NOV FGS Fitting

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PIPE INSTALLATION HANDBOOK Matched Tapered Bell & Spigot Joints • RED THREAD® II • GREEN THREAD® • SILVER STREAK® • F-CHEM® Manual No. F6000 January 1, 2009

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NOV Fiber Glass System Fitting

Transcript of NOV FGS Fitting

  • PIPE INSTALLATION HANDBOOK

    Matched Tapered Bell & Spigot Joints

    REDTHREADII GREENTHREAD SILVERSTREAK F-CHEM

    ManualNo.F6000January1,2009

  • FIBER GLASS SYSTEMS L. P.PIPE INSTALLATION HANDBOOK

    Matched Tapered Bell & Spigot Joints

    Thisfabricationmanualisofferedtoassistyouintheproperfabricationand installationprocedureswhenassemblingyourFiberGlassSystems(FGS)pipingsystem.

    If you do not find the answer to your questions in themanual,feelfreetocontactusoryourlocalFGSdistributor.

    FGSproductsmustbe installedandused inaccordancewithsound,provenpracticeandcommonsense.

    The information supplied by Fiber Glass Systems in its literaturemustbeconsideredasanexpressionofguidelinesbasedonfieldexperienceratherthanawarrantyforwhichFGSassumes responsibility. FGS offers a limited warranty of itsproductsintheTerms and Conditions of Sale.Theinformationcontained in the literature and catalogs furnished by FGScannotensure,ofitself,asuccessfulinstallationandisofferedtocustomerssubjecttotheselimitationsandexplanations.

    It is the policy of FGS to improve its products continually.Therefore, the company reserves the right, without notice, tochangespecificationsand/ordesignatanytimewithoutincurringan obligation for equipment previously sold. DescriptionscontainedinthiscatalogareforthepurposeofidentificationandneitherlimitnorextendthestandardproductlimitedwarrantysetforthintheTerms and Conditions of Sale and Trade Customs.

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  • TABLE OF CONTENTS

    Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iFabrication&InstallationAssistance . . . . . . . . . . . . . . . . . iv

    Part IPIPE PRODuCTS

    PipeProducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 DescriptionofPipeProducts . . . . . . . . . . . . . . . . . . . . .1 PipeGrades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 FabricationAccessories. . . . . . . . . . . . . . . . . . . . . . . . . .6JoiningSystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

    Part IISITE CONSIDERATIONS

    StorageandHandling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Tools,Equipment,andSupplies . . . . . . . . . . . . . . . . . . . . .10SuggestedCrewSetUp. . . . . . . . . . . . . . . . . . . . . . . . . . .12AdverseWeatherRecommendations. . . . . . . . . . . . . . . . .14BurialRecommendations . . . . . . . . . . . . . . . . . . . . . . . . . .15Anchors,GuidesandSupports. . . . . . . . . . . . . . . . . . . . . .22

    Part IIIGENERAL INSTALLATION

    ReadThisFirst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24CuttingFGSPipe................................25

    Part IVFABRICATION OF RED THREAD II, GREEN THREAD, AND

    SILVER STREAK PIPE AND FITTINGS

    TaperingFGSPipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26TaperingToolReferenceChart. . . . . . . . . . . . . . . . . . . . . .28JointPrep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29AdhesiveMixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30JointAssembly..................................31 CloseTolerancePiping . . . . . . . . . . . . . . . . . . . . . . . . .31 Take-OffDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .33 1-6BellxSpigotJoints. . . . . . . . . . . . . . . . . . . . . . . .37 8-24BellxSpigotJoints. . . . . . . . . . . . . . . . . . . . . . .38 T.A.B.Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40JointCure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

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  • HeatCollars&HeatPacks . . . . . . . . . . . . . . . . . . . . . .42Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

    PART VFABRICATION OF F-CHEM PIPE AND FITTINGS

    JointPrep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50JointAssembly..................................50JointCure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 HeatBlankets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 TappingintoaLine . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

    Part VI INSTALLATION CONSIDERATIONS

    Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63WaterHammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64ConnectingtoOtherSystems. . . . . . . . . . . . . . . . . . . . . . .73PaintingPipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

    Part VIIHELPFuL INFORMATION

    Conversions....................................76DecimalEquivalentsofFractions . . . . . . . . . . . . . . . . . . . .77DefinitionofTerms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78HowToReadFlangedorReducingFittings . . . . . . . . . . . .83

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    2005,NATIONALOILWELLVARCO

    TrademarkofVarcoI/P,Inc.

    RT REDTHREADIIpipingsystemsRTPP REDTHREADIIPerformance Plus pipingsystemsGT GREENTHREADpipingsystemsGTPP GREENTHREADPerformance Plus pipingsystemsSS SILVERSTREAKpipingsystemsFC F-CHEMpipingsystems

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    Standard Abbreviations

  • HowToFigurea45Offset . . . . . . . . . . . . . . . . . . . . . . . .84

    FABRICATION AND INSTALLATION ASSISTANCE

    Installing FGS fiberglass pipe is different from installingcarbon steel, stainless steel, lined steel and even otherfiberglass piping systems. Learning the proper methods toprepareandmake-upbell&spigotjointscanhelpensurethereliabilityandlong-termperformanceofyourpipingsystem.

    FGS offers the TQI Plus (ASME B31.3) Fabricationand Assembly certification program. Qualified Field ServiceRepresentativestrainfabricationandassemblycrews,conductandsupervisefabricationwork,andinspectworkinprogress.

    For complete information concerning these trainingseminars,contactyourlocalFGSdistributororFGS.

    Installationvideosareavailableforviewingonourwebsiteatwww.smithfibercast.comorwww.fgspipe.com.

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    SAFETYThissafetyalertsymbolindicatesanimportantsafetymessage.Whenyouseethissymbol,bealerttothepossibilityofpersonalinjury.

    CAuTIONAsthispipemaycarryhazardousmaterialand/oroperateatahazardouspressurelevel,youmustfollowinstructionsinthismanualtoavoidseriouspersonalinjuryorpropertydamage. Inanyevent, improper installationcancauseinjuryordamage.Inaddition,installersshouldreadandfollow all cautions andwarnings on adhesive kits, heatpacks, propane torches, etc. to avoid personal injury.Also, observe general safety practices with all saws,tools, etc. to avoid personal injury. Wear protectiveclothing when necessary. Make sure work surfacesare clean and stable and that work areas are properlyventilated.

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  • PART IPIPE PRODuCTS

    DESCRIPTION OF PIPE PRODuCTS

    The performance characteristics of a fiberglass pipesystem depend on several important elements including theresinandcuringagent,aswellasthemanufacturingprocessandtypeandthicknessofthepipescorrosionbarrier. FGSpipingsystemsaremanufacturedusingepoxy,vinylester,orisophthalicpolyesterresinsystems.Allareheatcuredfor optimum chemical resistance and physical properties.Match your temperature, pressure and chemical resistancerequirementstothepipingsystem.

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  • FGS PIPE GRADES

    RED THREAD II & RED THREAD II Performance PlusEpoxy pipe grade that provides long service life, lightweightand corrosion resistance. Used for light chemical servicesinsalts,solventsandpH2 to13solutionsup to210Fandpressures to 450 psig.Available in 2-24 pipe sizes.T.A.B.(Threaded and Bonded bell & spigot) is the primary joiningmethodfor2-6diameterpipe.Matchedtaperedbell&spigotjoiningmethodisusedfor8-24pipe.

    GREEN THREAD & GREEN THREAD Performance PlusEpoxy pipe with 15-35 mil resin-rich liner that providesexcellent chemical resistance to dilute acids and caustics.Rated for temperatures up to 225F and pressures to 450psig.Matchedtaperedbell&spigotconnectionisprovidedonall1-24pipesizes.

    SILVER STREAKCustomfilamentwoundpipeisspeciallydesignedforabrasiveand corrosive services found in flue gas desulfurization. Itis a proprietary blend of epoxy resin and abrasion-resistantadditives. Rated for temperatures to 225F and 225 psig.Availablein2-24pipesizes.

    F-CHEM Custom filament wound construction offers more flexibilityin resin systems, corrosion barriers andwall thickness thanourstandardproducts.Rated for temperatures to250Fand150 psig. Let us assist you in selecting the right pipe for aspecific application. Available in 1-72 pipe sizes. Joiningmethodsincludeplainendbuttandwrap,O-ringbell&spigotormatchedtaperedbell&spigot.

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  • FITTINGS

    FGSfittingsarecolorcoded.GREENTHREADfittingsaregreen andmay be usedwithREDTHREAD II andGREENTHREADpipe.SILVERSTREAKfittingsareblack.F-CHEMfittings are color matched to the pipe. Be sure to use thecorrectgradeofpipeandfittingsforyourservice.ConsultFGSFittings&AccessoriesBulletins for pressure rating limits onvariousfittings.Thelowestratedfittingdeterminesthesystempressurerating. Mostcompression-moldedfittingshaveacenterlinedotorcrosswhichwillassistyouinmakingmeasurements.

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  • ADHESIVES

    FGS adhesives are formulated for specific use withthe companion pipe grades. Use only the recommendedadhesivewitheachpipegrade-donotmixsystems!Standardadhesivesareatwo-componentsystem(PartsAandB)whichmustbemixedpriortouse.Detailedinstructionsforadhesivesareprovidedwitheachkit.Readtheseinstructionsthoroughlyandfollowtherecommendedprocedures.Thecuretimeandpot-life of the adhesive is dependent on temperature. Referto the adhesive instructions. Ambient temperatures above100Frequireextracarebythefabricatortoassuresufficientworking time of the adhesive. Refer to Adverse Weather Recommendationsonpage14.

    ADHESIVE SELECTION

    FGSstandardadhesivekitsaredesignedtobeusedwithspecificpipingsystemsasshowninTable2.

    ADHESIVE WORKING LIFE

    Workinglifeorpotlifeisthetimeittakesfortheadhesivetohardeninthemixingcan.RefertoTable1below.

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    TABLE 1. Fiber Glass Systems Adhesives Estimated Pot Life

    NOTE:Potlifeisthetimeavailableforfabrication.Timesmayvarydependingupontemperature,humidity,quantitymixed,etc.

    Pipe Resin

    Systems Adhesive

    Pot Life@ 70F (min.)

    (see note)

    Pot Life@ 90F (min.)

    (see note)

    Epoxy 2000 20 12

    Epoxy 7000 25 15

    Epoxy 8000 15 8

    VinylEster CL-100 20 10

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    1"11

    /2"

    2"3"

    4"6"

    8"10

    "12

    "14

    "16

    "18

    "20

    "24

    "

    RTII/G

    TPERF.PLU

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    2014

    1815

    135

    21

    1 /2

    1 /2

    2069

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    32

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    41 /2

    REDTHREADII

    (JointsPerCan

    )15

    0F

    7014

    2518

    106

    32

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    7024

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    2115

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    2012

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    14"

    16"

    18"

    20"

    24"

    30"

    36"

    42"

    48"

    54"-

    72"

    F-CHEM

    200F

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    011/2

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    1 /2

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  • FABRICATION ACCESSORIES

    Heat Collars and Heat Blankets:FGS offers high temperature heatcollars and silicone heat blanketsfor use in curing of adhesive joints.Theblanketsandcollarshaveapre-set thermostat which controls thetemperature of the unit. See page44 for heat collar page 54 for heatblanket cure times for adhesive jointfabrications.

    Heat Guns:Highwattageelectricheat guns are also available toheatF-CHEMadhesivejoints.Theheatgunsare1600wattcapacity.

    FGS Heat Packs: A heat pack unit consisting of ties andreactants in a plastic bag attached to foil paper is alsoavailable.Heatpackswillcurejointswithinonehour.

    Tapering Tools: FGSmatchedtaperedjointsrequirevarioustools formakingthetaperedspigot in the field(RT,GT,SS).Refer toTable6onpage28 forselectionofproper taperingtool.

    Come-Along: Specificallydesigned hydraulic come-alongsare available for 8-24 pipingsystems (RT,GT,SS).Especiallyuseful for long straight runs ofpipe.

    Manual Come-Along: Kit consistsof two manual cable puller come-alongsandonestrapclampkit.Itisamechanicalaidusedtojoinlargerdiameter piping. The come-alongismostuseful for8-16pipesizes

    toaidinthealignmentandlandingofthespigotendintothebell.

    Strap Clamp Kit: FGS offersStrap Clamp Kits that can beused in conjunction with come-alongsforbonding8-24fittings.

