KPS Inst Manual Ver 6[1].1 Eng

8/20/2019 KPS Inst Manual Ver 6[1].1 Eng

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KPS System Manual – Version 6.1 CONTENTS

About this manual:KPS reserves the right to update and revise this manual from time to time. The latest issue is alwayspublished on http://www.kpsystem.com and KPS accepts no liability for installation performedaccording to an outdated manual.

Installation Manual for the KPSPetrol Pipe System™

Content:

1. Introduction....................................................................2

2. General Requirements..................................................5

3. Product Descriptions...................................................10

4. Handling........................................................................12

5. Cutting...........................................................................16

6. Welding.........................................................................21

7. Pressure Testing...........................................................30

8. Backfill...........................................................................32

9. Pipe Welding Machine.................................................33

10. Installation Examples.................................................34

11. Conductivity Test Instruction...................................55


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KPS System Manual – Version 6.1 1. INTRODUCTION

2

1. INTRODUC TIO N

The KPS Petrol Pipe System™................................................................. 2

KPS Product Reference Manual...............................................................2

Polyethylene Pipe...................................................................................... 3

Multi-layer Lined Pipe............................................................................... 3

KPS Multi-layer Lined Conductive Pipe..................................................3

KPS Secondary Contained Lined Pipe..................................................... 3

The KPS Petrol Pipe System™

The KPS Petrol Pipe System™ is a comprehensive range of products

manufactured by Kungsörs Plast AB, a Swedish company with morethan 25 years experience of manufacturing polyethylene pipes andfittings for the petroleum industry. KPS is represented worldwide by anetwork of partners, providing an international 24 hour back up service.

The KPS Petrol Pipe System™ is a state-of-the-art, total solution tohandling liquid fuel through a polyethylene pipework system and has

built-in, active awareness of the environment.

The KPS product range is expanding and developing continuously toadapt and conform to the ever more stringent demands of the market. By

using state-of-the-art technology, the company offers highly competitive,long-term solutions with designs that have been developed to eliminate

all leakage. Zero tolerance is the basis of all our development work.

The wide range of KPS products ensures that whatever your

requirements you will find here the most appropriate solution. Whetherworking on suction or pressure systems, offset fills, vent lines or vapour

recovery, we will always provide you with products you can trust.

Kungsörs Plast AB is certified to ISO 9001 and ISO 14001.

KPS Product Reference Manual

Detailed descriptions, material properties and dimensions are given in

the KPS Product Reference Manual issued electronically and availableupon request.


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KPS System Manual – Version 6.1 1. INTRODUCTION

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Polyethylene Pipe

Polyethylene has excellent life expectancy – far above any other polymerused for underground pipework. KPS demonstrates this by offering a 30-year guarantee on all items manufactured by KPS and a 15 year

guarantee on complete systems. Polyethylene pipes are easy to installand are more resistant to puncture from sharp objects than any other polymer pipes. The KPS Petrol Pipe System™ is designed from 10 bar primary line classed pipe which means that the pipe is subjected to amomentary pressure test at 30 bar before being put into service.

Multi-layer Lined Pipe

There are multiple layers. The innermost and second layers act togetheras a permeation barrier, preventing hydrocarbons from diffusing through

the pipe wall (the rate of permeation is so small that it cannot bemeasured). The outer layer is of high strength polyethylene providing astrong outer case to ensure a long life.

To achieve even greater safety the multi-layer lined pipe may be placedinside an additional high strength pipe to protect the primary pipe from

damage thus preventing possible leaks. This is known as a coaxial pipeor ‘a pipe in a pipe’.

KPS Multi-layer Lined Conductive Pipe

KPS multi-layer lined conductive has been developed to meet the latesttechnical and safety requirements in Europe. All liquids flowing in pipescause a build up of static electricity. To avoid the risk of spark ignitionKPS has developed a polyethylene conductive pipe system which can be

earthed.

KPS multi-layer lined conductive has been tested by PTB

(Physikalische-Technische-Bundesanstalt) in accordance with theGerman regulations on flammable liquids and avoidance of staticelectricity. KPS conductive was found to be well within therequirements. Also the pipe’s performance is unchanged, guaranteeing

the same excellent performance as all other KPS products.

KPS Secondary Contained Lined Pipe

KPS Integrated Secondary Contained Pipe is a development of earlierKPS Systems. The KPS Patented Integrated Secondary Containedfittings design, which has been developed ‘in house’, reduces to aminimum the number of components used in an installation. This

reduces the assembly time and results in a much more cost-effectiveinstallation.


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KPS System Manual – Version 6.1 2. GENERAL REQUIREMENTS

5

2. GENERAL REQUIREMENTS

Application.................................................................................................. 5

Arrangement of Pipes............................................................................... 5

Installation of Pipes and Fittings.............................................................. 6

Inspection, Testing and Certification...................................................... 7

Registration................................................................................................ 8

Backfill......................................................................................................... 8

Application

All installations are to be in accordance with the arrangements shown inthe typical examples – see section 10, Installation Examples.

KPS Multi-layer lined (KP-E), Multi-layer lined Conductive (KP-EC) orSecondary Contained lined (KP-SC) can be used in all fuel systemapplications. For product descriptions see section 3,Product Descriptions.

Arrangement of Pipes

Pipes must be installed on a bed of at least 150 mm of pea gravel

(0 – 22 mm). Stones or sharp objects must not come into contact with the pipe.

Pipes must be laid on a gradient of at least 1% falling back to the tankunless otherwise specified by the inspecting authority. In vapourrecovery lines it is essential to prevent the accumulation ofcondensate in pipe dips and to avoid trapping vapour in lowsections or forming vapour locks.

