UPP Piping - Franklin Fueling Systems
Contents
1. Following inspection prior and subsequent to backfilling a tightness test should be carried out by a competent person on each pipe run chamber and sump to verify the integrity of joints and seals This testing should meet the requirements of local officials and engineers and comply with local health and safety regulations The following testing procedure is suggested for guidance only and should in no way override oil companies or local regulator s requirements Testing Guidelines Equipment Target test pressure should be 50 of scale on gauge e g if the test pressure is 1 Bar 14 5 psi use a 2 Bar 29 psi gauge Gauges should have serial numbers and be tested certificated yearly Pressure testing equipment should have fitted a relief valve set at around 0 5 bar 7 25 psi above the test pressure General Guidelines When applying pressure from gas cylinders use suitable valves to ensure test pressure is not exceeded Apply pressure or vacuum slowly to minimise risks When tightness testing primary pipe the secondary should be open to atmosphere this is critical whenever secondary pipe is filled with liquid Secondary pipe should ideally not be welded prior to testing primary to allow inspection of joints When tightness testing secondary pipe the primary should be open to atmosphere Wipe each joint with soapy water to check for leaking Caution To avoid explosion hazards nitrogen or2. Where using chemicals such as Acetone during the installation of UPP systems products follow all safety guidelines given on the chemical containers themselves or on any accompanying literature Confined Space Some installation of UPP products may occur in confined spaces where a lack of oxygen and a concentration of toxic vapors is likely to be experienced Such working conditions are dangerous and all local health and safety guidelines for working in such environments should be followed Material Handling Protective Equipment Ensure the correct personal protective equipment PPE is used at all times in line with local health and safety requirements Material Safety Data Ensure all safety data is accessed and used while installing UPP Systems Material Safety Data Sheets are available in the download area of the UPP website Transport amp Storage UPP products should be transported and stored in accordance with the guidelines contained in this manual Heavy items lt Heavy items should be handled using suitable lifting equipment operated by authorised personnel 2 Figure 1 Installation Overview Contents Introduction Underground Fuel Pipe Construction Transit Off loading and Storage Uncoiling Pipe Site Preparation Pipe Burial Guidelines Pipe Bend Radius Completion Records Pipe Detector Tape Pressure Testing Testing Guidelines 7 UPP Recommended Pipe Te
3. runs may be continuous or have electrofusion welded joints Any mechanical joints or compression fittings must be located within a containment chamber or sump Welding Connectors Heating Element Figure 6 Electrofusion Welded Fitting Detail Refer to FFS manual 405001007 for information about the electrofusion process lt UPP pipe exceeding 12m 39ft should be laid in a fused above ground UPP pipe should be protected series of large snake like curves and not in straight against mechanical climatic damage Additional lines Uncoiled pipe when laid will settle in a natural supports and anchor points may also be required curve Check fire codes for proper installation Also see document FFS 0134 UPP Piping Above Ground and Marina Installations Mark positions on the tank access chamber sump for penetration locations and install UPP seals Bend Radius The UPP piping systems have a semi rigid construction which gives both strength and flexibility Figure 9 Bend Radius Figure 8 Using Temporary Stakes to Snake Pipe Refer to Table 1 for allowable bend radius of UPP Pipe Generally any thermal expansion will be accounted for by following our guidelines for spacing backfilling and ensuring runs are snaked Pipes should be separated from each other by at least the diameter of the largest pipe Important Completion Records On completion of UPP installation make an as constructed drawing showin