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  • JOINING SYSTEMS

    Bell and Spigot Joint: The adhesive bonded, tapered belland spigot joint is a primary joining method for the followingproducts: 1"-24"GREENTHREADpipingandpipetofittings 2"-24"REDTHREADIIpipingandpipetofittings 2-24SILVERSTREAKpipetofittings 4-72F-CHEMpiping* *Pipetopipejointsalsoavailableinbutt&wrap. Pipe is suppliedwith one endtapered(thespigot)and the other endbelled (integral bellor factory bondedcoupling) to accept a tapered spigot. The joint ismade byapplyingadhesivewhich,whencured, iscompatiblewiththepipingsystemsforjointstrengthandcorrosionresistance.

    T.A.B. (Threaded and Bonded) Joint:TheT.A.B.jointisthe primaryjoiningmethodforthefollowingproduct:

    2"-6"REDTHREADIIpipingandpipetocou-plings.

    The joining sys-tem combinesboth threads andadhesives on thebonding surfaces.The mechanical locking action of these promotes positivemakeup which prevents backout during adhesive curing.Standardtaperedbellfittingsareusedwiththissystem.

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  • PART IISITE CONSIDERATIONS

    STORAGE AND HANDLING

    A. Pipe and Fittings Fiberglassreinforcedpipe,fittings,andadhesivesrequirespecial storage and handling. Care should be taken intransporting, unloading, handling, and storing FGS productstopreventimpactandotherdamage. When transportingpipe, thespacersunderandbetweenthe pipe joints must be of sufficient width to avoid pointloading, which could produce cracking or buckling damage.Aminimumoffourspacersshouldbeusedforsupporting14"andlarger40'longpipejoints.Morespacersshouldbeusedforsmallerpipeorifpipeisstackedovereightfeethigh. Due to its light weight, lifting equipment is usually notrequiredfor1"-14"pipe.Whenliftingequipmentisrequired,use nylon slings or chokers. Do not allow chains or cablesto contact thepipeduring transport orhandling. If apipeorfabricationismorethan20feetlong,useatleasttwosupportpoints. For storage, a board (2 x 4minimum) should be placedunder each layer of pipe approximately every five feet. Theintent is to support the pipe and distribute the load evenly.Thepipeshouldalsobebracedoneithersideofthepiperackto prevent unnecessary pipemovement.Avoid placing FGSpipeon sharpedges, narrowsupports, or other objects thatcouldcausedamagetothepipewall.WhenstoringFGSpipedirectlyontheground,selectaflatareafreeofrocksandotherdebristhatcoulddamagethepipe. FGSpipeisfurnishedfactorypackagedincompact,easy-to-handlebundlescompletewithprotectiveendcaps.Leavethesecaps inplaceuntil installation time toprotect thepipeendsaswellas topreventdirtorothermaterial fromgettingintothepipe.Fittingsarepackagedincardboardboxesandshouldbestored inadryarea. If fittingsare removed fromtheboxes,protectmachinedbellsandspigotsfromexposuretodirectsunlight. FGSpipecanbedamagedwhenjointsorbundlesofpipeare dropped during handling or shipping. Severe localizedimpactblowsmayresultindamagetothefiberglassreinforcedstructure in the pipe wall.Before installation, inspect the pipe's outer surface for any damage.DonotusedamagedpipeunlessinspectedandapprovedbyaFGSrepresentative.If impact damage occurs, the damaged areas may be

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  • recognizedbyastartypefractureonthepipe.Pipethathasbeendamagedshouldhavealengthcutawayapproximatelyonefooteithersideoftheimpactedsite.

    Note: weight. straps.

    B. AdhesiveFGS vinyl ester adhesives can be damaged by storage inwarm places. FGS recommends that CL-100 adhesive bestoredinadryareawheretemperaturesdonotexceed80F.Refertoadhesiveinstructionsincludedineachkitforstorageliferecommendations.

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    Material Safety Data Sheets (MSDS) are available from FGS at http://www.smithfibercast.com

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  • TOOLS, EQuIPMENT and SuPPLIES REQuIRED FOR INSTALLATION

    Formaximumefficiency,thefollowingtoolsandequipmentarerecommendedpriortoanyinstallation:

    clampkit HandTools -Level-MarkingPen-TapeMeasure-PipeWrap -Hacksaw(22-28teeth/inch) -Taperingtool(Seepages26-28) RT,GT,SS) PowerTools -Powertaperingtools(Seepages26-28) aluminumoxide,carbideordiamond cuttingblade -Heatgun,heatblanketorcollar -T.A.B.wrenches(for2-6T.A.B.jointpipingsystems) Expendables -Clean,Dry,Lint-FreeShopCloths SS),(30-60gritforF-Chem) -Impermeablegloves -Chemicalsplashgoggles

    NOTE: Youmustuse theproper tool for taperingeachsizeandtypeofpipe(seepages26-28).

    Equipment for Cool Weather (Below 70F) pipe assembly: Heatsource -Portabletorchwithspreadertip,or -Portableelectricheatlamp,or -Industrialhotairgun Ameansofmaintainingadhesivekitsat70-80F: -Aboxwitha25wattlightbulb,or -Insideofavehicle. Heatassistedcuring -Electricheatingcollarsorblankets -Chemicalheatpacks

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  • Additional equipment for 8-24 pipe assembly (RT, GT, SS):Hydrauliccome-alongortwocome-alongswithmanilarope ornylonslings(forreducedslippage)StrapclampkitSledgehammer,12-16lbs.,anda4x4blockofwood

    Additional equipment for applying saddles:Powersanderwith30-60gritsandingdisc(preferred for6andlargersaddles).Hoseclamps

    SuGGESTED LABOR TIMES FOR FGS BELL X SPIGOT PIPING SYSTEMS

    Table 2.1(1)Placinginhangersfiguresarebasedonone-workeroperationfor1"-4";twoworkersfor6"-10";threeworkersfor12"-24".Totaltimesshouldbefiguredbymultiplyingfiguresgivenbyworkersneededperoperation.(2)2000seriesPowerTools

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    PipeSize

    Placingin

    Hangers(Min/Ft)

    (1)

    SetUp(Min.)

    (10)

    Scribe&Cutting(Min/Jt)Hand/power

    HandTapering(Min/Jt)

    PowerTapering(Min/Jt)

    JointMakeup(Min)(7/8)

    1" .7 3.0 1.33/1.25 1.0 .25(2) 1.0

    11/2" .7 3.0 1.33/1.25 1.5 .25(2) 1.0

    2" .7 3.0 1.50/1.25 2.0 .25 1.5

    3" .7 3.0 2.0/1.33 3.0 .25 2.0

    4" .8 4.0 5.0/2.5 4.0 .25 3.0

    6" 1.0 5.0 7.0/3.0 5.0 2.5 (3) 4.08" 1.2 7.0 4.5/3.5 22.0 8.0(4,5,9) 5.0

    10" 1.4 7.0 NA/5.0 35.0 10.0(9) 6.0

    12" 1.7 8.0 NA/5.0 40.0 12.0(9) 8.0

    14" 2.3 9.0 NA/5.0 NA 12.0(5,9) 10.0

    16" 2.3 10.0 NA/6.0 NA 12.0(9) 12.0

    18" 2.5 12.0 NA/8.0 NA 25.0(6,9) 14.0

    20" 3.0 12.0 NA/8.0 NA 28.0(6,9) 16.0

    24" 3.0 14.0 NA/10.5 NA 30.0(6,9) 20.0

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  • (3)2"-6"HandTaperingTool(4)IndividualTaperingTool(5)8"-16"Taper/ScarfTool(6)18"-24"TaperTool(7)Eachjointmakeupcalculationincludescleaning,sand-ing,applyingadhesiveandproperengagement.Allowthreeminutesformixingadhesive.(8)Theunits(time)listedabovearebasedonusingexperi-encedcrewsonfittingintensiveruns.Forstraightrunpipe,contactyourlocalFGSrepresentative.(9)TimedoublesforPerformancePlusproducts.(10)Includessetupforhydraulicormanualcome-alongandsettingpipestandlevels.

    These numbers are based on installations using experi-enced crews in typical installation conditions. They do not include extreme weather conditions, time used for gathering supplies and tools, break time, manpower is-sues, etc. Assume 6 hours of productive labor for every 8 hours worked. Adjustment factors should be applied to these base units to compensate for prevailing production and job conditions. Because of all the variables involved, Fiber Glass Systems is not responsible for any differen-tial between these numbers and actual results.

    SuGGESTED CREW SET-uP AND ASSEMBLYManpowerrequirementschangedependingonwhether

    theinstallationissimple,consistingoflong,straightruns,orcomplex.Italsodependsonpipesize,installationtem-perature,andothersimilarinfluences.Followingaresomegeneralguidelinesthatareapplicabletomostinstallations.Ifyouhaveanyquestions,pleasecontactanFGSrepresenta-tiveforinformation.

    A. Suggested Crew Size for 1 - 6 straight run pipe (long runs)

    Athree-workercrewistheminimumrecommendedcrewsize.Afour-workercrewissometimesmoreefficient,evenwheninstalling1-6diameterpipe.

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  • Man # Crew Description #1 Clean/prep/align

    Removesendcaps,sandsandcleansjointandalignspipeforbonding.

    #2 Adhesive mixer/bonder Mixesadhesiveandappliestobellandspigot.

    #3 Assembly man Helpsmakeupjointandchecksforlockup.

    #4 Pre-heat/prep/supplies

    (optional through 4"; recommended on 6) Pre-heatsjointsandhelpskeeppipealigned.Alsoapplies

    heatcollarsduringcoolweather.(Allhelpinmovingsup-pliesandequipmentfromjointtojoint.)

    B. Suggested Crew Size for 8 - 48 straight run pipe (long runs)

    Asixorsevencrewmembersisrecommended.

    Man # Crew Description #1 Clean/prep/align

    Removesendcaps,sandsandcleansjointandhelpsalignjointforinsertion.

    #2 Adhesive mixer/bonder

    Mixesadhesiveandappliestobellandspigot.Marksinsertiondepthanddetermineswhenjointislockedup.Assistswithcome-along.

    #3 Adhesive mixer/Bonder

    Helps#2withadhesiveandassistswithcome-along.

    #4 Pre-heat/alignment man Pre-heatsjoints,helpsalignjointsandassistswithcome-

    along.

    #5 Alignment man Setslevelofpipeandalignsjointforproperinsertion;

    directstractordriver.

    #6 Truck driver/Supply man (optional) Drivessupplytruckandassistswithallaspectsofinstal-

    lation.Alsocoordinatesheatcollarsduringcoolweatherandicechestduringhotweather.

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  • #7 Tractor Operator Operatessideboomtractor,trachoeorbackhoe. (Allhelpinmovingsuppliesandequipmentfromjointto

    joint.)

    C. In more complex pipe assemblies,thecrewsizewilldependontheamountoftaperingandprefabricationneeded.Inmostcases,athree-workercrewisthemini-mumforanysizepipinginstallation.Insomeinstances(smalljobswithonlyafewjoints)onlyoneortwocrew-menwillberequired.

    RECOMMENDATIONS FOR FABRICATION IN ADVERSEWEATHER CONDITIONS

    FGSpipingcanbeinstalledinadverseweathercondi-tionswhenthenecessaryprecautionsaretaken.

    Actualworkwilloftenbemorequicklycompletedinhightemperatureconditions.Lowtemperaturescanincreasetheworktime20%-35%overnormalshopconditions.Asimilarincreaseiscommonforhighmoistureconditions.

    Hot Weather Installation TipsHotweatherconditions,temperaturesabove90F,will

    greatlyreducetheworkingtimeoftheadhesive.Thefollow-ingstepsarerecommendedwhenfabricatinginhotweatherconditions:1. Avoiddirectsunlightonthejoiningsurfaces.2. Storeadhesiveinacoolarea.3. KeepF-CHEMadhesiveinicechestpriortomixing.4. Keepmixedadhesiveinanicechestwithsealedbagof

    iceoricepack.4. Refertothefieldfabricationinstructionssuppliedinthe

    adhesivekitfortheproperamountofcatalystinCL-100.

    Cold Weather Installation TipsAdhesivecuretimeisdirectlyrelatedtothetemperature.

    Coldertemperaturesresultinlongercuretimes.Thefollowingstepsshouldbeusedwhenfabricatingin

    coldertemperatures:1. Adhesivekitsshouldbeplacedinawarmroomforsixto

    twelvehoursbeforeapplicationinordertoreachtempera-turesof80F-100F.Thiswillmakemixingmucheasierandspeedcuretimes.Oruseaboxwitha25-wattlightbulbtowarmadhesivekits.

