~~ ~~

A P I PUBL*Lbb3C 95 0732290 0542277 580 D

Underground Storage Tank Installation

Exhibit Book

API PUBLICATION 1663C

JANUARY 1995

peratiou
7-

---underground

American Petroleum institute

1220 L Street, Northwest
Washington, D.C.20005

Strategies jor To,day i

Environmental Partnership 11)

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 API PUBL*i<Lbb3C 95 0732290 0542278 417 m

STEP

One of the most significant long-term trends affecting the future vitality of the petroleum
industry is the public’s concerns about the environment. Recognizing this trend, API mem-
ber companies have developed a positive, forward looking strategy called STEP: Strategies
for Today’s Environmental Partnership. This program aims to address public concerns by
improving industry’s environmental, health and safety performance; documenting perfor-
mance improvements;and communicating them to the public. The foundation of STEP is
the API Environmental Mission and Guiding Environmental Principles. API standards, by
promoting the use of sound engineering and operational practices, are an important means
of implementing MI’SSTEP program.

API ENVIRONMENTAL MISSION AND GUIDING

ENVI RONM ENTAL PR IN CI PLES

The members of the American Petroleum Institute are dedicated to continuous efforts to
improve the compatibility of our operations with the environment while economically de-
veloping energy resources and supplying high quality products and services to consumers.
The members recognize the importance of efficiently meeting society’s needs and our re-
sponsibility to work with the public, the government, and others to develop and to use nal-
urd resources in an environmentally sound manner while protecting the health and safety
of our employees and the public. To meet these responsibilities, MI members pledge to
manage our businesses according to these principles:
To recognize and to respond to community concerns about our raw materials, products
and operations.
To operate our plants and facilities, and to handle our raw materials and products in a
manner that protects the environment,and the safety and health of our employees and the
public.
To make safety, health and environmental considerationsa priority in our planning, and
our development of new products and processes.
To advise promptly appropriate officials, employees, customers and the public of infor-
mation on significant industry-related safety, health and environmental hazards, and to
recommend protective measures.
To counsel customers, transporters and others in the safe use, transportation and disposal
of our raw materials, products and waste materials.
To economically develop and produce natunl resources and to conserve those resources
by using energy efficientiy.
To extend knowledge by conducting or supporting research on the safety, health and en-
vironmental effects of our raw materials, products, processes and waste materials.
To commit to reduce overall emissions and waste generation.
To work with others to resolve problems created by handling and disposal of hazardous
substances from our operations.
To panicipate with government and others in creating responsible laws, regulations and
standards to safeguard the community, workplace and environment.
To promote these principles and practices by sharing experiences and offering assistance
to others who produce, handle, use, transport or dispose of similar raw materials,
petroleum products and wastes.

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I P U B L a L b b 3 C 95 0 7 3 2 2 9 0 0542279 353

Underground Storage Tank Installation

Exhibit Book

Manufacturing, Distribution and Marketing Department

API PUBLICATION 1663C
JANUARY 1995

American
Petroleum
Institute

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I PUBL*i<Lbb3C 95 m 0 7 3 2 2 9 0 O542280 075 m

SPECIAL NOTES

1. API PUBLICATIONS NECESSARILY ADDRESS PROBLEMS OF A GENERAL

NATURE. WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STATE,
AND FEDERAL LAWS AND REGULATIONS SHOULD BE REVIEWED.
2. API IS NOT UNDERTAKING TO MEET THE DUTIES OF EMPLOYERS, MANU-
FACTURERS, OR SUPPLIERS TO WARN AND PROPERLY TRAIN AND EQUIP
THEIR EMPLOYEES, AND OTHERS EXPOSED, CONCERNING HEALTH AND
SAFETY RISKS AND PRECAUTIONS, NOR UNDERTAKING THEIR OBLIGATIONS
UNDER LOCAL, STATE, OR FEDERAL LAWS.
3. INFORMATION CONCERNING SAFETY AND HEALTH RISKS AND PROPER
PRECAUTIONS WITH RESPECT TO PARTICULAR MATERIALS AND CONDI-
TIONS SHOULD BE OBTAINED FROM THE EMPLOYER, THE MANUFACTURER
OR SUPPLIER OF THAT MATERIAL, OR THE MATERIAL SAFETY DATA SHEET.
4. NOTHING CONTAINED IN ANY API PUBLICATION IS TO BE CONSTRUED AS
GRANTING ANY RIGHT, BY IMPLICATION OR OTHERWISE, FOR THE MANU-
FACTURE, SALE, OR USE OF ANY METHOD, APPARATUS, OR PRODUCT COV-
ERED BY LE'ITERS PATENT. NEITHER SHOULD ANYTHING CONTAINED IN
THE PUBLICATION BE CONSTRUED AS INSURING ANYONE AGAINST LIABIL-
ITY FOR INFRINGEMENTOF LETTERS PATENT.
5. GENERALLY, API STANDARDS ARE REVIEWED AND REVISED, REAF-
FIRMED, OR WIT"AT LEAST EVERY FIVE YEARS. SOMETIMESA ONE-
TIME EXTENSION OF UP TO TWO YEARS WILL BE ADDED TO THIS REVIEW
CYCLE. THIS PUBLICATION WILL NO LONGER BE IN EFFECT FIVE YEARS AF-
TER ITS PUBLICATION DATE AS AN OPERATIVE API STANDARD OR, WHERE
AN EXTENSION HAS BEEN GRANTED, UPON REPUBLICATION. STATUS OF THE
PUBLICATION CAN BE ASCERTAINED FROM THE API AUTHORING DEPART-
MENT [TELEPHONE (202) 682-8000]. A CATALOG OF API PUBLICATIONS AND
MATERIALS IS PUBLISHED ANNUALLY AND UPDATED QUARTERLY BY M I ,
1220 L STREET, N.W., WASHINGTON, D.C. 20005.

Copyright O 1995 American P d m Institute

i¡

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 ~ ~

A P I PUBL*KLbb3C 95 m 0 7 3 2 2 9 0 0542283 TO3

FOREWORD

API publication!; may be used by anyone desiring to do so. Every effort has been made
by the Institute to assure the accuracy and reliability of the data contained in them; however,
the Institute makes no representation, warranty, or guarantee in connection with this p u b
lication and hereby expressly disclaims any liability or responsibility for loss or damage re-
sulting from its ust: or for the violation of any federal, state, or municipal regulation with
which this publication may conflict.
Suggested revisions are invited and should be submitted to the director of the Manufac-
turing, Distribution and Marketing Department, American Petroleum Institute, 1220 L
Sweet, N.W., Washington, D.C.20005.

...
111

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 ~ ~

A P I PUBLXLbb3C 95 0732290 0542282 748

EXHIBIT 1

TYPE TYPE TYPE

STABLE SPECIAL A 6 WELL ROUNDED
ROCK CASE LOOSE SANG
ORIGINAL GRADE LEVEL

For protective systems, there are four options permissible by law: (if different options result in different slope
angles, you may use the steepest slope.)

1. Slope excavation at an angle not steeper than 1I R feet horizontal to 1 foot vertical and in
accordancewith Type C soil described in 29 CFR 1926.650-652,
Subpart P,Appendix B;
2. Slope excavation in accordance with the OSHA simplifiedsoil classification system and
Subpart P,Appendices A and B;
29 CFR 1926.650-652,
3. Use tabulated data sealed by a registered professional engineer in the state of the excavation
for the protective system design;
4. Use a site specific protective system design sealed by a registered professional engineer in the
state of the excavation.
Akhough Option Number 4 is probablythe most commonly used, the information provided below is
based on Option Number 2.
Maxlmum Allowable Slope (H:V) for Excavations
Soil or Rock Type Less Than 20 Feet Depth
Stable Rock Vertical 90 degrees
Type A Soil w 4 : 1' 53 degrees
Type B Soil 1:l 45 degrees
Type C Soil 11R:1 34 degrees

Type A: Cohesive soils with an unconfined compressive strength of 1.5 tons per square foot (ts9 or
greater. Examples of cohesive soils are clay, silty clay, sandy clay, clay loam, and, in some
cases, silty clay loam and sandy clay loam.
Type B: Cohesive soils with an unconfined compressive strength greater than 0.5 tsf but less than
1.5 tsf, or granular cohesionless soils induding angular gravel (similar to crushed rock), silt,
siiî loam, sandy loam, and, in some cases, sihy clay loam and sandy clay loam.
Type C: Cohesive soils with an unconfirmed compressivestrength of 0.5 tsf or less, or granular soils
including gravel, sand, and loamy sand.
Unstable soils are soils which have an unconfinedcompressivestrength of less than 750 psf.
*OSHA regulations allow a maximum slope of M:l under the following conditions:
1. The excavation is in Type A soil.
2. The excavation is not open for more than 24 hours.
3. The depth of the excavation is 12 feet or less.

