Installation Manual UPP Piping

protecting your liquid assets
PRODUCT INSTALLATION MANUAL

Contents
Section
Title
Page
Transport, Loading and Storage
1.1
Transit, on-loading and off-loading
1.2
Storage on site
1.3
Summary of rules
1.4
Uncoiling Pipe
Site Preparation
2.1
Getting started
2.2
Digging trenches and bedding
Installation Instructions
3.1
Site installation overview
3.2
Electrofusion method - Coupling two primary pipes
3.3
Electrofusion method - Primary pipe to a non-fusion tting
3.4
Electrofusion method - Primary pipe to a fusion tting
10
3.5
Electrofusion preparation details
11
3.6
Welding - overview
13
3.7
Installing a UPP polyethylene tank chamber
24
3.8
Installing a UPP polyethylene dispenser sump
26
3.9
Installing a UPP mechanical entry seal - (Holesaw/Seal compatability chart)
28
3.10
Installing a UPP electrofusion entry seal
29
3.11
UPP electrofusion seal options
30
3.12
Installing a UPP electrofusion FRP entry seal on a single wall tank sump
34
3.13
Installing a UPP electrofusion FRP entry seal on a double wall tank sump
37
3.14
Installing a UPP access cover
40
3.15
Electrofusion method - Secondary containment (double wall) 90 elbow
42
3.16
Electrofusion method - Secondary containment (double wall) Tee
43
System Integrity Testing Instructions
44
Tightness testing
46
5.1
Pressure testing
47
5.2
Vacuum testing
48
5.3
Pressure line testing at maximum operating pressure
48
Modication And Repair Of UPP Sites
52
Pipe Re-t Through Ducts
54
Water Hammer Effects
56
Flow Loss Rates
57
10
Electrostatic Safety
59
11
Frequently Asked Questions
62
12
Safety
66
13
Notes
67
1. TRANSPORT, LOADING AND STORAGE

1.1 Transit, on-loading and off-loading
Although UPP polyethylene pipe and ttings are extremely hard wearing and
resilient, it is important to handle and store them with care to prevent scufng
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)
UPP products should be transported in a at-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 (19ft 8)
Allow for a slight bending of the pipe crates when on and off-loading
Standard 6m (19ft 8) crates may be moved using a forklift. A side loader
tted with a minimum of four supporting forks should be used for longer
lengths. 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
1.2 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 rm 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 at. 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
UPP ttings - all electrofusion ttings 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 ttings. These must be kept in their
packaging until ready for use to prevent any contamination or oxidisation
UIM-V1.00.11.04
1.3 Summary of rules

Always
Store pipes on at, rm level ground
able to withstand the weight of pipes

and lifting equipment
Keep pipe and ttings well away from
sharp objects such as ints and other
site debris
Use wide, non-metallic slings when
lifting pipe
Exercise special care when handling
pipe in wet or frosty conditions. Use
gloves for additional grip
Keep protective packaging intact until
pipe or ttings are required for use
Keep both pipe and ttings out of
direct sunlight or intense heat until
ready to use
Ensure lifting and storage points are
evenly spaced
Reject pipe if surface damage is
excessive. Minor abrasions can be
ignored
Light abrasion handling damage, limited
to a single area between a set of
tapes less than 5mm (3/16) wide is
permitted
Never
Expose pipe or ttings to prolonged
direct sunlight or excessive

temperatures
Throw, drop, drag or roll individual
pipes, bundles or ttings as this can
cause damage or subsequent leakage
Use metal slings or chains when
handling pipe
Stack pipe more than three coils or
three bundles high
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 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 nal 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 nd 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
2. SITE PREPARATION
2.1 Getting started
Dispenser mounting frames, offset-ll and vent frames should be positioned
rst and rmly xed at their nal 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 backll 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 1.5m (5ft)
A recommended 15cm (6) bed of backll material should be laid
underneath the pipe prior to installation and there must never be voids
under or around the pipe. Acceptable backll materials are:
Well-rounded pea gravel with a maximum particle size not exceeding
20mm (). No more than 3% of particles should pass through a 3.5mm
(1/8) screen
Crushed rock with a maximum particle size not exceeding 16mm (5/8). No
more than 3% of particles should pass through a 3.5mm (1/8) screen
Well-graded sand with a maximum particle size not exceeding 3.5mm (1/8)
The bed 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 ttings must be located 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, backlling 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
backll 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 re damage by wrapping it in radiation or thermal shielding
tape. Additional supports and anchor points may also be required
UIM-V1.00.11.04
3. INSTALLATION INSTRUCTIONS
This section provides practical information regarding the installation of all parts
of the UPP system.
Electrofusion, or welding by electrical heating, lies at the heart of the UPP system
and helps to create one homogenous and permanently leak tight system.
PetroTechnik 230 volt and 115 volt Welding Units have been designed to supply
the exact, controlled electrical energy necessary to fuse two UPP products
together and to provide complete safety 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 solidies to form a homogenous
union stronger than both the original pipe and tting
The simple welding procedure includes some preparation of the pipes and
ttings themselves to remove the outer layer of oxidised polyethylene and
ensure that there is no dirt or grease in the electrofusion zone - this ensures a
100% successful weld every time.
It is imperative that this preparation procedure is carried out to ensure the
integrity of the joints. A poorly prepared weld may leak and will be detected
during the tightness testing procedures outlined later in this manual, ultimately
leading to expensive and time consuming re-tting of faulty assemblies.
Welding coupler showing internal

heating element
3.1 Site installation overview

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 2.2)
The vent ll and pump/dispenser frames/sumps should be
in their nal position in relation to the nished forecourt
surface level
Ensure there is an adequate power supply for electrofusion
either from the mains or a suitable generator (minimum
4 KVA)
2. Uncoil the pipe into the installation area and
allow it to relax
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 1.4)
When using electrofusion welding joints, it is important

to follow the correct welding unit operating manual in
section 3.6.
Attach a termination tting to the tank steel work
Prepare pipe ends prior to passing through chamber
wall. Make sure any lengths have clean square cut ends.
Use appropriate UPP pipe scraper to remove layer of
oxidised pipe at the end that is to be welded
Note: It is best practice to terminate the UPP pipe
outside the diameter of the tank man lid. This makes it
easier to carry out future maintenance work. A pipe break
connection i.e. stub ange, DN Square Flange or union
tting should be installed at the tank man lid edge
3. Install the tank access chambers / sumps

Follow the manufacturers installation guidelines for tank
sumps/chambers. (see section 3.7 for UPP polyethylene
chamber)
Pass the pipe through the chamber wall via the penetration
tting, ensuring that all boots are in place. If using exible
boots, ensure jubilee clips are located correctly so the
boot can be tightened against pipe after welding
4. Make sure all the tank top steel ttings are

installed
Wipe scraped pipe end and the welding coupler/fusion

end of termination tting with an Acetone soaked lint
free cloth
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 1m every 100m (1/8
per foot), this may vary to meet Local Requirements. The
poisition of the entry ttings at the furthest dispenser
sump away from the tank chambers may be considerably
higher than that of the entry ttings 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
Cut the pipe ends square using the correct size of UPP
cutting tool. This gives a clean cut requiring no de-burring.
Do not use saw-toothed blades
Assemble to nal position (making sure Acetoned areas

are not touched by hand) and clamp. Check for full
insertion of pipe into tting and appropriate fall back of
that pipe section
Proceed with electrofusion weld
Once the weld has been cooling for 20 minutes, remove
clamps and tighten jubilee clips on any exible entry
boots or weld fusion entry boot if applicable
Lay the remaining pipe required to the ll point,
positioning, preparing and welding any inline couplers and
or elbows/tees as pipe is laid. All the time ensuring the
required fall back rates are adhered to
Fit UPP termination assembly to the ll point position at
the end of the Fill Pipeline
Install vents and vapour recovery stage 1b

(VR 1b)
If possible and applicable, lay vent lines into the same
trench as the offset ll lines
If vents are remote from offset ll lines a separate VR1b
line is required to connect the vent stack to the ll 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
For pipe preparation and welding refer to sections 3.53.6
Install VR Stage 2 (VR 2)

Exact requirements for VR 2 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
nal connection at either the tank chamber or VR1b
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
VR 1b should be laid between the vent stack and the ll

point with no fall-back i.e. completely horizontal
Note: This is a guideline. Local requirements and
regulations will need to be taken into consideration.
It may require manifolding and connection to the vapour
recovery stage 2 system
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
For pipe preparation and welding refer to sections 3.53.6
Important:
Earthing of metal terminations
All UPP metal terminations in the ll box, at the tank top
and under the dispense should be adequately earthed
according to local electrical regulations. If in doubt,
ensure resistance value of grounding is 100.
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. Care must be taken during
assembly that sufcient room is available not only for
terminations and the installation of ttings on Primary
lines, but also for ttings to terminate SC pipe
Refer to section 3.6b for information about alternative
welding leads for SC and different welding cycle
durations
3.2 electrofusion method

Two primary pipes
1
Cut pipe to length allowing for correct insertion
depth into welding coupler
3
Insert pipe into welding coupler until visibly
against stop and mark pipe to indicate insertion
depth
Clean bore of welding coupler with Acetone
Connect clamped assembly to welder and follow

welding unit instructions. 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.
At least 20 minutes should pass before any
stresses are exerted upon the assembly

