slotted conduit, pull box & pull rope - welcome to...

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Slotted Conduit, Pull Box & Pull Rope

InstallatIon InstructIons

THERMAL MANAGEMENT SOLUTIONS EN-TraceTekSlottedConduit-IM-H58175 01/13

DEScRIpTIONThese instructions are intended to guide the contractor through the process of installing the conduit, pull rope and pull boxes that are an essential part of the TraceTek pipeline leak detection system. The conduit and pull boxes are usually installed during the initial phase of the project when the trench has been opened and the pipeline is being laid.For technical support, call Pentair Thermal Management at (800) 545-6258.

TOOLS & MATERIALS REqUIRED• Sizingtool • PVCpipecutter• Razorknife • PVCadhesive•Hacksaw • Fishtape• Twodifferentcolorsofelectricaltape

• Keeptheconduitsystemstraightandclean.Avoidunnecessarydirectionchanges,anddon’tallowextraconduittoform“S”curvesalongthetrenchfloor.Makesuretheconduitisononesideofthepipe.

• Fixanyproblemsthatpreventthepullropeandsizingtoolfrommovingfreelybeforethecableinstallationbegins.• Useendcaps.Slipthecapsontotheconduiteverytimetheconduitisleftunattended,forexampleduringlunchbreaks,overnightorwhilewaitingformaterialsorotherdelays.

• Anysectionofconduitthatwillnotallowthesizingtooltopullfromonepullboxtothenextisnotreadyforsensorcableinstallation.Donottrytoforceit.Identifythesourceofanyclearanceproblemsandmakethenecessaryrepairsbeforethecableinstallationbegins.

IMPORTANT:

KIT cONTENTS

Item part # Description

A TT-PVC-Solid–1½ SolidwallPVC-3meterlength,nothreads

B TT-PVC-Slot–1½ SlottedPVC-3meterlength,threaded

C TT-RiserKit–1½ Cablerack/airlock

D TT-PR Pullrope

E TT-PVC-SlipFit PVCslipfitcouplingsforrisers

F TT-PVC–1½–Cap PVCcap

G TT-PVC-Sweep90–1½ 90degreePVClargeradiussweep

H TT-PullBox Gradelevelpullbox

G

F

E

H

(Components notnecessarily shown to scale)

A

B

C

D

THERMAL MANAGEMENT SOLUTIONS EN-TraceTekSlottedConduit-IM-H58175 01/13 2 / 10

Assembly Techniques

conduit issues

pull rope issues

pull rope techniques

• Keeptheconduitsystemstraightandclean,avoidunnecessary direction changes. Don’t allow extra conduit toform“S”curvesalongthetrenchfloor.

• Keepconduitononesideofpipe.• Useendcaps!• Slipthecapsontotheconduiteverytimetheconduitis

left unattended.• Preventrocksorheavyobjectsfromfallingontothe

conduit.• Repairanybreakswithacleancut,slipfittingsandnew

rope if necessary.• Alloftheconduitandropecomponentsareinexpensive

and easy to replace, but problems that are not corrected atthisearlystageareveryexpensivetorepairlater.

• Pullropeisinexpensive,sodon’ttrytosavemoneybyknotting or splicing.

• Eachlengthshouldbecontinuousfromonepullboxtothe next.

• Pullropeissuppliedonlargereels,sobesurethereissomeone at the reel to help pull the rope off of the reel and feed it into the conduit.

• Don’ttryaone-personpullthroughtheconduitfrom100meters away.

• ExcessiveforcewhenpullingthecablewillcutintoanddamagethePVCconduit.

• Theropeshouldpulleasilywithonehand.

• Thecontractormustprovide“jackstands”andanaxletosupport the reel and act as a payoff.

• Don’tplacethereelonthegroundbecauseitmaypickupdirt, rocks or mud that can get pulled into the conduit.

• Eachbendorchangeofdirectionmultipliesthepullingforceontherope.By“helping”thecableintothefirstbend,youcankeeptheinitialresistanceclosetozeroandthat greatly reduces the accumulated drag.

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• Cuttheropeendata45°angle. •Wraptheendwithelectrician’stapetomakeasharppoint.

Slip joint –use adhesive

carefully

Twist joint - no adhesive!

pVc issues

Making an eye-splice with hollow braid rope

•MostoftheslottedPVCconnectionsarethreadedjoints.Thereisnoneedforadhesiveorexcessforce.Simplytwistthenewsectionafewturnstoaddtothetotalconduitlength3metersatatime.

