ENDURANCE 50 CONTINUOUS CAST PIPE VINYL ESTER FRP

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1 CONTINUOUS CAST PIPE VINYL ESTER FRP Quantum Leap Manufacturg Process Conley s has developed break-through proprietary technology the manufacture of vyl ester fiberglass reforced thermoset we call Contuous Cast Pipe that produces a mache-made res rich pipe to exact side and outside diameter dimensions contuously. The process not only results an extremely consistent product but also allows for pipe lengths up to 50 feet. Superior to Competitors FRP Pipe Conley Endurance 50 Contuous Cast Pipe manufacturg strategically places contuous glass reforcement directly the axis of stress loadg, axial and hoop, providg outstandg strength each axis. The mache-positioned directional glass placement yields much greater stiffness offerg higher axial tensile and beam bendg capabilities for greater unsupported span situations and lower thermal expansion/ contraction, while matag excellent pressure safety factor for hoop strength. MADE IN USA Res Rich Nexus Mil Corrosion Barrier Endurance 50 ternal corrosion barrier consists of 6 layers of Nexus veil, each saturated with vyl ester res. The res rich Nexus veil reforcement provides creased strength and ductility that isn t easily cracked or fractured like Fragile, non reforced pure res is known to do with competitor s pipe. Endurance pipe has been proven to provide over 2 times the impact resistance over competitor pipes as well. Pressure and Temperature Endurance 50 pipe is rated to 300 psi from -40 F to 200 F. Conley fittgs also mata the same pressure/ temperature ratg as Endurance pipe. External Res Rich Nexus Corrosion Barrier Endurance 50 pipe also corporates a 10 mil res rich Nexus external corrosion barrier on the O.D. which provides an excellent barrier to environment and airborne corrosives. Endurance pipe also contas a UV hibitor to aid agast ultraviolet radiation from sunlight.

2 PRODUCT SCOPE Materials and Construction Endurance 50 is manufactured with two distct layers; the mil Nexus reforced vyl ester corrosion barrier with a heavy duty glass reforcement saturated with Vyl Ester res. The mil ternal corrosion barrier (ner ler) consists of a mimum of six layers of Nexus veil saturated with Vyl Ester res. The Nexus veil adds reforcement to crease strength and ductility of the res rich corrosion barrier. The glass reforcement, or cage, is manufactured with glass fiber bundles, pressure saturated with a highly chemical resistant formulation of premium vyl ester res to provide maximum exterior corrosion resistance. The unique pressure saturatg process elimates voids between fibers and res. The fiberglass bundles are oriented strict axial and hoop directions, which provide outstandg, stiffness and pressure capabilities. The unique manufacturg process used to produce Endurance 50 allows for lengths of straight spools to be manufactured up to 50 ft. allowg the end user to reduce the number of socket or flanged jots the field. Fittgs Conley fittgs are filament wound, and have a mimum double Nexus veil reforced Vyl Ester ternal corrosion resistant barrier (50-60 mils), filament wound glass reforced structural cage, and a Nexus veil external corrosion barrier. Connections - Straight Socket Jots Straight Adhesive Socket Jots are used with both pipe to fittg connections as well as pipe to pipe connections usg couplgs. Flange connections are used to jo the fiberglass pipe and fittgs to other equipment. Flanges are designed for the operatg pressure per the system requirements as a mimum. Flange dimensions conform to ANSI/ASME B lb drillg. Rotatable flanges (available on pipe spools only) exhibit enough strength to be connected to raised face surfaces (equipment connections, valves, etc.) and do not require a spacer rg to mata a flat surface to the O.D of the flange. Where rotatable spool flanges are connected to any frp fittgs, a full face gasket is required. Gaskets and Hardware Flat washers shall be used between bolt heads or nuts and the back side of flanges. Recommended gasket materials are a mimum of 1/8 ch thickness with a suitable chemical resistance to the service. Gaskets shall have a Shore A hardness of 50 to 70. PTFE envelope gaskets are not recommended. See the Conley Installation & Fabrication Manual for bolt torque requirements. PIPE ENDURANCE ADHESIVE STRAIGHT SOCKET PIPE COUPLING PIPE This type of jot shall be the only means of jog pipe and fittgs. No taperg of pipe end shall be allowed. Flanges Flanges are to be attached to a pipe section only with straight socket adhesive jots. Flanges through 8 diameter shall be serrated for improved gasket sealg. Full face gaskets are required at any flanged connection to fittgs. Rg gaskets are optional between rotatg spool flanges and raised face connections. Quality Assurance and Inspection Conley s Quality Assurance program is certified to ISO All pipe is dimensionally spected and measured as per Conley specifications. Fittgs are spected at each stage of manufacture for ler, reforcement and external corrosion barrier thickness. 2 Conley s PHONE: FAX:

