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Installation Manual - Franklin Fueling Systems

1. o o 9 9 o 0 o o o 9 o 9 10 Ensure plugs are replaced in Test Ports after testing to maintain liquid tight system e e e e oe 9 6 o 9 o 9 o o o o 0 o o 9 O 9 0 9 9 O Final backfilling Il Prior to backfilling the sump lid must be in position to prevent any deflection of the riser Acceptable backfill materials are Well rounded pea gravel size 3mm 1 8 to 20mm 3 4 Crushed rock size 3mm 1 8 to 16mm 5 8 Clean washed sand IMPORTANT Backfill material should be free from ice or any organic silt or peat Particular care should be taken to ensure enough backfill is laid down around the underside of the chamber where it overhangs the tank access shaft flange No mechanical compactor
2. O o o o o o o oo oo o o 9 o 9 9 9 Attach the harness assembly Deep Riser Pass Harness Assembly over deep riser and position Top Strap above lower rib Shallow Riser For shallow riser position Top Strap below top rib Pull Top Strap tight with cam buckle Position 4 Drop Straps in line with base corners Loop Harness Rings over corners N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 27 9 6 9 0 o 0 o o 9 o 9 o o o o o o 9 9 0 o o o 0 0 o o o o 0 o 0 O 0 o 0 eo oo 9 o o o 0 o O o o O 9 0 O 0 O 0 O 0 oo oo 9 9 9 e e 9 9 9 9 9 0 9 9 9 9 o
3. 9 o 9 9 e e e e o o o o o o o o o o o o o 28 7 6 Attach the harness assembly continued Connect welding lead to terminals Begin weld Ensure riser sits squarely on the base using TO T a spirit level Pull strap in tension and then gently ratchet until webbing has wound itself and is locked in place From this point add two full ratchets Repeat for opposite corner and two remaining corners IMPORTANT Ensure welding leads are supported Handle weld terminals with care Do NOT weld chamber more than once Weld Time Cooling Time 6 Minutes 20 Minutes After cooling time to release webbing pull and hold release tab on top assemblv to override ratcheting function IMPORTANT For EW8 black units ONLY Stop weld manuallv after 6 minutes Trim back welding lead shroud by 20
4. 9 0 9 9 0 0 9 9 9 Backing Plate x 4 Circular flange drawing PTL LA 008 001 Square flange drawing PTL LA 008 002 3 Mount chamber base onto tank Fit backing plates and bolt together using MI0 Bolt sets f Ensure all bolts are tightened equally UN Recommended torque 20Nm 14 751bft Bee S IMPORTANTI Based on Cookson amp Zinn standard tank flanges Other tank types may vary Please check with tank manufacturer M10x70 Bolt set DETAIL A 1 x Hex Bolt 2x Plain Washer 1 x Hex Nut 26 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION n 6a 6b 6c Backfill up to the top of the tank collar Ensure backfill is well compacted and is fully into the area under the tank sump Vacuum test using UPP Vacuum Test Unit to prove joint between tank collar and tank sump base Recommended depth setting 3ft See note on Tightness Testing in section Note Make sure plugs in tank manifold lid are in position Install Pipework as per customer specification Vacuum test to prove tightness of electrofusion entry seals fig l test Recommended depth setting 3ft See note on Tightness Testing in sectio
5. 62 8 3 EW8 HAND HELD WELDER OPERATING MANUAL WARNING UPP WELDING UNITS MUST NOT BE OPERATED IN ZONE 1 AREAS To weld inside zone 1 the units must be operated in zone 2 with only the welding cables extending into zone 1 NOTE EWS welding cables use special 7 pin connectors NOT regular 4 pin connectors 1 Construction of the welding machine Bridging cables EW8 Electrofusion x2 Welder 7pin Secondary KONT welding cable N welding cable Oy Application The EWS is designed to automatically weld UPP Primary and Secondary Containment electrofusion fittings Also using the white 7A welding leads the EW8 can be used to weld the UPP Fusion chamber riser to the chamber base It can be used in ambient temperatures between 15 C and 45 Only personnel fully trained in the use and installation of the UPP system should use this equipment Main Features UPP electrofusion fittings are welded using a constant current The EW8 automatically recognises the fitting when connected and applies the correct amount of energy for a successful weld The EW8 takes the ambient temperature into account when calculating the energy required to weld correctly It must therefore be allowed to reach ambient temperature before use and must be at the same temperature as the fitting to be welded The temperature sensor is located in the mains cable clamp close to the unit The EW8 works on standard alterna
6. 09 90 63EIF 09 1 10 90EIF 302 Flange 303 Flange 305 Flange 308 Flange Table 3 1 Primary Welding Fittings Weld Time 20 Seconds Resistance index number o M c A c G QG FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 7 3 5 WELDING SECONDARY CONTAINMENT PIPE AND FITTINGS Green welding cables should be used for welding secondary containment pipe Some welding unit displays will read Secondary Mode and after five seconds Connect welding element Attach the welding cable to the assembly to be welded via the welding pins on the coupler electrofusion fitting and then follow the operations in Section 3 4 JOINTS MUST NOT BE UNDER ANY STRESS DURING WELDING AND UNTIL AMBIENT TEMPERATURE IS REACHED AFTER WELDING N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 4 1 ELECTROFUSION METHOD 75 63 2 DOUBLE WALL SECONDARY CONTAINED 90 ELBOW amp OR TEE UPP Parts Required Tee assembly 90 Elbow assembly 00 1 075 063 XXX As required 001 075 063 As required 49 110 075 SC 3 49 110 075 SC 2 08 110 63 SC L 03 110 63 SC 02 63 3 02 63 2 Tools amp Consumables Required Tee amp 90 Elbow assembly P CUT Pipe cutter SCR HAR Hand held scraper Acetone Clamp A Angled clamp UPP welder FOLLOW INSTAL
7. 10 to 45 C Accessories Included Description Code Primary UPP Welding Cable Secondary UPP Welding Cable UPP Bridging Lead red or yellow Operating Manual Available as spare parts Description Code Primary UPP Welding Cable Secondary UPP Welding Cable UPP Bridging Lead red or yellow Approval PetroTechnik EW BC C EW BC SC EW BC BL PetroTechnik EW BC C EW BC SC EW BC BL This machine has the safety mark of the Swiss Approval Board Furthermore the machine carries the CE mark for European conformity Guarantee This guarantee includes the repair or replacement of the machine provided it has been used as described in this manual The guarantee period is one year from the date of purchase MAINTENANCE AND SERVICE From a safety point of view all cables need to be checked each time before use The other parts of the machine are maintenance free To clean the frame and the display only use soapy water or other non acid and non scratching cleaning liquids To ensure a long lifetime of the machine it is recommended that the machine is returned for service on a regular basis for a check by the PetroTechnik service organisation Maximum service interval 3 years Repairs to the machine may only be carried out by PetroTechnik or by their authorised service centres FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 6 7 Pin Fusion chamber _
8. Select 3ft chamber depth setting otes Turn on unit wait for calibration process to end flashing coloured lights otes Vacuum pump will run until correct test vacuum is reached and the blue light will show otes Green light PASS O Red light FAIL O If failed check for leaks around tank chamber base joint using soapy water or leak detection spray Rectify any failures and repeat testing until pass is achieved The above described chamber has been checked for correct installation visually and by means of a vacuum test It has been found to be installed in accordance with UPP Systems installation guidelines and has been certified by The information given above is true and correct Signed by day month year FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 83 10 10 WATER HAMMER EFFECT A quick change of the flow inside a piping system can cause a sudden pressure increase over and above the nominal working pressure This water hammer effect can occur everv time a valve is opened closed or a pump is started shut off The formula for pressure variation AP is given by c Av gZ Where p is the densitv of water g is accelration due to gravitv Av is the fluid velocitv change and c is the velocitv of a shock wave in the pipe c depends on the elasticitv of the fluid in the pipe wall and for a freelv supported pipe is given bv E 8 P P
9. with no stress both inside and outside sump during welding process FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 43 5 12 INSTALLING UPP FRP ENTRY FITTING FLAT FACED SUMPS ONLY lllustrations show some white fittings and some black Installation method is the same for all Basic Kit Needed o FRP entry fitting 2x FRP caps order separately NOTE internal and external caps differ in size external caps are marked with an X o Nitrile Gloves not included o Cleaning solvent Trichloroethylene or Acetone not included Bondmaster E32 two parts sealant hardener o Applicator Gun Composite bonding paste U POL brand only UPOL Code UP0779 using other paste invalidates warranty Fitting wrench FEB 075 TOOL or FEB II0 TOOL shown right o 80 120 Grit abrasive paper Emery cloth Fitting wrench Installation Overview Internal cap FRP entry seal fixed flange i External cap FRP entrv seal 4 moveable flange Sump wall external face 44 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Pre Installation Check Before commencing on the installation of the UPP FRP entry fittings make sure that the sump to be worked on has been fullv vacuum tested lf a leak is detected the sump must be replaced or fixed prior to entry fitting installation Installation Me
10. 1 Construction of the welding machine EWS Electrofusion Welder 7 pin Weld cable connector welding cable ey t amp v ha 7 pin Primarv di welding cable Application The EWS is designed to automatically weld UPP Primary and Secondarv Containment electrofusion fittings Bridging cables Secondary welding cable Also using the white 7 welding leads the EW8 can be used to weld the UPP Fusion chamber riser to the chamber base It can be used in ambient temperatures between 15 and 45 C Only personnel fully trained in the use and installation of the UPP system should use this equipment Main Features UPP electrofusion fittings are welded using a constant current The EW8 automatically recognises the fitting when connected and applies the correct amount of energy for a successful weld The EW8 takes the ambient temperature into account when calculating the energy required to weld correctly lt must therefore be allowed to reach ambient temperature before use and must be at the same temperature as the fitting to be welded The temperature sensor is located at the rear of the unit on the right hand side The EW8 works on standard alternating current and either a mains connection or a generator can be used Generators must have a rated output of at least 4kW and power input must be between 98 and l2lvolts at 45 to 65Hz The EW8 has an on off button a weld start button and
11. FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 59 60 Error messages Information on the displav Input voltage too high alternating with Input voltage too low alternating with Input voltage variable alternating with Switch off welding kit Current below lower limit alternating with Switch off welding kit Current above upper limit alternating with Switch off welding kit Open secondarv circuit alternating with Switch off welding kit after switching on machine fault alternating with Repeat after one hour Box internal temp too high General hardware error Meaning The input voltage of the power source is too high and outside the tolerances of the welding unit The input voltage of the power source is too low and outside the tolerances of the welding unit The input voltage of the power source is fluctuating The voltage regulation of the power source inteferes with the electronics of the machine The resistance value of the connected fitting is too high and is outside the tolerances of the machine wrong element In Primary mode too many fittings connected in series Input voltage too low Regulation error in the electronics Regulation error in the electronics Loose contact in the welding circuit or a poor connection to fitting terminal pin The previous weld has been interrupted for one of the reasons
12. Stock Stock Stock Stock Stock Stock Request_ me El TT 1 Nozzl e mL 1 1 1 90 I m 2 Nozzles or 1 Regular Diesel sn NER WE T E 135 I m V 4 48 1 72 1 08 0 53 0 35 0 30 0 16 1 Hi Flow Diesel e e 7 3005 cam IX 21 s 200 iis 6 28 2 55 1 60 0 78 0 52 0 45 0 23 0 15 5 Nozzles or i 2 Regular Diesel 400 5 10 3 22 1 57 1 05 0 46 0 29 58 32 8 0 08 o v fep vo ep oe ravity Fi mpUSGamm 8 4 0 99 22 8 8 eei Mj sep we em P d Fill 29005 7 SM 4M 2287 awm E T 789 sz 9 2 J88 mm ml 4 TET T T T T T Lp wussami L Liquid fuel flows upto 1 m s 200 ft min are considered best for Suction systems Liquid fuel flows upto 3 m s 600 ft min are acceptable for Pressure pumped svstems Airflows upto 10 m s 2 000 ft min may be acceptable in Pressure Equalization tank venting pipes Liquid fuel flows over 3 5 m s 700 ft min may be prohibited in certain countries and should be selected only by experienced engineers Please consult PetroTechnik Ltd 86 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 12 FREQUENTLY ASKED QUESTIONS Q1 Is UPP pipe flexible or rigid A UPP pipe combines the best of both worlds it is flexible enough to coil and bend for e
13. three UPP fittings provided that The sum of the resistance values circled number on UPP fittings does not exceed 10 e The UPP fittings are connected to the EW8 in series using the bridging leads provided see photos A amp B You can ensure that you have connected the fittings correctly and that the welds are successful by checking that all of the connected fittings get warm and that all of the indicator pins are exposed at the end of the welding time It is not possible to do multiple welds on Secondary fittings These can be identified by their smaller terminal pins and require the use of the green welding cables Other Useful Tips Switch off the machine during breaks and at the end of the job The weld cycle can be stopped at any time by pressing the START STOP button This will generate an error code and you must wait for the fitting to cool before attempting to continue If you have any doubt about a welded joint UPP fittings can be welded again provided they are left to cool at ambient temperature for a minimum of one hour NEVER RE WELD A FITTING THAT IS STILL WARM Serious fire damage can occur and hot material may be ejected from the weld zone creating a burning hazard Additionally power conducting elements may become exposed creating an electrical shock hazard 66 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Fault Indicators When
14. 16 3 5 Welding secondary containment pipe and fittings 18 4 1 Secondary containment double wall 90 elbow amp Tee installation 19 4 2 Secondary containment termination 49 series installation 22 5 1 Installing a UPP polyethylene tank chamber 24 5 2 Installing a UPP fusion tank chamber 26 5 3 Installing a UPP polyethylene dispenser sump 30 5 4 Installing a UPP stabiliser bar 32 5 5 Installing a UPP mechanical entry seal Holesaw Seal compatibility chart 33 5 6 Installing a UPP electrofusion entry seal 305 308 34 5 7 UPP electrofusion seal applications 35 5 8 Attaching a flexible entry boot 36 5 9 Fusion welding UPP polyethylene duct pipe 3 5 10 Installing a UPP electrofusion entrv seal 302 040 39 5 11 Installing a UPP electrofusion entrv seal 303 series with integrated coupler 42 5 12 Installing a UPP electrofusion FRP entrv seal on a flat walled sump 24 5 13 Installing access cover 48 5 14 UL Pipe installation instructions 50 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION CONTENTS Section Title Page Modification and Repair of UPP Sites Scraping Tool Instructions 8 2 E7 Welder Operating Manual 58 8 3 EW8 Hand Held Welder Operating Manual 62 8 4 EW8 Welder Operating Manual I 10V 65 EFI Hand Held Welder Operating Manual Hydrostatic Method 9 2 UPP Pneumatic Method 74 9 3 UPP Pipe Rating 1 9 4 System Integrity Testing Instructions 76
15. CERTIFICATION 9 10 11 Install VR Stage 2 VR 2 o Exact requirements for VR2 vary Local legislative requirements will need to be taken into consideration for system design and materials used Care needs to be taken to ensure adequate fall back is achieved at all times from the furthest point to the final connection at either the tank chamber or VRIb manifold The VR 2 system is usually a manifolded mainline with branches attached The under pump dispenser connections must allow for a fall back to the main manifolding line Important Earthing of metal terminations o All UPP metal terminations in the fill box at the tank top and under the dispenser should be adequatelv earthed according to local electrical regulations See section 7 for more details Completion Records On completion of UPP installation it is recommended that an as constructed drawing is made detailing the exact location of all below ground lines lt is also recommended that in addition a photographic record is provided FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 3 ELECTROFUSION INSTRUCTION Organise all necessary tools and equipment on the job site prior to commencing the installation of pipe and fittings The basic installation tool set should alwavs include e UPP Electrofusion welder Pipe cutter Pipe Scraper Cleaning Solvent Straight