    14

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  • 2. Whenpossible,pipingshouldbebondedindoorsintosubassemblies.Thewarmerconditionsoftheseareaswillallowfastercuretimes.

    3. Pre-warmbondingsurfacesto80F-100Fwhentempera-turefallsbelow70F.

    4. Refertothefieldfabricationinstructionssuppliedintheadhe-sivekitfortheproperamountofcatalystforvinylesterkits.

    5. Aheatgun,collarorblanketmaybeusedtoobtainafastercuretime.Applyalayeroffiberglassinsulationoraweldingblanketaroundtheheatcollarsorblanketswheninstallationtemperaturesarebelow50F.

    Extreme Moisture

    Adhesive Joints Iffittingsorpipehavemoistureonthebondingsurface,

    wipethemdrypriortosanding. Sandpipeorfittingsimmediatelybeforeapplyingthe

    adhesivetobondthejoint.Sandsurfacesuntilafresh,drysurfaceispresent,thenremovedustwithacleandrycloth,andapplyadhesive.

    Cureperthepreviousrecommendationsfornormal,ex-tremeheatorextremecoldtemperatures.

    BuRIED INSTALLATIONS

    Thesearegeneralguidelinesonly.FormoredetailsseeFGSEngineeringandPipingDesignGuideE5000.Forinstal-lationsusingULlistedREDTHREADIIApipingseespecialinstructionscontainedinManualNo.B2160.

    15

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  • 16

    Offset Bending Allowance for GREEN THREAD & RED THREAD II Pipe

    Size(In)

    X (Ft)(straight run)

    Y (Ft)(offset from straight

    run)

    2

    10 0.820 3.730 9.040 18.1

    3

    10 0.520 2.530 5.940 11.1

    4

    10 0.420 1.930 4.440 8.2

    6

    20 1.230 2.940 5.450 8.6

    8

    20 0.840 4.060 9.480 17.5

    10

    20 0.740 3.260 7.580 13.8

    12

    20 0.640 2.760 6.380 11.6

    14

    20 0.540 2.460 5.580 10.0

    16

    20 0.4640 2.1060 4.8080 8.80

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  • * Basedon1000psisoilmodulus.Contactthefactoryfordetailedinformationforyourspecificapplication.

    ** F-CHEMisdesignedforspecificburialapplicationsac-cordingtoAWWAC950.

    A. Burial Depth1. MinimumBurialDepth Minimumdepthinunpavedareasforpipesubjected

    tovehicularloadsdependsonpipegrade,pipesize,vehicleaxleweight,andthebeddingmaterial.Withastandardlegalaxleloadof34,000lbs.,themini-mumdepthofcover(fromthetopofthepipetothe

    17

    Size(In)

    X (Ft)(straight run)

    Y (Ft)(offset from straight

    run)

    18

    20 0.440 1.960 4.380 7.9

    20

    20 0.340 1.760 3.980 7.1

    24

    20 0.340 1.460 3.280 5.9

    TABLE 3. Burial Depths*

    Product Minimum (Ft.)Maximum

    (Ft.)1"-4"REDTHREADII 2 15

    6"-24"REDTHREADII 3 15

    1"-12"GREENTHREAD 2 15

    14"-24"GREENTHREAD 3 15

    1"-12"SILVERSTREAK 2 15

    14"-24"SILVERSTREAK 3 15

    F-CHEMCustomPiping** 3-5 12-20

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  • surface)formoderatelycompactednon-claybearingsoilsisshowninTable3.

    Thepipeshouldalwaysbeburiedbelowthefrostline.

    2. MaximumBurialDepth Maximumburialdepthisdependentonthebackfill

    material.Formoderatelycompactedsoilsthatdonotcontainlargeamountsofhighlyexpansiveclays,themaximumburialdepthisshowninTable3.

    B. Trench Preparation Finalbeddingofthetrenchmustbeasuniformandcon-

    tinuousaspossible.Beforebackfilling,fillallgapsunderthepipewithproperbeddingmaterial.Avoidsharpbendsandsuddenchangesinslope.Itisimportanttoremoveallsharprocks,cribbage,orotherforeignobjectsthatcouldcomeincontactwiththepiping.

    C. Bedding Requirements Fiberglasspipecanbedamagedbypointcontactorwear

    withthetrenchbottomandwalls,improperbeddingmate-rials,oradjacentpipe.Userecommendedbeddingmate-rialaminimumof6inchesthickatthebottom,sides,andtopofthepiping(refertoTable4).Adjacentpipesshouldbespacedthegreaterof6inchesoronepipediameter.Thepipingcanbelaiddirectlyontheundisturbedtrenchbottomifthenativesoilmeetstherequirementsofarecommendedbeddingmaterial(refertoTable4).Neverlayfiberglasspipingdirectlyagainstnativerockorshale.Alwaysusedry,unfrozenbeddingmaterialsthatdonotcontainforeignobjectsordebris.Neverusewaterfloodforcompaction.Slurriescanbeusedthatareintendedforburialofflexiblepipingsystems.Whenusingslurries,caremustbetakentopreventfloatingordeformationofthepiping.

    18

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  • D. Pipe Support Fiberglasspipeisflexibleandrequiresthesupportofthe

    beddingmaterialtokeepthepiperoundinburialapplica-tions.Itisveryimportantthatarecommendedbeddingmaterialisproperlycompactedaroundtheentirecircum-ferenceofthepipe.(RefertoTable4)Tampthebeddingmaterialunderthebottomhalfofthepipingtopreventvoidsorareasoflowcompaction.Vibratoryorsimilartampingequipmentcandrivesmallstonesordebrisintothepipewalliftheyarepresentinthebeddingmaterial.Avoidstrikingthepipewithtampingequipmentasthepipemaybefractured.

    19

    CompactedNativeFill

    Backfill

    Bedding

    Areasamustfirmlysupportpipehaunches

    TABLE 4. Recommended Bedding MaterialsBeddingMaterial CompactionProctor

    Density

    Crushedrockorpeagravel3/4maximumsize

    NotRequired

    Coarse-grainedsandorsoilwithlittleornofines

    75-85%

    Coarse-grainedsandorsoilwithmorethan12%fines

    85-95%

    Sandorgravelwithmorethan30%coarse-grainedparticles

    85-95%

    Sandorgravelwithlessthan30%coarse-grainedparticles

    Greaterthan95%

    6" Min.

    6" Min. SITE C

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  • Consult the factory if the pipe will be subject to vacuum or high water tables.

    E. Road Crossings Whenlayingfiberglass

    pipeunderroadcross-ings, itmaybeneces-sary to pass the pipethroughconduittopro-tect the pipe. Pad thepipetopreventrubbingor point loads againsttheconduit.

    F. Wall Penetrations Wherethepipegoesthroughorpassesunderaconcrete

    structure,precautionsmustbetakentopreventbendingorpointloadingofthepipeduetosettling.Aminimum2"thickpadofresilientmaterialshouldbewrappedaroundthepipetoprovideflexibilityandpreventcontactwiththeconcrete.Ifboltsareusedintheresilientmaterial,careshouldbetakenthatthebolts,nuts,orwasherscannotcomeintopointloadcontactwiththepipe.Beddingdepthunderthepipeshouldbeincreasedtoaminimumof12"oronepipediameter,whicheverisgreater,foronepipejointlengthawayfromtheconcrete.

    20

    Proper Bedding Improper Bedding

    EnsureFirmCompaction

    NoVoids

    SelectBedding

    ThickPadofRe-silientMaterial

    ORingBell&Spigot

    ThickProtectiveLayerofResilientMaterial

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  • G. Timing Testandcoverthepipeassoonaspossibletoreducethe

    chanceofdamagetothepipe,floatingofthepipeduetoflooding,orshiftingofthelineduetocave-ins.

    H. Two Point Lifting of Red Thread II

    ThistableprovidesinformationconcerningsafeliftpointsforRTIIduringinstallation.Thefollowingtablehasbeencompiledfortwoliftpointsandthemaximumlengthofpipethatmaybesafelyliftedandthecriticallocationoftheliftpoints.

    21

    TABLE 4.H

    NominalSize(In)

    PipeLengths(Feet)

    CantileverLength(Feet)

    Mid-SpanLengths(Feet)

    Number Length Min. Max. Min. Max.

    8 3 120 24 26 68 72

    10 3 120 20 28 64 80

    12 3 120 22 31 58 76

    14 3 120 22 31 58 76

    16 3 120 20 35 50 80

    18 3 120 19 36 48 82

    20 4* 160 31 37 86 98

    24 4* 160 29 40 80 102

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  • ANCHORS, GuIDES AND SuPPORTS

    A. Pipe Hangers Pipehangerssuchasthoseshownareoftenusedto

    supportFGSpipeinbuildingsandpiperacks.However,theuseoftoomanyhangersinsuccessioncanresultinanun-stablelinewhencontrolvalvesoperate,andduringpumpstart-upandshutdown.Toavoidthiscondition,thedesignershouldincorporateauxiliaryguidesperiodicallyinthelinetoaddlateralandaxialstability.

    B. Pipe Guides Guidesarerigidlyfixedtothesupportingstructureand

    allowthepipetomoveintheaxialdirectiononly.Properguideplacementandspacingareimportanttoensurepropermovementofexpansionjointsorloopsandtopre-ventbucklingoftheline.

    Theguidingmechanismshouldbeloosesoitwillallowfreeaxialmovementofthepipe.Ubolts,double-nuttedsotheycannotbepulleddowntight,areoftenutilizedforguides.

    Primaryandsecondaryguides,i.e.,thoseimmediatelyadjacenttoexpansionjoints,arespacedmorecloselythanintermediateguides.RefertoFGSManualNo.E5000,Engineering & Piping Design Manual, fordetails.

    Pipingenteringexpansionjointsorexpansionloopsre-quireadditionalguides.RefertoFGSManualNo.E5000, Engineering & Piping Design Manualfordetails.

    C. Pipe Supports: PipingsupportsforFGSpipeshould

    bespacedatintervalsasshownintheproductbulletins.

    22

    1/16Min.-1/8Max.clearanceperside

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  • NOTE:Properlyspacedsupportsdonotalleviatetheneedforguidesasrecommendedintheprecedingsection.Supportsthatmakeonlypointcontactorthatprovidenarrowsupportingareasshouldbeavoided.Somemeansofincreasingthesupportingareashouldbeused;sleevesmadefromhalfofaFGScouplingorpipearesuitable.Supportpumps,valvesandotherheavyequipmentindependentofthepipe.Refertopumpandvalveconnectioninstructionsonpage74.

    D. Pipe Anchors: Pipeanchorsdivideapipelineintoindividualexpandingsections.Inmostapplications,majorpiecesofconnectedequipment,suchaspumpsandtanks,functionasanchors.Additionalanchorsareusuallylocatedatvalves,nearchangesindirectionofthepiping,atblindendsofpipe,andatmajorbranchconnections.Provi-sionsforexpansionshouldbedesignedintoeachoftheindividualpipesec-tions.

    Caution: Donotinstallmorethanoneexpansionjointbe-tweenthesametwoanchorsinanystraightpipesection.

    DonotanchorFGSpipebyapplyingexternalpres-sureaspointloads,suchasa"U"-bolt,directlytothebarepipe.RefertoFGSManualNo.E5000,Engineering & Piping Design Guide,forathorough

    discussiononsupports,anchorsandguides.

    23

    !

    AnchorSleeves

    Clamp,snugbutnottight

    WeldorBoltAnchortosupportmember

    Snugfit

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  • PART IIIGENERAL INSTALLATION

    INSTRuCTIONS

    Beforebeginningtheactualassemblyprocedures,readandmakesureallinstallersthoroughlyunderstandthefollow-inginstructions.

    All bonding surfaces must be clean, dry and factory fresh in appearance before applying adhesive.Whenendcapshavebeenlost,surfaceswillweatherandresultinlossofbondstrengthWhensurfacesareweathered,re-taper(RT,GT,SS)spigots.SandbellsandF-CHEMspigotstoachieveafactoryfreshappearance.(Note:T.A.B.couplingsthathaveweatheredmustbereplaced.)

