Backlling Backll material should be the same as described in section 2. Note: The UPP electrofusion entry seals or R-1 can be installed before mounting dispenser sumps. Sump assembly sequence can be varied. If required the sump riser can be cut down to height, leaving 25mm 1 rainlip above the frame, and the mounting frame repositioned by drilling and rebolting in the new frame positions Install any UPP entry seals according to their specic Instructions.
Mount stabilizer bars Loosely mount stabilizer bars to the side rails using the four bolts nuts and washers supplied. 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 bolts supplied Adjust the shear valve height to ensure that the shear valve groove is ush with the island nish grade Tighten all stabilizer assembly bolts in their nal positions.
Assemble riser When using a UPP riser recommended install the termination tting e. Otherwise thread an appropriate length schedule 40 steel riser or exconnector into the bottom of the emergency shut off valve.
Electrical conduit The DS 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.
Concrete and backll The sump must be secured in the island form using the brackets in the sump mounting frame prior to backll and concrete pouring Backll in accordance with instructions given in backll section of this manual.
Select the correct size hole saw for the selected penetration seal and t to mandrill: I. Remove the bolts, nuts, washers and Jubilee Clips Hose Clamps from the seal and store in a safe place. Centre the Ring over the cut hole. Use the holes in the Ring as a template for the positions of the seal bolt holes and drill. Trim the rubber seal boot for the installation of either 63mm 2 or 75mm 2 double wall pipe using a sharp knife.
Select the correct size Jubilee Clip Hose Clamp and t00 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 seperately. Test tightness against sump wall all around the seal using a piece of card Ensures surfaces are in close contact Re-align seal with sump until all gaps are removed.
Clean the scraped spigot, the end of the boot and the inside of the Attach the boot to the spigot of the entry seal using the welding coupler. Ensure there are no external stresses acting on the assembly. Leave to cool for 20 minutes. Slide the pipe through the seal and the opening in the boot and cut to the desired length.
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 section 7 for details. Wipe clean with cleaning solvent. Ensure there are no external stresses acting upon the assembly.
Unscrew movable ange and remove from tting Add bonding paste to the grooved side of the ange. Fit entry tting from outside sump and tighten loose ange onto the thread from inside sump.
Welding UPP Coaxial Pipe to the Entry Fitting The UPP secondary containment pipe terminates on the outside of the sump wall where it is welded directly to the entry tting spigot using a secondary welding coupler The primary pipe passes through the tting and into the sump.
On the inside either an Electrofusion reducer or a termination boot can be used to seal off the interstitial space. Using the central location hole as a guide, drill through the inside wall of the sump using the same holesaw. Add bonding paste around the entry hole inside and out. Push bonding paste evenly into the cavity between the sump walls. Fit unit to sump wall with xed ange on outside of the sump.
Tighten loose ange onto thread by hand from inside the sump. The principles of reinforcing the surrounding concrete and water runoff angles are maintained through the entire UPP covers range. The large mm 37 diameter circular cover is slightly different as it has two springs inside the spring box, however the principle of seperating and retting the cover from the frame is the same.
Ensure there will be a 15 slope for surface water drainage from lip of frame to forecourt surface once frame is xed in nal position. 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 Ret the cover to the frame, once concrete is dry - see instructions below. Place the cover into the frame at circa Warning - In this position, the Spring Shaft must be correctly located into the seat in the frame - Photo Close the cover to between 30 and 60 - Photo Ret the Spring Box Cover.
Maintenance Apply grease to spring every year There is a rubber gasket on the underside of the cover. To ensure long-term water-tightness the drainage channel in the frame and the gasket should be kept clear of debris.
To renew 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.
Cut horizontal pipe to required length and trim back 75mm 2 double wall pipe to dimension shown in drawing. Slide reducers and mm 4 welding sockets far enough onto 75mm 2 double wall pipe at either extremity of the elbow to allow access to 63mm 2 welding sockets.
Prepare ends of 63mm 2 pipe and ttings as per instructions in section 3. Fit elbow and 63mm 2 welding sockets. Weld and allow to cool before proceeding to next step. Preparemm 4 welding sockets and sliding reducers as per instructions in section 3.
