Download Installation Manual - Franklin Fueling Systems
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protecting your liquid assets Installation Manual UPP Installation Manual INTRODUCTION $WWKHKHDUWRIWKH833V\VWHPLVDVLPSOHDQGKLJKO\HIÀFLHQWLQVWDOODWLRQSURFHGXUH 7KH(OHFWURIXVLRQV\VWHPDQGLQVWDOODWLRQSURFHGXUHLVH[SODLQHGLQGHWDLORQWKHIROORZLQJ SDJHV It is of paramount importance that these instructions are adhered to, failure to do so can result in the remoYal of certiÀed Installer status $ll pipes must Ee cut sTuare $ll pipes and spiJoted ÀttinJs must Ee scraped $ll pipes, ÀttinJs and ZeldinJ socNets must Ee cleaned Zith acetone $ll Moints should haYe the pipe inserted into the electrofusion ÀttinJ ensurinJ that the marNed insertion depth is reached -oints must not Ee under an\ stress durinJ ZeldinJ or until amEient temperature is reached after ZeldinJ FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. UPP Installation Manual CONTENTS Section Title PaJe 1 Transport, /oadinJ and StoraJe 6 1.1 Transit, on-loading and off-loading 6 1.2 Storage on site 6 1.3 6XPPDU\RIUXOHV 7 1.4 8QFRLOLQJ3LSH 7 2 Site Preparation 8 2.1 Getting started 8 2.2 'LJJLQJWUHQFKHVDQGEHGGLQJ 8 2.3 ,QVWDOODWLRQ2YHUYLHZ 9 3 Electrofusion Instructions 11 3.1 (OHFWURIXVLRQRYHUYLHZ 12 3.2 (OHFWURIXVLRQSUHSDUDWLRQGHWDLOV 13 3.3 :HOGLQJRYHUYLHZ 16 3.4 :HOGLQJSULPDU\SLSHDQGÀWWLQJV 16 3.5 :HOGLQJVHFRQGDU\FRQWDLQPHQWSLSHDQGÀWWLQJV 18 4 Secondar\ &ontainment 19 4.1 6HFRQGDU\FRQWDLQPHQWGRXEOHZDOO°HOERZ7HHLQVWDOODWLRQ 19 4.2 6HFRQGDU\FRQWDLQPHQWWHUPLQDWLRQVHULHVLQVWDOODWLRQ 22 5 Installation 24 5.1 ,QVWDOOLQJD833SRO\HWK\OHQHWDQNFKDPEHU 24 5.2 ,QVWDOOLQJD833IXVLRQWDQNFKDPEHU 26 5.3 ,QVWDOOLQJD833SRO\HWK\OHQHGLVSHQVHUVXPS 30 5.4 ,QVWDOOLQJD833VWDELOLVHUEDU 32 5.5 ,QVWDOOLQJD833PHFKDQLFDOHQWU\VHDO+ROHVDZ6HDOFRPSDWLELOLW\FKDUW 33 5.6 ,QVWDOOLQJD833HOHFWURIXVLRQHQWU\VHDO 34 5.7 833HOHFWURIXVLRQVHDODSSOLFDWLRQV 35 5.8 $WWDFKLQJDÁH[LEOHHQWU\ERRW 36 5.9 )XVLRQZHOGLQJ833SRO\HWK\OHQHGXFWSLSH 37 5.10 ,QVWDOOLQJD833HOHFWURIXVLRQHQWU\VHDO 39 5.11 ,QVWDOOLQJD833HOHFWURIXVLRQHQWU\VHDOVHULHVZLWKLQWHJUDWHGFRXSOHU 42 5.12 ,QVWDOOLQJD833HOHFWURIXVLRQ)53HQWU\VHDORQDÁDWZDOOHGVXPS 44 5.13 ,QVWDOOLQJD833DFFHVVFRYHU 48 5.14 8/3LSHLQVWDOODWLRQLQVWUXFWLRQV 50 FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. CONTENTS Section Title PaJe 6 ModiÀcation and 5epair of UPP Sites 54 6.1 0RGLÀFDWLRQDQG5HSDLURI8336LWHV 54 7 Electrostatic Safet\ 56 8 :eldinJ 57 8.1 6FUDSLQJ7RRO,QVWUXFWLRQV 57 8.2 (:HOGHU2SHUDWLQJ0DQXDO 58 8.3 (:+DQG+HOG:HOGHU2SHUDWLQJ0DQXDO 62 8.4 (::HOGHU2SHUDWLQJ0DQXDO9 65 8.5 ()+DQG+HOG:HOGHU2SHUDWLQJ0DQXDO 68 9 TiJhtness TestinJ 72 9.1 +\GURVWDWLF0HWKRG 73 9.2 8333QHXPDWLF0HWKRG 74 9.3 8333LSH5DWLQJ 75 9.4 6\VWHP,QWHJULW\7HVWLQJ,QVWUXFWLRQV 76 9.5 3ULPDU\VLQJOHZDOO7LJKWQHVV7HVWLQJ5HSRUW 78 9.6 6HFRQGDU\GRXEOHZDOO7LJKWQHVV7HVWLQJ5HSRUW 79 9.7 'XFWFRQWDLQPHQWSLSH7LJKWQHVV7HVWLQJ5HSRUW 80 9.8 'LVSHQVHU6XPS5HSRUW 81 9.9 8337DQN&KDPEHU9DFXXP7HVW 82 10 Water Hammer Effects 84 11 )uel )loZ 85 12 )reTuentl\ $sNed 4uestions 87 13 Safet\ 91 FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 1 1. TRANSPORT, LOADING AND STORAGE 1.1 TRANSIT, ON-LOADING AND OFF-LOADING $OWKRXJK 833 SRO\HWK\OHQH SLSH DQG ÀWWLQJV DUH H[WUHPHO\ KDUG ZHDULQJ DQGUHVLOLHQWLWLVLPSRUWDQWWRKDQGOHDQGVWRUHWKHPZLWKFDUHWRSUHYHQW VFXIÀQJRUJRXJLQJ$Q\GDPDJHGSLSHVPD\QHHGWREHUHMHFWHGDQGQRW LQVWDOOHG6HH¶WUDQVLWORDGLQJDQGVWRUDJHDQGVWRUDJHVXPPDU\RIUXOHV· RQQH[WSDJHIRUGHWDLOVRQZKDWFRQVWLWXWHVDGDPDJHGOHQJWKRISLSH 833SURGXFWVVKRXOGEHWUDQVSRUWHGLQDÁDWEHGGHGYHKLFOHIUHHIURP VKDUSREMHFWVDQGSURMHFWLRQV:LGHSRO\SURS\OHQHVOLQJVPXVWEHXVHG ZKHQOLIWLQJSLSHFUDWHVE\FUDQH$YRLGXVLQJFKDLQVKRRNVRUKDZVHUV $VSUHDGLQJEHDPVKRXOGEHXVHGZKHQOLIWLQJFUDWHVFRQWDLQLQJSLSH OHQJWKVJUHDWHUWKDQPIW $OORZIRUDVOLJKWEHQGLQJRIWKHSLSHFUDWHVZKHQRQDQGRIIORDGLQJ 6WDQGDUGPIWFUDWHVPD\EHPRYHGXVLQJDIRUNOLIW$VLGHORDGHU ÀWWHGZLWKDPLQLPXPRIIRXUVXSSRUWLQJIRUNVVKRXOGEHXVHGIRUORQJHU OHQJWKV2WKHUZLVHXVHDFUDQHÀWWHGZLWKDVSUHDGHUEHDP :KHQXVLQJDIRUNOLIWWRRQRURIIORDGFRLOVWKHIRUNVVKRXOGEHFRYHUHGWR DYRLGGDPDJHWRWKHFRLOHGSLSH 1.2 STORAGE ON SITE ,QGLYLGXDOSLSHOHQJWKVVKRXOGEHVWDFNHGQRWPRUHWKDQ1PKLJKIWZLWK WKHERWWRPOD\HUIXOO\UHVWUDLQHGE\ZHGJHV:KHUHSRVVLEOHWKHERWWRP OD\HURISLSHVVKRXOGEHODLGRQWLPEHUEDWWHQVDW1PIWFHQWUHVWRDYRLG DQ\GDPDJHIURPVKDUSREMHFWVO\LQJRQWKHJURXQG 3LSH FUDWHV VKRXOG EH VWRUHG RQ FOHDU OHYHO JURXQG DQG VKRXOG QHYHU EH VWDFNHGPRUHWKDQWKUHHFUDWHVKLJK &RLOVVKRXOGEHVWRUHGRQÀUPOHYHOJURXQGWKDWKDVVXLWDEOHSURWHFWLRQ IRUWKHERWWRPRIWKHFRLO6WDFNHGFRLOVVKRXOGQHYHUH[FHHGWKUHHFRLOV KLJK,QGLYLGXDOFRLOVVKRXOGEHVWDFNHGÁDW,IVWRUHGRQHGJHWKH\PXVW EHVHFXUHGDJDLQVWDSURSHUO\DQFKRUHGVXSSRUWDQGVWRUHGOLNHWKLVIRUD VKRUWSHULRGRIWLPHRQO\SDUWLFXODUO\LQZDUPZHDWKHUFRQGLWLRQV %DGO\ VWDFNHG FRLOV DQG SLSH OHQJWKV FDQ VOLS FDXVLQJ SHUVRQDO LQMXU\ RU GDPDJH WR WKH SURGXFW )DFLOLWLHV IRU VDIH OLIWLQJ DQG PRYLQJ PXVW EH DYDLODEOH 3LSHVDUHVXSSOLHGZLWKGLVWLQFWLYHFRORXUHGHQGFDSVWRSUHYHQWHQWU\RI DQ\FRQWDPLQDWLRQ7KHVHHQGFDSVPXVWEHNHSWLQSODFHGXULQJVWRUDJH 833ÀWWLQJVDOOHOHFWURIXVLRQÀWWLQJVDUHSDFNHGLQKHDWVHDOHGSRO\HWK\OHQH EDJVDQGGHOLYHUHGLQFDUGERDUGFDUWRQV)LWWLQJVVKRXOGEHVWRUHGLQWKHLU SDFNDJLQJDQGLQDGU\DUHDDZD\IURPGLUHFWVXQOLJKWXQWLOUHDG\IRUXVH 7KLV LV SDUWLFXODUO\ LPSRUWDQW IRU HOHFWURIXVLRQ ÀWWLQJV 7KHVH PXVW EH NHSWLQWKHLUSDFNDJLQJXQWLOUHDG\IRUXVHWRSUHYHQWDQ\FRQWDPLQDWLRQRU R[LGLVDWLRQ 6 FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 1 1.3 SUMMARY OF RULES Always 6WRUHSLSHVRQÁDWÀUPOHYHOJURXQG DEOHWRZLWKVWDQGWKHZHLJKWRISLSHV DQGOLIWLQJHTXLSPHQW .HHSSLSHDQGÀWWLQJVZHOODZD\IURP VKDUSREMHFWVVXFKDVÁLQWVDQGRWKHU VLWHGHEULV 8VHZLGHQRQPHWDOOLFVOLQJVZKHQ lifting pipe ([HUFLVHVSHFLDOFDUHZKHQKDQGOLQJ SLSHLQZHWRUIURVW\FRQGLWLRQV8VH gloves for additional grip .HHSSURWHFWLYHSDFNDJLQJLQWDFWXQWLO SLSHRUÀWWLQJVDUHUHTXLUHGIRUXVH .HHSERWKSLSHDQGÀWWLQJVRXWRI GLUHFWVXQOLJKWRULQWHQVHKHDWXQWLO UHDG\WRXVH (QVXUHOLIWLQJDQGVWRUDJHSRLQWVDUH HYHQO\VSDFHG 5HMHFWSLSHLIVXUIDFHGDPDJHLV H[FHVVLYH0LQRUDEUDVLRQVFDQEH ignored /LJKWDEUDVLRQKDQGOLQJGDPDJHOLPLWHG WRDVLQJOHDUHDEHWZHHQDVHWRI WDSHVOHVVWKDQPPZLGHLV permitted Never ([SRVHSLSHRUÀWWLQJVWRSURORQJHG GLUHFWVXQOLJKWRUH[FHVVLYH WHPSHUDWXUHV 7KURZGURSGUDJRUUROOLQGLYLGXDO SLSHVEXQGOHVRUÀWWLQJVDVWKLVFDQ FDXVHGDPDJHRUVXEVHTXHQWOHDNDJH 