• Theverticalrisersand90°bendsarenotthreadedandtheyarejoinedusingslipfittingsandPVCadhesive.StandardPVCadhesiveisusedforallslipfittings.Useenoughadhesivetomakeagoodjointbutdonotuseanexcessiveamount.Iftheadhesivedripsintotheinterioroftheconduit,uselessadhesive.

• Alloftheconduitandbendsaremadewith1½inchdiameter,Schedule80(thickwall)PVC.Itisveryrugged,butPVCisplasticanditcanbecrushedorbrokenwithsharp impacts or excess force.

• Caution:Atverylowtemperatures(belowfreezing)PVCbecomesmorebrittleandexcessivebendingcancauseittobreak.

• Inlonglengths,theconduitisflexibleenoughtoworkabovethepipetrenchandthen be lowered into place without damage.

• Becarefulwithrocks,tools,materialsordebrisalongthesideofthetrench.Dropping large rocks or tools onto the conduit can damage the conduit and necessitate repairs.

• Pullropeisusedforpullingsensorcable,jumpercable,sizingtoolsandcleaningragsthrough the completed conduit system. The bestwaytoattachvariouscableortoolstotherope is with an "eye-splice". The following steps illustrate how to form the splice.


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•Makealoopwithabout50cmofrope.(inthisphotoweareattachingasizingtool)

•Worktheendoftheropeintothehollowcoreoftheropeuntil almost all of the 50 cm is inserted.

• Feedthetapedendoftheropeintothehollowcoreoftheropejustbelowthesizingtool.

• Addanextrafewwrapsoftapeatthebaseofthesplicefor extra security.

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• Atthefirstpullboxlocation, position the reel of pull rope to one side of the trench.

• Formaneye-spliceinthe leading end of the pull rope.

•Useastiffpieceofwireora“fishtape”tothreadthepullropeintooneoftheverticalriserassembliesfromthetopdownandthroughthe90°bend.

• Useastiffwireor"fishtape"topulltheropethrough the first section of slotted conduit.

•Useaminimumamountofadhesivetogluethe slotted conduit into the slip fitting.

• Tojointhefirst3meterlengthofslottedPVCconduitusethePVCcutterorahack-sawtocutoffthefemalethreadend portion (about 5 cm).

• Assemblethehorizontalportionoftheconduitsystem,threadingadditionalropethrougheachincremental3msectionofslottedconduit.Donotuseanyglueoradhesiveon the threaded couplings. Twist them together by hand.

pVc & pull Rope Installation Instructions

conduit and pull rope installation sequence

• Prepareseveralverticalriserswith90°bendsandslipfitconnectors,usesufficientbutnottoomuchPVCadhesiveand set them aside to dry.

• Itisagoodpracticetopre-fabricateseveraloftheseverticalassembliesandsetthemasideuntiltheyareneeded.

• Everypullboxlocationwillrequiretworiserassembliesexcept for the first and last ones in the system.


2 m

250 m maximum

Blue tape(northbound)

Red tape(southbound)

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• Threadthepullropethroughtheriserassembly, then use a minimum amount of adhesivetogluetheverticalriserassemblyto the end of the slotted conduit. Be careful withthePVCadhesivesotheropeisnotglued by accident.

• IftheropechecksoutOK,thencutthe rope, bundle the extra 2 meters of rope at each end and push into the end of each riser, then install end caps without any glue.

• Iftheconduitisnotalreadyloweredonto the trench floor, now is a good time to do it.

• Afteramaximumof250mofslottedconduitisinstalled,use a hacksaw or conduit cutter to trim the last length of slotted conduit to adjust to the next pull box location.

• Theentireprocessofconduitassemblycanbestartedandcontinuedwhileworkingatgradelevelononesideofthe trench.

• Afterthesteelpipelinehasbeenpositionedonthebottomofthetrench,itistimetolowerthePVCconduitontothesame bedding sand.

• Thelongrunofconduitwillbeflexibleenoughtograduallymovetheconduitontothetrenchfloorwithoutdropping or breaking.

•Makeatesttomakesurethatthepullropemovesfreelywithoutbindingorexcessforce.Ifthereisanydoubtinvestigateandfixtheproblemnow.

• Preparingforbackfilling,and separating risers by using colored tape to mark“Northbound”and“Southbound”conduits.

• Blueisnorthboundandred is southbound. After the conduit is buried it willnotbeobviouswhichdirection either pull rope will run, so consistent identification on the end of the riser is necessary.


11 in(280 mm)

Use a board placedacross the trench as

a temporary braceto hold the riser

pipes vertical.