Primary pipe to a non-electrofusion tting
1
depth into welding coupler
3
Insert pipe into welding coupler until visibly
against stop and mark pipe to indicate insertion
depth
5
Clean bore of welding coupler with Acetone
7
Connect clamped assembly to welder and follow
welding unit instructions. 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
depth indication
8

Primary pipe to a fusion tting
2
depth into fusion tting
3
Insert pipe into tting until visibly against stop
inside tting and mark pipe to indicate insertion
depth
Clean scraped end of pipe using a lint free cloth

moistened with Acetone.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

depth indication
8
Connect welder and follow welding unit
instructions. Ensure appropriate welding cables
are used

UIM-V1.00.11.04
3.5 electrofusion preparation details

Before any welding can take place all pipes and ttings must be prepared for
electrofusion. Pipe ends must be cut square to ensure that they extend fully
into weld zones. All surfaces that do not incorporate welding elements (i.e.
all pipes and non-electrofusion ttings) that are to be welded must have the
outer layer of oxidised polyethylene removed. All surfaces must be wiped
down with Acetone or another UPP approved solvent to remove grease and
dirt. The following instructions detail the preparation of UPP products for
electrofusion.
3.5.a Cutting pipe
Cutting primary pipe using

UPP cutting tool
Primary pipe (single wall pipe)

Primary pipe should only be cut using the appropriate UPP pipe cutter tool
and never using a hand saw. The UPP cutting tool gives 100% straight cuts
every time and no burring ensuring that the cut ends t ush into any welding
couplers or ttings
There are four different pipe cutters available for varying pipe diameters
Tool
P.CUT SMALL
P.CUT
P.CUT MED
P.CUT.160
Pipe Diameter (mm)

32-50
50-110
110-160
160
Pipe Diameter (inches)

1-1
1-4
4-6
6
Cutting secondary pipe using

UPP cutting tool
Secondary containment pipe (double wall pipe)

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 pipe
It 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.
Scraping UPP primary pipe

using scraping tool
3.5.b Scraping and abrading

It is imperative that the scraping of pipes and abrading of ttings 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.
Primary pipe (single wall pipe)

Primary pipe must be scraped using the UPP scraping tool (SCR.K(1)). This
tool removes a controlled outer layer of oxidised polyethylene over the length
of the pipe which is inserted into a coupler or electrofusion tting.
Secondary containment pipe (double wall pipe)

Secondary containment pipe has to be scraped using the UPP hand scraper
(SCR.SKA). A layer of plastic must be removed all along the length of pipe to
be inserted into the welding coupler or electrofusion tting.
Scraping UPP secondary pipe

using hand scraper
11
Duct Pipe
Duct pipe must be abraded using emery cloth as its corrugated structure
doesnt allow the UPP scraping machine or the hand scraper to be used.
Care must be taken to abrade all around the corrugations.
Abrading duct pipe with
emery cloth
Non electrofusion Fittings

Non electrofusion ttings (i.e. those that need an electrofusion coupler to be
welded) must be abraded with emery cloth before welding can commence.
The spigot of these ttings must be abraded using emery cloth to remove a
layer of oxidised polyethylene along the whole length that is to be inserted
into the welding coupler
Electrofusion Fittings / Welding Couplers

Abrading all around
corrugations of duct
electrofusion ttings are those with welding elements built into them - these
do not require scraping before being used.
3.5.c Cleaning
To ensure that there is no grease, moisture or dirt in the electrofusion zone
during welding it is important to clean all the pieces of the assembly with
Acetone or another cleaning solvent prior to welding
This includes:
All scraped areas of pipes and ttings
Abrading UPP non
electrofusion tting with emery
The inside of electrofusion ttings and welding couplers

Once the areas of pipes and ttings to be welded have been wiped clean, avoid
contact with them and your hands or any other sources of grease/dirt
3.5.d Clamping
It is important to check for correct alignment of the assembly both vertically
and horizontally and ensure that it is not subjected to any bending load or
weight that could deform the joint while it is in a molten state
Cleaning a welding socket

with an acetone soaked cloth
Cleaning a seal spigot with an

acetone soaked cloth
12
Use UPP clamps to keep the assembly in the correct alignment position
preventing any movement during the welding and subsequent cooling process
If a clamp cannot be used, for example in the tank chamber, precautions need
to be taken to ensure the assembly is not under any stress
UIM-V1.00.11.04
3.6 Welding - overview
UPP 230 volt and 115 volt intelligent Welding Units have been designed to
supply the exact, controlled electrical energy necessary to fuse two UPP
products together and to provide complete safety 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 solidies to
form a homogenous union stronger than both pipe and ttings
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 ttings resistance values, it must be positioned in the
same environment as the joint it is welding
Note: In bad weather conditions,

a shelter may need to be
constructed to prevent any water
droplets from entering the fusion
area and contaminating the joint
prior to welding
A maximum of three primary couplers or primary electrofusion ttings may be

welded at the same time by using bridging leads. Most electrofusion couplers
and ttings have a resistance index number marked onto them inside a circle:
i.e. 6 . The total value of the index number of the three items to be welded
must not exceed 10. If the tting 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 3.6.a and 3.6b
Full welding unit instructions can be found in section 3.6.c and 3.6.d
3.6a Welding - primary pipe and ttings

Orange welding cables should be used for welding primary pipe. (Except 160
(6) and 200mm (8) which use special orange cable with 2mm (5/64inch)
welding pin available from PetroTechnik - do not use orange primary or green
secondary welding cables)
Apply power to welding unit
UPP Welder - 230 volt
The welding unit display should read: Primary Mode and after ve seconds
Connect welding element
Note: Older welding units do not have LCD displays
Attach the welding cable to the assembly to be welded via the welding pins on
the coupler/electrofusion tting
The display should read Welding start with ENTER
Press the ENTER key to begin the weld.The unit automatically detects the kind
of tting it is welding and 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 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
dont show perform a pressure test to check the joint.
UPP Welder - 115 volt
13
During the welding process and until the fusion coupler / tting has returned to
ambient temperatures, the polyethylene pipe and socket will be fusing together.
Any movement during this period could result in permanent misalignment and
could affect the integrity of the joint
Tables 3.1 and 3.2 show the available UPP primary and secondary contained
electrofusion ttings and show their individual resistance index values. 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 02.110
welding coupler
Primary welding socket
02.32
02.50
02.54
02.63
02.90
02.110
02.160
10
02.200
10
EIF Elbows 90 and 45, Tees and Reducers

electrofusion elbow 90
03.50EIF
03.63EIF
03.90EIF
03.110EIF
04.63EIF
04.90EIF
04.110EIF
electrofusion equal tee
08.50EIF
08.63EIF
08.90EIF
08.110EIF
electrofusion reducer
09.90.63EIF
electrofusion reducer
09.110.90EIF
electrofusion entry seal
305
electrofusion entry seal
308
Table 3.1 - Primary Welding Fittings
14
UIM-V1.00.11.04
3.6b Welding secondary containment pipe and

ttings
Green welding cables should be used for welding secondary containment
pipe
The welding unit display should read: Secondary Mode and after ve seconds
Connect welding element
Attach the welding cable to the assembly to be welded via the welding pins on
the coupler/electrofusion tting
The display should read Welding start with ENTER
Press the ENTER key to begin the weld.The unit automatically detects the kind
of tting it is welding and 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 should be left to cool
completely before welding is restarted - if the pins show on the second time
of welding the weld can be treated as successful, if not the joint should be
replaced
During the welding process and until the fusion coupler / tting has returned to
ambient temperatures, the polyethylene pipe and socket will be fusing together.
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
02.40(SC)
02.63(SC)
02.75(SC)
02.110(SC)
02.125(SC)
02.160(SC)
Sliding reducer
13.075.040(SC)
Sliding reducer
13.110.63(SC)
Sliding reducer
13.110.75(SC)
Sliding reducer
13.125.75(SC)
Sliding reducer
13.125.63(SC)
Terminating reducer
13.63.50 / TP
Terminating reducer
13.75.63 / TP
Terminating reducer
13.160.90 /TP
Terminating reducer
13.160.110 /TP
Secondary containment reducer
49.75.63
Note: A resistance value of X

means that there is no marked
resistance value on the ttings
and the should be treated as
having values of 10
Secondary reducers
Table 3.2 - Secondary Containment Fittings
15
3.6c 115v Welding Unit 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
1 Construction of the welding unit
Cable pockets
Booster control switch
ENTER key
Temperature sensor
Booster instruction label
Main switch
Green = On
Red= Off
SELECT key
Secondary welding
cable (in bottom
compartment)
Power cable
Primary welding cable
16
Bridging leads
2.1 Application
2.2 Operating the unit
The UPP welding machine EW/E5/115V is designed

for automatic welding of Primary and Secondary UPP
welding sockets and Primary electrofusion ttings.
It is suitable for use with environment temperatures
between -10 C (14F) and +45 C (113F).
UPP welding sockets and electrofusion ttings are

welded using a constant current. The welding machine
automatically applies the correct amount of energy for
the tting being welded.
The booster selector switch must be in correct

position for type of welding socket or the electrofusion
tting and electrical supply in use.The resistance unit of
the welding socket or the electrofusion tting e.g. , if
no resistance unit, coupler is X rated. If the electrical
supply is mains the booster selector switch is set to
position A. If the supply is from a generator the booster
selector switch is set to position B or C depending on
the total resistive values of the welding socket or the
electrofusion tting.
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 tting that is to be welded.The temperature sensor
is attached to the centre right hand side of the machine,
in contact with the steel frame.
The machine has a back lit LCD display with eight lines
of 16 characters each.The user guided menu is available
in eight different languages.
During the welding process, the following key value will
be shown on the display:
- Applied current
- Remaining welding time (counting down)
The welding machine operates on standard alternating
current. Normal, xed 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.
115 V ~ 15% (98 V - 132 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:
I: Temperature measured inside the machine
O: Ambient temperature measured by the sensor on
the outside of the machine
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. Release
the SELECT key to return to the previous display. The
welding machine is equipped with a earth leakage safety
switch.
This safety switch is also used for switching the machine

on and off. When disconnecting the machine from the
power source, this safety switch automatically switches
to the off position. The correct functioning of this safety
switch is automatically checked whenever the machine
is switched off by pressing the red button.
2.3 Safety Instructions

