Ameron International 3000-LCX Installation Manual

FP824D (11/07)

Dualoy®3000/LCX Installation

Installation Practices

for Dualoy 3000/LCX coaxial fiberglass piping system with bonded clamshell fittings

Bulletin 9903

FIBERGLASS-COMPOSITE PIPE GROUP

i. Training and Certification.........................................................2

ii. Glossary & Abbreviations ........................................................2

iii. Pressure Ratings.....................................................2

1 Introduction .............................................................3

2 Listings and approvals...........................................3

3 Inspection, handling & storage..............................3

4 Materials...................................................................4

Pipe...........................................................................4

Fittings.......................................................................4

Adhesive....................................................................4

Tools..........................................................................4

5 Field cutting & tapering primary pipe....................5

Cutting.......................................................................5

Removing containment .............................................5

Tapering with Ameron Taper Maker..........................5

Tapering with power tapering tools ...........................6

6 Piping system layout ..............................................6

Trenching, bedding & backfilling ...............................6

Supporting valves, accessories & vent lines.............7

Precise alignment and make-up................................8

Flexible sump penetration fitting installation..............8

Jump-overs and Cross-overs....................................9

Reducers...................................................................9

7 Bonding primary systems....................................10

Joint preparation......................................................10

Mixing Ameron adhesive.........................................10

Applying Ameron adhesive......................................10

Making the joint.......................................................10

Pot life & cure time for Ameron adhesive................11

Force curing Ameron adhesive ...............................11

Using heat blankets.................................................11

Connecting to non-Ameron fiberglass piping ..........11

8 Bonding containment piping................................12

Joint preparation......................................................12

Sealing containment piping.....................................12

Terminating the secondary containment.................12

Terminating inside the sump...................................12

9 NPT threaded connections...................................13

Thread preparation..................................................13

Making the joint.......................................................13

Isolating flex connections at the shear valve...........14

10 Repair procedures.................................................14

Minor damage .........................................................14

Major damage ........................................................14

11 Primary system testing.........................................15

Recommended practices.........................................15

12 Containment system testing................................15

Pneumatic testing....................................................15

Provisions for testing and monitoring......................15

13 Simultaneous testing............................................16

14 Health & safety information..................................16

Toxicity of adhesive.................................................16

Handling precautions for adhesive..........................16

First aid for adhesive users ....................................16

Important Notice......................................................16

Table of Contents

Training for Ameron Dualoy

Piping Systems

1. Installation training for Ameron Dualoy 3000/L piping systems, including secondarily contained systems and Dualoy 3000/LCX, shall be done by an Ameron employee, sales representatve or distributor.

2. Training shall, at minimum, consist of a thorough review of the installation instructions (Bulletins, 7501, 8702 and/or 9903) as applicable for the systems on which the installer is to be certified. It is recommended that an installation video, (such as “Dualoy 3000/LCX Installation”) be used during the training session. Also recommended is an examination of the installation tools, a demonstration of the joint preparation and bonding and, if possible, a “handson” execution of the installation procedures for a sample connection.

3. Upon completion of the training, each individual being trained shall complete the written examination for the systems on which they are to receive qualification.

4. The examinations will be signed by the trainee and the instructor and forwarded to Ameron for grading and registering of the individual as a “Certified Installer.”

5. Ameron will issue a training certificate with the individual identified and will include their name on a registration list. Wallet-sized certificates and hard hat stickers may also be provided. Training certificates are valid for three years.

ii.

Glossary & Abbreviations

iii.

Pressure Ratings & Specifications of Products

Dualoy 3000/LCX pipe specifications and ratings

Pipe Size Nominal O.D. Wall Thickness Weight Pressure Rating Pressure Rating

Primary Pipe Secondary Pipe

(inches) (inches) (inches) lb/ft (psig) (psig)

2 2.38 .080 .90 200 180 3 3.50 .085 1.30 200 100 4 4.50 .090 1.74 175 80

Dualoy 3000/L couplings & adapters ratings

Pipe Size Couplings Adapters BxF Adapters SxM Adapters SxF

(inches) (psig) (psig) (psig) (psig)

2 200 200 200 200 3 125 125 125 125 4 100 100 100 100

Pipe Size 45°,90° Elbows Reducer Bushings Tees Adapters BxM

(inches) (psig) (psig) (psig) (psig)

2 200 200 200 200 3 125 125 125 125 4 100 100 100 100

5Pipe Size Dualoy 3000/L Dualoy 3000/L Dualoy 3000/LCX

(inches) Repair Coupling Containment Fittings Containment Fittings

2 80 – 50* 340 50 50* 430 50 20

* Pressure rating with stiffening rings.

2-Piece Clamshell Fittings

Dualoy 3000/L fittings & adapters ratings

SC – Secondary containment fittings or pipe MV – Motor vehicle fuels NV – Normal vent line from tank CF – Concentrated fuels PC – Primary Carrier HB – High blend fuels PS – Primary/Secondary combined into one unit AM – Aviation and marine fuels VR – Vapor recovery

ULC

Underwriters Laboratories Inc.

Dualoy 3000/LCX pipe and fittings are manufactured from thermosetting epoxy resins reinforced with high tensile strength fiberglass filaments. The pipe is produced by filament winding. The pipe incorporates a resin-rich inner liner that is resilient and holiday-free and a resin-rich outer coating that protects the structural wall from UV degradation during storage and installation. The structural wall strength of Dualoy3000/LCX pipe is unsurpassed in the fiberglass pipe industry. Fittings are manufactured by filamentwinding or compression molding.