4. 2 2 2m 7ft 2 8m 26ft 3 8m 26ft 3 Table 3 Allowable Bend Radius Temperature Pipe Detector Tape UPP Detectable tape is used to allow the piping location to be found after it has been covered The tape is installed below ground at 250 mm 9 8 inches height directly above pipe runs to indicate the position of each pipe Detector Tape Max Depth Detection 3 m m Pea Gravel or Sand 250 mm Subsoil UPP Pipe Figure 10 Detector Tape Installation Both ends of the tape should be grounded during installation End of Tape Must be Grounded in Sumps Figure 11 Detector Tape must be Grounded When using a detection tool the near end of the detectable tape should be disconnected from the grounding point to allow the red cable from the transmitter to be connected to the tape and the black cable from the transmitter to be connected to the grounding point The far end of the tape should remain grounded to give the highest signal strength and the earth spike should be as far away from the trace path as possible at a 90 degree angle Use the lowest frequency possible from the transmitter around 577 Hz or 8 KHz to eliminate coupling to other grounded cables Use the receiver to follow the path of the tape to locate the buried pipe Follow direction included with the receiver and transmitter for detecting buried pipe location Pressure Testing
5. 473 243300 Franklin Fueling Systems Gmbh Rudolf Diesel Strasse 20 54516 WITTLICH Germany Tel 49 6571 105 380 Fax 49 6571 105 510 France Tel 49 6 57 11 05 380 China Tel 86 10 8565 4566 Fax 86 10 8565 4766 A802 ChaowaiMEN Center No 26 Chaowai Street Chaoyang District Beijing 100020 China
6. Fill the pipe work system to be tested with water making sure that any air relief valves are opened while filling the pipe work After filling the pipe work wait 1 hour for the temperature to stabilize Pressurize the system to 10 bar 145 psi and maintain this pressure for 30 minutes System pressure shall be maintained by means of refilling in order to compensate for the increase in volume due to the expansion of the pipe work At this time the system should be thoroughly inspected for leakage After any such areas have been remedied repeat the conditioning before proceeding to the testing phase Testing Phase Rapidly reduce the system pressure to 3 bar 43 5 psi by bleeding water from the pipe work Due to the visco elastic properties of polyethylene the pipe will contract Maintain 145 PSI 10 bar for 30 minutes 145 10 130 5 9 Pressure PSI bar co N 29 2 drop to 43 5 PSI 3 bar for 90 minutes 0 10 20 Conditioning Time mins During the test period of 90 minutes the pressure should be recorded with the frequency shown below Number of readings Test period Freguency of mins readings mins Table 4 Recording Test Results The test is passed if all the readings during the testing cycle are 3 bar 43 5 psi or above Decreasing readings failure of pressure test Note that the readings are likely to increase lt Ifthe system fails the pressure test make t
7. This may vary to meet local requirements The position of the entry fittings at the furthest dispenser sump away from the tank chambers may be considerably higher than that of the entry fittings on the closest dispenser sump Vapor return lines should have a slope of 2 m every 100 m 1 4 per foot and never less than 1 m every 100 m 1 8 per ft back towards the tank farm unless in line joints such as elbows are to be used Trench corners should have a radius of 1 5 m 5ft Arecommended 15cm 6 bed of backfill material should be laid underneath the pipe prior to installation and there must never be voids under or around the pipe Acceptable backfill materials are Well rounded pea gravel size 3mm to 20mm e Crushed rock size 3mm to 16 mm Clean washed sand Backfill material must not be contaminated with any petroleum product or other contaminant WARE Figure 7 Fall back slope to Tank 300mm min 12 150mm min Ne Ka NK KANGEN BK es ng 6 _ 150mm min 6 1 Figure 5 Pipe Spacing lt When laying duct onto a concrete base a 150 mm 6 thick bed of compacted sand should be laid on the concrete below the duct The minimum amount of sand should be 50mm 2 of compacted sand Allbeds should be laid so that the pipe will not dip or sag when it is installed lt Laying of pipe should start from the tank farm Underground pipe
8. an inert gas from a pressure cylinder should be used in place of compressed air for tightness testing if fuel has been used to ballast underground storage tanks or if pipe work has previously contained petroleum Pipe work should be disconnected isolated from underground storage tank prior to commencing tightness testing Any water used for testing should be disposed of through the oil water separator or by a specialist contractor and in accordance with any local environmental health and safety requirements and regulations There are two recommended tightness test methods for UPP pipe work hydrostatic and pneumatic In all instances the hydrostatic method is to be preferred as it allows high pressures to be used with relative safety However there will be instances where the introduction of water into the pipe work is undesirable in these cases the pneumatic method should be adopted paying particular attention to the safety aspects of working with compressed gas due to the high levels of potential energy that can be stored UPP Recommended Pipe Test Procedure Primary Pipe Hydrostatic Pressure Testing Method Equipment lt Pump rated for more than 10 bar 145 psig Hydrofor reservoir or pressure tank Two pressure gauges rated for 12 bar 174 psig min reading 0 1 bar 2 psig Check valve Ball valve Pressure relief valve rated for 20 bar 290 psig set at 11 bar 159 psig Conditioning Phase