16. Clean with acetone Fit external cover cap over fitting spigots and press Totally fill external cover cap with U POL SMC firmly against external sump wall bonding paste as shown Clean and smooth excess resin with thumb around edge of cap Allow the bonding paste to cure before electrofusion refer to manufacturers instructions Once cured the entry seal can be tightness tested as required Repeat steps 9 12 for internal cover cap The UPP secondary containment pipe terminates on the outside of the sump wall where it is welded directly to the entry fitting spigot using a secondary welding coupler 02 75 SC 02 1 10 SC The primary pipe passes through the fitting and into the sump On the inside either an Electrofusion reducer or a termination boot can be used to seal off the interstitial space FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 47 48 5 13 UPP ACCESS COVER INSTALLATION The following instructions refer specifically to the 760x760mm 29 14 16 x 29 14 16 UPP access cover The principles of reinforcing the surrounding concrete and water runoff angles are maintained through the entire UPP covers range The large 950mm 37 diameter circular cover is slightly different as it has two springs inside the spring box however the principle of separating and refitting the cover from the frame is the same Installation instructions Sepa
17. NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 57 8 2 E7 WELDER OPERATING MANUAL WARNING UPP WELDING UNITS MUST NOT BE OPERATED IN ZONE 1 AREAS To weld inside zone 1 the units must be operated in zone 2 with only the welding cables extending into zone 1 CONSTRUCTION OF THE WELDING MACHINE LCD Displa SELECT key ENTER ke GENERAL Application The UPP welding machine EW E7 230V is designed for automatic welding of Primarv and Secondarv UPP welding sockets and Primary electrofusion fittings It is suitable for use with environment temperatures between 10 C and 45 Operating The Machine UPP welding sockets and electrofusion fittings are welded using a constant current The welding machine automatically applies the correct amount of energy for the fitting being welded The machine takes into account the ambient temperature when welding For this reason the machine should always be at the same ambient temperature as the fitting that is to be welded The temperature sensor is on the power cable inside the unit The machine has a back light LCD display with 2 lines of 16 characters each The user guided menu is available in 8 different languages During the welding process the following key value will be shown on the display Applied current Remaining welding time counting down Temperature sensor on Power Cable Bridging Leads Primary welding cable Power C
18. SAFETY UPP Systems should only be installed by a fully trained installer following the guidelines given by Petro Technik or any local authority Electrofusion Safety UPP welding units must never be oberated in zone 1 areas Zone 1 indicates that a flammable vapour would normally be expected during routine operation i e during fuel filling transfer area bound by a dispenser and sump or tank sump Zone 2 is an area where a flammable atmosphere would not normally exist and if it did would be of a short duration i e spillage maintenance i e The area immediately surrounding the dispenser and sump This Zone takes the shape of a cone from the top of the pump to the floor level The base of the cone has a radius of 2 44m 8ft The reason for the extension of the Zone at ground level is that fuel vapour is denser than air Outside of this area it is deemed that any vapours would have diluted enough to be harmless o UPP Welders can be operated in zone 2 and the welding cables and fittings are zone 1 rated Welding can be carried out in zone l areas as long as only the cables are in this area and the welding unit itself is placed in zone 2 UPP welding cables are easily long enough to allow this procedure Chemical Safety Where using chemicals such as Acetone during the installation of UPP systems products be sure to follow all safety guidelines given on the chemical containers themselves or on any
19. accompanying literature Confined Space Legislation O Some installation of UPP products mav occur in confined spaces where a lack of oxvgen and a concentration of toxic vapours is likelv to be experienced Such working conditions are dangerous and all local health and safety guidelines for working in such environments should be followed FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 9 NoTES 92 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION NoTES FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 93 uH PetroTechnik Australia C PetroTechnik do Brasil ay Petro Technik France z 4 Petro lechnik Inc m e P amp D Japan VE PetroTechnik China 61 3 95 50 18 74 55 3159 0909 33 69 21 41 41 46 8 767 86 34 201 871 7300 81 03 3297 7870 86 10 84475126 HEAD OFFICE PetroTechnik Ltd PetroTechnik House Olympus Close Whitehouse Industrial Estate Ipswich Suffolk IP1 5LN United Kingdom tel 44 1473 243 301 fax 44 0 1473 243301 email info petrotechnik com www petrotechnik com IN FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION IM V7a 07 09
20. all use co extruded blow moulded fuel tanks and have done so for many years to reduce weight and increase resistance to splitting in accidents It is unthinkable that any responsible oil companv with all their fuel research facilities could ever market a fuel which destroyed automobile fuel tanks Pipe manufacturers test their products to various international standards UL971 and Institute of Petroleum Pipework Specification are two such examples UL971 tests include todav s fuels such as premium leaded gasoline unleaded regular gasoline plus ASTM reference fuel C toluene and No 2 fuel oil These common fuels are supplemented by increased severity fuels such as 100 methanol 100 ethanol 50 methanol 50 reference fuel and 50 ethanol 50 reference fuel C Q20 There are other types of thermo fusion welding socket available Can use the UPP welding set with them A No UPP welding sets designated EW CU are specifically made for use with UPP Electrofusion sockets and fittings designed for Constant Current fusion Note UPP Constant Current models may appear to work with other manufacturer s constant voltage devices however there can be no guarantee that the correct design fusion temperature was reached for the required time or that ambient temperature compensation was effected 90 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 3
21. an LED displav showing the weld progress The LEDs can also show anv fault conditions that mav affect the weld OFF Switch Power on Indicator Temperature Sensor Fault indicator Weld progress LED s button Safety The EWS is designed for usage on construction sites and meets applicable European and International safety standards The machine should be handled with the care usually given to electrical equipment especially during transport The machine must only be used outside of hazardous areas zones 0 and 2 Each time it is used check the condition of the machine particularly the mains power cable If any damage is discovered contact the supplier immediately and do not use the machine Check the state of the welding cables before use and replace them if there is any doubt about their condition Always check that the power source is within the parameters shown above before using the EW8 Never lift or pull the machine by its power cable or the welding cables Never disconnect welding cables by pulling the cable always pull off the connectors Liability Restrictions All liabilities of the supplier are invalidated in the following cases The EW8 is used outside the indicated application area e Non UPP fittings or pipe are used The operator has not been trained to use the EW8 or the UPP system Operating instructions have not been observed FOLLOW INSTALLATION INSTRUCTION
22. an error has occurred during the weld cycle that will have an effect on the success of the joint the red warning LED on the right side of the display will light up Also one of the weld progress lights will light up at the same time to show what type of fault has occurred Error Led Fault Indicated Power supply failure during weld Stop button pressed during weld Input supply frequency out of range Ambient temperature out of range No output current open circuit Low output current High output current Meaning The power supply was off at sometime during the weld Supply frequency not between 45 and 65 Hz Temperature of the EW8 is not between 15 c and 45 Loose connection to terminal pin Loose contact in the welding circuit Faultv fitting Start button not depressed for long enough Resistance value of fitting is too high Too many fittings connected in series Primarv mode oniv Input voltage too low Regulation error in electronics Solution Check and rectify power supply Check plug connection Re weld fitting only after it is allowed to cool at ambient temperature for 60 minutes Re weld fitting only after it is allowed to cool at ambient temperature for 60 minutes Check and rectify generator output Check mains supply Allow EW8 and fitting to cool in the shade Waait for ambient temperature to return to range Make sure connectors are pushed firmly on to
23. and angled clamps e Permanent marker or Chinagraph pencil white yellow or red Tape measure Refer to the following sections for more detailed information on the above tooling FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 3 1 ELECTROFUSION OVERVIEW Cut pipe to required length allowing for correct Prepare the pipes and fittings for welding insertion depth into welding coupler using the scraping tools provided in the UPP installation box Clean scraped areas of pipe or fitting using a Measure and mark pipe to indicate correct lint free cloth moistened with Acetone insertion depth into fusion fitting Acetone removes oils fingerprints and moisture Clean bore of welding coupler with Acetone Assemble the joint and use clamp to hold in place Check insertion is up to the premarked depth indication Connect welder to clamped assembly andfollow a Check insertion depth mark welding unit instructions Ensure appropriate for movement welding cables are used b Check indicators are out c Allow jointto cool to ambient temperature At least 20 minutes should pass before any stresses are exerted upon the assembly 2 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 3 2 ELECTROFUSION PREPARATION DETAILS Cutting pipe Primary pipe single wall pipe o Primary pipe should only be cut usin
24. cable Apblication The EFI is designed to automatically weld UPP Primary and Secondary Containment electrofusion fittings Electrofusion Chambers and Large diameter 10 amp fittings This is achieved by using colour coded welding leads as shown below Weld Time 20C Seconds Size of Welding Pim mm Type Welding Current amps of Fitting Fusion Chamber Large Diameter 10 The EFI can be used in ambient temperatures between 15 and 45 C Only personnel fully trained and certified in the use and installation of the UPP system should use this equipment Power on Indicator 7 pin Weld cable 74 connector Fault indicator ON OFF Switch 8 side of unit Weld progress LED s START STOP button Temperature sensor Main Features UPP electrofusion fittings are welded using a constant current The automatically recognises the fitting when connected and applies the correct amount of energy for a successful weld The EFI takes the ambient temperature into account when calculating the energy required to weld correctly It must therefore be allowed to reach ambient temperature before use and must be at the same temperature as the fitting to be welded The temperature sensor is located adjacent to the power cable entry gland The EFI works on standard alternating current and either a mains connection or a generator can be used Generators must
25. in damage or leakage to the system invali dation of warranty or personal injury Note Minimum bend radius of pipes should not be exceeded during installation Pipe work is intended for use in normal soil applications be reported to the site operator 2 If leakage or damage to the pipework system is verified the problems are to be reported to the site operator The manufacture must subsequently be in formed at the contact address below 3 Under no circumstances should leak detection equipment or alarms be dis abled Repair and replacement of PetroTechnik s UPP pipework should be performed by a qualified person The method of repairing pipework can be found in bulletin UPP pipework repair and replacement installation procedure see www petrotechnik com downloads 52 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Use PetroTechnik UPP pipe work is designed for use underground and should not be used without consultation above ground On installation site owners should be advised of best practices such as keeping sumps free from debris and any fuel spillage Maintenance Prior to burial and use Petro Technik UPP pipe work systems should be tested for leak tightness This should be performed by a qualified person PetroTechnik recommended method for assessing leak tightness can be found in bulletin UPP pipework tightness testing procedure see www petrotec
26. mandrel on mark from outside of chamber drill hole e Clean with acetone Clean this entire surface with acetone e Clamp the seal to the chamber wall using the 303 clamp e Clean the seal s fusion ring area using acetone 42 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Mark pipe either side of entry seal quac mm vi Connect welder and weld using red orange Insert clean UPP pipe through seal and leads mark either side of the pipe where it passes Mark finish time of weld eg 1 00am through the seal DO NOT WELD PIPE Allow 20 minutes cooling before removing clamp Remove pipe and scrape the area of the pipe Clean entire length of pipe to be passed which will be welded to the entry fitting through fitting using acetone between the two marks Clean inside of entry fitting with acetone Complete all internal Primary amp Secondary if applicable assemblies Ensure there is no stress on the joints during Attach green welding leads to the or for 20 minutes after welding If necessary integrated coupler on the seal and weld disconnect the termination fitting to assure this mark finish time of the weld N e not fit termination to matching steelwork e Allow 20 minutes for cooling before anv of svstem prior to welding stress is placed upon the pipe or entrv e Ensure pipe and assembiv are fullv supported fitting
27. mentioned above The internal temperature of the machine has reached the critical value This can happen especiallv in the Primarv mode after a large number of welds Software or hardware of the machine has been damaged Machine switches off during welding N FOLLOW INSTALLATION INSTRUCTIONS Solution Check the connection Get the generator checked by a service centre and reset If necessary connect a load approx 500 Watt in parallel with the unit Check the connection Get the generator checked by a service centre and reset Fully unwind the extension cable to minimise resistance Get the generator checked by a service centre and reset If necessary connect a load of approximately 300 to 500 Watt in parallel with the machine Use only UPP welding sockets and electrofusion fittings and the correct welding cables Check the resistance values The sum must not exceed 10 See input voltage too low Send machine for service If this error occurs several times in succession the machine should be sent back to the supplier Switch off machine and switch on again after 5 seconds Check welding cable Push connectors firmly on to terminal pins of the fitting and push down to the stop Switch off the machine and switch it on again after 5 seconds Let the fitting cool down for at least one hour before a new full welding process is started with the same fitting By pressing the ENTER key the machine will be r
28. not been observed Always check that the power source is within the parameters shown above before using the EFI Improper or inadequate maintenance Misuse or any use not in accordance with the Never lift or pull the machine by its power cable or operating manual or good industrv practice the welding cables Never disconnect welding cables bv pulling the cable alwavs pull off the connectors Physical abuse of the product Improper site preparation or site maintenance Using the EF1 Ensure that the machine is positioned outside hazardous zones ATEX 0 l and 2 Allow the machine and fittings to reach the ambient temperature of the site Keep the machine out of direct sunlight and free of anv obstruction Make sure fittings and pipe have been prepared in accordance with UPP Installation instructions Step Action Information on Display Connect the required welding lead to the EFI Welder PRIMARY fittings RED ORANGE cable SECONDARY fittings GREEN cable FUSION CHAMBER WHITE cable IO AMP fittings BLACK cable Connect welding lead to the UPP fusion fitting s 2 None making sure connectors are firmly pushed onto pins 3 Connect the EFI Welder None to suitable 230V power supply 4 Switch ON All LEDs light in sequence then green Power LED remains on n Disconnect welding lead from fitting 100 LED and Power LED remains on FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER
29. pins show on the second time of welding the weld can be treated as successful but should be duly noted in case of any system leaks during tightness testing If the pins don t show perform a pressure test to check the joint JOINTS MUST NOT BE UNDER ANY STRESS DURING WELDING AND UNTIL AMBIENT TEMPERATURE IS REACHED AFTER WELDING FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Type Welding of Cable Colour Fitting Primary Secondary Fusion Chamber Large Diameter 10 Description Primary Welding Sockets Primary welding socket Primary welding socket Primary welding socket Primary welding socket Primary welding socket Primary welding socket Primary welding socket Size of E Current Part number 02 32 02 50 02 63 02 90 02 110 02 160 02 200 EIF Elbows 90 and 45 Tees and Reducers electrofusion elbow 90 electrofusion elbow 90 electrofusion elbow 90 electrofusion elbow 90 electrofusion elbow 45 electrofusion elbow 45 electrofusion elbow 45 electrofusion equal tee electrofusion equal tee electrofusion equal tee electrofusion equal tee electrofusion reducer electrofusion reducer electrofusion entry seal electrofusion entry seal electrofusion entry seal electrofusion entry seal 03 50EIF 03 63EIF 03 90EIF 03 1 IOEIF 04 63EIF 04 90EIF 04 1 IOEIF 08 50EIF 08 63EIF 08 90EIF 08 1 I OEIF
30. rest out of its coiled 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 You need at least two people 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 shingle 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 shingle Or the hook end can be used to your advantage when turning direction into a chamber or pump sump N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 2 SITE PREPARATION 2 1 GETTING STARTED Dispenser mounting frames offset fill and vent frames should be positioned first and firm
31. riser TEST 2 suMP CHAMBER RISER Uncouple the hose connection from the vacuum lid and remove the vacuum lid from the base section Join the riser to the base section as detailed in the relevant chamber installation instructions o Place new vacuum lid on riser Connect vacuum hoses to riser lid Re run test as in 4 1 test If the vacuum is not held then the chamber should be investigated using a leak detection liquid spray Possible leak points include Centre section seal Riser seals Vacuum lid seal Vacuum test pipe connections 76 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION TEST 3 AFTER INSTALLATION Test 2 can be carried out at any time during the life time of the site to ensure UPP product Safe vacuum level the sump chamber is still leak free ePetro Technik suggest the test is carried on an annual basis DC4830 SB x O FAULT DIAGNOSIS Fault Solution Vacuum level not reached or keeps on Check and listen for leaks in all DS3617 W asss falling the areas outlined in the two tests Rectify faults if found Vacuum still falling All areas on Check manway tank flange and chamber are leak tight fittings for leak path Contact tank manufacturer if leak is found for alternative sealing solutions Fault on test unit send to Petro Technik for repair Vacuum equipment running but no Check c
32. within a containment chamber or sump UPP pipe exceeding 12m 39ft should be laid in a series of large snake like curves and not in straight lines Uncoiled pipe when laid will settle in a natural curve Generally any thermal expansion will be accounted for by following our guidelines for spacing backfilling and ensuring runs are not dead straight Pipes should be separated from each other by at least the diameter of the largest pipe If pipe runs cross each other they must be separated by at least as much backfill material as the diameter of the largest pipe or protected using at least 25mm 1 of styrofoam If used above ground UPP pipe should be protected against mechanical climatic UV and fire damage by wrapping it in radiation or thermal shielding tape Additional supports and anchor points may also be required FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 2 3 INSTALLATION OVERVIEW 1 Site inspection Make sure the site is prepared and ready To install the UPP pipework system The site should be free contamination from previous fuel The tanks should be in place The bottom layer of bedding and backfill material should have been laid in the trenches The vent fill and pump dispenser frames sumps should be in their final position in relation to the finished forecourt surface level Ensure there is an adequate power supply for electrofu
33. 0 5 bar 7 psi 30 kPa 80mbar 2 6psi 8kPa 30 minutes flexible boot Safety notes O Extreme care must be taken when testing with pressurised gas as high levels of compression energy are generated in the pipe work system o Check that all pipe work is disconnected isolated from the underground storage tank prior to commencing pipe pressure testing General notes O Pressure gauge with test pressure at mid scale is recommended O Prior to commencing any pressure test always record the ambient temperature at the beginning and at the end of testing as temperature variations will affect gas pressure inside the pipe O Pressurise the pipe system to the specified test pressure and allow 15 minutes for the temperature within the pipe system to equalize with ambient temperature Recommended testing medias are compressed air nitrogen or helium Air shall be avoided if there is flammable atmosphere inside the piping When testing primary pipe always ensure that the secondary pipe is vented open to atmosphere This requirement is critical whenever the secondary containment pipe is filled with liquid o During testing it is preferable to wipe each joint with a soapy water mixture to check for signs of leakage particularly in the area where the primary pipe exits from the secondary containment if applicable FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Pressure Var
34. 9 5 Primary single wall Tightness Testing Report 78 9 6 Secondary double wall Tightness Testing Report 19 9 7 Duct containment pipe Tightness Testing Report 80 9 8 Dispenser Sump Report 81 UPP Tank Chamber Vacuum Test Fuel Flow Safety IN FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 1 TRANSPORT LOADING AND STORAGE i l TRANSIT ON LOADING AND OFF LOADING 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 See transit loading and storage and storage summary of rules on next page for details on what constitutes a damaged length of pipe o 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 6m 19 8 o Allow for a slight bending of the pipe crates when on and off loading Standard 19 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 th
35. ANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Ratings Description Application 001 063 050 XXXPS 1 001 075 063 XXXPS 2 UPP Extra integral Primary 001 110 090 5 3 Secondary pipe system 001 125 1 10 XXXPS 4 001 MESSA UPP Extra normal vent and vapor UGN NV amp VR 27 recoverv pipe svstem OI AR A AA UPP Extra normal vent and vapor UGN NV amp VR 3 recovery pipe system Bend Radius 63 50mm 63mm 63 75mm 90mm Pa 2 3 Warm weather 2ft7 3ft3 3fc3 9ft 0 Cold weather 07 53 5ft3 6ft5 tha 1 6m 1 6 5m Very cold weather 6ft3 7ft2 7ft2 23ft i 1 9m 2 2m 2 2m 7m Petro Technik UPP pipe work is for underground use only It is designed for use with petroleum products alcohols and alcohol gasoline mixtures including Motor Vehicle Fuels Concentrated Fuels High Blend Fuels Aviation and Marine Fuels UPP pipe work is designed for operation between 20 and 20 F UPP pipe work system complies with Underwriters Laboratories UL971 standard Storage Pipes should not be stored in direct sunlight Product intended to be stored outside in excess of 6 months should be covered Pipes should be kept away from sharp objects e Drops and impacts during transit and storage may cause damage and leaking e UPP pipes are supplied with distinctive color cap to prevent contamination These caps must be kept in place during storage e ndiv
36. C D d E t Where E is the water elasticity modulus E the pipe elastictiy modulus P the water density D the mean pipe diameter and the pipe wall thickness The following diagram shows the water hammer effect for various types of piping the fluid considered in this test is water Thanks to its flexibility UPP pipework is the pipe system with the lowest peak pressure Water hammer effect for various piping systems 84 IN FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 11 FuEL FLOW N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 85 UPP READY RECKONER FOR FLOWS TO 3 000 LITRES PER MINUTE 790 US GAL MIN Velocity of liquid fuel and vapour flow is given in m sec and ft min Nominal Pipe Size innes 1 1 2 83 4 4 4 8 25 0 40 DN50 DN80 DN100 DN100 DN150 DN200 UPP Pipe code 01 110 inani m 1 Pressure Rating _ Foethyene peso PESO Peso PERO FERU EEI00 PENU Wall Thickness min m 30 46 58 82 101 66 118 147 Internal Diameter mm 26 0 408 514 736 X 90 968 1364 1706 AM N NM m NE UE Availability Stock
37. CERTIFICATION 69 Multible Welds In Primary mode the EFI can simultaneously weld up to three UPP fittings provided that The sum of the resistance values circled number on UPP fittings does not exceed 10 The UPP fittings are connected to the EFI in series using the bridging leads provided see photos amp B You can ensure that you have connected the fittings correctly and that the welds are successful by checking that all of the connected fittings get warm and that all of the indicator pins are exposed at the end of the welding time It is sometimes possible to do multiple welds on Secondary fittings These can be identified by their smaller terminal pins and require the use of the green welding cables Technical Bulletin T B29 gives details of Secondary Fittings that can have multiple welds Other Useful Tips Switch off the machine during breaks and at the end of the job The weld cycle can be stopped at any time by pressing the START STOP button This will generate an error code and you must wait for the fitting to cool before attempting to continue If you have any doubt about a welded joint UPP fittings can be welded again provided they are left to cool at ambient temperature for a minimum of one hour NEVER RE WELD A FITTING THAT IS STILL WARM Serious fire damage can occur and hot material mav be ejected from the weld zone creating a burning hazard Additionallv power conducting elements mav become ex
38. ER Welding starts bv pressing the ENTER Welding in prog key 4 0 168 sec The display shows the current Amps and the actual welding time in seconds corrected for ambient temperature counting down to 0 After approximately 3 seconds Unplug connectors Entrylaction by operator Information on display Welding completed Switch on the machine and wait for the information indicated on the right to appear on the display Connect No welding cables to be connected welding element during the set up operation Press the SELECT key and the ENTER key together to enter languages set up gt FR IT mode NL ES SE PL Choose the desired language by pressing the SELECT key several times GB DE FRJIT NL ES SE PL Complete this operation by pressing the ENTER key Raccodare The language of vour choice appears elemento Entrv action bv operator Information on display Switch on the machine and wait for the information indicated on the right to Connect appear on the display welding element Hold down the SELECT key 234V Input voltage Mode Primary or Secondary depending on which cable is connected 234V Mode 185s 185 Actual welding time l 28 C 21 I Internal temperature of the machine O Ambient temperature Press the SELECT key for at least IO seconds to show the following information Good 756 Faulty 11 Good number of successful welds Faulty number of faulty welds
39. LATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 9 Method Cut Co axial pipes to required length Trim or slide Secondary pipes back 40mm I Prepare Primary and Secondary pipe using hand scraper Clean secondary pipe with acetone at least 200mm Secondary pipe must be scraped all the way up to from end 5 from its end Pre clean Secondary pipe 600mm 2ft from end Ensure Elbow or Tee Primary spigots measure Slide reducer along Secondary pipe small end first 30mm I and cut to length if required Prepare Primary spigots of tee elbow with hand scraper Prepare Secondary spigots of tee elbow with hand scraper Clean Primary spigots of tee elbow with acetone Clean Secondary spigots of tee elbow with acetone 20 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION e Clean primary welding coupler 02 63 using acetone Insert Primary pipe into welding couplers ensure Fit couplers to primary Tee Elbow spigots pipe is fully inserted Before welding check that the Secondary Containment reducer is fitted in correct location over scraped zone of secondary pipe Weld Primary couplers Once weld is complete allow to cool for at least 30 minutes If required leave Secondary Containment unwelded to allow primary pressure tests to be carried out Sl
40. Lift the toolpost and lock it in the upper position with the bodv thumbscrew e Retain the cutting tool spring bv turning the thumbscrew on the top of the toolpost until the vee on its underside is disengaged from its locating slot f Hold the handtool depress and hold the release button on the side of the handtool Insert the pipe and mandrel into the bodv of the handtool and line up the cutter about 5mm further on the pipe than the mark Let out the release button and move the hand tool slightly until a click is heard the feedscrew is now engaged g Release the body thumbscrew and lower the toolpost until the toolpoint is in contact with the pipe surface Re tighten the body thumbscrew h Load the toolpoint by turning the toolpost thumbscrew until the vee under the thumbscrew is located in the slot i The tool is now set and ready to operate Simply rotate the body in a clockwise direction with the operating handle When the body has screwed fully back on to the mandrel the scrape is complete j Unload the toolpoint by disengaging the vee Remove the mandrel from the pipe ensuring that the prepared area is not touched or allowed to come into contact with any contaminating material k The mandrel may now be removed from the handtool by depressing the release button and separating the two items When finished return both items to the storage box I Re mark final insertion depth FOLLOW INSTALLATION INSTRUCTIONS
41. Petrolechnik protecting vour liquid assets g 27 SN 93 3 ZZ Pt zo A Installation Manual n 3 UPP SYSTEMS UPP Installation Manual INTRODUCTION At the heart of the UPP system is a simple and highly efficient installation procedure The Electrofusion system and installation procedure is explained detail on the following pages It is of paramount importance that these instructions are adhered to failure to do so can result in the removal of certified Installer status All pipes must be cut square All pipes and spigoted fittings must be scraped e All pipes fittings and welding sockets must be cleaned with acetone e All joints should have the pipe inserted into the electrofusion fitting ensuring that the marked insertion depth is reached e joints must not be under any stress during welding or until ambient temperature is reached after welding FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION UPP Installation Manual CONTENTS Section Title Page 1 1 Transit on loading and off loading 6 1 2 Storage on site 6 1 3 Summary of rules 7 1 4 Uncoiling Pipe 7 2 1 Getting started 8 2 2 Digging trenches and bedding 8 2 3 Installation Overview 9 3 1 Electrofusion overview 12 3 2 Electrofusion preparation details 13 3 3 Welding overview 16 3 4 Welding primary pipe and fittings
42. S NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 65 e Unauthorised repairs or maintenance have been carried out The EW8 has been used outside of its technical specification Safety instructions have not been observed Using the EW8 110V Ensure that the machine is positioned outside hazardous zones 0 l and 2 Allow the machine and fittings to reach the ambient temperature of the site Keep the machine out of direct sunlight and free of any obstruction Make sure fittings and pipe have been prepared in accordance with UPP Installation instructions Action Information on Display Connect the EW8 Welder None to a 0v power supply Connect the required weld ing lead to the EW8 Welder PRIMARY fittings RED ORANGE lead SECONDARY fittings GREEN lead All LEDs light in sequence then green Power LED remains on Connect welding lead to the UPP fusion fitting s making Power LED on sure connectors are firmly pushed onto pins First weld light comes on then successive LEDs light up until green 100 LED is lit showing weld is complete Disconnect welding lead 100 LED and Power from fitting LED remains on All LEDs light in sequence then green power LED remains on Switch ON Press orange START button until first weld light illuminates Reset for next weld by holding START button for 3 seconds Multiple Welds In Primary mode the EW8 can simultaneously weld up to
43. STALLER CERTIFICATION 55 7 ELECTROSTATIC SAFETY UPP metal termination fittings in the fill box at the tank top and under the dispenser should be adequately earthed according to local electrical regulations If in doubt the resistance of grounding should be 2100 lt I Earthing cables should be plastic covered copper conductors of at least 4mm cross sectional area and should be connected to an exclusive earth electrode Note The metal fittings at the tank manhole should be at equal potential so additional cables may be required to interconnect the metal fittings The drawings below show how to ground various types of UPP metal termination fittings UPP 11 series thermofused threaded termination UPP 05 06 07 series thermofused flanged termination showing optional coupling flanges requires earthing strap requires ring terminal pe UPP II series mechanical termination UPP 12 series mechanical wipex mechanical termination requires earthing strap requires ring terminal 56 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 8 WELDING 8 1 ScRAPING TooL INSTRUCTIONS CODE SCR K I Operation Method a Mark on the pipe the length to be scraped b Select the correct internal pipe mandrel and push it into the bore of the pipe c Hold the handtool and release the toolpost by loosening the body thumbscrew d