    Matching tapered bell and spigot joints require a very thin adhesive bond line for maximum strength and du-rability. Theadhesiveusedwithtaperedjointsisverystrongwhenusedinbondlinesafewthousandthsofaninchthick.Thesameadhesivemaybebrittleinthicksectionsresult-inginpoorbondstrength.Toachieveathinbondline,thematchedtaperedanglesofthejointaredesignedtomechani-callylock-upwhenwedgedtogether.

    using mechanical force assures lock up and a thin bond line. Hammeringawoodenblockplacedagainstthebellendofpipe,orusingmechanicaldevicessuchascome-alongsshouldbeusedtolockupthejoint.

    Note:ForT.A.Bjoints,specialT.A.B.wrenchesarerequiredtoachievethemechanicallockupinthejoint.

    Adverse weather conditions require special precau-tions when bonding pipe.(Seepage14,Recommendations for Fabrication in Adverse Weather Conditions)Theadhesiveisveryviscous(thick)whencoolorwhenappliedtocoolpipe.Thethickadhesivecanactuallybestiffenoughtopreventjointlockup.Whentheadhesiveishotorwhenitisappliedtohotpipe,theavailableworkingtimemaybesignificantlyreduced.

    Matched tapered bell and spigot joints that are not locked up can fail prematurely.

    24

    IMPORTANT READ THIS FIRST

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • CuTTING FIBERGLASS PIPE

    FGSpipeshouldbecutusingoneofthemethodsreferredtounderToolsandEquipmentonpage10.

    1. Measurepipe,rememberingtoallowforspigotandfittingdimensions.

    2. Scribeacuttingguidearoundthepipetoensureaper-pendicularcutforproperfit.

    3. Holdthepipefirmlybutnottothepointofcrushing.Ifchainvisesorothermechanicalholdingdevicesareused,careshouldbetakentopreventcrushingorpointloadingofthepipe.Topreventdamagetothepipe,180degreesectionsofFGSpipecanbeusedforprotectivecovers.

    4. Sawthepipeassmoothlyaspossible.Thepipeendsshouldbesquarewithin1/8inch.

    PART IV

    25

    Note:Forintegraljoint(IJ)bellends,thebellendmustbecutoffbeforetapering.MeasuretheO.D.ofthepipenearthebellenduntilyouseetheO.D.starttogetlarger.Cutthepipeatthispoint.Dependingonpipesizethedistancefromtheendofthebellcanvaryanywherefrom12"to36".

    RT, G

    T, SS FA

    BR

    ICATIO

    N

  • FABRICATION OF RED THREAD II, GREEN THREAD AND SILVER STREAK PIPE AND FITTINGS

    TAPERING FGS PIPEVarioustoolsareavailablefromFGSformakingtheta-

    peredspigotinthefield.Toreproduceastandardtaper,thetaperingtoolmustbe

    markedoradjusted.Theprocessvariesdependingonthetoolbeingusedandtheproductbeingtapered.Pleaserefertoindi-vidualtoolinstructionsfortapering.

    RefertoTable6onpage28forspecificbulletinnumberandpropertaperangleforeachsizeandtypeofpipe.

    Do not taperoverthebellendofintegraljointpipe.Seepage25forcuttinginstructions.

    A. 1"-6" Tool (Bulletin F6600)-Ahand-heldtoolthatcanbeadaptedforpowerwhenalargenumberoftapersisnecessary.Differentpipingsystemsrequiredifferentmandrels.

    B. Model 2100/ 2102 Tool (Bulletin F6625/ F6624) -PowertoolfortaperingandscarfingREDTHREADIIandREDTHREADIIApiping.

    C. Model 2300 Tool (Bulletin F6627)-Powertoolespeciallydesignedfortapering1-4GREENTHREADpiping.

    D. 8", 10", or 12" Tapering Tool (Bulletin F6608 or F6612)-Thesetoolsaredesignedformanualorpower(i.e.,Ridgid300or700powerdriveorequal)operation;thereisatoolforeachsizepipe.

    26

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • E. 2"-12" Remote Power Tool (Bulletin F6601)-Tapers2"-12"pipe.Mustchangeanglefor8"andlargerpipe.Recommend-edforall6"tapers.

    Additional material will be needed: 1.Sturdyworkbench(preferablywithametaltop)orstandtoholdthetool2.Two20"longpiecesof1"diametersteelpipe.Mounttheseontopofthebenchparalleltoeachother,ona2-footcenter,extendingoffthebench12".3.Twoadjustablepipestandswithhardrubberrollersat90degreeangletopipe,i.e.thestandmustallowthepipetorotate.4.Thistoolrequiresapproximately3,000wattsof115vacpowerforoperation(30ampbreaker).Werecommend5,000watts(50ampbreaker).Asthelengthofextensioncordsin-creases,thepowerlostinthecordincreases.Table5showsmaximumallowablelengthsforvarioussizecords:

    F. 8"-16" Taper/Scarf Tool (Bulletin F6622)-Thisisanelectricallypoweredtaperingtool.Thetoolcomeswithdifferentsizemandrelstotaper8"-16"pipe.

    G. 18"-24" Tapering Tool (Bulletin F6621)-Thisisanelectricallypow-eredtaperingtool.Thetoolcomes

    withdifferentsizemandrelstotaper18"-24"pipe.

    Note: Sometoolsmaybeusedwithotherpipesystemswithspecial-ordertooling.Inthesecases,supplementaltoolinstruc-tionsarealsoavailable.Besuretospecifywhichpipesystemyouwillbetaperingwhenorderingtools.

    JOINT PREP forRED THREAD II, GREEN THREAD and SILVER STREAK

    27

    TABLE 5. Extension Cord LengthWire Size

    (AWG)Suggested Length

    (Ft.)Maximum Length

    (Ft.)12 20 22

    10 30 36

    8 50 57

    RT, G

    T, SS FA

    BR

    ICATIO

    N

  • 28

    TABLE 6. Tapering, Scarfing and Cutting Tool Reference Chart

    Tool

    Prod

    uct

    Tool

    Tap

    er A

    ngle

    Bul

    letin

    #C

    omm

    ents

    1"-6"Han

    dTape

    ring

    RT

    GT

    1"=3;1

    1 /2=21/2

    2"-6"=13/4

    F660

    0Spe

    cifyprodu

    ctto

    receivecorrectm

    andrels.Orderscarfing

    ad

    apterk

    itfors

    ec.con

    t.Pow

    erada

    ptersep

    arate.UsesRidg-

    id700

    ore

    quivalen

    tpow

    erdrivewithaRidgid77

    4ad

    apter.

    2100

    Pow

    erRT

    13/4

    F662

    5Tape

    rs2&

    3;Scarfs

    3&

    4

    2102

    Pow

    erRT

    13/4

    F662

    4Tape

    rs2-4

    ;Scarfs

    3

    2300

    Pow

    erGT

    13/4

    F662

    7Tape

    rs2-4

    ,

    2700

    Pow

    erSS

    13/4

    F663

    2Tape

    rs2"-4"SilverStre

    ak8"Tap

    eringor

    Scarfing

    Too

    lRT/GT

    GTMOS

    0or1

    0F6

    608Tape

    rF6

    609Scarf

    Tape

    rsand

    scarfs

    .Orderscarfing

    ada

    pterkitforS

    .C.U

    ses

    Ridgid70

    0orequ

    ivalen

    tpow

    erdrivewithaRidgid77

    4ad

    apter.

    10"&12"Tap

    erorScarfing

    Too

    lRT/GT

    GTMOS

    0or1

    0F6

    612Tape

    rF6

    613Scarf

    Tape

    rsand

    scarfs

    .Orderscarfing

    ada

    pterkitforS

    econ

    dary

    Con

    tainmen

    t.UsesRidgid70

    0orequ

    ivalen

    tpow

    erdrivewith

    aRidgid77

    4ad

    apter.

    6"-12"CERAM

    CORE

    CERAM

    CORE

    Non

    eF6

    620

    Scarfs

    6"-12

    "Ceram

    Core

    8"-16"Single

    PointTap

    erToo

    l8"-16"RT,

    GT,M

    OS

    0or1

    F662

    2Tape

    rsors

    carfs

    8"-16

    "RT,GT,SS.Scarfs

    8"-12

    "GTMOSor

    8"-16"secon

    darycon

    tainmen

    t.

    2"-12"Rem

    ote

    Pow

    erToo

    lRT,GT,SS

    2"-6"-13/4

    8"-12"-1

    F660

    1Tape

    rs2"-12

    "pipe

    .Mustcha

    ngean

    glefor8

    "an

    dlargerpipe.

    Recom

    men

    dedfora

    ll6"Tap

    ers.

    18"-24

    "Tape

    rTool

    RT,GT,SS

    GTMOS

    011/4

    F662

    1Tape

    r18"-24"

  • JOINT ASSEMBLY forRED THREAD II, GREEN THREAD and SILVER STREAK

    A. Close Tolerance Piping ThetaperedbellandspigotsystememployedbyFGScanbereadilyusedtoachievedimensionalaccuracywhererequiredbyaparticularpipelayout.Aswithanymatchedtaper,minorvariationsintoleranceinthebellorspigotwillaf-fecttheinsertiondepth.Inapplicationswherethefinalmake-uplengthofanassemblyisnotcritical,thesevariationsareofnoconsequence.However,whentheinstallationissuchthatclosetolerancesmustbemaintained,youmustcompensateforthesevariations.Itispossibletoaccuratelyreproducetapers(spigots)inthefieldwiththefieldtaperingtools.Thisprovidesameansofachievingdimensionalaccuracy.Calculation to Achieve a Desired Length

    Mostclosetoleranceinstallationsaremadetoprintscall-ingoutCLtoCL(centerlinetocenterline)dimensions.

    Whenfabricatingtothesedimensions,followthesepro-ceduresperthefigurebelow.1. Obtainthecenterlinetofacedimension(A)offittings

    tobeusedfromTables8or9onpages33-36.2. Createaninsertiongaugebycuttingashortsection

    ofpipe;12longforsmalldiametersand18longforlargerdiameters.Taperthepipeusingtheinstruc-tionssuppliedwitheachtool.Checkdryinsertion.Theinsertionlengthshouldbewithin+1/8ofafactoryspigotinsertion.

    3. Obtaininsertionlength(IL)byinsertingthegauge(madewiththetoolbeingused)intoafittingandmeasuring.(Note:Measureeachendofeachfitting,becausetheinsertionmayvaryforeachbell.)Youcanprepareanduseashortnippleasastandardinsertion

    29

    RT, G

    T, SS FA

    BR

    ICATIO

    N

  • gauge.(Note:Youmustprepareanewgaugeifyouchangetaperingtoolsormakeanychangestothetoolyouareusing.)Alwaysaddamake-updimension(refertoTable7)tothismeasurement,sincetheadhesivewillactasalubricantandallowgreaterpenetrationthanwhenthesurfacesaredry.TABLE 7. Approximate Make-up Dimensions (M)*

    Pipe Diameter (In.) Approximate Make-up Dimensions* (In.)1and11/2 1/16

    2 1/83and4 3/16

    6 1/48 3/8

    10and12 5/814 3/416 118

    Usefielddevelopeddimensions2024

    4. ToachieveaspecifiedCLtoCLdimension,thelengthofpipetocutisequaltotheCLtoCLdistanceminusthesumofthecenterlinetofacedimensionofthefittings(Adimension)plusthesumofthemeasured

    insertionlengths(IL)plusthesumofthemake-upallowance(M),or

    LengthofPipetoCut=(CLtoCL)-(A+A)+(IL+IL)+(M+M)

    Note:Eachbellofeachfittingmayhaveaslight-lydifferentinsertiondepthwithastandardtaper.Eachbellofeachfittingshouldbechecked

    withastandardtaperandmarked.

    ConsultFGSFittingsBulletinsNo.A1350orA1355forcompletefit-tingdimensions.

    30

    *CAUTION:Make-updimensionsdependonthetightnessofthedryfit.Ifthefielddevelopeddimensionsvary,usefielddevelopeddimensions.

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • JOINT PREP forRED THREAD II, GREEN THREAD, and SILVER STREAK

    Allbondingsurfacesmustbecleananddrybeforebonding. ForT.A.B.joints,cleanwithanacceptablesolventand

    cleanrag.WirebrushesmayalsobeusedforcleaningT.A.B.surfaces;however,theymustbecleanandfreeofoilycontaminates.

    Forsmoothtapers,sandpaperorsolvent(orboth)maybeused.Sandjustlightenoughtoremoveanycontami-nates.

    Usecautionasoversandingcanchangethetaperangleorenddimension,andcreateflatspotsonthespigot.