Dualoy 3000/LCX pipe and fittings are electrically nonconductive and never require cathodic protection or sacrificial anodes. Installed systems are immune to external corrosion from stray-current electrolysis and cathodic interference. They are unaffected by alkaline or acidic soil conditions.

The containment on the pipe is coaxial and an integral part of the piping. The containment over the fittings is made by applying matched clamshell fittings over the primary fitting, connecting the pipe containment jackets.

The primary piping and containment fittings are joined using the same, strong, reliable, bonded joint as in Dualoy 3000/L single wall piping.

Dualoy 3000/L single-wall piping systems

Detailed installation instructions for Dualoy 3000/L single-wall piping may be found in Ameron Bulletin 7501 (FP104) available from Ameron Fiberglass Pipe Group or your Ameron distributor.

Introduction

Listings and approvals

Dualoy 3000/LCX is Listed in the United States with Underwriters Laboratories for nonmetallic underground piping for motor vehicle fuels (MV), concentrated fuels (CF), high blend fuels (HB) and aviation and marine fuels (AM). It is also Listed with Underwriters Laboratories Canada (ULC)for the same fuel categories. It can be used for integral primary/secondary (PS) services where both layers are combined into one unit under UL File No. MH 15596. The ULC File No. is CMH 715.

Inspection, handling and storage

Inspection

Careful inspection of the outer (secondary) layer of pipe is especially important on coaxial containment installations. Since damage to the primary is not visible once the pipe is installed, it is essential to check the outer pipe jacket for damage. Testing and experience has proven that no damage will occur to the primary pipe without an indication of damage on the outer jacket.

Upon receipt at the job site, inspect the pipe fully. Locate, cut out, repair or replace damaged pipe. Impact damage is usually recognizable as rounded pale areas just under the surface or as deep gouges, scratches or cracks. Remove end protectors to inspect tapers for damage and then replace protectors.

Handling

Dualoy 3000/LCX has higher impact resistance than single-wall pipe, however, fiberglass pipe is susceptible to damage if handled improperly. Adhere to the following recommendations when handling:

• Do not transport pipe without proper protection against impact.

• Truck pipe racks should be padded with carpeting or like material to prevent damage.

• Tie the pipe down during transport to prevent it from bouncing on the racks.

• Do not use chains to tie down the pipe on a truck: Use nylon straps or hemp rope.

• Do not drop the pipe from truck bed when stringing: Lay the pipe down by hand.

• Pipe loads that are properly separated and supported can be unloaded by padded forklifts.

Storage

Dualoy 3000/LCX pipe incorporates a resin-rich outer coating which provides outstanding UV resistance. Pipe stored out-of-doors for extended periods may assume a chalky appearance. However, this change in appearance is superficial and does not affect the pipe’s performance. Protect stored pipe from impact damage by stacking on padded racks.

Tools

The following tools are recommended to install Dualoy 3000/LCX piping:

• 1½ inch diameter by 1 inch wide coarse-grit flapper sander

•

/8-inch electric drill or equivalent air-driven motor

• Fine blade hacksaw, radial cut off saw or circular saw

• 6-inch hole saw for installing sump penetration fittings

• Large pliers capable of gripping a 4-inch object

• Containment jacket stripping tool

•1

/2-inch disc grinder wheel for abrading sump wall at penetration

•

Heat blankets, heavy-duty heat guns, or hot air blowers for cool/cold-weather installation.

When using pneumatic tools,

the air supply must be dry and

oil-free as moisture or oil on

bonding surfaces will interfere

with the adhesive.

Materials

Pipe

Manufacturer tallies pipe on the basis of overall length. Allow for cutting losses and wastage when ordering.

Fittings

Contained fitting assemblies are sold in the following boxed quantities.

Adhesive

Ameron supplies PSX

™

•20 and PSX™•34 adhesives. The PSX™•20 and PSX™•34 adhesives are polysiloxane-modified epoxy formulations. They are designed to make permanent bonds in primary or containment systems transferring MV, CF, HB or A&M fuels. They are also approved for use with MTBE fluids. Each is supplied as a two-part system consisting of a resin and a hardener.

Each adhesive kit contains:

Refer to the layout drawings to estimate the number of adhesive kits required. Include bonds for all fittings, elbows, tees, reducers, adapters and couplings plus a waste factor. Short pot life at higher temperatures may not allow as many bonds to be made as indicated in the table: allow a greater waste factor at higher temperatures. For further information refer to the adhesive product data sheet.

Clamshell Fittings per Shipping Box

Nominal

Pipe Size

90° 45° Sleeve Termination

(in) (mm) Elbows Elbows Tees Couplings Sleeves

25055 510 10 38055 510 10 410055 510 10

Note: Fasteners are included with fittings.

•

Resin

•

Hardener

•

Mixing stick

•

Spatula and brush

•

Detailed usage instructions

•

Emery paper

•

Gloves

•

Paper towels

Primary Bonds per Kit

Nominal

Adhesive Kit Size

Pipe Size

(in) (mm) 3 oz.

5 oz.28 oz.

2,3

2 50 6 12 – 3 80 3 8 14 4 100 2 6 9

1 The average number of primary system bonds

obtainable by an experienced crew at 75°F. 2 Available in six-pak kits. 3 Excessive waste may result when using the 8-oz

kit to make 2-inch bonds.

Containment Bonds per Kit

Nominal

Adhesive Kit Size

Pipe Size

(in) (mm) 3 oz.

5 oz.28 oz.

2 50 1 3

3 80 1

1 2

4 100

1 The average number of primary system bonds

obtainable by an experienced crew at 75°F. 2 Available in six-pak kits. 3 Fewer bonds on tees would be typical, more

for termination sleeves.

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