44. The information given above is true and correct Signed by dav month vear N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 8 9 9 UPP TANK CHAMBER VACUUM TEST PART 1 2 Site Name Chamber installed on Tank Compartment No Once the chamber base has been bolted to the tank flange using sealing gasket on flange and backing plates the joint should be tested to ensure integritv This can be done at the Cookson and Zinn factory before the tank is shipped to site or it can be done onssite Check hoses to ensure thev are in good condition and connect to test unit and lid Ensure unit power switch is in 0 position and connect power lead to power supply Select 3ft chamber depth setting Nm o o Turn on unit wait for calibration process to end flashing coloured lights 8 Note Vacuum pump will run until correct test vacuum is reached and the blue light will show FO Notes Green light PASS O Red light FAIL O If failed check for leaks around tank chamber base joint using soapy water or leak detection spray Rectify any failures and repeat testing until pass is achieved Pipe up the UPP product fill vent vapour recovery siphon and electrical conduit lines into the chamber base as appropriate using UPP electrofusion or mechanical entry seals Once complete repeat the test to ensure that all the entry seals are leak tight Ensure vacuum Id gaskets and ch
45. Tighten up all the bolts in turn and complete one final tightening check 11 Select the correct size Jubilee Clip Hose Clamp and fit to the seal before passing pipe through The 63mm 2 pipe uses supplied Jubilee Clamp Hose Clamp and 75mm 2 double wall pipe requires an additional Jubilee Clamp Hose Clamp that needs to be ordered separately FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 33 5 6 INSTALLING A UPP ELECTROFUSION ENTRY SEAL 305 308 sERIES Cut hole in sump wall Scrape around fusion area Use 140mm 5 hole saw for 305 fitting e Use scraper provided in UPP tool kit e tara with Acetone e Clean fusion area on seal with Acetone e Removes oils fingerprints and moisture Test tightness against sump wall all around e Clamp seal to sump the seal using a piece of card e Cross the clamp bars for best results i Ensures surfaces are In close contact Re align seal with sump until all gaps are removed Connect welder and weld using red orange leads mark time of weld eg I 1 00am Allow joint to cool to ambient temperature approximately 20 minutes 34 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 5 7 UPP ELECTROFUSION SEAL APPLICATIONS Once the fusion seal has been successfully welded onto the sump it must be left to cool stress fre
46. able The welding machine operates on standard alternating current Normal fixed power connections can be used or an electrically stable portable generator with a rated output of at least 4 kW The power input must be maintained between the following values 230V 15 195 5 V 264 5 V and 45 65 Hz The input voltage will be automatically measured by the machine and can be shown on the display by keeping the SELECT key pressed down At the same time the following information will be shown Welding mode Primary Mode Primry or Secondary Mode Secndr depending on which welding cable is connected Actual welding time depending on the ambient temperature Measured temperatures Temperature measured inside the machine O Ambient temperature measured by the sensor temperature N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION OPERATING INSTRUCTIONS Welding Step Entrv action bv operator Information on display Switch the machine on using the ON OFF switch on the side of the main PetroTechnik panel Primary Mode After approximately 5 seconds Connect welding element The welding mode is displayed depending on the which welding cable is connected the display shows Red Orange cable Primary Mode Green cable Secondary Mode Push the connectors firmly on to the terminal pins of the fitting and push Welding start with down to the stop ENT
47. ackaging until ready for use to prevent any contamination or oxidisation 6 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 1 3 SUMMARY OF RULES Always Never Store pipes on flat firm level ground Expose pipe or fittings to prolonged able to withstand the weight of pipes direct sunlight or excessive and lifting equipment temperatures Keep pipe and fittings well away from Throw drop drag or roll individual sharp objects such as flints and other pipes bundles or fittings as this can site debris cause damage or subsequent leakage O Use wide non metallic slings when O Use metal slings or chains when lifting pipe handling pipe O Exercise special care when handling O Stack pipe more than three coils or pipe in wet or frosty conditions Use three bundles high gloves for additional grip O Keep protective packaging intact until pipe or fittings are required for use Keep both pipe and fittings out of direct sunlight or intense heat until ready to use Ensure lifting and storage points are evenly spaced O Reject pipe if surface damage is excessive Minor abrasions can be ignored O Light abrasion handling damage limited to a single area between a set of tapes less than 5mm 3 16 wide is permitted 1 4 UNCOILING PIPE Take care when releasing pipe from the coil as the pipe can straighten with considerable force It is also important to let the pipe
48. afetv legislation should alwavs be adhered to The following checklist gives a step by step guide to ensuring that the modification is carried out in the safest possible manner However relevant local health and safety regulations should take precedence over the advice given here Method 1 Switch off shut down submersible pump and dispensers in works area 2 Tag out remove fuses or isolating breaker to pumps and dispensers 3 Prepare to empty product into an approved sealable containment vessel 4 Operate the hose of the product dispenser closest to the underground storage tank to release pipeline pressure and empty product into container Continue this process until no further liquid petroleum is discharged 5 Check the sump where the repair is to be made with an O meter and record the presence of sufficient oxygen 21 O before any personnel enter the sump Air exchange if necessary 6 Isolate the submersible pump by closing the isolation valve ball valve 7 All secondary containment lines will need to have their test boots removed 8 Break disconnect the product supply line at the tank sump allowing for any residual petroleum liquid contained within the product line to flow out into the approved sealable containment vessel 9 Open the shear valve access ports of the affected lines to allow the petroleum liquid to drain down to the tank sump 10 Shut close all the shear valve access ports once no further fuel flows ou
49. amber base fangs are and fe from dre orders El Notes Properly position vacuum Kd on chamber ass fange EE noe Ensure vacuum eee unie is placed outside one Check hoses to ensure they are in good conden and connect to wast unitand id m Notes Ensure unit power switch postion and connect power tead ta power supply El Notes Select chamber depthsettng Turn on unit va forebrain process to end Washing coloured gs H Nores pump wil run uni correct test vacuum is reached and the ue ighe wil show Noter Green light PASS O Red light FAIL O If failed check for leaks around tank chamber base joint using soapy water or leak detection spray Rectify any failures and repeat testing until pass is achieved 82 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 9 9 UPP TANK CHAMBER VACUUM TEST PART 2 2 Weld electrofusion chamber riser to base section Once complete conduct this test to ensure the joint is leak tight Ensure vacuum lid gaskets and chamber base flange are clean and free from dirt or debris otes Properly position vacuum lid on chamber base flange otes Ensure vacuum test kit unit is placed outside zone 2 otes otes Check hoses to ensure they are in good condition and connect to test unit and lid Ensure unit power switch is in 0 position and connect power lead to power supply otes
50. ar over test period VACUUM TEST 500milibar Test time Start Time End Time PASS at least 30 minutes Start temperature End Temperature C O FAIL The above described pipe run has been checked for correct installation visually and by means of an integrity test It has been found to be installed in accordance with the UPP Systems installation guidelines and has been certified by The information given above is true and correct Signed by day month year N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 9 6 SECONDARY DOUBLE WALL TIGHTNESS TEST REPORT Suction L Pressure Fill DIVent LI Syphon VR Ib LIVR2 LI Electircal Conduit FROM TO Secondarv Pipe Colour LI Green LI Black LI Black with Green Stripes Select Secondarv Pipe Size highlight or circle relevant column Pear me me m Number of compression joins in lines Notes Number of welded joints in ine Nos _ Welding times marked on alljoints Noe _ Type of Line PRESSURE TEST Test Pressure 1bar for welded SC boots 500milibar for flexible SC boots Test Medium Air Inert Gas Nitrogen Test time Start Time End Time at least hour Start temperature C End Temperature Pressure drop mbar over test period VACUUM TEST 500millibar for welded SC boots BOmillibar for flexible SC boots Test
51. ase of installation but rigid enough to be used for vapour recovery VR lines Q2 Within which ambient temperature range can electrofusion welding can be carried out A From 10 C to 45 C 14 F to 1 13 F Q3 What are the recommended backfill materials for bedding and burial of UPP pipe and fittings A See section 2 2 of this manual for bedding and backfill instructions Q4 What is the minimum burial depth recommended for UPP pipe and fittings 300mm 1 2 Q5 Can point loading damage affect pipes that cross each other below ground A Yes crossing pipes should be protected by a minimum of 5 cm 2 of compacted backfill or 2 5 cm 1 of protective Styrofoam 5 it important to align pipe and fittings both during welding and cooling process A Yes it is very important to align pipe and fittings both during welding and cooling process and ensure there are no external stresses or loading acting on weld assemblies Q7 In the event of a power shortage can electrofusion welding be restarted A Yes but the assembly must have completely cooled down to ambient temperature before electrofusion is restarted Q8 Whatare the differences between the UPP pipe system versus the braided flexible piping systems A UPP is different from braided flexible piping systems in that the polyethylene layer that provides the mechanical strength of the system is a pressure grade Polyethylene widely used through out the world for the c
52. ates 100 LED and Power LED remains on All LEDs light in sequence then green power LED remains on Disconnect welding lead from fitting ALWAYS Reset for next weld by holding START button for 3 seconds Multiple Welds In Primary mode the EWS can simultaneously weld up to three UPP fittings provided that The sum of the resistance values circled number on UPP fittings does not exceed 10 The UPP fittings are connected to the EW8 in series using the bridging leads provided see photos A amp B You can ensure that you have connected the fittings correctly and that the welds are successful by checking that all of the connected fittings get warm and that all of the indicator pins are exposed at the end of the welding time It is not possible to do multiple welds on Secondary fittings These can be identified by their smaller terminal pins and require the use of the green welding cables Other Useful Tips Switch off the machine during breaks and at the end of the job The weld cycle can be stopped at any time by pressing the START STOP button This will generate an error code and you must wait for the fitting to cool before attempting to continue If you have any doubt about a welded joint UPP fittings can be welded again provided they are left to cool to ambient temperature NEVER RE WELD A FITTING THAT IS STILL WARM Serious fire damage can occur and hot material may be ejected from the weld zone c
53. b VR Ib If possible and applicable lay vent lines into the same trench as the offset fill lines o If vents are remote from offset fill lines a separate VRI b line is required to connect the vent stack to the fill point The most direct route should be used Installation of vents should commence at the tank end again allowing for appropriate fall backs for the laying of pipe between the vent stack and the tank chamber VR Ib should be laid between the vent stack and the fill point with no fall back i e completely horizontal 9 Install product lines Depending on whether it is a suction or pressure system you will need to consider carefully the appropriate fall backs from the furthest pump dispenser sump to the tank farm If it is a pressure system for example the pump dispenser sump penetrations at the furthest point will be higher than those nearest to the tank farm Laying of pipe should again commence from the tank farm 10 Secondary Containment SC t is common practice for SC systems to be used with the pipework for pressure systems o The laying and fall back considerations are identical to Primary pipe installations Care must be taken during assembly that sufficient room is available not only for terminations and the installation of fittings on Primary lines but also for fittings to terminate SC pipe FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER
54. cuum test kit unit is placed outside zone 2 Check hoses to ensure they are in good condition and connect to test unit and lid Ensure unit power switch is in 0 position and connect power lead to power supply Select correct depth setting for local groundwater conditions Turn on unit wait for calibration process to end flashing coloured lights Vacuum pump will run until correct test vacuum is reached and the blue light will show Green light PASS 1 Red light FAIL O If failed check for leaks around pipe entry seals using soapy water or leak detection spray Rectify any failures and repeat testing until pass is achieved Once the dispenser sump has been positioned correctly anchored into position and all pipework is installed using electrofusion or mechanical entry seals a hydrostatic test can be carried out to ensure the integrity of all pipe penetrations Ensure all pipe penetrations are free from bedding or backfill material or any other obstruction Mark the water evel inside wi a marker pen or chimagraph pencil amine the pipe entry seals fr signs of water W e rn mnan PASS FAIL L Rectify any failures and repeat testing until pass is achieved The above described sump has been checked for correct installation visually and by means of a vacuum or hydrostatic test It has been found to be installed in accordance with UPP Systems installation guidelines and has been certified by
55. e e Mark pipe inside the sump against the seal pipe end for 30mm 1 2 towards the spigot end of the pipe Clean reducer U e Clean from end of pipe to 100mm 4 past the scraped zone with acetone e Scrape the spigot of the seal inside the sump e Clean inside of the seal with acetone e Clean inside of 49 series reducer with acetone e Slide pipe through 302 040 seal e Ensure 49 040 032 reducer is slid onto the primarv pipe as it passes into sump large end first e Slide 49 040 032 reducer onto spigot of the 302 040 seal e Weld 49 040 032 to seal spigot and primarv pipe using green welding cable e Allow 20 minutes for the weld to cool before putting anv stress on the assemblv Complete the termination of the primary pipe to the tank top dispenser vent stack or fill point 40 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Cut primary pipe N e Cut Secondary pipe at outer seal spigot Slide primary pipe through the seal and cut at final termination position 3 e Clean from end of primary pipe to 100mm past the scraped zone with acetone Clean scraped end of Secondary Containment pipe with acetone Slide 02 40 SC onto outer seal spigot Slide Secondary pipe into other side of 02 40 SC Weld using green welding leads allow 20 minutes cooling time after welding Complete the termination of the primary pipe to the tank
56. e for 20 minutes Depending on the specification of the site there are three options to take from this point onwards o 5 7 a Fusion weld a polyethylene boot o 3 l4 b Attach a flexible entry boot 3 14 Fusion weld a UPP polyethylene duct pipe line 5 7 FUSION WELDING A POLYETHYLENE BOOT Scrape the fusion seal spigot using UPP hand Scrape the 125mm 5 end of the boot using scraper cloth UPP hand scraper 02 125 SC welding coupler Clean the scraped spigot the end of the boot and Attach the boot to the spigot of the entry seal the inside of a 02 125 SC welding coupler with using the welding coupler Ensure there are no cleaning solvent Acetone recommended external stresses acting on the assembly Weld the coupler using the green secondary containment welding leads Leave to cool for 20 minutes FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 35 5 8 ATTACHING A FLEXIBLE ENTRY BOOT Trim the flexible boot to the desired pipe Slide the boot over the seal lip and tighten on diameter with a jubilee clip Slide the pipe through the seal and the opening indie bect ancl ami iv dis ersi Tighten the boot on to the pipe using another jubilee clip 36 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 5 9 FUSION WELDING UPP POLYETHYLENE DUCT PIPE The duct pipe is 10mm 4 and so
