FPE-SERIES RETROFIT INSTALLATION INSTRUCTIONS

Transcription

1 FPE-SERIES RETROFIT INSTALLATION INSTRUCTIONS BRAVO FIBERGLASS RETROFIT-S SERIES FOR SINGLE WALL FRP SUMPS ONLY FOR RETROFITTING BOLTED FLEXIBLE ENTRY BOOTS POLYETHYLENE EXTERIOR PIPE ONLY BUILT LIKE A TANK High-end materials match fiberglass UST specs to ensure long term fuel compatibility READ THIS MANUAL FRONT TO BACK Note: Actual products may vary in appearance from illustrations in this manual 1 ii-fpe-retrofit-11a S. Bravo Systems, Inc. - The Leader in Secondary Containment 2929 Vail Ave. Commerce, CA FAX: A

2 The FPE-Series Singlewall Retrofit Fittings from S. Bravo Systems, Inc. MUST be installed by a Bravo Retrofit-Certified Installer. KEEP TRACK of your job by taking advantage of the Complete checkboxes paired with each major step. TABLE OF CONTENTS Fitting Warnings, Requirements & Warranty Terms... p. 3 Fitting Specifications and part numbers...p. 4 Fitting Components and Tools... p. 5 INSTALLATION SUMMARY... p. 6 Step 1 Cleaning your sump interior(s)... p. 7 Step 2 Removing the existing fitting on the interior... p. 7 Step 3 Wrapping pipe with rubber strip... p. 8 Step 4 Cutting and grinding down old fitting bolts... p. 8 STEP 5 PREPARING YOUR PIPE BY HAND SANDING...p. 9 MIXING YOUR ADHESIVE - CRITICAL STEP... p. 10 Step 6 Dry-fitting and marking for alignment... p. 11 Step 7 Gluing and Installing angle flange to wall... p. 11 Step 8 Aligning and bonding fitting body to angle flange with clamp... p. 12 Step 9 Securing fitting to wall via clamp and beading adhesive... p. 13 Step 10 PE Adhesive Injection to lock PE pipe to fitting...p. 14 Step 11 Hand sanding PE adhesive at injection port and pipe seam...p. 14 Step 12 Applying FRP adhesive over the PE adhesive areas...p. 15 If you have any problems with Bravo Systems components or accessories, Contact Bravo Systems Immediately: BRAVO support@sbravo.com LIMITED WARRANTY Products sold by S. Bravo Systems, Inc. are warranted to be free from defects in material and workmanship for a period of one year from date of purchase. This warranty will be limited to the repair and replacement of Bravo parts only and will exclude all claims for labor or consequential damage. No other express warranties are given and no affirmation of S. Bravo Systems, Inc., or its agents and/or representatives, by words or action, will constitute a warranty. IT IS EXPRESSLY AGREED THAT THIS WARRANTY WILL BE IN LIEU OF ALL WARRANTIES OF FITNESS AND IN LIEU OF THE WARRANTY OF MERCHANTABILITY. This warranty is void if there is any evidence of modification, abuse, negligence, or improper installation - including but not limited to installation or maintenance by a Non-Specialist Certified individual. If any fittings or components, other than S. Bravo Systems approved fittings or components, are used in conjunction with any S. Bravo Systems product, the warranty pertaining to these products is immediately void. 2 ii-fpe-retrofit-11a

3 VENTILATE YOUR AREA WEAR MASK, SAFETY GLASSES, GLOVES AND OTHER PROTECTION NO > > ELECTRIC TOOLS IGNITION SOURCES Ensure that the workspace is operating below the LEL (lower explosive limit). Test regularly or monitor continuously. WARRANTY IS VOID OR YOUR CERTIFIED STATUS WILL BE REVOKED: IF ANY OF THE FOLLOWING OCCUR A) NOT Installing an FPE-Series Retrofit fitting with Bravo ADHESIVE-RETROFIT-EPOXY-KIT. B) Installing a FPE-Series Retrofit fitting with adhesives that are not specified in this manual. C) FPE-Series Retrofit Fittings are NOT installed by a Bravo Certified Contractor. D) Installing a FPE-Series Retrofit fitting on Polyethylene sumps, steel pipe or FRP pipe. E) Installing a FPE-Series Retrofit fitting without monitoring the lower explosive limit (LEL). 3 ii-fpe-retrofit-11a