Where two or more pipes run in a trench the minimum

clearance between adjacent pipes is 100 mm.

The minimum clearance between a pipe and the side of atrench is 200 mm.

Pea gravel Ø 0–22mm

100 mm

150 mm

200 mm

Top fill (dug up material)

300 mm

Asphalt or other pavement


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Allowance is to be made for the thermal expansion of pipes. The

expansion coefficient is 0.2% per 10K (10ºC or 18ºF). Wherever possible pipes should be laid in slow curves to absorb thermal expansion.

The minimum bend radii for curved pipes are:

Min bend Radius (mm)

KP 25 500KP 32 640KP 54 1080

KP 63 1260KP 75/63 1500

KP 90 1800KP 110 2200KP 125/110 2500

KPS recommends that KP 90, KP110 and KP125/110 are handled asstraight pipes only.

Pipes and fittings may only be cut within the limits given in section 5,Cutting.

Where conductive piping is installed the system must be connected to

earth at every point where the piping ends with a fitting type KP C11,KP C12, KP 5, KP 6 or KPW. The earth cable shall have an area of at

least a 6 mm2 and a maximum resistance to earth of 10 ohms. It can be

connected to an earthing point at the dispenser, the steel tank or by anearth rod driven into the ground, not less than 1500 mm deep. See alsoInspection, testing and certification later in this section.

KPS recommends that fill pipes be installed with conductive pipe(ground to earth) in order to avoid the risk of problems related to

electrostatic discharges.

Installation of Pipes and Fittings

HandlingAll materials should be stored in the original packing until required. Thesurface of the storage area shall contain no sharp objects. For otherrequirements see section 4, Handling.

CuttingAll pipes and fittings should be cut using KPS approved cutting tools.Contact the KPS office for product details. For other requirements see

section 5, Cutting.

Welding

All welding should be undertaken using a KPS approved weldingmachine and welding fixtures. For other requirements see section 6,Welding.


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Metallic Connectors Never bury metallic fittings directly in soil without applying proper and

extra corrosion protection.

Pressurised Pipe System

Special attention must be paid to the installation of pressurised systems.

Direct burial with backfill in accordance with this manual is strongly

recommended. The use of an outer “chase” or duct pipe around thesystem is not recommended.

KPS strongly recommends that pressurised systems with secondarycontainment be equipped with a leak detection system.

An adequate and cost effective alternative is when the interstitial space is

filled with water (when necessary mixed with anti-freeze agent). When amanometer is applied (set to 0 bar) a continuous check can be performedat regular intervals. A change in pressure indicates the systems needs to be checked for functionality.

The interstitial space of a secondary contained system must always be

sealed using KP T-fittings at both ends and the ends is best accessible inthe chambers at both ends of the system.

The fixation of the piping system is extra important in pressurisedsystems. If the piping system is not thoroughly fixed the operating

pressure and hammer effects (of up to 12 Bar) that occur duringoperation can damage the system.

The use of KPS flexible hoses under the dispenser is recommended and

steel pipe risers shall not be used. Rigid risers in a flexible system maydamage the shear valve.

For proper design of pressure systems always consult KPS for specific

advice.

Inspection, Testing and Certification

Pressure TestingOn completion of all work on the piping but before any backfilling isundertaken the system is to be pressure tested in accordance with the

requirements of section 7, Pressure Testing.

Testing Conductive Pipes and ComponentsFor conductivity testing, see section 11, Conductivity Test Instructions.


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All KPS products 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 to provide a minimum of 10-cm free space on either side of

every pipe.

All pipes have been installed on a smooth, more than 10-cm, thick, bed of pea gravel (0-22mm).

All KPS pipes were cut squarely with KPS recommended pipe cutters, not a hacksaw.

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

expansion and contraction.

All pipe-ends were dry and thoroughly cleaned with emery cloth and acetone before welding.

All welding sockets have been signed and welded in accordance with the KPS installation

manual.

Pressure Test has been performed in accordance with the KPS Installation manual and no leaks

were detected.

All parts in the pipe work system are KPS products or products distributed by KPS and were

installed in accordance with the KPS installation manual.

All refilling material consists of fine gravel (less than 22 mm) and the refilling has been

performed according to KPS installation manual.

Installing Contractor acknowledges that the warranty will be void unless a Certified Installer, i.e.

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

Conductivity test on all pipes is performed according to the KPS manual (applies only when KPS

conductive pipes are used).

____________________________________ ___________________________________Certified Installer (signature and company name) Installing Contractor (signature and company name)

____________________ ____________ _______________________ ___________Print Name Date Print Name Date

KPS Petrol Pipe System

Installation Checklist

TO BE COMPLETED BY THE INSTALLING CONTRACTOR AND TO BE FILED BY THE DISTRIBUTOR

DURING THE WARRANTY PERIOD

Installing Contractor information:

Installer: ______________________________

Address: ______________________________

______________________________

Phone: ______________________________

Contact: ______________________________

Site Information:

Owner: ______________________________

Site address: ______________________________

______________________________

Phone: ______________________________

Contact: ______________________________


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KPS System Manual – Version 6.1 3. PRODUCT DESCRIPTIONS

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3. PRODUCT DESCRIPTIONS

KPS Petrol Pipe System™ Product Range........................................... 10

Fittings and Accessories.......................................................................... 11

Tools.......................................................................................................... 11

KPS Petrol Pipe System™ Product RangeThe KPS Petrol Pipe System™ product range comprises three classes of

polyethylene pipes and the associated fittings:

• Multi-layer lined pipe

• Multi-layer lined conductive pipe

• Secondary Contained lined pipe

In general pipes are joined together and fittings are joined to pipes byelectrofusion welding. Fittings are supplied with moulded-in heatingelements. Mechanical joints and fittings and fittings for polymer to metal

transition are included in the range.

