KPS LPG Installation Manual 1.2.1. Manual in english

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1. IMPORTANT INSTALLATION POINTS

3 min

Pipes must be cut squarely to fit the

Wait 3 minutes between each notch

Lubricate stainless steel bolts, washers

LPG10S compression coupling.

when bending the pipe.

and nuts with copper paste, ceramic

paste or MoS2.

20 Nm

40 Nm

180°

180°

180°

5 min

180°

15 min

Make sure the edges of the

3 x

2 x

LPG10S are fitted into the

groove of the LPG10-AS-

Use a torque wrench to tighten the LPG10S

•

2 times up to 40 Nm, waiting 15 minutes in

NPT or LPG10-BS insert.

coupling in steps:

between, and finally

•

3 times up to 20 Nm waiting 5 minutes in

between, then...

47 Nm

180°

180°

30 min

•

Repeatedly up to 47 Nm, waiting 15-30

Measure conductivity when the LPG10S

Provide earthing according to

minutes in between, until the coupling is

and LPG10-AS-NPT or LPG10-BS cou-

standards and regulations. Consult a

completely closed.

plings are mounted.

competent electrical engineer.

25.0

Pressure test the pipe at 25 bar (363

Perform tightness test with soaping

Backfill with sand.

psi) or according to local regulations,

before backfill.

but max 40 bar (580 psi).

Important installation points

2

KPS LPG Installation Manual 1.2

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CONTENTS

1.

Important installation points

2

2.

The KPS LPG Pipe System

5

2.1

Product Range

5

2.2

How to Order

5

2.3

Warranty

5

3.

About LPG

7

4.

The LPG filling station

8

5.

Transport, Handling and Storage

9

5.1

On Site

9

5.2

Coils

9

6.

Site Preparation and Pipe Arrangement

10

6.1

Site Readiness

10

6.2

Pipe Arrangement & Preparing Trenches and Beds

10

6.3

Uncoiling Pipes

11

7.

Installation

12

7.1

Pipe Installation

12

7.2

Cutting the Pipe

12

7.3

Bending the Pipe

13

7.4

Mounting the Transition Fittings

15

7.5

Testing conductivity

17

7.6

Earthing

17

7.7

Connecting to the tank and dispenser

18

8.

Pressure and Tightness Testing

21

8.1

Pressure Test - Mandatory

21

8.2

Tightness Test - Mandatory

22

8.3

Tightness Testing During Backfill - Optional

23

8.4

Tightness Testing After Backfill - Optional

23

9.

Completing the Installation

24

9.1

Documentation

24

9.2

Backfill

24

9.3

Before commissioning

24

10.

Modification and Repair of Installations

25

10.1

Preparations and Safety Considerations

25

10.2

Modification and Repair

25

10.3

Pressure and Tightness Testing After Modification and Repair

25

11. Safety Considerations

26

11.1

Releasing and Cutting Coils

26

11.2

Use of Equipment

26

11.3

Pressure Testing

26

Important installation points

3

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11.4

Repair, Maintenance and Upgrading Work

26

11.5

Hazardous Substances

26

Appendices

28

A. LPG Installation Example

29

B. LPG InstallationExample

30

C. LPG Pipe Installation Checklist

31

D. LPG Pipe Test Document

32

E. LPG Pipe Tightness Test

33

Disclaimer

This document contains recommendations and information regarding KPS LPG Pipe System products and their installation. It

is based on currently available information and is believed to be representative under specific conditions. However, factors as

environment, applications, installation or changes in operating procedure may cause different results. KPS makes no representa-

tion of warranty of any kind, express or implied, as to the accuracy, adequacy or completeness of the recommendations or

information contained herein. KPS neither assumes nor authorizes any representative or other person to assume for it any

obligation or liability other than such as is expressly set forth. Attention is drawn to any relevant local, national or regional

regulations.

KPS reserves the right to update and revise this manual without prior notice. The current version is always published at http://

www.kpsystem.com. KPS accepts no liability for installations that are not fully compliant with the instructions given in the cur-

rent installation manual.

Important installation points

4

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2. THE KPS LPG PIPE SYSTEM

The KPS LPG pipe is the first polyethylene pipe designed for

microorganisms present in the ground.

the high pressures used in LPG distribution. With an operat-

KPS pipes have a unique construction with layers chemically

ing pressure of 25 bars, our LPG pipe is designed to meet the

bonded on a molecular level. This technology is exclusive

high standards of safety in the LPG industry.

to KPS and by avoiding the use of an adhesive agent, as is

The KPS LPG pipe with its protective liner is completely

common on the market, we can guarantee that the layers

corrosion resistant. The permeation barrier and a conductive

are inseparable.

plastic liner ensure that there will be no permeation of the

This results in the most efficient permeation barrier on the

hydrocarbons, and that static electricity can dissipate safely.

market, preventing hydrocarbons from diffusing through the

Installation of KPS LPG Pipe System is easy and quick com-

pipe wall.

pared to conventional steel pipe installations. The KPS LPG

The conductive layer makes it possible to ground the pipe,

pipe is a semi flexible plastic pipe, easily rolled out into the

thus preventing build-up of static electricity that otherwise

trenches of the station from end to end, and then connected

would accumulate when the fuel flows in a plastic pipe.

to the tank and dispensers. No welding or complicated

installation procedures are needed, and the installation can be

completed in less than one day!

KPS provides a 30 year warranty on all our plastic pipes,

including our LPG pipe.

Conductive layer

Product and installation costs are kept at a minimum with the

new KPS LPG pipe. Since the estimated life time of the pipe is

Polyethylene

over 30 years, KPS provide lower total cost of ownership and

higher return on investment than any other LPG pipe on the

market.