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 ~~~

API PUBLxLbb3C 95 0732290 0 5 4 2 2 8 3 884

EXHIBIT 2

BACKFILL MATERIAL

6 FT,

I I
8 1
l i
I I

BACKFILL MATERIAL I/

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 ~

API PUBLXLbb3C 95 D 0 7 3 2 2 9 0 0 5 4 2 2 8 4 ïL0 D

EXHIBIT 3

QU'CK VALVES
COUP LER
AIR SOURCE i1J L 2

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 ___ ~ ~~~

A P I PUBL*lbb3C 95 0732290 0542285 b 5 7 M

EXHIBIT 4

c 3

a
>
t

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I PUBL*lbb3C 9 5 W 0732290 0 5 4 2 2 8 6 5 9 3

EXHIBIT 5A

>

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
-
-I=-
 A P I PUBL*Lbb3C 9 5 O 7 3 2 2 9 0 0 5 4 2 2 8 7 42T

EXHIBIT 5B

U
c
v)
W
t

+
an
/ss
W
c

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 ~
~

A P I PhlBL*llb63C 95 m O732290 0 5 4 2 2 8 8 3 6 6

EXHIBIT 6

SEALING METHODS

I GASKET I METALWASHER I O-RING

RISER

SECONDARY
PIPING
TYPE A

PRIMARY PIPE 9 THREADEDTEE

SOFT METAL
WASHER

FLEXIBLE PIPE PLASTIC GASKET

TYPE B

FLANGED FITTING
CO-EXTR UDE D CLAMP
SECONDARY PIPE

TYPE C

IVED
ANT

u COUPLING
SHANK

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I P U B L * L b b 3 C 95 D O732290 0542289 2 T 2

EXHIBIT 7

o-
W
v)
z

z
U

U
w
n
a

I
I "
(o

f
m

-I U

î
LI o w
-i>
ow
k-i
zn

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 =
~ ~~ ~

API PUBL*Lbb3C 75 0732270 0542270 TL4

EXHIBIT 8

ìEAL

/ I

ANNULAR HAND PLACE

SPACE GRAVEL
MONITOR BACKFILL
UNDER SUMP

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I P U B L U L b b 3 C 95 W O732290 0542293 950 m

EXHIBIT 9

... *-
5

. .... #

**
Ø

s
.... *

I
.
-
*. c
8
h
-1
~

w
a w
O=;

0
*
*
0
*

8
1 8
I 8
I 8
I 8
1 8
I 8
I
I

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I PUBL*lbb3C 95 W 0732290 0542292 897 =
EXHIBIT 1O

8
8 I
8 I
8 I
8 I
8 I
8 I
8
I
8
8 I
8 I

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I P U B L * % b b 3 C 95 = 0732290 0 5 4 2 2 9 3 723 m

EXHIBIT 11

LIP

>NNECTION

HYDROCARBON
ABSORBANT

FLEXIBLE BOOT

4 ' GA LVANIZED
PRIMARY RISER

-NPT THREADS

STEEL
~.
DEFLECTOR
PLATE
BYPASS
VALVE

8,,
er
i,\

:
1 (98% UST CAPACITY

(
FOR 8' DIAMETER TANK)

8% APPROX.
UST CAPACITY
FOR 8' DIAMETER TANK)

4' TO 6'
OR LOCAL CODE)

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I P U B L X L b b 3 C 95 0 7 3 2 2 9 0 O542294 bbT

EXHIBIT 12

u
CI)
z
\ u1
CI)

/
t-
I

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I PUBL*Lbb3C 9 5 0 7 3 2 2 9 0 0 5 4 2 2 7 6 432

1-01400- l/owc(3El

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I P U B L * l b b 3 C 95 0732290 0542295 5 T b

American Petroleum institute

1220 L Street. Northwest

Order No. 804-1663C

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I P U B L * L b b 3 C 95 0732270 0542297 379

Underground Storage Tank Installation

Workbook

API PUBLICATION 1663C

JANUARY 1995

i- peratiou

American Petroleum Institute

1220 L Street. Northwest
Washington, D.C. 20005

Strategies for Today?

Environmental Partnershzp 11’
COPYRIGHT American Petroleum Institute
Licensed by Information Handling Services
 A P I PUBL*Lbb3C 95 m 0 7 3 2 2 9 0 0 5 4 2 2 9 8 205 m

STEP

One of the most significant long-term trends affecting the future vitality of the petroleum
industry is the public's concerns about the environment. Recognizing this trend, AF'I mern-
ber companies have developed a positive, forward looking strategy called STEP: Strategies
for Today's Environmental Partnership. This program aims to address public concerns by
improving industry's environmental, health and safety performance; documenting perfor-
mance improvements; and communicating them to the public. The foundation of STEP is
the API Environmental Mission and Guiding Environmental Principles. API standards, by
promoting the use of sound engineering and operational practices, are an important means
of implementing API's STEP program.

API ENVIRONMENTAL MISSION AND GUIDING

ENVIRONM ENTAL PR INCIPLES

The members of the American Petroleum Institute are dedicated to continuous efforts to
improve the compatibility of our operations with the environment while economically de-
veloping energy resources and supplying high quality products and services to consumers.
The members recognize the importance of efficiently meeting society's needs and our re-
sponsibility to work with the public, the government, and others to develop and u) use nat-
ural resources in an environmentally sound manner while protecting the health and safety
of our employees and the public. To mcet these responsibilities, API members pledge to
manage our businesses according to these principles:
To recognize and to respond to community concerns about our raw materials, products
and operations.
To opcrate our plants and facilities, and to handle our raw materials and products in a
manner that protects the environment, and the safety and health of our employees and the
public.
To make safety, health and environmental considerationsa priority in our planning, and
our development of new products and processes.
To advise promptly appropriate officials, employees, customers and the public of infor-
mation on significant industry-related safety, health and environmental hazards, and to
recommend protective measures.
To counsel customers, transportersand others in the safe use, transportation and disposal
of our raw matcriais, products and waste materiais.
To economically develop and produce natural rcsources and to conserve those resources
by using energy efficiently.
To extend knowledge by conducting or supporting research on the safety, health anden-
vironmental effects of our raw materials, products, processes and waste materials.
To commit to rcducc overall cmissions and waste generation.
To work with others to resolve problems created by handling and disposal of hazardous
subslanccs from our operations.
To participate with government and others in creating responsible laws, regulations and
standards to safeguard the community, workplace and environment.
To promote thcse principles and practices by sharing experiences and offering assistance
to others who produce, handle, use, transport or dispose of similar raw materials,
petrolcum products and wastes.

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 API PUBLXlbh3C 95 m 0732290 0542299 141 m

Underground Storage Tank Installation

Workbook

Manufacturing, Distribution and Marketing Department

API PUBLICATION 1663C
JANUARY 1995

American
Pet roleum
Institute

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I PUBLXLbb3C 95 0 7 3 2 2 9 0 0542300 7 9 3

SPECIAL NOTES

1. API PUBLICATIONS NECESSARILY ADDRESS PROBLEMS OF A GENERAL

NATURE. WITH RESPECT TO PARTICULAR CIRCUMSTANCES,LOCAL, STATE,
AND FEDERAL LAWS AND REGULATIONS SHOULD BE REVIEWED.
2. API IS NOT UNDERTAKING TO MEET THE DUTIES OF EMPLOYERS, MANU-
FACTURERS, OR SUPPLIERS TO WARN AND PROPERLY TRAIN AND EQUIP
THEIR EMPLOYEES, AND OTHERS EXPOSED, CONCERNING HEALTH AND
SAFETY RISKS AND PRECAUTIONS, NOR U N D E R T m G THEIR OBLIGATIONS
UNDER LOCAL, STATE, OR FEDERAL LAWS.
3. INFORMATION CONCERNING SAFETY AND HEALTH RISKS AND PROPER
PRECAUTIONS WITH RESPECT TO PARTICULAR MATERIALS AND CONDI-
TIONS SHOULD BE OBTAINED FROM THE EMPLOYER, THE MANUFACTURER
OR SUPPLIER OF THAT MATJXIAL, OR THE MATERIAL, SAFETY DATA SHEET.
4. N ( Y ï " G CONTAINED IN ANY API PUBLICATION IS TO BE CONSTRUED AS
GRANTING ANY RIGHT,BY IMPLICATION OR OTHERWISE, FOR THE MANU-
FACTURE, SALE, OR USE OF ANY METHOD, APPARATUS, OR PRODUCT COV-
ERED BY LETTERS PATENT. NEITHER SHOULD ANYTHING CONTAINED IN
THE PUBLICATION BE CONSTRUED AS INSURING A"E AGAINSTLIABIL-
ITY FOR INFRINGEMENT OF LETTERS PATENT.
5. GENERALLY, API STANDARDS ARE REVIEWED AND REVISED, R E M -
FIRMED, OR WIT"AT LEAST EVERY FIVE YEARS. SOMETIMES A ONE-
TIME EXTENSION OF UP TO TWO Y E A R S WILL BE ADDED To THIS REVIEW
CYCLE. THIS PUBLICATION WILL NO LONGER BE IN EFFECT FIVE YEARS AF-
TER ITS PUBLICATION DATE AS AN OPERATIVE API STANDARD OR, WHERE
AN EXTENSION H A S BEEN GRANTED, UPON REPUBLICATION. STA'IZTS OF THE
PUBLICATION CAN BE ASCERTAINED FROM THE API AUTHORING DEPART-
MENT [TELEPHONE (202)682-8000]. A CATALOG OF API PUBLICATIONS AND
MATERIALS IS PUBLISHED ANNUALLY AND UPDATED QUARTERLY BY API,
1220L STREET, N.W., WASHINGTON, D.C.20005.

