FABRICATION SEMINAR

Presented by

Field Services Department

of
Conley Corporation

The following information consists of the following documents:

1. FABRICATION SEMINAR CHECKLIST, 7 pages, Revision 4 dated May 19,

1999.

2. Project specific reference procedures for various types of installations, which

may include, but is not limited to:

a. Saddle Installation Procedure.

b. Large Diameter ...Joint Procedure.
c. Double Containment Piping Installation Instructions.
d. Bulletin No. 202.
e. Sign-off checklist for selected training points.

RESPONSIBILITY: Field Services Manager APPROVAL _ Stan Wenzel_

Form FABSEM001 Revision Date: May 19, 1999 Revision: 4
Conley Corporation Fabrication Seminar Checklist Orig. Issue Date: Oct 28, 1996 Page 1 of 7
 FABRICATION SEMINAR CHECKLIST

GENERAL GUIDELINES: UPON ARRIVAL OF CONLEY PRODUCTS,

PRE-INSPECT ALL PIPE AND FITTINGS FOR DAMAGE INTERNALLY
AND EXTERNALLY. GENERALLY, SEVERE EXTERNAL SHIPPING
DAMAGE TRANSLATES TO INTERNAL DAMAGE. INSPECT PIPE AND
FITTINGS FOR CRACKS AND GOUGES IN THE INTERNAL
CORROSION BARRIER. MATERIALS RECEIVED IN BOXES OR
CARTONS MAY BE INSPECTED WHILE ON PALLETS. IT IS NOT
NECESSARY TO REMOVE FROM PALLETS TO PERFORM A VISUAL
CHECK FOR SHIPPING DAMAGE. MAKE NOTATIONS OF ANY
DAMAGED PRODUCTS ON BILL OF LADING BEFORE ACCEPTANCE
AND UNLOADING THE MATERIALS.

1. UNLOADING PIPE AND FITTINGS

a. FRP is lightweight and can normally be handled easily by two people.
b. Carefully lift and handle pipe to prevent excessive bending. Do not drop or
impact pipe.
c. Store the pipe off the ground and support evenly to avoid point loading.
d. Cover pipe to avoid contamination.
e. With lifting equipment, use a sling rigged to two (2) points on the pipe.
f. DO NOT USE FORKS OR LIFT POLES IN THE END OF THE PIPE.
g. DO NOT USE CHAINS OR CABLES TO LIFT PIPE.
h. Avoid dropping fittings when loading by hand.
i. Cover fittings to avoid contamination and protect from falling objects.
j. IN GENERAL, AVOID POINT LOADING PIPE AND FITTINGS.

2. HANDLING PIPE AND FITTINGS

a. DO NOT DROP OR THROW PIPE AND FITTINGS.
b. Cut off any damaged section of pipe BEFORE use.

3. TOOLS REQUIRED FOR FABRICATION OF CONLEY PRODUCTS

a. Cuttings Tools
(1) Circular saw with abrasive blade.
(2) Band Saw / Portable or stationary
(3) Hack saw - 22-28 teeth/inch

RESPONSIBILITY: Field Services Manager APPROVAL _ Stan Wenzel_

Form FABSEM001 Revision Date: May 19, 1999 Revision: 4
Conley Corporation Fabrication Seminar Checklist Orig. Issue Date: Oct 28, 1996 Page 2 of 7
 b. Preparation
(1) 4 2" angle grinder with rubber backing pad and 24-60 grit disk.
(2) Emery cloth - 40-60 grit.
(3) Clean, oil free file.
c. Mixing of adhesive - Tools
(1) Flat mixing board, preferable 3 ft x 3 ft (any material which is clean &
oil free).
(2) 3" stiff putty knife for mixing part AA@ (Part 1) and part AB@ (Part 2).
(3) 1" flexible putty knife for scrub in and applying adhesive.
(4) Wooden paint sticks to remove adhesive from containers to apply
adhesive to large diameter pipe.
(5) Wooden tongue depressors for scrub in and applying adhesive to
small diameter fittings.
d. Safety - IN ADDITION TO FOLLOWING OSHA AND JOBSITE SAFETY
REGULATIONS.
(1) Wear safety glasses or face shield for cutting, grinding, and mixing of
adhesive.
(2) Wear dust masks for cutting and grinding.
(3) Wear vinyl gloves for mixing and applying of adhesive.
e. Curing of adhesive
(1) POST CURE REQUIRED ON ALL JOINTS.
(2) See AConley Heat Tape@ chart, page 7 of 7, for cure settings and
times.