The KPS LPG Pipe System and KPS Petrol Pipe System™ are

manufactured by Kungsörs Plast AB that is certified to both

ISO 9001 and ISO 14001.

Permeation barrier

2.1

Product Range

When used with cathodic ptotection, KPS LPG pipes do not

The KPS LPG Pipe System includes:

need to be isolated from the tank, since the conductivity is

too low to interfer with the cathodic protection.

•

Pipes

The KPS LPG pipes are designed for long term operating

•

Stainless steel fittings and bends

conditions with temperatures between -20 ºC (14 ºF) and

+40 ºC (104 ºF).

•

Bending tool

•

Cutting scissors

2.2

How to Order

•

Conductivity test equipment

You can place your order by phone, e-mail or fax from your

For a complete listing, detailed descriptions, properties and

local KPS representative. To locate your nearest distributor,

dimensions, see the current KPS Product Catalogue, available

see information on our web site www.kpsystem.com.

for download at www.kpsystem.com.

The KPS LPG pipe is made of polyethylene for mechanical

2.3

Warranty

strength, a permeation barrier that prevents permeation of

hydrocarbons through the pipe wall - and a conductive inner

The KPS LPG Pipe System has been developed to offer

layer that dissipates static electricity.

reliable performance over many years. Careful attention

has been paid to minimize the environmental impact during

Polyethylene is well suited for underground use at filling

manufacturing and during operation.

stations as it is corrosion free and resistant to water and

The KPS LPG Pipe System

5

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4. THE LPG FILLING STATION

Many LPG filling stations have the tank installed above ground, but there are also stations where the tank is buried. All LPG

filling stations are pressure systems, i.e. there is continuous pressure in the pipes. The operating pressure is usually around 15

bar. The high pressure is necessary to keep the LPG in its liquid form. The pressure in the tank is lower, usually between 3 and

5 bar depending on mixture and temperature.

From the tank to each dispenser runs a product line that feeds the liquid LPG to the dispenser. In parallell with the product line

runs a vapor return line where LPG vapor from re-fuelling operations is returned to the tank. These lines are usually mani-

folded at the tank end if there is more than one dispenser.

In the case of an above ground tank, the pump sits under the tank. The liquid fuel is tapped from the bottom of the tank, goes

through a filter that removes any water, into a tranquillizing zone before it enters the pump. To tranquillize the fuel is impor-

tant to minimize turbulence that could cause cavitation (formation of bubbles on the suction side of the pump) and mechanical

damage to the pump.

From the pump, the fuel will go in the product supply pipe to the dispensers. The transition from steel pipes to KPS LPG pipes

is done at ground level in both ends. To regulate the pressure in the supply line, there is an automatic bypass that returns liquid

fuel to the tank as needed to achieve the correct pressure. A manual bypass line goes in parallell with the automatic bypass to

allow for adjustment of pressure even if the automatic bypass is blocked. The tank can be filled from an entry on the bypass line

or at a dedicated fill opening.

On the tank and on all lines, including sections of pipe that can be shut by any valve, there is a safety relief valve set to 25 bar.

The LPG filling station

8

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5. TRANSPORT, HANDLING AND STORAGE

The KPS polyethylene pipes are of the highest quality, resilient

•

Do not stack coils more than three coils high.

and particularly suited for underground installation as the

•

Never drag, roll or throw pipes or fittings.

polyethylene material is strong, will not corrode like steel

pipes or suffer from the microbes that are present in the

•

Never expose pipes to open flame or excessive heat, for

ground. Nevertheless pipes and fittings need to be handled

example sparks from metallic welding or cutting.

with care to prevent damage.

•

Keep fittings in their protective packaging until installa-

V-shaped scratches from sharp objects may weaken the

tion. Damaged fittings may be difficult or impossible to

polyethylene material and lead to propagating cracks.

install.

•

Protect pipes from scratches during loading, transport,

•

Make sure that the O-rings and gaskets are kept clean.

unloading and storage.

•

Use a flatbed vehicle for transport and stack products in

5.2

Coils

an orderly and secure fashion.

•

Be careful when releasing coils as the pipe can straighten

•

Cover any sharp edges on forks of forklifts or use slings

with considerable force. A minimum of two people is

that cannot cause scratches to avoid damage to the pipes.

needed to uncoil the pipe. The end of the pipe should be

constrained with a rope and a slipknot before cutting the

Polyethylene will expand slightly and become more flexible

bands around the coil.

in high temperatures. Under cold conditions the material will

shrink slightly and become stiffer.

•

When cutting coils, one person should do the cutting and

another person should hold the pipe.

•

Pipe coils should be stored flat, unless properly sup-

ported and secured, in order to avoid deformation of the

•

Uncoil pipes the day before installation. To help straight-

pipe, especially in warm climates.

en the pipe it can be tied at either end to solid fixings.

•

In colder climates coils should, if possible, be gently pre-

warmed before uncoiling either by being stored indoors

in a heated building overnight or in a container with a

construction heating fan. Take care to not subject the

pipe to excessive heat (over 60°C) that may damage the

material.

When coils are stored upright they need to be supported to avoid deformation of

the pipe.

UV-radiation will damage the permeation barrier.

•

Pipes should always be stored with end caps on to pro-

tect from UV radiation and contamination.

5.1

On Site

•

Inspect all material for damage upon delivery and before

installation. Reject pipes with scratches or any other

significant damage. Using material that has been damaged

during transport, storage or handling will invalidate the

warranty.