Copyright O 1995 American Petroleum institute

II

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 API PUBL*lbb3C 95 0732290 0542303 b 2 T

FOREWORD

API publications may be used by anyone desiring to do so. Every effort has been made
by the Institute to assure the accuracy and reliability of the data contained in them; however,
the Institute makes no representation, warranty, or guarantee in connection with this pub-
lication and hereby expressly disclaims any liability or responsibility for loss or damage re-
sulting from its use or for the violation of any federal, state, or municipal regulation with
which this publication may conflict.
Suggested revisions are invited and should be submitted to the director of the Manufac-
turing, Distribution and Marketing Department, American Petroleum Institute, 1220 L
Street, N.W., Washington, D.C.20005.

. .<

111

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 API PUBLaLbb3C 95 0732290 0 5 4 2 3 0 2 566

UNDERGROUNDSTORAGE
TANK INSTALLATION
CONTENTS PAGE

INTRODUCTION................................................................................... i

HOW TO USE THE PROGRAM MATERIALS....................................... iii

HOW TO USE THE SELF-TEACHING FRAMES.................................. v

SAMPLE FRAMES................................................................................ vi

Workbook Period 1................................................................................ 1

Workbook Period 2 ................................................................................ 17

Workbook Period 3 ................................................................................ 29

Workbook Period 4 ................................................................................ 53

Workbook Period 5................................................................................ 103

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I PUBL*lbb3C 95 = 0732290 0542303 4T2

INTRODUCTION

In surveys, the American Petroleum Institute and the U.S. Environmental Protection Agency have
determined that a great many of the problems with underground petroleum storage tanks don't just
"happen," but maybe the result of improper installation practices. This program provides you with
important information regarding proper tank installation practices as recommended by the American
Petroleum Institute (API), the Petroleum Equipment Institute (PEI), National Fire Protection Association
(NFPA), various equipment manufacturers, and the construction-related requirements of the
Occupational Health and Safety Administration (OSHA). The overall objective of the program is to help
all persons involved in the installation of underground storage tanks improve their ability to perform their
jobs safely and correctly.

The program covers five major subject areas:

1. Excavation.
2. Preinstallation handling and storage procedures.
3. Liners, anchoring, installation, and backfill.
4. Piping components and installation (including metal, FRP, and flexible systems).
5. Secondary containment, spill containment and overfill prevention, and release detection.
Before starting the program, read "HOW TO USE THE PROGRAM MATERIALS and "HOW TO USE
THE SELF-TEACHING FRAMES" on the following pages.

TURN TO THE NEXT PAGE AND READ THE

MATEU

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 API PUBL*Lbb3C 95 m 0732290 0542304 3 3 9 m

HOW TO USE THE PROGRAM MATERIALS

In this program you begin by watching the video portion of the program. This section runs about five
minutes. Then you turn to an exercise in the workbook when instructed by the narrator. The workbook
introduces you to new learning material and reviews what you learned in the video segment. Once
you have finished working and reviewing the material in the workbook, you will be given instructions to
view the next part of the videotape.

Going from the video material to the manual and then back to the video material again helps you
apply what you are learning. This instructional method also reinforces important information so that
you thoroughly understand one concept before moving on to the next.

Here is how instructions in the workbook are arranged:

INSTRUCTIONS TELLING YOU TO

TURN TEE PAGE, REFER TO ART-
WORK, OR WORK PROBLEMS IN
THE WORKBOOK WILL APPEAR
TO THE LEFT OF THE PAGE IN
CAPITAL LETTERS LIKE THIS.

Most workbook exercises will follow this outline:

1. You view part of the videotape program.

2. The taped narration tells you to stop the equipment.

3. In the workbook, you read over several vocabulary words until you are familiar with them.

4. You read a short paragraph that introduces some new learning material.

COPYRIGHT American Petroleum Institute

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 A P I P U B L * L b b 3 C 95 = 0732290 0 5 4 2 3 0 5 275 m

5. Next, you work the new learning material, which is a series of self-teaching "frames." You read
and answer the questions at your own pace.

6. At the end of the workbook period, you work a short review. The review questions are a self-
test for your benefit so you can check your learning progress.

7. After the review, you view the next part of the program.

Before you start the program, you should get instructions from the person who administers your
training on how to operate the equipment.

NOW, READ "HOW To USE THE SELF-

TEACHING FRAMES" ON THE NEXT

COPYRIGHT American Petroleum Institute

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 A P I PUBLrLbb3C 95 O732290 0542306 101

HOW TO USE THE SELF-TEACHING FRAMES

The workbook questions and problems included in the new learning material are written in a series of
self-teaching "frames." Each frame gives you some infomation and asks you to make use of it. Or,
the frame refers to a drawing and asks questions or poses a problem about it.

Self-teaching frames are divided into two columns, The left-hand column on the page has the learning
material. You read this material first. The right-hand column has the correct response or responses for
the frame. You read the right-hand column after you wdte in or select a correct answer to the frame.

Here's an example:

The material to learn or read is always on the left-hand

side of the page. Answers are on the right-hand side.

You should cover up the ( right- / left- ) hand side of the right-
page.
It's important to know that self-teaching frames are not a test. They are a way to help you learn faster
and more effectively. You learn the correct response to each frame before you move to the next frame
and learn additional material.

I I
GO TO THE NEXT PAGE AND WORK
THE SAMPLE FRAMES. BE SURE TO
USE TEE CARDBOARD MAS&
1 I

COPYRIGHT American Petroleum Institute

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 A P I PUBLSLbb3C 95 m 0732290 0542307 048 m

SAMPLE FRAMES

Read this frame and use the information it gives to fill in the blank. Cover the right-hand column.

A micrometer is an instrument designed to measure in

thousandths of an inch.

A micrometer is a good tool for measuring very

differences in size. small

Move the mask down to uncover the work at the right of the frame. If you have filled the blank with
"small" or a word that means the same, go to the next frame.

This drawing of a micrometer provides information that will

help you fill in the next blanks:

OBJECT
TO BE
MEASURED

ANVIL ma,!,
/ HUB
THIMBLE
PINDLE I 1

CAM CAP
LOCK

FRAME

Seven major parts are shown in the drawing, but only the
and the contact anvil; spindle
the object to be measured.

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I PUBL*<Lbb3C 95 0732290 0542308 T 8 4

The next sample frame calls for a choice. Circle or underline the appropriate word.

Of the two parts that contact the object, only the

( anvil / spindle ) moves. spindle

The self-teaching frames in the workbook will be similar to the frames you just worked. Remember to
cover the response column with the cardboard mask.

Read the frame.

Use the information, a set of drawings, or information you have already learned to fill in the blanks or
make a choice.

Move the mask down and check the response column.

Go on to the next frame.

Be sure that you write in all your answers. This helps you learn more than if you just think about the
correct answer for each frame.

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
 A P I PUBL*lbb3C 95 O732290 0542309 910 =

WORKBOOK PERIOD
NUMBER 1
EXCAVATION

VOCABULARY Read over these definitions until you are familiar with them.

OSHA SIMPLIFIED SOILS

CLASSIFICATION METHOD - a method for determining the sloping requirements for
excavations less than 20 feet deep.

NEW LEARNING MATERIAL

This part of the program covers the basics of tank excavation, including clearances, depthkover
requirements, sloping and shoring, and trenching.

TURN TO THE "I

! PAGE.

1
COPYRIGHT American Petroleum Institute
Licensed by Information Handling Services
 A P I P U B L a l b b 3 C 95 0732290 0542330 632

SELF-TEACHING FRAMES Use the cardboard mask to cover the response column.

Clearances
1. This drawing shows the minimum clearances and
separations recommended for steel tanks.

1' MIN. 1' MIN. 1' MIN. 1' MIN. 1' MIN.
--it-

The minimum clearance between the sides and ends

of the tank and the walls of the hole is 12, or twelve
inches.

2. The minimum separation between steel tanks is

inches. 12, or twelve

3. This drawing shows the clearances and separations

recommended for fiberglass reinforced plastic (FRP)
tanks in stable soil.

The minimum recommended clearance around the

fiberglass tanks is inches. 18, or eighteen

4. And, 18 inches is also the minimum

separation

3
COPYRIGHT American Petroleum Institute
Licensed by Information Handling Services
 A P I PUBLXLbb3C 75 = 0732270 05423LL 579

5. The Petroleum Equipment Institute (PEI), in

PEI/RP100-90, recommends 24 inches minimum
separation and clearance.
This larger separation and clearance allows easier
placement and compaction of backfill

6. This drawing shows the minimum clearances and

separations for FRP tanks in unstable soil.

The minimum clearance between the sides of the

tank(s) and the walls of the excavation is one half of
the tank diameter

7. For a tank that is eight feet in diameter, the minimum

clearance is feet. 4, or four

8. The minimum clearance between the tank end cap and

the excavation wall is feet. 4, or four

9. The minimum separation between tanks is

inches. 18, or eighteen

Excavation DeptWCover Requirements

1O. A dry area is defined as an area where the water table
is not expected to reach the bottom of the tank.
So, an area where the water table may be expected
to rise above the bottom of the hole is a(n)
area. wet

4
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 A P I PUBL+Lbb3C 95 m 0732290 05Y23L2 Li05 m

11. The excavation and minimum cover recommendations

are basically the same for both steel and FRP tanks.
But, different tank manufacturers and local jurisdictions
may have their own requirements, or
recommendations

12. You should be sure to check if you have any doubts

regarding the depth of the excavation or the minimum
cover

13. This drawing shows the minimum depth and cover

requirements for a tank in a dry area not subject to
traffic.