4. PIPE AND FITTING PREPARATION

a. Abrading - Sanding - Grinding
(1) Remove exterior Aglaze@ (glossy appearance) on pipe O.D. to a
distance 1" greater than socket depth. Lightly sand the end
of the pipe. Complete removal of the exterior corrosion barrier layer
is not required.
(2) Lightly sand to remove paint from face of socket and lightly sand and
clean inside the socket including the bevel.
b. Degreasing if necessary - AVOID PETROLEUM BASED CLEANERS
(1) Use only Clean rags or towels.
(2) Wipe down the sanded surfaces of the pipe and fitting with the
degreaser.
(3) If a degreaser is not available, lightly sand the socket with sand cloth
or a flapper wheel as stated before. Then use a clean, dry cloth to
remove any dust from the pipe and fitting surfaces.

RESPONSIBILITY: Field Services Manager APPROVAL _ Stan Wenzel_

Form FABSEM001 Revision Date: May 19, 1999 Revision: 4
Conley Corporation Fabrication Seminar Checklist Orig. Issue Date: Oct 28, 1996 Page 3 of 7
 (4) Check carefully for oily or other chemical contamination on both
surfaces to be joined. Strong detergent soap (Tide) and water may be
used with a stiff brush for thorough cleaning, but joining surfaces
must be clean and dry.
(5) Denatured Alcohol is an acceptable degreaser.
AVOID PETROLEUM BASED CLEANERS.

AFTER CUTTING AND SURFACE PREPARATION OF THE PIPE AND SOCKET,

ADRY FIT@@ THE PIPE AND FITTING - CHECK FOR PROPER DIMENSIONS BEFORE
PROCEEDING TO MIXING.

5. ADHESIVE MIXING

IMPORTANT NOTE:
ADHESIVE KITS ARE PRECISION WEIGHED TO PROVIDE ACCURATE
QUANTITIES FOR MAXIMUM STRENGTH AND OPTIMUM CHEMICAL
RESISTANCE. DO NOT ATTEMPT TO RATIO SMALLER QUANTITIES FROM THE
KIT. ALWAYS REMOVE ALL OF PART AA@@ AND ALL OF PART AB@@ FROM THE
CONTAINERS AND ONTO THE MIXING BOARD.

a. It is useful to anchor the mixing board.

b. In low ambient temperatures, warm adhesive before mixing.
c. Use correct adhesive. CHECK LABELS FOR ADHESIVE KIT SIZE MATCH
(1) C-Weld for Epoxy Piping (Buff color inner liner)
(2) E-Weld for Vinyl Ester Piping (Red, Blue, Green, White inner liner)
(3) Furex for Furan Piping (medium to dark brown)
d. Refer to Bulletin 202 to match the kit size to the number and size of joints to
be fabricated.
e. Using a 3" putty knife, thoroughly blend the 2-part adhesive pastes by turning
and spreading.
f. Use another putty knife, tongue depressor, or other scraper to clean the
mixing knife of unmixed adhesive. This material, as well as any unblended
material along the edges of the mixing board, should be carefully mixed with
the main bulk of the adhesive to insure proper ratios and complete blending.
g. All Conley Part AB@ (Part 2) is black, and the Part AA@ (Part 1) is lighter in
color. CONTINUE MIXING UNTIL THE ADHESIVE MATERIAL IS UNIFORM
IN COLOR, WITH NO STREAKS.
h. After mixing, spread the adhesive in a thin layer over the board to extend Apot
life@ of the adhesive.