•

Pipe coils should be stored flat with suitable protection

for the bottom of the coil.

Transport, Handling and Storage

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6. SITE PREPARATION AND PIPE ARRANGEMENT

Asphalt

6.1

Site Readiness

(tarmacadam)

Top fill

•

Check that no fuel contamination is present.

(dug-up material)

•

Construction equipment and materials should be

Warning tape or

mesh

removed from the working area.

Sand

•

The tank should be in position and the concrete base for

the dispensers should be ready before the pipe installa-

tion begins.

6.2

Pipe Arrangement & Preparing

Trenches and Beds

Minimum clearances.

KPS LPG pipes are designed for direct burial in the ground.

When calculating the depth of the trench, consider that when

They should not be laid in ducts made of steel, plastic, con-

the installation is complete, the pipe should be buried at a

crete or bricks or be used above ground. Consult KPS before

minimum of 600 mm from the top of the pipe to finished

installing KPS LPG pipes in other ways than those described

forecourt level. Deeper burial depths may be required in

and recommended in this manual.

areas with car or truck traffic and in warmer climates. Follow

standard requirements and national regulations for ground

Pipe trenches and bedding

work.

Trenches should then be prepared with a bottom layer of 20

Dig trenches wide enough to lay pipes no closer than 10 cm

cm of clean sand, free of stones and sharp particles, on which

to each other and no closer than 20 cm to the side of the

the pipes are then placed.

trench or any sharp object. Dig trenches that allow for soft

bends rather than sharp 90° bends.

The best result is achieved when pipes are placed directly

onto the bed. For minor adjustments, use bags filled with

Pipe arrangement

sand, placed under the pipe at minimum 1 meter intervals.

Bags filled with sand should also be used to separate pipes

Lay pipes on a bed of 20 cm of bedding material with a

that are crossing. Do not use wooden pieces as these will

minimum of 10 cm between parallel or crossing pipes and a

deteriorate over time leaving a void. Do not use stones or

distance of minimum 20 cm to the side of the trench or any

bricks as the sharp edges can damage the pipe. Styrofoam as

sharp object.

a means of supporting or separating pipes should be avoided

Asphalt

(tarmacadam)

because the material will deteriorate fast if in contact with

Top fill

hydrocarbons. Pieces of plastic pipe risk being displaced dur-

(dug-up material)

ing backfill and are often insufficient for pipe support, but can

Warning tape or

be used to separate parallel pipes.

mesh

Sand

When pipes canot be laid directly onto the bed, bags with sand should be used to

support the pipe at close intervals.

The sand used for bedding and backfill will need to be

Minimum clearances for crossing pipes.

mechanically compacted with a machine approximately every

20 cm. The optimal layer depth depends on the machine used.

To compensate for movement of the pipe due to temperature

Saturating sand with water can help compacting, but is not

changes or movement/settlement in the soil, lay coils in slight

sufficient as the only compacting method.

curves.

Avoid:

•

Pipes crossing each other if another solution is possible

using a different pipe layout.

Site Preparation and Pipe Arrangement

10

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•

Burying metal parts in the soil.

The minimum bend radius allowed for the LPG pipe is 1

meter (20 x the pipe diameter).

6.3

Uncoiling Pipes

•

Uncoil pipes the day before installation. To help straight-

en the pipe it can be tied at either end to solid fixings.

•

Be careful when releasing coils as the pipe can straighten

with considerable force. A minimum of two people is

needed to uncoil the pipe. The end of the pipe should be

restrained with a rope and a slipknot before cutting the

bands around the coil.

•

The natural curves of a coiled pipe can be used to change

direction of the pipe or to achieve the correct angle at

the end points. Bags filled with sand or stakes can be

used to keep it in position until installation and backfill.

A good way to roll out the pipe

Try to avoid this way

Use bags with sand to keep the pipes in place during installation.

•

In colder climates coils should, if possible, be gently pre-

warmed before uncoiling either by being stored indoors

in a heated building overnight or in a container with a

construction heating fan. Take care to not subject the

pipe to excessive heat that may damage the material.

Site Preparation and Pipe Arrangement

11

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7. INSTALLATION

The KPS rotating pipe cutter is the best tool for cutting KPS

7.1

Pipe Installation

LPG pipes and ensures a square cut.

•

Uncoil pipes the day before installation and check that all

necessary tools and equipment are available.

•

Depress the release nut to open the cutter.

•

Place the pipes in the trench from tank to dispenser and

•

Place the cutter with the rollers under the pipe and press

cut to approximate length.

the cutting wheel into contact with the pipe. Turn the

cutting wheel feed knob clockwise half a turn.

•

Bend the pipe in the ends using the bending tool.

•

Rotate the cutter away from yourself and around the

•

Measure the exact height needed, mark the pipe and trim

pipe for one lap. Turn the feed knob clockwise half a

the pipe to desired height using the rotating pipe cutter.

turn.

•

Mount the compression couplings KP LPG10S with

•

Now rotate the cutter towards yourself and for each

LPG10-AS-NPT or LPG10-BS inserts.

revolution turn the feed knob about 45° to press the

cutting wheel further into the pipe. Repeat until the cut is

•

Measure conductivity.

completed.

•

Prepare connections to the dispenser and to the tank.

Tip!

Start with installing the longest pipe run. Then if you make a

mistake, you can use the pipe for the next long pipe run.

Use the pipe scissors to quickly cut the pipe to the ap-

proximate length, then use the rotating cutter for the

final trim.

7.2

Cutting the Pipe

To ensure that pipes can be properly used with the KP

LPG10S coupling it is important that they are cut absolutely

square. Always cut pipes with the KPS approved tools. Never

cut pipes using a saw-edged blade of any kind.