Allow to cool before putting any stress on the assembly Position of ttings during welding of 63mm 2 joint. Prepare secondary contained elbow and welding sockets for welding as per instructions in section 3.
Allow to cool to ambient temperature. Cut pipes to required length and trim back 75mm 2 double wall pipe to dimension shown in drawing below. Slide reducers and mm 4 welding sockets far enough onto 75mm 2 double wall pipe to allow access to 63mm 2 welding sockets. If required leave secondary containment un-welded to allow primary pressure tests to be carried out. Prepare mm 4 welding sockets and sliding reducers as per instructions in section 3.
Allow to cool before putting any stress on the assembly. The versatile unit can also be used to test double wall dispenser and tank sumps and also the interstitial space in secondary contained double wall pipe systems. 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 ashing 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. Join the riser to the base section as detailed in the relevant chamber installation instructions Place new vacuum lid on riser Connect vacuum hoses to riser lid Re-run test as in 4.
Possible leak points include:. Check and listen for leaks in all the areas outlined in the two tests. Rectify faults if found. Check manway tank ange and ttings for leak path. Contact tank manufacturer if leak is found for alternative sealing solutions. Fault on test unit, send to PetroTechnik for repair Check connection to vacuum lid 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. Testing can be done by pressure or vacuum. 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 ofcials and engineers and to comply with local health and safety regulations. All gauges should bear a unique mark serial number and be tested at least annually to ensure that they comply with the accuracy specied in local standards.
The ttings which are used to introduce air or an inert gas into the pipes must incorporate 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 ow from the pressure supply the pressure in the pipe cannot exceed 0. The line under test should be slowly pressurized or de-pressurized for vacuum to minimize any risks. 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. Check that all pipework is disconnected isolated from the underground storage tank prior to commencing pipe pressure testing.
Pressure Testing Non-pressure lines suction, ll, vent,VR Pressure lines Secondary containment terminated with exible boot Secondary containment terminated with electrofusion boot Duct line. HG -0 to 0. Note: Due regard must be taken of pressure variations due to temperature effects.
If during the 30 minute test period the pressure variation exceeds the allowed value see table above it must be assumed there is a leak in the system. 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 Use Nitrogen from a pressure cylinder in lieu of air for testing if a fuel has been used to ballast an underground storage tank Check that all pipework is disconnected isolated from the underground storage tank prior to commencing pipe pressure testing.
Pump rated for more than 10 bar psig Hydrofor Two pressure gauges, rated for 12 bar psig , min. Meter marking or applied ID.. Test Medium Pressure drop.. The information given above is true and correct. Signed by: This copy for:. Meter marking or applied ID. Water Inert Gas Nitrogen Air.. Signed by:. 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 any modication or repair work to UPP pipework, the safety of on-site personnel is paramount and all national, regional and local health and safety legislation should always be adhered to. The following checklist gives a step-by-step guide to ensuring that the modication is carried out in the safest possible manner. However relevant local health and safety regulations should take precedence over the advice given here. 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. Air exchange if necessary. Break disconnect the product supply line at the tank sump, allowing for any residual petroleum liquid contained within the product line to ow out into the approved sealable containment vessel. Open the shear valve access ports of the affected lines to allow the petroleum liquid to drain down to the tank sump. Shut close all the shear valve access ports once no further fuel ows out of the product line.
Undertake and complete the repair to the UPP pipework and ttings up to the point of welding in accordance with UPP installation instructions. The repair assembly of UPP pipework and tting 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 not be connected to the welding machine at this stage. Connect the nitrogen supply to a shear valve access port and ood the product line and sump, the O2 meter should record the presence of no oxygen in the sump.
Once no oxygen is recorded on the O2 meter, the welding machine and power supply can be located above ground 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 15 minutes.
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. The new welded joint should be wiped with soapy water to make it easier to check for signs of leakage. On completion of a successful pressure test, the submersible pump can be re-connected and the dispensers re-commissioned. Site preparation Seal off the area where the work is to take place Check underground tank for water and record the result Check and pump out any water or product from the tank sump and manifold sump following disposal regulations Isolate power to the dispensers and tag out Isolate power to the submerged turbine pump STP and tag out Old pipe system being removed for replacement with UPP.