57. e chamber follow these instructions o Make sure the vacuum lid gaskets and chamber base flange are clean and free from dirt and debris Place the vacuum lid on to the chamber base with gasket against flange all around Place unit outside zone 2 but as close to the chamber as possible and within 4m of electrical power source Connect the hoses between the lid and the test unit checking hose ends are in good condition o Make sure on off switch is in 0 position and connect the lead from the test unit to the power supply Measure ground water depth X as shown in diagram Select chamber depth setting to correspond with ground water depth X acting on chamber Turn on power unit will go through calibration process with coloured lights flashing When calibration is complete vacuum pump will run until the correct test vacuum is reached Then pump will stop and the blue light will be on When the vacuum has been held for the required test time the green light will illuminate and the chamber can be considered leak tight If the vacuum is not held then the red light will illuminate and the chamber should be investigated using a leak detection liquid spray Possible leak points include Pipe seal interface electrofusion chamber interface e Tank sump chamber mounting flange 7 Conduit seals Vacuum lid seal Vacuum test pipe connections Once the chamber base is leak tight move on to check the
58. e forks should be covered to avoid damage to the coiled pipe 1 2 STORAGE ON SITE Individual pipe lengths should be stacked not more than 1m high 3ft with the bottom layer fully restrained by wedges Where possible the bottom layer of pipes should be laid on timber battens at 1m 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 that 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 coloured end caps to prevent entry of any contamination These end caps must be kept in place during storage o 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 p
59. e welding Position 49 Series fitting into final position over end Allow joint to cool to ambient temperature of Secondary pipe ensuring position markings can be approximately 20 minutes before putting any observed stress on the fitting FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 73 24 5 1 INSTALLING A UPP POLYETHYLENE TANK CHAMBER Installing chamber base o Check the size and shape of the tank access shaft flange o Mark base of the UPP chamber for cutting to fit access shaft flange witness lines show common flange style photol Use a round holesaw to cut pilot holes in all four corners of the base This is important as corners which are not radiused by a circular hole saw and are cut square may cause the polyethylene to crack photo 2 Use a hand saw or jigsaw to cut out the base along marked lines starting from one corner and moving to the next photo 3 Remove cut out O Mark bolt hole positions on sump base and drill o Cut straight lengths of gasket material from the roll to fit over tank access shaft flange photo 4 o Clean tank access flange using a cleaning solvent Acetone recommended Remove backing layer from sticky side of gasket and stick the gasket to the flange Corners should be square and butted together to create a watertight seal Bolt chamber to tank access shaft flange The bolts will easily push through gasket ma
60. erforms at 400 It may be pressurised as part of a Leak Detection system 017 Because UPP is semi rigid what Bend Radius is possible during installation A This is largelv temperature debendent but in general you may use these values for UPP Coils 80 cm m 5 m 2 7 3ft 3 4ft 11 n a 40 cm l 6 m 2 5 m n a 4ft 7 5ft 3 8ft 2 n a 190 2 2 3 5 6ft3 7ft 2 1 1ft6 n a Straight lengths 1 5m 2m 3m 4m 4ft 11 6ft 7 9ft 10 1 3ft 2 3m 3m 5m 6m 9ft 10 9ft 10 1 6ft 5 19 8 4m 4m 7m 8m 13f 2 13ft 2 23ft 26ft3 For smaller radii use the UPP range of elbows and formed bends Bend radius m m 3m 4m 3ft 3 3ft 3 9ft 10 13ft 2 l 6m l 6m bm 6 ma 5ft 3 5ft 3 16ft 5 19 8 2 2 m 2 2 m 7m 8m 7ft 2 7ft 2 23ft 26ft 3 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 89 Q18 What Products apart from petroleum products can be carried by UPP Extra lined pipe A UPP Extra bolyethylene bibe with its bolyamide lining is generally suitable for many hydrocarbon products including Ethanol Iso Octane Methanol MTBE and Toluene Remember to refer to Petrolechnik Technical Department for specific concentrations and temperatures 019 How do l know the pipe install today will resist fuel changes in the future A Vehicle manufacturers nearly
61. eset for welding Switch off the machine and let it cool down in the shade for a few minutes Sent the machine for service and repair at Petro Technik Wrong power supply incorrect input voltage electrical instability Resolve temporary or permanent interruption Other useful tips Positioning the machine Always place the welding machine in the same ambient temperature to the fittings to be welded The rear of the machine needs to be free and it should not be directly exposed to the sun The welding machine should only be operated in areas outside zones 0 l and 2 Switch off the machine during breaks in the work and at the end of the job Connectors The connectors at the end of the welding cables need to be pushed firmly onto the UPP welding sockets and electrofusion fittings down to the stop Disconnecting the cable from the UPP welding sockets and electrofusion fittings must not be done by pulling the cable Repeating a weld Adding extra energy after the welding process immediate repetition of a weld by disobeying the repetition lock and without allowing the fitting to cool down is strictly prohibited Overheating of the fitting can damage the components and cause hot material to be ejected from the weld zone causing severe burns of the skin In addition power conducting elements could become touchable In case of doubt about the weld UPP welding sockets and electrofusion fittings can be welded again afte
62. ework is disconnected isolated from the underground storage tank prior to commencing pipe pressure testing Tightness testing on operational sites O Special precautions must be taken when testing on operational pipework or pipework connected to any tank or pipework that has previously contained petroleum to avoid the possibility of explosion hazards from vapour or air mixtures An inert gas normally nitrogen must be used for pressurisation instead of air Any water used must be disposed of either through the oil water separator by a specialist contractor as contaminated waste In all other aspects the pressure testing requirements are as detailed above 9 1 HYDROSTATIC METHOD Equipment needed Pump rated for more than 10 bar 145 psig Hydrofor 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 Ibar 159 psig Conditioning Phase Fill the pipe work system to be tested with water making sure that any air relief valves are opened while filling the pipe work o After filling the pipe work wait hour for the temperature to stabilize Pressurise the system to 10 bar 145 psi 1000 kPa 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
63. g the appropriate UPP pipe cutter tool and never using a hand saw The UPP cutting tool gives 100 straight cuts everv time and no burring ensuring that the cut ends fit flush into anv welding couplers or fittings o Thereare four different pipe cutters available for varving pipe diameters Tool Pipe Diameter mm Pipe Diameter inches PCUT SMALL 32 50 I l PCUT 50 110 5 4 PCUT MED 110 160 4 6 Secondary containment pibe double wall pipe O Secondary containment pipe should be cut in exactly the same way as primary pipe using the UPP pipe cutting tools When cutting coaxial pipe it is possible to cut through both pipe layers in one go Be careful of this if you want your primary pipe length longer than the secondary sheath inside sumps and chambers etc Duct pibe t is not possible to cut UPP corrugated duct pipe using the UPP pipe cutting tools A hand saw should be used to cut the duct using the corrugations as guides to help create a clean straight cut FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 13 ScRAPING It is imperative that the scraping of pipes and fittings is carried out exactly as described here to remove the layer of oxidised material that builds up on the pipe when it is exposed to air This oxidised layer hinders the quality of the weld and must be removed NEVER under any circumstance use sand paper Primary pipe single wall pipe Prima
64. have a rated output of at least 4kVV and power input must be between 98 and 12 l volts at 45 to 65Hz The EFI has an on off button a weld start button and an LED display showing the weld progress The LEDs can also show any fault conditions that may affect the weld FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Safety Liability Restrictions The EFI is designed for usage on construction sites All liabilities of the supplier are invalidated in the and meets applicable European and International safety following cases standards The machine should be handled with the care usually given to electrical equipment especially during transport The EFI is used outside the indicated application area i i d The machine must only be used outside of hazardous Non UPP fittings or pipe are use areas zones 0 l and 2 The operator has not been trained to use the EFI or Each time it is used check the condition of the the UPP system machine particularly the mains power cable If any damage is discovered contact the supplier immediately Unauthorised repairs maintenance or modifications and do not use the machine have been carried out Operating instructions have not been observed Check the state of the welding cables before use The EFI has been used outside of its technical and replace them if there is any doubt about their specification condition Safety instructions have
65. hnik com downloads Following installation site owners should be advised of any information concerning inspection periods and leak testing requirements Problems In the event of a leakage the following options should be taken If leakage or damage is detected in any part of the system the problems are to be reported to the site operator 2 If leakage or damage to the pipework system is verified the problems are to be reported to the site operator The manufacture must subsequently be informed at the contact address below 3 Under no circumstances should leak detection equipment or alarms be disabled Repair and replacement of PetroTechnik s UPP pipework should be performed by a qualified person The method of repairing pipework can be found in bulletin UPP pipework repair and replacement installation procedure see www petrotechnik com downloads FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 53 6 1 MODIFICATION AND REPAIR UPP SITES This section is designed as an advisorv guideline on the how to modifv or repair an existing UPP site The site should be prepared in advance to either close or restrict access to the work area and all equipment should be checked to ensure that it is in operational condition During anv modification or repair work to UPP pipework the safetv of on site personnel is paramount and all national regional and local health and s
66. iations net pressure variation after temperature compensation of 2 is typically considered acceptable to take into account eventual micro leakage of testing devices The test parameters are given below Initital Temperature variation AT C Pressure 1251 1120 ie en or fo vo io v vs Initital Temperature variation AT F Pressure psi 30 20 0 20 3 9 3 UPP PiPE RATINGS IP Rating Unlined 50 63 90mm 1 5 2 3 IO bar 145 Psi Lined 32 50 63 90 110 160mm 1 1 5 2 3 4 6 Mx Lined 10mm fill pipe 4 fill pipe 6 bar 87 Psi Terminated by fusion fitting 4 bar 58 Psi Terminated by flexible boot 0 5 bar 7 Psi 05 bar 7 Ps see UL installation instruction sheet for UL ratings FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 75 9 4 SYSTEM INTEGRITY TESTING INSTRUCTIONS VTU 115V amp VTU 230V Models The UPP System Integritv Testing Kit is simple to use and allows for precise testing of the tightness of underground tank sump and chambers and dispenser sumps by using a vacuum The versatile unit can also be used to test double wall dispenser and tank sumps spill buckets containers and the interstitial space in secondary contained double wall pipe systems TEST suMP CHAMBER BASE After installing the tank chamber seals and pipe runs test the base for air leaks To test th
67. ide reducers into place ensure full insertion Clean inside of reducer spigot and outside of the Tee e Weld secondary Elbow spigots with acetone e Allow to cool for at least 30 minutes before putting anv stress on the joint N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 2 THIS PROCEDURE MUST BE FOLLOWED NON COMPLIANCE WILL VOID WARRANTY AND INSTALLER CERTIFICATION 4 2 SECONDARY TERMINATION INSTALLATION METHOD 75 63MM 2 DOUBLE WALL These instructions cover installation of the following fittings 49 075 063 TP 49 063 050 TP 49 040 032 TP 49 075 063 49 063 050 49 040 032 Mark pipe here Cut Secondary pipe to correct length ensuring not to damage Primary pipe at least 40mm Primary exposed Insert 49 series fitting over Primary pipe and slide up to Secondary Pipe and into final position e Mark pipe to show insertion depth into 49 series fitting Remove 49 series fitting Mark pipe here Ensure entry seals are fitted providing correct and unstressed alignment between entry seal pipe and termination Wipe clean pipe and entry seal before any pipe insertion Mark insertion depth of pipe into Electrofusion Scrape the surface of the Secondary Containment Coupler 44mm I gap between 49 series fitting pipe to be welded thoroughly using UPP hand scraper and Electrofusion Coupler is recommended Clean scraped pipe
68. idual pipe lengths should be stacked in a pyramid not more than 3m high with the bottom layer fully restrained by wedges Where possible the bottom layer of pipes should be laid on timber battens Bundled packs of pipes should be stored on clear level ground supported by timber battens Bundles should not be stored more than 3m high Coils should be stored flat on firm level ground that has suitable protection for the bottom of the coil A stack should not exceed 3m high If stored on edge coils must be secured against a properly anchored support for a short time period only particularly in warm weather UL Rating PS ve 90 psig ve 26 6 Hg SC tve 58 psig ve 15 Hg ve 90 psig ve 26 6 Hg ve 90 psig ve 26 6 Hg 90 1 10mm 125 1 10mm 3 4 3ft2 4m 9ft8 6m 26ft3 8m n a n a n a 20m FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 5 Handling bed vehicle free from sharp objects or projections should be used for transporting pipe lengths or coils Never drag pipes or coils Wide band non metallic slings should be used when lifting pipe bundles by crane Do not use chains hooks or hawsers Coils of small diameter are easily man handled Forklifts can be used to lift larger diameter coils but the forks must be protected to avoid damage to the pipe Allow for some bend of pipe during l
69. itting Start button not depressed See operating sequence step 5 for long enough No output current open circuit Resistance value of fitting is Use only UPP electrofusion fittings and correct welding too high cable Low output Too many fittings connected Check resistance codes on fittings do not exceed a sum current in series Primary mode total of 10 only Check supply voltage Input voltage too low Check extension leads being used are to specification Switch off machine and switch on again after 10 seconds Ensure welder is within temperature range If problem persists return EFI to supplier High output Regulation error in current electronics Led Loose connection to 5 The EFI can be reset after a fault has been rectified by pressing and holding the START STOP button for 3 seconds Technical Details UPP Stock Code Number EFI 230V Operating Voltage 230V 15 194 to 264v Supply Current IQA ac maximum Supply Power 4 000 W Supply Protection Class Earthed Operating Frequency 45 to 65Hz Welding Power Rating I670VA Protection Class IP65 Operating Temperature 15 C to 45 C Shipping Dimensions 460mm wide x 210mm deep x 210mm high Shipping Weight 3 60kg FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 7 9 TIGHTNESS TESTING Every completed UPP systems installation must be tightness tested by a competent person to verify the integ
70. ler with a cleaning solvent e Attach the duct pipe to the reducer using e Wipe down the scraped duct pipe using a the 110mm 4 coupler cleaning solvent acetone Ensure there are no external stresses acting upon the assembly Weld with the primary orange welding lead Allow to cool for at least 20 minutes 38 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 5 10 INSTALLING A UPP ELECTROFUSION SEAL 302 040 Cut hole in sump wall Use 51 2 hole saw HSCS2 for 302 040 seal Scrape around fusion area using UPP hand held scraper e Clean fusion face of seal with acetone Connect welder and weld using red orange leads mark time of weld eg 11 00am Allow 5 minutes cooling before removing clamp e Clamp seal to sump using 302 CLAMP tool Cross the clamp bars for best results Allow joint to cool to ambient temperature elf using just primary 32mm pipe go to 9 approximately 20 minutes before putting any elf using secondary containment 40 32mm stress on the fitting pipe go to 17 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 39 Installing a 302 040 seal with primary 32mm for 30mm Mark pipe from marking e Slide primarv pipe through 302 040 seal to e Remove pipe from seal final position e Scrape from closest marked area to th
