UPP Piping

Installation Guide Overview

Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA

Tel:  +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.com
 Safety
Important!
UPP Systems must only be installed by fully trained and certified installers.
Failure to follow installation instructions will invalidate warranty and installer
certification!
Piping Installation Safety Confined Space
• UPP Welding Units must never be operated in Zone • Some installation of UPP products may occur
1 or Zone 0 areas (Hazardous area definitions are in confined spaces where a lack of oxygen and
from IP Model Code of Safe Practice Part 15 and a concentration of toxic vapors is likely to be
are available in the APEA Blue Book 2nd Edition). experienced.
• Ensure Welding Units are connected to a power Such working conditions are dangerous and all local
supply that meets the requirements detailed in the health and safety guidelines for working in such
user manual and are within the requirements of any environments should be followed.
local authority or regional legislation.
Material Handling
• Important to any type of piping system is to safely Protective Equipment
connect all metallic components to ground. Metallic • Ensure the correct personal protective equipment
components, and more general conductive materials, (PPE) is used at all times in line with local health
due to their high capacitance, can have the potential and safety requirements.
to store high amount of electrostatic energy (sparks
Material Safety Data
discharge can only be observed over conductive
• Ensure all safety data is accessed and used while
elements).
installing UPP Systems (Material Safety Data
• All exposed metal parts used in UPP System Sheets are available in the download area of the
installations should be adequately grounded to a UPP website).
dedicated earth electrode and brought to a potential Transport & Storage
equal to that of other metal parts in the close
• UPP products should be transported and stored in
proximity.
accordance with the guidelines contained in this
Chemical Safety manual.
• Where using chemicals (such as Acetone) during Heavy items
the installation of UPP systems products, be sure • Heavy items should be handled using suitable lifting
to follow all safety guidelines given on the chemical equipment operated by authorised personnel.
containers themselves or on any accompanying
literature. Contents
Safety.................................................................2
Introduction.......................................................3
Underground Fuel Pipe Construction............... 3
Transit, On-loading and Storage.....................4
Uncoiling Pipe................................................... 4
Site Preparation................................................5
Pipe Burial Guidelines.....................................5
Pipe Bend Radius............................................. 6
Completion Records......................................... 6
Pipe Detector Tape........................................... 7
Pressure Testing...............................................7
Testing Guidelines. .......................................... 7
UPP Recommended Pipe Test Procedure....... 8
Hydrostatic Pressure Testing Method............... 8
Sump Inspection Register.............................10

2
Introduction Underground Fuel Pipe Construction
Underground Fuel Pipe Systems Black outer structural layer of the pipe is High Density
Several types of underground fuel pipe are available for Polyethylene (HDPE), grade PE80 or PE100 which allows
different applications and to meet various engineering and the use of electrofusion couplers and fittings to construct a
legal requirements: variety of pipeline configurations. HDPE PE80 and PE100
has well proven resistance to: stress cracking, puncture,
• U
PP Extra lined primary pipe with 100% nylon barrier scratch, impact, microbial and rodent attack.
for product, suction, pressure, vapor vent and fill lines
The intermediate layer is a tie-layer (adhesive) which
• U
PP Integral Secondary Containment pipe - for permanently bonds the polyethylene layer to the barrier layer.
pressure systems or environmentally sensitive sites.
The yellow inner barrier layer of UPP Extra pipe is specially
• U
PP electrical conduit pipe- for underground electrical formulated “fuel proof” barrier layer which has exceptional
wiring protection. resistance to absorption and permeation of both gasoline
UPP piping systems are designed in various diameters, and alcohol fuel blends.
from 32-160 mm (I”-6”) for the transfer of fuels in filling The smooth bore and low friction loss of UPP pipe permits
station fore courts, marinas, and airports. UPP systems higher fuel and vapor flows when than steel pipe, reducing
are also used for government and military installations as the pumping energy costs.
well as many industrial sites such as mines and rail depots.
UPP underground fuel pipe is pressure rated to 90 psi (6.2
There is no requirement for a concrete trench because bar) according to UL971. Rupture pressure is typically
fusion welded HDPE pipe is structurally resistant to weight exceeding 580 psi (40 bar) providing a large margin of
of backfill material and dynamic traffic loads. Over 20 safety.
years experience show no failures in underground fuel pipe
systems and no loss into the ground.