4 FITTING SPECS FPE-SERIES Si RETROFIT FITTINGS FOR SECONDARY EXTERIOR POLYETHYLENE PIPE FPE FRP Split Retrofit Fittings for Flat Fiberglass Walls Model #: F-40-Si-RETROFIT-PE F-50-Si-RETROFIT-PE F-63-Si-RETROFIT-PE F-75-Si-RETROFIT-PE F-90-Si-RETROFIT-PE F-110-Si-RETROFIT-PE F-125-Si-RETROFIT-PE F-160-Si-RETROFIT-PE Description: FRP Split Retrofit Fitting for 40mm (1.6 ) PE Secondary Pipe FRP Split Retrofit Fitting for 50mm (2 ) PE Secondary Pipe FRP Split Retrofit Fitting for 63mm (2.5 ) PE Secondary Pipe FRP Split Retrofit Fitting for 75mm (3 ) PE Secondary Pipe FRP Split Retrofit Fitting for 90mm (3.5 ) PE Secondary Pipe FRP Split Retrofit Fitting for 110mm (4.3 ) PE Secondary Pipe FRP Split Retrofit Fitting for 125mm (4.9 ) PE Secondary Pipe FRP Split Retrofit Fitting for 160mm (6.3 ) PE Secondary Pipe FPE FRP Split Retrofit Fittings for Curved Fiberglass Walls Model #: F-40-Si-RETROFIT-PE-RND F-50-Si-RETROFIT-PE-RND F-63-Si-RETROFIT-PE-RND F-75-Si-RETROFIT-PE-RND F-90-Si-RETROFIT-PE-RND F-110-Si-RETROFIT-PE-RND F-125-Si-RETROFIT-PE-RND F-160-Si-RETROFIT-PE-RND * EACH * * ** * * * ** * Description: FRP Split Retrofit Fitting for 40mm (1.6 ) PE Secondary Pipe FRP Split Retrofit Fitting for 50mm (2 ) PE Secondary Pipe FRP Split Retrofit Fitting for 63mm (2.5 ) PE Secondary Pipe FRP Split Retrofit Fitting for 75mm (3 ) PE Secondary Pipe FRP Split Retrofit Fitting for 90mm (3.5 ) PE Secondary Pipe FRP Split Retrofit Fitting for 110mm (4.3 ) PE Secondary Pipe FRP Split Retrofit Fitting for 120mm (4.9 ) PE Secondary Pipe FRP Split Retrofit Fitting for 160mm (6.3 ) PE Secondary Pipe FPE-SERIES FITTING INCLUDES ADHESIVE FOR BONDING THE FITTING TO THE SUMP. THE PE PIPE ADHESIVE IS SOLD SEPERATELY AND REQUIRES A MANUAL GUN. PART NUMBERS ARE BELOW. CONSULT THE FITTING SPECS CHART FOR QUANTITIES. Mandatory Tools for FPE-Series FRP Fittings Model #: ADHESIVE-PE-KIT MAN-GUN-FS-10 Model # * * Description: One (1) dual Adhesive Cartridge for FRP to PE bonding Manual dual adhesive gun for ADHESIVE-PE-KIT Wall Type Pipe Size and Type (INCHES ARE ROUNDED) Maximum Outer Dia. Length from interior wall Bravo Glue Kits Incl. * Fittings per PE F-40-Si-RETROFIT-PE Flat 40mm (1.6 ) PE 127mm (5 ) 86mm (3.4 ) 1 8 F-50-Si-RETROFIT-PE Flat 50mm (2 ) PE 203mm (8 ) 86mm (3.4 ) 1 8 F-63-Si-RETROFIT-PE Flat 63mm (2.5 ) PE 203mm (8 ) 86mm (3.4 ) 1 8 F-75-Si-RETROFIT-PE Flat 75mm (3 ) PE 203mm (8 ) 86mm (3.4 ) 1 5 F-90-Si-RETROFIT-PE Flat 90mm (3.5 ) PE 203mm (8 ) 86mm (3.4 ) 1 5 F-110-Si-RETROFIT-PE Flat 110mm (4.3 ) PE 203mm (8 ) 86mm (3.4 ) 2 3 F-125-Si-RETROFIT-PE Flat 125mm (4.9 ) PE 269mm (10.6 ) 102mm (4 ) 2 2 F-160-Si-RETROFIT-PE Flat 160mm (6.3 ) PE 269mm (10.6 ) 102mm (4 ) 2 2 F-40-Si-RETROFIT-PE-RND ø Curved 40mm (2 ) PE 127mm (5 ) 86mm (4.4 ) 2 8 F-50-Si-RETROFIT-PE-RND ø Curved 50mm (2 ) PE 203mm (8 ) 86mm (4.4 ) 2 8 F-63-Si-RETROFIT-PE-RND ø Curved 63mm (2.5 ) PE 203mm (8 ) 86mm (4.4 ) 2 8 F-75-Si-RETROFIT-PE-RND ø Curved 75mm (3 ) PE 203mm (8 ) 86mm (4.4 ) 2 5 F-90-Si-RETROFIT-PE-RND ø Curved 90mm (3.5 ) PE 203mm (8 ) 86mm (4.4 ) 2 5 F-110-Si-RETROFIT-PE-RND ø Curved 110mm (4.3 ) PE 203mm (8 ) 86mm (4.4 ) 2 3 F-125-Si-RETROFIT-PE-RND ø Curved 125mm (4.9 ) PE 269mm (10.6 ) 102mm (5 ) 3 2 F-160-Si-RETROFIT-PE-RND ø Curved 160mm (6.3 ) PE 269mm (10.6 ) 102mm (5 ) ii-fpe-retrofit-11a

