The document describes the UPP® Piping Installation Guide by Franklin Fueling Systems, detailing the installation, testing, and maintenance of their underground fuel pipe systems.
Function Description
The UPP® piping system is designed for underground fuel transfer, primarily in retail fueling applications, marinas, and airports. It is a high-density polyethylene (HDPE) pipe system that utilizes electrofusion fittings to create a robust, leak-proof, and environmentally secure network for conveying various fuels. The system is designed to meet stringent regulatory requirements for underground fuel storage and transfer.
Important Technical Specifications
Piping System:
- Material: High-Density Polyethylene (HDPE), grade PE100.
- Structure: Available in primary, secondary, and double-wall configurations. The primary pipe is a fuel-proof liner, while the secondary pipe provides containment and environmental sensitivity. The double-wall pipe integrates both primary and secondary functions.
- Pressure Rating (UL971):
- UPP Primary: 6.2 Bar (90 PSI)
- UPP Secondary: 4 Bar
- Pressure Rating (EN14125):
- UPP Primary: 10 Bar (145 PSI)
- UPP Secondary: 5 Bar (72.5 PSI)
- Rupture Pressure: Typically exceeds 10 Bar (90 PSI) for primary and 4 Bar (58 PSI) for secondary piping.
- Pipe Sizes: Available in various diameters, including 32mm, 40mm, 50mm, 63mm, 75mm, 90mm, 110mm, and 125mm.
- Coil Lengths: Pipes are supplied in coils, with lengths varying by pipe size (e.g., 50m, 100m, 150m).
- Bend Radius: Minimum allowable bend radii are specified for different pipe sizes and configurations (e.g., 0.5 m for 32mm single wall, 1 m for 63mm double wall).
- Burial Depth: Recommended burial depth is a minimum of 300 mm (12").
- Backfill Material: Requires 150mm (6") of suitable backfill material (pea gravel, crushed rock, or sand) above and below the pipe.
Electrofusion Fittings:
- Technology: Utilizes electrofusion welding for secure, homogeneous connections between pipe sections and fittings.
- Components: Includes various fittings such as entry seals, entry clamps, and mandrels for hole saws.
- Tools: Requires specific electrofusion entry seal clamps (303-CLAMP-1, 304-CLAMP) and hole saws (HS3-58/92 mm, HS5-140 mm, HS6-160 mm) for proper installation.
- Epoxy: E-32 Epoxy is used for dispensing E-32 on FEB entries.
Testing Equipment:
- Pressure Gauges: Two pressure gauges, rated for 12 Bar (174 psig), min. reading 0.1 Bar (2 psig).
- Hydrophone: For reservoir or pressure tank.
- Check Valve: Ball valve.
- Pressure Relief Valve: Rated for 20 Bar (290 psig), set at 11 Bar (159 psig).
- Test Manifold: For connecting testing equipment.
Usage Features
Installation Process:
- Site Preparation: Requires a clean, dry, and level site for installation. Trenches, sumps, fill points, and vents must be in place.
- Uncoiling: Pipes are supplied in coils and must be uncoiled carefully to avoid damage. The "tail" of the coil must be secured to a stable anchor point.
- Cutting Straps: Straps securing the coil should be cut sequentially from the outside in.
- Staking: Pipes must be staked at least 1-2 meters in length and at least 30 mm x 30 mm to maintain proper alignment and prevent movement during backfilling.
- Pipe Laying: Pipes should be laid in their final position to "relax" before connecting up. The coil is taped up in layers to make it easier to uncoil at manageable intervals.
- Pipe Burial: Recommended burial depth is 300mm (12"). Trenches should be sloped back towards storage tanks. Vapor return lines should have a slope of 2 m/100 m (1/4 in/ft).
- Thermal Expansion: Adequate spacing and running loops are necessary to accommodate thermal expansion and contraction.
- Detector Tape: UPP® Detectable tape is used to allow the piping location to be found after it has been covered. The tape is installed below ground at 254 mm (10 inches) height directly above pipe runs.
Safety Guidelines:
- General Safety: Always secure the work area from moving vehicles, wear appropriate PPE (Personal Protective Equipment), and ensure proper ventilation in confined spaces.
- Electrical Safety: All electrical circuits must be turned off during installation to prevent shock.
- Hazardous Materials: Be aware of the risks associated with flammable liquids and hydrocarbon vapors. Ensure proper ventilation and avoid ignition sources.
- Manual Handling: Use lifting equipment for heavy items and ensure proper lifting techniques to prevent injury.
- Storage: Store pipes and fittings in a flat-bedded vehicle, free from sharp objects. Avoid using chains, hooks, or hawser.
Maintenance Features
Pressure Testing:
- Purpose: To verify the integrity of joints and seals after installation and backfilling.
- Procedure:
- Preparation: Fill the pipe system with water, ensuring all air relief valves are opened while filling.
- Pressurization: Pressurize the system to 10 Bar (145 psig) and maintain this pressure for 30 minutes.
- Stabilization: Allow the pipe to stabilize for 1 hour for temperature adjustment.
- Test Period: Reduce the system pressure to 3 Bar (43.5 psi) by bleeding water from the pipe-work.
- Monitoring: Monitor the pressure for 90 minutes, recording readings at specified intervals (0-10 mins, 10-30 mins, 30-90 mins).
- Acceptance Criteria: The pressure drop during the test cycle must be 3 Bar (43.5 psi) or above. Decreasing readings indicate an increase in pressure, while increasing readings indicate a decrease.
- Recommended Tightness Testing:
- Primary pipe: 3.5 Bar (50 PSI)
- Secondary pipe with Welded Reducers: 1.0* Bar (15 PSI) (*when the primary pipe pressure is higher than the recommended test value in Table 5)
- Secondary pipe with Rubber Reducers: 0.5 Bar (7 PSI)
- Hydrostatic Test Graph: A graph is provided to illustrate the conditioning time and test reading times for maintaining 145 PSI (10 bar) for 30 minutes and dropping to 43.5 PSI (3 bar) for 90 minutes.
- Environmental Factors: Temperature fluctuations can affect test results; direct sunlight and cooler temperatures should be avoided during testing.
- Documentation: Record all test results on the Sump Inspection Register and have the fault(s) corrected if found. Use the provided form (part number 408001011) from the FFS website.
Inspection and Site Organization:
- Equipment Storage: Inspect all equipment and UPP Piping and containment for damage. Store all equipment properly.
- Welder Certification: Confirm welder and welding leads are in good condition and within required inspection dates.
- Cleaning: Acetone and lint-free rags are used for cleaning.
- Installation Steps: Follow all trenching/backfill requirements, proper pipe slope, and welding steps (cutting, scraping, cleaning with acetone, marking insertion depths, assemble and weld stress free).
- Initial Testing: Test all primary piping to 3.5 Bar (50 PSI) for a minimum of one hour. Test all secondary piping at 1 Bar (15 PSI) or 17" Hg Vacuum for a minimum of one hour. Apply soapy water to all fittings during initial test and mark any fittings that fail for replacement.
- Final Testing: Performed after initial testing has passed and prior to backfilling. Primary piping to remain under pressure at minimum of 1 Bar until dispenser installation. Secondary piping to remain under 17" Hg of vacuum until vacuum monitoring installation.
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