The welding machine meets all applicable European and
international safety standards and is designed specically
for usage on construction sites (protected against small
amounts of water and dust).
The machine should be handled with the care usually
given to electrical equipment especially during
transport
Each time the welding machine is used, the condition of
the machine, and especially the power cable needs to
be checked. If damage is discovered, the machine needs
to be returned directly to the supplier or an authorised
service centre. It is also advisable to check the welding
cables
Before connecting the machine, the power source needs
to be checked with regard to the values given above (i.e.
115 V and 45-65 Hz)
Never pull and/or lift the machine by its power or welding
cables. To disconnect the machine, the connectors need
to be pulled off, never pull the cable
The EW/E5/115V welding machine fulls a variety of
safety standards.These approvals can only be maintained
if any repairs are done by the supplier or an authorised,
service centre. Disobeying this recommendations will
invalidate the warranty
2.4 Liability restrictions

In each of the following cases, all liabilities of the supplier
are invalidated:
The machine is used outside the indicated application
area
Welding sockets and electrofusion ttings other than
the UPP Primary and Secondary range are being used
The operator is not trained to weld with this welding
machine
The recommended maintenance intervals are not
observed
The safety instructions are not observed
Repairs have been performed by other than the supplier
or their authorised agent
17
Step
The display shows the current in Amps
and the actual welding time in seconds
(corrected for ambient temperature),
counting down to zero)
After welding
Press the [SELECT] key and the [ENTER]

key together to enter languages set-up
mode
Entry/Action by operator
Releasing [SELECT] will take you back to

the start position
3
Choose the desired language by pressing
the [SELECT] key to cycle through the
available options
GB DE FR IT
NL ES SE PL
Complete this operation by pressing the

[ENTER] key
The language of your choice is now
selected
Raccodare elemento
Switch on the machine and wait for the

information, indicated on the right, to
appear on the display.
Connect welding
element
Keep the [SELECT] key pressed

117V = input voltage
Mode = Primary/Secondary
I = Internal temp. O =External temp.
117V Mode 185s

I: 28C O:21C
Keep the [SELECT] key pressed for at

least 10 seconds to display the following
information:
Good: 756
Faulty: 1
= Number of good and

faulty welds
Connect welding
element
GB DE FR IT
NL ES SE PL
3.3 Displaying welder data
Information on display
Internal temperature
of welder has reached
critical. 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. too

high
Check welding cable. 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
Switch off the welder and switch on

again after 30 seconds.
If this error consistently re-occurs send
for service
3.2 Choosing the language

Regulation error in the
electronics
Unplug connectors
Current above upper

limit - alternating with
- switch off welding kit
After approximately 3
seconds
Meaning
Welding Completed
Use only UPP welding couplers and

fusion ttings with the correct welding
cables.
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.
4.0A 168sec
The resistance value of the

connected tting is too high
(wrong element)
In primary mode: too many ttings
connected in series
Input voltage too low
Regulation error in the electronics
Welding starts by pushing [ENTER] key.
Current below lower

4
Welding Start with
ENTER
Get the generator checked by a service

centre and reset. If neccessary contact a
load of 300-500 watts in parallel with the
machine
Push connectors rmly on to the terminal

pins of the tting and push down to the
stop
The input voltage of the power

source is uctuating and interfering
with the welder
Input voltage variable

off welding kit
Connect welding
element
Displayed Information

appear on the display. (No welding cables
should be connected during this set-up
operation)
After approximately.5
seconds:
Check the connection. 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

source is too low for the machine
tolerances
Switch the machine on by pressing the

green button
(top-left on the machine)

off welding kit

checked by a service centre and reset. If
necessary connect a load approximately
500 watt in parallel with the machine
Connect power cable to power source

source is too high for the machine
tolerances
18
1
Input voltage too high

off welding kit
Step
Solution
Step
Solution
3.1 Welding
Operating Instructions
Meaning
3.4 Error Messages
3.5 Other Useful Tips
Positioning the machine

Always place the welding machine in the same ambient
temperature to the ttings to be welded. The rear of
the machine needs to be free and it should not be
directly exposed to the sun.
4.1 Welding Machine
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 rmly onto the UPP welding
sockets and electrofusion ttings down to the stop.
Disconnecting the cable from the UPP welding sockets
and electrofusion ttings must not be done by pulling
the cable.
Repeating a weld
Technical Details
UPP Combi Welder Unit 115V EW/E5/115V
Voltage
115 V~ 15% (98 V to 132 V)
Frequency 50 Hz (45 to 65 Hz)
Power rating 1000 W
Fuses input side : min. 5 A slow
Welding voltage : 8 V to 230 V
Switching power of the FI safety switch : 10 mA
Protection class
: IP 65
II (reinforced isolation)
Ambient temperature limits : - 10C to + 45C
Dimensions:
Width
425 mm (1ft 4)
Depth
265 mm (10 7/16)
Height
260 mm (10 1/4)
Total weight 25kg
4.2 Accessories
Warning: Adding extra energy after the welding
process by disobeying the repetition lock and
without allowing the tting to cool down is strictly
not advised.
Overheating of the tting can damage the
components and cause hot material to be ejected
from the weld zone.
In case of doubt about the weld, UPP welding sockets

and electrofusion ttings, can be welded again after
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 UPP welding sockets
ttings provided the following rules are applied:
The sum of the connected resistance values (circled
gure 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 tting is always
connected by two cables of a different colour (red or
yellow)
To ensure that it is OK check that all the ttings get
warm during the welding process.
Welding in Secondary (Secndr) Mode
UPP Secondary welding sockets may not be welded in
series. These ttings can be recognised by their special
smaller terminal pins. These connections require the
use of a green Secondary welding cable.
Included:
UPP Code
Primary welding cable :
EW/BC/C
Secondary welding cable :
EW/BC/SC
UPP bridging lead red/yellow : EW/BC/BL
Carry strap
Protective cover (with operating manual inside
pocket)
All the above come as standard on the UPP welding
kit, but replacements can be ordered direct from
PetroTechnik
4.3 Approval
This machine has the safety mark of the Swiss Approval
Board. Furthermore the machine carries the CE mark
for European conformity.
4.4 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 to PetroTechnik. Maximum service
interval: three years.
19
3.6d 230v Welding Unit 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
1 Construction of the welding unit

Temperature sensor
at rear
Cover
Cable pocket (at rear)
Main switch
Green = On
Red= Off
LCD Display
ENTER key
SELECT key
Power cable
Bridging leads
Primary welding cable
Secondary welding
cable (in bottom
compartment)
20
2.1 Application
2.2 Operating the unit
The UPP welding machine EW/E5/230V is designed

for automatic welding of Primary and Secondary UPP
welding sockets and Primary electrofusion ttings.
It is suitable for use with environment temperatures
between -10C (14F) and +45C (113F).
UPP welding sockets and electrofusion ttings are

welded using a constant current. The welding machine
automatically applies the correct amount of energy for
the tting 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 tting that is to be welded.The temperature sensor
is attached to the centre right hand side of the machine,
in contact with the steel frame.
2.3 Safety Instructions

The welding machine meets all applicable European
and international safety standards and is designed
specically for usage on construction sites (protected
against water and dust)
The machine has a back light LCD display with two

lines of 16 characters each. The user guided menu is
available in eight different languages.
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. If damage is discovered, the machine needs
to be returned directly to the supplier or an authorised
service centre. It is also advisable to check the welding
cables
The welding machine operates on standard alternating

current. Normal, xed 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.
230 V ~ 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:
I: Temperature measured inside the machine
O: Ambient temperature measured by the sensor on
the outside of the machine.
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. Release the
SELECT key to return to the previous display.
The welding machine is equipped with a earth leakage
safety switch. This safety switch is also used for
switching the machine on and off. When disconnecting
the machine from the power source, this safety switch
automatically switches to the off position. The correct
functioning of this safety switch is automatically checked
whenever the machine is switched off by pressing the
red button.
Before connecting the machine, the power source

needs to be checked with regard to the values given
above (i.e. 230 V and 45-65 Hz)
Never pull and/or lift the machine by its power
or welding cables. To disconnect the machine, the
connectors need to be pulled off, never pull the cable
The EW/E5/230V welding machine fulls all applicable
safety standards.These approvals can only be maintained
if any repairs are done by the supplier or an authorised,
service centre. Disobeying this recommendations will
invalidate the warranty
2.4 Liability restrictions

