IMPORTANT INFORMATION FOLLOW ALL … · Series routing is most desirable for pressure systems. The...

Co-Flex™ Double Wall Pipe Installation Instructions

IMPORTANT INFORMATION FOLLOW ALL INSTRUCTIONS

INTRODUCTION:

Co-Flex piping is an environmentally compatible, double wall, flexible piping system designed to be installed in Rockguard; our approved chase conduit. Continuous piping runs connecting tanks and dispensers utilize sumps to contain and protect pipe terminations.

This installation guide is to be used by trained and certified installers. Please contact Western Fiberglass for certification information. Co-Flex warranty is valid only if installation and testing procedures described within this manual are followed by certified installation personnel.

CONTACT US FOR MORE INFORMATION!1555 Copperhill Parkway / Santa Rosa, CA 95403

Ph: (800) 688-3375 or (707) 523-2050www.westernfg.com

COPYRIGHT 2006 BY WESTERN FIBERGLASS, INC.ALL RIGHTS RESERVED. USE BY WRITTEN PERMISSION ONLY. Page 1 of 12

Co-Flex piping is currently available in 3", 2", 1 1/2”, 1", 3/4", 1/2" I.D.

Pipe Diameter (ID) Swivel Fittings System Coax Fitting System- 1 1/2" & 2" Only

3/4" Co-Flex SPC-0075 SMA-7575 SFA-7575 STB-0075 GTT-3836

Use w/Double Wall Only

1" Co-Flex SPC-0100 SMA-1010 SFA-1010 STB-0100 GTT-3836


1 1/2" Co-Flex SPC-0150 SMA-1520 SMA-1515 SCC-1515 STF-1515 CPC-1501 CPA-1520 CTF-1515 CEF-1515

Use w/Single Wall Only SEF-1515 SCC-1520 STB-0150 GCT-3810 GTT-3836 CRA-1515 CCC-1515 CPC-1502

Use w/Double Wall Only DAF-2150

2" Co-Flex SPC-0200 SMA-2020 SMA-2015 SCC-2020 STF-2020 CPC-2001 CPA-2020 CTF-2020 CEF-2020

Use w/Single Wall Only STF-2215 SEF-2020 SRE-2015 SRT-2151 SRT-2152 CRA-2020 CRA-2015 CPC-2002

Use w/Double Wall Only STB-0200 GCT-3811 GTT-3836

3" Co-Flex SPC-0300 SMA-3030 SCC-3030 STF-3030 SRT-3320

Use w/Single Wall Only SRT-3230 STB-0300 GCT-3812 GTT-3836


Co-Flex flexible piping system installation and testing procedures are unique. Traditional rigid metal or fiberglass piping procedures do not apply.

Please read this manual completely prior to installation. Obey all local regulations and requirements.

Western Fiberglass, Inc. is pleased to assist you in your site planning. Forward a copy of your site plan to our office for a prompt, computer generated piping layout and materials print out.

SPECIFICATIONS:

Compatibility: The Co-Flex piping system shall be UL-971 Listed to be compatible with all current UL tested motor vehicle fuels and blends:

100% ASTM Reference Fuel No. 2 100 % ASTM Reference Fuel C 85% Reference Fuel C – 15% MTBE 70% Reference Fuel C – 30% Ethanol 85% Reference Fuel C – 15% Methanol

Piping Applications: Co-Flex double wall piping is intended for underground use only. Co-Flex may be used for the following applications:




Pressure System Supply Piping Suction System Supply Piping Tank Vent Piping Stage II Vapor Recovery Piping Remote Fill Lines

Terminations: All piping terminations are to be within contained, accessible, sump areas to facilitate testing and inspection after installation.

Operating Pressures & Vacuums: Operating pressure should not exceed 75 psi or a vacuum of 29” Mercury.

Operating Temperatures: Operating temperatures should not exceed 150 degrees F or 66 degrees C.

Bend Radius: The listed bend radius should be followed to prevent cracking, kinking or breaking. Any kinked sections should not be used.

Pipe Diameter (ID) Minimum Bend Radius 3" 72" 2" 36"

1 1/2" 24" 1" 18"

3/4" 18"

On site air temperature does affect the flexibility during installation, the piping is more pliable when warm.