KPS also supplies the cutting and welding equipment required to ensurethat installation work can be carried out correctly and efficiently.

Multi-layer Lined and Secondary Contained Lined Pipe (KP-E)The Multi-layer lined pipe has several layers. The innermost layers forma permeation barrier. The outer layer is of strong polyethylene to providestrength and resistance to puncturing. It is used to contain the flow ofliquid fuels.

To provide additional security the multi-layer lined pipe can be inserted

in a further polyethylene pipe to provide a secondary contained lined piping system.


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KPS System Manual – Version 6.1 3. PRODUCT DESCRIPTIONS

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Multi-layer Lined Conductive Pipe (KP-EC)This is multi-layer lined pipe with an additional conductive inner layer.

The system provides for all pipe surfaces in contact with the liquid to begrounded to earth.

This pipe is used to contain the flow of liquid fuels and to prevent the

accumulation of static electricity thereby avoiding the risk of sparking.

Secondary Contained Lined Pipe (KP-SC)This system is used to contain the flow of liquid fuels but providesadditional environmental protection and the possibility to monitor thewhole system for leakage.

Multi-layer lined pipe (primary pipe) is enclosed in a larger polyethylene pipe (secondary pipe). A controlled, interstitial space is provided between the primary and secondary pipes and specially developedfittings ensure that continuity is maintained in this space throughout the

system, which enables monitoring with a leak detection device.

Fittings and Accessories

For each of the above classes there is a comprehensive range of fittingsand accessories to make up a complete piping system.

The range of sizes and the relevant fittings are listed on the following pages under Product specification references.

Detailed descriptions, material properties and dimensions are given in

the KPS Product Reference Manual, a separate publication availableelectronically upon request.

ToolsKPS supplies special tools for cutting and welding all of the above pipesystems. The tools are listed with further details in the KPS ProductReference Manual issued electronically and available upon request.


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KPS System Manual – Version 6.1 4. HANDLIN G

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4. HANDLING

Introduction.............................................................................................. 12

Transportation......................................................................................... 12

Loading and Unloading............................................................................ 13

Releasing Coils.......................................................................................... 13

On site: Storing the Pipe......................................................................... 13

Summary of Handling and Storage Requirements..............................15

Introduction

All components in the KPS Petrol Pipe System™ are of the highestquality, resilient and are easy to handle. However care must always betaken to avoid damage to the pipe surfaces during transport, handling andstorage.

Transportation

• Pipes and ancillary fittings for the KPS Systems are delivered in protective packaging to avoid any damage during transportation.Deliveries should be made on a flat bed vehicle, free from any sharpobjects.

• When loading pipes, racks or coils onto the truck, make sure that theracks and coils are stacked in a proper way.

• Pipes/Coils should not protrude from the surface on which they areloaded.

• Pipe/Coils should be set down horizontally onto the truck bed, useropes or similar equipment to harness the load.


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• Straight lengths are packed in wooden racks. Always keep the pipesin the racks until required for installation. Alternatively, stack themin a pyramid, not more than three metres high, with the bottom layer

fully restrained by wedges. If possible, the bottom layer of pipesshould be laid on timbers, at approximately one metre centres, to protect the pipes from sharp objects etc.

• Bundled packs of pipes should be stored on clear, level ground,supported by timbers. Never stack the bundles more than three

metres high.

• Always store pipes, coils on firm, level ground, able to withstand theweight of the pipes and lifting gear and devoid of sharp objects.

• Never store KPS Pipes without end caps and in direct exposure tosunlight.

IMPORTAN T NOT ICE

Exposure to UV rays from the sun may damage the lining.

Trucks or heavy plant equipment running over pipes can cause internaldamage. Deep scratches, more than 10%of the wall thickness, or markson the outside will weaken the pipe and are grounds for invalidating theguarantee.

Small ancillary fittings and sockets are delivered in plastic bags, withinboxes. Upon arrival at site, all boxes and materials should be checkedfor signs of damage. All fittings and sockets should be kept in the plasticbags until ready for use. The plastic bag protects the fittings and socketsfrom contamination and oxidation.

Coiled pipe should be unrolled and straightened the day before use forrelaxation and easier handling.

During cold conditions coiled pipe should be pre-heated to roomtemperature for easier handling.


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Summary of Handling and Storage Requirements

ALWAYS

• Use wide, non-metallic, slings for lifting materials (i.e.Polypropylene or Nylon).

• Store pipes on flat, firm ground, able to withstand the weight of thematerials and lifting gear.

• Keep pipes and fittings well away from sharp objects and intenseheat.

• Keep protective packaging intact until materials are required for use.

• If surface damage exceeds 10% of the material thickness, thedamaged section should be rejected.

• Under cold conditions, pre-heat coiled pipe to room temperature.

• Store pipes under cover.

NEVER

• Throw/drop pipes or fittings from delivery vehicle.

• Use metal slings, hooks or chains when handling pipes.

• Drag or roll individual pipes, bundles or coils.

• Stack bundles more than three metres high.

• Release coils carelessly

• Expose pipes or fittings to prolonged sunlight.


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KPS System Manual – Version 6.1 5. CUTTING

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5. CU TT ING

Introduction.............................................................................................. 16

Cutting Tools............................................................................................ 17

Cutting Single Pipes................................................................................. 17

Cutting Formed Bends............................................................................ 18

Cutting Secondary Containment Pipes................................................. 18

Cutting Secondary Containment Pipes................................................. 19

Cutting Secondary Containment bends................................................20

IntroductionTo ensure that the KPS Petrol Pipe System™ can be assembled correctlyit is important that the cutting of the pipes and fittings are to the requiredlength and that preparation is carried out in accordance with KPS

procedures. To ensure a high quality joint, it is important that the pipesare cut square. Only then can the cut end be properly joined to other parts in the KPS Petrol Pipe System™.