5 FPE-SERIES RETROFIT COMPONENTS Included Parts (Per fitting) A) 1x Fiberglass Split Retrofit Injection Body (two halves) with SS Pipe Clamp B) 1x Loose Fiberglass Angle Flange (two halves) with 2 Zip-Ties C) Bravo ADHESIVE-RETROFIT-EPOXY-KIT: (quantity chart on page 4) 1x Bravo Epoxy Adhesive Can 6oz 1x Bravo Epoxy Catalyst bottle 1oz 2x Pair of Industrial Nitrile gloves (Large) 1x Stir stick 1x 1 chip brush D) 1x 60 grit emery cloth strip E) 1x 80 grit sheet of sandpaper F) 1x 3-bolt compression clamp G) 1x 15 long Rubber Strip REQUIRED TOOLS (NOT PROVIDED) Triclorethylene or Acetone. Eye protection. Air Drill and/or sander. Respiratory protection / ventilation ADHESIVE-PE-KIT MAN-GUN-FS-10 One (1) dual Adhesive Cartridge for FRP to PE bonding Manual dual adhesive gun for ADHESIVE-PE-KIT EACH FPE-SERIES FITTING INCLUDES ADHESIVE FOR BONDING THE FITTING TO THE SUMP. THE PE PIPE ADHESIVE IS SOLD SEPERATELY AND REQUIRES A MANUAL GUN. PART NUMBERS ARE ABOVE. CONSULT CHART ON PAGE 4. A Confined-space Certification is required when installing this fitting inside Tank Sumps USE ONLY BRAVO SYSTEMS ADHESIVE WHEN INSTALLING THIS FITTING TO FIBERGLASS PIPE OR CONDUIT DO NOT SUBSTITUTE ADHESIVES, MIX THEM OR ADD LIQUIDS SUCH AS WATER OR ANOTHER RESIN. DO NOT USE ANOTHER CATALYST OTHER THAN WHAT IS PROVIDED. 5 ii-fpe-retrofit-11a