Testing: Primary piping for 3”, 2”, 1 ½”, 1” and ¾” shall be capable of maintaining 50 psi for a minimum of one (1) hour. Secondary interstitial space for 3”, 2”, 1 ½”, 1”, ¾” shall be capable of maintaining 10 psi for a minimum of one (1) hour. These tests may be performed after installation is complete, but before backfill. Allowed monitoring methods are by Pressure, Vaccum or Interstitial Liquid Level Monitoring (ILLM). Please note: the interstitial space of Co-Flex Piping has a capacity of approx. one (1) fluid ounce per linear foot. Care needs to be taken when pressurizing the secondary, add pressure slowly and do not exceed 10 psi during pressurization process. Always use safe procedures when pressure testing piping systems. Western Fiberglass, Inc. assumes no liability or responsibility for testing procedures.




Assembly: Co-Flex Co-Flex double wall piping may only be installed within Rockguard(PI4531) using Western Fiberglass tools and fittings. Failure to do so may result in product failure and/or a void in system warranty.

Burial Requirements: Co-Flex requires proper burial procedures to ensure product durability. Please be sure to follow all trenching, backfill materials and burial depth requirements.

PLEASE NOTE: Co-Flex double wall piping is intended for installation in normal soil applications.

Storage & Transit: Co-Flex double wall pipe and fittings are not intended for storage or transport in direct sunlight or excessive temperatures. Mishandling during transport may cause product damage or result in leaks. Please be sure to inspect all materials prior to installation. Any product determined to have been damaged may not be used.

Please see product technical data for additional information.

PIPING ROUTE DESIGN:

Flexible piping system routes and excavation requirements are quite different than for traditional ridged pipe. Direction changes are made with “sweeps” rather than 90’s or 45’s. In most installations, pipe trenching requirements are reduced.

Series system type piping runs are continuous, with the piping originating from one sump and passing through additional sumps until termination.




Series routing is most desirable for pressure systems. The piping system runs from the tank sump to each successive dispenser. All piping terminations are to be within enclosed sump areas, not direct buried. Single and/or dual pipe lines can be installed to accommodate any total number of product dispensers. Note: 1 1/2” I.D. Co-Flex piping is typically suitable for continuous operation of up to six (6) product dispenser nozzles.

Suction system routing requires direct runs where each dispenser is connected to the tank sump via it’s own pipe line.

Co-Flex flexible piping must be installed in our approved chase conduit -4” Rockguard (PI4531). After installation of conduit, the flexible pipe is pulled through the conduit by threading a cap with an “I” bolt to the pipe termination and attaching a rope or cord.

PIPING TRENCHES:

Trenches should be at least twice the width of all piping and/or conduits to be installed within. One pipe diameter spacing between each pipe run is required.

Piping systems requiring “fall” should have a minimum of 1% or 1/8” per linear foot from pipe run termination point back to the tank sump(s).

The recommended backfill and trench bed material is rounded pea gravel 1/8” to 3/4” in diameter. Crushed stone, 1/8” to 3/4”, and \ or river sand may be used if washed and it is free flowing.

A 6” bed of recommended backfill material, free from any debris, is placed in the piping trench prior to installation.




Co-Flex piping installed under reinforced concrete surfaces of a minimum of 4” (100mm) thickness require a minimum cover of 6” (150 mm) of the recommended backfill material.

Asphalt, 2” (50mm) minimum thickness, requires 6” (150mm) minimum cover of the recommended backfill material.

Unpaved surfaces require a minimum of 14” (350mm) cover of recommended backfill material.

After pressure testing is complete, care must be taken to insure even distribution and packing of the backfill material around the piping during the back fill process. Hand shovel material around and over piping to insure correct spacing is maintained. Backfill slowly.

Additional care should be taken when initially filling the piping system to insure that all air is removed from the product piping prior to starting any pumps to prevent damage. Be certain that the operating pressure of the pumping system does not exceed the maximum operating pressure of the Co-Flex piping of 75 psi.

Periodic testing of both the primary and secondary sections of the Co-Flex system may be performed at any time after installation.