In each of the following cases, all liabilities of the supplier
are invalidated:
The machine is used outside the indicated application
area
Welding sockets and electrofusion ttings other than
the UPP Primary and Secondary range are being used
The operator is not trained to weld with this welding
machine
The recommended maintenance intervals are not
observed
The safety instructions are not observed
Repairs have been performed by other than the supplier
or their authorised agent
21
Step
After welding

appear on the display. (No welding cables
should be connected during this set-up
operation)

appear on the display.
Keep the [SELECT] key pressed

234V = input voltage
Mode = Primary/Secondary
I = Internal temp. O =External temp.
Keep the [SELECT] key pressed for at

least 10 seconds to display the following
information:
Releasing [SELECT] will take you back to

the start position
Press the [SELECT] key and the [ENTER]

key together to enter languages set-up
mode
GB DE FR IT
NL ES SE PL
3
Choose the desired language by pressing
the [SELECT] key to cycle through the
available options
GB DE FR IT
NL ES SE PL
Complete this operation by pressing the

[ENTER] key
The language of your choice is now
selected
Raccodare elemento
Connect welding
element
234V Mode 185s

I: 28C O:21C
Good: 756
Faulty: 1
= Number of good and

faulty welds
Connect welding
element
3.3 Displaying welder data
Internal temperature
of welder has reached
critical. This occurs after
a large number of welds
Software or hardware
damage to machine
Box internal temp. too

high
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
3.2 Choosing the language

Check welding cable. Push connectors
rmly on to terminal pins of tting
Switch off and then on again after 30
seconds
Unplug connectors
Loose contact in the
welding circuit or a poor
connection to tting
terminal pin
Welding Completed
Open secondary circuit

off welding kit
Welding Start with

ENTER
Switch off the welder and switch on

again after 30 seconds.
If this error consistently re-occurs send
for service
After approximately. 5
seconds:
Regulation error in the

electronics
PetroTechnik
Primary Mode
Meaning
Current above upper

3.1 Welding
After approximately. 3
seconds
Use only UPP welding couplers and

fusion ttings with the correct welding
cables.
Check the resistance index value of the
ttings -the sum must not exceed 10
See input voltage too low
Send machine for service
The display shows the current in Amps

and the actual welding time in seconds
(corrected for ambient temperature),
counting down to zero
The resistance value of the

connected tting is too high
(wrong element)
In primary mode: too many ttings
connected in series
Regulation error in the electronics
Welding in prog.
4.0A 168sec
Current below lower

Welding starts by pushing [ENTER] key.
Get the generator checked by a service

centre and reset. If neccessary contact a
load of 300-500 watts in parallel with the
machine

source is uctuating and interfering
with the welder
Push connectors rmly on to the terminal

pins of the tting and push down to the
stop
Input voltage variable

off welding kit

checked by a service centre and reset
Fully unwind extension cable to minimise
resistance
Connect welding
element

source is too low for the machine
tolerances
Display the welding mode

Depending on which welding cable is
connected,
the display shows:
Orange cable: Primary mode
Green cable: Secondary mode

off welding kit
Switch the machine on by pressing the

green button
(top-left on the machine)

checked by a service centre and reset. If
neccessary connect a load approximately.
500 watt in parallel with the machine
Solution
Connect power cable to power source

source is too high for the machine
tolerances
22
1
Input voltage too high

off welding kit
Step
Solution
Step
Meaning
3 Operating Instructions
3.4 Error Messages
3.5 Other useful tips
4 Technical details
Positioning the machine

Always place the welding machine in the same ambient
temperature to the ttings to be welded. The rear of
the machine needs to be free and it should not be
directly exposed to the sun.
4.1 Welding machine
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 rmly onto the UPP welding
sockets and electrofusion ttings down to the stop.
Disconnecting the cable from the UPP welding sockets
and electrofusion ttings 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 tting to cool
down is strictly prohibited. Overheating of the tting
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 ttings, can be welded again after
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 UPP welding sockets
ttings provided the following rules are applied: The sum of the connected resistance values (circled
gure 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 tting is always
connected by two cables of a different colour (red or
yellow)
To ensure that it is OK check that all the ttings get
warm during the welding process.
Welding in secondary (Secndr) mode
UPP Secondary welding sockets may not be welded in
series. These ttings can be recognised by their special
smaller terminal pins. These connections require the
use of a green Secondary welding cable.
UPP Combi Welder Unit 230V EW/E5/230V
Voltage
230 V~ 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 : 8 V to 230 V
Switching power of the FI safety switch : 10 mA
Protection class : IP 65 II (reinforced isolation)
Ambient temperature limits : - 10C to + 45C
Dimensions:
Width
310 mm
Depth
200 mm
Height
315 mm
Total weight 6.2kgs
4.2 Accessories
Included:
UPP Code
Primary welding cable :
EW/BC/C
Secondary welding cable :
EW/BC/SC
UPP bridging lead red/yellow : EW/BC/BL
Carry strap
Protective cover (with operating manual inside
pocket)
All the above come as standard on the UPP welding
kit, but replacements can be ordered direct from
PetroTechnik.
4.3 Approval
This machine has the safety mark of the Swiss Approval
Board. Furthermore the machine carries the CE mark
for European conformity.
4.4 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 to PetroTechnik. Maximum service
interval: three years.
23
3.7 Installing a UPP polyethylene tank chamber

Installing chamber base
Check the size and shape of the tank access shaft ange
Mark base of the UPP chamber for cutting to t access shaft ange
(witness lines show common ange style - photo1)
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
Mark bolt hole positions on sump base and drill

Cut straight lengths of gasket material from the roll to t over tank access
shaft ange - photo 4
Clean tank access ange using a cleaning solvent (Acetone recommended)
Remove backing layer from sticky side of gasket and stick the gasket to the
ange. Corners should be square and butted together to create a watertight
seal
Bolt chamber to tank access shaft ange. The bolts will easily push through
gasket material
Installing tank chamber riser to base

Cut riser to required height using castleations as a guide - photo 5
Clean gasket surfaces of chamber using cleaning solvent (Acetone)
Stick quarter circle gasket pieces one by one to top of chamber base - ensure
holes in gasket line up with holes in chamber for best t 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
5
24
UIM-V1.00.11.04
Backlling
Backll material should be the same as described in section 2.2 of this
document: Digging Trenches and Bedding
Acceptable backll materials are:
Well-rounded pea gravel with a maximum particle size not exceeding 20mm ().
No more than 3% of particles should pass through a 3.5mm (1/8) screen
Crushed rock with a maximum particle size not exceeding 16mm (5/8). No more
than 3% of particles should pass through a 3.5mm (1/8) screen
Well-graded sand with a maximum particle size not exceeding 3.5mm (1/8)
Particular care should be taken to ensure enough backll is laid down around
the underside of the chamber where it overhangs the tank access shaft ange
Care should be taken when backlling as excessive compacting can lead to the
chamber being structurally damaged
Tightness testing
The chamber can be tested for tightness using the UPP System
Integrity Testing Unit - see section 4 of this manual for details
25
3.8 Installing a UPP Polyethylene Dispenser Sump

Mount dispenser sump
The top of the sump mounting frame must be ush with the nished island
surface
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 1m per 100m
or 1/4 - 1/8 inch per foot) to the Underground Storage Tank (UST) or next
dispenser sump
Note: The UPP electrofusion

entry seals (305 or 305-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.g.
81.063.1NPT) 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 tting
Welding can be done in sump or prior to hanging shear valve.
Otherwise thread an appropriate length schedule 40 steel riser (or
exconnector) 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
26
UIM-V1.00.11.04
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
Inspection/Maintenance
UPP dispenser sumps are designed to provide secondary containment of
dispensers and piping or connections
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 rectied
Long term presence of petroleum products in sumps would invalidate
PetroTechniks UPP System warranty
Tightness testing
The chamber can be tested for tightness using the UPP System
Integrity Testing Unit - see section 4 of this manual for details
27
3.9 Installing a UPP mechanical entry seal

Entry Seal / Hole Saw
compatability chart
Holesaw
mm
51
67
73
Compatible
Seal(s)
302-040
U150
U200
U250/300
303-063EIF
102
303-075EIF
127
140
210
2
83
168
FEB-D 075
U400
305 Seals
FEB-D 110
308 Seals
SB2.C01
PS3
PS6
1.
Measure and mark the centre position of the required pipe sump
penetration
2.
Select the correct size hole saw for the selected

penetration seal and t to mandrill:
I.e 83mm (3 1/4) hole saw for PS3 seal and 168mm (6 5/8) hole saw
for PS6 seal
3.
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.
Trim the rubber seal boot for the installation of either 63mm
(2) or 75mm (2 double wall) pipe using a sharp knife
7.
Re-t 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.
Tighten up all the bolts in turn and complete one nal tightening check
11.
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
Code
HS1
HS2
HS3
HS4
HS5
HS8
HSCS2
HSP3
HSP6
Note: When drilling GRP (FRP)

sumps, safety equipment should
be worn. i.e. mask and goggles
28
For installation on at sump surfaces
3.10 Installing a UPP electrofusion entry seal (300 series)
2
Cut hole in sump wall
Use 140mm (5 inch) hole saw for 305 tting
Scrape around fusion area