6 Summary of Installation These steps are not a substitute for the detailed installation steps contained in the following pages. DO NOT ATTEMPT TO INSTALL THIS PRODUCT BASED ONLY ON THE SUMMARIZED STEPS LISTED ON THIS PAGE 1) Verify that the exterior material of the pipe is polyethylene. Remove any necessary components that will obstruct your access to the Interior sump wall. 2) Clean interior and bottom of each sump. Remove all fuel, contaminants, water and debris. Monitor LEL lower explosive limits. 3) Ensure each sump will be completely dry during installation. Any/all water intrusion must be prevented. Seal breaches with water-barrier foam as possible. 4) Remove the interior boot and any gaskets or seals from the wall. 5) Protect the pipe with the provided rubber strip and cut and grind down any bolts until just under flush with the fiberglass wall. 6) Clean and abrade the fiberglass wall in preparation of gluing. 7) Prepare the exterior polyethylene surface of the pipe by removing excess adhesive, contaminants or fuel oils with solvents and/or sandpaper. 8) Clean, dry and rough up pipe surface by hand sanding with sandpaper ONLY in preparation for gluing. 9) Dry-fit your split flange and body for correct fit and mark a stripe across all the assembled fitting components including the wall with a permanent marker. Ensure the adhesive injection port on the body is at the 12-o-clock position. 11) Glue and assemble angle flange and body to wall, keeping marked stripe aligned. 12) Clamp full fitting assembly firmly to the wall with provided 3-prong clamp. 13) Shape a heavy bead of adhesive on every joint and seam, making sure to not get adhesive anywhere near the interior of the fitting. 14) Inject PE adhesive into the adhesive injection port to seal pipe to fitting. Bead PE adhesive around pipe seam with gloved finger. Let cure. 15) After PE adhesive fully cures, hand sand injection port area and pipe seam, dust off and coat heavily with FRP Adhesive. Let cure. 6 ii-fpe-retrofit-11a

7 VENTILATE YOUR AREA WEAR SAFETY PROTECTION NO > > ELECTRIC TOOLS IGNITION SOURCES Ensure that the workspace is operating below the LEL (lower explosive limit) before starting work. Test regularly or monitor continuously STEP 1 READ THIS ENTIRE MANUAL FRONT TO BACK BEFORE BEGINNING ANY PART OF THIS INSTALLATION Begin work by entering all the sumps the FPE-Series Retrofit fitting will be installed in and: 1) Verify that the exterior of the piping is Polyethylene. Also verify that the sump material is Fiberglass. If it is not, you cannot install this Retrofit fitting. 2) Remove any necessary components that will obstruct your access to the sump wall. 3) Clean interior and bottom of each sump. Remove all fuel, oils, sealants, contaminants, water and debris. Dispose of HAZMAT per local codes. STEP 2 Interior Bolts Before cutting or grinding, ensure all fuels and flammbles have been removed. Test/monitor your LEL s and/or ventilate. Remove interior boot from the wall to expose the fitting interior and bolts. MANDATORY: The interior of the sump must be completely dry at all times during installation. The use of injectable Interior boot components foam sealant is recommended to seal all sump wall breaches and prevent against water intrusion. Some products for this are Water Stop and Water Block. Local alternatives to these may be used. 7 ii-fpe-retrofit-11a

8 STEP 3 Cutting down the bolts pipe wrapped with provided rubber strip Before cutting or grinding, ensure all fuels and flammbles have been removed. Test/monitor your LEL s and/or ventilate. Wrap the provided rubber strip around your pipe to prevent damage to it during the cutting or grinding steps. Secure with zip-tie or strong tape. Use another protective material if necessary. Cut away and grind down any exposed bolts so that they are just under-flush with the wall. STEP ABRADE Maintain the provided rubber strip secured around your pipe. Proceed to grind your walls clean of any paint, gel-coat, adhesives or sealants until open fiberglass is clearly visible 3 INCHES AWAY FROM THE HOLE. 360 degrees around your pipe. DO NOT DAMAGE THE PIPE! 8 ii-fpe-retrofit-11a

9 STEP 5 ROUGHING-UP YOUR PIPE WITH EMERY SANDPAPER ABRADE PIPE APPROXIMATELY 5 AWAY FROM SUMP WALL, 360 AROUND 5 DO NOT USE POWER TOOLS TO GRIND OR ABRADE THE PIPE DO NOT USE ANY POWER TOOLS ON PIPE, EVER! DO NOT USE SANDPAPER COARSER THAN 80 GRIT 9 ii-fpe-retrofit-11a