Cutting is best achieved by the use of a KPS pipe cutters. These toolsgive a clean and square cut without burrs.

IMPORTAN T NOT ICE

Do not cut the pipe with a saw-edged blade.

The following cutting instructions explain the type of cutting tools thatcan be used, how to use them, restrictions and important measurements

when cutting KPS components.

It is important to note that formed products in the KPS System must not

be cut too close to the curved section, as this will prevent them fromfitting correctly into the welding fitting.

In the Secondary Containment System, the inner pipe has to protrude a

specified distance beyond the outer pipe to suit both welding areas in theKP- 2 SC and KP-T SC welding sockets. Further details are given below

in ‘Cutting Secondary Containment Pipes’.


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Cutting Tools

Cutting ScissorsThe KPS cutting scissors can cut KP pipes up to 63 mm diameter. They

are fast and reliable and ensure a clean and square cut.

(Spare blades are available from your KPS Petrol Pipe System™distributor.)

Rotating Pipe CuttersThe KPS rotating pipe cutter is for pipe diameters 48 mm to 125 mm.

These pipe cutters are the most reliable tools for ensuring a clean, squarecut without deformation of the roundness of the pipe.

(Spares are available from your KPS distributor.)

Cutting Single Pipes

When cutting single wall pipes, make sure that the pipe ends are cut

squarely. Preparation, careful handling and correct application of thecutting tools will ensure a square and clean cut that is the basis of aquality weld.

Scissors:When cutting, position the scissors with one blade on top of the pipe andmove them forward until they make contact with the pipe. Check that thehandles are square to the pipe and that the blades line up square. Then

proceed with the cutting.

Rotating Pipe Cutters:To operate, depress the release nut and open the cutter. Place it with therollers under the pipe, bring the cutting wheel into contact with the pipeand turn the cutting wheel feed knob clockwise half a turn after thecutting wheel brushes against the pipe. Rotate the cutter twice around the pipe and then, for each further revolution, turn the knob about 20º to press the cutting wheel further into the pipe. Repeat until the cut has

been completed.


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Cutting Formed Bends

The bends are formed from KPS multi layer pipe, KP-E or KP-EC.KP 3- F/FC; KP 3- FL/FCL must not be cut too close to the curved

section see illustration below.

90° Bends, Formed Bends KP 3On either side of the bent section, the length from the elongation of onestraight leg to the cut on the other straight leg must be of minimumdimensions shown below:

Prod nr ± A B min length

KP 3-54 54 320 mm

KP 3-63 63 330 mmKP 3-90 90 390 mmKP 3-110 110 450 mm

45° Bends, KP 4These bends must not be shortened.

B min


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Cutting Secondary Containment Pipes

Cutting Secondary Containment Pipes for Use With KP-2 SCWelding SocketsThe Secondary Containment (SC) pipes have to be cut with the inner pipe protruding from the outer pipe to allow correct fitting of the KP 2-SC integrated welding socket. This is where both the inner and outer

pipes are welded in one operation.

The black inner pipe shall be longer than the green outer pipe in

accordance with the illustrations to the right.

Measure the insert depth of the fitting and cut so that it corresponds with

the protruding primary pipe.

Cutting Secondary Containment pipes for use with KP T75/63SCtransition fittingWhen the KP T75/63 SC integrated transition fitting is used, the blackinner pipe must be even longer to allow space for accommodating asingle pipe KP 2-63 welding socket outside the KP T75/63 SC fitting.See drawing below illustrating the minimum lengths.

Minimum length:

75/63SC L=130 mm

IMPORTAN T NOT ICE

Joining two primary pipes using a KP T75/63SC is not allowed!

L

KP 125/110SC

A

A= Insert depth of fitting

KP 75/63 SC

A


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Cutting Secondary Containment Pipes for Use with KPT125/110SC-L Transition FittingWhen the KP T125/110SC-L integrated transition fitting is used it is possible to make a joint inside the fitting. See drawing below.

Cutting Secondary Containment bends

90° bends, KP 3-SCBends must not be cut too close to the curve.

On either side of the bent section, the length from the elongation of one

straight leg to the cut on the other straight leg must be of minimumdimensions shown below:

Dimensions on illustration to the right:

Product no. B-minKP 3-125/110SCEC 450 mm

KP 3-75/63SCEC 330 mm

Measure the insert depth of the fitting and cut so that it corresponds withthe protruding primary pipe.

45° bends, KP 4-SCThese bends must not be shortened.

B-min


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KPS System Manual – Version 6.1 6. WELDING

6. WELDING

Introduction.............................................................................................. 12

Transportation......................................................................................... 12

Loading and Unloading............................................................................ 13

Releasing Coils.......................................................................................... 13

On site: Storing the Pipe......................................................................... 13

Summary of Handling and Storage Requirements..............................15

IntroductionThis is a general instruction for welding KPS pipe designs and welding

fittings. Due to the hazardous area where the welding procedure takes

place, please note:

WARNING

Do not weld where there is risk of flammable liquids or vapours.Always ensure that petrol or petrol vapours have been completelyremoved before welding.

Preparation for welding of the pipes and fittings is extremely important.

All loose dirt or surface contamination should be removed using a lintfree cloth or paper towel. Surface oxidation should be removed from the pipe over the entire area that is to be welded. This is an essential procedure and should be achieved by abrading the fusion area withemery cloth.

IMPORTANT NOT ICE

Do not use sandpaper as a substitute for emery cloth.