8VHPHWDOVOLQJVRUFKDLQVZKHQ handling pipe 6WDFNSLSHPRUHWKDQWKUHHFRLOVRU WKUHHEXQGOHVKLJK 1.4 UNCOILING PIPE 7DNH FDUH ZKHQ UHOHDVLQJ SLSH IURP WKH FRLO DV WKH SLSH FDQ VWUDLJKWHQ ZLWK FRQVLGHUDEOHIRUFH,WLVDOVRLPSRUWDQWWROHWWKHSLSHUHVWRXWRILWVFRLOHGVWDWH IRUDERXWHLJKWKRXUV+LJKDPELHQWWHPSHUDWXUHVFDQUHGXFHWKLV´OD\RXWµWLPH DQGORZWHPSHUDWXUHVPD\LQFUHDVHLW3LSHFDQEHODLGLQLWVÀQDOSRVLWLRQWR ´UHOD[µEHIRUHFRQQHFWLQJXS <RXQHHGDWOHDVWWZRSHRSOHWRXQFRLODQGFXWWKHSLSH7KHFRLOLVWDSHGXSLQ OD\HUVWRPDNHLWHDVLHUWRXQFRLODWPDQDJHDEOHLQWHUYDOV 7KHDUHDLQZKLFKWKHSLSHLVXQFRLOHGRQVLWHPXVWEHFOHDUVDIHDQGIUHHRI VKDUSREMHFWV 5HPRYHWKHWDSHDURXQGWKHWDLOHQGRQWKHRXWHUZLQGLQJDQGVHFXUHWKLVHQG :LWKWKHFRLOLQWKHYHUWLFDOSRVLWLRQUROOWKHFRLORXWFXWWLQJDQGUHPRYLQJWDSH DV\RXÀQGLWHQVXULQJWRUHOHDVHRQO\WKHQH[WWXUQRISLSHLQWKHFRLO Do not drag the pipe 7KHQDWXUDOFXUYHVIURPFRLOLQJFDQEHXVHGWRFKDQJHSLSHGLUHFWLRQDQGEDJV RIVDQGSHDVKLQJOHRUVWDNHVFDQEHXVHGWRKROGLWLQSODFHXQWLOLWLVUHDG\IRU FRQQHFWLQJ 2QHSHUVRQVKRXOGKROGWKHSLSHZKLOVWDQRWKHUFXWVLWWRWKHGHVLUHGOHQJWK 7KHFXWHQGVZLOOKDYHDSURPLQHQWKRRNWKDWFDQEHSDUWLDOO\UHPRYHGZKHQ ZHLJKWLVSODFHGRQLWEDJVRIVDQGRUSHDVKLQJOH2UWKHKRRNHQGFDQEH XVHGWR\RXUDGYDQWDJHZKHQWXUQLQJGLUHFWLRQLQWRDFKDPEHURUSXPSVXPS FOLLOW INSTALLATION INSTRUCTIONS. 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SITE PREPARATION 2.1 GETTING STARTED 'LVSHQVHUPRXQWLQJIUDPHVRIIVHWÀOODQGYHQWIUDPHVVKRXOGEHSRVLWLRQHG ÀUVWDQGÀUPO\À[HGDWWKHLUÀQDOFRUUHFWOHYHOWRHQVXUHWKDWDOOSLSHZRUN FDQEHODLGZLWKDFRQWLQXRXVIDOOEDFNWRWKHWDQN 2.2 DIGGING TRENCHES AND BEDDING ,W LV LPSRUWDQW WR FRQVWUXFW SURSHU WUHQFKHV EHIRUH OD\LQJ 833 SLSH 7UHQFKHVVKRXOGEHZLde aQGGHHSHQRXJKWRFRPIRUWDEO\DOORZSLSHUXQV UHFRPPHQGHGVSDFLQJDQGEDFNÀOOPDWHULDOV 5HFRPPHQGHGEXULDOGHSWKRI833SLSHLVDPLQLPXPRIPP $OO WUHQFKHV VKRXOG EH VORSHG EDFN WRZDUGV WKH VWRUDJH WDQNV ZLWK D UHFRPPHQGHGJUDGLHQWRI 9DSRXUUHWXUQOLQHVPXVWKDYHDVORSHRISHUIRRWDQGQHYHUOHVVWKDQ SHUIWEDFNWRZDUGVWKHWDQNIDUPXQOHVVLQOLQHMRLQWVVXFKDVHOERZV DUHWREHXVHG 7UHQFKFRUQHUVVKRXOGEHUDGLXVHGWRPIW $ UHFRPPHQGHG FP EHG RI EDFNÀOO PDWHULDO VKRXOG EH ODLG XQGHUQHDWK WKH SLSH SULRU WR LQVWDOODWLRQ DQG WKHUH PXVW QHYHU EH YRLGV XQGHURUDURXQGWKHSLSH$FFHSWDEOHEDFNÀOOPDWHULDOVDUH :HOOURXQGHGSHDJUDYHOVL]HPP1/8WRPP/4") &UXVKHGURFNVL]HPP/4WRPP5/8 &OHDQZDVKHGVDQG :KHQOD\LQJGXFWRQWRDFRQFUHWHEDVHDPPWKLFNEHGRI FRPSDFWHGVDQGVKRXOGEHODLGRQWKHFRQFUHWHEHORZWKHGXFW $EVROXWHPLQLPXPDPRXQWRIVDQGVKRXOGEHPPRIFRPSDFWHG VDQG $OO EHGV VKRXOG EH ODLG VR WKDW WKH SLSH ZLOO QRW GLS RU VDJ ZKHQ LW LV installed 8QGHUJURXQGSLSHUXQVPD\EHFRQWLQXRXVRUKDYHHOHFWURIXVLRQZHOGHG MRLQWV$Q\PHFKDQLFDOMRLQWVRUFRPSUHVVLRQÀWWLQJVPXVWEHORFDWHGZLWKLQ DFRQWDLQPHQWFKDPEHURUVXPS 833SLSHH[FHHGLQJPIWVKRXOGEHODLGLQDVHULHVRIODUJHVQDNHOLNH FXUYHV DQG QRW LQ VWUDLJKW OLQHV 8QFRLOHG SLSH ZKHQ ODLG ZLOO VHWWOH LQ D QDWXUDOFXUYH *HQHUDOO\ DQ\ WKHUPDO H[SDQVLRQ ZLOO EH DFFRXQWHG IRU E\ IROORZLQJ RXU JXLGHOLQHVIRUVSDFLQJEDFNÀOOLQJDQGHQVXULQJUXQVDUHQRWGHDGVWUDLJKW 3LSHVVKRXOGEHVHSDUDWHGIURPHDFKRWKHUE\DWOHDVWWKHGLDPHWHURIWKH largest pipe ,ISLSHUXQVFURVVHDFKRWKHUWKH\PXVWEHVHSDUDWHGE\DWOHDVWDVPXFK EDFNÀOOPDWHULDODVWKHGLDPHWHURIWKHODUJHVWSLSHRUSURWHFWHGXVLQJDW OHDVWPPRIVW\URIRDP ,I XVHG DERYH JURXQG 833 SLSH VKRXOG EH SURWHFWHG DJDLQVW PHFKDQLFDO FOLPDWLF89DQGÀUHGDPDJHE\ZUDSSLQJLWLQUDGLDWLRQRUWKHUPDOVKLHOGLQJ WDSH$GGLWLRQDOVXSSRUWVDQGDQFKRUSRLQWVPD\DOVREHUHTXLUHG FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 2 2.3 INSTALLATION OVERVIEW 1. Site inspection: 0DNHVXUHWKHVLWHLVSUHSDUHGDQGUHDG\ 7. Install offset Àll lines if applicable 7RLQVWDOOWKH833SLSHZRUNV\VWHP 6WDUWZLWKWKHLQVWDOODWLRQRIWKHRIIVHWÀOOOLQHVIURPWKH WDQNDQGZRUNWRZDUGVWKHRIIVHWÀOOSRLQW 7KH VLWH VKRXOG EH IUHH IURP SUHYLRXV IXHO FRQWDPLQDWLRQ 8. Install vents and vapour recovery staJe lb 95 Ib 7KHWDQNVVKRXOGEHLQSODFH 7KHERWWRPOD\HURIEHGGLQJDQGEDFNÀOOPDWHULDOVKRXOG KDYHEHHQODLGLQWKHWUHQFKHV 7KHYHQWÀOODQGSXPSGLVSHQVHUIUDPHVVXPSVVKRXOGEH LQWKHLUÀQDOSRVLWLRQLQUHODWLRQWRWKHÀQLVKHGIRUHFRXUW VXUIDFHOHYHO (QVXUHWKHUHLVDQDGHTXDWHSRZHUVXSSO\IRUHOHFWURIXVLRQ HLWKHUIURPWKHPDLQVRUDVXLWDEOHJHQHUDWRUPLQLPXP .9$ 2. Uncoil the pipe into the installation area and allow it to relax $OZD\VXVHDPLQLPXPRIWZRSHRSOHWRXQFRLODQGFXWWKH SLSH7RXQFRLOVHFXUHRQHHQGDQGUROORXWRQO\UHOHDVLQJ VHFXULQJWDSHVDVUHTXLUHGVHHVHFWLRQ 3. Install the tank access chambers / sumps )ROORZWKHPDQXIDFWXUHU·VLQVWDOODWLRQJXLGHOLQHVIRUWDQN VXPSVFKDPEHUV 4. 0ake sure all the tank top steel ÀttinJs are installed 5. Mark positions on the tank access chamber/sump for penetration locations and install UPP seals %HDULQPLQGWKDWIDOOEDFNIRUDOOSLSHZRUNWRWKHWDQN FKDPEHUVVKRXOGEHDPLQLPXPRIPHYHU\P SHUIRRWWKLVPD\YDU\WRPHHWORFDOUHTXLUHPHQWV7KH SRVLWLRQ RI WKH HQWU\ ÀWWLQJV DW WKH IXUWKHVW GLVSHQVHU VXPSDZD\IURPWKHWDQNFKDPEHUVPD\EHFRQVLGHUDEO\ KLJKHU WKDQ WKDW RI WKH HQWU\ ÀWWLQJV RQ WKH FORVHVW GLVSHQVHUVXPS 6. Install pipework ,W LV QRW HVVHQWLDO WKDW WKH ZRUN LV FDUULHG RXW LQ WKLV RUGHU EXW LW KHOSV WR JLYH VRPH VWUXFWXUH WR WKH VLWH installation ,WLVDGYLVHGWRQRWHGRZQWKHEDWFKQXPEHURIWKH833 SLSHDVLWLVOD\HGRXWLQWKHWUHQFKHVIRUIXWXUHUHIHUHQFH WKLVFDQEHIRXQGSULQWHGRQWKHSLSHLWVHOI ,I SRVVLEOH DQG DSSOLFDEOH OD\ YHQW OLQHV LQWR WKH VDPH WUHQFKDVWKHRIIVHWÀOOOLQHV ,IYHQWVDUHUHPRWHIURPRIIVHWÀOOOLQHVDVHSDUDWH95E OLQHLVUHTXLUHGWRFRQQHFWWKHYHQWVWDFNWRWKHÀOOSRLQW 7KHPRVWGLUHFWURXWHVKRXOGEHXVHG ,QVWDOODWLRQ RI YHQWV VKRXOG FRPPHQFH DW WKH WDQN HQG DJDLQDOORZLQJIRUDSSURSULDWHIDOOEDFNVIRUWKHOD\LQJRI SLSHEHWZHHQWKHYHQWVWDFNDQGWKHWDQNFKDPEHU 95OEVKRXOGEHODLGEHWZHHQWKHYHQWVWDFNDQGWKHÀOO SRLQWZLWKQRIDOOEDFNLHFRPSOHWHO\KRUL]RQWDO Note:7KLVLVDJXLGHOLQH/RFDOUHTXLUHPHQWVDQG UHJXODWLRQVZLOOQHHGWREHWDNHQLQWRFRQVLGHUDWLRQ ,WPD\UHTXLUHPDQLIROGLQJDQGFRQQHFWLRQWRWKHYDSRXU UHFRYHU\VWDJHV\VWHP 9. Install product lines 'HSHQGLQJRQZKHWKHULWLVDVXFWLRQRUSUHVVXUHV\VWHP \RX ZLOO QHHG WR FRQVLGHU FDUHIXOO\ WKH DSSURSULDWH IDOO EDFNV IURP WKH IXUWKHVW SXPS , GLVSHQVHU VXPS WR WKH WDQN IDUP ,I LW LV D SUHVVXUH V\VWHP IRU H[DPSOH WKH SXPSGLVSHQVHUVXPSSHQHWUDWLRQVDWWKHIXUWKHVWSRLQW ZLOOEHKLJKHUWKDQWKRVHQHDUHVWWRWKHWDQNIDUP /D\LQJ RI SLSH VKRXOG DJDLQ FRPPHQFH IURP WKH WDQN farm 10. Secondary &ontainment S& ,WLVFRPPRQSUDFWLFHIRU6&V\VWHPVWREHXVHGZLWKWKH SLSHZRUNIRUSUHVVXUHV\VWHPV Note:7KHVFUDSLQJRI6&SLSHPXVWEHGRQHXVLQJD KDQGVFUDSHU 7KH OD\LQJ DQG IDOO