If the tank is covered by backfill only, the cover depth

may be as little as inches. 24, or twenty-four

14. The backfill cover is reduced to 12 inches if the

finished grade is to be covered by 4 inches of
reinforced concrete

5
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 A P I PUBL*Lbb3C 95 m 0732290 0542313 341 m

15. This drawing shows the forces acting on a tank in a

wet area (subject to flooding).

*
TRAFFIC (LIVE) LOAD

C C * C
DEAD LOAD

The buoyant forces on the tank are offset partially by

the restraining forces, that is, by the weight of the tank,
backfill, and pavement

16. If the restraining forces are smaller than the buoyant

force, the tank will out of the ground. float, rise, or pop

17. Or, if the tank can't break through the concrete (or
maybe even if it does), it very likely will be damaged
badly so that it product. leaks or releases

18. To prevent flotation of tanks in wet areas, most tank

manufacturers require some sort of holddown device.

DEADMAN ANCHORS

The holddown device may be a concrete anchoring

slab or, as in the drawing, two deadman
anchors.

6
COPYRIGHT American Petroleum Institute
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 AP'I' PUBLlkLbb3C 95 0732290 0542314 288 D

19. The minimum depth of the cover from finished grade to

the top of the tank is inches. 36, or thirty-six

20. This drawing shows the minimum depths for a tank

installation in a dry area that is subject to traffic.

ASPHALT REINFORCED
6" l CONCRETE
I
'

The minimum cover is 30 inches of backfill and

6 inches of asphalt

21. Or, 18 inches of backfill and 6 inches of

reinforced concrete

22. This drawing shows the minimum depths for a tank in a

wet area that is subject to traffic.

Holddown devices ( are / are not ) required. are

23. The minimum cover is 30 inches of backfill and
inches of asphalt. 8, or eight

24. Or 30 inches of backfill topped by 6 inches of

reinforced concrete

COPYRIGHT American Petroleum Institute

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 A P I PUBL*lbb3C 95 W 0732290 0542335 134

25 In all these examples, there is a layer of backfill under

I

the tank that is inches thick. 12, or twelve

26. For steel tanks with a concrete pad this layer can be
inches thick. 6, or six

27. This drawing shows the support requirements for a

tank with an anchoring slab.

SLAB BACKFILL

The tank sits ( directly on the slab / on a 12-inch layer

of backfill ). on a 12-inch layer
of backfill

28. Setting the tank directly on the slab is not allowed,

because it might result in uneven loading of the tank.
Uneven loading could cause structural failure and a
of product. leak or release

Sloping and Shoring

Please refer to Exhibit 7, which provides information on the sloping
requirements for excavations less than 20 feet deep according to the OSHA
Simplified Soil Classification Method.

29. According to Exhibit 1, there are options 4, or four

for designing an excavation protective system.

30. Of these options, two require the approval of a

professional engineer

31. As determined by the different options, the angles of

the slope for a given excavation ( will be the same /
may be different ). may be different

8
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 A P I PUBLaLbb3C 95 m 0732290 0542336 050 m

32. If different options result in different slope angles, you

may use the ( steepest / flattest ) angle. steepest

33. Options 1 and 2 do not require soil testing or a

professional engineer.
The quickest option for determining an acceptable
slope is number ( 1 / 2 ). 1

34. But this option may result in the excavation of ( more /

less ) soil. more

35. The more soil removed, the ( more / less ) expensive more
the excavation.

36. Compared to the cost of excavating additional soil, it is

usually less expensive to be more exact in determining
the of the excavation. slope

37. The most important objective of excavation design

is improved ( cost / schedule / safety / regulatory
compliance ). safety

38. Unstable soils are defined as those soils whose

unconfined compressive strength is less than 750 psf
(0.375 tsf).
According to the data in Exhibit 1, Type C soils ( are
stable / are unstable / may be stable or unstable ). may be stable
or unstable

39. The lowest slope is required for well-rounded loose

sand

40. The slope for this type of soil may be no greater than
:I. 2

41. The slope for Type C soils, as given in both the table
and the drawing, cannot be greater than :I 1%

42. Type B soils are ( stable / unstable ). stable

43. The slope for Type B soils may not be greater than
: I. 1

44. Type A soils are stable

45. Shoring or sloping ( is / is not ) required for Type A IS

soils.

46. The slope for Type A soils normally may not exceed
: 1.

9
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 A P I PUBLxLbb3C 95 0732270 0 5 4 2 3 3 7 T ï 7

47. The type which does not require shoring or sloping is

stable rock

48. According to the asterisked (*) note on Exhibit 1,

OSHA regulations sometimes allow a maximum slope
of :1.

49. This slope is allowed only under certain conditions.

First, the excavation must be in Type
soil. A

50. Second, the excavation cannot be open for more than

hours. 24, or twenty-four

51. Third, the excavation can be no deeper than

feet. 12, or twelve

Now let's take a look at how to figure the size of an excavation. (Please refer to
Exhibit 2.) We want to bury two 1O, O00 gallon tanks, each 8 feet in diameter by
27 feet long, in Type A stable soil, with dry hole conditions, subject to trafic,
and asphalt pavement.

52. The minimum bury depth to the top of the tank is

feet. 3, or three

53. The tank diameter is feet. 8, or eight

54. The minimum backfill under the tank is ft. 1, or one

55. The total depth of the excavation is the sum of these,

ft. 12, or twelve

56. The %A maximum allowable slope ( can / cannot ) can

be used if the excavation is not open for more than 24 hours.

57. For an FRP tank, the length at the bottom of the hole is
the length of the tank, 27 ft., plus the clearance at each
end (2 ft. minimum) for an additional 4 feet.
So the total length at the bottom of the hole is
ft. 31, or thirty-one

58. The length at the top of the excavation equals the

length at the bottom of the hole, plus the setback
from the vertical necessary to achieve the %:l
slope

59. For an excavation 12 ft. deep, the setback is 6 ft. on

each end, or ft. total. 12, or twelve

60. So the total length at the top of the hole is

31ft.+12ft.= ft. 43, or forty-three

10
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 A P I PUBL*lbb3C 75 W O732290 0 5 4 2 3 3 8 723 W

61. The width at the bottom of the hole is equal to:

a) the diameters of the tanks,
8ft.+8ft.= ft.; 16, or sixteen
b) the clearance at the sides and separation between
the tanks, 2 ft. + 2 ft. + 2 ft. = ft.; 6, or six
c) for a total of ft. 22, or twenty-two

62. The width at the top of the excavation is equal to the

width at the bottom plus the setbacks on each side
to achieve the %:l slope which, as before, totals
ft. 12, or twelve

63. So the width at the top of the hole is ft. 34,or thirty-four
64, Suppose the owner specified a 12-inch concrete
anchoring slab.
You would have to excavate another foot, making the
hole ft. deep. 13, or thirteen

65. According to Exhibit 1, because the hole is deeper

than 12 ft., the sides of the hole have to be sloped at
the ratio of :1. 3/4

66. That makes the setback on each side to be

%~13ft.= ft. 934

67. That is, a total of ft. in both length and 19 1R

width.

68. The dimensions at the bottom of the hole, 31 ft. long by

22 ft. wide, ( change / do not change ). do not change

69. Due to the increased setback requirement, the

dimensions at the top of the excavation become:
a) length, 31 ft. + 19.5 ft. = ft. 50.5
b) width, 22 ft. + 19.5 ft. = ft. 41.5
70. The volume of the original hole was 444 yds.; the
volume of this hole is 577 yds., for a difference of
133 yds.
The requirement for an additional foot of depth for
the anchoring slab significantly increased the
of the excavation. size, dimensions,
or volume

11
COPYRIGHT American Petroleum Institute
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 A P I PUBLrLbb3C 95 m O732290 0 5 4 2 3 3 9 BbT

71. This drawing illustrates the recommended location of

an excavation with regard to adjacent buildings or
structures.

I
DEPTHOF
FOUNDATION I i I

You don't want your excavation to undermine a

building foundation

72. Also, you don't want the foundation load transferred to

the after it's installed. tank

73. Be sure to check: there are usually local ordinances or

building codes which specify the minimum distance
from underground tanks to property lines or existing
structures.
In the absence of local codes or regulations, the PEI
recommends a minimum distance of 5 feet from the
edge of the excavation to the property line or the
bottom of the building foundation

74. Then, as indicated in the drawing, the 45 degree line

shown should strike the ( upper / lower ) quadrant lower
of the tank.

12
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 ~~

A P I PUBL*lbb3C 75 0732290 0542320 581 m

Trenching
75. This drawing shows the depth and cover requirements
for product piping trenching.

I SUBMERSIBLE PUMP I

The minimum depth of backfill under the piping is

inches. 6, or six

76. The minimum cover of backfill and pavement above the

piping is inches. 18, or eighteen

77. The trench is excavated so that the product piping

slopes uniformly downward ( toward / away from ) the toward
underground tank.