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The welding fitting should be removed from its packing and checked that

it is clean. It should not be touched, abraded or come into contact withcontaminated material such as silicones, lanoline from human skin orother greasy substances. Use a cloth moistened with acetone to wipeclean the prepared pipe, fitting and the bore of the welding fitting.

For detailed information on how to use the welding machine,

see section 9, Pipe Welding Machine.

The Process

Polyethylene pipes and fittings in the KPS system are joined byelectrofusion welding. The method is suitable for use on an installationsite, because it is not sensitive to weather conditions. However, all jointsmust be kept dry and clean during the welding process.

The ambient temperature when welding can be between -15ºC and +45ºC(-5ºF and +110ºF). The lower temperatures are applicable only undercalm, protected conditions.

The principle of electrofusion welding is that a resistance wire just below

the inner surface of the welding fitting is heated to a temperaturesufficient to melt the PE (polyethylene) material on the outside of the

pipe and on the inside of the fitting. The temperature reaches about200ºC. Heat transfer in the polyethylene is slow and only the material inthe vicinity of the wire is melted. The polyethylene expands duringheating and the pressure in the fusion area increases as the surrounding

cold material prevents the melt from expanding. Thus, a homogenousand strong fusion weld is created.

The power, energy and welding times are automatically calculated andapplied when KPS welding machines are used. Other welding machines

must not be used.

Preparing the Weld

Before starting the pipe jointing process, check that the designspecification of the piping conforms to the KPS installation instructions.

See section 2, General Requirements and the Cutting Instructions in

Section 5, Cutting.


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Welding Single Wall Pipes

Check that the ends are square and without burrs. If necessary use adeburring tool or a knife to chamfer the pipe bore and remove anyexternal burrs. Check that the pipes and fittings have been cleaned.

Check that the products have not been damaged during transportation orhandling.

Arrange the pipes so that they are approximately in line and push themuntil they meet. Place the welding fitting alongside where the two pipesmeet. Mark each pipe where the fitting ends and renew the mark if itfades or is erased during the subsequent stages.

Thoroughly clean the outer surface of each pipe by roughing from the

mark back to the pipe end. Use emery cloth, about 120-180 grit. Do not

use sandpaper.

IMPORTANT NOT ICE

Make sure the surfaces are kept clean and dry. Protect with plasticsheeting whenever necessary.


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Clean the outside of the pipe and the inside of the fitting with a clean

cloth moistened with acetone.

Connect the fitting onto the pipe and push it firmly to the bottom of the

socket.

IMPORTANT NOT ICE

Always ensure that the pipe/pipes are pushed to the bottom of thefitting.

IMPORTA NT NOT ICE C ONDUCT IVE SYSTEMS

When the KPS Multi-layer lined conductive pipe is being used a KPCCconnector must at all times be fitted in all pipe joints as well as betweenall pipe ends and end fittings. This is crucial to ensure the continuity ofthe electrical connection throughout the pipe system.

The electrical continuity must be tested on all conductive pipelinesystems according to the KPS Installation Manual before the stationcommences service.

Push the pipe ends into the bottom of the welding socket. Mark on both pipes the outer ends of the fitting. After welding both of these marks

must still be close to the socket ends.

Clamp both pipes into the welding fixture, so that they cannot moveduring the welding process.

Connect the welding machine to the welding fitting with the appropriate

welding cable.


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IMPORTANT NOT ICE

Only cables supplied by KPS can be used with KPS welding machines.

Ensure that the dimensions of the cable connector and the pin size ofthe welding socket conform.

After welding, remove the cables with care to avoid damage on theconnectors.

Start the welding process and follow the procedures for the weldingmachines as appropriate.

When the welding has been completed, check that the welding machine

indicates a correct weld.

Sign or mark the fitting to indicate that it has been welded and checked.

Wait at least 20 minutes or until the socket has cooled off to bodytemperature before removing the clamping fixture. Normally after 2hours the weld has reached its full strength.

Testing of the welded joints should take place after the whole installationhas been completed.

Welding Secondary Contained pipes, KPT-fitting

To ensure satisfactory welds in both inner and outer pipes in the KPSSecondary Containment System it is important to ensure that the inner pipe is located in its correct position inside the welding fitting.Therefore, these instructions should be followed to make the weldingeasier and to produce high quality welds.

Always start the installation of a Secondary Contained System within asump or a fixed position.


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With the KPT integrated transition fitting the inner and outer pipes are

fixed relative to each other.

After cutting back the outer pipe to fit the entry boot, roughen the fusionarea surfaces on both the inner and outer pipes with emery cloth (the

entire area must be abraded) over the following lengths:

Cleaning length:

125/110SC outer pipe 60 mminner pipe 70 mm

75/63SC outer pipe 30 mm

inner pipe 40 mm

Clean the roughened area and the inside of the fitting using a clean clothmoistened with acetone.

Weld the KP T- SC fitting to the pipes. (Note that the illustration to theright shows the installation of a KP T75/63SC.)


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Weld the KP 2 fitting to the pipe.

When the welding has been completed, check that the welding machineindicates a correct weld.

Sign or mark the fitting to indicate that it has been welded and checked.

Pay careful attention not to apply any force to the fitting or pipe duringthe welding process. After 2 hours the weld has reached its full strength.

Testing of the welded joints should take place after the whole installation

has been completed.

IMPORTANT NOT ICE

Under hot conditions, there may be a need to adjust to longer coolingtimes before removing the fixture in order to obtain a proper weld.


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Welding Secondary Contained Pipes, KP2 SC-fitting

Always start the installation of a Secondary Contained System within asump or a fixed position.