EDFN FRQVLGHUDWLRQV DUH LGHQWLFDO WR 3ULPDU\ SLSH LQVWDOODWLRQV &DUH PXVW EH WDNHQ GXULQJ DVVHPEO\ WKDW VXIÀFLHQW URRP LV DYDLODEOH QRW RQO\ IRU WHUPLQDWLRQV DQG WKH LQVWDOODWLRQ RI ÀWWLQJV RQ 3ULPDU\ OLQHVEXWDOVRIRUÀWWLQJVWRWHUPLQDWH6&SLSH FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 2 11. Install 95 StaJe 95 ([DFW UHTXLUHPHQWV IRU 95 YDU\ /RFDO OHJLVODWLYH UHTXLUHPHQWV ZLOO QHHG WR EH WDNHQ LQWR FRQVLGHUDWLRQ IRUV\VWHPGHVLJQDQGPDWHULDOVXVHG &DUH QHHGV WR EH WDNHQ WR HQVXUH DGHTXDWH IDOO EDFN LV DFKLHYHGDWDOOWLPHVIURPWKHIXUWKHVWSRLQWWRWKHÀQDO FRQQHFWLRQDWHLWKHUWKHWDQNFKDPEHURU95EPDQLIROG 7KH 95 V\VWHP LV XVXDOO\ D PDQLIROGHG PDLQOLQH ZLWK EUDQFKHV DWWDFKHG 7KH XQGHU SXPS GLVSHQVHU FRQQHFWLRQV PXVW DOORZ IRU D IDOO EDFN WR WKH PDLQ manifolding line Important: EarthinJ of metal terminations $OO833PHWDOWHUPLQDWLRQVLQWKHÀOOER[DWWKHWDQNWRS DQG XQGHU WKH GLVSHQVHU VKRXOG EH DGHTXDWHO\ HDUWKHG DFFRUGLQJWRORFDOHOHFWULFDOUHJXODWLRQV See VHFWLRQIRUPRUHGHWDLOV &ompletion 5ecords 2QFRPSOHWLRQRI833LQVWDOODWLRQLWLVUHFRPPHQGHGWKDW DQ´DVFRQVWUXFWHGµGUDZLQJLVPDGHGHWDLOLQJWKHH[DFW ORFDWLRQRIDOOEHORZJURXQGOLQHV,WLVDOVRUHFRPPHQGHG WKDWLQDGGLWLRQDSKRWRJUDSKLFUHFRUGLVSURYLGHG FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 3 3. ELECTROFUSION INSTRUCTION 2UJDQLVHDOOQHFHVVDU\WRROVDQGHTXLSPHQWRQWKHMREVLWHSULRUWR FRPPHQFLQJWKHLQVWDOODWLRQRISLSHDQGÀWWLQJV 7KHEDVLFLQVWDOODWLRQWRROVHWVKRXOGDOZD\VLQFOXGH UPP (lectrofusion welder Pipe cutter Pipe Scraper &leaninJ Solvent StraiJht and anJled clamps Permanent marker or &hinaJraph pencil white yellow or red 7ape measure 5HIHUWRWKHIROORZLQJVHFWLRQVIRUPRUHGHWDLOHGLQIRUPDWLRQRQWKHDERYH WRROLQJ FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 3 3.1 ELECTROFUSION OVERVIEW &ut pipe to reTuired lenJth alloZinJ for correct insertion depth into ZeldinJ coupler &lean scraped areas of pipe or ÀttinJ usinJ a lint free cloth moistened Zith $cetone $cetone remoYes oils, ÀnJerprints and moisture Measure and marN pipe to indicate correct insertion depth into fusion ÀttinJ 6 &lean Eore of ZeldinJ coupler Zith $cetone 7 $ssemEle the Moint and use clamp to hold in place &hecN insertion is up to the premarNed depth indication &onnect Zelder to clamped assemEl\ and folloZ ZeldinJ unit instructions Ensure appropriate ZeldinJ caEles are used Prepare the pipes and ÀttinJs for ZeldinJ usinJ the scrapinJ tools proYided in the UPP installation Eo[ a &hecN insertion depth marN for movement E &hecN indicators are out c $lloZ Moint to cool to amEient temperature $t least 2 minutes should pass Eefore an\ stresses are e[erted upon the assemEl\ FOLLOW INSTALLATION INSTRUCTIONS. 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NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 4 THIS PROCEDURE MUST BE FOLLOWED NON-COMPLIANCE WILL VOID WARRANTY AND INSTALLER CERTIFICATION 4.2 SECONDARY TERMINATION INSTALLATION METHOD 75/63MM (2" DOUBLE WALL) 7KHVHLQVWUXFWLRQVFRYHULQVWDOODWLRQRIWKHIROORZLQJÀWWLQJV 73 73 73 Mark pipe here (QVXUHHQWU\VHDOVDUHÀWWHGSURYLGLQJFRUUHFWDQG XQVWUHVVHGDOLJQPHQWEHWZHHQHQWU\VHDOSLSHDQG termination :LSHFOHDQSLSHDQGHQWU\VHDOEHIRUHDQ\SLSH insertion &XW6HFRQGDU\SLSHWRFRUUHFWOHQJWKHQVXULQJQRW WRGDPDJH3ULPDU\SLSHDWOHDVWPP3ULPDU\ H[SRVHG ,QVHUWVHULHVÀWWLQJRYHU3ULPDU\SLSHDQGVOLGH XSWR6HFRQGDU\3LSHDQGLQWRÀQDOSRVLWLRQ 0DUNSLSHWRVKRZLQVHUWLRQGHSWKLQWRVHULHV ÀWWLQJ 5HPRYHVHULHVÀWWLQJ Mark pipe here 6FUDSHSLSHKHUH 6FUDSHWKHVXUIDFHRIWKH6HFRQGDU\&RQWDLQPHQW SLSHWREHZHOGHGWKRURXJKO\XVLQJ833KDQGVFUDSHU 0DUNLQVHUWLRQGHSWKRISLSHLQWR(OHFWURIXVLRQ &RXSOHUPPJDSEHWZHHQVHULHVILWWLQJ DQG(OHFWURIXVLRQ&RXSOHULVUHFRPPHQGHG 6FUDSHSLSHKHUH &OHDQSLSHÀWWLQJKHUH ZLWKDFHWRQH 6 6FUDSHZHOG]RQHVIRU(OHFWURIXVLRQ&RXSOHUDQG VHULHVÀWWLQJ 6FUDSHZHOG]RQHRI7HUPLQDWLRQ &OHDQVFUDSHGSLSHZLWKDFHWRQH ,QVHUWSLSHWKURXJKHQWU\6HDO &OHDQLQVLGHVHULHVÀWWLQJHOHFWURIXVLRQFRXSOHU DQGZHOG]RQHRIWHUPLQDWLRQZLWKDFHWRQH 6OLGHVHULHVÀWWLQJDORQJSULPDU\SLSHDQGSXVK LQWRÀQDOSRVLWLRQRYHU6HFRQGDU\SLSH FOLLOW INSTALLATION INSTRUCTIONS. 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NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.1 INSTALLING A UPP POLYETHYLENE TANK CHAMBER InstallinJ chamber base &KHFNWKHVL]HDQGVKDSHRIWKHWDQNDFFHVVVKDIWÁDQJH 0DUNEDVHRIWKH833FKDPEHUIRUFXWWLQJWRÀWDFFHVVVKDIWÁDQJH ZLWQHVVOLQHVVKRZFRPPRQÁDQJHVW\OH SKRWR 8VHDURXQGKROHVDZWRFXWSLORWKROHVLQDOOIRXUFRUQHUVRIWKHEDVH7KLVLV LPSRUWDQWDVFRUQHUVZKLFKDUHQRWUDGLXVHGE\DFLUFXODUKROHVDZDQGDUH FXWVTXDUHPD\FDXVHWKHSRO\HWK\OHQHWRFUDFNSKRWR 8VHDKDQGVDZRUMLJVDZWRFXWRXWWKHEDVHDORQJPDUNHGOLQHVVWDUWLQJ IURPRQHFRUQHUDQGPRYLQJWRWKHQH[WSKRWR 5HPRYHFXWRXW 0DUNEROWKROHSRVLWLRQVRQVXPSEDVHDQGGULOO &XWVWUDLJKWOHQJWKVRIJDVNHWPDWHULDOIURPWKHUROOWRÀWRYHUWDQNDFFHVV VKDIWÁDQJHSKRWR &OHDQWDQNDFFHVVÁDQJHXVLQJDFOHDQLQJVROYHQW$FHWRQHUHFRPPHQGHG 5HPRYHEDFNLQJOD\HUIURPVWLFN\VLGHRIJDVNHWDQGVWLFNWKHJDVNHWWRWKH ÁDQJH&RUQHUVVKRXOGEHVTXDUHDQGEXWWHGWRJHWKHUWRFUHDWHDZDWHUWLJKW seal %ROWFKDPEHUWRWDQNDFFHVVVKDIWÁDQJH7KHEROWVZLOOHDVLO\SXVKWKURXJK gasket material InstallinJ tank chamber riser to base &XWULVHUWRUHTXLUHGKHLJKWXVLQJFDVWOHDWLRQVDVDJXLGHSKRWR &OHDQJDVNHWVXUIDFHVRIFKDPEHUXVLQJFOHDQLQJVROYHQW$FHWRQH 6WLFNTXDUWHUFLUFOHJDVNHWSLHFHVRQHE\RQHWRWRSRIFKDPEHUEDVHHQVXUH KROHVLQJDVNHWOLQHXSZLWKKROHVLQFKDPEHUIRUEHVWÀWDQGPDNHVXUHDOO MRLQWV EHWZHHQ JDVNHW TXDUWHU FLUFOHV DUH EXWWHG WRJHWKHU WR PDNH D ZDWHU tight seal - photo 6 3ODFHULVHURQEDVHDQGOLQHXSEROWKROHV 7LJKWHQ DOO EROWV DURXQG FKDPEHU LQLWLDOO\ EHIRUH UHSHDWLQJ WR PDNH VXUH DOO EROWVDUHIXOO\WLJKWHQHGphoto 7 7 6 FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 %ackÀllinJ Prior to EacNÀllinJ the chamEer lid must Ee in position to prevent an\ deÁection of the riser $FFHSWDEOHEDFNÀOOPDWHULDOVDUH :HOOURXQGHGSHDJUDYHOVL]HPP1/8WRPP/4") &UXVKHGURFNVL]HPP1/8WRPP5/8") &OHDQZDVKHGVDQG IMP25T$1T: %acNÀll material should Ee free from ice or an\ orJanic silt or peat 3DUWLFXODUFDUHVKRXOGEHWDNHQWRHQVXUHHQRXJKEDFNÀOOLVODLGGRZQDURXQG WKHXQGHUVLGHRIWKHFKDPEHUZKHUHLWRYHUKDQJVWKHWDQNDFFHVVVKDIWÁDQJH 1RPHFKDQLFDOFRPSDFWRUVVKRXOGEHXVHGVXFKDVYLEUDWLQJSODWHVFRPSDFWRUV RUURDGUROOHUV 7iJhtness testinJ The chamEer can Ee tested for tiJhtness usinJ the UPP S\stem InteJrit\ TestinJ Unit 'etailed in the toolinJ section of the UPP Installation Manual FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.2 INSTALLING A UPP FUSION POLYETHYLENE TANK CHAMBER Gasket roll supplied with chamber Install base section 1 &lean tanN containment collar Zith acetone and appl\ adhesive EacNed JasNet to access shaft flanJe ensurinJ there are no Japs Scarf Moint (cut at 45°) 2a MarN Ease for access shaft openinJ and Eolt holes as per access shaft dimensions &ut Ease openinJ usinJ MiJ saZ or hand saZ onl\ 'rill Eolt holes 12TE: )or sTuare collars, use hole saZ to cut all corners of the openinJ 2E /oZer access cover shaft details for /$ series chamEers Ø1027 Ø959 PCD 3 Backing Plate x 4 Circular Àange drawing PTL LA-008-001 STuare Àange drawing PTL LA-008-002 Mount chamEer Ease onto tanN )it EacNinJ plates and Eolt toJether usinJ M1 %olt sets Ensure all Eolts are tiJhtened eTuall\ 5ecommended torTue: 21m (1475lEft) IMP25T$1T %ased on &ooNson =inn standard tanN flanJes 2ther tanN t\pes ma\ var\ Please checN Zith tanN manufacturer $ DETAIL A M10x70 Bolt set 1 x Hex Bolt 2x Plain Washer 1 x Hex Nut FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 4 %acNfill up to the top of the tanN collar Ensure EacNfill is Zell compacted and is full\ into the area under the tanN sump )iJ 1 9acuum test usinJ UPP 9acuum Test Unit to prove Moint EetZeen tanN collar and tanN sump Ease 5ecommended depth settinJ: 3ft (See note on TiJhtness TestinJ in section 11) 1ote: MaNe sure pluJs in tanN manifold lid are in position 5 Install PipeZorN as per customer specification )iJ 2 9acuum test to prove tiJhtness of electrofusion entr\ seals fiJ1 test 5ecommended depth settinJ: 3ft (See note on TiJhtness TestinJ in section 11) :eldinJ riser to %ase a Scrape Zeld area on Ease Zith Hand Scraper and clean Zeld area on Eoth riser and Ease Zith acetone E Place riser on Ease and ensure it is mounted sTuarel\ ,QLWL O , H '7 c $ttach the harness assemEl\ 'eep 5iser: 3DVV+DUQHVV$VVHPEO\RYHUGHHS ULVHUDQGSRVLWLRQ7RS6WUDSDERYHORZHUULE ShalloZ 5iser: )RUVKDOORZULVHUSRVLWLRQ 7RS6WUDSEHORZWRSULE Pull Top Strap tiJht Zith cam EucNle Position 4 'rop Straps in line Zith Ease corners /oop Harness 5inJs over corners FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 c $ttach the harness assemEl\ continued Ensure riser sits sTuarel\ on the Ease usinJ a spirit level Pull strap in tension and then Jentl\ ratchet until ZeEEinJ has Zound itself and is locNed in place )rom this point add tZo full ratchets 5epeat for opposite corner and tZo remaininJ corners d &onnect ZeldinJ lead to terminals IMP25T$1T: / Ensure ZeldinJ leads are supported Handle Zeld terminals Zith care e %eJin Zeld 'o 12T Zeld chamEer more than once Weld Time 6 Minutes Cooling Time 20 Minutes $fter coolinJ time, to release ZeEEinJ pull and hold release taE on top assemEl\ to override ratchetinJ function IMP25T$1T: ()or EW8 ElacN units 21/<) Stop Zeld manuall\ after minutes Trim EacN ZeldinJ lead shroud E\ 2mm for riser Zith shrouded Zeld pins E)1 oranJe units Zill stop automaticall\ after minutes +eiJht adMustment to suit Ànal Jrade level 7 Select the trim marN closest to the desired heiJht HiJhliJht Trim marN on riser Zith a marNer pen Trim riser usinJ hiJhliJhted trim marN as a Juide and ensure cut edJe is sTuare and flat 5emove an\ Eurrs usinJ hand scraper 0DLQWDLQPP XSVWDQGWRHQVXUH ZDWHUWLJKWOLG ORFDWLRQLVFRUUHFW Maintain 30mm upstand to ensure water tight lid location is correct. Trim usinJ handsaZ or MiJ saZ 21/< FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 8 $ttach JasNet to channel in underside of lid Position ends of JasNet toJether first and ZorN the JasNet around the channel 9 Place lid on riser and attach latches as shoZn D $fter ZeldinJ riser to tanN sump Ease, vacuum test to prove tiJhtness of the complete sump 5ecommended 'epth SettinJ: 1ft Ma[ (See note on TiJhtness TestinJ in section 11) 1 Ensure pluJs are replaced in Test Ports after testinJ to maintain liTuid tiJht s\stem DETAIL D )inal backÀllinJ 11 Prior to EacNfillinJ the sump lid must Ee in position to prevent an\ deflection of the riser $cceptaEle EacNfill materials are: Wellrounded pea Jravel si]e 3mm (18µ) to 2mm (34µ) &rushed rocN si]e 3mm (18µ) to 1mm (58µ) &lean Zashed sand IMP25T$1T: %acNfill material should Ee free from ice or an\ orJanic silt or peat Particular care should Ee taNen to ensure enouJh EacNfill is laid doZn around the underside of the chamEer Zhere it overhanJs the tanN access shaft flanJe 1o mechanical compactors should Ee used such as viEratinJ plates, compactors or road rollers TiJhtness testinJ The chamEer can Ee tested for tiJhtness usinJ the UPP S\stem InteJrit\ TestinJ Unit detailed in the toolinJ section of the UPP Installation Manual FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.3 INSTALLING A UPP POLYETHYLENE DISPENSER SUMP Mount dispenser sump 7KHWRSRIWKHVXPSPRXQWLQJIUDPHPXVWEHÁXVKZLWKWKHÀQLVKHGLVODQG VXUIDFH 6HFXUH WKH VXPS ZLWK WLPEHU EDWWHQV DQG RU VFUHZV RU DQJOH LURQ LVODQG IRUP 0DUN WKH SLSH HQWULHV IRU SURGXFW DQG YDSRXU OLQHV IRU WKH DSSURSULDWH dispenser model 0DUNWKHFRUUHFWHQWU\KHLJKWWRDOORZFRUUHFWIDOOQRUPDOO\PSHUP or - LQFK SHU IRRW WR WKH 8QGHUJURXQG 6WRUDJH7DQN 867 RU QH[W GLVSHQVHUVXPS ,IUHTXLUHGWKHVXPSULVHUFDQEHFXWGRZQWRKHLJKWOHDYLQJPPUDLQ OLSDERYHWKHIUDPHDQGWKHPRXQWLQJIUDPHUHSRVLWLRQHGE\GULOOLQJDQGUH EROWLQJLQWKHQHZIUDPHSRVLWLRQV ,QVWDOODQ\833HQWU\VHDOVDFFRUGLQJWRWKHLUVSHFLÀF,QVWUXFWLRQV Mount stabilizer bars Note:7KH 833 HOHFWURIXVLRQ HQWU\ VHDOV RU 5 FDQEHLQVWDOOHGEHIRUHPRXQWLQJ GLVSHQVHUVXPSV6XPSDVVHPEO\ VHTXHQFHFDQEHYDULHG 6HH6WDELOLVHUEDULQVWUXFWLRQVIRU'6'6'6'6 6XPSVLQWKH833,QVWDOODWLRQ0DQXDO AdMust shear valve position 6HFXUH WKH HPHUJHQF\ VKXW RII YDOYH WR WKH PRXQWLQJ SODWH XVLQJ WKH WKUHH $OOHQVHWVFUHZV $VVHPEOHWKHVKHDUYDOYHPRXQWLQJSODWHWRWKHVWDELOL]HUXVLQJWKH8EROWV VXSSOLHG $GMXVWWKHVKHDUYDOYHKHLJKWWRHQVXUHWKDWWKHVKHDUYDOYHJURRYHLVÁXVK ZLWKWKHLVODQGÀQLVKJUDGH 7LJKWHQDOOVWDELOL]HUDVVHPEO\EROWVLQWKHLUÀQDOSRVLWLRQV Assemble riser :KHQ XVLQJ D 833 ULVHU UHFRPPHQGHG LQVWDOO WKH WHUPLQDWLRQ ÀWWLQJ HJ 137LQWRWKHHPHUJHQF\VKXWRIIYDOYH 7KHULVHUPXVWEHFXWWKHFRUUHFWOHQJWKVRWKDWWKH833WHHRUHOERZFHQWUH OLQHLVLQOLQHZLWKWKHHQWU\ÀWWLQJ :HOGLQJFDQEHGRQHLQVXPSRUSULRUWRKDQJLQJVKHDUYDOYH 2WKHUZLVH WKUHDG DQ DSSURSULDWH OHQJWK VFKHGXOH VWHHO ULVHU RU ÁH[ FRQQHFWRULQWRWKHERWWRPRIWKHHPHUJHQF\VKXWRIIYDOYH (lectrical conduit 7KH'6VXPSIUDPHLVSUHGULOOHGZLWKWKUHHKROHVJLYLQJWKHRSWLRQWR URXWHWKHFRQGXLWH[WHUQDOWRWKHVXPSEXWZLWKLQWKHIUDPH(QVXUHKROHVDUH FRUUHFWZD\DURXQG )RURWKHUVXPSPRGHOVFRQGXLWVHDOVZLOOKDYHWREHLQVWDOOHGDVWKH\GRQRW have pre-drilled frame holes FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 &oncrete and backÀll 7KHVXPSPXVWEHVHFXUHGLQWKHLVODQGIRUPXVLQJWKHEUDFNHWVLQWKHVXPS PRXQWLQJIUDPHSULRUWREDFNÀOODQGFRQFUHWHSRXULQJ %DFNÀOO LQ DFFRUGDQFH ZLWK LQVWUXFWLRQV JLYHQ LQ EDFNÀOO VHFWLRQ RI WKH 833 ,QVWDOODWLRQ0DQXDO Inspection/Maintenance 833 GLVSHQVHU VXPSV DUH GHVLJQHG WR SURYLGH VHFRQGDU\ FRQWDLQPHQW RI GLVSHQVHUVDQGSLSLQJRUFRQQHFWLRQV 6XPSVPXVWEHUHJXODUO\LQVSHFWHGDQGFKHFNHGIRUWKHSUHVHQFHRISHWUROHXP SURGXFWV $Q\OLTXLGGHWHFWHGPXVWEHUHPRYHGSURPSWO\DQGGLVSRVHGRIFRUUHFWO\DQG WKHFDXVHRIWKHSUREOHPUHFWLÀHG /RQJ WHUP SUHVHQFH RI SHWUROHXP SURGXFWV LQ VXPSV ZRXOG LQYDOLGDWH 3HWUR7HFKQLN·V8336\VWHPZDUUDQW\ 7iJhtness testinJ The chamEer can Ee tested for tiJhtness usinJ the UPP S\stem InteJrit\ TestinJ Unit detailed in the toolinJ section of the UPP Installation Manual FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.4 INSTALLING A UPP STABILISER BAR (FOR USE IN DS3017 / DS4417 / DS2111 / DS4111 SUMPS) 8QGRPRXQWLQJEROWV +ROGVWDELOLVHUEDULQSRVLWLRQDQGFKHFNWKHQXPEHU RIVSDFHUSODWHVUHTXLUHGRQHDFKVLGH 3ODFHFLUFXODUFKDQQHOQXWVLQDSSUR[LPDWHO\WKHFRUUHFW ORFDWLRQRQHDFKVLGHRIWKHVXPS $VVHPEOHRQHVLGHRIWKHVWDELOLVHUEDU3DVVEROWV WKURXJKKROHVLQVWDELOLVHUEDUDQGWKURXJKVSDFHU SODWHVLIUHTXLUHG 6 ,QWURGXFHWKHDVVHPEOHGHQGRIWKHVWDELOLVHUWRWKHQXW FKDQQHORQWKHVXPS/LQHXSQXWVWREROWVDQGLQVHUW +DQGWLJKWHQEROWV ,QVHUWVSDFHUSODWHVRQRSSRVLWHVLGHLIUHTXLUHG ,QVHUWEROWVWKURXJKVWDELOLVHUEDUDQGSODWHVDQG LQWRWKHFKDQQHOQXW+DQGWLJKWHQEROWV 7 $WWDFKDQGFRPSOHWHDOOLQWHUQDOVXPSSLSHZRUN LQFOXGLQJVKHDUYDOYHDVVHPEO\ 7LJKWHQEROWVIXOO\RQFHVKHDUYDOYHVDUHFRUUHFWO\ ORFDWHG FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.5 INSTALLING A UPP MECHANICAL ENTRY SEAL Entr\ Seal Hole SaZ compatiEilit\ chart HolesaZ Ø mm &ompatiEle Seal(s) 8 (,) )(%' 6HDOV )(%' 6HDOV 6%& 36 PS6 1. 0HDVXUHDQGPDUNWKHFHQWUHSRVLWLRQRIWKHUHTXLUHGSLSHVXPS penetration 2. 6HOHFWWKHFRUUHFWVL]HKROHVDZIRUWKHVHOHFWHGSHQHWUDWLRQVHDO DQGÀWWRPDQGULOO ,HPPKROHVDZIRU36VHDODQGPPKROHVDZIRU PS6 seal 3. 5HPRYHWKHEROWVQXWVZDVKHUVDQG-XELOHH&OLSV+RVH&ODPSV IURPWKHVHDODQGVWRUHLQDVDIHSODFH 4. 5HPRYHWKH%DFNLQJ5LQJIURPWKHVHDO 5. &HQWUHWKH5LQJRYHUWKHFXWKROH8VHWKHKROHVLQWKH5LQJDVD WHPSODWHIRUWKHSRVLWLRQVRIWKHVHDOEROWKROHVDQGGULOO 6. 7ULPWKHUXEEHUVHDOERRWIRUWKHLQVWDOODWLRQRIHLWKHUPP RUPPGRXEOHZDOOSLSHXVLQJDVKDUSNQLIH 7. 5HÀWWKH%DFNLQJ5LQJRYHUWKHVHDOUXEEHUERRW 8. 3RVLWLRQWKHVHDOUXEEHUERRWDQGULQJRQWKHLQVLGHZDOORIWKH FKDPEHUVXPSOLQLQJXSWKHEROWKROHV 9. 3DVVWKHEROWWKURXJKWKHFKDPEHUVXPSZDOOIURPWKHRXWVLGH DQGDWWDFKQXWDQGZDVKHUVHFXULQJWKHVHDOLQWRSRVLWLRQ 10. 7LJKWHQXSDOOWKHEROWVLQWXUQDQGFRPSOHWHRQHÀQDOWLJKWHQLQJFKHFN 11. 6HOHFWWKHFRUUHFWVL]H-XELOHH&OLS+RVH&ODPSDQGÀWWRWKH VHDOEHIRUHSDVVLQJSLSHWKURXJK 7KHPPSLSHXVHVVXSSOLHG-XELOHH&ODPS+RVH&ODPSDQG PPGRXEOHZDOOSLSHUHTXLUHVDQDGGLWLRQDO-XELOHH&ODPS+RVH &ODPSWKDWQHHGVWREHRUGHUHGVHSDUDWHO\ &ode +6&6 +6 (,) )or installation on Áat sump surfaces +6 +6 +6 +6&6 +63 +63 Note: :KHQ GULOOLQJ *53 )53 VXPSV VDIHW\ HTXLSPHQW VKRXOG EH ZRUQ LH PDVN DQG JRJJOHV FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.6 INSTALLING A UPP ELECTROFUSION ENTRY SEAL (305/308 SERIES) &ut hole in sump Zall Use 14mm (5ô") hole saZ for 35 ÀttinJ &lean fusion area on sump Zith $cetone 5emoves oils, ÀnJerprints and moisture &lean fusion area on seal Zith $cetone 6 &lamp seal to sump &ross the clamp Ears for Eest results 7 Test tiJhtness aJainst sump Zall all around the seal usinJ a piece of card Ensures surfaces are in close contact 5ealiJn seal Zith sump until all Japs are removed &onnect Zelder and Zeld (usinJ red (oranJe) leads) marN time of Zeld (eJ 11am) Scrape around fusion area Use scraper provided in UPP tool Nit $lloZ Moint to cool to amEient temperature: appro[imatel\ 2 minutes FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.7 UPP ELECTROFUSION SEAL APPLICATIONS 2QFHWKHIXVLRQVHDOKDVEHHQVXFFHVVIXOO\ZHOGHGRQWRWKHVXPSLWPXVWEHOHIWWRFRROVWUHVVIUHHIRUPLQXWHV 'HSHQGLQJRQWKHVSHFLÀFDWLRQRIWKHVLWHWKHUHDUHWKUHHRSWLRQVWRWDNHIURPWKLVSRLQWRQZDUGV 57a )usion Zeld a pol\eth\lene Eoot 314E $ttach a Áe[iEle entr\ Eoot 314c )usion Zeld a UPP pol\eth\lene duct pipe line 5.7.a FUSION WELDING A POLYETHYLENE BOOT Scrape the fusion seal spiJot usinJ UPP hand scraper cloth Scrape the 125mm (5") end of the Eoot usinJ UPP hand scraper 6& ZHOGLQJ FRXSOHU &lean the scraped spiJot, the end of the Eoot and the inside of a 2125(S&) ZeldinJ coupler Zith cleaninJ solvent ($cetone recommended) $ttach the Eoot to the spiJot of the entr\ seal usinJ the ZeldinJ coupler Ensure there are no e[ternal stresses actinJ on the assemEl\ Weld the coupler usinJ the Jreen secondar\ containment ZeldinJ leads /eave to cool for 2 minutes FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.8 ATTACHING A FLEXIBLE ENTRY BOOT Trim the Áe[iEle Eoot to the desired pipe diameter Slide the pipe throuJh the seal and the openinJ in the Eoot and cut to the desired lenJth Slide the Eoot over the seal lip and tiJhten on Zith a MuEilee clip TiJhten the Eoot on to the pipe usinJ another MuEilee clip FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.9 FUSION WELDING UPP POLYETHYLENE DUCT PIPE 7KHGXFWSLSHLVPPDQGVRPXVWEHDWWDFKHGWRPPHQWU\VHDOVSLJRWXVLQJDQHOHFWURIXVLRQUHGXFHU2QFH ZHOGHGWKHGXFWSURYLGHVDMRLQWIUHHOLQNEHWZHHQWZRXQGHUJURXQGVHUYLFHDUHDVDQGDFWVDVDFRQGXLWIRUIRUHFRXUWIXHO OLQHV7KLVPHDQVWKDWWKHSLSHVDUHQRWGLUHFWEXULHGDQGFDQEHUHSODFHGWKURXJKWKHGXFWVZLWKRXWWKHQHHGIRUH[FDYDWLRQ 6HH3LSH5HÀW7KURXJK'XFWVVHFWLRQRI833,QVWDOODWLRQ0DQXDO Uncoil the 'uct pipe into appro[imate Ànal position Use a hacN saZ to cut the pipe, ensurinJ the end is as sTuare as possiEle Scrape o[idised surface of the 125mm (5") end of the reducer usinJ UPP hand scraper Wipe Zith lint free cloth soaNed in cleaninJ solvent Scrape surface of the 3551 spiJot usinJ hand scraper Wipe clean Zith cleaninJ solvent &lean the inside of the 2125(S&) usinJ cleaninJ solvent and attach the reducer to the seal spiJot usinJ the 2125(S&) 6& ZHOGLQJ FRXSOHU 6 Weld this assemEl\ usinJ secondar\ ZeldinJ lead (*reen) $lloZ to cool for at least 2 minutes )ull\ aErade surface of the part of the duct that is to Ee Zelded usinJ emer\ cloth FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 7 The edJes of the corruJations must also Ee aEraded usinJ emer\ cloth Scrape the 11mm (4") end of the reducer usinJ UPP hand scraper &lean the 11mm (4") end of the reducer usinJ a cleaninJ solvent (acetone) Wipe inner surface of the 11mm (4") coupler Zith a cleaninJ solvent Wipe doZn the scraped duct pipe usinJ a cleaninJ solvent (acetone) $ttach the duct pipe to the reducer usinJ the 11mm (4") coupler Ensure there are no e[ternal stresses actinJ upon the assemEl\ Weld Zith the primar\ (oranJe) ZeldinJ lead $lloZ to cool for at least 2 minutes FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.10 INSTALLING A UPP ELECTROFUSION SEAL (302-040) &ut hole in sump Zall Use 51mm (2") hole saZ, HS&S2, for 324 seal Scrape around fusion area usinJ UPP handheld scraper &lean fusion area on sump Zith acetone &lean fusion face of seal Zith acetone 6 &lamp seal to sump usinJ ¶32 &/$MP· tool &ross the clamp Ears for Eest results &onnect Zelder and Zeld (usinJ red (oranJe) leads) marN time of Zeld (eJ 11am) $lloZ 5 minutes coolinJ Eefore removinJ clamp $lloZ Moint to cool to amEient temperature: appro[imatel\ 2 minutes Eefore puttinJ an\ stress on the ÀttinJ \F GDU RQ 7 6HF Prim ar y RQ WD LQP pip e HQ WS LSH If usinJ Must primar\ 32mm pipe Jo to 9 If usinJ secondar\ containment 432mm pipe Jo to 17 FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 InstallinJ a seal with primary mm pipe 6FUDSHIRUPP from marking Mark pipe Slide primar\ pipe throuJh 324 seal to Ànal position MarN pipe inside the sump aJainst the seal spiJot 5emove pipe from seal Scrape from closest marNed area to the pipe end for 3mm (12") toZards the end of the pipe &OHDQUHGXFHU 6FUDSH Scrape the spiJot of the seal inside the sump Slide Slide pipe throuJh 324 seal Ensure 49432 reducer is slid onto the primar\ pipe as it passes into sump (larJe end Àrst Slide 49432 reducer onto spiJot of the 324 seal &omplete the termination of the primar\ pipe to the tanN top, dispenser, vent stacN or Àll point Clean &lean from end of pipe to 1mm (4") past the scraped ]one Zith acetone &lean inside of the seal Zith acetone &lean inside of 49 series reducer Zith acetone Slide PP Weld 49432 to seal spiJot and primar\ pipe usinJ Jreen ZeldinJ caEle $lloZ 2 minutes for the Zeld to cool Eefore puttinJ an\ stress on the assemEl\ FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 InstallinJ a seal with secondary &ontainment /mm &XW6&SLSH &XWSULPDU\ pipe 6FUDSH]RQH$ PP PP 6FUDSH &ut Secondar\ pipe at outer seal spiJot Slide primar\ pipe throuJh the seal and cut at Ànal termination position PP6FUDSH PP Scrape inner and outer seal spiJots as shoZn Scrape areas of pipes as shoZn Clean Clean Clean Zone A PP &lean from end of primar\ pipe to 1mm past the scraped ]one Zith acetone &lean scraped end of Secondar\ &ontainment pipe Zith acetone Clean Clean &lean Eoth spiJots of the seal Zith acetone &lean inner Eore of 24(S&) Zith acetone &lean inner Eore of 49432 Zith acetone Slide Slide 24(S&) onto outer seal spiJot Slide Secondar\ pipe into other side of 24(S&) Weld usinJ Jreen ZeldinJ leads alloZ 2 minutes coolinJ time after ZeldinJ Slide 49432 reducer, larJe end Àrst) over primar\ pipe and onto the spiJot of the 324 seal &omplete the termination of the primar\ pipe to the tanN top, dispenser, vent stacN or Àll point Weld 49432 to seal spiJot and primar\ pipe usinJ Jreen ZeldinJ caEle $lloZ 2 minutes for the Zeld to cool Eefore puttinJ an\ stress on the assemEl\ FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.11 INSTALLING A UPP ELECTROFUSION SEAL (303 SERIES WITH INTEGRATED COUPLER) 7KH(,)6HDOFDQDFFRPPRGDWHHLWKHUPP3ULPDU\RUPP6HFRQGDU\&RQWDLQPHQW SLSH,QWKLVLQVWDOODWLRQJXLGHWKHSULPDU\SLSHLVEHLQJXVHG:KHQXVLQJ6HFRQGDU\&RQWDLQPHQW HQVXUH WKHUH LV VXIÀFLHQW VSDFH LQVLGH WKH VXPSFKDPEHU WR DFFRPPRGDWH \RXU 6HFRQGDU\ &RQWDLQPHQWWHUPLQDWLRQÀWWLQJV Ensure the metal tanN top ÀttinJs are perpendicular to the chamEer Zall )it UPP Termination ÀttinJ to tanN ÀttinJs )ind the centre of the pipe (stuE) and e[tend this line to the chamEer Zall and marN UsinJ 12mm (4") (UPP HolesaZ HS3) place mandrel on marN from outside of chamEer and drill hole 6FUDSH here then FOHDQ ZLWK DFHWRQH Scrape the area of the chamEer around the drilled hole usinJ a handscraper (UPP S&5 H$5) &lean Zith acetone Clean this entire VXUIDFHZLWK DFHWRQH 6 &lean the seal·s fusion rinJ area usinJ acetone &lamp the seal to the chamEer Zall usinJ the 33 clamp FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 Mark pipe either side of entry seal 7 &onnect Zelder and Zeld (usinJ red (oranJe) leads) MarN Ànish time of Zeld (eJ 11am) $lloZ 2 minutes coolinJ Eefore removinJ clamp Insert clean UPP pipe throuJh seal and marN either side of the pipe Zhere it passes throuJh the seal '2 12T WE/' PIPE 5emove pipe and scrape the area of the pipe Zhich Zill Ee Zelded to the entr\ ÀttinJ (EetZeen the tZo marNs) &lean entire lenJth of pipe to Ee passed throuJh ÀttinJ usinJ acetone &lean inside of entr\ ÀttinJ Zith acetone &omplete all internal Primar\ Secondar\ (if applicaEle) assemElies Ensure there is no stress on the Moints durinJ or for 2 minutes after ZeldinJ If necessar\ disconnect the termination ÀttinJ to assure this 'o not Àt termination to matchinJ steelZorN of s\stem prior to ZeldinJ Ensure pipe and assemEl\ are full\ supported Zith no stress Eoth inside and outside sump durinJ ZeldinJ process $ttach Jreen ZeldinJ leads to the inteJrated coupler on the seal and Zeld, marN Ànish time of the Zeld $lloZ 2 minutes for coolinJ Eefore an\ stress is placed upon the pipe or entr\ ÀttinJ FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.12 INSTALLING UPP FRP ENTRY FITTING FLAT FACED SUMPS ONLY Important Information ,OOXVWUDWLRQVVKRZVRPHZKLWHÀWWLQJV DQGVRPHEODFN Installation method is the same for all Only install one seal at a time 832/60&LVWKHRQO\833DSSURYHGERQGLQJSDVWH832/&RGH83 