Remove pressure from product line if applicable by operation of the closest dispenser to the underground storage tank until no more product is discharged Close all ball valves and shear valves along the pipe-line that is to be replaced. Dispenser removal Disconnect wiring from the dispenser Disconnect pipeline to the dispenser and collect any residual product in an approved sealable containment vessel Move the dispenser to allow adequate access to the dispenser sump.
Removal of existing pipework Isolate pipe-line by disconnecting termination ttings from the steel ttings at the tank top UPP towing eye for coaxial double wall pipe. Connect a towrope to isolated pipe-line using a UPP towing head, ensuring towrope is longer than the duct pipe-run.
Use a cap to prevent any spillage of residual product from the pipe Remove existing pipes by pulling on the pipe itself from one end and ensure that the towrope is pulled through the outer duct pipe as this happens. A pulley system may be required to achieve a horizontal pull through the duct Remove residual product from pipes into an approved sealable containment vessel Ensure duct is clear of residual product and ush if required.
This is because the UPP towing eye damages the area of the pipe into which it is inserted and this must be removed after towing Fit UPP towing head into pipe and secure the towrope Ensure the non-towing ends are capped to prevent contamination from existing outer pipe into new UPP pipe Install UPP through the duct by pulling on the towrope and pushing on the opposite pipe end if necessary.
A pulley system may be required to achieve a horizontal pull through the duct. Remove the towing eye and cut back the pipe where it was attached as this will have a damaged liner Install appropriate UPP ttings at either end of new pipeline and re-attach pipeline to steel tanktop ttings Install exible connectors and ball valves Tightness test the pipelines following our guidelines in Section 5 - Tightness Testing.
Re-t and re-commission dispenser Replace dispenser and secure with bolts Re-connect exible connector to dispenser via the shear-valve and connect the shear-valve to the sump stabiliser bar framework Re-connect electrics Open Ball valves and re-instate power to STP and dispenser. Flush new lines The line needs to be bled of air to ensure the STP mechanical leak detector returns to its normal operating position Conduct a visual inspection of piping connections paying particular attention to threaded joints on ball valves, exible connectors and shear-off valves checking for seepage Correct ushing means dispensing litres 53gallons of product from furthest dispenser on product line and 50 litres from all other dispenser nozzles Ask the station manager to verify the quality of the product being dispensed Place the dispenser back into operation.
Where Ew is the water elasticity modulus, Ep the pipe elastictiy modulus, P the water density, Dm the mean pipe diameter and the pipe wall thickness. The following diagram shows the water hammer effect for various types of piping, the uid considered in this test is water.
Thanks to its exibility UPP pipework is the pipe system with the lowest peak pressure. Please consult PetroTechnik Ltd. If in doubt the resistance of grounding should be k 1 M. Earthing cables should be plastic covered copper conductors of at least 4mm2 cross sectional area and should be connected to an exclusive earth electrode.
Note: The metal ttings at the tank manhole should be at equal potential so additional cables may be required to to interconnect the metal ttings The drawings below show how to ground various types of UPP metal termination ttings. UPP 11 series thermofused threaded termination showing optional coupling anges requires earthing strap.
This question and answer section has been compiled to answer the most commonly found questions on the issues of electrostatic generation in fuelcarrying plastic pipeline systems.
What is static electricity and why is it considered a hazard? Static electricity is an electrical charge which is produced when two surfaces are brought together and then separated for example fuel and pipe.
It is possible for an electrical charge to accumulate on insulating materials, such as plastic, and on ungrounded conductors, such as metal parts or even personnel. Static electricity becomes an ignition hazard only when an electrostatic discharge ESD occurs, such as by the generation of a spark.
Static electricity is a low power but potentially a high voltage phenomenon and ESDs only pose a threat to sensitive materials such as ammable hydrocarbons and ne combustible dusts. Is any electrostatic charge generated during fuel ow through a pipe? How does the level of electrostatic charge generation compare between metal and plastic pipes? Generally, the level of charge generation in the fuel is higher with metal pipes than with plastic pipes.