71. ly fixed at their final correct level to ensure that all pipe work can be laid with a continuous fall back to the tank 2 2 DIGGING TRENCHES AND BEDDING It is important to construct proper trenches before laying UPP pipe Trenches should be wide and deep enough to comfortably allow pipe runs recommended spacing and backfill materials Recommended burial depth of UPP pipe is a minimum of 300mm 12 All trenches should be sloped back towards the storage tanks with a recommended gradient of 1 100 Vapour return lines must have a slope of 1 4 per foot and never less than 1 8 per ft back towards the tank farm unless in line joints such as elbows are to be used Trench corners should be radiused to 5 5ft recommended l5cm 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 eCrushed rock size 3mm 2 to 16mm 1 7 eClean washed sand When laying duct onto a concrete base a 150mm 6 thick bed of compacted sand should be laid on the concrete below the duct Absolute minimum amount of sand should be 50mm 2 of compacted sand All beds should be laid so that the pipe will not dip or sag when it is installed Underground pipe runs may be continuous or have electrofusion welded joints Any mechanical joints or compression fittings must be located
72. mm for riser with shrouded weld pins EFI orange units will stop automatically after 6 minutes Height adjustment to suit final grade level Select the trim mark closest to the desired F height z Maintain 30mm upstand to ensure y water tight lid Highlight Trim mark on riser with a marker 5 location is correct pen Trim riser using highlighted trim mark as guide ensure cut edge is square l flat Remove any burrs using hand scraper N 8 Trim using handsaw or jig saw ONLY N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 8 Attach gasket to channel in underside of lid Position ends of gasket together first and work the gasket around the channel 9 Place lid on riser and attach latches as shown After welding riser to tank sump base vacuum test to prove tightness of the complete sump Recommended Depth Setting ft Max See note on Tightness Testing in section I 1 e e o 9 o o o o
73. must be attached to 125mm 5 entry seal spigot using an electrofusion reducer Once welded the duct provides a joint free link between two underground service areas and acts as a conduit for forecourt fuel lines This means that the pipes are not direct buried and can be replaced through the ducts without the need for excavation See Pipe Refit Through Ducts section of UPP Installation Manual Uncoil the Duct pipe into approximate final Scrape oxidised surface of the 125mm 5 end position of the reducer using UPP hand scraper Use a hack saw to cut the pipe ensuring the end Wipe with lint free cloth soaked in cleaning is as square as possible solvent Scrape surface of the 305R I spigot using hand Clean the inside of the 02 125 SC using scraper cleaning solvent and attach the reducer to the Wipe clean with cleaning solvent seal spigot using the 02 125 SC 02 125 SC welding coupler Weld this assembly using secondary welding lead Fully abrade surface of the part of the duct that Green is to be welded using emery cloth Allow to cool for at least 20 minutes N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 37 The edges of the corrugations must also be e Scrape the 110mm 4 end of the abraded using emery cloth reducer using UPP hand scraper e Clean the I 10mm 4 end of the reducer Wipe inner surface of the l0mm 4 using a cleaning solvent acetone coup
74. n 11 e e e 0 o 9 9 oe o 9 0 9 9 9 O 0 9 9 Welding riser to Base Scrape weld area on base with Hand Scraper and clean weld area on both riser and base with acetone e e 0 9 o 9 0 o o o o o o o 9 0 o 0 Place riser on base and ensure it is mounted squarely e e 9 9 o o o o o o o o o o 9 0 O o oo 9 0 O o
75. n the tooling section of the UPP Installation Manual 4 dis Au A n p FII Tt ss aa g rS eh dE sel a aa 1 a ri Backfill Material Pav special attention to this area underneath the chamber base Tank Top Termination FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 25 5 2 INSTALLING A UPP FUSION POLYETHYLENE TANK CHAMBER Gasket roll supplied with chamber Install base section I Clean tank containment collar with acetone and apply adhesive backed gasket to access shaft flange ensuring there are no gaps Scarf joint cut at 45 2a Mark base for access shaft opening and bolt holes as per access shaft dimensions Cut base opening using jig saw or hand saw only Drill bolt holes NOTE For square collars use hole saw to cut all 4 corners of the opening 2b Lower access cover shaft details for LA series 01027 chambers 959 PCD 745 L 145 295 il il Ba ES E 45 s 301 l e e 9 e 0 0 9 9 9 0 9 0 9
76. nnections Sumps must be regularly inspected and checked for the presence of petroleum products Any liquid detected must be removed promptly and disposed of correctly and the cause of the problem rectified Long term presence of petroleum products in sumps would invalidate Petro Technik s UPP System warranty Tightness testing The chamber can be tested for tightness using the UPP System Integrity Testing Unit detailed in the tooling section of the UPP Installation Manual FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 3 5 4 INSTALLING A UPP STABILISER BAR For use IN DS3017 054417 DS2111 4111 Sumps Hold stabiliser bar in position and check the number Undo mounting bolts of spacer plates required on each side Assemble one side of the stabiliser bar Pass bolts through holes in stabiliser bar and through spacer plate s if required Place circular channel nuts in approximately the correct location on each side of the sump Introduce the assembled end of the stabiliser to the nut Insert spacer plate s on opposite side if required channel on the sump Line up nuts to bolts and insert Insert bolts through stabiliser bar and plate s and Hand tighten bolts into the channel nut Hand tighten bolts Attach and complete all internal sump pipework Tighten bolts fully once shear valves are correctly including shear val
77. oading and unloading Ensure that lifting points are evenly spread Take extra care when releasing coils Coils are secured by outer restraining bands with additional inner bands being provided to protect the inner layers With coil standing upon ground as shown in photo remove the bands carefully from the outer layer first so that only the length of pipe required is released Successive layers of pipe can be released by removing the inner bands as the pipe is drawn away form the coil Exercise special care when handling pipe in wet or frosty conditions Use gloves for additional grip Visual inspection should be performed on the pipes prior to assembly and Uncoiling position installation Any pipe showing significant signs of damage or cracks should not be used Assembly amp Installation PetroTechnik UPP pipe work is designed for use with the latest PetroTechnik fittings parts and accessories and should be installed using tools equipment and practices detailed in the latest PetroTechnik Installation Guide Product Catalog see www petrotechnik com downloads The preparation of pipe if electrofusion fittings are used assembly of fittings installation and backfilling of trenches should only be undertaken by a trained and certified PetroTechnik UPP systems installer using UPP installation procedures Any assembly by non trained installers or deviation from PetroTechnik UPP sys tems installation procedure could result
78. of this manual for detailed instructions for installing UPP on a live site Q14 Can modify UPP pipework once installed or make repairs to a system which has been physically abused A Yes Unlike flexible plastic hoses which can only be joined with mechanical fittings which are not allowed to be direct buried UPP s welding system allows modifications to be made rapidly and safely CAUTION NEVER WELD LIVE LINES PetroTechnik has instructions for welding on live sites fully describing how to isolate and purge pipes which have carried fuel or vapour see section 6 for details Q15 What is the difference between UPP unlined pipe and UPP Extra with its polyamide liner _UPP Extra has a yellow nylon liner This is its barrier layer that prevents permeability and pipe swelling Regular UPP has no such liner and is self coloured black Specify UPP Extra for all your fuel carrying pipes suction or pressure lines 88 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Q16 What Working Pressure has UPP been design for From the outset all UPP primary pipe in all its diameter sizes has been rated PNIO bar 145 psi and regular product tests show that this rating is exceeded 400 showing a great margin of safetv UPP primarv pipe is designed for suction negative pressure or pressurised systems All UPP secondary containment pipe is rated PN4 4 bar 58 psi and p
79. olts supplied Adjust the shear valve height to ensure that the shear valve groove is flush with the island finish grade Tighten all stabilizer assembly bolts in their final positions Assemble riser When using a UPP riser recommended install the termination fitting e g 81 063 INPT into the emergency shut off valve The riser must be cut the correct length so that the UPP tee or elbow centre line is in line with the entry fitting Welding can be done in sump or prior to hanging shear valve Otherwise thread an appropriate length schedule 40 steel riser or flex connector into the bottom of the emergency shut off valve Electrical conduit The DS 3617 sump frame is pre drilled with three holes giving the option to route the conduit external to the sump but within the frame Ensure holes are correct way around For other sump models conduit seals will have to be installed as they do not have pre drilled frame holes 30 IN FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Concrete and backfill The sump must be secured in the island form using the brackets in the sump mounting frame prior to backfill and concrete pouring Backfill in accordance with instructions given in backfill section of the UPP Installation Manual Inspection Maintenance UPP dispenser sumps are designed to provide secondary containment of dispensers and piping or co
80. one during welding it is important to clean all the pieces of the assembly prior to welding The following Solvent may be used e Acetone Isopropyl alcohol Triclorethane Do not use solvents that leave film on the joining surface such as turpentine petrol synthetic dilutents The surfaces to be cleaned include e All scraped areas of pipes and fittings e Theinsideofelectrofusion fittings and welding couplers Once the areas of pipes and fittings to be welded have been wiped clean avoid contact with them and your hands or any other sources of grease dirt 4 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION MARKING o Mark the insertion depth on pipe ends using a permanent marker or Chinagraph pencil and ruler o The following table reports the correct insertion depth into UPP primary electrofusion fittings Description Product Insertion Length Inches 02 32 25 02 50 25 02 63 30 Welding Coupler 90 02 90 36 13 0 02 110 41 EP lO 02 160 48 7 03 50EIF 44 3A 7 BOE 03 63EIF 48 7l Electrofusion 90 03 90EIF 62 Lig LE 03 110EIF 71 2 04 63EIF 48 7 45 Elbow 04 90EIF 62 27 lm DEM 04 110 71 23 CLAMPING t is important to check for correct alignment of the assembly both vertically and horizontally and to ensure that it is not subjected to any bending load or weight that c
81. onnection to vacuum lid vacuum being produced and pump To check pump block one end of pipe and monitor the movement of the vacuum gauge Send to PetroTechnik for repair if a vacuum is not generated Pump not running Check power to unit and electrical fuse Vac test levels and corresponding water pressures Vacuum Test Level x Ground Water Pressure Lm mm 177 t 260 2 60 Ground Level ud d PD OD DL ee ee k Diagram Water Table Level N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 77 9 5 PRIMARY SINGLE WALL TIGHTNESS TEST REPORT Suction LI Pressure L Fill LIVent LI Syphon LIVR Ib LIVR2 LJ Electircal Conduit FROM TO Pipe type LI Lined LI Un lined Thin wall fill vent Select Secondary Pipe Size highlight or circle relevant column Pressure Rating PN6 PN6 PNIO Tvpe of Line Number of compression joints in line Notes Number of welded joints in line Notes Welding times marked on all joints Notes Scraping marks Notes Joints square Notes Welding pins extended HAW Notes Pipe routing separations Notes Minimum fall back correct EN Notes PRESSURE TEST Pressure Test Obar Test Medium Air LI Inert Gas Nitrogen Test time Start Time End Time at least hour Start temperature Temperature Pressure drop mb
82. onveyance of natural gas Pressure grade means that independent laboratories have determined the product lifetime when it is subject to pressure Q9 Is UPP pipework a suction only system How do UPP pipe and fittings perform under constant positive operating pressures of up to 58 psi 4 bars or 400 kPa A UPP pipe has been installed in both pressure and suction type systems In fact the majority of PetroTechnik pipe has been installed in pressure applications since 1995 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 87 Q10 What the advantages of the UPP secondary containment double wall pipe system versus other secondarily contained pipe systems A The advantages are that the UPP Secondary Containment pipe is in fact a real pressure bibe system and can be continuously 24 7 operated at 58 psi 4 bars or 400 kPa Secondarv containment or double wall svstems used bv other competitors are merely a jacketing conduit with no mechanical strength Also UPP Secondarv Containment is a semi rigid pipe which complies with CARB TP 201 2G Bend Radius Determination for Underground Storage Tank Vapour Return Piping Also UPP svstems includes genuine secondarv containment tees and elbows with a complete interstitial space Q11 Is UPP affected by Permeation A Since swelling and growth are side effects of permeation these effects can be more serious and prejudicial to pipe integ
83. ork applications as UGN PS NV amp VR UPP Extra lined pipe should be used Petro Technik UPP Product Codes include UPP Pipe Codes Description Diameter 001 1 10 090 019PS UL971 Pipe Double wall pipe 3 Stick 19 001 110 090 038PS UL971 Pipe Double wall pipe 3 Stick 38 001 125 110 019PS UL971 Pipe Double wall pipe 4 Stick 9 02 XX ZZ Weld socket 03 XX NV ZZ 90 Elbow Size 04XXZZ 4 Size if applicable OXX pe e Sub ZAAL Description 06 XX Flange NPT National pipe thread 07 XX Gasket SC Secondary containment 08 XX YY ZZ Tee TP Test port 09 XX YY ZZ Reducer EIF Electro integrated fusion 10 22 End BSPT Bristish standard pipe thread 1 XX ZZ Termination PS Integral Primary Secondary 12XX ZZ Coupling 0 0 V Normal vent vapor recovery 3 XX YY ZZ Reducer with socket L Extended 49 XXX YYY SC Termination UPP Integral Primary Secondary Pipe System UPP Integral Primary Secondary polyamide lined polyethylene pipe is designed for use with highly aggressive fuels achieving zero or near zero permeation UPP Normal Vent amp Vapor Recovery Pipe System UPP Extra polyamide lined polyethylene pipe is designed for use as NV amp VR lines A wide range of fittings are available from PetroTechnik for UGN PS NV amp VR applications with UPP pipework UPP pipework should only be used with UPP fittings 50 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLI
84. orporate a shut off valve between the pipe and the pressure gauge and a shut off valve between the pressure supply and the gauge To ensure that excess pressure cannot be applied to a pipe under test a relief valve must also be incorporated in the system The relief valve should be set so that at possible full flow from the pressure supply the pressure in the pipe cannot exceed 0 5 bar 7 25 psig above test pressure e g test pressure of bar 15 psig relief valve set to 1 5 bar 21 76 psig When air or inert gas is to be applied from high pressure cylinders a suitable control valve must be used to control the flow from the cylinder The outlet pressure from the cylinder must be set to ensure that it does not exceed the required approved test pressure whilst pressure is being applied to the pipe When conducting the pressure vacuum test on the primary pipework any secondary containment must be open to atmosphere The reverse is true when conducting the pressure vacuum test on any secondary containment the primary must be open to atmosphere The line under test should be slowly pressurized or depressurized for vacuum to minimize any risks 72 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION o Caution Nitrogen from a pressure cylinder shall be used in lieu of air for testing if a fuel has been used to ballast an underground storage tank o Check that all pip
85. ors Liability Restrictions All liabilities of the supplier are invalidated in the following cases The EWS is used outside the indicated application area Non UPP fittings or pipe are used The operator has not been trained to use the EW8 or the UPP system Operating instructions have not been observed Unauthorised repairs or maintenance have been carried out The EWS has been used outside of its technical specification Safety instructions have not been observed FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Using the EW8 Ensure that the machine is positioned outside hazardous zones 0 I and 2 Allow the machine and fittings to reach the ambient temperature of the site Keep the machine out of direct sunlight and free of any obstruction Make sure fittings and pipe have been prepared in accordance with UPP Installation instructions Action Information on Display Connect the required welding lead to the EW8 Welder PRIMARY fittings RED lead None SECONDARY fittings GREEN Connect welding lead to the UPP fusion fitting s making sure connectors are firmly pushed onto pins Connect the EW8 Welder to 3 None a 230v power supply None All LEDs light in sequence then green Penn power LED remains on First weld light comes on then lights up until green 100 LED is lit showing weld is complete Press orange START button until first weld light illumin