    Whensurfaceshaveweathered,sandorretaperspigotsandsandbellstoachieveafactoryfreshappearance.Cutatleast1fromspigotsbeforeretapering.T.A.B.couplingsmustbereplaced.

    Bondingsurfacesmustbedry,sobesureallsolventhasevaporatedbeforeapplyingadhesive.

    Note: use of a solvent as a cleaning method is optional.Somealternatecleaningsolventsareacetone,methylenechloride,andmethylethylketone.Aftercleaning,besureanyresidualsolventhasevaporatedbeforeapplyingadhesive.DONOTUSESOLVENTSTHATLEAVEANOILYFILMONTHEBONDINGSURFACES.

    WARNING: Somedegreasersandsolventsareextremelyflammable.Donotsmokeorusenearanopenflame.Weareyeprotection.Besuretoreadwarninglabelsoncontainers.

    Neverusegasoline,turpentine,ordieselfueltocleanjoints.

    Solventcontainersmaybeunderpressure.Usecautionwhenremovinginnerseals,especiallyinwarmweather.Usewithadequateventilation.

    31

    !

    RT, G

    T, SS FA

    BR

    ICATIO

    N

  • ADHESIVE MIXING

    Whentheweatheriscoolortheadhesivehasbeenstoredinacoolenvironment(below70F),prewarmtheadhesivekits.(Donotheatabove100F!)1. Forepoxyemptyallofthecontentsofthehardenerbottle

    intothecanofbaseadhesive.2. Mixallofthebaseepoxyadhesivewithallofthehardener.

    NEVERATTEMPTTOSPLITAKIT.Cutthroughtheadhe-sivewiththeedgeofthemixingsticktoassistinmixingthetwocomponents.

    3. Mixuntiltheadhesivehasauniformcolorandaconsistentflowoffthemixingstick.Wipedownthesides,bottom,andundertherimofthecanwiththemixingsticktoassurecom-pletemixture.

    Completeinformationandsafetyprecautionsarepackagedwitheachadhesivekit.Reviewallsafetyprecautionsthor-oughlybeforemixingtheadhesive.

    32

    ADHESIVE DISPOSAL: Once the adhesive and hardener havebeen mixed and reacted, nothing can be extracted, and it is classified as non-hazardous material. Dispose of in a nor-mal manner as other solid waste. Excess adhesive andhardener can be mixed, allowed to react, and disposed of asabove. If extra jars of adhesive or hardener have accumulatedwithouttheothercomponenttomixandreact,contactyourFGS regionalmanager.Hardener jars,whenemptyarenotsubject toEPAregulationandcanbedisposedofinanormalmanner.Theseguidelinesarebasedonfederalregulations.Stateandlocalregula-tionsandordinancesshouldbereviewed.

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • 33

    TAB

    LE 8

    . T

    ake-

    off D

    imen

    sion

    s fo

    r RT,

    GT

    Fitti

    ngs

    (Con

    tact

    FG

    S fo

    r SS

    Dim

    ensi

    ons)

    Dim

    ensio

    ns

    are

    used

    tocal-

    culatep

    ipe

    leng

    th

    requ

    iremen

    ts

    to

    mee

    tpipe

    linecen-

    terline

    tocenter

    linedimen

    sion

    s.

    A

    AA

    A A

    Size

    45

    Elbo

    wA

    90

    Elbo

    wA

    Tee A

    Late

    ral

    Cro

    ss AM

    /FW

    *B

    M/F

    W*

    C*F

    lang

    esM-M

    olde

    dFW

    -Filamen

    tWou

    nd

    AB

    123/8

    23/4

    23/4

    37/8

    21/2

    23/4

    13/4

    3 /4

    11/2

    27/8

    33/8

    33/8

    51/4

    31/4

    33/8

    13/4

    3 /4

    225/8

    33/8

    33/8

    65/8

    23/4

    33/8

    21/4

    / 21/8

    3 /4

    333/4

    45/8

    45/8

    73/4

    41/4

    45/8

    25/8

    13/8

    437/8

    51/8

    51/8

    943/8

    51/8

    25/8

    / 31/2

    13/8

    643/8

    61/8

    61/8

    121 /2

    53/4

    61/8

    3 / 3

    3 /4

    11/2

    881/8

    115 /

    811

    5 /8

    161 /

    473/8

    115 /

    84

    13/4

    1085/8

    131 /

    813

    1 /8

    195 /

    883/4

    131 /

    843/4

    2

    1291/2

    1414

    243 /

    411

    3 /4

    145

    21/4

    1412

    1 /2

    1919

    321 /2

    153 /

    416

    31/8

    21/2

    1613

    1 /4

    201 /

    420

    1 /4

    353 /

    417

    3 /4

    171 /

    431/8

    21/2

    RT, G

    T, SS FA

    BR

    ICATIO

    NB

    C

  • 34

    Table8.1Dryinsertion

    dep

    thsfors

    tand

    ardREDTHREADIIand

    GREENTHREADpipean

    dfittings.

    Size

    90&45Deg

    ree

    Elbow

    s&Tee

    sCrosses

    Laterals

    Molde

    dFlan

    ges

    FWFlan

    ges

    TheXvalue

    sare

    the

    nominaldry

    spigotinsertion

    sused

    tosetupta-

    perin

    gtools.T

    he

    tolerancesfo

    rdry

    insertion

    are"

    for1"-6"an

    d

    "for

    8"-16"pipe

    sizes.Th

    efinal

    insertion

    referred

    toasthe

    wet

    locked

    up

    po

    si-

    tionwillbelarger

    than

    theXdimen

    -sion

    .Dono

    tuse

    these

    dry

    inser-

    tion

    depthsfor

    close

    tolerance

    piping

    calcula-

    tions.

    In.

    X-RT

    X-G

    TX-RT

    X-G

    TX-RT

    X-G

    TX-RT

    X-G

    TX-RT

    X-G

    T

    1-

    1-

    1-

    1NA

    1-

    1

    1

    -1

    -1

    -1

    -1

    -1

    21

    11

    11

    11

    1

    11

    31

    11

    1

    11

    1

    21

    2

    41

    11

    1

    11

    1

    21

    2

    62

    22

    22

    22

    22

    2

    83

    33

    23

    22

    23

    3

    103

    33

    33

    23

    33

    312

    33

    33

    33

    33

    33

    146

    63

    33

    3-

    -2

    2

    166

    63

    3

    3

    3

    -

    -1

    2

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • 35

    INSERTION DEPTHS FOR SILVER STREAK

    SizeCoupled/Mitered

    FittingsFilament Wound

    Fittings

    2 1 2

    3 2 2

    4 2 3

    6 2 2

    8 3 5

    10 4 5

    12 4 6

    14 5 4

    16 6 5

    Table8.2Takeoffandnominaldryinsertiondimensionsforlowpressure,150/225 psig, SILVERSTREAK products. Refer to BulletinA2000orwww.smithfibercast.comformoreinformation.

    RT, G

    T, SS FA

    BR

    ICATIO

    N

  • 36

    TAB

    LE 9

    . T

    ake-

    off D

    imen

    sion

    s fo

    r RT/

    GT

    Perf

    orm

    ance

    Plu

    s Fi

    tting

    s

    Size

    (In)

    45Elbow

    (Lon

    gRad

    ius)(In)

    90Elbow

    (Lon

    gRad

    ius)(In)

    Tee(In

    )Flan

    ges(In

    )

    Ax-RT

    x-GT

    Ax-RT

    x-GT

    Ax-RT

    x-GT

    A-Van

    Stone

    812

    6

    519

    6

    5

    13

    65

    6

    1014

    6

    6

    23

    6

    6

    15

    6

    6

    712

    16

    77

    277

    717

    7

    77

    14

    17

    55

    305

    5

    19

    5

    5

    816

    205

    5

    345

    5

    21

    5

    5

    918

    24

    4026

    10

    20

    29

    47

    31

    12

    2435

    57

    3515

    Xdimensionsarenominaldry insertionlengths.Pipemustbedriventogetherandfullylockeduptoassurefulljointstrength.Actualinsertionsshouldbe+"for8"andlargerjoints.Insertion depths are for tool set up only. Do not use insertion depths (x) for close tolerance piping. Refer to joint assembly instructions forcompleteinformationonjointlockup.

    Dimensionsareusedtocal-culatepipelengthrequirementstomeetpipelinecenterlinetocenterlinedimensions.

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • B. 1 - 6 Bell & Spigot Joint THESPIGOTMUSTBEALIGNEDANDLOCKEDINTHEBELL.Acockedormisalignedjointwillresultinfalselockupandprematurejointfailureeitherduringtestingoratalaterdate.

    1. Whenambienttemperatureisbelow70F,prewarmthebondingsurfaces.Useahotairgun,propanetorchorothercleanburningheatsourcethathasaspreader

    typetip,andapplyheatuniformlytobellandspigotuntilwarmtothetouch.Checktemperaturebytouchingbondingsurfaceswiththebackofyourhand.Donottouchwiththefrontofyourhandasthismaycontaminatethejoint.Ifhottothetouch,letcoolbeforeapplyingadhesive.Whenusingatorchtopreheat,warmthebellfirst.Itisthickerandwillholdheatlonger.Ifan

    electricheatingcollarisusedtoprewarm,placethejointtogetherdry,thenheattheO.D.ofthebelltoavoidcontaminatingthespigot.CAuTION: Donotusechemicalheatpacksforprewarming.

    2. Brushadhesiveonboththebellandspigotbondingsurfaces,applyingathinuniformcoatingtoeach.To

    minimizecontamination,applyadhesivetothebellfirst.Adhesiveshouldalwaysbeworkedintothemachinedsurfacebyapplyingpressureduringapplication.Thiswillwetoutthemachinedsurfaceandmaintaintherequiredthinbondline.Besurethatadhesiveisdeepdownintothebellpasttheinsertiondepthandthatallmachinedtapersurfacesonthespigot

    andthecutendofthepipeareuniformlycovered.Excessadhesivewillmakethejointmoredifficulttolock.

    3. Alignandlockthejoint.For2"orsmallerpipe,insertthespigotintothebelluntilsurfacestouch,thenpush

    andturnatthesametimeuntilalockisachieved.Onlyaquartertoahalfturnisusuallyneeded.On3-6diameterpipeoronfittings,pushingandturningtolockthejointisimpracticalanddrivingforcemustbeused.Ahammermaybeusedtoassistinjointlock-up.Placea2x4board

    flatacrossthebell.Thefirstfewrapsshouldbelighttopreventanytendencyofthejointtobackout.

    37

    RT, G

    T, SS FA

    BR

    ICATIO

    N

  • Iftheadhesiveorthepipesurfacesarecool,pushandholdforafewsecondstoallowtimefortheadhesivetostartflow-ingoutofthetaperedjoint.

    4. Checklockupbymovingfreeendofthepipeinanupanddownorsidetosidemotion.Themovementmustbesufficienttomovethejointbeingchecked.Nomovementshouldbevisibleinthejoint.Ifanymove-mentexists,thejointisnotproperlylockedup.Avoidexcessmovementasthiscoulddamagethespigot.

    C. 8 - 24 Bell & Spigot Joint1. Longruns(ditchpiping)mustbesupportedatthejoint

    sectionatalltimesuntilfullycured.Liftingnearthecenterofthepipewithabackhoeorsideboomtractorwithoutpropersupportunderthejointcancausedam-agetojointsthatarenotcured.Liftingnearthecenterofthepipeforalignmentisacceptableaslongasthejointdoesnotsupporttheweightofthepipingsection.Blocksorskidsshouldbeusedtosupporttheentirejointsectionuntilthejointisfullycured.Installpipeinstraightalignment;neverinstallpipeinabind.

    2. 8"-24" hydraulic come-alongisrecommendedforpipe-to-pipeconnections.Formoredifficultbondingsitu-ationsinapiperackorintightquarters,amanualcome-alongkitwithstrapclampsisavailablefromFGSandisrecommendedforsizesthrough16".Alljoints18"andlargermustuseahydrauliccome-alongtoachievefulljointlockup.Alljointspulledtogetherwiththistypeofdevicemustbevibratedduringinstallationtohelpalignthespigotinthebellandpreventafalselockuporcock-ingofthejoint.RefertoBulletinsNo.F6618orF6619fordetailedinstructionsonhydrauliccome-alongs.

    a. Whenusingahydrauliccome-alongon8-24pipe,makesurepipeisrestingonblocksbeforecome-alongcollarsareremoved.Donotremovecollarswhilepipeisstillattachedtocableortractor.Ifcollarsarerestingonblocksafterbonding,leave

    38

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • pressureoncome-alongandliftgentlywiththechains,justenoughtoremovecollars.Donotplaceexcessivebendingstressacrossthejoint.