Figure 1: UPP Pipe Structure

Figure 2: Installation Overview

3
 Transit, On-loading and Storage • U
PP fittings - all electrofusion fittings are packed
Although UPP polyethylene pipe and fittings are extremely in heat-sealed polyethylene bags and delivered
hard wearing and resilient, it is important to handle and in cardboard cartons. Fittings should be stored in
store them with care to prevent scuffing or gouging. Any their packaging and in a dry area, away from direct
damaged pipes may need to be rejected and not installed. sunlight, until ready for use. This is particularly
important for electrofusion fittings. These must be kept
UPP products should be transported in a flat-bedded in their packaging until ready for use to prevent any
vehicle, free from sharp objects and projections. Wide contamination or oxidation.
polypropylene slings must be used when lifting pipe crates
by crane. Avoid using chains, hooks or hawsers. Uncoiling Pipe
A spreading beam should be used when lifting crates
containing pipe lengths greater than 19 ft 8" (6 m)
• Allow for a slight bending of the pipe crates when on
and off-loading.
• S tandard 19 ft 8" (6 m) crates may be moved using
a forklift. A side loader fitted with a minimum of four
supporting forks should be used for longer lengths.
Otherwise use a crane fitted with a spreader beam.
• W hen using a forklift to on or off-load coils, the forks
should be covered to avoid damage to the coiled pipe.

Figure 4: Uncoiling Pipe

The pipe can straighten with
Caution considerable force. Take care when
releasing pipe from the coil and secure
the straightened pipe.
Let the pipe rest in its uncoiled state for about eight hours.
High ambient temperatures can reduce this “layout” time
and low temperatures may increase it. Pipe can be laid in
its final position to “relax” before connecting up.
• 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.
Figure 3: Moving Coils
• The area in which the pipe is uncoiled on site must be
Storage on site clear, safe and free of sharp objects.
• I ndividual pipe lengths should be stacked not more than • R emove the tape around the tail end on the outer
3 ft (1 m) high with the bottom layer fully restrained by winding and secure this end.
wedges. The bottom layer of pipes should be laid on
timber battens at 3 ft (1 m) centres to avoid any damage • W ith the coil in the vertical position, roll the coil out
from sharp objects lying on the ground. cutting and removing tape as you find it (ensuring to
release only the next turn of pipe in the coil).
• P ipe crates should be stored on clear, level ground and
should never be stacked more than three crates high. • D o not drag the pipe.
• C oils should be stored on firm level ground that has • The natural curves from coiling can be used to change
suitable protection for the bottom of the coil. Stacked pipe direction and bags of sand, pea gravel or stakes
coils should never exceed three coils high. Individual can be used to hold it in place until it is ready for
coils should be stacked flat. If stored on edge, they connecting.
must be secured against a properly anchored support • O ne person should hold the pipe whilst another cuts it
and stored like this for a short period of time only, to the desired length.
particularly in warm weather conditions. • The cut ends will have a prominent hook that can be
• B adly stacked coils and pipe lengths can slip causing partially removed when weight is placed on it (bags
personal injury or damage to the product. Facilities for of sand or pea gravel), or use the hook end to your
safe lifting and moving must be available. advantage when turning direction into a chamber or
• P ipes are supplied with distinctive colored end caps to pump sump.
prevent entry of any contamination. These end caps
must be kept in place during storage.