The rotating pipe cutter will cut the pipe absolutely square.

Safety

Pipes must be cut squarely to fit the KP LPG10S fitting.

Be careful when cutting pipe that have been coiled, even

LPG pipes can be cut using the KPS pipe scissors. To use the

if it has already been uncoiled as the cut ends tend to

cutter, place the curved section on top of the pipe and the

bend back into a curved form and risk hitting you or

others causing injury. One person should do the cutting

cutting blade under the pipe. Positioning the scissors this way

while another person holds the pipe.

is important as it helps achieving a square cut. Keep the bot-

tom handle still and use the upper handle to cut. Check that

your cut is square.

Use the deburring tool that comes with the pipe cutter to

chamfer the inside of the pipe. This simplifies the mounting of

the KP LPG10-AS-NPT and KP LPG10-BS-NPT inserts. Do

not use a regular knife, as there is a risk of unintentionally

create v-shaped notches that may lead to cracks in the pipe.

To access the deburring tool, tip the cutter and press the

release pin.

Pipe scissors can be used to cut KPS LPG pipes.

Installation

12

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7.3

Bending the Pipe

1

2

3

Unscrew the wing nut and pull out the

Turn down the roller castor runner.

Release and swing the large catch over to

extension runners fully. Tighten the nuts.

the other side.

4

5

6

Unscrew the wing nut and pull out the

Lift the handle and set the large catch in

Place the pipe so that it protrudes at least

handle to full length. Tighten the nut.

starting position with the locking pin in the

1.4 meter from the bend edge. This is will

first notch.

give a bend suitable for pipe burial at 60 cm.

When deeper burial depths are required,

adjust the pipe position accordingly.

7

8

9

Make sure the pipe rests on the roller cas-

Stand with your feet on the runners on each

When the locking device clicks into the first

tor and between the two heels on the back

side of the pipe and slowly pull the handle to

notch, release the handle.

of the bending tool.

start bending the pipe.

10

11

12

3 min

3 min

Pause for 3 minutes to allow for the pipe to

Stand on the runners and slowly pull the

Release the handle and wait for 3 minutes.

adjust.

handle until the bending tool clicks into the

Repeat the process until the pipe is fully

next notch.

bent. Pause 3 minutes between each notch.

Installation

13

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13

14

15

Take out the fixing strap. Measure the

Mount the bolts, washers and nuts with the

Make sure the metal band is at approxi-

approximate position for the clamps.

metal band directly under the bolts.

mately a 45 degree angle before tightening

the bolts.

16

17

18

Press the handle slightly and release the

Remove the pipe from the bending tool.

The bend should be minimum 70 cm high,

locking mechanism.

more if you have a burial depth greater than

60 cm.

19

20

Place the pipe in the trench and measure

Cut the pipe to its finished length using a

and mark the exact height required. The

KPS rotating pipe cutter.

pipe should end at finished forecourt level.

Installation

14

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7.4

Mounting the Transition Fittings

For transition from plastic to metal, use the KP LPG10S compression coupling in combination with either the KP LPG10-AS-

NPT threaded insert och KP LPG10-BS flange insert.

Always use a torque wrench to control the torque when mounting

the LPG10S compression coupling. If you apply too much force too

quickly you may crack the bolts or even the coupling.

The LPG10-AS-NPT and LPG10-BS inserts.

1

2

3

You need: hex key, wrench n:o 17, torque

Make sure the pipe is cut squarely.

Lubricate the smaller mounting screw using

wrench (20-47 Nm) with socket n:o 17 and

copper paste, ceramic paste or MoS2.

a rubber mallet.

4

5

6

Insert the screw and screw it clockwise to

Mount the coupling onto the pipe end.

Use a rubber mallet to hit the insert KP

open the coupling.

LPG10-AS-NPT or KP LPG10-BS completely

into the pipe.

7

8

Unscrew the mounting screw.

Make sure the edge of the LPG10S

rests in the groove of the KP

LPG10-AS-NPT or BS insert.

Installation

15

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9

10

11

Remove the mounting screw.

Lubricate the bolts, washers and nuts with

Mount the bolts, washers and nuts on the

copper paste, ceramic paste or MoS2.

coupling.

12

13

20 Nm

40 Nm

180°

180°

180°

5 min

180°

15 min

3 x

2 x

Set the torque wrench to 20 Nm. Tighten the bolts

Set the torque wrench to 40 Nm. Tighten the bolts

alternatively, half a turn each, up to 20 Nm.

alternatively, half a turn each, up to 40 Nm.

Wait 5 minutes before continuing.

Wait 15 minutes before continuing.

Repeat 3 times.

Repeat 2 times.

14

15

47 Nm

OK!

180°

30 min

180°

Set the torque wrench to 47 Nm. Tighten the bolts alternatively, half a turn each, up to 47

Nm.

Wait 30 minutes before continuing.

Repeat until the coupling is completely closed.

Installation

16

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7.5

Testing conductivity

7.6

Earthing

The KPS LPG pipe has a conductive inner layer that dissipates

The conductive LPG piping system must be connected to the

static electricity. The pipe, the transition fittings and other

main earth at the installation point and adjacent conductive

connected metallic fittings and pipes will form a continuous

objects bonded according to applicable regulations and legisla-

conductive path that, when connected to earth, eliminates

tion.

electrostatic hazards.