NOW TURN TO "EE NEXT PAGE AND

WORB THE SHORT REVIEW.
I I

13
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 A P I PUBLblbb3C 95 0732290 0542323 438 W

REVIEW
WORKBOOK PERIOD
NUMBER 1

1. The dimensions of a tank excavation at grade depend

upon:
A. the dimensions of the tank(s).
B. the type of the tanks.
C. the type of soil.
D. All of the above
E. None of the above

2. Hole conditions (wet or dry), pavement type, and

bedding requirements all help determine the:
A. dimensions of the hole at grade.
B. slope of the excavation.
C. depth of the excavation.
3. Which of the following does not affect the depth of an
excavation?
A. Tank diameter
B. Wet or dry hole conditions
C. The slope of the excavation
D. Tank bunakover requirements

4. To prevent flotation of tanks in wet hole conditions,

most tank manufacturers require some form of:
A. holddown device.
B. reinforced concrete paving.
C. ballast.

5. The recommended minimum distance between the

edge of an unshored excavation and an adjacent
structure is:
A. 2ft.
B. 5 fi.
c. loft.

TURN TO TEE BACK OF THIS PAGE

F'OR "F€E ANSWERS TO THESE l'l'EMS.
I I

15
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 A P I PUBL*Lbb3C 75 0732270 0542322 354

ANSWERS
ITEMS 1 THROUGH 5

1. [Link] of the above

2. [Link] of the excavation.
3. [Link] slope of the excavation

4. A. holddown device.

5. B. 5ft.

16
COPYRIGHT American Petroleum Institute
Licensed by Information Handling Services
 ~ ~ ~~

A P I P U B L x Z b b 3 C 95 D 0732290 0542323 290 D

WORKBOOK PERIOD
NUMBER 2
PRE-INSTALLATION HANDLING AND STORAGE PROCEDURES

VOCABULARY Read over these definitions until you are familiar with them.

SPREADER BAR - A lifting device that limits the forces acting on a tank to the
vertical only.

SOAP TEST - A leak test method in which a pressurized tank is

completely coated with a soap and water solution.

INTERSTICE - The space between the inner and outer walls of a double
wall tank.

NEW LEARNING MATERIAL

This part of the program covers the proper methods for handling tanks, storing them on-site prior to
installation, and testing them for leaks and other defects.

' '
I "TO THE NEXT PAGE.

COPYRIGHT American Petroleum Institute

Licensed by Information Handling Services
17
 A P I PUBLXLbb3C 75 W 0732290 0542324 127

SELF-TEACHING FRAMES Use the cardboard mask to cover the response column.

1. This drawing indicates the proper method for handling

tanks.

The lifting lines are attached ( around the tank/

to the lifting lugs ). to the lifting lugs

2. The lifting lines must be long enough so that the angle

between them and the vertical does not exceed
degrees. 30, or thirty

3. Use handlines attached to the lifting lugs to control the

of the tank. movement, motion,
or position

19
COPYRIGHT American Petroleum Institute
Licensed by Information Handling Services
 API PUBL*lbb3C 95 0732290 0542325 Ob3 =

4. This drawing shows an alternative method of lifting a

tank.

I
1 SPREADER BAR \

The lifting lines are attached to a(n)

spreader bar

5. The spreader bar assures that the lifting forces acting

on the tank act ( in the vertical direction only / both
horizontally and vertically ). in the vertical direction
only

6. This drawing shows the correct method for storing a

tank prior to installation.
-
1/2’ NYLON OR HEMP ROPES

The area must be clear of rocks or other foreign

objects which may cause to damage
the tank.

20
COPYRIGHT American Petroleum Institute
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 = 0732290 OSLI2326
~
~

A P I PUBL*<lhb3C 95 TTT

7. To prevent the tank from rolling while it is stored,

use rubber tires or other non-abrasive material as
chocks

a. If you expect high winds which might move the

tanks around, secure them with nylon or hemp
rope

9. The tie-down ropes must be at least one-half inch

in diameter and must be tied to secure
stakes

1o. While you want the tanks tied down securely, make
sure that the tension in the ropes is not so great that
it will the tanks. damage

11. This drawing shows what can happen if a tank is tied

down too tightly.

DE FLECTION
I
I l
I

The tank has become deflected

12. The maximum allowable vertical deflection is specified

by the manufacturer

13. The typical maximum deflection, as shown in this

example, is % of the tank diameter. 1%

14. When tanks, equipment and material arrive at the

jobsite, give them a thorough visual inspection

15. Promptly report any damage you find to the owner and
the tank manufacturer

16. Repairs to damaged tanks must be made either by the

manufacturer's personnel or by manufacturer-certified
contractor personnel, in strict accordance with the
manufacturets instructions, directions,
or specifications

21
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 A P I PUBL+Lbb3C 95 0732290 0542327 936

17. The most important step before installing a tank

is pressure-testing it to make sure it doesn't
leak
18. This drawing shows how to set up for a pressure test
on a single-walled tank.
QUICK
COUPLER

RELIEF
DEVICE

In one opening, you install a quick-connect fitting with a

valve and two pressure gauges
19. Two gauges are used so that, if one fails, you can still
the pressure in the tank. read, or measure
20. This helps you avoid applying a pressure that is too
( high / low ). high
21. The maximum test pressures allowed by most
manufacturers range from 3 to 5 psig.
Pressure gauges read most accurately at the middle of
their ranges, so you should use gauges which indicate
a maximum of to 15 psig. 10, or ten
22. Test gauges usually read in increments of $4 or % psi.
On the gauges shown, the scales read in increments of
psig. M, or one-half
23. At another tank opening, you install a pressure
valve. relief

22
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 A P I P U B L * L b b 3 C 95 = 0732290 05Lt2328 8 7 2

24. The relief valve is set to open at a maximum pressure

of 1 psig above the maximum test
pressure.

25. The source of pressure for the test is an air

compressor

26. When the pressure in the tank reaches the test value,
you first close the valve

27. The flattened ends of a steel tank are its structurally

weakest points.
When you're testing any tank, it's a good idea to put
up barricades to keep people away from the
of the tank. ends

28. After disconnecting the compressor, you use a mop or

spray to uniformly coat the tank with a soap solution.

Coat all seams, bungs, manholes, and the whole

of the tank. shell, or outside

29. Carefully check the entire tank for leaks which are
indicated by bubbles

30. If you detect a leaking fitting, repair or replace

it, and re-pressurizethe tank.

31. Promptly report leaks in the shell or at the seams to the

owner and manufacturer

23
COPYRIGHT American Petroleum Institute
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 A P I PUBL*lbb3C 95 0732290 O542329 709

32. Please refer to Exhibit 3, which illustrates the Set-up to

test a double-walled tank.
Between the walls of the tank, there is a cavity, or
interstice, which provides for the containment and
detection of any product which leaks
from the inner tank.

33. The space between the inner and outer walls of the
tank is called the interstice, or
annulus

34. The equipment arrangement shown in the exhibit

allows you to test ( both the inner and outer tanks / the
inner tank only ). both the inner and
outer tanks

35. A major concern is avoidance of too much pressure on

the interstice, or annulus

36. Compared to the volume of the inner tank, the volume

of the interstice is much ( larger / smaller ). smaller

37. Most compressors that are used in tank testing can

pressurize the large volume of the inner tank in 10 to
20 minutes or so.
With that much capacity, a compressor could over-
pressurize the small volume of the interstice in a few
seconds

38. Overpressurizing the interstice puts excessive outside

pressure on the ( inner / outer ) tank. inner

39. Overpressurizing the interstice may severely

the inner tank. damage

40. With your equipment set up as shown in Exhibit 3,

first pressurize the inner tank with Valve 1 open and
Valve 2 ( open / closed ). closed

41. When the pressure reaches the test value specified by

the manufacturer, close Valve 1 and disconnect the
compressor or air

42. Monitor the pressure in the inner tank for about an

hour.
If the inner tank has a large (fast) leak, the pressure
will drop, or decrease

43. Small (slow) leaks ( are / are not ) always detectable are not
by this method.

24
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 A P I PUBL*lbb3C 95 0732290 0542330 420 =

44. If the pressure in the inner tank holds for an hour,

bleed air into the interstice by slowly opening
Valve ( 1 / 2 ). 2
45. Because the volume of the interstice is small compared
to the volume of the inner tank, the interstice should
pressurize ( slowly / quickly ). quickly

46. The pressure decrease in the inner tank should be

( large /small ). small

47. Continue to monitor the pressure in the inner tank

while you soap the outer tank and check it for
leaks, or bubbles

48. Maintain the pressure in both tanks for the period of

time, usually 30 minutes, required by the manufacturer,
or the local jurisdiction or codes

49. When the test is done, close Valve 2 and relieve

the pressure inside the inner tank by opening Valve
( 1 /2). 1

50. Monitor the pressure on the interstice for about an

hour, and look for a pressure drop that may indicate a
leak in the ( inner / outer ) tank.

51. If the inner tank checks out OK, remove your test
equipment and replace all the
in the tank openings.

NOW '
i "TO THE " i 'PAGE AND
WORE THE SHORT REVIIEW.

25
COPYRIGHT American Petroleum Institute
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 A P I PUBL*lbb3C 75 m 0732290 0 5 4 2 3 3 3 367

REVIEW
WORKBOOK PERIOD
NUMBER 2

1. The proper method for lifting a tank is to:

A. wrap cables or slings around the tank at each end.
B. remove the factory-installed plugs and attach lifting
hooks in the tank openings.
C. attach lifting lines to the lifting lugs.
2. The maximum allowable angle between the lifting lines
and a center vertical line is:
A. 30 degrees.
B. 60 degrees.
C. 90 degrees.
D. 120 degrees.