4
Site Preparation
Site inspection:
Make sure the site is prepared and ready. The tanks and
sumps should be in place

IMPORTANT!
The site should be free from previous
fuel contamination. Figure 5: Pipe Spacing
• W hen laying duct onto a concrete base a 6" (150 mm)
Pipe Burial Guidelines thick bed of compacted sand should be laid on the
Recommended burial depth of UPP pipe is a minimum of concrete, below the duct. (The minimum amount of
12" (300 mm). sand should be 2" (50 mm) of compacted sand)
• All beds should be laid so that the pipe will not dip or
• All trenches should be sloped back towards the storage
sag when it is installed.
tanks. The fall back (slope) for all pipework to the tank
chambers should be a minimum of 1/8" per foot or • L aying of pipe should start from the tank farm
1 m every 100 m (Figure 7). This may vary to meet local • U nderground pipe runs may be continuous or have
requirements. The position of the entry fittings at the electrofusion welded joints. Any mechanical joints
furthest dispenser sump away from the tank chambers or compression fittings must be located within a
may be considerably higher than that of the entry containment chamber or sump.
fittings on the closest dispenser sump.
• V apor return lines should 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 have a radius of 5 ft (1.5 m).
• A recommended 6" (15 cm) bed of backfill material
should be laid underneath the pipe prior to installation
and there must never be voids under or around the
pipe. Acceptable backfill materials are:
• W ell-rounded pea gravel size ⅛" (3 mm) to ¾" (20 mm)
Figure 6: Electrofusion Welded Fitting Detail
• C rushed rock size ¾" (3 mm) to 5/8" (16 mm)
• Clean washed sand Refer to manual FFS-0123 for information about the
electrofusion process.
• Backfill material must not be contaminated with any
petroleum product or other contaminant

1:100 Fall-back (Slope) to tank

Figure 7: Fall-back (slope) to Tank

5
 • U
PP pipe exceeding 12 m (39 ft) should be laid in a • I f used above ground, UPP pipe should be protected
series of large snake-like curves and not in straight lines. against mechanical, climatic damage. Additional
Uncoiled pipe, when laid, will settle in a natural curve. supports and anchor points may also be required.
Check fire codes for proper installation.
• M ark positions on the tank access chamber/sump for
penetration locations and install UPP seals.
Bend Radius
The UPP piping systems have a semi-rigid construction
which gives both strength and flexibility.

Figure 9: Bend Radius

Refer to Table 1 for allowable bend radius of UPP Pipe.
Figure 8: Using Temporary Stakes to Snake Pipe

• G enerally any thermal expansion will be accounted for
by following our guidelines for spacing, backfilling and Important:
ensuring runs are “snaked”. Completion Records
• O
n completion of UPP installation make an “as
• P ipes should be separated from each other by at least
constructed” drawing showing the exact location of
the diameter of the largest pipe.
all below ground lines. It is also recommended that,
• I f pipe-runs cross each other they must be separated by in addition, a photographic record is preserved.
at least as much backfill material as the diameter of the
largest pipe or protected using at least 1" (25 mm)
of Styrofoam.

Pipe Bend Radius

Single Wall Pipe
Temperature (1 ") 32 mm (1½") 50 mm (2") 63 mm (3") 90 mm (4") 110 mm
>59˚F (>15˚C ) 1 ft 7" (0.5m) 2 ft 6" (0.75 m) 3 ft (0.9 m) 7ft 4" (2.25 m) 9 ft (2.75 m)
32 - 59˚F (0 - 15˚C) 2 ft 7" (0.8 m) 4 ft 1" (1.25 m) 5ft 2" (1.58m) 10ft 4" (3.15m) 12ft 8" (3.85m)
< 32˚F (< 0˚C) 3 ft 8" (1.12 m) 5 ft 9" (1.75 m) 7 ft 3" (2.2 m) 13 ft 2" (4 m) 16 ft (4.9 m)