86. ost electrofusion couplers and fittings have a resistance index number marked onto them inside a circle ie 6 The total value of the index number of the three items to be welded must not exceed 10 If the fitting does not have a resistance index number marked on itself then it must be treated as having an index number of 10 A list of resistance numbers can be seen in sections 3 1 and 3 2 Full welding unit instructions can be found in the following sections 3 4 WELDING PRIMARY PIPE AND FITTINGS Red Orange welding cables should be used for welding primary pipe Except some 32mm I 160 6 and 200mm 8 fittings which use specialRed Orange cable with 2mm 7 welding pin available from PetroTechnik do not usered orange primary or green secondary welding cables Apply power to welding unit o Attach the welding cable to the assembly to be welded via the welding pins on the coupler electrofusion fitting Press the ENTER key or START button to begin the weld The unit automatically detects the kind of fitting it is welding and on some welders displays the remaining weld time and the electric current in amps Once the welding operation is complete you need to ensure that both indicator pins on the welding coupler have extended If either of these indicators fails to extend the joint must be treated as suspect and the assembly should be left to cool fully approx one hour before welding is restarted if the
87. ould deform to the joint whilst it is in a molten state O Use UPP clamps to keep the assembly in the correct alignment position preventing any movement during the welding and subsequent cooling process o f a clamp cannot be used for example in a small tank chamber precautions need to be taken to ensure that the assembly is not under any stress FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 5 16 3 3 WELDING OVERVIEW o UPP 230 volt and 115 volt intelligent Welding Units have been designed to supplv the exact controlled electrical energv necessarv to fuse two UPP products together and to provide complete safetv on site The resultant heat causes the pipe and joint surfaces to melt and fuse Once electrofusion has taken place the assembly is left to cool while the polyethylene solidifies to form a homogenous union stronger than both pipe and fittings o UPP welders use a constant current output UPP components must never be welded with other brands of welding unit Both types of welder can be used from the mains supply or from a generator As the welding machine measures the ambient temperature and the welding coupler electrofusion fittings resistance values it must be positioned in the same environment as the joint it is welding A maximum of three primary couplers or primary electrofusion fittings may be welded at the same time by using bridging leads M
88. ound at the furthest point at which the welding lead will reach the welding machine without any tension on the lead Shut off stop the nitrogen supply just prior to the welding machine being switched on and the welding cycle activated On completion of welding cycle the welder should be isolated from the power supply and the nitrogen purging should recommence and continue for a period no less than 5 minutes During this time period no personnel should enter the tank sump to remove the welding leads The sump air supply should be exchanged until the O meter records the presence of sufficient oxygen 21 before any personnel enter the sump Before undertaking any additional work on any of the other sumps the atmosphere should be checked with the O meter and records the presence of sufficient oxygen 72176 initiate air exchange if in any doubt All the effected shear valves should have the access port re sealed ready for the product line to be pressure tested The product line should be pressure tested to the UPP guidelines 60psi or 4 2bar for hour The new welded joint should be wiped with soapy water to make it easier to check for signs of leakage Perform any regulatory testing requirements and sign off as required On completion of a successful pressure test the submersible pump can be re connected and the dispensers re commissioned FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND IN
89. period The above described pipe run has been checked for correct installation visually and by means of a pressure test It has been found to be installed in accordance with UPP Systems installation guidelines and has been certified by The information given above is true and correct Signed by day month year N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 9 8 UPP DisPENsER SUMP REPORT Sump Installed under Dispenser This test can only be carried out on vac testable UPP sumps Regular sumps with penetrating bolt holes between the mounting frame and the uni strut are not vac testable For these sumps it is recommended that a Hvdrostatic test is performed following the test procedure set out at the bottom of this page Once the dispenser sump has been positioned correctiv anchored into position and all pipework is installed using electrofusion or mechanical entrv seals a vacuum test can be carried out to ensure the integritv of all pipe penetrations This test can be carried out before or after the shear valves are installed or If the test is being carried out with shear valves already in position ensure that the tops of the shear valves are in line or below the level of the sump lip so that the test lid sits correctiv on top of the sump Ensure vacuum lid gasket and sump lip are both clean and free from dirt or debris Properly position vacuum lid on top of the sump Ensure va
90. posed creating an electrical shock hazard 70 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Fault Indicators When an error has occurred during the weld cycle that will have an effect on the success of the joint the red warning LED on the right side of the display will light up Also one of the weld progress lights will light up at the same time to show what type of fault has occurred Error Fault Indicated Meaning Solution Check and rectify power supply The power supply was off Check plug connection at sometime during the Check cables are not damaged or broken weld Re weld fitting only after it is allowed to cool to ambient temperature Power supply failure during weld Stop button pressed during weld Re weld fitting only after it is allowed to cool to ambient temperature Supply frequency not between 45 and 65 Hz or Voltage not between 194 amp 264V Power supply out of limits Check and rectify generator output Check mains supply Make sure supply is to required specification Ambient Temperature of the temperature is not between 15 c and out of range 45 c Allow EFI and fitting to cool in the shade Wait for ambient temperature to return to range terminal pin Make sure connectors are pushed firmly on to terminal Loose contact in the pins welding circuit Check welding cable connection and continuity Faulty fitting Replace f
91. r allowing them to cool for at least one hour Welding in series Primary Primry mode In the Primary Primry mode the welding machine can simultaneously weld two to three maximum UPP welding sockets fittings provided the following rules are applied The sum of the connected resistance values circled figure on UPP sockets must not be higher than 10 The UPP welding sockets to be welded need to be connected in series using the coloured bridging leads red or yellow in such a way that each fitting is always connected by two cables of a different colour red or yellow To ensure that it is OK check that all the fittings get warm during the welding process NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Welding in Secondary Secndr Mode UPP Secondary welding socket may not be welded in series These fittings can be recognised by their special smaller terminal pins These connections require the use of a green Secondarv welding cable TECHNICAL DETAILS Welding machine UPP Combi Welder Unit 230V EW E7 230V with European Stvle plug Voltage 230V 15 195 5 V to 264 5 V Frequency 50 Hz 45 to 65 Hz Power rating 1000 W Fuses input side min 10 A slow Welding voltage 8V to 230V Switching power of the FI safety switch 10 mA Protection class IP 65 II reinforced isolation Ambient temperature limits Dimensions width 340 mm depth 300 mm height 50 mm total weight 4 68 kgs
92. rate the cover from the frame see instructions below Create a reinforced concrete foundation for the frame maintaining a clear opening under the frame 800x800mm 31 Where specified connect a 1 26mm plastic drainage pipe between outlet on frame and oil water separator or backfill material surrounding tank access chamber Otherwise ensure bottom of Spring Box Photo 3 is sealed against water exit Pour water into drainage channel in frame to check that drainage operates correctly Pour concrete around frame and check surface water drainage slope is 15 Refit the cover to the frame once concrete is dry see instructions below Separating the cover from frame two operators required Unlock and open the cover to between 30 and 60 using the locking handle PC76 H Photos 1 2 Lever up and remove Spring Box Cover Photo 3 Continue opening cover to totally open position circa 120 Photo 4 Lift cover from frame Photo 4 Refitting the cover to frame two operators required Place the cover into the frame at circa 20 Refit the Spring Box Cover FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Maintenance Apply grease to spring every year There is a rubber gasket on the underside of the ensure long term water tightness the drainage channel in the frame and the gasket should be kept clear of debris To rene
93. reating a burning hazard Additionally power conducting elements may become exposed creating an electrical shock hazard FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 63 64 Fault Indicators When an error has occurred during the weld cycle that will have an effect on the success of the joint the red warning LED on the right side of the display will light up Also one of the weld progress lights will light up at the same time to show what type of fault has occurred Error Led Fault Indicated Meaning Solution Check and rectify power supply Power supply failure The power supply was off at Check plug connection during weld sometime during the weld Re weld fitting only after it is allowed to cool to ambient temperature Stop button pressed Re weld fitting only after it is allowed to cool during weld to ambient temperature Supply frequency not between 45 and 65 Hz or Voltage not between 194 amp 264V Power supply out of limits Check and rectify generator output Check mains supply Allow EW8 and fitting to cool in the shade Wait for ambient temperature to return to range Ambient temperature Temperature of the EW8 is not out of range between 15 c and 45 Loose connection to terminal Make sure connectors are pushed firmly on to pin terminal pins Loose contact in the welding Check welding cable connection and circuit continuity Faulty fi
94. rity and site safety than a small amount of gas diffusion UPP Extra pipe was filled with Super Unleaded gasoline and tested for 80 days at 23 C During that time no weight loss or growth was recorded UPP pipe will not swell because the internal liner is impervious to hydrocarbons Hydrocarbons do not reach the Polyethylene layer which provide mechanical strength Q12 It was reported recently that a thermoplastic flexible pipe system swelled expanded grew in length because of continuous exposure to hydrocarbon vapours within a containment sump The abnormal growth caused a failure of the containment sump entry fittings Will UPP pipe swell expand in length due to continuous exposure to hydrocarbon vapours A UPP primary and UPP secondary containment pipe will not noticeably swell or expand in length when exposed continuously to hydrocarbon vapours in sumps The reason is that pipe and fittings employ proprietary high density materials which ensure a higher degree of hydrocarbon resistance Q13 Can the UPP welding units be used on a live construction site a site where fuel is stored in the underground tanks for the purpose of electro welding UPP pipe and fittings A The UPP welding units are rated to be used in zone 2 areas of live forecourt sites The welding cables however are rated to be used in zone I areas of a site and are long enough to reach into zone whilst the unit itself remains safely in zone 2 See section 6
95. rity of the line s prior to backfilling Testing can be done by hydrostatic pressure or a combination of pneumatic pressure and vacuum Primary pipe and secondary containment pipe where applicable shall be tested separately It is recommended that wherever possible the primary containment pipe work is tested prior to the secondary containment pipe work being welded thus facilitating checking and leak detection if necessary Tightness testing using a Hydrostatic Method is seen as being safer than Pneumatic Methods and either method 9 1 Hydrostatic Method 9 2 UPP Pneumatic Method is acceptable for testing UPP pipe work systems Guidelines for these tests are set out below but these procedures may need to be validated and amended to meet the requirements of the local officials and engineers and to comply with local health and safety regulations Testing Guidelines t is recommended for accuracy of observation that the test gauge scaling is such that the target test pressure is approximately 50 of the gauges maximum range e g test pressure bar I 5psig gauge range is 0 to 2 bar 0 to 30psig All gauges should bear a unique mark serial number and be tested at least annually to ensure that they comply with the accuracy specified in local standards A current test certificate certificate of compliance should be held for each gauge The fittings which are used to introduce air or an inert gas into the pipes must inc
96. ry pipe must be scraped using the UPP scraping tool SCR 025 110 or SCRK II These tools remove a controlled outer layer of oxidised polyethylene over the length of the pipe which is inserted into a coupler or electrofusion fitting See Scraper tool instruction page for more information Secondary containment pipe double wall pipe Secondary containment pipe has to be scraped using the UPP hand scraper SCR HAR A layer of plastic must be removed all along the length of pipe to be inserted into the welding coupler or electrofusion fitting Duct Pipe Duct pipe must be abraded using emery cloth as its corrugated structure doesn t allow the UPP scraping machine or the hand scraper to be used Care must be taken to abrade all around the corrugations Non electrofusion Fittings Non electrofusion fittings i e those that need an electrofusion coupler to be welded must be scraped with the UPP hand scraper before welding can commence The spigot of these fittings must be scraped using the UPP hand scraper to remove a layer of oxidised polyethylene along the whole length that is to be inserted into the welding coupler Electrofusion Fittings Welding Couplers electrofusion fittings are those with welding elements built into them these do not require scraping before being used but must be cleaned with a solvent eg Acetone CLEANING To ensure that there is no grease moisture or dirt in the electrofusion z
97. s should be used such as vibrating plates compactors or road rollers Tightness testing The chamber can be tested for tightness using the UPP System Integrity Testing Unit detailed in the tooling section of the UPP Installation Manual FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 79 5 3 INSTALLING A UPP PoLYETHYLENE DISPENSER SUMP Mount dispenser sump o The top of the sump mounting frame must be flush with the finished island surface O Secure the sump with timber battens and or screws or angle iron island form Mark the pipe entries for product and vapour lines for the appropriate dispenser model Mark the correct entry height to allow correct fall normally Im per 100 or inch per foot to the Underground Storage Tank UST or next dispenser sump If required the sump riser can be cut down to height leaving 25mm 1 rain lip above the frame and the mounting frame repositioned by drilling and re bolting in the new frame positions Install any UPP entry seals according to their specific Instructions Mount stabilizer bars See Stabiliser bar instructions DS3017 054417 DS2111 054111 Sumps in the UPP Installation Manual Adjust shear valve position Secure the emergency shut off valve to the mounting plate using the three Allen set screws Assemble the shear valve mounting plate to the stabilizer using the U b
98. sion either from the mains or a suitable generator minimum 4 KVA 2 Uncoil the pipe into the installation area and allow it to relax o Always use a minimum of two people to uncoil and cut the pipe To uncoil secure one end and roll out only releasing securing tapes as required see section 4 3 Install the tank access chambers sumps Follow the manufacturer s installation guidelines for tank sumps chambers 4 Make sure all the tank top steel fittings are installed 5 Mark positions on the tank access chamber sump for penetration locations and install UPP seals Bear in mind that fall back for all pipework to the tank chambers should be a minimum of Im every 100m 1 8 per foot 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 6 Install pipework It is not essential that the work is carried out in this order but it helps to give some structure to the site installation It is advised to note down the batch number of the UPP pipe as it is layed out in the trenches for future reference this can be found printed on the pipe itself 7 Install offset fill lines if applicable Start with the installation of the offset fill lines from the tank and work towards the offset fill point 8 Install vents and vapour recovery stage I