Electricaltape

Center pull boxabove vertical risers

Center pull box above vertical risers

Hand dig trench wall asnecessary fo fit pull boxHand dig trench wall as

necessary fo fit pull box

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• Placealongpieceofwoodacrossthetrenchandusethiswoodasabracetoholdthetworisersinverticalpositionat the start of the back fill process.

•Holdspacersinplacewithtie wraps or electrician’s tape. A short piece of conduitwitha45°notchcut in each end is a good alternativeifthewoodenspacersarenotavailable.

• Theriserswillnotbedirectlyoverthepipelinebutwillbetoonesideofthetrenchdirectlyabovethepathoftheslotted conduit.

•Heavyequipmentcanbeusedforthebackfillexceptinthe area around the pull-boxes.

•Usehandtoolstowidentheareaaroundtheriserandpartiallyfilltowardsgradelevel.

• Sliptwo-holewoodenspacersoverthetworiserstokeeprisersseparated at pull boxes. The two risers should be 280 mm ± 50 mm (11 in ± 2 in) apart center to center. Iftheyaretooclosetogetheritwillbe difficult to cut the risers to their proper length; if they are too far apart, they will not fit under the air lockcover.

• Aftertherisersarebracedintheverticalposition,theywilllikelyextendabovethefinishedgrade.

pull Box & Riser Kit Instructions


Add 10 cm of fill to bottom of pull box

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230 mm +/- 50 mm (9 in ± 2 in)

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• Addabout10cmoffillinsideofboxtoadjust“floorheight”forthecablesupportstandandairlockbucket.

• Compactthesoilinandaroundthepullboxasmuchaspossible.

• Assembletheriserkitcablesupportstand,placeitoverrisers, place the air-lock (upside down, blue bucket) overthecablestandandthecapped off riser ends.

•Withoutcuttingthepullrope,carefullycuttheverticalriserssothattheystickoutofthe“floor”fillby230mm±50mm (9in±2in).

• Itmaybeeasiertopushtheropefurtherdownintotheriserduring the cutting operation.

• Usemoreoftheredandbluetapetoclearlyindicatewhichriser is headed north and which riser is headed south.

• Makesurethepullropeendscanbereached,replacetheend caps to keep out dirt and rocks.

• Positionthepullboxcoverandboltit into place.

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• Cleanandverifyeachsectionafterbackfillingbyusingaragandthesizingtoolforafinalcleaningandtocheckforclearance.

• Useaneye-splicetoconnectacoilofrope(10mlongerthanthelongestanticipatedpull)tooneendofthesizingtool.

• Useaneye-splicetoconnecttheotherendofthesizingtoolto one end of the pull rope already installed in a section of conduit.

• Tieapieceoftowelorragthroughtheeyespliceinadvanceof the tool.

• Nowpullthesizingtoolfromoneendoftheconduitsectionto the other.

proof the pipe

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• Asyoupull,coilthepullropebyhandtokeepitoutofthedirt.• Afterpullingthetoolthroughtheentirelengthofconduit,replacetheragwithcleanmaterialifnecessary,movetheragtootherendofthepullingtoolandreversetoprocesstopull the original pull rope back into the conduit.

• Theideaistomakesurethattheconduitisfreefromanyaccumulated dirt or mud and to make sure that there are no crushed or broken sections of conduit.

Inspector check List1. Verifythatthesizingtoopullsfreelythrougheachsectionof

conduit.2. Verifythatthepullropeisfreeofknotsandsplicesandthat

there is 2 m of extra rope at both ends of each section.3. Verifytrimmedheightofrisertubesabovebackfillis230

mm±50mm(9in±2in).4. Verifyspacingofrisertubesis280mm±50mm(11in±2

in) mm center to center.5. Verifyconduitsaremarkedwithdifferentcolortapeto

indicate directions.6. Verifyendcapsareusedtocovertheextrapullropeand

riser when the inspection is completed.


WWW.THERMAL.PENTAIR.COM

©2007-2013Pentair.

NORTH AMERICA Tel: +1.800.545.6258Fax: +1.800.527.5703Tel: +1.650.216.1526Fax: [email protected]

EuROPE, MIddLE EAsT, AfRICATel: +32.16.213.511Fax: [email protected]

AsIA PACIfICTel: +86.21.2412.1688Fax: [email protected]

LATIN AMERICATel: +55.11.2588.1400Fax: [email protected]

PentairandTraceTekareownedbyPentairoritsglobalaffiliates.Allothertrademarksarethepropertyoftheirrespectiveowners.Pentairreservestheright to change specifications without prior notice.

slotted conduit, pull box & pull rope - welcome to...

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