3. The maximum vertical deflection allowed by most FRP

tank manufacturers is:
A. 1%Yo of the tank diameter.
B. 3% of the tank diameter.
C. 6% of the tank diameter.
4. When testing tanks, you should use pressure gauges
that indicate a maximum of:
A. 50 to 100 psig.
B. 25 to 50 psig.
C. 10 to 15 psig.
5. Test gauges should read in increments of:
A. to 112 PSig.
114
B. in to 1 psig.
c. 1 to 1 in psig.
6. You should never pressurize the interstice directly from
the:
A. atmosphere.
B. compressor.
C. inner tank.

"URN To THE BACK OF THIS PAGE

FOR THE A N S W E W TO THESE ITEMS.
I I

27
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 A P I P U B L X l b b 3 C 75 m 0 7 3 2 2 9 0 0 5 4 2 3 3 2 2T3 =

ANSWERS
ITEMS 1 THROUGH 6

1. [Link] lifting lines to the lifting lugs.

2. A. 30 degrees.

3. A. 1%%of the tank diameter.

4. C.1O to 15 psig.
5. A. I4 to % psig.

6. B. compressor.

28
COPYRIGHT American Petroleum Institute
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 A P I PUBLmLbb3C 75 0 7 3 2 2 9 0 0542333 L 3 T

WORKBOOK PERIOD
NUMBER 3
LINERS, ANCHORING, INSTALLATION, AND BACKFILL

I VOCABULARY
I Read over these definitions until you are familiar with them.
I
SECONDARY CONTAINMENT - Any of a number of systems designed to prevent an
accidental release of product into the soil in the event of
failure of the primary containment; these systems allow for
recovery of product.

FILTER FABRIC - A permeable geotextile liner.

DEADMAN - A heavy (usually reinforced concrete) object used to help

prevent flotation of a tank due to the action of high
groundwater.

BACKFILL - Approved material placed in the excavation under and

around a tank to help stabilize and support it.

NEW LEARNING MATERIAL

This part of the program discusses the uses of permeable and impermeable excavation liners,
anchoring methods, proper placement of tanks in the excavation, and the specifications for
backfill and proper backfill placement.

TURN TO TBE NEXT PAGE.

29
COPYRIGHT American Petroleum Institute
Licensed by Information Handling Services
 = 0732290 0542334
~~
~

A P I PUBL*Lbb3C 75 076

SELF-TEACHING FRAMES Use the cardboard mask to cover the response column.
i

Liners
1. Secondary containment systems are designed to
prevent accidental releases of product into the soil
from underground tank installations in cases where the
primary containment has been damaged or developed
a leak.
By confining spilled or leaked product to a definite
small area, these systems also make it easy to
when a release has occurred. detect, find, or tell

2. Also, confining product releases makes it easier to

recover the released product.

TYPICAL CONTAINMENT
MANHOLE FOR. OBSERVATION WELL
FILL OPENING \ V

IMPERVIOUS LINER FOR

TANK EXCAVATION

In this drawing, the secondary containment system is

an impervious liner

3. It is a full underliner, primarily for ( single- / double- ) single-

walled tanks.

4. To make release detection easier, the excavation is

sloped slightly toward the observation
we1I
5. And, because it does not allow ground or flood water to
enter the excavation, the impervious liner ( prevents / prevents
does not prevent ) soil and backfill migration.

31
COPYRIGHT American Petroleum Institute
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 A P I P U B L * L b b 3 C 95 = 0732290 0542335 TO2 =

6. This drawing shows a tank installation with a partial

overliner.

OBSERVATION IMPERVIOUS
WELL LINER

\.\..\......
............ .............. \..................
..............................

These tanks are ( single- / double- ) walled. double-

7. Any product released from the inner tank is contained
by the outer tank, or tank
interstice

8. Any product released by piping or other equipment is

contained by the overliner

9. The overliner provides secondary containment

protection for the ( tanks / piping ). piping

1O. The overliner does not protect against

of backfill from around the tank. migration

32
COPYRIGHT American Petroleum Institute
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 A P I P U B L a L b b 3 C 95 m 0732290 054233b 949

11. Filter fabric liners are permeable,that is, they allow

water to pass through them, but not soil or backfill
particles.

Filter fabric allows to enter the groundwater, or water

excavation.

12. Filter fabric helps prevent backfill migration, but does

not provide containment. secondary, product,
or release

13. Before you can install a liner, you must first clear the
excavation of any dirt clumps, rocks, or sharp objects
which may the liner. puncture, tear, or
damage

14. How the liner is handled during installation is very

important.
Workers must be careful not to puncture or
the material. tear, or damage

33
COPYRIGHT American Petroleum Institute
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 A P I P U B L * L b b 3 C 95 0732290 0542337 A A 5 =

Anchoring
15. This drawing illustrates some of the forces which can
act on an underground tank.

..........

The weight of the tank, product, backfill, and paving

combine to counteract the force. buoyant

16. During flooding or high groundwater conditions, the

buoyant force ( increases / decreases ). increases

17. If the buoyant force exceeds the restraining forces, the

tank will float, or rise

18. The maximum buoyant force equals the weight of the

volume of water that the tank can displace.
If the weight of the tank plus the weight of the anchor-
ing devices equals the maximum buoyant force, the
tank ( will / will not ) float. will not

19. Flotation of a tank often causes a release of product,

either from damage to the tank itself or to the product
piping

34
COPYRIGHT American Petroleum Institute
Licensed by Information Handling Services
 API PUBL*Lbb3C 95 0732290 0542338 711

20. Anchoring is a means of increasing the holddown force

acting on a tank.

This tank is anchored in place by two concrete

deadmen

21. The deadmen are placed to the outside of the tank

diameter, or shadow

22. This placement of the deadmen allows the weight of

the pavement and "wedges" to act backfiII
on the deadmen.

35
COPYRIGHT American Petroleum Institute
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 API P U B L U L b b 3 C 95 O732290 O542339 658 =

23. This drawing and table provide more information on the

size and placement of deadmen (as specified by one
tank manufacturer). The minimum burial depth (to the
top of the tank) is 36 inches (44 inches for 12-foot
diameter tanks).

k LENGTHOFTANK
TANK MIN.
DIAMETER HEIGHT WIDTH

4' 6" X 6"

6'- 8' 12" X 12"
1O' 12" X 18"
12' 8" X 36"

As the table shows, both the height and width of the

deadman depend on the of the diameter
tank.

24. Examine the deadman labeled "A."

If one deadman is used to anchor two tanks, it must
be twice as ( wide / thick ) as a deadman that anchors wide
only one tank.

25. Otherwise, each tank requires 2, or two

deadmen.

26. Because the deadmen must be located completely

outside the diameter of the tanks, the minimum
separation between tanks is the width of
deadmen. 2, or two

27. For 1O foot tanks, the minimurn separation is

inches. thirty-six or 36

36
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 A P I PUBL*lbb3C 95 = 0732290 0542340 37T m

28. This drawing illustrates how deadmen are constructed.

-- AA
#6 REBARS EVENLY SPACED

SMOOTH RADIUS

34
REBAR ANCHOR POINT
CENTERED

Each deadman is reinforced with two ## 6

rebars.
29. The rebars are evenly spaced across the
of the deadman. width

30. Each anchor point is embedded ( Underneath / on underneath

top of ) the rebar.

31, The anchor points are fabricated so that they rise

inches above the center of the deadman. 13, or thirteen

32. This drawing shows typical details for a concrete

holddown pad.

THICKNESS

The minimum pad thickness is inches. 8, or eight

37
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 A P I PUBL*Lbb3C 95 0732290 0542343 20b W

33. The pad is reinforced with ## rebar. 6

34. The anchor points are located 12 inches outside of the
tanks diameter, or shadow

35. This drawing shows a plan view of a tank installation

with a holddown pad.

UNDISTURBED
NATIVE SOIL J-
in both directions the rebars are on inch
centers. 12, or twelve

36. The pad extends at least inches beyond 18, or eighteen

the sides of the tanks.

37. And the pad extends at least inches 12, or twelve

beyond the ends of the tanks.

38. Preferably, the pad extends out to the undistutbed

native soil

39. In the excavation, the tanks rest on a bed of backfill

that is at least inches thick. 12, or twelve

40. You place the backfill bed either on the bottom

of the excavation , or on top of the holddown

38
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 A P I PUBL*Lbb3C 95 = O732290 0542342 1 4 2

41, This drawing illustrates different methods for attaching

tanks to their holddown devices.

Preferably, the holddown straps should be provided

by the manufacturer, and are usually made of flexible
non-metallic material, such as fiberglass or nylon,
which won't deteriorate or corrode, or abrade the
of the tank. shell, material, or outside

42. The straps are placed on designated ribs or through

strap guides.
The straps are connected to the anchor points
using wire rope and a tensioning device such as
a , or other similar hardware. tumbuckle

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 A P I PUBLrLbb3C 95 0732290 0 5 4 2 3 4 3 O89 =

43. The turnbuckles are placed alternately on opposite

sides of the tank.