10 MIXING YOUR ADHESIVE Your adhesive should be stored in a cool place until ready to be mixed. You should warm your adhesive and fiberglass fitting components if the ambient temperature is below 70 F. DO NOT MIX MORE THAN ONE CAN AT A TIME DO NOT ATTEMPT TO MIX HALF A CAN ONLY USE 1 BOTTLE OF CATALYST PER ADHESIVE CAN USE ONLY BRAVO SYSTEMS ADHESIVE WHEN INSTALLING THIS FITTING TO A FIBERGLASS SUMP WALL DO NOT SUBSTITUTE ADHESIVES, MIX THEM OR ADD LIQUIDS SUCH AS WATER OR ANOTHER RESIN. DO NOT USE ANOTHER CATALYST OTHER THAN WHAT IS PROVIDED. ADHESIVE HAS AN ACTIVE COLORANT ADD CATALYST TO ADHESIVE AND MIX THOROUGHLY UNTIL THE COLOR IS EVEN AND CONSISTENT WITH NO SWIRLS - NOT MIXED - NOT MIXED NOT MIXED - NOT MIXED - NOT MIXED - - THOROUGHLY MIXED THOROUGHLY MIXED THOROUGHLY MIXED - 10 ii-fpe-retrofit-11a -

11 CAUTION WINTER WARNING FOR COLD WEATHER AT 50 F DEGREES OR LESS: OBSERVE AND FOLLOW THE WARNINGS BELOW BRAVO SYSTEMS FPE-SERIES SPLIT RETROFIT FITTINGS ARE THICKER THAN THE TYPICAL FIBERGLASS CLAMSHELLS COMMONLY INSTALLED IN FIBERGLASS PIPING APPLICATIONS. YOU MUST APPLY ADEQUATE HEAT TO THE PARTS AND BONDING ADHESIVES TO ALLOW A FULL CURE TIME DURING EXTREME COLD TEMPERATURES. FAILING TO ALLOW THE INSTALLATION TO FULLY CURE MAY CAUSE THE ADHESIVE BOND TO THE FITTING TO FAIL. JUST BEFORE EACH ADHESIVE APPLICATION DRY FIT YOUR COMPONENTS ONE LAST TIME 1) PRE-HEAT THE SUMP TO NO MORE THAN 150 F TO ELIMINATE MOISTURE. 2) PRE-HEATING COMPONENTS IN EXTREME COLD WEATHER IS CRITICAL: > PRE-HEAT THE FIBERGLASS FITTING THOROUGHLY TO ~100 F > PRE-HEAT THE ADHESIVE TO ~80 F. DO NOT HEAT CATALYST!! 3) DO NOT ASSUME THE ADHESIVE IS CURED BECAUSE IT HAS HARDENED ON THE EXTERIOR. IT MAY ONLY BE A CURED CRUST IN THIS TEMPERATURE AND ANY MOVEMENT OR WATER TESTING MAY CAUSE DELAMINATION AND TOTAL FAILURE OF THE BOND. 4) DO NOT ADJUST, MOVE, SHIFT OR OTHERWISE DISTURB THE SUMP, FITTINGS OR PIPING DURING THE CURING PROCESS. 5) YOU MUST ENSURE A FULL CURE BEFORE WATER TESTING. FOLLOW YOUR ADHESIVE INSTRUCTIONS FOR TEMPERATURE GUIDELINES.

12 STEP 6 STRIPE MARK mark across the wall and all components DRY FIT ONLY Dry fit both the angled flange and the body to the pipe to find the best orientation that will evenly contact the pipe and the wall with the least amount of play, while also keeping the injection port INJECTION PORT FACING UP between 10 and BETWEEN 10 and 2-o-Clock 2 o-clock. Use a permanent marker to mark a large stripe across the sump wall and all of the assembled parts. 10-o-clock 2-o-clock STEP 7 ADHESIVE APPLIED TO ALL CONTACT SURFACES ZIP-TIE ANGLE FLANGE MARKED STRIPE CONTACT SURFACES BETWEEN HALVES Apply your epoxy adhesive to all Contact Surfaces; between both halves of the first angle flange where they contact each other, the wall, and the entire surface of the angle flange that will contact the wall. Use provided zip-tie to lock these halves together tightly. Stick this assembly to the wall by applying a slight pressure. You must also align the marked stripe in this step. 11 ii-fpe-retrofit-11a