    3. Strap clamp kitsareavailablefromFGSforpipetofittingconnections.Whenusedinconjunctionwiththehydrauliccome-along,aheavydutyband(strap)clampandtworingbeltstrapsareusedtopullthejointtogeth-er.RefertoBulletinNo.F6641fordetailedinstructionsonStrapClampKits.

    4. Ratchet-type come-alongscanbeusedasanalterna-tivetothehydrauliccome-alongs.Usetwo,oneoneachsideofthejoint.Useaheavy-dutystrapclampkittoat-tachthecome-alongstothepipe.Slings,or5/8orlargermanilaropes,arealsoac-ceptable.Aseriesofhalf-hitcheswillgripthepipewhenusingrope.Allowroomtooperatethecome-alongsbyplacingthestrapclamps,slingsorropes18-24oneachsideofthejoint.Takeupcome-alongstogethersothatthejointstaysinalignment.Forcethejointtogetheruntilitissolid.Rapthejointtogetherwitha5lb.deadblowhammer(s)whilekeepingpressureonthecome-alongstoensurethejointisfullyengaged.

    39

    RT, G

    T, SS FA

    BR

    ICATIO

    N

    TABLE 10. Hydraulic Come-Along Pressures

    PipeGrade PipeSize HydraulicPressure

    (In.) (psig)

    RT,GT,SS 8-1012-16

    1500-17501750-2000

    RTPP,GTPP 8-1012-1618-24

    1500-20002000-2500

    3000

  • D. T.A.B. Joint: T.A.B.Jointinstallationproce-duresfollowthenormalbellandspigotoperationsofcleaning,ad-hesivemixing,etc.asdescribedabove.TwoT.A.B.wrenchesarerequiredwhenjoiningT.A.B.pipe.SeparatewrenchesareavailablefromFGSforeachsizepipe.Thewrencheslockaroundthepipeandforcethepipeintoaveryslightovalshape.Therefore,thewrenchesmustbe6"to12"awayfromthejointtoassuregoodjointmakeup. 1. Coverallmachinedareasonthespigotandatleastone-halfinchbeyondthelastthreadinthebellwiththeproperadhesive.

    2. ScrewthepipetogetheruntilfirmusingT.A.B.jointwrenches.DONOTOVERTIGHTEN.

    Connectionsintofittingsaremadeusingthenormalbellandspigotmethods.Athreadedspigotcanbebondedintoasmoothbell(fitting),orasmoothspigotcanbebondedintoathreadedbell.

    E.SaddlesandReductionsNote:ZC-275or3033Adhesiveisrecommendedfor saddles.

    Positionthesaddleonthepipeandmarkaroundthesaddlebase.Useafile,asander,orroughsandpaper(16to40grit)toremoveallsurfaceglossfromthepipeO.D.wherethesaddleistobebonded.(Forlargediameterpipe,adiscsanderisusuallymorepractical.)Usecircularorrandompat-ternmotionduringsandingtoeliminategroovesonthepipesurface.Aftersanding,positionthesaddleonthepipeandmarktheholetobecutinthepipe.Cutaholethesamesizeasthesaddleoutletusingapilotdrillandcircularholesaworsabresaw.Donotforcethecutteroritwillfraytheedgesoftheholeexcessively.Cleanallbondingsurfacesasrequired.Note:Besurecleaner(ifused)hasevaporatedbeforeap-plyingadhesivetothebondingsurfaces.ApplyaheavycoatofadhesivetotheO.D.ofthepipe,I.D.ofthesaddle,andtheedgesofthepipewallexposedbythehole.Placethesaddleovertheholeandclampwithtwohoseclampsorabandingtool.(Note:Bandingtoolmustbeatypethatdoesnotleaveslackinthebandswhenthetoolisremoved.Use

    40

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

    T.A.B.Wrenches

  • 41

    metalbanding.)Usingalargescrewdriver,handtightenthehoseclampsalternatelyuntilsecureandadhesivesqueezesoutallthewayaroundthesaddle.ThiswillensurethatthepipeO.D.conformstothesaddleI.D.Youcanremovetheclampsorleavetheminplaceaftertheadhesiveiscured.Allow adhesive to cure before bonding in the side run. Usetwobandingtoolstopullthesidesofthesaddledownalternately.Iftwotoolsarenotavailable,tightenthefirstbandsnug,thesecondbandtight,andaddathirdband,pulledtight,onthefirstside.Three-quarterinchbandingisrecommended.Ifthesaddlesareusedonnon-standardpipe(pipenotlistedinFGSlitera-ture),contactyourFGSrepresen-tativeforspecialinstructions.

    F.Reducer BushingsInstallreducerbushingsusingablockofwoodandahammerandthesameproceduresasforbellandspigotpipe.Thewoodblockshouldbesizedtoallowthereducerbushingtobecounter-sunkinthebell.Somereducerbushingswillbecoun-ter-sunkbeforetheyareactuallylockedup.Formaximumchemicalresistancewith8"andlargerGreenThreadreducerbushings,coatallmachinedsurfaceswithadhesivejustbeforeassembly.

    RT, G

    T, SS FA

    BR

    ICATIO

    N

  • 42

    JOINT CuRE

    A. Ambient CureCuretimeisthetimerequiredfortheadhesiveinthe

    assembledjointtoharden.Curetimedependsonthetypeofadhesiveandtheambienttemperature,asshowninTable11.

    Youcanshortencuretimebyapplyingheat.Althoughalloftheadhesiveswillcureatambienttemperaturesabove70F,itisrecommendedtheybeheat-curedattemperaturesofatleast275Ftomaximizephysicalpropertiesandcorro-sionresistance.Seepage43forinstructionsforusingFGSheatcollarsforheat-curingjoints.

    B. High Temperature Heat CollarRefer to Bulletin No. F6640 for complete operating

    instructions.

    TABLE 11. Adhesive Ambient Cure TimeAdhesive Type Temperature (F) Cure Time (hrs.)

    2000

    110 1

    90 380 470 9

    60 16

    50 24

    8000

    110 1

    90 2

    80 470 6

    60 12

    55 18

    NOTE:Curetimeisthetimebeforethelinecanbetested.Timesmayvarydependingupontemperature,humidity,etc.

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • NOTE: Donotbendorfoldheatingcollarasthismaybreaktheheatingelementsandcausethecollartoworkimproperlyornotatall.

    For Pipe and Fittings:1. Usethesamesizeheatingcollarasthepipesizeyou

    areinstalling,withtheexceptionofflanges.Donotuseaheatingcollarthatisdesignedforalargersizepipe.

    2. Withtheun-insulatedflaponthebottom(nexttothefitting),carefullywraptheheatingcollararoundthejoint.Feedthestrapthroughthesquarering.CAUTION:Theun-insulatedflapisextremelyhotwhenthecollarison.DONOTTOUCHwithbarehands.

    3. Tightenthestrapsuntiltheheatingcollarissnugagainstthejoint.

    For Flanges:1. For1",11/2"and2"flanges,anindustrialheatgunmaybe

    usedtocurethejoint.Besurethattheendofthegunisatleastsixinchesfromtheopeningoftheflange.

    2. For3"through16"flangejoints,useaheatingcollarthatisonepipesizesmaller.Removethestrapsfromtheheatingcollar.

    3. CarefullyturnthecollarinsideoutwiththeheatedareafacingtheI.D.ofthepipe.PlacetheheatingcollarintheI.D.oftheflange.Asplitringofpipemaybeusedtoholdthecollarinplacewhilethejointiscuring.

    For Saddles:1. Placetheheatingcollaroverthesaddleoutlet.During

    coolweather,awindshieldisrecommendedtokeepheatonthejoint.Saddlesmustbeheatcuredfortwohours.

    Allowthejointtoreturntoambienttemperaturebeforeapply-ingstresstothejoint. NOTE: FGSHighTemperatureelectricheatingcollarsarede-signedtofitaroundfittings,andwilloverlaponpipejointsandcouplings. Exceeding the recommended cure time on pipejointswheretheheatingcollaroverlapsmayshortenthelifeoftheheatingcollarand/ordamagethepipe.

    Theuseofinsulationmaybenecessarybelow40Ftopreventheatloss.

    43

    RT, G

    T, SS FA

    BR

    ICATIO

    N

  • NOTE: Thesecuretimesareforenvironmentswarmerthan70F.Ifcooler,see"ColdWeatherInstallationTips"onpage14orconsultFGS.Adhesiveswillcurein24hoursatambienttemperaturesof70-100F.(1) Includessleevecouplings.

    250F.(3) 18"-36"collarsareun-insulated.(4) Below50F,theheatingcollarsshouldbewrappedininsulationtoreduce heatloss.(5) 36"heatcollarsrequirespecial20ampconnectors.

    C. FGS Heat Packs FGSheatpacksthatcurejointsinapproximatelyonehourarealsoavailable.RefertoBulletinNo.D4500forcompleteinstructionsthatareincludedwitheachkit.Observeallsafetyprecautionslistedontheinstructionsheetsthataccompanytheheatpacks.

    44

    TAB

    LE 1

    2. A

    dhes

    ive

    Cur

    e Ti

    mes

    for

    Elec

    tric

    Hea

    ting

    Col

    lars

    Pipe

    Sys

    tem

    &

    Adh

    esiv

    e G

    rade

    Pipe

    Siz

    e (I

    n.)

    Cur

    e Ti

    me

    (Min

    utes

    )Pi

    pe (1

    )Fi

    tting

    Flan

    ge (2

    )Pe

    rf. P

    lus

    Red

    Threa

    dII

    Green

    Threa

    dSilverStre

    ak20

    00or80

    00SeriesAdh

    esive

    1-6

    1220

    15N/A

    820

    2020

    3010

    2727

    2735

    1230

    3030

    4014

    3434

    3445

    1638

    3838

    6018

    -24

    (3,4)

    9090

    9012

    030

    -36

    (3)(5)

    120

    120

    90NA

    GT17

    5/25

    030

    33Adh

    esive

    1-6

    8-12

    30 6030 60

    30 60NA

    NA

    GT17

    5/25

    080

    00Adh

    esive

    14-16

    6060

    60NA

    18-24

    9090

    90NA

  • Caution:Theadhesivebeadwillcurefasterthantheadhesiveinthejoint.Itisimportantthatthejointnotbepressurizeduntilithasbeensubjectedtothe

    propertime-temperaturecycle.Atemperatureversustimetopressurecurveisindicatedintheinstructionspackagedwitheachadhesivekit.

    REPAIRS for RED THREAD, GREEN THREAD & SILVER STREAK Piping Systems

    Fiberglasspipingsystemsarerelativelysimpletorepair.Normally,repairmeanscuttingoutafittingoradamagedsec-tionofpipeandreplacingitwithnewmaterial.

    Caution:Alwaysdetermineexactlywhatfluidhasbeeninthepipingsystem.Contactmaybeharmfultohumans.Takenecessaryprecautions.

    Alwaysusethesamepipegrade,fittings,andadhesiveonnewpartsasisintheexistingsystem.Donotmixpipegrades.

    Inspecting for Potential Causes of Joint Failure

    Joint BackoutIfthebeadisnolongernexttotheedgeofthebell,thejointbackedoutbeforetheadhesivecured.

    Cocked JointIfajointiscockedormisaligned,therewillusuallybealargegapbetweenthebellandspigotononeside.

    Improperly Cured JointIftheadhesivebeadissoftorflexible,theadhesiveisnotsufficientlycured.

    Weathered JointIfthemachinedareaappearsyellow,thejointmayhavebeenexposedtoUVdegradation.

    Alldamagedorimproperlyassembledjointsmustberepairedorreplacedasindicatedbelow.

    REPAIRING WEATHER DAMAGEIfmachinedsurfacesofpipeorfittingsareexposedto

    directsunlightpriortoinstallation,alossofjointbondingstrengthmayoccur.Ifultravioletexposureisgreaterthantwohours,thefollowingstepsmustbetaken: 1. Forexposedspigotends,use60to80gritsandpaperor

    EmeryclothandlightlysandtoremoveUVdegradation.Avoidoversandingasthismayalterthetaperangleofthespigotandmayresultinvoidsinthebondline.IfUVdeg-radationistoosevere,cut1fromtheendofthepipeandretaper.