Static electricity occurs in the fuel due to a charge separation process at the pipe wall. If the pipe wall is a grounded conductor it can supply more electrical energy to the charge separation process. You need an electrostatic discharge ESD to ignite fuel vapour. Where are these likely to occur? The most likely electrostatic ignition source is a spark from an ungrounded piece of metalwork that has in some way acquired sufcient electrical charge.
Can you get electrostatic sparks from the surface of plastic pipes? Spark discharges only occur from conductive objects and plastic pipes are insulating in nature.
Plastic surfaces can give rise to the less incendive brush discharges if they have acquired a high level of surface charge density.
Wolfson Electrostatics has not observed this due to fuel ow in any plastic pipe system so far tested. Are plastic materials commonly in use for fuel handling? The use of plastics is now widespread in a number of applications.
GRP, Nylon and polyethylene pipe have been installed in tens of thousands of forecourts in over countries throughout the world and virtually all modern motor vehicles now incorporate a plastic fuel tank and ller pipe.
Some fuel storage vessels are also constructed from plastic, such as the common 5-litre emergency fuel tank. Have there been any reports of electrostatic ignitions attributed specically to the use of plastic underground pipework? There have been no reported incidents relating to UPP pipe. Five million metres of UPP pipe has been installed in 15, sites over countries.
Which Standards apply to this subject? Is there a safety audit that can be applied to such pipework systems? A test method has been developed which has been accepted and approved for example by the London Fire Brigade and Civil Defence Authority in the UK and other re authorities worldwide. Q10 How well does the UPP system fare in this audit? A Results from the audit show that the UPP system performs safely with respect to electrostatic hazard, provided that the system is installed correctly according to the manufacturers instructions and any additional industry specic regulations.
Q11 Have plastic pipes been tested under worst case conditions for electrostatic hazard? A Certainly. UPP pipework passed the wolfson audit to the current European standards and therefore is also certied by the Institute of Petroleum.
Is UPP pipe exible or rigid? UPP pipe combines the best of both worlds, it is exible enough to coil and bend for ease of installation but rigid enough to be used for vapour recovery VR lines. Within which ambient temperature range can electrofusion welding can be carried out? From C to 45C 14F to F. What are the recommended backll materials for bedding and burial of UPP pipe and ttings?
See section 2. Yes, crossing pipes should be protected by a minimum of 5 cm 2 of compacted backll or 2. Yes, it is very important to align pipe and ttings, both during welding and cooling process and ensure there are no external stresses or loading acting on weld assemblies. In the event of a power shortage, can electrofusion welding be restarted? Yes, but the assembly must have completely cooled down to ambient temperature before electrofusion is restarted What are the differences between the UPP pipe system versus the braided exible piping systems?
UPP is different from braided exible 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 conveyance of natural gas. Pressure grade means that, independent laboratories have determined the product lifetime when it is subject to pressure Is UPP pipework a suction only system?
How do UPP pipe and ttings perform under constant positive operating pressures of up to 58 psi 4 bars or kPa? 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 Q10 What are the advantages of the UPP secondary containment double wall pipe system versus other secondarily contained pipe systems? Secondary containment or double wall systems used by other competitors are merely a jacketing conduit with no mechanical strength.
Also UPP systems includes genuine secondary contaiment tees and elbows with a complete interstitial space. A Since swelling and growth are side effects of permeation, these effects can be more serious and prejudicial to pipe integrity and site safety than a small amount of gas diffusion.
During that time no weight loss or growth was recorded. UPP pipe will not swell because the internal liner is impervious to hydrocarbons. The abnormal growth caused a failure of the containment sump entry ttings. 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 ttings 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 ttings? 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 1 areas of a site and are long enough to reach into zone 1 whilst the unit itself remains safely in zone 2.