3 PROPERTIES Nomal Dimensional Data Nomal Pipe Size O.D. I.D. Total Wall Thickness Reforcement Thickness Weight Capacity Internal Pressure at 75 F Internal Pressure at 200 F mm mm mm mm lb/ft gal/ft psi psi psi Full 1 1/ Full Full Full Full Full Full Vacuum Ratg at 200 F Properties of Pipe Nomal Pipe Size Reforcement End Area 2 Nomal Wall End Area 2 Reforcement Moment of Inertia 4 Reforcement Section Modulus / Typical Properties Thermal Expansion Coefficient ASTM D696 Thermal Conductivity Specific Gravity - ASTM D x 10-6 // o F 0.1 BTU/hr-ft- o F Density - ASTM D lb/ 3 Haze-Williams Coefficient 150 Manng s Roughness Coefficient, n Absolute Surface Roughness Cantilevered Bendg 40,000 psi Average Physical Properties Property 75 F 24 C 175 o F 80 o C 200 o F 93 o C psi MPa psi MPa psi MPa Axial Tensile - ASTM D638 Ultimate Stress 66, , , Design Stress 16, , , Modulus of Elasticity 4.5 x , x , x ,600 Poisson s Ratio ν 0.39 Axial Compression - ASTM D695 Ultimate Stress 58, , , Design Stress 14, , , Modulus of Elasticity 5.1 x , x , x ,090 Hydrostatic Burst - ASTM D1599 Ultimate Hoop Tensile Stress 13, , , Design Stress 3, , , Hoop Tensile Modulus of Elasticity 2.5 x , x , x ,340 Beam Bendg Ultimate Stress 48, , , Design Stress 6, , , Modulus of Elasticity 4.0 x , x , x ,550 ENDURANCE COMPOSITE PIPE WITH COMPOSITE VALVE Conley s PHONE: FAX:

4 Supports Pipg must be properly supported to prevent excessive deflection and loadg. Pipg support spans depend on total pipe weight, i.e. liquid full weight dependent on fluid density, and operatg temperatures. Elevated operatg temperatures affects the bendg modulus of the pipg material. The established maximum support spans ensure a mid-span deflection limited to 0.5 with an 8:1 safety factor for ultimate bendg stress. Support conditions are defed as Type I, II, III and IV. Type II conditions are the most common, which the pipe is analyzed as a contuous beam spanng two or more supports. Types I, III, and IV conditions refer to uniform distributed loads with sgle-span, four-spans, and fixed end supports respectively. Any additional external loads applied to the pipg system such as sulation, wd or seismic loadg require further analysis. There are six key prcipals to properly support FRP Pipe: 1. Avoid Pot g 2. Do not exceed recommended mimum support spans 3. Protect pipe from abrasion at support locations 4. Support heavy valves and equipment dependently 5. Avoid excessive bendg durg handlg and stallation 6. Properly support vertical runs to avoid excessive loadg and cantilever loads Size Unsupported Spans (ft) ( * ) Support Type Type I Type II Type III Type IV *For fluids with specific gravity of 1.0 and max mid-span deflection of 0.5 Temperature Correction Factors 75 o F 150 o F 175 o F 200 o F Adjustment Factors For Various Spans with Unsupported Fittgs at Changes Direction SPAN TYPE FACTOR A Contuous terior or fixed end spans 1.00 B Second span from supported end or 0.80 unsupported fittg c + d Sum of unsupported spans at fittg <0.75* e Simple supported end span 0.67 *Example: If contuous support is 10 ft., c + d must not exceed 7.5 ft. (c = 3 ft. and d = 4.5 ft.) would satisfy this condition. a a a b c d b a b e Thermal Expansion Proper thermal expansion review and appropriate design of supports and guides for FRP pipg systems is an important consideration. Thermal expansion can duce high stresses an FRP pipg system and even cause bucklg if improperly supported or not designed to address thermal growth. Various methods can be used to manage stresses caused by thermal expansion above ground stallations. These methods are listed below order of economic preference: 1. Designg enough flexibility to the pipg system with direction changes 2. Anchorg and guidg to restra axial movement and prevent bucklg 3. Additions of expansion loops to absorb thermal growth 4. Use of mechanical PTFE expansion jots to absorb thermal growth Specific Gravity Correction Factors Specific Gravity GAS/ AIR Multiplier Example: 4 simply supported 150 F with a 1.25 specific gravity fluid, Maximum support spacg = 18.4 x 0.91 x 0.95 = 15.9 ft ETHYLENE PTFE EXPANSION JOINT WITH DURCOR STRUCTURAL COMPOSITE FLANGES 4 Conley s PHONE: FAX:

5 ENGINEERING DATA Thermal Expansion cont. Proper thermal analysis of a pipg system requires the followg formation: 1. Isometric layout of the entire pipg system 2. Material properties of the pipe 3. Design temperature 4. Ambient stallation temperature 5. Equipment allowable loads (i.e. nozzle loads) 6. Support movements Thermal Growth Change Temperature o F Change Length /100 Ft The coefficient of thermal expansion for Endurance TM pipe is 7.9 x 10-6 // o F. Expansion and contraction from changes temperature pipe runs can be determed by terpolation from the above data. Distance from Expansion Jot and Expansion Loop to Primary and Secondary s Elbow Strength Recommended Allowable Bendg Moments for 90 o Elbows Nomal Pipe size Allowable Moment Nomal Pipe size Allowable Moment lb-ft lb-ft / , , Nomal Pipe Size Primary Secondary / Primary and secondary guides are recommended adjacent to expansion jots and expansion loops to direct the movement of the pipg and mimize axial misalignment. Restraed s and Spacg Size Spacg Operatg Temperature o F (1) 100 o F 125 o F 150 o F 175 o F 200 o F Spacg Spacg Spacg Spacg ft lbs ft lbs ft lbs ft lbs ft lbs , , / , , , , , , , , , , , , , , , , , , , , , , , , , , ,628 (1) Based on an stallation temperature of 75 o F Conley s PHONE: FAX:

6 Expansion Loop Leg Sizg Expansion loops are used to accommodate thermal expansion pipg systems that otherwise do not have enough herent flexibility the system design. See below table for mimum leg lengths for various amounts of expected expansion 1 crements up to 10. Two guides placed on each side of expansion loops control the direction of thermal growth to the expansion loop and ensure proper alignment. Nomal Pipe Size ENDURANCE 50 Mimum A Leg Length (ft) for Total Thermal Expansion () (1) Total Thermal Growth is L1+ L2 as shown below (2) B leg length is typically 1/2 A leg length 100 Pipe Pressure Loss Curves for Water Basis: Specific Gravity of 1.0 and Viscosity of 1.0 cps Pressure Drop psi/100 Feet of Pipe / Nomal Pipe size, Velocity, ft./sec. Flow Rate Gal/m Equivalent Feet of Head Loss Through Fittgs Size 90 o Elbow 45 o Elbow Tee Thru Run Tee Thru Branch / Pressure Ratg for Fittgs up to 200 F (1) Nomal Pipe Size Flanged and Socket Fittgs psi / (1) Static Pressure Ratgs 6 Conley s PHONE: FAX:

7 ENGINEERING DATA Fastener Specifications The below fastener recommendations are for use with flanged connections. Recommended fastener materials are ASTM A193 B7 studs with ASTM A194 Gr 2H heavy hex nuts. Washer must be dimensional equivalent to AN960 or SAE FBN. All nuts, fasteners and washers shall be of materials suitable for use the operatg environment and for operatg conditions. HEAVY HEX CAP SCREW BOLT LENGTH Raw Materials Standard Test Method ASTM D543 Test for Resistance of Plastics to Chemical Reagents ASTM D638 Test for Tensile Properties of Plastics ASTM D648 Test for Deflection Temperature of Plastics under ASTM D695 Test for Compressive Properties of Rigid Plastics ASMT D696 Test for Coefficient of Lear Thermal Expansion ASTM D790 Test for Flexural Properties of Plastics Fished Product Standard Test Methods ASTM D1599 Test for Short-Time Rupture Strength of Plastic Pipe, Tubg and Fittgs ASTM D2105 Test for Longitudal Tensile Proper ties of Reforced Thermosettg Plastic Pipe and Tube ASTM D2412 External g Properties of Plastic Pipe by Parallel Plate g ASTM D2925 Test for Beam Deflection of Fiberglass Pipe Maximum Recommended g Size Pipe Size Fastener Size HHCS Length Stud Length 1 1/ /2 3-3/4 1-1/2 1/ /2 3-3/4 2 5/ /4 3 5/ /2 4-1/2 4 5/ /2 5-1/4 6 3/ /4 5-1/4 8 3/ /2 See the Conley Installation & Fabrication Manual for bolt torque requirements and procedure. Axial Tensile s Axial Compressive Parallel Plate g Max. lbs s Max. lbs (1) ASTM D2412 (2) Temperature Temperature Stiffness Factor Pipe Stiffness Conley s PHONE: FAX: Hoop Modulus 75 o F 200 o F 75 o F 200 o F 3 lb/ 2 psi x10 6 psi 1 4,800 2,900 4,300 2, , /2 7,000 4,200 6,100 3, , ,800 7,000 10,400 6, , ,800 16,100 23,700 14, , ,600 23,700 35,000 21,000 1,508 1, ,000 43,800 64,500 38,700 2, ,500 68, ,300 60,200 3, (1) Compressive loads are for short columns only (2) Values listed for 5% diameter reduction AN 960 OR SAE FBN WASHER HEAVY HEX NUT

8 ACCESSORIES ENDURANCE 50 SPOOL ROTATABLE FLANGE OPTION The rotatg structural composite Durcor flange elimates problems with 2-holg bolt holes makg fabrication and stallation much easier. Flanged PTFE Expansion Jots Size Range 1-42 Flanged, Wafer Swg Check Valves & Ball Check Valves Size Range 1-30 Butterfly Valves Size Range 2-48 Ball Valves Size Range 1-10 Floor Dras Size Range 3-12 In-le & Y Straers Size Range 1-1/2-30 Flanged 360 View Sight Gages Size Range 1-12 Diaphragm Valves Size Range 1-1/2-6 CONLEY COMPOSITES LLC. INFORMATION IS BASED ON TECHNI- CAL DATA AND TESTING THAT CONLEY COMPOSITES BELIEVES TO BE RELIABLE AND IS SUBJECT TO CHANGE WITHOUT NOTICE. THE INFORMATION IS INTENDED FOR USE BY PERSONS HAVING TECHNICAL SKILL, AND AT THEIR OWN DISCRETION AND RISK. SINCE CONDITIONS OF PRODUCT ARE OUTSIDE OF CONLEY COMPOSITES CONTROL, CONLEY COMPOSITES MAKES NO WAR- RANTIES, EXPRESS OR IMPLIED, AND ASSUMES NO LIABILITY IN CONNECTION WITH ANY USE OF THIS INFORMATION. DURCOR IS A REGISTERED TRADEMARK OF PUREFLEX INC. FLEXIJOINT IS A REGISTERED TRADEMARK OF ETHYLENE LLC. NEXUS IS A REGIS- TERED TRADEMARK OF PRECISION FABRICS GROUP, INC East 91st Street Tulsa, Oklahoma Phone: Fax: END-517