To join two lengths of SC pipe use a KP 2- SC integrated weldingsocket. Start with the fixed pipe and cut back the outer pipe as follows:

Cutting lengths:

125/110SC 65 mm

75/63SC 40 mm

Roughen the surface and clean as described previously in Welding

Single Wall Pipes.

Connect the welding fitting onto the fixed pipe and ensure that the outer pipe is pushed to the bottom of the fitting. Because the inner and outer

pipes are now integrated, the inner pipe will also be pushed to the bottomof the fitting.

Prepare the opposite SC-pipe to be inserted into the fitting by markingthe inner and outer pipe lengths that shall be inserted into the fitting (see

drawing). Roughen the surface and clean as described previously inWelding Single Wall Pipes. Note the restrictions valid for KP 3- SC andKP 4- SC bends in section 5, Cutting.

Marking lengths on inner pipe a):

KP 2-125/110SC 120mmKP 2-75/63SC 75mm

Marking lengths on outer pipe b):

KP 2-125/110SC 55mmKP 2-75/63SC 35mm

a

b


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Fit the opposite pipe into the fitting. Start with the inner pipe and push it

fully into the bottom of the socket so that the marking matches the edgeof the fitting (illustration).

Continue with the outer pipe and push it fully into the bottom of thesocket so that the marking matches the edge of the fitting

(see illustration).

IMPORTANT NOT ICE

When certain that the pipes are fully inserted, clamp the pipes into theclamping fixture to ensure that the pipes will not move out of thewelding fitting. Attach the welding cables and weld in accordance withthe instructions in ÂWeldingÊabove.


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KPS System Manual – Version 6.1 7. PRESSURE TESTING

7. PRESSURE TESTING

Introduction.............................................................................................. 30

Single Wall Systems................................................................................ 30

Secondary Containment Systems.......................................................... 31

Introduction

Pressure testing of the system is vital to ensure the system performance.

The purpose of the pressure test is twofold: To test the strength of the piping system and to detect potential leakage.

All pressure testing must be undertaken by and in the presence of a KPScertified installer.

Pressure tests are undertaken after completion of all assembly and

welding but before any backfilling takes place.

WARNING

When using air to pressure test the system make sure to take allnecessary actions to avoid air blowouts. All personnel must keep asecure distance from the system when pressure is applied. High-pressure air contained in a pipe creates a substantial force that couldcause an air blow-out in case of failure.

Single Wall Systems

Primary (inner) Pipe Pressure Test:Pressurise primary non-pressure and pressure lines with water, air or gas

to 520 kPa (5.2-bar, 75PSI) and maintain pressure for 5 minutes. Thistest is to ensure the strengths of the piping system.

Primary (inner) Pipe Leakage Test:Reduce the pressure back to zero, then take it up to 70 kPa (0.7 bar, 5 psi) for 30 minutes. During this period test all fittings by applying soapsolution over the joints. Air bubbles indicate leakage. This test is purely

to detect possible leakage.


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KPS System Manual – Version 6.1 7. PRESSURE TESTING

31

Secondary Containment Systems

Secondary (outer) Pipe Pressure Test:Always perform pressure test on the secondary (outer) pipe first.Pressurise the interstitial space with water, air or gas to 520 kPa (5.2 bar,75 psi) and maintain pressure for 5 minutes. This test is to ensure thestrengths of the piping system.

Secondary (outer) Pipe Leakage Test:Reduce the pressure back to zero then take it up to 70 kPa (0.7 bar, 5 psi)for 30 minutes. During this period test all fittings by applying soapsolution over the joints. Air bubbles indicate leakage. This test is purelyto detect possible leakage.

Primary (inner) Pipe Pressure Test:Remove the valve caps on the KP T-fittings prior to pressure testing the

primary (inner) pipe. Then pressurise the primary pipe with water, air orgas to 520 kPa (5.2 bar, 75 psi) and maintain pressure for 5 minutes. Thistest is to ensure the strengths of the piping system.

Primary (inner) Pipe Leakage Test:Take the pressure back to zero, then take it up to 70 kPa (0.7 bar, 5 psi)for 30 minutes. During this period test all fittings by applying soap

solution over the joints. Air bubbles indicate leakage. Put the valve caps back on the KP T-fittings.

IMPORTANT NOT ICE

The pressure may vary slightly during a leakage test. This may be due tosome movement of the piping system. The pressure may vary by up to4 kPa (0.04 bar, 0.6 psi) during a leakage test without indicating leaks.


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KPS System Manual – Version 6.1 8. BAC KFILL

32

8. BACKFILL

Backfill....................................................................................................... 32

BackfillBackfilling may be undertaken only after satisfactory completion of pressure testing and after approval by the KPS certified installer.

Proper backfill supports the pipe system and protects it from mechanicaldamage and handles the effects of heavy traffic or other loading imposed

on the pipe system.

The depth of the top depends on the top paving. With pavement ofreinforced concrete it is possible to reduce the top layer to 150 mm butwith other pavement such as asphalt, the top layer must be at least 300mm.

The space within 150 mm of the pipe shall be filled with pea gravel 0 – 22mm. Do not compact material immediately on top of the pipe,

compacting should be done in 150 – 200 mm layers on both sides.

On top of the gravel, it is usually possible to fill with the previously dugup material, but with heavy stones removed. See drawings below.

IMPORTANT NOT ICE

Improper backfill may damage the pipe!

Never install the KPS flexible piping in a contaminated soil.