/ TURNBUCKLE

ANCHOR DEADMAN

This arrangement helps reduce the tendency of the

tank to roll as you the straps. tighten, or tension

44. To minimize the movement of the tank as you tighten

the straps, tighten opposing pairs of turnbuckles ( at
the same time / one at a time ). at the same time

45. You must be careful not to overtighten a strap.

Overtightening may cause a to lift deadman
off the ground.
46. Or, ifyou are using a holddown slab, you may cause
the tank to flatten, or deflect

47. Check the tank for flattening after tightening the straps
by measuring its vertical diameter

40
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 A P I PUBLXLbb3C 95 = 0732290 0542344 TL5

Installing and Backfilling

48. Before beginning to backfill the excavation, you may
want to install the observation wells.

TYPICAL CONTAINMENT OBSERVATION WELL

MANHOLE FOR FILL OPENING
\ I
Lockable
cap
g
h
t$:-* .......,...... ....,.....,.....,.....,...
:Surface water

otted
ted-
I

1 Dedh: 2 f i . below
bottom of tank or
within 6 in. of low
IMPERVIOUS LINER FOR ‘ri point of secondary
TANK EXCAVATION contgmment

This installation, with an impermeable liner, requires

only one well. observation

49. The observation well is a piece of 4-inch, factory-

PVC pipe. slotted

50. The bottom of the well is capped and fits into a sump
that is two feet below the of the bottom
tank.

51. The top of the well has a water-tight cap which is

lockable

52. This drawing shows an installation with an unlined

excavation.

@+OBSERVATION WELL (Lowest Corner)

OBSERVATION WELL+@

It requires two observation weIIs

41
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 A P I PUBL*Lbb3C 95 0732290 0542345 951

53. The observation wells are located at diagonally

opposite of the excavation. comers

54. One of the wells should be placed in the

comer. lowest

55. This drawing shows how the observation wells are

placed in the excavation.

You can hold the observation wells in place by piling

around them. backfill

56. Then place the deadmen in the excavation.

POSITION DEADMAN ANCHORS FIRST

The deadmen can rest on ( a layer of backfill /

the undisturbed native soil ) at the bottom of the undisturbed native soil
excavation.

42
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 A P I PUBL*Lbb3C 95 0732290 O542346 898 W

57. Your backfill material should be clean and free

of ice, snow, and organic matter or other foreign
material or objects

58. This drawing illustrates the size requirements for

backfill material.

Naturally rounded pea gravel can range in size from

118 inch to inch. 3/4

59. Crushed rock can range in size from 118 to

inch. li2

60. Backfill particles smaller than 118 inch tend to migrate,

reducing consolidation of the backfill and
of the tanks. support

61. Before placing any backfill in the excavation, you first

remove any large rocks, clumps of clay and foreign
objects.

LONG-HANDLED TOOL I I LONG-HANDLED TOOL II

+It's critical that this area offer full support under tank and end caps

Then place and level a 12-inch of bed or layer

backfill in the hole.

43
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 API PUBL*Lbb3C 75 0732270 0542347 724

62. The purpose of the backfill bed is to provide firm, even

support for the of the tanks. bottom

63. Then, carefully set the tanks in place in the excavation.

Unless your specifications call for setting the tank on a
slight slope, use a transit or string level to make sure
each tank is plumb and level

64. Installing a tank that is not level can cause problems.

There may be difficulty in testing the tank, or in contents or product
measuring its

65. You want to give special attention to the placement

and consolidation of backfill underneath the tank.
The tank must be firmly supported at the bottom, and
for FRP tanks, under the end caps

66. Spread the first lift of backfill material evenly around

the tanks.
As shown in the drawing, it is inches 12, or twelve
thick.

67. It is critical that the first lift of backfill provides full

support under the 5- to 7-o'clock area of the tank and
end caps, and preferably under the whole area
between 4 and 8 o'clock, that is, the bottom
of the tank. quadrant

68. In some cases,workers may be able to push back-

fill material under the tanks using long-handled
tools

69. If they can use long-handled tools, workers will not

have to enter the excavation, or hole

70. To avoid injury due to shock, long-handled tools used

to consolidate backfill should be made of insulating
material, such as wood.
While consolidating backfill with long-handled tools,
workers should avoid contact with any overhead
lines. power, or electrical

44
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 A P I PUBLXLbb3C 95 0 7 3 2 2 9 0 0 5 4 2 3 4 8 660 M

71. This drawing illustrates correctly and incorrectly

consolidated backfill.

Whatever method you use to consolidate the backfill,

there must be no open spaces, or "voids," beneath the
bottom or of the tank. ends

72. Voids underneath the bottom or ends of FRP tanks

may cause the tanks to flatten, or buckle

73. A straight tool may not work in tight areas with straight-
walled holes.

ILONG-HANDLED TOOL/ I

4 ' CURVED SECTION

In this case, you can compact the backfill under the

tank using a tool. curved

45
COPYRIGHT American Petroleum Institute
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 API PUBL*Lbb3C 95 m O732290 0542349 5T7 m

74. When you have consolidated the first lift properly,

place a second 12-inch lift around the tanks.

I \ ~ G - H A N D L E D TOOL

'It's critical that this area offer full

support under tank and end caps.

As in the case of the first lift, you must distribute and

consolidate the second lift so that it provides full
under the tank and end caps. support

75. This drawing illustrates a method of handling wet hole

conditions.

The backfill bed is inches deep. 18, or eighteen

76. The tank is ballasted with just enough liquid to

it onto the bed. sink

77. A t no time do you allow the level of the water

in the tank to exceed the level of the water or
in the excavation. backfill

78. While you're adding ballast, hold the tank in place

using the lines. lifting

46
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79. Control the movement of the tank using

lines. tag, or hand

80. This drawing illustrates how you can reach the areas
between the tanks in multiple tank installations so that
you can consolidate the backfill.

SAFETY L I N E 1
I 1Jr 3

Across the excavation, you rig a safety

line

81. Then a worker wearing a safety harness and lanyard

attached to the line can out on walk
top of the tanks.

82. This method ( works / does not work ) in both dry and works
wet hole conditions.

83. When using this method, you need to double check

and make sure that the worker's safety equipment
and the safety line are secure and in good
condition, or shape

84. And, as long as the worker is on the tanks, be sure that

someone is standing by as safety watch

I 1
NOW TO THE NEFI' PAGE AND
WORB THOSE REVIEW iTEMS.
I I

47
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 A P I PUBLXLbb3C 95 0 7 3 2 2 9 0 0542351 1 5 5

REVIEW
WORKBOOK PERIOD
NUMBER 3

1. Impermeable liners help to:

A. prevent backfill migration.
B. contain released product.
C. Both Aand B
D. Neither A nor B

2. Filter fabric does not

A. prevent backfill migration.
B. allow groundwater intrusion.
C. provide secondary containment.
3. The maximum buoyant force that can act on a tank
equals:
A. the weight of the tank.
B. the weight of the water displaced by the tank.
C. the weight of the tank, its contents, the backfill, and
the paving.

4. Additional holddown force can be provided by:

A. digging a deeper hole, thus increasing the weight
of the cover.
B. anchoring the tank.
C. using heavier backfill material.
5. Holddown straps may be made from:
A. flexible, non-metallic, non-corrosive material.
B. wire rope.
C. bent rebar.

I
TURN To THE BACK OF THIS PAGE
FOR THE ANSWERS TO THESE ITEMS.
I I

49
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 A P I PUBL*1bb3C 75 0732270 0542352 O91 =

ANSWERS
ITEMS 1 THROUGH 5

1. [Link] A and B
2. [Link] secondary containment.
3. B. the weight of the water displaced by the tank.

4. B. anchoring the tank.

5. A. flexible, non-metallic, non-corrosive material.

TURN TO THE NEXT PAGE AND WORK

TBE REST OF TEE REVIEW ITEMS.
I I

50
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 ~

API PUBL*:Lbb3C 95 0732290 0542353 T28

6. Pea gravel backfill can range in size:

A. from 1/16 to 3/8 inch.
B. from 1/8 to 3/4 inch.
C. from 1/4 to 1 inch.
7. The first lift of backfill must provide full support under:
A. the bottom ribs and end caps of the tank.
B. the bottom half of the tank and end caps.
C. the bottom quadrant of the tank and end caps.

I1
TURN TO THE BACK OF THIS PAGE
FOR THE ANSWERS TO THESE l'l'EMS.
I
I

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 API P U B L * l b b 3 C 95 H 0 7 3 2 2 7 0 0 5 4 2 3 5 4 964 H

ANSWERS
ITEMS 6 AND 7

6. B. from ID to 314 inch.

7. [Link] bottom quadrant of the tank and end caps.

52
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 A P I PUBL*lbb3C 95 m 0732290 0542355 A T O m

WORKBOOK PERIOD
NUMBER 4
PIPING COMPONENTS AND INSTALLATION

VOCABULARY Read over these definitions until you are familiar with them.

FLEXIBLE CONNECTOR - A device used to connect piping joints and components

where a piping run changes direction or attaches to a
relatively rigid object.

NPT - National Pipe Taper, a standard thread that is

tapered to provide increased metal-to-metal contact
between pipe joint threads, resulting in an improved liquid-
tight seal.

FRP - Fiberglass Reinforced Plastic, a material that is used to

make tanks, piping, and other components for
underground petroleum storage installations.