Please see installation instructions for DMA, dispenser mounting assemblies, and Western Fiberglass, Inc. tank sumps for details on piping penetrations.




MEASURING PIPE RUNS:

Co-Flex piping is available in 250’, 500’ or 1000’ lengths. It may be ordered by the foot if required. The greatest care is taken after manufacture to package and ship your piping to insure against damage. Do not drag Co-Flex along the ground, step or place heavy objects on top of the pipe. Cold weather will affect the flexibility. Leaving the pipe coils in the sun prior to installation will make them more pliable and easier to handle. In extreme cold weather, store the piping indoors, at room temperature before measuring and cutting. A personal type hair dryer can be inserted into one end of the pipe coil to warm up and relax the pipe. Cut and discard the first 12” (300mm) of pipe where any heating device has been attached. This section may be damaged by heat exposure.

The Co-Flex termination fittings are 5” in length. 2” of pipe is inserted within the termination. An additional 3” is added to the total pipe length at each end of each pipe run by the installation of the terminations. For example, if the required pipe length between the internal or “T” connections inside two separated dispenser boxes is a total of 32’ 9”, you must subtract 6” to account for the terminations at each end of the pipe length. This pipe length will now be 32’ 3” before termination.

When measuring pipe lengths, use a pre-stretched line or flat tape to calculate the distance between connection points.

Be certain to account for all sweeps and additional pipe lengths required within containment sumps for all connections before cutting.

Co-Flex piping may be installed “lazy” within the piping trench. It does not have to be stretched straight or tight and can be routed to accommodate any pipe run requirements. It is important to maintain proper fall or slope.

Piping lengths can be cut and terminated outside of the piping trench for ease of installation.

Piping lengths may be pre-cut and terminated off-site.

CUTTING AND TERMINATION:

Co-Flex piping may be cut with any clean, sharp instrument. Be certain to make all cuts square and even.




1). Cut Co-Flex pipe to proper lengths.

PLEASE NOTE: Slip Test/Crossover boot over pipe ends prior to installation of pipe terminations.

2). Strip off final 2” (50mm) of outer containment jacket and remove. This can be done with a razor knife. Be careful not to cut primary pipe outer jacket.

FOR SWAGE FITTINGS:

3). The swaging machine may be manual, electric or pneumatic (See product data). The procedure for preparation of the pipe end is the same for all types.

4). Attach proper guide block to swage ram unit. (Not used with female fittings.)

5). Insert draw bar through ram unit.

6). Carefully oil or grease the inside of the piping termination.

7). Insert pipe termination thread first into guide block on ram unit.

8). Screw swage mandrel onto draw bar and firmly against and partly within the pipe termination.

9). Grease or oil swage mandrel to insure a smooth swage draw cycle.

10). Slide termination swage sleeve (silver) over termination.




11). Insert pipe onto termination and inside swage sleeve. Must be in at least 1 1/2” or until just visible through holes in swage sleeve.

12). Hand pump or push button to draw swage mandrel through pipe termination.

13). Release pump pressure and remove fitting.

14). When installing swage fittings, hand-tighten the coupling onto the Western Fiberglass fitting until snug. Using a Co-Flex wrench, tighten the coupling nut ¼ turn more or to 200 in/lbs. without allowing the pipe to rotate while tightening.

CAUTION: Do not over tighten. This may result in damage to the coupling or potential leaks in the system.

CAUTION: Do not allow sealant to contact the threads of the swage fitting.

15). Remove the protective cap from the coax pipe coupling and verify that the o-ring seals are clean and properly seated in their o-ring grooves. Remove the plastic protective cap from the coax adapter, fitting or connector and inspect the inside sealing surface to make sure it is smooth, undamaged and free of dirt. Position the coax coupling to the male threaded port of the coax fitting. This connection seals by way of static o-ring seals and does not require pipe sealant. Thread the coax swivel nut onto the male threaded port by hand, until the coupling bottoms out onto the fitting and stop. DO NOT TIGHTEN THE NUT.

CAUTION: Do not use sealant inside coax couplings or on the connection threads. This may result in a gasket failure.