See section 6 of this manual for detailed instructions for installing UPP on a live site Q14 Can I modify UPP pipework once installed, or make repairs to a system which has been physically abused? A Yes. Unlike exible plastic hoses which can only be joined with mechanical ttings which are not allowed to be direct buried, UPPs welding system allows modications to be made rapidly and safely. PetroTechnik has instructions for welding on live sites fully describing how to isolate and purge pipes which have carried fuel or vapour.
A 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. UPP primary pipe is designed for suction negative pressure or pressurised systems. A This is largely temperature dependent, but in general you may use these values for UPP:. Remember to refer to PetroTechnik Technical Department for specic concentrations and temperatures Q20 How do I know the pipe I install today will resist fuel changes in the future?
A Vehicle manufacturers nearly 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 company 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; UL and Institute of Petroleum Pipework Specication are two such examples.
UL tests include todays fuels such as: premium leaded gasoline, unleaded regular gasoline plus ASTM reference fuel C, toluene, and No. Q21 Plastic pipe is non-conductive and will hold a static charge caused by fuel ow. How much risk is there of a static electricity discharge and explosion? A None. Pipes lled with fuel have no oxygen present and cannot explode. Q22 There are other types of thermo-fusion welding socket available. Can I use the UPP welding set with them? Note: UPP Constant Current models may appear to work with other manufacturers 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.
Electrofusion Safety UPP welding units must never be operated in zone 1 areas Zone 1 indicates that a ammable vapour would normally be expected during routine operation i. Zone 2 is an area where a ammable atmoshere would not normally exist and if it did would be of a short duration i.
The area immediately surrounding the dispenser and sump. This Zone takes the shape of a cone from the top of the pump to the oor level. The base of the cone has a radius of 2. 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 UPP Welders can be operated in zone 2, and the welding cables and ttings are zone 1 rated.
Welding can be carried out in zone 1 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 accompanying literature. Conned Space Legislation Some installation of UPP products may occur in conned spaces where a lack of oxygen and a concentration of toxic vapours is likely to be experienced Such working conditions are dangerous and all local health and safety guidelines for working in such environments should be followed.
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Flag for inappropriate content. Download now. Related titles. Carousel Previous Carousel Next. Jump to Page. Search inside document. Otherwise use a crane tted with a spreader beam When using a forklift to on or off-load coils, the forks should be covered to avoid damage to the coiled pipe 1. Site inspection: Install offset ll lines if applicable Make sure the site is prepared and ready.
Start with the installation of the offset ll lines from the tank and work towards the offset ll point To install the UPP pipework system: The site should contamination be free from previous fuel The tanks should be in place The bottom layer of bedding and backll material should have been laid in the trenches see section 2.
If using exible boots, ensure jubilee clips are located correctly so the boot can be tightened against pipe after welding 4. 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 Cut the pipe ends square using the correct size of UPP cutting tool.
Do not use saw-toothed blades Assemble to nal position making sure Acetoned areas are not touched by hand and clamp. See section 10 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.
It is also recommended that, in addition, a photographic record is provided Secondary Containment SC It is common practice for SC systems to be used with the pipework for pressure systems Note: The scraping of SC pipe must be done using a hand scraper The laying and fall back considerations are identical to Primary pipe installations. Ensure appropriate welding cables are used 2 Prepare the pipes for welding using the pipe scraping tool provided in the UPP tool kit 4 Clean ends of pipe using a lint free cloth moistened with Acetone.
Acetone removes oils, ngerprints and moisture 6 Assemble the joint and use clamp to hold in place. Check insertion is up to the premarked depth indication 8 Allow joint to cool to ambient temperature. Ensure appropriate welding cables are used 2 Prepare the pipe for welding using the pipe scraping tool provided in the UPP tool kit. The tting spigot must also be abraded using emery cloth 4 Clean scraped end of pipe and tting spigot using a lint free cloth moistened with Acetone 6 Assemble the joint and use clamp to hold in place.
Acetone removes oils, ngerprints and moisture Clean inside of fusion tting using a lint free cloth moistened with Acetone 10 Prepare the pipe for welding using the pipe scraping tool provided in the UPP tool kit Assemble the joint and use clamp to hold in place.