9. g the exact location If pipe runs cross each other they must be separated of all below ground lines It is also recommended by at least as much backfill material as the diameter that in addition a photographic record is of the largest pipe or protected using at least 25mm preserved 1 of expanded polystyrene Styrofoam Pipe Bend Radius Single Wall Pipe Temperature 32mm 1 50mm 1 63mm 2 90mm 3 110mm 4 gt 15 C gt 59 F 0 5m 1ft 7 0 75m 2ft 6 0 9 m 3ft 2 25m Tft 4 2 75m 9ft 0 15 C 32 59 F 0 8m 2ft 7 125m 4ft 1 1 58m 5ft 2 3 15m 10ft 4 3 85m 12ft 8 lt 0 C lt 32 F 1 12m 3ft 8 1 75m 5ft 9 2 2m 7ft 3 4m 13ft 2 4 9m 16ft Double Wall Pipe 40 32 mm 63 50mm 75 63mm 110 90 mm 125 110mm 1 1 2 2 3 4 gt 15 C gt 59 F 0 6m 2ft 0 9m 3ft 1 12m 3ft 8 2 75m 9ft 3 1m 10ft 2 Temperature 0 15 C 32 59 F 1m 3ft 3 1 5m 4 ft 11 1 88 m 6 ft 2 3 85 m 12 ft 8 4 4m 14 ft 5 0 C lt 32 F 1 4m 4ft 7 2 2m 7 ft 3 2 6 m 8ft 6 4 9 m 16ft 5 6 m 18ft 4 UL971 Pipe 63mm 90 mm vog 75 63mm 110 90 mm Eois 2 3 1 1 2 2 3 4 gt 15 C gt 59 F 1m 3ft 3 3m 9ft 10 1 m 3ft 3 1 m 3ft 3 4m 13ft 2 4m 13ft 2 0 15 C 32 59 F 1 6 m 5ft 3 5m 16ft 5 1 6m 5ft 3 1 6m 5ft 3 6 m 19ft 8 6 m 19ft 8 lt 0 C lt 32 F 2 2m 7ft 2 7 m 23ft 2 2m 7ft
10. he following checks Check all mechanical connections Check welded joints When the failure point has been located and remedied repeat the full conditioning and testing sequence To Pass Test Pressure Must remain at 43 5 PSI 3 bar or above 300246810 15 20 25 30 40 50 60 70 80 90 Test Reading Times mins Hydrostatic Testing Graph UPP Pneumatic Tightness Testing Pressure Testing Safety Procedure Follow these guidelines when conducting pneumatic The following testing procedure is suggested for testing guidance only and should in no way override oil companies or local regulator s requirements Wear Safety glasses Relieve air pressure before any corrective actions are Never exceed the pressure ratings of components taken shown on Table 1 amp Table 2 on page 3 of this document when testing Allow only necessary and authorized persons in the proximity of pipe being tested Restrain the movement of connections joints and seals during testing Test Procedure Record Temperature and Pressure at start of each test time Condition and test the piping as follows Recommended Pipe Tightness Testing 1 Pressurise the piping to 10 of test Pressure pressure hold pressure for 30 minutes and Pipe Type Bar PSI inspect for leakage or pressure drop 2 Increase pressure to 50 of test pressure rimay pipa 3 5 50 and again inspect for leakage while holding Secondary pipe with 3 0 44 pressure for 30 m
11. inutes Welded Reducers 3 Increase pressure to 100 of test pressure Secondary pipe with and again inspect for leakage while holding Rubber Reducers 0 5 T pressure for 30 minutes Record Temperature and Pressure at end of each Table 5 Recommended Pipe Tightness Testing Pressures test time If results are within criteria of Table 6 Tightness Test is passed Acceptable Pressure Variation Initial Pressure 3 5 bar Temperature variation A T C 15 10 5 0 5 10 15 Final pressure due to temperature change bar 3 42 3 50 3 58 Temperature variation AT F 30 20 10 0 10 20 30 Final pressure due to temperature change psi 48 8 50 0 51 2 Temperature variation AT C 15 10 5 0 5 10 15 Final pressure due to temperature change bar 2 93 3 00 3 07 Temperature variation A T F 30 20 10 0 10 20 30 Final pressure due to temperature change psi 42 9 44 0 45 1 Temperature variation A T C 15 10 5 0 5 10 15 Final pressure due to temperature change bar 0 47 0 50 0 53 Temperature variation T F 30 20 10 0 10 20 30 Final pressure due to temperature change psi Table 6 Acceptable Pressure Variation o Franklin Fueling Systems Sump Inspection Register Date of Inspection or Test Results of Inspection or Test Signature of Inspector or Tester Required Monthly And Or Annual Inspection Containment sumps located on the property at which the FFS products are installed must be vis