Double Wall Pipe

(1 ")  (1½") (2") (3")  (4")
Temperature
40/32 mm  63 / 50 mm  75 / 63 mm 110/90 mm 125/110 mm
> 59˚F (> 15˚C) 2 ft (0.6 m) 3 ft (0.9 m) 3 ft 8" (1.12 m) 9 ft (2.75 m) 10 ft 2" (3.1 m)
32 - 59˚F (0 - 15˚C) 3 ft 3" (1 m) 4 ft 11" (1.5 m) 1.88 m (6 ft 2") 3.85 m (12 ft 8") 4.4 m (14 ft 5")
< 32˚F< (0˚C) 4 ft 7" (1.4 m) 7 ft 3" (2.2 m) 8 ft 6" (2.6 m) 16 ft (4.9 m) 18 ft 4" (5.6 m)

UL971 Pipe
(2")  (3") (1½") (2") (3") (4")
Temperature
63 mm 90 mm 63 / 50 mm 75 / 63 mm 110 / 90 mm 125 / 110 mm
> 59˚F (>15˚C) 3 ft 3" (1 m) 9 ft 10" (3 m) 3 ft 3" (1 m) 3 ft '3" (1 m) 13 ft 2" (4 m) 13 ft 2" (4 m)
32 - 59˚F (0 - 15˚C) 5 ft 3" (1.6 m) 16 ft 5" (5 m) 5 ft 3" (1.6 m) 5 ft 3" (1.6 m) 19 ft 8" (6 m) 19 ft 8" (6 m)
< 32˚F (< 0˚C) 7 ft 2" (2.2 m) 23 ft (7 m) 7 ft 2" (2.2 m) 7 ft 2" (2.2 m) 26 ft 3" (8 m) 26 ft 3" (8 m)

Table 1: Allowable Bend Radius

6
Pipe Detector Tape Pressure Testing
UPP Detectable tape is used to allow the piping location Following inspection and prior to backfilling, a tightness
to be found after it has been covered. The tape is installed test should be carried out by a competent person on each
below ground at 9.8 inches (250 mm) height directly above pipe run, chamber and sump to verify the integrity of joints
pipe runs to indicate the position of each pipe. and seals. This testing should meet the requirements of
local officials and engineers and comply with local health
and safety regulations.
The following testing procedure is suggested for guidance
only and should in no way override oil companies or local
regulator’s requirements.
Detector Tape
Testing Guidelines.
Equipment
• Target test pressure should be 50% of scale on gauge,
Max Depth
Detection 3 m
e.g. if the test pressure is 14.5 psi (1 Bar) , use a 29 psi
(2 Bar) gauge.
• G auges should have serial numbers and be tested /
Pea Gravel
or Sand 250 mm
certificated yearly.
• P ressure testing equipment should have fitted a relief
valve set at around 7.25 psi (0.5 bar) above the test
Subsoil
pressure.
UPP Pipe
General Guidelines
• W hen applying pressure from gas cylinders, use
Figure 10: Detector Tape Installation
suitable valves to ensure test pressure is not exceeded.
Both ends of the tape should be grounded during
• Apply pressure or vacuum slowly to minimise risks.
installation.
• W hen tightness testing primary pipe the secondary
should be open to atmosphere this is critical whenever
End of Tape Must be Grounded in Sumps secondary pipe is filled with liquid.
• S econdary pipe should ideally not be welded prior to
testing primary to allow inspection of joints.
• W hen tightness testing secondary pipe the primary
should be open to atmosphere.
• W ipe each joint with soapy water to check for leaking.
Caution
• To avoid explosion hazards, nitrogen or an inert gas
from a pressure cylinder should be used in place of
compressed air for tightness testing if fuel has been
Figure 11: Detector Tape must be Grounded used to ballast underground storage tanks or if pipe-
When using a detection tool, the near end of the work has previously contained petroleum.
detectable tape should be disconnected from the • P ipe-work should be disconnected (isolated) from
grounding point to allow the red cable from the transmitter underground storage tank prior to commencing
to be connected to the tape and the black cable from the tightness testing.
transmitter to be connected to the grounding point. • Any water used for testing should be disposed of
The far end of the tape should remain grounded to give through the oil / water separator or by a specialist
the highest signal strength and the earth spike should be contractor and in accordance with any local
as far away from the trace path as possible at a 90 degree environmental health and safety requirements and
angle. regulations.
There are three tightness testing methods suitable for use
Use the lowest frequency possible from the transmitter
with UPP systems: Pneumatic, Vacuum and Hydrostatic;
around 577 Hz or 8 KHz to eliminate coupling to other
any of these methods can be used to prove the tightness
grounded cables.
of a line. Tightness testing using a Hydrostatic method is
Use the receiver to follow the path of the tape to locate the suitable for testing at high pressures. The UPP pneumatic
buried pipe. Follow direction included with the receiver and and vacuum tightness tests should both be carried out to
transmitter for detecting buried pipe location. ensure confidence in the installation at lower pressures.