    45

    RT, G

    T, SS FA

    BR

    ICATIO

    N

    !

    !

  • 2. Forexposedbellends(pipeorfittings),sandthoroughlyuntiltheentiresurfaceappearsfresh.Handsandingwith40gritsandpaperisrecommended.Usealightsandingoperationtopreventchangingthetaperangle.

    NOTE:COUPLINGSORINTEGRALBELLSWITHT.A.B.THREADSTHATHAVEBEENOVEREXPOSEDMUSTBEREPLACED.

    REPAIRING MINOR DAMAGEFordamagedareaslessthanoneinchindiameterinlightchemicalorwaterservice.

    A. Flanged Systems:Ifpossible,simplyreplacetheentireflangedlength.Otherwise,cutoutthedamagedsection,thenbondnewflangestotheremainingpipeendsaccord-ingtorecommendedprocedures.Next,fabricateanewflange-by-flangespooltothelengthrequired.Boltinthenewpipesection.

    Flangedfittingsshouldberemovedfromthesystemwhen

    damagedandreplacedwithanewfitting.

    B. Tapered Systems: Makeapatchtocoverdamagedarea.1. Cutalengthofgoodpipetoadequatelycoverthe

    damagedareaandextend3-4oneithersideofthedamagedarea.

    2. Slitthispatchlength-wisetwiceandremoveasectionsothataboutthree-fourthsofthecircumferenceremainsfor1"-4"pipeandone-halfthecircumferencefor6"andlargerpipe.

    3. Thoroughlysandtheinnersurfaceofthepatchandsandacorrespondingareaonthepipearoundthedamagedsection.

    4. Cleanthebondingsurfaces,thenap-plyathickcoatingofadhesivetobothsurfaces,snapthepatchinplace,andapplypressurewithhoseclamps.Theclampsmaybeleftonorremovedaftercuring.

    46

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

  • REPAIRING EXTENSIVE DAMAGEWhenthedamagedareainthepipewallislargerthanoneinchindiameter,orforrepairofpipeinseverechemicalser-vicethatrequiresalinedproduct,followtheseinstructions:

    1. Whendamageislocal(lessthanoneinchlong,butmorethantwoinchesaroundthecircumferenceofthepipe),checktoseeifthereisenoughslackinthepipetocutoutthedamagedsec-tion,re-taperthecutends,andbondasleevecouplingbetweenthetaperedends.

    2. Whendamageisextensive(toolargeforreplacementbyasinglesleevecoupling),cutoutthedamagedsection,taperthecutends,andinstalltwosleevecouplingsandapipenipple.This procedure requires sufficient slack in the line to make the final joint by lifting the pipe (or moving the pipe to one side) to engage the bell and spigot joint.

    3. Ifthelinecannotbemovedsufficientlytoinstallasleevecouplingorasleevecouplingspoolpiece,taperbothendsofthepipeandinstallflanges.

    4. Ifitisimpossibletotaperthepipeintheditch,youcaninstallanewsectionofpipebyoverwrappingtheplaincutends.a. Cleananarealargeenoughforinstallerstoworkon

    bothsidesandunderthepipe.Cutoutthedamagedsectionofpipeandmeasurethegap.Cutasectionofgoodpipethatisnotmorethanone-halfinchshorterthanthelengthtobereplaced(1/4"maximumgaponeachend).

    b. Sandtheendsofthepipetoremoveallresingloss.Alignthereplacementpipesectionwiththepipelineandblockupallsectionstomaintainalignment.Allsectionsmustberigidsotheywillnotmoveduringtheoverwrappingprocedure.Tackweldsshouldbeusedbyplacing1"x2"patchesofglassclothandad-hesive(fourpatchesspacedat90intervalsaroundthepipe).SeeOverwrapping on p. 48.

    47

    RT, G

    T, SS FA

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  • REPAIRING LEAKING JOINTSOverwrappingIfajointleaksbecauseofimproperinstal-lation,youcanrepairitbyoverwrappingwithglassclothandresin.Thetemperatureintheworkareashouldbe75F-90F.Besuretoprotecttheoverwrapfromthesun.

    1. Use7-10oz.glassclothfromFGS.Componentsfortheepoxyoverwrapareavailableinan8088repairkits(seeTable13).

    2. Useagrinderorsanderwithcoarsegrittoremoveglossfiveinchesoneithersideofthejoint.

    3. Beveltheshoul-dertoblendinwiththepipewallandaddputtytomakeasmoothtransitionfromfittingtopipe.Thelengthofthisputtyshouldbeheldtoaminimum,becausetheputtyhaslimitedpressurecapabilities.

    48

    TABLE 13. WELDFAST 8088-S Overwrap Repair KitsPipe

    Size (In.)Layers

    of GlassGlass Width

    (In.)Number of kits

    Required per Joint1 4 8 0.25

    11/2 4 8 0.252 6 8 0.753 6 8 0.754 6 8 1.006 6 8 1.508 8 8 2.5010 10 8 3.5012 12 8 5.0014 14 8 6.5016 16 8 8.00

    RT,

    GT,

    SS

    FAB

    RIC

    ATIO

    N

    NOTE: An 8088L (Large) repair kit is available from FGS for 8" andlargeroverwraps.A2088overwrapkitisavailableforapplicationswithtemperaturesatorbelow200F.

  • CAuTION: There must not be any pressure on the line or any fluid leaking from the joint when performing this procedure.

    4. Re-sandandcleansurfacesincludingbevel.5. Thoroughlymixtheadhesiveandhardenerwiththestir

    stickuntilthereisauniformcolorandaconsistentflowoffthestirstick.

    6. Usingapaintbrush,applythemixedadhesivetoallsandedareas.

    7. Eachpieceofglassclothmustbeslightlylongerthanthepreviouspiece,becausetheO.D.ofthepipebecomeslargerasyouaddglasscloth.Cutthefirstpiecetoallowfortwoinchesofoverlap.Whenthislengthisnolongersufficienttooverlapatleastone-halfinchontheends,determineanewlengthwithtwoinchesofoverlap.

    8. Centerapieceofglassclothoverthejoint.Pullontheclothwhilepositioningitandwetitoutbypaintingwithadhesive.Brushtoremoveanytrappedairbubblesinthewrap.Startatoneendoftheclothandworkaroundthecircumference,wettingtheclothwithresin.Worktheclothawayfromthestartingendandfromthecenteroftheclothtothesides.Theclothmustbethoroughlywet-tedwithadhesive,butdonotspendalotoftimeinoneareaastheclothwillwetout(loseitsshiny,whiteappear-ance)withtime.Bythetimetheclothhasbeenworkeddownsmoothlywithnoairbeneathit,mostofitwillbewettedout.

    9. Topreventthicksectionsorhumpsintheoverwrap,cen-terthenextpieceofglassclothonthejointstartingfromanewpointonthecircumference.RepeatStep8untilalllayersareapplied.

    10.Shouldtheoverwrapstarttogiveoffheat,discontinuewrappingandletthejointcureandcoolwithafan.Sandthecuredlayerstoremovetheglossbeforerestartingtheoverwrapprocedure.

    11. Payparticularattentiontothebottomoftheoverwrapasthisistheareathatmaysagandismostdifficulttosee.

    12. Intemperaturesabove90F,protecttheoverwrapfromdirectsunlight.

    49

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  • PART VFABRICATION OF F-CHEM PIPE AND FITTINGS

    A. Matched Tapered Bell and Spigot Joint PrepNote:Itisessentialthatpipeandfittingsurfacesbe

    sanded,clean,dry,andfreeofoil,grease,andsolventcon-tamination.

    1. Preparethebellandspigotendsofthepipebysandingthebondingsurfaceswith36to60gritabrasive.

    Thesandedareashouldextendatleast1/2"beyondthelengthofthebell.

    2. Neversandmorethantwo(2)hoursbeforemakingthejoint.

    3. Wipethesandedareawithaclean,dry,lint-freecloth,andavoidtouchingthesurfaceswithbarehandsordirtygloves.

    DO NOT uSE SOLVENTS.

    Note:F-CHEMfittingsareavailablewithflangedorplainendsonly.SeeManualNo.F6080, Pipe Installation Hand-book for Socket Joints and Butt & Wrap Joints,forjoiningF-CHEMfittingsandpipewithbutt&wrapjoints.

    B. Joint Assembly1. Coupler Instructions Attachthebandsorchains

    tothepipe.Havethejacksandallothermaterialready,priortomixingtheresinandcatalyst.

    Placebandclampsorchainsapproximately3to4feetfromthejointonboththebellandthespigotpieces.Slipthe"D"ringsintoplaceonthehorizontalcenterline,onbothsidesofthepipe,priortoattachingthecouplerhooks.

    Unreelthecouplersandhookthejacksintoplace.Thecablesmaybeleftunattachedtoallowworkingroomfortheapplicationoftheadhesive.

    50

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  • 51

    2. Mixing Weldfast CL-100 Adhesivea. MixthecanofPart"A"resin

    tofullydisperseanyliquidwhichmayhaveseparatedduringstorage.Itshouldbealightpurplecolor.

    b. AddtherecommendedtubesofPart"B"catalysttothePart"A"resincan.

    c. Mixthoroughlyforaminimumof twominutesoruntilthecolorisa consistentlightgreen.

    3. Pot Life Potlife(workingtime)mayvarywithchangesintempera-

    tureandhumidity.

    4. Applying Weldfast CL-100 and Bonding Pipea. Usethebrushtoapply

    generousamountsofcatalyzedresintothebellendfirst,thenapplytothespigotend.

    b. Alignthejointandguidethespigotendintothebell.

    c. Attachcouplerhooksandjackthejointintofirmengagement.Checkaroundthejointlinetobesurethatitiseven,whichindicatesproperalignment.

    d. Usebrushtofillinanygapsinadhesive.Leavecouplerinplaceduringinitialcure(approximatelyonehour).

    TABLE 14. CL-100 Adhesive Estimated Pot Life

    Pipe PotLife PotLifeResin @70F @90FSystem Adhesive (min.) (min.)

    VinylEster CL-100 20 10

    F-CH

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    ATION

  • C. Joint CureCuretimeisthetimerequiredfortheadhesiveinthe

    assembledjointtohardenanddependsontheambienttem-perature.Cure Time for CL-100 Adhesive is 24 hours.Curetimecanbedecreasedandjointstrengthincreasedbyheatingthejointfrom175Fto225F.Heatcureisstronglyrecom-mendedforpipingsystemscarryingfluidsattemperaturesabove120F.

    52

    ADHESIVE DISPOSAL: Once the adhesive and catalyst havebeenmixedandreacted,nothingcanbeextracted,anditisclassi-fiedasnon-hazardousmaterial.Disposeofinanormalmannerasothersolidwaste.Excessadhesiveandcatalystcanbemixed,al-lowedtoreact,anddisposedofasabove.Ifextracansofadhesiveor tubesof catalysthaveaccumulatedwithout theother compo-nenttomixandreact,contactyourFGSregionalmanager.Cata-lysttubes,whenemptyarenotsubjecttoEPAregulationandcanbedisposedof inanormalmanner.Theseguidelinesarebasedonfederalregulations.Stateandlocalregulationsandordinancesshouldbereviewed.

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  • INSTRuCTIONS FOR uSING FGS SILICON RuBBER HEAT BLANKET

    Caution:ReadOperatingInstructionsBeforeUsing. Useonlywith120voltpoweroutlet. Blanketshouldnotbeusedinwetconditions. Tears,cutsorpuncturesintheblanketcancreatea

    potentialsafetyhazard. Thethermostatmustbewrappedintheblankettoprevent

    overheating.

    1. Useonlythepropersizeheatblanketforthepipebeingjoined.

    2. Aftertheadhesivefillethashardened,wraptheblanketaroundthejointbyfirstplacingthethermostatendoftheblanketagainstthejointwiththethermostatfacingout.Wraptheremainderoftheblankettightlyaroundthepipe.Holditinplaceduringtheheatingprocess.

    NOTE:Checkheatblankettemperaturetobesureitis heatingproperly.

    3. Avoidexcessflexingoftheblanket.Abnormalflexingcancausebreakageandshortentheservicelifeoftheblanket.DONOTcreasetheheatblanket.