5HIHUWRLQVWUXFWLRQVDWWKHEDFNRIWKLVLQVWDOODWLRQJXLGHIRUFRUUHFWXVHRIERQGLQJSDVWH 2QO\PL[HQRXJKERQGLQJSDVWHIRURQHHQWU\ÀWWLQJDWDWLPH ,IZRUNLQJLQDFOLPDWHKRWWHUWKDQ)&VWRUHERWKUHVLQDQGKDUGHQHUDFWLYDWRULQFROGZDWHUIRU DSSUR[LPDWHO\PLQVEHIRUHXVH .HHSERQGLQJSDVWHRXWRIGLUHFWVXQOLJKW 2QFHWKHKDUGHQHUKDVEHHQDGGHGWKHERQGLQJSDVWHLVRQO\ZRUNDEOHIRUPLQXWHV$IWHUWKLVLWEHFRPHV XQZRUNDEOHDQGORVHVLW·VERQGLQJSURSHUWLHV :KHQXVLQJ%RQGPDVWHU(DOZD\VHQVXUHWKDWVTXLUWVRIPL[HGFRPSRXQGDUHVTXLUWHGIURPWKHPL[LQJQR]]OH SULRUWRSXWWLQJDQ\FRPSRXQGRQÀWWLQJV7KLVZLOOHQVXUHWKDWFRPSRXQGLVIXOO\PL[HGEHIRUHEHLQJDGGHGWRWKH ÀWWLQJV %asic .it 1eeded )53HQWU\ÀWWLQJ [)53FDSVRUGHUVHSDUDWHO\127(LQWHUQDODQGH[WHUQDOFDSVGLIIHULQVL]HH[WHUQDO FDSVDUHPDUNHGZLWKDQ¶;· 1LWULOH*ORYHVQRWLQFOXGHG &OHDQLQJVROYHQW7ULFKORURHWK\OHQHRU$FHWRQHQRWLQFOXGHG %RQGPDVWHU(WZRSDUWVVHDODQWKDUGHQHU $SSOLFDWRU*XQ &RPSRVLWHERQGLQJSDVWH832/EUDQGRQO\832/&RGH83XVLQJRWKHUSDVWH LQYDOLGDWHVZDUUDQW\ )LWWLQJZUHQFK)(%722/RU)(%722/VKRZQULJKW *ULWDEUDVLYHSDSHU(PHU\FORWK )LWWLQJZUHQFK Installation 2vervieZ ,QWHUQDOFDS )53HQWU\VHDOÀ[HGÁDQJH ([WHUQDOFDS )53HQWU\VHDO PRYHDEOHÁDQJH 6XPSZDOOH[WHUQDOIDFH FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 PreInstallation &hecN %HIRUHFRPPHQFLQJRQWKHLQVWDOODWLRQRIWKH833)53HQWU\ÀWWLQJVPDNHVXUHWKDWWKHVXPSWREH ZRUNHGRQKDVEHHQIXOO\YDFXXPWHVWHG,IDOHDNLVGHWHFWHGWKHVXPSPXVWEHUHSODFHGRUÀ[HGSULRUWR HQWU\ÀWWLQJLQVWDOODWLRQ Installation Method 'ULOOKROHXVLQJKROHVDZ PPIRU)(%'&RGH+6 ôPPIRU)(%'&RGH+6 &KHFNÀWWLQJZLOOSDVVWKURXJKWKHVXPSZDOOEHIRUH FRQWLQXLQJ 8VLQJ*5,7HPHU\RUDUHG6FRWFKEULWHDEUDVLYH SDGDEUDGHERWKIDFHVRIPRYDEOHDQGÀ[HGÁDQJHV RI)53VHDO 8VLQJHPHU\DEUDGHLQWHUQDODQGH[WHUQDODUHDVRI sumpWREHERQGHG 8QVFUHZPRYDEOHÁDQJHDQGUHPRYHIURPÀWWLQJ 3UHFOHDQÀWWLQJÁDQJHVZLWKDFHWRQH &OHDQallDEUDGHGDUHDVRIÀWWLQJDQGVXPSDQG XVLQJFOHDQLQJVROYHQW 6 $GG%RQGPDVWHU(WRWKHJURRYHRIWKHÀ[HGÁDQJH XVLQJWKHDSSOLFDWRUJXQ $GG%RQGPDVWHU(WRWKHJURRYHRQPRYDEOHÁDQJH XVLQJWKHDSSOLFDWRUJXQ FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 7 )LWXQLWWRVXPSZDOOÀ[HGÁDQJHRQH[WHUQDOZDOO DQGWLJKWHQPRYDEOHÁDQJHRQWRWKUHDGE\KDQG IURPLQVLGHWKHVXPS )LOOSLHUFLQJ·VLQÁDQJHVZLWK%RQGPDVWHU(DQG FUHDWHÀOOHWULQJRI(DURXQGRXWVLGHRIERWK ÁDQJHV 7LJKWHQIXOO\XVLQJÀWWLQJZUHQFK $OORZWRFXUHDWOHDVWKRXUV MidInstallation &hecN Point %HIRUHFRPPHQFLQJstep 9RIWKHLQVWDOODWLRQHQVXUHWKHIROORZLQJLVWUXH (UHVLQKDVFXUHG 'RXEOHZDOOVXPSVKDYHEHHQWHVWHGZLWK833YDF7HVWXQLW $Q\HQWU\OHDNVGHWHFWHGKDYHEHHQUHZRUNHG $OOHQWU\ÀWWLQJVWHVWHGWLJKW 7KHQH[WSDUWRIWKHLQVWDOODWLRQLVWKHDVVHPEO\RIWKHFRYHUGLVFVXVLQJUPOLERQGLQJSDVWH7KLVFDQEHFDUULHGRXWEHIRUH FRPPHQFLQJSLSLQJ25DVWKHODVWZRUNRQWKHSLSLQJV\VWHPSURYLGHGWKHGLVFVDUHORRVHÀWWHGEHIRUHSLSLQJ USI1* UPOL Precautions Zith UPOL 'RQRWVWRUHDWWHPSHUDWXUHVDERYH) ,IDPELHQWWHPSHUDWXUHH[FHHGV)WKHQFRROWLQLQFROGZDWHUIRUPLQXWHV +LJKWHPSHUDWXUHGUDPDWLFDOO\VKRUWHQVZRUNLQJWLPHWROHVVWKDQUHTXLUHGIRULQVWDOODWLRQ 'RQRWXVH832/RQFHLWVWDUWVWRJRRIIPDWHULDOORVHVDGKHVLRQDQGVHDOLQJSURSHUWLHVGLVFDUGDQGXVHQHZPL[ :RUNLQJWLPHLVDSSUR[LPDWHO\PLQXWHVDW) +DYHHYHU\WKLQJUHDG\WRDVVHPEOHEHIRUHVWDUWLQJ 2QO\SUHSMXVWEHIRUHXVLQJ832/WRDYRLGUHFRQWDPLQDWLRQRUR[LGLVDWLRQ Wear nitrile gloves Mi[inJ UPOL 2QO\PL[HQRXJKIRURQHFRYHUGLVFDWDWLPH 0L[5DWLRUHTXLUHGLVSDUWVKDUGHQHUWRSDVWH $JRRGJXLGHLVDJROIEDOORISDVWHWRDSHDRIKDUGHQHU 2SWLRQDOFRORUHGKDUGHQHUDVVLVWVYLVXDOPL[HIIHFWLYHQHVV (QVXUHHYHQPL[RIKDUGHQHUDQGSDVWH 2QFHPL[HGZRUNLQJWLPHLVDSSUR[LPDWHO\PLQXWHV FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 &OHDQEUDVVÁDQJHVZLWKDFHWRQH $EUDGHEUDVVÁDQJHVZLWKHPHU\FORWK 5H&OHDQEUDVVÁDQJHVZLWKDFHWRQH &OHDQLQWHUQDOIDFHDQGHGJHVRIFDSVZLWKDFHWRQH $EUDGHÀWWLQJFDSVZLWKHPHU\FORWK &OHDQZLWKDFHWRQH 7RWDOO\ÀOOH[WHUQDOFRYHUFDSZLWK832/60& ERQGLQJSDVWHDVVKRZQ )LWH[WHUQDOFRYHUFDSRYHUÀWWLQJVSLJRWVDQGSUHVV ÀUPO\DJDLQVWH[WHUQDOVXPSZDOO &OHDQDQGVPRRWKH[FHVVUHVLQZLWKWKXPEDURXQG HGJHRIFDS 5HSHDWVWHSVIRULQWHUQDOFRYHUFDS $OORZWKHERQGLQJSDVWHWRFXUHEHIRUH HOHFWURIXVLRQUHIHUWRPDQXIDFWXUHUVLQVWUXFWLRQV 2QFHFXUHGWKHHQWU\VHDOFDQEHWLJKWQHVVWHVWHG DVUHTXLUHG WeldinJ UPP &oa[ial (douEle Zall) Pipe to the Entr\ )ittinJ 7KH833VHFRQGDU\FRQWDLQPHQWSLSHWHUPLQDWHVRQWKHRXWVLGHRIWKHVXPSZDOOZKHUHLWLVZHOGHGGLUHFWO\WRWKHHQWU\ ÀWWLQJVSLJRWXVLQJDVHFRQGDU\ZHOGLQJFRXSOHU6&6&7KHSULPDU\SLSHSDVVHVWKURXJKWKHÀWWLQJDQGLQWR WKHVXPS2QWKHLQVLGHHLWKHUDQ(OHFWURIXVLRQUHGXFHURUDWHUPLQDWLRQERRWFDQEHXVHGWRVHDORIIWKHLQWHUVWLWLDOVSDFH FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 5 5.13 UPP ACCESS COVER INSTALLATION The folloZinJ instructions refer speciÀcall\ to the 7[7mm (29 14/16 x 29 14/16") UPP access cover The principles of reinforcinJ the surroundinJ concrete and Zater runoff anJles are maintained throuJh the entire UPP covers ranJe The larJe 95mm (37µ) diameter circular cover is sliJhtl\ different as it has tZo sprinJs inside the sprinJ Eo[, hoZever the principle of separatinJ and reÀttinJ the cover from the frame is the same Installation instructions 6HSDUDWHWKHFRYHUIURPWKHIUDPHVHHLQVWUXFWLRQVEHORZ &UHDWH D UHLQIRUFHG FRQFUHWH IRXQGDWLRQ IRU WKH IUDPH PDLQWDLQLQJ D FOHDU RSHQLQJXQGHUWKHIUDPH[PP :arninJ7RIDFLOLWDWHGUDLQDJHRIVXUIDFHZDWHUWKHIUDPHVKRXOG EHLQFOLQHGWRZDUGVWKHUHDU(QVXUHWKHUHZLOOEHDVORSHIRUVXUIDFH ZDWHUGUDLQDJHIURPOLSRIIUDPHWRIRUHFRXUWVXUIDFHRQFHIUDPHLVÀ[HGLQÀQDO SRVLWLRQ :KHUHVSHFLÀHGFRQQHFWDPPSODVWLFGUDLQDJHSLSHEHWZHHQRXWOHW RQIUDPHDQGRLOZDWHUVHSDUDWRURUEDFNÀOOPDWHULDOVXUURXQGLQJWDQNDFFHVV FKDPEHU2WKHUZLVHHQVXUHERWWRPRI6SULQJ%R[3KRWRLVVHDOHGDJDLQVW ZDWHUH[LW 3RXUZDWHULQWRGUDLQDJHFKDQQHOLQIUDPHWRFKHFNWKDWGUDLQDJHRSHUDWHV FRUUHFWO\ 3RXUFRQFUHWHDURXQGIUDPHDQGFKHFNVXUIDFHZDWHUGUDLQDJHVORSHLV 5HÀWWKHFRYHUWRWKHIUDPHRQFHFRQFUHWHLVGU\VHHLQVWUXFWLRQVEHORZ SeparatinJ the cover from frame two operators reTuired 8QORFNDQGRSHQWKHFRYHUWREHWZHHQDQGXVLQJWKHORFNLQJKDQGOH 3&+3KRWRV /HYHUXSDQGUHPRYH6SULQJ%R[&RYHU3KRWR &RQWLQXHRSHQLQJFRYHUWRWRWDOO\RSHQSRVLWLRQFLUFD3KRWR /LIWFRYHUIURPIUDPH3KRWR :arninJ 7KHFRYHULVKHDY\NJ 5eÀttinJ the cover to frame two operators reTuired 3ODFHWKHFRYHULQWRWKHIUDPHDWFLUFD :arninJ,QWKLVSRVLWLRQWKH6SULQJ6KDIWPXVWEHFRUUHFWO\ORFDWHGLQWRWKH VHDWLQWKHIUDPH3KRWR &ORVHWKHFRYHUWREHWZHHQDQG3KRWR 5HÀWWKH6SULQJ%R[&RYHU FOLLOW INSTALLATION INSTRUCTIONS. 