7
 UPP Recommended Pipe Test Procedure • D
uring the test period of 90 minutes the pressure
Primary Pipe Hydrostatic Pressure Testing should be recorded with the frequency shown below:
Method Test period Frequency of Number of
Equipment (mins) readings (mins) readings
• P ump rated for more than 145 psig (10 bar) 0-10 2 6
• H ydrofor (reservoir or pressure tank) 10-30 5 4
• Two pressure gauges, rated for 174 psig (12 bar), min. 30-90 10 6
reading 2 psig (0.1 bar)
Table 2: Recording Test Results
• C heck valve
• The test is passed if all the readings during the testing
• B all valve cycle are 43.5 psi (3 bar) or above.
• P ressure relief valve rated for 290 psig (20 bar), set at • D ecreasing readings = failure of pressure test. (Note
159 psig (11 bar) that the readings are likely to increase)
Conditioning Phase
• I f the system fails the pressure test make the following
• Fill the pipe work system to be tested with water, checks:
making sure that any air relief valves are opened while
filling the pipe work. • Check all mechanical connections
• After filling the pipe work wait 1 hour for the • C heck welded joints
temperature to stabilize. • W hen the failure point has been located and remedied
• P ressurize the system to 145 psi (10 bar) and maintain repeat the full conditioning and testing sequence.
this pressure for 30 minutes. (System pressure shall be
maintained by means of refilling in order to compensate
for the increase in volume due to the expansion of
the pipe-work). At this time the system should be
thoroughly inspected for leakage. After any such areas
have been remedied repeat the conditioning before
proceeding to the testing phase.
Testing Phase
• R apidly reduce the system pressure to 43.5 psi (3
bar) by bleeding water from the pipe-work. (Due to the
visco-elastic properties of polyethylene the pipe will
contract).

145 (10)
Maintain 130 PSI (9 bar) for 30 minutes
130.5 (9)
116 (8)
Pressure PSI (bar)

101.5 (7)
87 (6)
72.5 (5)
58 (4)
43.5 (3)
29 (2) drop to 43.5 PSI (3 bar) for 90 minutes
To Pass Test Pressure Must remain at 43.5 PSI (3 bar) or above
14.5 (1)
0
0 10 20 30 0 2 4 6 8 10 15 20 25 30 40 50 60 70 80 90
Conditioning Time (mins) Test Reading Times (mins)
Hydrostatic Testing Graph