Check insertion is up to the premarked depth indication 8 Connect welder and follow welding unit instructions. Ensure appropriate welding cables are used Allow joint to cool to ambient temperature. Scraping UPP primary pipe using scraping tool 3.
Abrading duct pipe with emery cloth Non electrofusion Fittings Non electrofusion ttings i. Any number of UPP ttings can be welded simultaneously using the available bridging leads as long as their combined index resistance values do not exceed 10 Note: A resistance value of X means that there is no marked resistance value on the ttings and these should be treated as having values of 10 Description Part number Resistance index number Primary Welding Sockets Photo of resistance index number on a UPP Any movement during this period could result in permanent misalignment and could affect the integrity of the joint Description Part number Resistance index number Secondary welding sockets Secondary welding socket Disobeying this recommendations will invalidate the warranty 2.
This occurs after large numbers of welds Software or hardware damage to machine General hardware error Send for service Switch off the machine and let it cool in the shade for a few minutes Let the tting cool down for at least one hour before re-starting the weld process with the same tting. Press [ENTER] to reset machine for welding The previous weld was interrupted by an error Weld was faulty alternating with - repeat after one hour Box internal temp.
Push connectors rmly on to terminal pins of tting Switch off and then on again after 30 seconds Loose contact in the welding circuit or a poor connection to tting terminal pin Open secondary circuit - alternating with - switch off welding kit Information on display Switch off the welder and switch on again after 30 seconds. If this error consistently re-occurs send for service 3. Check the resistance index value of the ttings -the sum must not exceed 10 See input voltage too low Send machine for service Welding in prog.
Current below lower limit - alternating with - switch off welding kit 4 Welding Start with ENTER Get the generator checked by a service centre and reset. Get the generator checked by a service centre and reset Fully unwind extension cable to minimise resistance Display the welding mode Depending on which welding cable is connected, The display shows: Orange cable: Primary mode Green cable: Secondary mode PetroTechnik Primary Mode The input voltage of the power source is too low for the machine tolerances Switch the machine on by pressing the green button top-left on the machine Input voltage too low - alternating with - switch off welding kit Check the connection.
Maintenance and Service From a safety point of view, all cables need to be checked each time before use. The machine should be handled with the care usually given to electrical equipment especially during transport During the welding process, the following key value will be shown on the display: - Applied current - Remaining welding time counting down Each time the welding machine is used, the condition of the machine, and especially the power cable needs to be checked.
It is also advisable to check the welding cables The welding machine operates on standard alternating current. This occurs after a large number of welds Software or hardware damage to machine Box internal temp. Press [ENTER] to reset machine for welding The previous weld was interrupted by an error Information on display Weld was faulty alternating with - repeat after one hour 3.
These connections require the use of a green Secondary welding cable. Furthermore the machine carries the CE mark for European conformity. The guarantee period is one year from the date of purchase. 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 to PetroTechnik.
Maximum service interval: three years. It is also advisable to check the welding cables The welding machine operates on standard alternating current. When the SELECT key is pressed for more that 10 seconds, the display will show the number of faulty and good welds completed with the machine. This occurs after a large number of welds Software or hardware damage to machine Box internal temp. Press [ENTER] to reset machine for welding The previous weld was interrupted by an error Information on display Weld was faulty alternating with - repeat after one hour 3.
If this error consistently re-occurs send for service After approximately. If neccessary connect a load approximately. In addition power conducting elements could become touchable. C01 PS3 PS6 1. Measure and mark the centre position of the required pipe sump penetration 2. Remove the bolts, nuts, washers and Jubilee Clips Hose Clamps from the seal and store in a safe place 4.
Remove the Backing Ring from the seal 5. Centre the Ring over the cut hole. Use the holes in the Ring as a template for the positions of the seal bolt holes and drill 6. Ensure there are no external stresses acting on the assembly 5 Weld the coupler using the green secondary containment welding leads. Leave to cool for 20 minutes 30 3.
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.
Ensure there are no external stresses acting upon the assembly 13 Weld with the primary orange welding lead Allow to cool for at least 20 minutes 33 protecting your liquid assets 3. On the inside either an Electrofusion reducer or a termination boot can be used to seal off the interstitial space.