Use scraper provided in UPP tool kit
3
Clean fusion area on sump with Acetone
Removes oils, ngerprints and moisture
Clean fusion area on seal with Acetone
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
Clamp seal to sump

Cross the clamp bars for best results
8
Connect welder and weld (using Orange
leads) - mark time of weld (eg. 11.00am)
Allow joint to cool to ambient

temperature: approximately 20 minutes
29
3.11 UPP electrofusion seal applications

Once the fusion seal has been successfully welded onto the sump it must be left to cool, stress-free, for 20 minutes
Depending on the specication of the site there are three options to take from this point onwards:
3.11.a - Fusion weld a polyethylene boot
3.11.b - Attach a exible entry boot
3.11.c - Fusion weld a UPP polyethylene duct pipe line
3.11.a Fusion welding a polyethylene boot
Abrade the fusion seal spigot using emery cloth
Abrade the 125mm (5) end of the boot using

emery cloth
Clean the scraped spigot, the end of the boot and

the inside of the 02.125(SC) welding coupler with
cleaning solvent (Acetone recommended)
Attach the boot to the spigot of the entry seal

using the welding coupler. 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
3.11.b Attaching a exible entry boot
Trim the exible boot to the desired pipe

diameter
Slide the boot over the seal lip and tighten on

with a jubilee clip
Slide the pipe through the seal and the opening

in the boot and cut to the desired length
Tighten the boot on to the pipe using another

jubilee clip
31
3.11.c Fusion welding UPP polyethylene duct pipe

The duct pipe is 110mm (4) and so 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 section 7 for details
1
Uncoil the Duct pipe into approximate nal
position
Use a hack saw to cut the pipe, ensuring the end
is as square as possible
3
Abrade surface of the 305R-1 spigot using emery
cloth.
Wipe clean with cleaning solvent
5
Weld this assembly using secondary welding lead
(Green)
Allow to cool for at least 20 minutes
32
2
Abrade oxidised surface of the 125mm (5) end
of the reducer using emery cloth
Wipe with lint free cloth soaked in cleaning
solvent
4
Clean the inside of the 02.125(SC) using
cleaning solvent and attach the reducer to the
seal spigot using the 02.125(SC)
6
Fully abrade surface of the part of the duct that
is to be welded using emery cloth
7
The edges of the corrugations must also be
abraded using the emery cloth
9
Wipe the 110mm (4) end of the reducer with a
lint free cloth soaked in cleaning solvent
11
Wipe the scraped duct pipe with a lint free cloth
soaked in cleaning solvent
8
Abrade the 110mm (4) end of the reducer
using emery cloth
10
Wipe the inner surface of the 110mm (4)
coupler with a lint free cloth soaked in cleaning
solvent
12
Attach duct pipe to reducer using the 110mm
(4) coupler.
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
3.12 Installing UPP Electrofusion FRP Entry Fitting

On A Single Wall Flat/Round Sump
The installation instructions shown here refer to the installation of the FRP entry tting
(FEB-D 075 or FEB-D 110) on a single wall FRP sump/chamber only.
Basic kit needed
Fusion entry tting

2x FRP caps supplied with tting - NOTE internal caps differ from external cap
Gloves (not included)
Cleaning solvent - Trichloroethylene or Acetone (not included)
Composite bonding paste (U-POL brand only- using other paste invalidates warranty)
Fitting wrench - FEB-075-TOOL or FEB-110-TOOL (shown right)
Fitting wrench
Installation method
34
Drill hole using hole saw:

4 1/8 (105mm) for FEB-D 075 (Code: HS075)
5 (140mm) for FEB-D 110 (Code: HS5)
Abrade external area of sump to be bonded

Use emery cloth
Abrade inner area of sump to be bonded

Use emery cloth
Clean inner and outer sump surfaces

Use cleaning solvent
Clean both anges

Unscrew movable ange and remove from tting

Add bonding paste to the grooved side of the
ange
7
Add bonding paste to the grooved side of the xed
ange
8
Add bonding paste to inner and outer side of sump
wall around the entry tting hole
10
Fit entry tting from outside sump and tighten loose

ange onto the thread from inside sump
Tighten fully using supplied wrench tool
11
Smooth bonding paste around anges on both sides
of the sump wall
Ensure there are no gaps
13
Fill the cover caps with bonding paste
12
Abrade inside of the cover caps using emery
Wipe down with cleaning solvent
14
Fit cover caps over entry tting spigots and press
rmly against sump wall
Clean off excess resin and smooth with thumb
around edge. of cap
35
15
Allow the paste to cure for 35 minutes (ambient
temperature of 71.6F/22c) before electrofusion
The unit can now be tightness tested as required.
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 (02.75.SC / 02.110.SC). 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.
36
3.13 Installing UPP Electrofusion FRP Entry Fitting

On A Double Wall Flat/Round Sump
The installation instructions shown here refer to the installation of the FRP entry tting
(FEB-D 075 or FEB-D 110) on a double wall FRP sump/chamber only.
Basic kit needed
Fusion entry tting

2x FRP caps supplied with tting - NOTE internal caps differ from external cap
Gloves (not included)
Cleaning solvent - Trichloroethylene or Acetone (not included)
Composite bonding paste (U-POL brand only- using other paste invalidates warranty)
Fitting wrench - FEB-075-TOOL or FEB-110-TOOL (shown right)
Fitting wrench
Installation method
Drill hole using hole saw:

4 1/8 (105mm) for FEB-D 075 (Code: HS075)
5 (140mm) for FEB-D 110 (Code: HS5)
Using the central location hole as a guide, drill

through the inside wall of the sump using the same
holesaw
Abrade internal and external area of sump to be

bonded
Use emery cloth
Clean inner and outer sump surfaces

Add bonding paste around the entry hole inside and

out.
Push bonding paste evenly into the cavity between the
sump walls
Unscrew movable ange and remove from tting

Add bonding paste to the grooved side of the
ange
37
Add bonding paste to the grooved side of the xed

ange
Fit unit to sump wall with xed ange on outside of

the sump.
Tighten loose ange onto thread by hand from
inside the sump
Tighten fully using supplied wrench tool
11
Abrade inside of the cover caps using emery
Wipe down with cleaning solvent
13
Cover caps should be lled as shown above
38
10
Smooth bonding paste around anges on both sides
of the sump wall
Ensure there are no gaps
12
Fill the cover caps with bonding paste
14
Fit cover caps over entry tting spigots and press
rmly against sump wall
Clean off excess resin and smooth with thumb
around edge. of cap
15
Allow the paste to cure for 35 minutes (ambient
temperature of 71.6F/22c) before electrofusion
The unit can now be tightness tested as required.
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 (02.75.SC / 02.110.SC). 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.
39
3.14 UPP access cover installation

The following instructions refer specically 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 seperating and
retting the cover from the frame is the same.
Installation instructions
Separate 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 4/8)
Warning - To facilitate drainage of surface water, the frame should be inclined
1: 100 towards the rear. 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
Where specied, connect a 1 inch (26mm) plastic drainage pipe between

outlet on frame and oil/water separator or backll 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
Ret the cover to the frame, once concrete is dry - see instructions below
Seperating the cover from frame - (two operators required)

4
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
Warning - The cover is heavy (85 kg)
Retting the cover to frame - (two operators required)

5
Place the cover into the frame at circa 120

Warning - In this position, the Spring Shaft must be correctly located into the
seat in the frame - (Photo 4-5)
Close the cover to between 30 and 60 - Photo 1-2
Ret the Spring Box Cover
40
UIM-V1.00.11.04
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
1:100 incline towards rear of cover

to facilitate drainage of surface
water.
Reinforced
Concrete.
15 Slope for Surface Water Drainage

FromLip of Frame to Forecourt Surface
PC76 Cover
Drainage Pipe: 26mm

1
Drainage Pipe Runs into Pea Shingle

Or Connects to a Drainage Line,
Running To The Oil/Water separator
41

75/63mm (2 double wall) secondary contained 90 elbow
1.
Cut horizontal pipe to required length and trim back 75mm (2 double wall) pipe to dimension shown in drawing
2.
Prepare ends of 75mm (2 double wall) pipe and ttings as per the instructions in section 3.5
3.
Slide reducers and 110mm (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.
4.
Prepare ends of 63mm (2) pipe and ttings as per instructions in section 3.5. Fit elbow and 63mm (2) welding
sockets. Weld and allow to cool before proceeding to next step
6.
Prepare110mm (4) welding sockets and sliding reducers as per instructions in section 3.5 (the 110mm (4) end
of the reducers should be treated as secondary pipe). Abrade secondary elbow spigots using emery cloth - slide
reducer/coupler onto spigots and weld. Allow to cool
before putting any stress on the assembly
Position of ttings during welding of 63mm (2) joint
7.
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 3.5 and weld.
Allow to cool to ambient temperature
Item
1
2
3
4
5
42
Description
75/63mm coaxial (2 double wall) pipe
63mm (2) welding socket
110mm (4) secondary containment 90 elbow
110-75mm (4-2 double wall) secondary containment sliding reducer
110mm (4) secondary containment welding socket
Code
01.75.63.LS
02.63
03.110.63(SC)
13.110.75(SC)
02.110(SC)
Qty
N/A
2
1
2
2

75/63mm (2 double wall) secondary contained tee
1.
Cut pipes to required length and trim back 75mm (2 double wall) pipe to dimension shown in drawing below
2.
Prepare ends of 75mm (2 double wall) pipes and ttings as per the instructions in section 3.5
3.
Slide reducers and 110mm (4) welding sockets far enough onto 75mm (2 double wall) pipe to allow access to
63mm (2) welding sockets
4.
Prepare ends of 63mm (2) pipe and ttings as per instructions in section 3.5
5.
Fit tee and 63mm (2) welding sockets. Weld and allow to cool before proceeding to next step
6.
If required leave secondary containment un-welded to

allow primary pressure tests to be carried out
6.
Prepare 110mm (4) welding sockets and sliding reducers

as per instructions in section 3.5 (the 110mm (4) end
of the reducers should be treated as secondary pipe).
Abrade secondary tee spigots using emery cloth - slide
reducer/coupler onto spigots and weld. Allow to cool
before putting any stress on the assembly
7.
Allow to cool before stressing the pipe
Position of ttings during welding of 63mm (2) joint
Item
1
2
3
4
5
Description
75/63mm coaxial (2 double wall) Pipe
110-75mm (4-2 double wall) secondary containment sliding reducer
63mm (2) welding socket
110mm (4) secondary containment welding socket
110/63mm (4/2) secondary containment tee
Code
01.75.63.LS
13.110.75(SC)
02.63
02.110(SC)
08.110.63(SC)
Qty
N/A
3
3
3
1
43
4. SYSTEM INTEGRITY TESTING INSTRUCTIONS

VTU-115V & VTU-230V Models
The UPP System integrity testing kit is simple to use and allows for precise
testing of the tightness of underground tank sump and chambers and dispenser
sumps. 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.
4.1 Test 1
After installing the UPP tank chamber, seals and pipe runs, test the base for air
leaks. To test the chamber, follow these instructions:
Make sure the vacuum lid gaskets and chamber base ange are clean and free
from dirt and debris
Place the vacuum lid on to the chamber base, with gasket against ange 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
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 1. 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. Possible leak points
include:
Pipe/seal interface
Tank sump/chamber mounting ange
Vacuum lid seal
electrofusion/chamber interface
Conduit seals
Vacuum test pipe connections
Once the chamber base is leak tight, move on to check the riser
4.2 Test 2
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
Place new vacuum lid on riser
Connect vacuum hoses to riser lid
Re-run test as in 4.1 test 1
If the vacuum is not held then the chamber should be investigated using a leak
detection liquid spray. Possible leak points include:
44
Centre section seal

Vacuum lid seal
Riser seals
Vacuum test pipe connections
UIM-V1.00.11.04
4.3 Fault diagnosis

Fault
Solution
Vacuum level not reached or keeps on

falling
Check and listen for leaks in all

the areas outlined in the two tests.
Rectify faults if found
Vacuum still falling. All areas on

chamber are leak tight
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
Vacuum equipment running but no

vacuum being produced
Pump not running
UPP Product
DC4830.SB
DS2111
DS4111
DS3017
DS4417
DS3617
Max Vaccum Level
Check power to unit and electrical

fuse
Vac test levels and corresponding water pressures

Vacuum Test Level (x)
Ground Water Pressure
Test Time
mm
ft
mbar
Psi
in Hg
mins
300
30
0.43
0.89
10
600
60
0.87
1.77
10
900
90
1.30
2.66
15
1200
120
1.74
3.54
20
1800
180
2.60
5.32
20
45
5. TIGHTNESS TESTING
Every completed UPP systems installation must be tightness tested by a
competent person to very the integrity of the line(s) prior to backlling.
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
Testing Guidelines
It 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 = 4 bar (58psig) gauge range is 0 to 8 bar (0 to 116psig).
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. A current test certicate /certicate of compliance should be held
for each gauge.
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 0.5 bar (7.25 psig) above test pressure.
e.g. test pressure of 4 bar (58 psig) relief valve set to 4.5 bar
When air or inert gas is to be applied from high pressure cylinders, a suitable
control valve must be used to control the ow 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 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.
46
UIM-V1.00.11.04
5.1 Tightness testing procedure

A vacuum/pressure should be applied to the pipework being tested for at
least 30 minutes - the table below shows the respective pressures/vacuums
that should be applied to the various types of UPP pipe systems
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
Test Pressure/
Vacuum level
Allowable pressure
variation over 30
minutes
0.7 bar 0.04 bar

10 Psi 0.5 Psi
4.2 bar 0.04 bar
60 Psi 0.5 Psi
0.5 bar 0.04 bar
7 Psi 0.5 Psi
-0 to 0.04 bar
-0 to 0.5 Psi
-0 to 0.04 bar
-0 to 0.5 Psi
-0 to 0.04 bar
-0 to 0.5 Psi
4 bar 0.04 bar

58 Psi 0.5 Psi
-0 to 0.04 bar
-0 to 0.5 Psi
0.5 bar 0.04 bar

7 Psi 0.5 Psi
-0 to 0.04 bar
-0 to 0.5 Psi
-0.6 bar 0.04 bar

- 8.7 Psi 0.5 Psi
-17.71 in.HG 1.02
-0.3 bar 0.04 bar
-4.4 Psi 0.5 Psi
-8.96 in.HG 1.02
-0 to 0.04 bar
-0 to 0.5 Psi
-0 to 1.02 in.HG
-0 to 0.04 bar
-0 to 0.5 Psi
-0 to 1.02 in.HG
Note: Due regard must be taken

of pressure variations due to
temperature effects
Vacuum Testing
Primary product, ll, vent and VR
lines
Secondary Containment
(in.HG = inches of mercury)
There must be no visual or any other indication of leakage of air/gas or water

during the test period
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
47
5.12 Tightness testing on operational sites

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 or
by a specialist contractor as contaminated waste
In all other aspects the pressure testing requirements are as detailed above
5.2 Testing at maximum operating pressure

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 11bar (159 psig)
Procedure
Leak test with air (2 bar / 29 psig) and soapy water on all welds and
terminations
Protect the pipe from direct sunlight, preferably with sand
Fill the pipe with liquid, preferably water (or oil)
Apply working pressure to the pipe after the temperature has equalized
Maintain the pressure on the pipe until the pressure stabilizes i.e. pressure
drop is less than 0.1 bar (2 psig)
Close the ball valve; note time and pressure
Test pressure should continue to be applied for four hours
If the pressure drop is less than 0.1 (2 psig) bar, the pipe may be considered as
being tight
5.3 UPP Pipe ratings

IP Rating
UL Rating
ULC Rating
6.2 bar
(90Psi)
6.2 bar
(90Psi)
UPP primary pipe (single wall)

10 bar
Unlined: 50/63/90mm
(1.5/2/3)
(145 Psi)
Lined: 32/50/63/90/110/160mm
(1/1.5/2/3/4/6)
10 bar
(145 Psi)
2 bar
Lined: 110mm ll pipe
(29 Psi)
(4 ll pipe)
UPP Secondary containment (double wall)
4 bar
4 bar
Terminated by fusion tting
(58 Psi)
(58 Psi)
0.5 bar
1.03 bar
Terminated by exible boot
(1.03 Psi)
(15 Psi)
0.5 bar
Duct Pipe
(1.03 Psi)
48
1.03 bar
(15 Psi)
1.03 bar
(15 Psi)
5.4 Primary (single wall) - tightness test report

TEST REPORT
Intermediate / Final Tightness PRESSURE TEST on UPP pipework system
Single Wall - Primary Containment
Installation Details
Site name & address
..
Site Owner / operator ..

Pipe Type & Usage
Suction
Pressure (Atmospheric / Pumped)
VR 1b
VR 2
UPP mm
32mm
Wall thickness
3.2 mm
Pressure Rating
PN10
Syphon
UPP Extra (lined)
UPP (unlined)
50 mm
63 mm
90 mm
110 mm
110 mm Fill
160 mm
4.6 mm
5.8 mm
8.2 mm
10.0 mm
6.5 mm
11.8 mm
PN10
PN10
PN10
PN10
PN2
PN10
Meter marking or applied ID ..

Conformance Control
Pipe marking
Pipe routing / crossings
Fusion welds
Minimum Fall
Tightness Test
Test Pressure
Test Duration ...
Test Medium
Pressure drop ..
. %
No. of welds .
... bar / psig

minutes / hours
Start ..
Finish ..
Air
Inert Gas (Nitrogen)
Water
mbar over test period
Ambient temperature C
Certification
The above described pipe run has been installed in accordance with the Installation Instructions for UPP by
personnel employed / supervised by:
....
The information given above is true and correct.
Signed by:
This copy for:
..
Control Authority
Date: dd
Site Owner
/ mm
Contractor
/ 200
..
49
5.5 Secondary (double wall) - tightness test report

TEST REPORT
Double Wall - Secondary Containment
Site name & address
..
Pipe Type & Usage

Suction
VR 1b
VR 2
UPP mm
Syphon
UPP Extra (lined)
UPP Extra Co Axial (lined)
UPP Secondary
40 mm
63 mm
75 mm
110 mm
160 mm
200 mm
3.0 mm
Pressure Rating
PN4
3.0 mm
3.0 mm
4.2 mm
6.2 mm
7.7 mm
PN4
PN4
PN4
PN4
PN4
Wall thickness
Meter marking or applied ID .