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NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 9 9.8 UPP DISPENSER SUMP REPORT TEST OF UPP DISPENSE5 SUMP 5EPO5T 6LWH1DPH 6XPS,QVWDOOHGXQGHU'LVSHQVHU 1) V$&UUM TEST Sump inteJrit\ test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´µSRVLWLRQDQGFRQQHFWSRZHUOHDGWRSRZHUVXSSO\ 1RWHV 6HOHFWFRUUHFWGHSWKVHWWLQJIRUORFDOJURXQGZDWHUFRQGLWLRQV 1RWHV 7XUQRQXQLWZDLWIRUFDOLEUDWLRQSURFHVVWRHQGÁDVKLQJFRORXUHGOLJKWV 1RWHV 9DFXXPSXPSZLOOUXQXQWLOFRUUHFWWHVWYDFXXPLVUHDFKHGDQGWKHEOXHOLJKWZLOOVKRZ 1RWHV 7(675(68/7 *reen liJht 3$66 5ed liJht )$,/ ,IIDLOHGFKHFNIRUOHDNVDURXQGSLSHHQWU\VHDOVXVLQJVRDS\ZDWHURUOHDNGHWHFWLRQVSUD\ 5HFWLI\DQ\IDLOXUHVDQGUHSHDWWHVWLQJXQWLOSDVVLVDFKLHYHG 2) H<D5OST$TI& TEST Sump inteJrit\ test 2QFHWKHGLVSHQVHUVXPSKDVEHHQSRVLWLRQHGFRUUHFWO\DQFKRUHGLQWRSRVLWLRQDQGDOOSLSHZRUNLVLQVWDOOHGXVLQJ HOHFWURIXVLRQRUPHFKDQLFDOHQWU\VHDOVDK\GURVWDWLFWHVWFDQEHFDUULHGRXWWRHQVXUHWKHLQWHJULW\RIDOOSLSH SHQHWUDWLRQV 7(67352&(66 (QVXUHDOOSLSHSHQHWUDWLRQVDUHIUHHIURPEHGGLQJRUEDFNÀOOPDWHULDORUDQ\RWKHU 1RWHV REVWUXFWLRQ )LOOWKHVXPSZLWKIUHVKZDWHU 1RWHV 0DUNWKHZDWHUOHYHOLQVLGHWKHVXPSZLWKDPDUNHUSHQRUFKLQDJUDSKSHQFLO 1RWHV ([DPLQHWKHSLSHHQWU\VHDOVIRUVLJQVRIOHDNLQJZDWHU 1RWHV /HDYHZDWHULQVXPSIRUKRXU 1RWHV 7(675(68/7 PASS 5HFWLI\DQ\IDLOXUHVDQGUHSHDWWHVWLQJXQWLOSDVVLVDFKLHYHG FAIL &ertiÀcation SiJn Off 7KHDERYHGHVFULEHGVXPSKDVEHHQFKHFNHGIRUFRUUHFWLQVWDOODWLRQYLVXDOO\DQGE\PHDQVRIDYDFXXPRUK\GURVWDWLFWHVW ,WKDVEHHQIRXQGWREHLQVWDOOHGLQDFFRUGDQFHZLWK8336\VWHPVLQVWDOODWLRQJXLGHOLQHVDQGKDVEHHQFHUWLÀHGE\ __________________________________________________________________________________________ 7KHLQIRUPDWLRQJLYHQDERYHLVWUXHDQGFRUUHFW 6LJQHGE\BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB'DWHBBBBBBBBBBBBBBBBGD\PRQWK\HDU FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 9 9.9 UPP TANK CHAMBER - VACUUM TEST P$5T 1/2 V$&UUM TEST OF UPP T$N. &H$M%E5 6LWH1DPH &KDPEHULQVWDOOHGRQ7DQN&RPSDUWPHQW1R Test 1 ² &hamEer %ase to TanN TiJhtness Test 2QFHWKHFKDPEHUEDVHKDVEHHQEROWHGWRWKHWDQNÁDQJHXVLQJVHDOLQJJDVNHWRQÁDQJHDQGEDFNLQJSODWHVWKHMRLQW VKRXOGEHWHVWHGWRHQVXUHLQWHJULW\7KLVFDQEHGRQHDWWKH&RRNVRQDQG=LQQIDFWRU\EHIRUHWKHWDQNLVVKLSSHGWRVLWH RULWFDQEHGRQHRQVLWH 7(67352&(66 (QVXUHYDFXXPOLGJDVNHWVDQGFKDPEHUEDVHÁDQJHDUHFOHDQDQGIUHHIURPGLUWRUGHEULV 1RWHV 3URSHUO\SRVLWLRQYDFXXPOLGRQFKDPEHUEDVHÁDQJH 1RWHV (QVXUHYDFXXPWHVWNLWXQLWLVSODFHGRXWVLGH]RQH 1RWHV &KHFNKRVHVWRHQVXUHWKH\DUHLQJRRGFRQGLWLRQDQGFRQQHFWWRWHVWXQLWDQGOLG 1RWHV (QVXUHXQLWSRZHUVZLWFKLVLQ´µSRVLWLRQDQGFRQQHFWSRZHUOHDGWRSRZHUVXSSO\ 1RWHV 6HOHFWIWFKDPEHUGHSWKVHWWLQJ 1RWHV 7XUQRQXQLWZDLWIRUFDOLEUDWLRQSURFHVVWRHQGÁDVKLQJFRORXUHGOLJKWV 1RWHV 9DFXXPSXPSZLOOUXQXQWLOFRUUHFWWHVWYDFXXPLVUHDFKHGDQGWKHEOXHOLJKWZLOOVKRZ 1RWHV 7(675(68/7 *reen liJht 3$66 5ed liJht )$,/ ,IIDLOHGFKHFNIRUOHDNVDURXQGWDQNFKDPEHUEDVHMRLQWXVLQJVRDS\ZDWHURUOHDNGHWHFWLRQVSUD\ 5HFWLI\DQ\IDLOXUHVDQGUHSHDWWHVWLQJXQWLOSDVVLVDFKLHYHG Test 2 ² PipeZorN Entr\ Seals TiJhtness Test 3LSHXSWKH833SURGXFWÀOOYHQWYDSRXUUHFRYHU\VLSKRQDQGHOHFWULFDOFRQGXLWOLQHVLQWRWKHFKDPEHUEDVHDVDSSURSULDWH XVLQJ833HOHFWURIXVLRQRUPHFKDQLFDOHQWU\VHDOV2QFHFRPSOHWHUHSHDWWKHWHVWWRHQVXUHWKDWDOOWKHHQWU\VHDOVDUH OHDNWLJKW 7(67352&(66 (QVXUHYDFXXPOLGJDVNHWVDQGFKDPEHUEDVHÁDQJHDUHFOHDQDQGIUHHIURPGLUWRUGHEULV 1RWHV 3URSHUO\SRVLWLRQYDFXXPOLGRQFKDPEHUEDVHÁDQJH 1RWHV (QVXUHYDFXXPWHVWNLWXQLWLVSODFHGRXWVLGH]RQH 1RWHV &KHFNKRVHVWRHQVXUHWKH\DUHLQJRRGFRQGLWLRQDQGFRQQHFWWRWHVWXQLWDQGOLG 1RWHV (QVXUHXQLWSRZHUVZLWFKLVLQ´µSRVLWLRQDQGFRQQHFWSRZHUOHDGWRSRZHUVXSSO\ 1RWHV 6HOHFWIWFKDPEHUGHSWKVHWWLQJ 1RWHV 7XUQRQXQLWZDLWIRUFDOLEUDWLRQSURFHVVWRHQGÁDVKLQJFRORXUHGOLJKWV 1RWHV 9DFXXPSXPSZLOOUXQXQWLOFRUUHFWWHVWYDFXXPLVUHDFKHGDQGWKHEOXHOLJKWZLOOVKRZ 1RWHV 7(675(68/7 *reen liJht 3$66 5ed liJht )$,/ ,IIDLOHGFKHFNIRUOHDNVDURXQGWDQNFKDPEHUEDVHMRLQWXVLQJVRDS\ZDWHURUOHDNGHWHFWLRQVSUD\ 5HFWLI\DQ\IDLOXUHVDQGUHSHDWWHVWLQJXQWLOSDVVLVDFKLHYHG FOLLOW INSTALLATION INSTRUCTIONS. 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NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 10 10. WATER HAMMER EFFECT $TXLFNFKDQJHRIWKHÁRZLQVLGHDSLSLQJV\VWHPFDQFDXVHDVXGGHQSUHVVXUH LQFUHDVHRYHUDQGDERYHWKHQRPLQDOZRUNLQJSUHVVXUH7KLV´ZDWHUKDPPHUµ HIIHFWFDQRFFXUHYHU\WLPHDYDOYHLVRSHQHGFORVHGRUDSXPSLVVWDUWHGVKXW RII7KHIRUPXODIRUSUHVVXUHYDULDWLRQ¨3LVJLYHQE\ ¨3 F¨YJ= :KHUHSLVWKHGHQVLW\RIZDWHUJLVDFFHOUDWLRQGXHWRJUDYLW\¨YLVWKHÁXLG YHORFLW\FKDQJHDQGFLVWKHYHORFLW\RIDVKRFNZDYHLQWKHSLSH F GHSHQGV RQ WKH HODVWLFLW\ RI WKH ÁXLG LQ WKH SLSH ZDOO DQG IRU D IUHHO\ VXSSRUWHGSLSHLVJLYHQE\ Ep J P F Ep + EZ Dm t Where EZLVWKHZDWHUHODVWLFLW\PRGXOXV(p WKHSLSHHODVWLFWL\PRGXOXV3WKH ZDWHUGHQVLW\'m WKHPHDQSLSHGLDPHWHUDQGWKHSLSHZDOOWKLFNQHVV 7KHIROORZLQJGLDJUDPVKRZVWKHZDWHUKDPPHUHIIHFWIRUYDULRXVW\SHVRI SLSLQJWKHÁXLGFRQVLGHUHGLQWKLVWHVWLVZDWHU 7KDQNVWRLWVÁH[LELOLW\833SLSHZRUNLVWKHSLSHV\VWHPZLWKWKHORZHVWSHDN SUHVVXUH UPP )LEUHJODVV Steel 3HDN3UHVVXUHEDU ,QLWLDO9HORFLW\ :DWHUKDPPHUHIIHFWIRUYDULRXVSLSLQJV\VWHPV FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 11 11. FUEL FLOW UPP EXTRA LINED PIPE - FLOW LOSS R ATES 6 PP PP +HDG/RVVPP /LWUHVSHUPLQXWH UPP EXTRA LINED PIPE AND FILL PIPE - FLOW LOSS RATES PP PP PP)LOO +HDG/RVVPP /LWUHVSHUPLQXWH FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 11 UPP READY RECKONER FOR FLOWS TO 3,000 LITRES PER MINUTE (790 US GAL /MIN) 9HORFLW\RIOLTXLGIXHODQGYDSRXUÁRZLVJLYHQLQPVHFDQGIWPLQ Velocity of liquid fuel and fuel vapour flow is given in m/sec and ft/min Nominal Pipe Size inches 01.32.x UPP Pipe code Pressure Rating Polyethylene Grade Wall Thickness min. mm Internal Diameter nom. Cross Sectional Area mm² mm in² Availability FLOW 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 V= ft/min V= ft/min V= ft/min V= ft/min 600 l/m = Gravity Fill 160 US Gal/min V= m/s 1 M³/m = Pumped Fill 260 US Gal/min V= m/s 2 M³/m V= m/s V= ft/min 530 US Gal/min 3 M³/m 790 US Gal/min PN10 PE80 3.0 26.0 531 0.82 1 ½” 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 - - - - - - - - - - - - - - - - - - - - - - - - - - > 45 l/m = 1 Nozzle 12 US Gal/min 105 US Gal/min 1” DN25 V= ft/min V= ft/min V= m/s V= ft/min 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 NOTE x x x x 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 FOLLOW INSTALLATION INSTRUCTIONS. NON-COMPLIANCE WILL INVALIDATE WARRANTY AND INSTALLER CERTIFICATION. 12 12. 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