12. le to uncoil and cut the pipe The coil is taped up in layers to make it easier to uncoil at manageable intervals The area in which the pipe is uncoiled on site must be clear safe and free of sharp objects Remove the tape around the tail end on the outer winding and secure this end With the coil in the vertical position roll the coil out cutting and removing tape as you find it ensuring to release only the next turn of pipe in the coil Do not drag the pipe The natural curves from coiling can be used to change pipe direction and bags of sand pea gravel or stakes can be used to hold it in place until it is ready for connecting One person should hold the pipe whilst another cuts it to the desired length The cut ends will have a prominent hook that can be partially removed when weight is placed on it bags of sand or pea gravel or use the hook end to your advantage when turning direction into a chamber or pump sump Site Preparation Site inspection Make sure the site is prepared and ready The tanks sumps fill points vents etc should be in place IMPORTANT The site should be free from previous fuel contamination Pipe Burial Guidelines Recommended burial depth of UPP pipe is a minimum of 300 mm 12 All trenches should be sloped back towards the storage tanks The fall back slope for all pipework to the tank chambers should be a minimum of 1m every 100m or 1 8 per foot Figure 7
13. o Franklin Fueling Systems UPP Piping Installation Guide Overview 408001016 Oct 2014 Show EVOH pipe lining for both EN UL Franklin Fueling Systems 3760 Marsh Rd Madison WI 53718 USA Tel 1 608 838 8786 800 225 9787 Fax 1 608 838 6433 www franklinfueling com Safety Important UPP Systems must only be installed by fully trained and certified installers Failure to follow installation instructions will invalidate warranty and installer certification Piping Installation Safety UPP Welding Units must never be operated in Zone 1 or Zone 0 areas Hazardous area definitions are from European Directive 1999 92 EC and guidelines can be found in the APEA Blue Book 3rd Edition Ensure Welding Units are connected to a power supply that meets the requirements detailed in the user manual and are within the requirements of any local authority or regional legislation lt Important to any type of piping system is to safely connect all metallic components to ground Metallic components and more general conductive materials due to their high capacitance can have the potential to store high amount of electrostatic energy sparks discharge can only be observed over conductive elements All exposed metal parts used in UPP System installations should be adequately grounded to a dedicated earth electrode and brought to a potential equal to that of other metal parts in the close proximity Chemical Safety
14. st Procedure Hydrostatic Pressure Testing Method UPP Pneumatic Tightness Testing Method Procedure Sump Inspection Register Introduction Underground Fuel Pipe Systems Several types of underground fuel pipe are available for different applications and to meet various engineering and legal requirements lt UPP primary pipe a fuel proof liner for product suction pressure vapor vent and fill lines lt UPP Secondary containment pipe used with EN primary pipe for pressure systems or environmentally sensitive sites UPP Integral Secondary Containment pipe UL971 spec for pressure systems or environmentally sensitive sites lt UPP electrical conduit pipe for underground electrical wiring protection UPP Electrical duct for underground electrical wiring protection UPP piping systems are designed in various diameters from 32 160 mm I 6 for the transfer of fuels in filling station forecourts marinas and airports UPP systems are also used for government and military installations as well as many industrial sites such as mines and rail depots There is no requirement for a concrete trench because fusion welded HDPE pipe is structurally resistant to weight of backfill material and dynamic traffic loads Over 30 years experience showing no failures in underground fuel pipe systems and no loss into the ground Underground Fuel Pipe Construction Black outer structural layer of the pipe is High Densit
15. t has suitable protection for the bottom of the coil Stacked coils should never exceed three coils high Individual coils should be stacked flat If stored on edge they must be secured against a properly anchored support and stored like this for a short period of time only particularly in warm weather conditions Badly stacked coils and pipe lengths can slip causing personal injury or damage to the product Facilities for safe lifting and moving must be available Pipes are supplied with distinctive colored end caps to prevent entry of any contamination These end caps must be kept in place during storage UPP fittings all electrofusion fittings are packed in heat sealed polyethylene bags and delivered in cardboard cartons Fittings should be stored in their packaging and in a dry area away from direct sunlight until ready for use This is particularly important for electrofusion fittings These must be kept in their packaging until ready for use to prevent any contamination or oxidation Uncoiling Pipe Figure 4 Uncoiling Pipe The pipe can straighten with considerable force Take care when releasing pipe from the coil and secure the straightened pipe Let the pipe rest in its uncoiled state for about eight hours High ambient temperatures can reduce this layout time and low temperatures may increase it Pipe can be laid in its final position to relax before connecting up Caution You need at least two peop
