liner the interior surface of the pipe or fitting. Generally, liners are resin-rich areasfrom 0.060 to 0.100 in. thick, reinforced with Nexus veil, that provide the corrosion


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protection for chemical service. Liners can also contain abrasive resistant materials forerosion protection from abrasive services.

lug [style butterfly] valve a butterfly valve with threaded holes on both sides of the

body for installing between two flanges using bolts WITHOUT nuts.part 1 the resin component of a two-part thermoset resin system.

part 2 the hardener, catalyst or curing component of a two-part thermoset resinsystem.

part A the resin component of a two-part thermoset resin system.

part B the hardener, catalyst or curing component of a two-part thermoset resinsystem.

pot life the time available to use thermoset adhesives after the reactive materialshave been mixed.

push-out the excess adhesive from an adhesive bonded joint.

saddle a fitting which is bonded to the exterior of a pipe to make a branch connection.

scrub-in the action of working or scrubbing the adhesive into the prepared surface tobe joined by adhesive bonding.

shelf life the storage time for a material until it becomes unusable.

socket joint a joining system in which two straight cylindrical surfaces come together(male to female and bell and spigot) and bond with adhesive.

squeeze in (see squeeze out) the excess adhesive from an adhesive bonded jointthat remains on the inside of the joint. Sometimes called an adhesive doughnut or ring.

squeeze out (see squeeze in) the excess adhesive from an adhesive bonded jointthat remains on the inside of the joint. Sometimes called an adhesive doughnut or ring.

thermoset a polymeric resin cured by chemical reaction and heat. Once cured, athermoset resin becomes infusible, (cannot be re-melted) and insoluble.

wafer [style butterfly] valve a butterfly valve installed between two flanges and keptin place by using the bolts or studs and nuts from flange to flange centering the valvefrom the outside of the valve body.


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water hammer pressure surges in a piping system caused by sudden operation of avalve, pump, or other component.

wet in the action of coating the prepared surfaces of an adhesive bonded joint withadhesive. Also see buttering and scrub-in.

wetting the action of coating the prepared surfaces of an adhesive bonded joint withadhesive. Also see buttering and scrub-in.

wicking The longitudinal flow of liquid in the pipe wall due to capillary action.

veil surfacing mat of porous fabric made from filaments and used to providereinforcement for a resin rich layer or liner.


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INDEX

Note: f . indicates figure; t. indicates table

90M, 16-17 ABS, 17, 23-25 Adhesive, 3-5, 12-13 ASME Code, 23-24Bonder certification, 23-25Bonding procedure specification (BPS),23-25BPS, 23-25Buttering, 6Cold weather, 3, 8, 9, 26Conductive piping, 17-18Conversion factors, 30Curing, 8DNV, 23Double containment, 19-20Fabrication training, 23-26Fire Protection Coating, 16-17Flanged connections, 18, 20-21Ground strap, 18 f .Grounding lug, 17-18Grounding, 17-18 f .Handling, 1Heat tapes, 8t.Hot weather, 26Hydrotesting, 11-12Interlocking union, 19f.Joint coating kit, 17Joint fabrication, 5


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Conley Corporation

2795 East 91st Street

Tulsa, Oklahoma USA 74137 (800)-331-5502(918) 299-5051

Fax (918) 299-5907

Conley Installation and Fabrication Manual

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