Always consult a competent electrical engineer, familiar with

When the KP LPG10S and LPG10-AS-NPT or LPG10-BS have

national regulations, to make sure that earthing and potential

been mounted on the pipes ends you should test the conduc-

equalization of the piping system and adjacent installations are

tivity in the pipe from end to end using the KPS conductivity

done in a correct way to prevent electrostatic hazards.

tester.

Calibrate the tester at the beginning and end of each work

day. Test both the red and the green signal according to the

picture.

Calibrate the conductivity tester at the beginning and the end of the day.

1.

Connect the cables to the tester and to the ends of the

pipe run.

2.

Press the “TEST” button. A green light and a beep indi-

cate OK. A red light and no beep indicate not OK.

When the battery indicator light turns red, replace the 9V

battery.

Installation

17

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7.7

Connecting to the tank and dispenser

Transition with threaded flange

Use the LPG10-AS-NPT insert and LPG21S threaded flange.

KP LPG67

LPG10S

LPG10-AS-NPT

LPG21S-NPT

Assembly for transition via threaded flang

Finished assembly.

Use a pipe wrench or wrench 41 to hold the LPG10-AS-NPT insert when the threaded flange is mounted.

LPG21S-

LPG16

LPG20S

LPG29

NPT

Use a fibre gasket between flanges.

Finished assembly.

Installation

18

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Transition with weldable flange

For transition directly to a weldable flange, use the LPG10-BS insert, the LPG22S flange halves and the LPG20S weldable flange.

The weldable flange LPG20S must be welded before it is mounted.

LPG10-BS

LPG10S

LPG22S

LPG20S LPG29

Assembly for transition via weldable flange.

Finished assembly.

Check that the O-ring in the LPG10-BS insert is undamaged. A damaged O-ring will result in an untight installation. If necessary,

replace with a LPG17 O-ring.

If the LPG10-BS insert needs a new O-ring, use the LPG17 O-ring only.

Manifolding LPG lines

When manifolding two LPG product or vapor return lines the following assembly can be used. See also Appendix B for drawing

with bill of materials.

Manifolding of LPG lines.

Installation

19

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Sealing of threads

KP LPG67

All fittings are NPT threads and should be sealed with thread sealing tape (gas resistant).

The conical seals on fittings, tees and elbows must NOT be lubricated and no sealant must be used.

Lubrication of threads

All threads on bolts and nuts must be lubricated with copper paste, ceramic paste or MoS2.

Safety relief valves

A seafety relief valve must be fitted on all sections of pipe that may be shut by valves of any kind. The safety relief valve should

be set to max 25 bar to prevent excessive pressure caused by thermal expansion of the LPG or any system malfunction.

Manifold prepared to be fitted with safety relief valve.

Installation

20

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8. PRESSURE AND TIGHTNESS TESTING

Correctly performed pressure and tightness tests are essential to ensure the quality of the installation and problem-free opera-

tion.

All pressure and tightness testing must comply with local, national or regional rules and regulations. The pressures and test

times specified here are the minimum requirements for a valid KPS warranty. Local, national or regional rules and regulations

may require stricter testing to be performed. Special accreditations or permits may be required for pressure testing with gases

at high pressures.

Safety

Equipment.

When fuel has been present in any part of the system

•

Equipment to blank off the pipe run in both ends.

to be tested, nitrogen must be used for testing. Ensure

•

Metal flanges or plugs with test ports.

that all pipes have been thoroughly flushed from fuel

and fuel vapors using nitrogen before commencing any

•

Pneumatic tubing.

work.

•

Compressed air or nitrogen.

Unauthorized people must not have access to the site

•

Soap solution, made from water and a bit of detergent,

during the time when high pressures are applied to

such as soap, washing-up liquid or similar. Put in a spray

the system. Only the necessary personnel should be

bottle for easy application or use sponge and a bucket.

present. Everyone on site should be warned about

the pressure test and avoid standing at an angle where

•

Pressure gauge for pressure test.

they risk being hit by any components from the piping

•

Pressure gauges for tightness test. The scale of the gauges

system that may come loose during the pressure test.

should show the pressure used for testing in the middle

Before applying pressure to the system, make a risk

of the scale.

assessment and ensure that all personnel keep a se-

•

Mirror.

cure distance to the system when it is under pressure.

All national, regional and local safety regulations must

be adhered to.

8.1

Pressure Test - Mandatory

Objective

Test method

Verification

•

Finding potentially weak parts in

•

25 bar (363 psi) for 5 minutes.

•

No parts should come loose.

the system.

(Max. 40 bar / 580 psi)

•

Always disconnect or separate the pipe run to be tested from the tank and from the dispenser. Any testing of the tank or

the connection of the pipes to the tank should be done in a separate step.

•

Pressurize with air or nitrogen to a pressure of 25 bar (363 psi) and hold the pressure for 5 minutes. If regulations require

testing with a higher pressure, follow the regulations, but do not apply a higher pressure than 40 bar (580 psi).

If correctly installed, no parts should come loose.

Pressure and Tightness Testing

21

KPS LPG Installation Manual 1.2

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8.2

Tightness Test - Mandatory

Objective

Test method

Verification

•

Finding any leaks in the system.

•

0.02-0.70 bar (0.3-10 psi) for 1 hour.

•

Bubbles indicate leakage.

Adapt the pressure to the resolution

•

Declining pressure that cannot be

of the manometers used.

explained by a temperature drop

(Max. 25 bar / 363 psi)

indicates leakage.

•

Soaping of all joints.

•

Document pressure and tempera-

ture during test period.

The tightness of a piping system before backfill is validated by:

1.

Soaping all joints when the pipe is pressurized. Bubbles indicate leakage.

2.

Reading any pressure and temperature variations during a test period. A declining pressure indicates leakage.