The principles of reinforcing the surrounding concrete and water runoff angles are maintained through the entire UPP covers range.
Reinforced Concrete. Weld and allow to cool before proceeding to next step 6. If required leave secondary un-welded for primary pressure tests to be carried out 8.
Prepare secondary contained elbow and welding sockets for welding as per instructions in section 3. LS If required leave secondary containment un-welded to allow primary pressure tests to be carried out 6. Allow to cool before putting any stress on the assembly 7.
The versatile unit can also be used to test double wall dispenser and tank sumps and also the interstitial space in secondary contained double wall pipe systems. Rectify faults if found Vacuum still falling. Contact tank manufacturer if leak is found for alternative sealing solutions. Fault on test unit, send to PetroTechnik for repair Check connection to vacuum lid and pump. To check pump, block one end of pipe and monitor the movement of the vacuum gauge.
Testing can be done by pressure or vacuum. HG -0 to 0. Test Medium Pressure drop ….. Finish ….. The information given above is true and correct. Signed by: This copy for: ……………………….. Test Medium Pressure drop …. Water Inert Gas Nitrogen Air ….. Signed by: 50 ……………………….. 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.
However relevant local health and safety regulations should take precedence over the advice given here. Method 52 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. The new welded joint should be wiped with soapy water to make it easier to check for signs of leakage 27 Perform any regulatory testing requirements and sign offs as required 28 On completion of a successful pressure test, the submersible pump can be re-connected and the dispensers re-commissioned 53 protecting your liquid assets 7.
Internal Diameter nom. Cross Sectional Area Please consult PetroTechnik Ltd Earthing cables should be plastic covered copper conductors of at least 4mm2 cross sectional area and should be connected to an exclusive earth electrode. This question and answer section has been compiled to answer the most commonly found questions on the issues of electrostatic generation in fuelcarrying plastic pipeline systems.
Q1 A What is static electricity and why is it considered a hazard? Static electricity is an electrical charge which is produced when two surfaces are brought together and then separated for example fuel and pipe.
It is possible for an electrical charge to accumulate on insulating materials, such as plastic, and on ungrounded conductors, such as metal parts or even personnel. Static electricity becomes an ignition hazard only when an electrostatic discharge ESD occurs, such as by the generation of a spark.
Q3 How does the level of electrostatic charge generation compare between metal and plastic pipes? Generally, the level of charge generation in the fuel is higher with metal pipes than with plastic pipes.
Static electricity occurs in the fuel due to a charge separation process at the pipe wall. If the pipe wall is a grounded conductor it can supply more electrical energy to the charge separation process. Where are these likely to occur?
Q5 A Can you get electrostatic sparks from the surface of plastic pipes? Spark discharges only occur from conductive objects and plastic pipes are insulating in nature. Plastic surfaces can give rise to the less incendive brush discharges if they have acquired a high level of surface charge density.
Q6 A Are plastic materials commonly in use for fuel handling? The use of plastics is now widespread in a number of applications. Some fuel storage vessels are also constructed from plastic, such as the common 5-litre emergency fuel tank.
There have been no reported incidents relating to UPP pipe. Five million metres of UPP pipe has been installed in 15, sites over countries.
Q8 A Which Standards apply to this subject? Q11 Have plastic pipes been tested under worst case conditions for electrostatic hazard? A Certainly. See section 2. In the event of a power shortage, can electrofusion welding be restarted? UPP pipe has been installed in both pressure and suction type systems. Secondary containment or double wall systems used by other competitors are merely a jacketing conduit with no mechanical strength. Also UPP systems includes genuine secondary contaiment tees and elbows with a complete interstitial space.
A Since swelling and growth are side effects of permeation, these effects can be more serious and prejudicial to pipe integrity and site safety than a small amount of gas diffusion. During that time no weight loss or growth was recorded. UPP pipe will not swell because the internal liner is impervious to hydrocarbons.
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 welding cables however are rated to be used in zone 1 areas of a site and are long enough to reach into zone 1 whilst the unit itself remains safely in zone 2.
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