Conformance Control
Pipe marking
Fusion welds
Minimum Fall
Tightness Test
Test Pressure
Test Duration ...
Test Medium
Pressure drop
. %
No. of welds .
... bar / psig

minutes / hours
Start ..
Finish ..
Water
Air
..
Certification
....
Signed by:
50
..
This copy for:

TEST REPORT
Control Authority
Date: dd
Site Owner
/ mm
Contractor
/ 200
..

Single Wall - Duct Containment
5.6 Duct Containment Pipe - tightness test report

Single Wall - Duct Containment
Site name & address
..
Duct Pipe Used In Conjunction With

Suction
VR 2
UPP Extra (lined)

UPP Extra Co Axial Extra (lined)
UPP (unlined)
UPP mm
Wall thickness
Pressure Rating
110 mm
125 mm
Corrugate 8.0 mm
Material 0.5 mm
Corrugate 8.0 mm
Material 0.5 mm
N/a
N/a
Meter marking or applied ID .

Conformance Control
Pipe marking
Fusion welds
Minimum Fall
Tightness Test
Test Pressure
Test Duration ...
Test Medium
Pressure drop
. %
No. of welds .
... bar / psig

minutes / hours
Start ..
Finish ..
Water
Air
..
Certification
....
Signed by:
This copy for:
..
Control Authority
Date: dd
Site Owner
/ mm
Contractor
/ 200
..
51
6. MODIFICATION AND REPAIR OF UPP SITES

This section is designed as an advisory guideline on the how to modify 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 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.
Method
52
Switch off - shut down submersible pump and dispensers in works area
Tag out - remove fuses or isolating breaker to pumps and dispensers
Prepare to empty product into an approved sealable containment vessel
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
Check the sump where the repair is to be made with an O2 meter

and record the presence of sufcient oxygen (~21% O2) before any
personnel enter the sump. Air exchange if necessary
Isolate the submersible pump by closing the isolation valve (ball valve)
All secondary containment lines will need to have their test boots
removed
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
10
Shut (close) all the shear valve access ports once no further fuel ows
out of the product line
12
The sump air supply should be exchanged until the O2 meter records
the presence of sufcient oxygen (~21% O2) before any personnel reenter the sump
13
Remove the petroleum liquid containment vessel from the tank sump
UIM-V1.00.11.04
14
Undertake and complete the repair to the UPP pipework and ttings up
to the point of welding in accordance with UPP installation instructions
15
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
16
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 / tting in preparation for electrofusion. The
welding lead should not be connected to the welding machine at this
stage
17
The atmosphere of the sump is to be continually monitored with the

O2 meter for the presence of sufcient oxygen (~21% O2) during repair
whilst personnel are within the sump
18
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
19
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
20
Shut off (stop) the nitrogen supply just prior to the welding machine
being switched on and the welding cycle activated
21
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
22
During this time period no personnel should enter the tank sump to
remove the welding leads
23
The sump air supply should be exchanged until the O2 meter, records
the presence of sufcient oxygen (~21% O2) before any personnel enter
the sump
24
Before undertaking any additional work on any of the other sumps, the
atmosphere should be checked with the O2 meter and records the
presence of sufcient oxygen (~21% O2), initiate air exchange if in any
doubt
25
All the effected shear valves should have the access port re-sealed ready
for the product line to be pressure tested
26
The product line should be pressure tested to the UPP guidelines (60psi
or 4.2bar) for 1 hour. 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
7. PIPE RE-FIT THROUGH DUCTS

This section details the method of retraction of non UPP product and suction
pipe lines and replacement with UPP pipe through existing ducts with no site
excavation
Pipe replacement of non-working ducted pipes can be carried out while the
rest of the petrol station is operational
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
54
UIM-V1.00.11.04
Installing UPP pipe

Mark and cut UPP pipe 1m (3ft) longer than necessary.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
UPP pipe being guided into

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
Site operational whilst

retting work is still ongoing
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 200 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
55
8. WATER HAMMER EFFECT

A quick change of the ow inside a piping system can cause a sudden pressure
increase over and above the nominal working pressure. This water hammer
effect can occur every time a valve is opened/closed or a pump is started/shut
off. The formula for pressure variation (P) is given by
P = p . c . v
Where p is the density of water, v is the uid velocity change and c is the
velocity of a shock wave in the pipe.
c depends on the elasticity of the uid in the pipe wall and, for a freely
supported pipe is given by:
Ep
c=
Ep
Ew
Dm
t
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.
60,00
UPP
50,00
Fibreglass
Steel
Peak Pressure (bar)
40,00
30,00
20,00
10,00
0,00
0.5
1.5
2
2.5
Initial Velocity
3.5
Water hammer effect for various piping systems
56
4.5
UIM-V1.00.11.04
9. FUEL FLOW
UPP Extra lined pipe - Flow loss Rates
50mm (1 1/2)
5
63mm (2)
Head Loss (m/100m)
4
3
2
1
0
10
20
30
40
50
60
70
80
90
100
Litres per minute
0.30
UPP Extra lined pipe and ll pipe - Flow loss rates

90mm (3)
0.25
110mm (4)
110mm (4) Fill
Head Loss (m/100m)
0.20
0.15
0.1
0.05
0
10
20
30
40
50
60
70
80
90
100
Litres per minute
57
PetroTechnik
UPP readyLtd
reckoner
for ows to 3,000 litres per minute (790 USwww.upp.co.uk

gal/min)
UPP Ready Reckoner for Flows to 3,000 litres per minute
Velocityofof
liquid
vapourflow
ow
is given
in m/sec
and ft/min
Velocity
liquid
fuelfuel
and and
fuel vapour
is given
in m/sec
and ft/min
Nominal Pipe Size
inches
UPP Pipe code

Pressure Rating
Polyethylene Grade
Wall Thickness min.
Internal Diameter nom.

Cross Sectional Area
01.32.x
mm
mm
mm
in
Availability
FLOW
45 l/m =
1 Nozzle
12 US Gal/min
V=
m/s
90 l/m =
2 Nozzles, or
1 Regular Diesel
24 US Gal/min
V=
m/s
135 l/m =
3 Nozzles or
1 Hi-Flow Diesel
36 US Gal/min
V=
m/s
200 l/m =
5 Nozzles or
2 Regular Diesel
50 US Gal/min
V=
m/s
400 l/m
V=
m/s
V=
ft/min
105 US Gal/min
V=
ft/min
V=
ft/min
1 M/m =
Pumped Fill
260 US Gal/min
V=
m/s
2 M/m
V=
m/s
V=
ft/min
790 US Gal/min
NOTE
58
V=
ft/min
V=
m/s
3 M/m
V=
ft/min
600 l/m =
Gravity Fill
160 US Gal/min
530 US Gal/min
1
DN25
V=
ft/min
V=
ft/min
V=
m/s
V=
ft/min
PN10
PE80
3.0
26.0
531
0.82
1
DN40
01.50.x
PN10
PE80
4.6
40.8
1,308
2.03
2
DN50
3
DN80
4
DN100
4
DN100
6
DN150
8
DN200
01.63.x
01.90.x
01.110.x
01-110FILL
PN2
PE80
6.6
96.8
7,359
11.41
01.160.x
01.200.x
PN10
PE100
11.8
136.4
14,612
22.65
PN10
PE100
14.7
170.6
22859
35.44
Request
PN10
PE80
5.8
51.4
2,075
3.22
PN10
PE80
8.2
73.6
4,255
6.60
PN10
PE80
10
90
6,362
9.86
Stock
Stock Stock
Stock
Stock
Stock
Stock
< - - - - - - - - - - - - - - - - - - - Velocity - - - - - - - - - - - - - - - - - - - - - - - - - - >
1.41
0.57
0.36
0.18
282
114
72
36
2.83
1.15
0.72
0.35
566
230
144
70
4.48
1.72
1.08
0.53
0.35
0.30
0.16
836
344
216
106
70
60
32
6.28
2.55
1.60
0.78
0.52
0.45
0.23
0.15
1256
510
320
156
104
90
46
30
5.10
3.22
1.57
1.05
0.90
0.46
0.29
1020
644
314
210
180
92
56
7.66
4.82
2.35
1.57
1.36
0.69
0.44
1532
964
470
314
272
138
88
8.04
3.92
2.62
2.27
1.14
0.73
1608
784
524
454
228
146
7.84
5.24
4.53
2.28
1.46
1568
1048
906
456
292
3.42
2.19
684
438
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) systems
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
10. ELECTROSTATIC SAFETY

All UPP metal termination ttings in the ll 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 100 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
UPP 05/06/07 series thermofused anged termination
UPP 11 series mechanical termination
UPP 12 series mechanical wipex mechanical

termination
requires ring terminal
requires earthing strap
requires ring terminal
59
It should be noted that PetroTechniks UPP System complies with BS 5958

and with the spirit of the CENELEC R044-001 document (buried plastic
pipes having been rigorously tested for electrostatic safety by independent
organisations).
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. 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.
Q2
A
Is any electrostatic charge generated during fuel ow through a pipe?

Yes. Some modern fuels have a low electrical conductivity (measured in
picoSiemens/m) and will generate an electrostatic charge during handling
operations such as pouring, splashing, agitation and transport through pipes
and lters.
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.
60
Q4
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.
Q5
A
Can you get electrostatic sparks from the surface of plastic pipes?
No. 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.
Q6
A
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 120 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.
UIM-V1.00.11.04
Q7
A
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 15,000 sites over 120 countries.
Q8
A
Which Standards apply to this subject?