Tip!

Soaping is the best method for locating a leak.

The formation of bubbles is a sure indication of leakage.

Procedure

•

Pressurize the pipe with air or nitrogen to a pressure of 0.02 to 0.70 bar (0.3-10 psi). Adapt the test pressure to the

resolution of the pressure gauges used so that variations in pressure can be read easily. If regulations require testing with a

higher pressure, follow the regulations, but do not use a pressure higher than 25 bar (363 psi) for tightness testing.

•

Document the starting pressure.

•

Apply soap solution to all joints (starting with the test equipment and its connections) and look for bubbles that indicate

leakage. Pay attention to the soaping under the pipes and if necessary use a mirror for a clear view of the bottom of the

pipes.

•

Document the pressure and ambient temperature at 10 minute intervals for a period of 1 hour. There should be no pres-

sure variations that do not have a reasonable explanation in recorded temperature variations.

•

After 1 hour re-test all joints with soap solution.

If using a less accurate pressure gauge, prolong the test period to 4-24 hours.

Guidelines for judging pressure variations during tightness testing

All pressure variations should have a reasonable explanation in documented temperature variations. The pressure of the gas

used for tightness testing increases and decreases with the temperature.

1)

2)

3)

Temperature and pressure as a function of time. Green curve = pressure. Black curve = temperature.

Pressure and Tightness Testing

22

KPS LPG Installation Manual 1.2

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Scenario 1

Over the test period the pressure has varied and dropped some, but the temperature shows very similar changes. Unless any

leaks were identified during soaping, the system is likely to be tight.

Scenario 2

Over the test period the pressure has increased some. This is explained by the increase in ambient temperature recorded dur-

ing the same period. Unless any leaks were identified during soaping, the system is likely to be tight.

Scenario 3

The temperature has kept quite still during the test period, but the pressure dropped slightly. This is very likely due to a leak.

Identify the place of the leak by soaping.

8.3

Tightness Testing During Backfill - Optional

Objective

Test method

Verification

•

Get immediate indication of dam-

•

0.02-0.20 bar (0.3-2.9 psi).

•

Declining pressure indicates leak-

age caused by backfill operations.

age.

By maintaining a low pressure in the pipes during backfill operations, any damage caused by operations may be detected at once

as sudden pressure changes.

As people will be working close to the piping system during backfill, a pressure of 0.02 bar to maximum 0.20 bar (0.3-2.9 psi) is

recommended during this time.

8.4

Tightness Testing After Backfill - Optional

Objective

Test method

Verification

•

Finding any leaks in the system.

•

0.02-0.70 bar (0.3-10 psi) for 1

•

Declining pressure indicates leak-

Temperature changes should be

hours. Adapt the pressure to the

age.

minimal after backfill and pressure

resolution of the manometers used.

stable during the test period.

•

Document pressure during the test

period.

After backfill, pressure variations due to temperature changes are reduced to almost zero. A repeated tightness test will con-

firm that the piping system has not been damaged by backfill operations.

Procedure

•

Check that the pipe is blanked off at both ends.

•

Pressurize the pipe with air or nitrogen to a pressure of 0.02 to 0.70 bar (0.3-10 psi). Adapt the test pressure to the

resolution of the pressure gauges used so that variations in pressure can be read.

•

Document the starting pressure.

•

Document the pressure at 10 minute intervals for a period of 1 hours.

A dropping pressure indicates leakage.

Pressure and Tightness Testing

23

KPS LPG Installation Manual 1.2

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9. COMPLETING THE INSTALLATION

Asphalt

9.1

Documentation

(tarmacadam)

Top fill

The KPS LPG Installation Checklist must always be filled in

(dug-up material)

by the installing contractor and saved for the duration of the

Warning tape or

warranty period. This is a requirement for the 30 year KPS

mesh

product warranty.

Sand

It is a strong recommendation to also save the following

documentation:

•

Documentation of conductivity testing.

•

Documentation of pressure and leakage testing.

Minimum clearances.

•

Photos of the installation before backfill.

Special attention should be given to backfill under the pipes

•

As-installed-drawing.

to make sure there are no voids under the pipe. Compact the

sand also under, on the sides of, and in between the pipes for

9.2

Backfill

best long term performance.

Backfill may be undertaken only after successful completion

of conductivity, pressure and leakage tests. Check that pipe

arrangement is according to instructions.

Proper backfill supports the pipe, protects it from mechani-

cal damage and handles the effects of thermal expansion/

retraction, heavy traffic or other loading imposed on the pipe

system.

Clean sand (3 mm grains) shall be used for backfill. The sand

needs to be mechanically compacted with a machine approxi-

mately every 20 cm. The optimal layer depth depends on

the machine used. Compacting can be done using hand-held

tampers, diesel driven impact tampers or vibratory plates.

Saturating sand with water can help compacting, but is not

sufficient as the only compacting method.

Backfill carefully under the pipes.

Take care that the pipes are not damaged or moved out of

position during compacting. Do not compact on top of the

The pipe should be buried at a minimum of 600 mm from

pipes until at least 30 cm of backfill material has been put

the top of the pipe to finished forecourt level. Deeper burial

over the pipes. Increase this distance when heavy or powerful

depths may be required in areas with car or truck traffic and

devices are used.

in warmer climates. Follow standard requirements and regula-

tions for ground work.

The space within 200 mm of the pipes should always be filled

with sand. The sand must be free of organic material, snow,

Place marker tape minimum 30 cm above the pipes

ice or fuel contamination.

or according to applicable laws and regulations.

9.3

Before commissioning

Make sure the inside of the piping system is free from dirt and

contamination. Flush with air or nitrogen to clean the pipes.

Completing the Installation

24

KPS LPG Installation Manual 1.2

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11. SAFETY CONSIDERATIONS

KPS recommends that a job safety analysis is done to assess

has been present in the system.

potential risks for work on site. Appropriate safety measures

Blank off the pipe from the tank before pressurizing. Do not

should then be taken and protective equipment used to pre-

pressurize a tank with fuel in it.

vent accidents, injuries and incidents. Special attention should

be paid to safety in potentially hazardous areas when doing

Unauthorized people must not have access to the site during

repair, maintenance or upgrading work.

the time when high pressures are applied to the system. Only

the necessary personnel should be present. Everyone on site

should be warned about the pressure test and avoid standing

11.1

Releasing and Cutting Coils

at an angle where they risk being hit by any components from

the piping system that may come loose during the pressure

Be careful when releasing coils as the pipe can straighten with

test.

considerable force. A minimum of two people is needed to

uncoil the pipe. The end of the pipe should be constrained

with a rope and a slipknot before cutting the bands around

11.4

Repair, Maintenance and Up-

the coil.

grading Work

Before starting modification and repair work, make detailed

risk assessments and take due precautions to eliminate or

minimize risks. Follow all applicable health and safety regula-

tions and make sure permit-to-work systems are in place.

It is a strong recommendation that the filling station is closed

during any modification or repair works. Access to the site

should be restricted and all relevant safety regulations strictly

adhered to. Equipment used at the site should be checked to

ensure operational condition and suitablity for intended use.

The tanks and the piping system must be emptied and flushed

clean or otherwise secured to make sure no fuel or fuel

residue or vapors are present where work is to be done.

Electrical equipment such as dispensers and submersible

One person should hold the pipe and another do the cutting.

pumps should be disconnected.

Be careful when cutting pipe that have been coiled, even if

Equipment and tools to be used in potentially hazardous

it has already been uncoiled as the cut ends tend to bend

areas, where an explosive atmosphere may be present, must

back into a curved form and risk hitting you or others caus-

be classified as safe for this use according to national or

ing injury. One person should do the cutting while another

regional regulations. See for example the European ATEX

person holds the pipe.

directive at http://ec.europa.eu/enterprise/atex/guide/.

11.2

Use of Equipment

11.5

Hazardous Substances

To avoid personal injury, exercise caution when using cutting

LPG

tools.

Hazard summary

Always perform the conductivity test in an area free from

•

Liquefied petroleum gas can affect you when breathed in.

flammable liquids or vapors.

•

Contact with liquefied petroleum gas may cause frostbite.

11.3

Pressure Testing

•

Exposure to high levels can cause you to feel dizzy and

lightheaded. Higer levels can cause suffocation and death

Follow any local, national or regional regulations and make a

from lack of oxygene.

risk assessment before applying high pressures.

•

Liquefied petroleum gas is highly flammable and a danger-

Use nitrogen for pressure and tightness testing whenever fuel

ous fire hazard.

Safety Considerations

26

KPS LPG Installation Manual 1.2

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Ways of reducing exposure to hazardous substances

•

Work in a well ventilated area.

•

Wear protective clothing.

•

Wash thoroughly immediately after exposure.

•

On skin contact, immediately submerse the affected body

part in warm water.

First aid

Eye Contact

•

Immediately flush with large amounts of water for at

least 15 minutes, occasionally lifting upper and lower lids.

Remove contact lenses, if worn, while rinsing.

Skin Contact

•

Immerse affected part in warm water. Seek medical

attention.

Breathing

•

Remove the person from exposure.

•

Begin rescue breathing (using universal precautions)

if breathing has stopped and CPR if heart action has

stopped.

•

Transfer promptly to a medical facility.

Safety Considerations

27

KPS LPG Installation Manual 1.2

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DENNA HANDLING ÄR KUNGSÖRS PLAST AB EGENDOM THIS DOCUMENT IS THE PROPERTY OF KUNGSÖRS PLAST AB

SKYDDAD ENLIGT GÄLLANDE LAG

PROTECTED IN ACCORDANCE WITH PREVAILING LAW

6

3

5

4

9

Ground level

7

10

8

2

1

10

1

KP LPG10-BS

Straight insert Coupling 50/25 flange

9

1

KP LPG29

LPG-Screw/Nut/Washer

8

2

KP LPG10S

Compression coupling Ø50mm with bolts

7

1

KP LPG10-AS-NPT

Straight insert Coupling 50/25 1" NPT

6

1

KP LPG20S

Weldable flange Ø105mm

5

1

KP LPG22S

Flange half Ø105

4

1

KP LPG21S-NPT

Threaded Flange 1" NPT Ø105mm

3

1

KPKLPG16

Flange gasket fiber Ø60x3

2

2

KP LPG34

Bending bracket

1

1

KP 50LPG100

LPG-Pipe

ITEM

QTY.