    4. Usealuminumfoiltoprotectheatblanketfromadhesive.5. DONOTusecleaningsolvents.Solventspenetratethe

    rubberanddamagetheheatingwires.6. DONOTcarryormovetheblanketbyliftingitwiththe

    cordalone.Supporttheweightoftheblanketseparatelyfromthecordtoavoidabusingthecord-to-blanketcon-nection.

    Impropersizingoruseoftheheatblanketscancauseexcessheatingwhichcandamageboththepipingandheatblankets.

    53

    TABLE 15. 110 Volt Silicon Rubber Heat Blanket Models(For use with F-CHEM pipe)

    PipeSize 4-8 10-14 16-20

    Model C D E

    F-CH

    EM

    FAB

    RIC

    ATION

  • TABLE 16. Silicon Rubber Heat Blanket Cure Times for Adhesive Joint Fabrication

    NOTE:Heatblanketcuretimereferstothattimewhentheheatsourcecanberemovedandthepipeinstalledandtestedatrecommendedpressures.Heatblankethourspertainto70-100Ffabricationenvironment.Curetimeswillbelongerforcoldertemperatures.Fortemperaturesbelow70F,see"ColdWeatherInstallationTips"onpage14orconsultFGSTechnicalServices.Ifnoheatsourceisavailable,adhesiveswillcureatambienttemperaturesof70-100Fin24hours.

    54

    Piping System/Adhesive Grade

    Pipe Size(In.)

    B&S Joints(hrs.)

    F-CHEMCL-1004-14 1

    16-20 4

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    REPAIR & MODIFICATIONfor F-CHEM PIPING SYSTEMS

    Fiberglasspipingsystemsarerelativelysimpletorepair.Normally,repairmeanscuttingoutafittingoradamagedsec-tionofpipeandreplacingitwithnewmaterial.

    Caution:Alwaysdetermineexactlywhatfluidhasbeeninthepipingsystem.Contactmaybeharmfultohumans.Takenecessaryprecautions.

    Alwaysusethesamepipegrade,fittings,andadhesivewhenrepairingorreplacingdamagedsections,ormodifyingthesystem.

    Ifyouhaveanyquestionsaboutthechemicalservice,pipegradeselection,orsystemoperatingconditions,callyourlocalFGSDistributororFiberGlassSystemsdirect.

    NOTE: Whenmakingrepairs,besureallsurfacestobebonded

    aredry,cleanandthoroughlysanded.Goodadhesiveconnectionscannotbemadeonwetorcontaminatedsurfaces.

    REPLACING DAMAGED PIPEPipeleaksthroughthepipewallarealmostalwaystheresultofphysicaldamagetothepipefromimpact,vacuum,excessivebending,orotherabusiveconditions.Thedam-agedsectionshouldalwaysbereplacedusingthefollowingprocedures:

    Flanged Systems: Ifpossible,simplyreplacetheentireflangedlength.Other-wise,cutoutthedamagedsection,thenbondnewflangestotheremainingpipeendsaccordingtorecommendedproce-dures.Next,fabricateanewflange-by-flangespooltothelengthrequired.Boltinthenewpipesection.

    Flangedfittingsshouldberemovedfromthesystemwhendamagedandreplacedwithanewfitting

    !

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    F-C

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    Tapered Bell & Spigot Systems:Cutoutthesectionofpipewhichleaks,makingsurecutsaresquare.Drythepipeends.Cutanewlengthofpipethesamelengthasthepiecethatwascutout.UsetwoFGSbutt&wrapkitstobondthenewpipeintoplace.RefertoManual No. F6080 for Butt & Wrap Jointdetailedinstructions.

    REPLACING DAMAGED FITTINGSIfaleakdevelopsinanF-CHEMfitting,itwillusuallybenecessarytocutouttheleakingpartandreplaceit.UseFGSbutt&wrapkitstobondthenewfittingintoplace.Referto Manual No. F6080fordetailedinstructions.TEMPORARY FIXES, OVERWRAP

    ButtWrap ButtWrap

    ButtWrapJoint

    ProblemFitting

    Step1-CutoutSection

  • Asatemporaryrepair,aleakingfitting,pipeorjointcanbeoverwrappedwitharesinandglasslay-up.Thisrequiresresin,catalyst,fiberglassreinforcement,tools,andaclean,dryworkarea.Manytimesanoverwrapisthepreferredmethod,particularlywhenfittingsareinaclose,complexmanifoldorassembly.Customoverwrapkitsareavailableforeachpipesizeandpressureclassification.ContactFGS.

    Application Procedure:Beforemakingtheover-wrap,readtheseinstructionscarefully.1. Sandthesurfaceareathoroughlyforanequaldistance

    oneachsideoftheleak.Thesandedsurfaceshouldextendatleast1/2beyondthewidestlayerofglasssup-pliedwiththekit.Removeallsurfaceglazes,paint,oil,grease,scale,moisture,orotherforeignmaterialtoen-sureproperbondingoftheresinmaterialtothesurface.

    2. Usetheapplicatorbrushtoremovealldustfromthesandedarea.

    3. Ifrepairingabell&spigotpipejoint,usetheWELDFASTadhesiveputtysup-pliedinthekittoformataperedbeadasshowninthissketch.Thebeadwillprovideasmoothtransitionfromfittingtopipe.

    4. Layouttheprecutfabmatandsurfacingveilonaflat,clean,drysurface(i.e.,cardboard,plywood,etc.).

    5. AddcontentsofPart"B"tube(s)tocontainerofPart"A"(resin).Usingoneofthewoodenstirrers,mixthecontentsthoroughlyforatleastoneminute.

    6. Usetheapplicatorbrushtoapplyaliberal,evencoatingoftheresinmixturetotheentiresandedsurface.

    7. Usingthe3"roller,thoroughlysaturatethefabmatlaidoutonyourworkingsurface.Applywet-outfabmattothejointtobeoverlaidplacingthematsidedown.Usingthe3"roller,continuetorolloutthematerialuntilallentrappedairhasbeenrolledoutandthefabmatiscontouredsmoothlytothesurface.

    8. Forjointsizes4"andlarger,repeatStep#7above.

    57

    TaperedWeldfastBead

    Veil &FabmatOverlay

    SpigotEnd

    BellEnd

    F-CH

    EM

    FAB

    RIC

    ATION

  • 9. Placesurfacingveiloverthefabmatand,againusingthe3"roller,applyaliberalamountofresinandworkoutallairasinStep#7.

    Be sure that the pipe surface is thoroughly wet out with catalyzed resin.

    Some guidelines on the overwrap are:1. Theoverwrapshouldbeequallyspacedoneachsideof

    thepointoftheleak.2. Theoverwrapshouldbearoundtheentirecircumference

    ofthepipeorfitting.3. Thepressureratingandpipediameterwilldeterminethe

    overwrapthickness.ConsultFGStechnicalservicestodeterminespecificinformationaboutdesignoftheover-wrap.

    4. Theresinsystemoftheoverwrapshouldbecompatiblewiththeresinsystemoftheexistingpipeorfittings.

    5. Curetheoverwrapcompletelybeforepressuretesting.

    RefertoManualNo.F6080Butt & Wrap Joint Sectionfordetailedinstructions.

    TAPPING INTO AN F-CHEM LINEThemostcommonmethodfor

    addingabranchortappingintoanexistingF-CHEMlineistheuseofaT-Miter.Forcompleteinstruc-tions,seeBulletin Nos. D4235, D4240 or D4242,suppliedwitheachT-Miterkit.

    Application of a T-Miter:1. Cuttheendofthenewbranchpipewithacontourto

    matchtheexistinglinepipeoutsidediameter.2. Trialfitthebranchpipetothelinepipetoensureminimal

    gapsandmarkfortheholeinthelinepipe.3. Cutaholeinthelinepipethesamediameterasthe

    branchpipeinsidediameter.4. Sandbothpipeswitha36-60gritabrasivetocomplete

    roughenthebondingsurface1/2beyondthewidestlayeroffiberglasstobeapplied.

    5. Usetheadhesivesuppliedinthekittosealtheedgesofthepipeandbondthebranchtotheexistingpipe.

    58

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  • 6. Mixtheresinsuppliedinthekitandwetoutthesandedpipesurfacesandsuppliedfiberglass.

    7. ApplythefiberglasstothepipejointaccordingtotheinstructionssuppliedintheT-Miterkit.

    8. Curethefiberglasslayup.

    59

    F-CH

    EM

    FAB

    RIC

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  • 60

    PART VIINSTALLATION CONSIDERATIONS

    TESTING RECOMMENDATIONS

    THESE PROCEDuRES MuST BE FOLLOWED IN OR-DER TO AVOID SERIOuS PERSONAL INJuRY OR PROP-ERTY DAMAGE. FAILuRE TO DO SO WILL RESuLT IN LOSS OF WARRANTY, AND BuYER, INSTALLER, OR ANY EMPLOYEE, AGENT, OR REPRESENTATIVE THEREOF, ASSuMES THE RISK OF ANY DAMAGE OR INJuRY TO PERSON OR PROPERTY.

    NOTE:Followallapplicablelocalcodesandprudentengineeringpractices.

    HYDROSTATIC TESTINGWhereverpossible,FGSpipingsystemsshouldbehydro-

    staticallytestedpriortobeingputintoservice.Careshouldbetakenwhentesting,asinactualinstallation,toavoidwaterhammer.Locatealltestequipmentawayfromtheendofthepipingsystem.

    AboveGround:Allanchors,guidesandsupportsmustbeinplacepriortotesting.

    BuriedSystems:Beforetesting,makesurethepipingsys-temissecureintheditchwithcompletebeddingunderthepipeandenoughbackfillmaterialinthemiddleofthepipetoholdthepipeinplace.Jointsshouldbeleftopenforvisualinspectionduringtest.

    Tohydrostaticallytesttheline,observethefollowing:Watershouldbeintroducedatthelowestpointinthesystemandtheairbledoffthroughapartiallyopenvalveorlooseflangeatallthehighpoints.Slowlyclosethevalve,andbringthesystemgraduallyuptothedesiredpressure.

    A. Test Procedures (RT, GT, SS) Thenormalrecommendedprocedureistoconducta

    cyclicpressuretest.Thepipingsystemissubjectedto10pressurizationcyclesat11/2timestheanticipatedordesignoperatingpressure.Pressureisthenkeptonthesystemfor1-8hourswhilethelineisinspectedforleaks.Whenhighertestpressuresaredesired,thetestpressureshouldnotexceed11/2timesthemaximumratedcyclicpressureforthelowestratedcomponentinthesystem.Forlowpressureapplications,suchasdrainlines,thecyclictestmaybereplacedbyasteadypressuretest.Linesthatcanbesubjectedtoseveretemperaturecycles,suchas

    INST

    ALL

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    CO

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  • steamcondensatelines,hotwaterlines,andcoldwaterlines,shouldbe testedusingthecyclictestprocedureat11/2timesthecyclicpressurerating,evenifthesystemistooperateatrelativelylowpressure.Vacuumorexternalpressuretestingmustnotexceedtheexternalpressurerating.

    B. Test Procedures (F-CHEM) Testpressureshouldnotbemorethan1-1/2timesthe

    workingpressureofthepipingsystem,andneverexceed1-1/2timestheratedoperatingpressureofthelowestratedcomponentinthesystem.Whentestingiscomplet-ed,openalloftheairbleedsbeforedrainingthepiping.Thiswillpreventvacuumcollapseofthepipe.

    WARNINGS:Air Testing:Hydrostatictestshouldbeusedinsteadofairorcompressedgasifpossible.Whenairorcompressedgasisusedfortesting,tremendousamountsofenergycanbestoredinthesystem.Ifafailureoccurs,theenergymaybere-leasedcatastrophically,whichcanresultinpropertydamageandpersonalinjury.Incaseswheresystemcontaminationorfluidweightpreventstheuseofhydrostatictest,airtestmaybeusedwithextremecaution.Toreducetheriskofairtesting,usethetablebelowtodeterminemaximumpressure.Whenpressurizingthesystemwithairorcompressedgas,theareasurroundingthepipingmustbeclearedofpersonneltopreventinjury.Holdairpressureforonehour,thenreducethepressuretoonehalftheoriginal.Personnelcanthenentertheareatoperformsoaptestofalljoints.Again,extremecautionmustbeexercisedduringairtestingtopreventpropertydam-ageorpersonnelinjury.If air or compressed gas testing is used, FGS will not be responsible for any resulting injury to personnel or damage to property, including the piping system.Airorcompressedgastestingisdoneentirelyatthediscretionandriskofmanagementatthejobsite.

    Forlargerdiameters,contactFibe


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