RESPONSIBILITY: Field Services Manager APPROVAL _ Stan Wenzel_

Form FABSEM001 Revision Date: May 19, 1999 Revision: 4
Conley Corporation Fabrication Seminar Checklist Orig. Issue Date: Oct 28, 1996 Page 4 of 7
 NOTE: Special color coded piping systems may have colored adhesive
which matches the system. These adhesives may require extra
visual care when mixing to assure that both parts are mixed
thoroughly.

6. APPLICATION OF ADHESIVE AND JOINT FABRICATION

a. SCRUB IN - for maximum joint strength and chemical resistance
(1) Using a small amount of adhesive, spread a thin layer over all the
prepared area of the pipe and the fitting, including the cut edge of
pipe and face of fitting.
(2) Using the side edge of the putty knife, scrape the prepared area. This
is best accomplished on the pipe by moving the knife in the direction
of the length of the pipe. This important procedure drives the
adhesive into the abraded surface and insures maximum Awet
out@@ which is critical to fabrication of a strong mechanical bond.
b. ADHESIVE APPLICATION - Abuttering@
(1) Apply a thin even coat of adhesive in the fittings socket and face.
NOTE: Nominal thicknesses for fitting sockets are 1/16" for
fittings 3" and smaller and 1/8" for 4" and larger.
(2) Apply a heavy coat of adhesive on the scrubbed area of the pipe.
NOTE: Always apply a heavy layer on the pipe. Any excess
will be pushed out to the end of the fitting where you
will pull your filet.
(3) Push the pipe into the fitting or the fitting onto the pipe. DO NOT
TWIST WHILE PRESSING THE PARTS TOGETHER.
NOTE: Make sure you see a complete ARing@@ of adhesive at
the end of the fitting. If you see any area where no
adhesive has pushed out, remove the fitting and re-
butter the pipe with a heavier layer, the re-insert the
pipe.
c. Scrape the excessive adhesive (Asqueeze in@) from the interior of the joint,
usually possible in larger diameter piping.
d. Use the excessive adhesive (Asqueeze out@) on the pipe exterior to make an
attractive fillet, and remove the additional material.
e. Wrap the Conley Heat Tape around the pipe and fitting at the joint.
f. TAKE CARE TO AVOID DISTURBING THE SURFACE OF THE ADHESIVE.
g. All Field Joints MUST be Post Cured. You may begin the curing process
while the joint is Awet@@ OR wait until several joints have hardened
under ambient conditions and use the heat tape to cure multiple joints
at the same time. Either way, use the AConley Heat Tape@ chart, page 7
of 7, for cure settings and times. NOTE: Do not overlap the heat tape,
this may cause Ahot spots@@ on the tape.

RESPONSIBILITY: Field Services Manager APPROVAL _ Stan Wenzel_

Form FABSEM001 Revision Date: May 19, 1999 Revision: 4
Conley Corporation Fabrication Seminar Checklist Orig. Issue Date: Oct 28, 1996 Page 5 of 7
7. BOLTING UP CONLEY MATERIAL
a. Conley flanges are fiberglass and will not take the torque that a metal
flange would.
b. Use the Conley torque chart when bolting Conley flanges.
c. DO NOT OVER-TORQUE THE FLANGES. This will cause the flanges to
crack and the nuts and bolts to cut into the face of the flange.
d. Use a cross torque pattern to tighten flange bolts. Snug the first bolt, snug
the second bolt on the opposite side of the flange. Continue to snug the
bolts in this cross fashion. Starting with the first bolt, torque to specified ft-
lbs. Cross torque in the previous manner.
e. On larger flanges use half the torque value to draw the flanges together and
then continue with the full torque.