Pea gravel Ø 0–22mm

100 mm

150 mm

200 mm

Asphalt or other pavementTop fill (dug up material)

300 mmPea gravel Ø 0–22mm 150 mm100 mm

Concrete reinforced


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KPS System Manual – Version 6.1 9. PIPE WELDING MACHINE

33

9. PIPE WELDING MAC HINE

General Information................................................................................ 33

General Information

KPS welding sockets are welded using a constant current. The energyinput is controlled by the voltage applied to the socket and the weldingtime. Before welding is started, the resistance in the socket wire ismeasured and, using the measured value, the welding machineautomatically calculates and applies the required energy for proper

welding.

The machine also takes into account the ambient temperature andautomatically adjusts the amount of energy required. Therefore themachine should always be placed close to the welding socket to attainthe same temperature. If the machine is moved from one place to another

with a large difference in temperature, the machine should be given atleast 30 minutes to adjust to the correct working conditions. Thetemperature sensor is attached to the rear (bottom left) of the machine, incontact with the steel frame.

For further information and details regarding the KPS welding machinesrefer to the product manuals delivered with the product.


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KPS System Manual – Version 6.1 10. INSTALLATION EXAMPLES

34

10. INSTALLA TIO N EXAMPLES

Introduction.............................................................................................. 34

Off-Set Fill Systems................................................................................. 35

Delivery Systems...................................................................................... 40

Tanks Venting System............................................................................. 50

General Layouts....................................................................................... 50

General Layouts....................................................................................... 51

Introduction

KPS has considerable experience in the application of its pipes andfittings. The drawings included in this section show the KPSrecommended solution for all applications at filling stations.

Installers should note that in addition to complying with the informationgiven on these drawings all installations must conform to the KPS

General Requirements (section 2).

The drawings are organised in the following sections

Filling Systems (from KPS-INST- 1)

Delivery Systems (from KPS-INST-11)Ventilation Systems (from KPS-INST-25)General Layouts (from KPS-INST-30)


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35

Off-Set Fill Systems

KPS-INST-1

Termination of a Single Walled polyethylene off-set fill pipe, within thetank chamber line. Connect to threaded steel pipe for entry into the tank.Components type:

1: KP C11 (Termination fitting)

2: KP2 (Welding Socket)3: KPM (Entry boot)4: Lined Pipe (Single Wall)

1 432


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36

KPS-INST-2

Termination of a Single Walled polyethylene off-set fill pipe withflanged connection, within the tank chamber liner. Connect to steelflange for entry into the tank. Components type:

1: KP7 (Gasket)2: KP5 (Stub flange)3: KP6 (Steel flange)4: KP2 (Welding socket)

5: KPM (Entry boot)6: KP-E (Lined Pipe)

1 432 5 6


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37

KPS-INST-3

Termination of a Secondary Contained polyethylene off-set fill pipe,within the tank chamber liner. Connect to threaded steel pipe for entryinto the tank. Components type:

1: KPC11 (Termination fitting)2: KP2 (Welding socket)3: KPT-SC (Transition fitting)4: KPM (Entry boot)

5: KP-SC (Secondary contained pipe)

1 432 5


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38

KPS-INST-4

Alt 1: Tank side termination of a Secondary Contained polyethylene off-set fill pipe with flanged connection, within the tank chamber liner.Connect to a steel flange for entry into the tank. Components type:


5: KPT-SC (Transition fitting)6: KPM (Entry boot)7: KP-SC (Secondary contained Pipe)

1 432 5 6 7


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39

KPS-INST-4

ALT 2: Termination of a Secondary Contained polyethylene off-set fill pipe with flanged connection, within the tank chamber liner. Connect tothreaded steel pipe for entry into the tank. Components type

1: KPC 12 (Complete Steel flange with threaded connection, stub flangeand gasket)

2: KP2 (Welding socket)3: KPT-SC (Transition fitting)

4: KPM (Entry boot)5: KP-SC (Secondary Contained Pipe)

14 35 2


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40

Delivery Systems

KPS-INST-11

Alt 1: At the tank top. Connection to a Secondary Contained polyethylene pipe, from the tanks threaded steel delivery pipe. Thenexiting the tank chamber liner. Components type:

1: KPC12 (Termination flange, complete with gasket, stub-flange and

bolts)2: KP2 (Welding socket)3: KPT-SC (Transition fitting)4: KPM (Entry boot)

5: KP-SC (Secondary Contained Pipe)

1 432 5


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41

KPS-INST-11

Alt 2: At the tank top. Connection to a Secondary Contained polyethylene pipe, from the tanks threaded steel delivery pipe. Thenexiting the tank chamber liner. Components type:

1: KPC 11 (Termination fitting)2: KP2 (Welding socket)3: KPT-SC (Transition fitting)4: KPM (Entry boot)

5: KP-SC (Secondary Contained Pipe)

1 432 5


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42

KPS-INST-12

Alt 1: At the tank top. Connection to a single wall polyethylene pipe,from the tanks threaded steel delivery pipe. Then exiting the tankchamber liner. Components type:

1: KPC12 (Termination flange, complete with gasket, stub-flange and bolts)

2: KP2 (Welding socket)3: KPM (Entry boot)

4: KP-E (Single wall lined pipe)

1 32 4


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43

KPS-INST-12

Alt 2: At the tank top. Connection to a single wall polyethylene pipe,from the tanks threaded steel delivery pipe. Then exiting the tankchamber liner. Components type:

1: KPC 11 (Termination fitting)2: KP2 (Welding socket)3: KPM (Entry boot)4: KP-E (Single wall lined pipe)

1 32 4


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44

KPS-INST-13

At the tank top. Flanged connection to single wall polyethylene pipework, from the delivery pipe tank flange. Then exiting the tankchamber liner. Components type:


5: KPM (Entry boot)6: KP-E (Single Wall Lined Pipe)

1 432 65


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45

KPS-INST-14

At the tank top. Flanged connection to Secondary Contained polyethylene pipework from the delivery pipe tank flange. Then exitingthe tank chamber liner. Components type:


5: KPT-SC (Transition fitting)6: KPM (Entry boot)7: KP-SC (Secondary Contained Pipe)

1 432 5 6 7


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46

KPS-INST-15

At the dispenser end. Entry of the single wall polyethylene pipework intothe dispenser sump. Tee off and convert to threaded steel pipe fordispenser entry. Primary polyethylene line to continue and exit the

dispenser sump. Components type:

1: KPC 11 (Termination fitting)2: KP2 (Welding socket)3: KP8-FCL (Tee connection long leg)

4: KPM (Entry boot)5: KP-E (Single Wall Lined Pipe)

1

4

3

2

5


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47

KPS-INST-16

At the dispenser end. Entry of the single wall polyethylene pipework intothe dispenser sump. Turn through 90º into the vertical and connect tothreaded steel pipe for entry into the dispenser. Components type:

1: KPC 11 (Termination fitting)2: KP2 (Welding socket)3: KP3-FCL (900 bend with long leg)4: KPM (Entry boot)

5: KP-E (Single Wall Lined Pipe)

14 3 25


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48

KPS-INST-18

At the dispenser end. Entry of the Secondary Contained polyethylene pipe into the dispenser sump. Tee off and terminate the secondarycontainment in the vertical plane. Connect the primary to threaded steel

pipe for dispenser entry. Continue the double containment, bridge formonitoring and exit the dispenser sump. Components type:

1: KPC 11 (Termination fitting)2: KP2 (Welding socket)

3: KP8-FCL (Tee connection long leg)4: KPT-SC (Transition fitting)5: KPM (Entry boot)6: KP-SC (Secondary Contained Lined Pipe)

1

4

3

2

5

6


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49

KPS-INST-19

At the dispenser end. Entry of the Secondary Contained polyethylene pipe into the dispenser sump. Terminate the secondary containment, turninto the vertical and connect to threaded steel pipe for entry into the

dispenser. Components type:

1: KPC 11 (Termination fitting)2: KP2 (Welding socket)3: KP3-FCL (900 bend with long leg)

4: KPT-SC (Transition fitting)5: KPM (Entry boot)6: KP-SC (Secondary Contained Pipe)

1 432 5 6


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50

Tanks Venting System

KPS-INST-25

Polyethylene vent pipe termination at the vent stack’s location.Protection of any part of the transition fitting from the concrete slab can be achieved by wrapping the area in ‘Denso’ tape. Components type:

1: KPC 11 (Termination fitting)

2: KP2 (Welding socket)3: KP3-FC (90

0 bend)

4: KP-E (Single Wall Lined Pipe)

1 432


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51

General Layouts

KP-INST-30

Example of layout for a suction system (split lines) with 4 tanks, 4 fueltypes, 4 dispensers, venting system with stacks and both stage 1b andstage 2 vapour recovery system.


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52

KP-INST-35

Example layout for a pressure system with 4 tanks, 4 fuel types, 4dispensers, venting system with stacks and both stage 1 and stage 2vapour recovery system.


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53

KP-INST-37

Secondary Contained off-set fill line, from the sump at the road tankerdelivery point, to the fuel tank top chamber liner. 90º and 45º bends usedto permit expansion and contraction.


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54

KP-INST-38

Secondary Contained off-set fill line, from the sump at the road tankerdelivery point, to the fuel tank top chamber liner. 90º bends used to permit expansion and contraction.


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KPS System Manual – Version 6.1 11. CONDUCTIVITY TEST INSTRUCTION

55

11. CO NDUC TIVITY T EST INSTRUCT ION

Conductivity Testing of KP-EC Pipes....................................................55

Conductivity Testing of KP-EC Pipes

KP-EC (Lined Conductive) is a multiple layer pipe lined on the inside

with an electrically conductive layer, that when ground to earth preventsspark ignition. To ensure electrical continuity in the conductive systemKPCC connectors must connect all components to each other.KP-EC is available in diameters 54, 63, 90 and 110 mm.

During installation the resistance shall be continuously measured in

order to check when maximum values are obtained or if the electricalconnection is broken. An insulation multimeter shall be used when performing the conductivity test. For more information regardingresistance measuring please refer to IEC 60093.

IMPORTANT NOT ICE

Testing shall be performed in a non-hazardous area free frominflammable liquids and vapours!

To obtain an accurate value, the insulation multimeter shall be read afterone (1) minute of 1000 V-applied voltage. Please note, due to the low

resistance in KP-EC pipes and fittings, it is sometimes necessary tomeasure with lower voltage than 1000 V to determine the exact

resistance in a circuit (KP-EC line).

Discharging of static electricityIf a plastic pipe (made of a conductive or dissipative material) is connected to earth, the build-up of static electricity is prevented.

Approved range Exceeded range

101 102 103 104 105 106 107 108 109 1010 1011 1012 1013 1014 1015

Conductive Dissipative Insulating

Maximum recommended resistance by KPS is 1x107. (10 MΩ)


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KPS System Manual – Version 6.1 11. CONDUCTIVITY TEST INSTRUCTION

IMPORTANT NOT ICE

KPS recommends that the maximum allowed surface resistance in one(1) circuit (KP-EC pipe) is 10 MΩ when using 1000 V.

When the test result in a circuit is between 0,01 – 10 MΩ this is adequateto ground the circuit (KP-EC pipe) to earth. This is necessary to avoidrisks of problems related to static electricity.

At occasions when the resistance is higher than 10MΩ, for example invery long fill or suction lines, it is necessary to ground the circuit to earthmore frequently. For grounding details please refer to BS 7430.

KPS Inst Manual Ver 6[1].1 Eng

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