13 STEP 8 ADHESIVE APPLIED TO ALL CONTACT SURFACES APPLY EPOXY ADHESIVE TO THE CONTACT SURFACES WHERE THE TWO SPLIT HALVES WILL CONTACT EACH OTHER. DO NOT APPLY ADHESIVE WITHIN 3/8 OF THE FITTINGS INTERIOR! GENEROUSLY APPLY ADHESIVE HERE NO ADHESIVE HERE KEEP THIS AREA CLEAN NO ADHESIVE KEEP THIS AREA CLEAN IMPORTANT! MAKE SURE THAT YOUR PIPE SURFACE IS SANDED (STEP 5) With your split body in hand, apply epoxy adhesive generously to all contact surfaces; the entire surface of the flange on the wall, the surfaces of the fitting body halves that will meet each other, and the entire surface of the body that will contact the angle flange already on the wall. DO NOT APPLY ADHESIVE DIRECLTY TO THE PIPE OR TO THE FITTINGS INTERIOR - KEEP THESE AREAS CLEAN AND DRY!! 12 ii-fpe-retrofit-11a

14 STEP 9 BEAD ADHESIVE BEADING EXCESS ADHESIVE ON ALL SEAMS STRIPE MARK ROTATE COMPONENTS TO ALIGN THE STRIPE PIPE CLAMP SEAL YOUR FITTING BODY TOGETHER MAKE SURE TO BEAD ADHESIVE ALONG THE SPLIT HALF LINES OF THE FITTING, BUT DO NOT APPLY ADHESIVE ANYWHERE NEAR THE PIPE! FITTING CLAMP SECURE FITTING TO THE WALL WHILE THEADHESIVE CURES Assemble the two halves of the body -aligning the marked stripe- with the stainless steel pipe clamp provided for the body. Tighten well and make sure the marked stripe is aligned correctly. Use provided clamp to hold the assembly against the wall while it cures. First clamp to the pipe, then turn each bolt until they press against the fitting evenly. Bead adhesive generously so it is visibly built up on all joints. Do not use a paint brush to brush seams clean. It is OK to coat the zip-tie(s) and the SS Pipe Clamp. Make sure that the seams between all halves are coated generously. Allow a full and complete cure time. After a full cure, remove the 3-bolt clamp that holds the fitting to the wall and re-apply adhesive if areas look thin.!! DO NOT REMOVE EXCESS ADHESIVE!! Continue to build up the adhesive around every seam. DO NOT APPLY ADHESIVE ANYWHERE NEAR THE PIPE 13 ii-fpe-retrofit-11a

15 STEP 10 Prepare the Bravo ADHESIVE-PE-KIT. It should have a Neon-Green label on it. Install the mixing tip and dispense adhesive until it flows evenly mixed from the tip. When ready, push the tip snug into the adhesive injection port on the body and pump adhesive slowly into the fitting until it oozes from the FACE of the fitting at the pipe. Your pipe is now sealed to the fitting. Bead the oozed adhesive from the interior face around the seam with a gloved finger. Inject ADHESIVE-PE-KIT until adhesive oozes from the face of the fitting Allow a full cure time before moving on to the next step. Adhesive will be fully cured when it is physically dense and can be hand sanded easily. USE BRAVO ADHESIVE-PE-KIT ONLY FOR INJECTION STEP. DO NOT INJECT ANY OTHER FOREIGN MATERIALS! STEP 11 HAND SAND DOWN ANY EXCESS ADHESIVE FROM THE INJECTION PROCESS HAND SAND UNTIL THE AREA IS FLUSH AND CLEAN WITH NO ADHESIVE FROM THE INJECTION 14 ii-fpe-retrofit-11a

16 STEP 12 apply ADHESIVE-RETROFIT-EPOXY-KIT adhesive to these two critical areas For this final step, the fitting area around the injection port should be sanded flat and clean with no PE adhesive present on the surface. The seam of PE adhesive where the pipe meets the fitting should also be lightly sanded. All sanded surfaces should be dusted clean and dry. Mix another Bravo ADHESIVE-RETROFIT- EPOXY-KIT and apply over the top of the injection port completely sealing it with epoxy adhesive. Also apply adhesive to the pipe seam over the existing PE adhesive, covering both the pipe and the face of the fitting. Allow a full and complete cure time before moving water testing your fitting installation.! Install with Confidecnce Compatible when submerged in fuels, biofuels and alcohol blends up to E100 and B100 WWW. SBRAVO. COM/ FS If you have any problems with Bravo Systems components, DoubleWall Containment Systems, or accessories, Call Bravo Systems Immediately: BRAVO info@sbravo.com 15 ii-fpe-retrofit-11a