8. HYDRO TESTING, REPAIRS, PRESSURE TESTING - GENERAL NOTE:

PRESSURE TESTING WITH AIR IS NOT GENERALLY RECOMMENDED. IF AIR
IS USED, 5 PSI IS ADEQUATE. HIGH PRESSURE AIR TESTING IS
HAZARDOUS, AND SHOULD BE AVOIDED.
a. After the adhesive has properly cured, the system should be Hydro Tested in
sections.
b. Slowly fill the system with water while bleeding off the air. When all air is
evacuated from the system, slowly increase the pressure.
c. While pressurizing, stop at 25 to 50 psi increments and check for leaks.
d. At peak test pressure, close off inlet valve and check all joints for leaks or
weeping.
e. If a weep is discovered in the pipe wall, it is generally the result of impact
damage. Cut out damaged area and repair with new pipe and couplings.
f. If the leak appears in the wall of the fitting, cut it out and inspect the interior
carefully for impact damage. Leaking can appear in the fitting wall as a result
of joint starvation, which provides an air channel for the fluid to move into the
fitting wall through the face of the fitting. If the problem was fabrication error
and the fitting is sound, the pipe sections may be removed and the fitting
reused.
BE AWARE THAT THIS PROCEDURE REQUIRES CONSIDERABLE SKILL
AND EXPERIENCE TO ACCOMPLISH.
g. If a leak appears in the adhesive joint, cut out the joint and repair with a
coupling.
h. Special OVERWRAP procedures for repair of lines carrying clean water can
be done. CONSULT WITH FACTORY TECHNICAL REPRESENTATIVES
BEFORE PROCEEDING WITH THIS TYPE OF REPAIR. FACTORY KITS
ARE AVAILABLE.

FOR ASSISTANCE PLEASE CALL CONLEY FIELD SERVICES

AT 1-800-331-5502.

RESPONSIBILITY: Field Services Manager APPROVAL _ Stan Wenzel_

Form FABSEM001 Revision Date: May 19, 1999 Revision: 4
Conley Corporation Fabrication Seminar Checklist Orig. Issue Date: Oct 28, 1996 Page 6 of 7
 CONLEY HEAT TAPE

Heat Tape A Heat Tape B

The following data was collected over a period of time by Conley Lab personnel to be used by the customer as a guide to
cure time in the field and fabrication shop. While these values are a good representation of the behavior of Conley
adhesive, it must be noted that variations in humidity, exposure to sunlight, and exposure to wind chill cause variations
from these curing times. These general curing times experienced are given as a guide only.

ADHESIVE CURE CHARACTERISTICS

Ambient Pipe Size Heat Tape - A Heat Tape B Heat Tape - A Heat Tape B Total Cure
Temperature B Stage Time B Stage Time Full Cure Time Full Cure Time Time
Setting Setting Setting Setting
80 90F ALL 30 Min. Low-Med 30 Min. - 2 1 Hr. High 1 Hr. Full 1 Hr. 30 Min.
70 80F 1 to 4 30 Min. Low-Med 30 Min. - 2 1 Hr. High 1 Hr. Full 1 Hr. 30 Min.
70 80F 6 to 12 45 Min. Low-Med 45 Min. - 2 1 Hr. High 1 Hr. Full 1 Hr. 45 Min.
70 80F 14 to 30 1 Hr. Low-Med 1 Hr. - 2 1 Hr. High 1 Hr. Full 2 Hr.
Below 70F ALL 2 Hr. Low-Med 2 Hr. - 2 2 Hr. High 2 Hr. Full 4 Hr.

Note: 1. Temperature conditions above 90F necessitate lowering of the initial setting to avoid adhesive percolation which
could cause air channeling and leakage.
2. Exposure to direct sunlight may lower the setting and cure time.
3. Exposure to wind chill will necessitate longer setting and cure time.

Material Safety Data Sheets

Available upon request

See Conley Engineering Guide for line testing

CAUTION: Under no circumstances should a
Conley Piping System be tested with air or gas
because of the safety hazards created.

RESPONSIBILITY: Field Services Manager APPROVAL _ Stan Wenzel_

Form FABSEM001 Revision Date: May 19, 1999 Revision: 4
Conley Corporation Fabrication Seminar Checklist Orig. Issue Date: Oct 28, 1996 Page 7 of 7