The Cenelec CLC/TR 50404 and 7.4 of EN 13463-1:2001 reports are
considered the best standards for this subject
Q9
A
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. Tests by Wolfson ElectroStatics have used low conductivity fuel (down
to ~ 20pS/m) at high ow velocities up to 12m/s [8]. UPP pipework passed the
wolfson audit to the current European standards (and therefore is also certied
by the Institute of Petroleum)
Department of Electronics & Computer Science

University of Southampton
Southampton SO17 1BJ England
Wolfson Electrostatics
Telephone: +44 (0)23 8055 2266

Fax: +44 (0)23 8059 3015
E-mail: glh@soton.ac.uk
www.soton.ac.uk/~wolfson
Certificate of Electrostatic Safety

Presented to
PetroTechnik Ltd
for
UPP Piping System

This is to certify that the UPP piping system (including UPP Extra primary pipe and UPP SC
secondary contained pipe and respective HD-PE and metal terminations) audited by Wolfson
Electrostatics at the University of Southampton has been rigorously tested and has been
found to be safe in respect of electrostatic ignition hazards.
The system also meets Institute of Petroleum Performance Specification for Underground
Pipework Systems at Petrol filling Stations 2nd Edition (Feb 2001) Section 6.9 and IEC
60243 Part 2 (2001).
The UPP products encompassed in this audit and detailed in Wolfson Electrostatics Technical
Reports 187/99 *, 363/96 **, 369/96 *** and 378/97 **** are suitable for use in fuel
handling applications involving gasoline (petrol) liquids and vapours and Diesel.
*- earthed metal couplings
** - velocities upto 12 m/s
*** - Jet A1 and Fuel C
**** - fuel conductivity from 5 pS.m-1
_____________________________________
For and on behalf of Wolfson Electrostatics
4th June 2003
2001RAE
61
11. FREQUENTLY ASKED QUESTIONS

Q1
A
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
Q2
Within which ambient temperature range can electrofusion welding can

be carried out?
From -10C to 45C (14F to 113F)
A
Q3
A
Q4
A
Q5
A
Q6
A
Q7
A
Q8
A
Q9
A
62
What are the recommended backll materials for bedding and burial of
UPP pipe and ttings?
See section 2.2 of this manual for bedding and backll instructions
What is the minimum burial depth recommended for UPP pipe and
ttings?
300mm (12)
Can point loading damage affect pipes that cross each other below
ground?
Yes, crossing pipes should be protected by a minimum of 5 cm (2) of compacted
backll or 2.5 cm (1) of protective Styrofoam
Is it important to align pipe and ttings, both during welding and cooling
process?
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 400 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 1995
UIM-V1.00.11.04
Q10 What are 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 pipe system and can be continuously (24/7) operated at 58 psi (4
bars or 400 kPa). Secondary containment or double wall systems used by other
competitors are merely a jacketing conduit with no mechanical strength.
Also UPP Secondary 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 systems includes genuine secondary contaiment 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 integrity and site safety than a small
amount of gas diffusion.
UPP Extra pipe was lled with Super Unleaded gasoline and tested for 180 days
at 23C. 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 exible 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 ttings. 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 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.
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
63
Q15 What is the difference between UPP (unlined pipe) and UPP Extra with its
polyamide liner?
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.
Specify UPP Extra for all your fuel carrying pipes; suction or pressure lines
Q16 What Working Pressure has UPP been design for?
A
From the outset, all UPP primary pipe in all its diameter sizes has been rated
PN10 - 10 bar ~ 145 psi, and regular product tests show that this rating is
exceeded 400% showing a great margin of safety.
UPP primary pipe is designed for suction (negative pressure) or pressurised
systems.
All UPP secondary containment pipe is rated PN4 - 4 bar ~ 58 psi and performs
at 400%. It may be pressurised as part of a Leak Detection system
Q17 Because UPP is semi-rigid, what Bend Radius is possible during
installation?
A
This is largely temperature dependent, but in general you may use these values
for UPP:
Coils
Warm weather
15 x
Cold weather
25 x
Very Cold
35 x
Straight lengths
Warm weather
Cold weather
Very Cold
15 x
25 x
35 x
50 mm
1 1/2
80 cm
(2ft 7)
140 cm
(4ft 7)
190 cm
(6ft3)
63 mm
2
1m
(3ft 3)
1.6 m
(5ft 3)
2.2 m
(7ft 2)
90 mm
3
1.5 m
(4ft 11)
2.5 m
(8ft 2)
3.5 m
(11ft6)
110 mm
4
n/a
(n/a)
n/a
(n/a)
n/a
(n/a)
50 mm
1 1/2
1.5 m
(4ft 11)
3m
(9ft 10)
4m
(13ft 2)
63 mm
2
2m
(6ft 7)
3m
(9ft 10)
4m
(13ft 2)
90 mm
3
3m
(9ft 10)
5m
(16ft 5)
7m
(23ft)
110 mm
4
4m
(13ft 2)
6m
(19ft 8)
8m
(26ft 3)
For smaller radii use the UPP range of elbows and formed bends
64
UIM-V1.00.11.04
Q19 What Products (apart from petroleum products) can be carried by UPP
Extra lined pipe?
A
UPP Extra polyethylene pipe with its polyamide lining is generally suitable for
many hydrocarbon products including: Ethanol, Iso-Octane, Methanol, MTBE,
and Toluene.
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; UL971
and Institute of Petroleum Pipework Specication are two such examples. UL971
tests include todays 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 C, and 50% ethanol +
50% reference fuel C.
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. Extensive
testing at ow velocities up to 12 m/s conducted by Wolfson Electrostatics at
University of Southampton (Report 363/GLH available on request) concluded
that ignition hazard cannot occur with PetroTechnik product because the static
energy generated by fuel ow in UPP pipe were below the minimum ignition
energy of fuel vapour.
Q22 There are other types of thermo-fusion (welding) socket available. Can I
use the UPP welding set with them?
A
No. UPP welding sets designated EW/CU are specically made for use with UPP
electro-fusion sockets and ttings designed for Constant Current fusion.
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.
65
12. SAFETY
UPP Systems should only be installed by a fully trained installer following the
guidelines given by PetroTechnik or any local authority.
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.e. during fuel lling / transfer.
i.e. The area bound by a dispenser and sump or tank sump
Zone 2 is an area where a ammable atmoshere 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 oor 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
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
66
UIM-V1.00.11.04
13. NOTES
67
+61 3 95 50 18 74
PetroTechnik do Brasil
+55 11 3159 0909
PetroTechnik France
+33 1 69 21 41 41
PetroTeknik AB
+46 8 767 86 34
PetroTechnik Inc.
+1 201 871 7300
tel. +44 (0) 1473 243300
PetroTechnik Ltd
PetroTechnik House
Olympus close, Whitehouse Industrial Estate
Ipswich, Suffolk, IP1 5LN
United Kingdom
fax. +44 (0) 1473 243301
www.petrotechnik.com
email. info@petrotechnik.com
IM-01-01/05
PetroTechnik Australia

Installation Manual UPP Piping

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protecting your liquid assets

PRODUCT INSTALLATION MANUAL

Transport, Loading and Storage

Transit, on-loading and off-loading

Digging trenches and bedding

Site installation overview

Electrofusion method - Coupling two primary pipes

Electrofusion method - Primary pipe to a non-fusion tting

Electrofusion method - Primary pipe to a fusion tting

Electrofusion preparation details

Installing a UPP polyethylene tank chamber

Installing a UPP polyethylene dispenser sump

Installing a UPP mechanical entry seal - (Holesaw/Seal compatability chart)

Installing a UPP electrofusion entry seal

UPP electrofusion seal options

Installing a UPP access cover

Electrofusion method - Secondary containment (double wall) 90 elbow

Electrofusion method - Secondary containment (double wall) Tee

System Integrity Testing Instructions

Pressure line testing at maximum operating pressure

Modication And Repair Of UPP Sites

Pipe Re-t Through Ducts

Water Hammer Effects

Flow Loss Rates

Frequently Asked Questions

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1. TRANSPORT, LOADING AND STORAGE

1.2 Storage on site

1.3 Summary of rules

able to withstand the weight of pipes

direct sunlight or excessive

1.4 Uncoiling pipe

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2.2 Digging trenches and bedding

Welding coupler showing internal

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3.1 Site installation overview

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

To install the UPP pipework system:

The tanks should be in place

When using electrofusion welding joints, it is important

3. Install the tank access chambers / sumps

4. Make sure all the tank top steel ttings are

Wipe scraped pipe end and the welding coupler/fusion

5. Mark positions on the tank access chamber/sump

Assemble to nal position (making sure Acetoned areas

Install vents and vapour recovery stage 1b

Install VR Stage 2 (VR 2)

VR 1b should be laid between the vent stack and the ll

Install product lines

Secondary Containment (SC)

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3.2 electrofusion method

Clean bore of welding coupler with Acetone

Connect clamped assembly to welder and follow

3.3 electrofusion method

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3.4 electrofusion method

Clean scraped end of pipe using a lint free cloth

Clean inside of fusion tting using a lint free

Prepare the pipe for welding using the pipe

Assemble the joint and use clamp to hold in