16. ually inspected for liquid monthly Sump sensors if installed must be tested annually Any leaks must be corrected at the time they are found Recommended Monthly Inspection Verify sump lids are tight and sealed Inspect sumps for dirt debris liquid or any physical cracks or holes that would allow leakage Check for evidence of staining or new staining Verify penetration boots are in good condition and the pipe entry into the sump is positioned properly near perpendicular entry Verify sump liquid sensors are positioned correctly if installed Verify the piping and other equipment in the sump are in good condition Record any faults on this Sump Inspection Register and have the fault s corrected at the time found Additional copies of this form can be downloaded from the FFS website www franklinfueling com End user proprietary inspection check register log formats or any form to record these inspections is acceptable From FFS form FFS 0131 Rev1 From FF torm o U121 REV Franklin Fueling Systems 3760 Marsh Rd Madison WI 53718 USA Tel 1 608 838 8786 800 225 9787 Fax 1 608 838 6433 www franklinfueling com 10 Page Intentionally Blank 11 FFS 2014 408001016 Rev 4 Franklin Fueling Systems www franklinfueling com 3760 Marsh Road Madison WI 53718 USA Tel 1 608 838 8786 Fax 1 608 838 6433 USA amp Canada Tel 1 800 225 9787 M xico Tel 001 800 738 7610 Brazil Tel 55 11 3395 0606 UK Tel 44 1
17. ure Rating Transit Off loading and Storage Although UPP polyethylene pipe and fittings are extremely hard wearing and resilient it is important to handle and store them with care to prevent scuffing or gouging Any damaged pipes may need to be rejected and not installed UPP products should be transported in a flat bedded vehicle free from sharp objects and projections Wide polypropylene slings must be used when lifting pipe crates by crane Avoid using chains hooks or hawsers A spreading beam should be used when lifting crates containing pipe lengths greater than 6 m 19ft 8 Allow for a slight bending of the pipe crates when on and off loading e Standard 6m 19ft 8 crates may be moved using a forklift A side loader fitted with a minimum of four supporting forks should be used for longer lengths Otherwise use a crane fitted with a spreader beam When using a forklift to on or off load coils the forks should be covered to avoid damage to the coiled pipe Figure 3 Moving Coils Storage on site Individual pipe lengths should be stacked not more than 1 m 3ft high with the bottom layer fully restrained by wedges The bottom layer of pipes should be laid on timber battens at 1 m 3ft centres to avoid any damage from sharp objects lying on the ground Pipe crates should be stored on clear level ground and should never be stacked more than three crates high Coils should be stored on firm level ground tha
18. y Polyethylene HDPE grade PE80 or PE100 which allows the use of electrofusion couplers and fittings to construct a variety of pipeline configurations HDPE PE80 and PE100 has well proven resistance to stress cracking puncture scratch impact microbial and rodent attack The intermediate tie layer causes a permanent bond to occur between the polyethylene and the liner material The liner of UPP primary pipe is a specially formulated fuel proof barrier layer manufactured from either EVOH EN UL or Nylon UL Both liners have exceptional resistance to absorption and permeation of both hydrocarbon and alcohol fuel blends The smooth bore and low friction loss of UPP pipe permits higher fuel and vapor flows than steel pipe reducing the pumping energy costs UPP underground fuel pipe is pressure rated to 10 bar EN or 90 psi to UL971 Rupture pressure is typically exceeding 40 bar 580 psi providing a large margin of safety Carrier PE Black _ Tie Layer Liner EVOH clear EN UL L Nylon Yellow UL Figure 2 UPP Pipe Structure Pressure Ratings Pressure Rating UL 971 Pipe type Pressure Pressure Rating Bar Rating PSI UPP Primary 6 2 90 UPP Secondary 9 2543 Table 1 UL971 Pipe Maximum Pressure Rating Pressure Rating EN14125 Pipe type Pressure Pressure Rating Bar Rating PSI UPP Primary 10 145 UPP Secondary 5 V2 8 Table 2 EN14125 Pipe Maximum Press
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