Artikel nr/ Part no

DESCRIPTION

NO.

sign

Designed by

Drawn by

Checked by

General tolerance

Format

First angleprojection

Scale

E

Date

KPS

A3

1:5

ISO 128:1982

Title/Name

KPS LPG Product or VR Line

Date

for overground tank installation

2010-03-04

Drawing number

Revision

Sheet

1/1

-

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Manifold example

In dispenser example

1

1

2

2

3

3

4

5

4

5

6

Position

Quantity

Article number

Description

Position

Quantity

Article number

Description

1

1

KP LPG30S-NPT

Adapter NPT thread

1

1

KP LPG29

4 x Screw, nut,

male/male

washer

2

1

KP LPG31S-NPT

Tee coupling NPT

2

2

KP LPG21S-NPT

Threaded female

thread 3 x female

flange NPT Ø 105mm

3

2

KP LPG23S-NPT

Elbow 90° NPT

3

1

KP LPG16

Flange gasket fiber

thread female/male

4

2

KP LPG10-AS-NPT

Straight insert

4

1

KP LPG23S-NPT

Elbow 90° NPT

coupling 50/25 NPT

thread female/male

1” male

5

1

KP LPG10-AS-NPT

Straight insert

5

2

KP LPG10S

Compression

coupling 50/25 NPT

coupling Ø 50mm

1” male

6

1

KP LPG10S

Compression

coupling Ø 50mm

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LPG PIPE INSTALLATION CHECKLIST

To be completed and filed by the installing contractor during the warranty period.

Installing Contractor Information:

Site Information:

Installer:

______________________________

Owner:

______________________________

Address:

______________________________

Site address:

______________________________

______________________________

______________________________

Phone:

______________________________

Phone:

______________________________

Contact:

______________________________

Contact:

______________________________

All KPS products used for installation were checked upon arrival at the site and free from freight and

handling damages.

All KPS products were handled with care during unloading and installation.

All pipe trenches were excavated for a burial depth of 60 cm or more and to provide a minimum of 10 cm

free space on either side of every pipe and minimum 20 cm free space to the trench wall.

All pipes have been installed on a correctly prepared, 20 cm thick bed of sand (3 mm).

All KPS pipes were cut squarely with KPS recommended pipe scissors or pipe cutters.

The pipe was bent using the KPS LPG bending tool according to instructions in the KPS LPG installation

manual.

All KPS fittings were installed in accordance with instructions in the KPS LPG installation manual.

All pipes were installed in accordance with the KPS LPG installation manual in order to allow for

expansion and contraction.

Conductivity test on all LPG pipes is performed according to the KPS LPG installation manual.

Pressure test (of pressure lines) and leakage test (of all lines) with soaping has been performed in

accordance with the KPS LPG installation manual and no leaks were detected.

All backfill material consists of sand (3 mm) and the backfill has been performed according to the KPS LPG

installation manual.

The conductivity of the pipe runs has been tested and all lines passed the test.

The system has been properly earthed and adjacent conductive objects bonded as advised by a competent

electrician.

Installing Contractor acknowledges that the warranty will be void unless a KPS certified LPG installer, i.e.

trained and approved by a KPS approved instructor, has carried out the installation.

__________________________________________

_______________________________________

Certified Installer (license number, signature and company name)

Installing Contractor

(signature and company name)

______________________________ ____________

_____________________________ _________

Print Name

Date

Print Name

Date

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LPG PIPE TEST DOCUMENT

To be filled in and saved by the installing contractor. Copy to customer/authorities if

required.

Installing Contractor Information:

Site Information:

Installer:

______________________________

Owner:

______________________________

Address:

______________________________

Site address:

______________________________

______________________________

______________________________

Phone:

______________________________

Phone:

______________________________

Contact:

______________________________

Contact:

______________________________

Conductivity test:

Before the pipe is connected to tank or to dispenser.

Strength test:

25 bar (363 psi) for 5 minutes.

Tightness test:

0.02 - 0.7 bar (0.29 psi - 10.15 psi) for 1 hours + soaping.

Pipe:

1

2

3

4

5

6

7

8

VR

VR

VR

VR

VR

VR

VR

VR

1

2

3

4

5

6

7

8

Conductivity

Strength

Tightness

__________________________________________

_______________________________________

Certified Installer (license number, signature and company name)

Installing Contractor (signature and company name)

______________________________ ____________

_____________________________ _________

Print Name

Date

Print Name

Date

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LPG PIPE TIGHTNESS TEST

To be filled in during tightness test.

Site name: ______________________________________________ Date: ___________________

Line: __________________________

Time

Temperature

Pressure

(minutes)

(°C/°F)

(bar/psi)

0

10

20

30

40

50

60

Soaping:

Tightness confirmed:

Yes

No

__________________________________________

Certified Installer (license number and signature)

______________________________ ____________

Print Name

Date

-------------------------------------------------------------------------------------------------------------------------------------------------------------

KPS LPG Product Range

KP 50LPG100

KP LPG30S-NPT

KP LPG22S

LPG pipe PN25

Adapter NPT thread

Flange halves Ø 105mm

Ø 50 mm 100 m

Male / Male

for KP LPG10-BS

KP LPG10S

KP LPG32S-NPT

KP LPG16

Compression coupling

Adapter NPT thread

Flange gasket fiber

Ø 50mm

Female / Male

Ø 60x3

KP LPG10-AS-NPT

KP LPG33S-NPT

KP LPG29

Straight insert coupling

Adapter NPT thread

4 x Screw, nut, washer

50/25 NPT 1” male

Female / Female

KP LPG10-AS-NPT-3/4

KP LPG17

KP LPG34

Straight insert coupling

O-ring 1”

LPG Fixing strap

50/25 NPT 3/4” male

for LPG10-BS NBR 70

KP LPG10-BS

KP LPG50

KP LPG20S

Straight insert coupling

LPG Bending tool

Weldable flange

50/25 Flange

Ø 105 mm

KP LPG67

KP LPG23S-NPT

KP LPG21S-NPT

Thread sealing tape for

Elbow 90° NPT thread

Threaded female flange NPT

LPG

Female / Male

Ø 105mm

KP LPG31S-NPT

Tee coupling NPT thread

3 x Female

www.kpsystem.com

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