PLEASE NOTE: Use only Dow Corning 55 O-Ring Lubricant or equivalent when cleaning or replacing coax o-rings.

16). The ¾” and 1” Co-Flex pipe couplings are fixed male NPT fittings and are assembled as rigid steel pipe. After installing the appropriate test boot, apply a liberal amount of thread sealant or Teflon tape to the threads of the coupling and tighten to 20 ft/lbs.

17). The jacket of double wall Co-Flex piping must be tested to ensure liquid tightness. Connect all test and connector tubes into the test boot or coax fittings. Tighten all band clamps to 30 in/lbs. For coax fittings, use only




CTT-3836 test tubes with Teflon tape. DO NOT USE METALLIC FITTINGS IN COAX TEST PORTS – THIS WILL RESULT IN DAMAGE TO THE COAX FITTING.

CAUTION: Swaging must be done in one complete action, do not stop once you have started.

PLEASE NOTE: Use only Western Fiberglass approved terminations.

DIRECT CONNECTION™ FITTINGS:

Direct Connection fittings use (2) band clamps per fitting. Install with bolts in opposing directions (see details).

18). Clamps are to be placed no more than ¼” apart. First clamps is to be no more than ¼” from pipe end nearest to termination fitting.

19). LUBRICATE clamp bolt threads and clamp tongue with WD-40 or light machine oil. Do not lubricate inside of pipe or outside barbed section of termination fittings!

20). For 1.5” fittings, initial band clamp torque set is 12 foot pounds. For 2” fittings, initial band clamp torque set is 20 foot pounds.

21). Tighten clamp nearest pipe termination fitting first. Prior to testing and after all clamps have been torqued, re-check all torque settings.

CAUTION: Keep all fittings and pipe ends clean!

PLEASE NOTE: Use only Western Fiberglass approved terminations.

INSTALLING PIPE LENGTHS:

After test/crossover boots, and if required crossover supports, have been installed and pipe termination has been swaged on, insert pipe through pipe penetration boots one side at time. Remove penetration hose clamp or loosen first for ease of installation.




Prepare coupling fitting and attach Co-Flex termination fitting (male or female) to connector within sump area/s. Tighten.

Position pipe within trench. Lay out piping runs while maintaining separation between pipe lengths and at crossover points.

TEST & CROSSOVER BOOT/TUBING INSTALLATION:

The Test/Crossover Assembly Boots are attached to the Co-Flex Piping ends to provide a sealed access and test point for the interstitial/secondary space within the pipe. The Test/Crossover Boots utilizes two (2) #28 stainless steel hose clamps which when tightened around the termination fitting swage sleeve and the Co-Flex outer jacket isolate the interstitial space. An air valve stem is installed in the boot on the bottom for an outlet opening for connecting the crossover and/or test tubes. These tubes are used for the testing of and the interconnection of the interstitial space from pipe section to pipe section. Crossover tube assemblies are used for junctions within dispenser sumps, pipe to pipe in line connections, piping run termination points, tank sump connection points and any piping manifold connection points.

Test/Crossover Boots and tubes are fitted and tightened in place after the piping terminations and their connections have been made.

After installation and tightening of all test and crossover boots and tubes pressure testing may be done. (See Above).




INITIAL PIPE SYSTEM FILLING:

Upon completion of connection and testing of your Co-Flex system, initial filling of the system may begin. Be careful to provide a venting point or place that will allow any air within the piping to escape during this initial filling. Do not operate any pumping devices until all air has been purged from piping system. Small bubbles trapped within the system will be purged under normal operating conditions. Do not exceed the safe operating pressure of the Co-Flex piping of 75 psi.

MAINTENANCE AND INSPECTION:

Monthly inspections are recommended inside all containment sumps. All sumps must be kept free of fuel, water and debris. While changing fuel filters, be sure to clean any excess fuel that may spill into the containment sump. Any fuel leaks must be reported and investigated by the site owner. If any leaks or damage to the piping system are detected, immediately notify Western Fiberglass at (800) 688-3375 or (707) 523-2050.

CAUTION: Ignoring or disabling leak detection alarms can lead to further damage and possible system failure.




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