99. t of the product line 11 The sump air supply should be exchanged until the O meter records the presence of sufficient oxygen 72176 before any personnel re enter the sump 12 Remove the petroleum liquid containment vessel from the tank sump 54 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Undertake and complete the repair to the UPP pipework and fittings up to the point of welding in accordance with UPP installation instructions The repair assembly of UPP pipework and fitting s is to be clamped or supported and not subject to strain during welding and cooling periods The pipe should be open to the sump to allow the Nitrogen purge to inert the sump as well as the line The welding lead should be attached to the welding coupler fitting in preparation for electrofusion The welding lead should not be connected to the welding machine at this stage The atmosphere of the sump is to be continually monitored with the meter for the presence of sufficient oxygen 21 during repair whilst personnel are within the sump Connect the nitrogen supply to a shear valve access port and flood the product line and sump the O meter should record the presence of no oxygen in the sump Once no oxygen is recorded on the O meter the welding machine and power supply can be located above gr
100. terial Installing tank chamber riser to base Cut riser to required height using castleations as a guide photo 5 o Clean gasket surfaces of chamber using cleaning solvent Acetone o Stick quarter circle gasket pieces one by one to top of chamber ensure holes in gasket line up with holes in chamber for best fit and make sure all joints between gasket quarter circles are butted together to make a water tight seal photo 6 Place riser on base and line up bolt holes Tighten all bolts around chamber initially before repeating to make sure all bolts are fully tightened photo 7 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Backfilling Prior to backfilling the chamber lid must be in position to prevent any deflection of the riser Acceptable backfill materials are Well rounded pea gravel size 3mm to 20mm 2 e Crushed rock size 3mm to 16mm Clean washed sand IMPORTANT Backfill material should be free from ice or any organic silt or peat o Particular care should be taken to ensure enough backfill is laid down around the underside of the chamber where it overhangs the tank access shaft flange No mechanical compactors should be used such as vibrating plates compactors or road rollers Tightness testing The chamber can be tested for tightness using the UPP System Integrity Testing Unit Detailed i
101. terminal pins Check welding cable connection and continuity Replace fitting See operating sequence step 5 Use only UPP electrofusion fittings and correct welding cable Check resistance codes on fittings do not exceed sum total of 10 Check supply voltage Switch off machine and switch on again after 10 seconds If problem persists return EW8 to supplier The EWS8 can be reset after a fault has been rectified by pressing and holding the Start Stop button for 3 seconds Technical Details UPP Stock Code Number Operating Voltage Operating Frequency Power Rating Protection Class Operating Temperature Shipping Dimensions Shipping Weight EW8 I IOV 10 10 45 to 65Hz 150 IP65 15 C to 45 C 420mm wide x 340mm deep x 180mm high 1 3kg FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 67 68 7pin Secondary welding cable 8 5 EF1 HAND HELD WELDER OPERATING MANUAL WARNING UPP WELDING UNITS MUST NOT BE OPERATED IN ZONE 1 AREAS To weld inside zone 1 the units must be operated in zone 2 with only the welding cables extending into zone 1 NOTE EFI welding cables use special 7 pin connectors NOT regular 4 pin connectors 1 Construction of the welding machine EF1 Electrofusion Welder m d Bridging cables x2 7 pin Primary welding cable Power cable S 7 Pin Fusion chamber welding
102. thod Unscrew movable flange and remove from fitting Pre clean fitting flanges with acetone Drill hole using hole saw 4 7 105mm for FEB D 075 1 Code HSO75 5 140mm for FEB D 110 I Code HS5 Check fitting will pass through the sump wall before continuing Using 80 GRIT emery or a red Scotchbrite abrasive pad abrade both faces of movable and fixed flanges of FRP seal Using emery abrade internal and external areas of sump to be bonded Clean all abraded areas of fitting and sump and using cleaning solvent Add BondmasterE32 to the groove of the fixed flange Add BondmasterE32 to the groove on movable flange using the applicator gun using the applicator gun N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 45 e Fit unit to sump wall fixed flange on external wall and tighten movable flange onto thread by hand from inside the sump Fill piercing s in flanges with BondmasterE32 and create fillet ring of E32 around outside of both flanges Tighten fully using fitting wrench Allow to cure at least 24 hours Mid Installation Check Point Before commencing step 9 of the installation ensure the following is true E32 resin has cured o Double wall sumps have been tested with UPP vac lest unit Any entry leaks detected have been re worked All entry fittings tested tight The next part of the installa
103. time Start Time End Time PASS at least 30 minutes Start temperature k End Temperature C FAIL Vacuum Loss mbar over test period The above described pipe run has been checked for correct installation visuallv and bv means of a pressure test It has been found to be installed in accordance with UPP Systems installation guidelines and has been certified by The information given above is true and correct Signed by dav month vear FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 79 80 9 7 DucT CONTAINMENT PIPE TIGHTNESS TEST REPORT Pipeline From Tank Number LIFil Vent Syphon AVR Ib LIVR2 LiElectircal Conduit Type of Line C Suction Pressure to dispenser number s Select Duct Pipe highlight or circle relevant column Pressure Rating n a n a Number of welded joints in line 8 Notes Welding times marked on all joints Ld Notes Scraping marks EN Notes Joints square Notes Welding pins extended Notes Pipe routing separations correct Notes Minimum fall correct Notes PRESSURE TEST Test pressure 300millibar Test time Start Time End Time PASS at least hour Start temperature End Temperature C FAIL VACUUM TEST Test vacuum 80millibar Test time Start Time End Time PASS at least 30 minutes Start temperature C End Temperature C CI FAIL Vacuum Loss mbar over test
104. 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 30 kPa by bleeding water from the pipe work Due to the viscoelastic properties of polyethylene the pipe will contract o During the test period of 90 minutes the pressure should be recorded with the frequency shown below Test period mins Frequency of readings mins Number of readings 90 E j 6 O The test is passed if all the readings during the testing cycle are 3 bar 43 5 psi 30 kPa or above FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 73 Decreasing readings failure of pressure test note that the readings are likely to increase If the system fails the pressure test make the following checks a Check all mechanical connections b Check welded joints o When the failure point has been located and remedied repeat the full conditioning and testing sequence 9 2 UPP PNEUMATIC METHOD The test parameters are given below Type of Pipe Test Pressure Test Time Test Vacuum Test Time Primary Pipe 0 bar 14 5 psi 100 kPa hour 0 5bar 7 psi 50kPa 30 minutes Secondary Pipe terminated with 0 bar 14 5 psi 100 kPa 0 5 7 psi 50kPa 30 minutes electrofusion boot Secondary Pipe terminated with
105. ting current and either a mains connection or a generator can be used Generators must have a rated output of at least 4kW and power input must be between 195 and 264volts at 45 to 65Hz The EWS has an on off button a weld start button and an LED display showing the weld progress The LEDs can also show any fault conditions that may affect the weld ON OFF Switch on side of unit rIF D p F 7 pin Primary welding cable 7 Power cable 7 pin Weld cable connector Power on Indicator Fault indicator Weld progress LED s START STOP button Temperature sensor Safetv The EWS is designed for usage on construction sites and meets applicable European and International safety standards The machine should be handled with the care usually given to electrical equipment especially during transport The machine must only be used outside of hazardous areas zones 0 and 2 Each time it is used check the condition of the machine particularly the mains power cable If any damage is discovered contact the supplier immediately and do not use the machine Check the state of the welding cables before use and replace them if there is any doubt about their condition Always check that the power source is within the parameters shown above before using the EW8 Never lift or pull the machine by its power cable or the welding cables Never disconnect welding cables by pulling the cable always pull off the connect
106. tion is the assembly of the cover discs using UPOL bondinsg paste This be carried out before commencing piping OR as the last work on the piping system provided the discs are loose fitted before piping USING UPOL Precautions with U POL Do not store at temperatures above 70 F If ambient temperature exceeds 70 F then cool tin in cold water for 30 minutes High temperature dramatically shortens working time to less than required for installation Do not use U POL once it starts to go off material loses adhesion and sealing properties discard and use new mix Working time is approximately 4 minutes at 70 F Have everything ready to assemble before starting Only prep just before using U POL to avoid re contamination or oxidisation O O O O O O OO Wear nitrile gloves Mixing U POL Only mix enough for one cover disc at a time Mix Ratio required is 2 parts hardener to 100 paste A good guide is a golf ball of paste to a pea of hardener Optional colored hardener assists visual mix effectiveness Ensure even mix of hardener and paste Once mixed working time is approximately 4 minutes O O O O O O 46 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION Clean brass flanges with acetone Clean internal face and edges of caps with acetone Abrade brass flanges with 80 120 emery cloth Abrade fitting caps with 80 120 emery cloth Re Clean brass flanges with acetone
107. top dispenser vent stack or fill point Installing a 302 040 seal with secondary Containment 40 32mm Scrape inner and outer seal spigots as shown Scrape areas of pipes as shown Clean both spigots of the seal with acetone Clean inner bore of 02 40 SC with acetone Clean inner bore of 49 040 032 with acetone Slide 49 040 032 reducer large end first over primary pipe and onto the spigot of the 302 040 seal Weld 49 040 032 to seal spigot and primary pipe using green welding cable Allow 20 minutes for the weld to cool before putting any stress on the assembly FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 4 5 11 INSTALLING A UPP ELECTROFUSION SEAL 303 sERIES WITH INTEGRATED COUPLER The 303 063 EIF Seal accommodate either 63mm Primary or 63mm Secondary Containment pipe In this installation guide the primary pipe is being used When using Secondary Containment ensure there is sufficient space inside the sump chamber to accommodate your Secondary Containment termination fittings Ensure the metal tank top fittings are e Fit UPP Termination fitting to tank fittings Find the centre of the pipe stub and extend he chamberwal this line to the chamber wall and mark Using 102mm 4 UPP Holesaw HS3 place Scrape the area of the chamber around the drilled hole using a handscraper UPP SCR
108. tting Replace fitting Start button not depressed for See operating sequence step 5 long enough No output current open circuit Resistance value of fitting is too Use only UPP electrofusion fittings and high correct welding cable Low output current Too many fittings connected in Check resistance codes on fittings do not series Primary mode only exceed a sum total of 10 Input voltage too low Check supply voltage Switch off machine and switch on again after High output current Regulation error in electronics IO seconds If problem persists return EW8 to supplier The EWS can be reset after a fault has been rectified by pressing and holding the Start Stop button for 3 seconds Technical Details UPP Stock Code Number EW8 230V TR Operating Voltage 230v 15 194 to 264v Operating Frequency 45 to 65Hz Power Rating 150vA Protection Class IP65 Operating Temperature 15 C to 45 C Shipping Dimensions 410mm wide x 230mm deep x 200mm high Shipping Weight 3 25kg N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 7 Pin Fusion chamber Power cable 8 4 EW8 WELDER OPERATING MANUAL 0 V WARNING UPP WELDING UNITS MUST BE OPERATED IN ZONE 1 AREAS To weld inside zone 1 the units must be operated in zone 2 with only the welding cables extending into zone 1 NOTE EWS8 welding cables use special 7 pin connectors NOT regular 4 pin connectors
109. ve assembly located 32 FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 5 5 INSTALLING UPP MECHANICAL ENTRY SEAL For installation on flat sump surfaces Entry Seal Hole Saw compatibilitv chart P y 1 Measure and mark the centre position of the required pipe sump Holesaw Compatible penetration mm Seal s 4 Remove the Backing Ring from the seal 2 Select the correct size hole saw for the selected penetration seal 20 and fit to mandrill U250 300 l e 83mm 3 hole saw for PS3 seal and 168mm 6 hole saw for 102 303 063EIF HS3 PS6 seal enm 3 R he bol hers and Jubilee Clips Hose Clamps emove the bolts nuts washers and Jubilee Clips Hose Clamps ate from the seal and store in a safe place 305 Seals 140 HS5 m0 usa 2 5 C he Ri h hole Use the holes in the Ri i entre the Ring over the cut hole Use the holes in the Ring as SB pee template for the positions of the seal bolt holes and drill HSP3 a68 PS6 HSP6 6 the rubber seal boot for the installation of either 63mm 2 or 75mm 2 double wall pipe using a sharp knife FEB D 110 T Re fit the Backing Ring over the seal rubber boot 8 Position the seal rubber boot and ring on the inside wall of the chamber sump lining up the bolt holes 9 Pass the bolt through the chamber sump wall from the outside and attach nut and washer securing the seal into position 10
110. w the gasket Scrape off old gasket Clean off all old adhesive from cover using alcohol meths or similar Apply adhesive Superglue Gel or similar to channel on underside of cover Push new gasket into channel Clean off any excess adhesive around gasket and close and lock cover Cast iron cover may be re painted with any non slip paint for aesthetic purposes 1 100 incline towards rear of cover to facilitate drainage of surface water ra Reinforced 15 Slope for Surface Water Drainage Concrete FromLip of Frame to Forecourt Surface PC76 Cover 55553 SU ee Drainage Pipe 26mm Drainage Pipe Runs into Pea Shingle Or Connects to a Drainage Line FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION 49 5 14 UL PIPE INSTALLATION INSTRUCTIONS General These instructions cover Petro Technik UPP pipework systems for applications in volving non metallic underground pipework for flammable liquids as Integral Primary Secondary PS Normal Vent NV Vapor Recovery VR Assembly and installation should only be undertaken by a trained and certified Petro Technik UPP systems installer using UPP installation procedures Any assem bly by non trained installers or deviation from PetroTechnik UPP systems instal lation procedure could result in damage or leakage to the system invalidation of warranty or personal injury For pipe w
111. with acetone Insert pipe through entry Seal Clean inside 49 series fitting electrofusion coupler and weld zone of termination with acetone Slide 49 series fitting along primary pipe and push into final position over Secondary pipe Scrape weld zones for Electrofusion Coupler and 49 series fitting Scrape weld zone of Termination 22 N FOLLOW INSTALLATION INSTRUCTIONS NON COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION DO NOT FIT TERMINATION TO MATCHING STEELWORK OF SYSTEM PRIOR WELDING AS THIS WILL CAUSE STRESS e Ensure assembly is supported and unable to move during the welding process with no stress on any part of the assembly Support termination during the welding process Support Pipe if required both inside and outside the Sump during the welding process Allow fitting to cool to ambient temperature normallv 20 minutes before movement is allowed Fit electrofusion Coupler onto Primary Pipe fully up to Marked insertion depth Fit termination fully into electrofusion Coupler ensuring pipe is not displaced from electrofusion Coupler Fit termination to matching part of System Attach welding green leads to 49 series fitting Weld entry Seal to pipe using green welding leads Ensure pipe is inside fitting up to marked insertion and ensuring the pipe is held horizontallv inside and depth and that there is no stress on pipe or fitting outside Sump Commenc

Installation Manual - Franklin Fueling Systems

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