8
UPP Pneumatic Tightness Testing Method Procedure Vacuum Testing
Refer to ASTM International Document F2786-10 for
overall pneumatic testing information. Pneumatic Vacuum Tightness Testing
Type of Test Conditioning Test Vacuum Test Time
Test Pressure (Mins)
• 50 PSI ( 3.5 bar) for pipe up to 2" Tank Chamber / 3 mins @ 2x -30 mbar, -0.44 7
• Use operating pressure for Piping / Fittings over 2". Dispenser Sump Test Vacuum psi, -3 kPa
• When testing secondary pipe terminated with Spill Container 3 mins @ 2x Test -30 mbar, -0.44 psi, 1.5
Vacuum -3 kPa
flexible boot, pressure test at 0.5 bar (7 psi) for 30
Table 4: Vacuum Testing
minutes following a 15 minutes conditioning at test
pressure. Pressure Ratings
• Never exceed the maximum pressure rating (table 5).
Maximum Pressure Rating (UL 971)
• R
ecord Temperature and Pressure at start of each test
time. Pipe type Pressure Pressure
Rating (Bar) Rating (PSI)
• Condition the piping as below:
1. Pressurize the piping to 10% of test pressure. Hold UPP Primary 6 90
pressure for 30 minutes and inspect for leakage or UPP Secondary 4 58
pressure drop. Table 5: UL971 Pipe  Maximum Pressure Rating
2. Increase pressure to 50% of test pressure and
again inspect for leakage while holding pressure Maximum Pressure Rating (EN14125)
for 30 minutes. Pipe type Pressure Pressure
3. Increase pressure to 100% of test pressure and Rating (Bar) Rating (PSI)
again inspect for leakage while holding pressure UPP Primary 10 145
for 30 minutes. UPP Secondary 4 58
• R ecord Temperature and Pressure at end of each test
Table 6: EN14125 Pipe  Maximum Pressure Rating
time.
• I f results are within criteria of Table 3 Tightness Test Secondary Pipe Testing Pressure Rating
is passed. Secondary Test Bar PSI
Pressure Testing Safety Pressure
Follow these guidelines when doing pneumatic testing: Rubber boots 0.5 7
• Wear Safety glasses. Welded Boots 3.5 50
• Relieve air pressure at the completion of each test Table 7: Secondary Testing Pressures
phase and before any corrective actions are taken.
• Never exceed the pressure rating of components when
testing.
• Allow only necessary and authorized persons in the
proximity of pipe being tested.
• Restrain the movement of connections, joints and seals
during testing.

Acceptable Pressure Variation

Initial Pressure 3.5 bar
Temperature variation Δ T (°C) -15 -10 -5 0 5 10 15
Final pressure due to 3.32 3.38 3.44 3.5 3.56 3.62 3.68
temperature change (bar)

Initial Pressure 50 psi

Temperature variation Δ T (°F) -30 -20 -10 0 10 20 30
Final pressure due to 47.2 48.1 49.1 50 50.9 51.9 52.8
temperature change (psi)
Table 3: Pressure Variation with Temperature Change

9
 Sump Inspection Register
Date of Inspection or Test Results of Inspection or Test Signature of Inspector or Tester

Required Monthly And/Or Annual Inspection: Containment sumps located on the property at which the FFS products are installed must be visually inspected for liquid
monthly. Sump sensors, if installed, must be tested annually. Any leaks must be corrected at the time they are found.

Recommended Monthly Inspection: Verify sump lids are tight and sealed. Inspect sumps for dirt, debris, liquid or any physical cracks or holes that would allow leakage.
Check for evidence of staining or new staining. Verify penetration boots are in good condition and the pipe entry into the sump is positioned properly (near perpendicular
entry). Verify sump liquid sensors are positioned correctly if installed. Verify the piping and other equipment in the sump are in good condition.
Record any faults on this Sump Inspection Register and have the fault(s) corrected at the time found.
Additional copies of this form can be downloaded from the FFS website www.franklinfueling.com
End user proprietary inspection check register log formats or any form to record these inspections is acceptable.
From FFS  form FFS-0131 Rev1
Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA
Tel: +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.com
10
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11
 www.franklinfueling.com

3760 Marsh Road

Madison, WI 53718, USA
Tel: +1 608 838 8786
Fax: +1 608 838 6433
USA & Canada Tel: 1 800 225 9787

México Tel: 001 800 738 7610

Brazil Tel: +55 11 3395 0606

UK Tel: +44 1473 243300

Franklin Fueling Systems Gmbh

Rudolf-Diesel-Strasse 20
54516 WITTLICH, Germany
Tel: +49 6571 105 380
Fax: +49 6571 105 510

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Fax: + 86 10 8565 4766
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No. 26 Chaowai Street
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©FFS 2011 408001016 Rev 1