BELL-AND-SPIGOT - A tapered, non-threaded joint used to join pieces of

FRP pipe.

POT LIFE - The working life of an adhesive; the time it takes to

harden, measured from when it is first mixed.

NEW LEARNING MATERIAL

This part of the program discusses the general requirements for underground product piping systems,
and covers major points of concern regarding the installation of metal, FRP, and flexible piping
systems. Stage II vapor recovery piping is also briefly discussed.

! TURN TO "EIE NEXT PAGE.

53
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 A P I PUBL*:Lbb3C î 5 0732290 0542356 737

I SELF-TEACHING FRAMES I Use the cardboard mask to cover the response column.
I
1. Surveys conducted by the API and EPA have shown
that a substantial proportion of underground product
leaks are a result of piping failure, and that most
failures are the result of improperly made joints.
The more complex the system, the ( more / more
fewer ) components.

2. The more piping and components, the ( more / more

fewer ) joints.

3. Each piping joint is a possible location for a

leak

4. As the number of components increases, the chances

for a leak ( increase / decrease ). increase

5. The chances for leaks can be reduced if the piping

system design is as as possible. simple

IR

I I

NOTE: Slope all piping to tanks. i,,,,,J

You want to keep the piping runs as ( long I short ) short
as possible.

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7. Also, you want to keep the number of crossovers to a
minimum

8. The installation shown above has ( one / two / two

several ) crossover locations.

9. This drawing shows some details of a typical product

piping installation.

STAOE 1 VAPOR
SUBMERSIBLE RECOVERY (2 PlJ

The piping is sloped downward ( toward / away from ) toward

the tank.

10. The minimum slope of the piping is inch 118

per foot of run.

11. The ends of the piping run are at the dispenser and at
the submerged turbine Pump

56
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 A P I PUBLtLbb3C 75 H 0732290 0 5 4 2 3 5 8 S O T

12. Where the piping changes direction or attaches to a

relatively rigid object at the end of a run, such as at the
submersible pump, there is a swing joint or flexible
connector.

RAIDED ARMOR

FLEX IBLE
CONNECTO R

The swing joint consists of short nipples and at least

two 90-degree ells, or elbows

13. Some jurisdictions may prohibit swing joints because

they have numerous fittings and joints that may
leak

14. The flexible connector consists of a flexible, product-

compatible inner hose protected by an outer layer of
braided armor

15. At the tank, the flex connector (or swing joint)

connects directly to the ? or Pump
to the pipe leading to it.

57
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 A P I PUBL*Lbb3C 95 O732290 0542359 44b =
16. This drawing shows details ofa typical flex connector
attachment at the dispenser.

. SHEAR
,/ SECT ION

EMERGENCY
SHUT-OFF VALVE
‘ANCHOR
BRACKET
STAINLESS STEEL FLEX CO1NNECTOR
1% NPT MALE BOTH ENDS

The flex connector attaches to the bottom of the

emergency shut-off valve

17. The emergency shut-off valve - sometimes called a

-
shear valve, or impact valve is attached securely to
an) bracket. anchor

18. A flex connector with metal amor should be protected

from contact with the soil (and possible corrosion) by
a(n) jacket. isolation

19. As an alternative, the flex connector may be made

from a dielectric material, such as a rubber compound
or similar substance, that is product
-compatible.

20. Another alternative is to place the flex connector inside

a pump sump, dispenser pan, or similar containment
device.
As in the case of the isolation jacket, corrosion is
prevented by isolating the flex connector from
with the backfill. contact

58
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 A P I PUBL*<Lbb3C 75 = 0732270 0542360 168
21. This drawing shows the minimum trench dimensions
for underground piping installations.

(2X PIPE DIAMETER \

The backfill bed under the piping must be at least
inches thick. 6, or six

22. The minimum separation between piping runs is twice

the pipe diameter

23. The minimum burial depth below finished grade is

inches. 18, or eighteen

24. The burial depth must allow the piping to

downward to the tank area. slope

'ron Piping
25. Piping diameter and wall thickness (schedule) are
generally determined by the service requirements for
the system.
For service at high temperatures and high pressures,
such as in a boiler, you would want a pipe with a
relatively ( thick / thin ) wall. thick

26. If you wanted a high flow rate, as in a tanker loading

facility, you would probably want to use pipe with a
( larger diameter / thicker wall ). larger diameter

27. Product delivery piping for underground tanks is

designed for service at relatively ( high / low ) low
pressure, temperature and flow conditions.

59
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 A P I PUBLX3bb3C 95 0732290 0542363 O T 4

28. But, because of potential stress due to settling or other

soil movement, or abrupt pressure changes due to
the pump starting or stopping, it must be fairly ( strong / strong
large in diameter ).

29. This table shows the dimensions of 2 inch pipe of

different schedules (wall thickness).
1
Schedule inside Wail Weight
Number Diameter (in.) Thickness (in.) (LbJFt.)
40 2.067 0.1 54 3.653

80 1.939 0.218 5.022

160 1.689 0.343 7.444

XXS 1SO3 0.436 9.029

Schedule 80 (and above) piping is heavier than

necessary for service station work, so a reasonable
choice for an underground system is 2 inch schedule
40, or forty

30. This drawing shows the type of iron pipe and fittings
which are commonly used in underground tank
installations.

150# TEE 150# ELBOW

0.154
.l.

375'

2" SCHEDULE 40 -
COATED OR WRAPPED

The pipe is Schedule 40, and is wrapped or

coated

31. It is a nominal inches in inside diameter. 2, or two

32. From the table, you can tell that the "nominal" diameter
refers to the ( inner / outer ) diameter. inner

33. The outer diameter (OD) of 2 inch ID schedule 40 pipe

is inches. 2.375

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A P I PUBL*Ibb3C 95 0732290 0.542362 T30

34. The wall thickness is inches. 0.154

35. The threaded fittings must be at least 150 pound extra

heavy malleable iron

36. Threaded piping systems depend on liquid-tight,

metal-to-metal contact to prevent leaks

37. Threaded connections ( are / are not ) susceptible are

to leaks at the joints.

38. To cut the threads, you have to remove some

from the wall of the pipe. metal, or material

39. The threaded connections are the ( strongest /

weakest ) points of a piping system. weakest

40. Added stress due to soil movement or settling may

cause a connection to leak, or break

41. Also, a run of threaded piping that is not properly

measured can cause on the stress
connections.

42. To properly determine the overall length of a piece of

piping, you have to determine the length
of the threaded ends.

43. Here's an example.

I I
5 FT. d
The length of the pipe from the face of one fitting to the
face of the other is feet. 5, or five

44. From the drawing, you ( can / can't ) determine the can't
length of the threads.

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Pipe Thread
Diameter (in.) Engagement (In.)
1 11/16
2 3/4

As the pipe diameter increases, the length of the

threads ( increases / decreases ). increases

46. For 2 inch pipe, the length of the thread on one end is
inches. %

47. The total thread length for both ends is 1in

inches.

48. So, in this example, the total pipe length is 5 feet

inches. 1ln

49. Once you have determined the length of the pipe that
you need, you are ready to the pipe. cut

50. Iron pipe for underground systems usually comes in

21 foot lengths, threaded on both ends, with thread
protectors.
So, when you have to cut a piece of pipe to length, you
have to thread ( both ends / only the cut end ). only the cut end

51. Here’s how you can thread pipe in the field.

YOKE VISE POST CHAIN VISE

The first step is to secure the pipe in some sort of

vise

62
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 API PUBL*Lbb3C 95 0732290 05423b4 ô03 D

52. A yoke vise is usually attached to a work

bench, table, or surface
(e.g., truck)

53. For work in the field, you can use a

vise. post chain

54. To keep the pipe from bending, you should place the
unsecured end of the pipe on a rack, table, or other
solid support

55. To secure the pipe in the vise, you must apply enough
to hold it firmly in place. pressure, or force

56. Excessive tightening will almost surely damage the

protective wrapping, or coating

57. To cut the pipe, use a large hand cutter like this one.

SLIDING WHEEL
CUTTING SLIDING ADJUSTMENT
WHEEL

Center the pipe between the cutting and sliding

wheels

58. To push the cutting wheel into the pipe, tighten the
sliding wheel adjustment at the knob
end of the handle.

59. Apply a little lightweight oil to the wheels and rotate

the cutter around the pipe to score a cutting
track

60. For every rotation of the cutter, you tighten the handle
half a turn.
This gradually deepens the cutting track until the
cutting wheel cuts ( partially / completely ) through completely
the pipe.

61. Be sure to follow the instructions manufacturer's

for the cutter you're using.

63
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62. And, always follow all procedures. safety

63. The freshly cut pipe ends may contain burrs and metal
chips.

SPIRAL FLUTE

You can clear these out by using a hand tool called a

reamer

64. The reamer is spiral fluted

65. As the handle is turned, the reamer twists into the pipe,
clearing the ends. inside, burred or rough

66. You can remove b u m from the outside of the pipe

by dressing it up with a rat-tail or half-round
file

67. Now you're ready to thread the pipe.

HAND THREADER

In the field, this may be done by or hand

by machine.

68. A typical hand threader consists of a

and a ratchet; die

64

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 A P I PUBLULbb3C 9 5 = 0732290 0542366 686
69. The part of the threader that actually cut the threads is
the ( ratchet / die ). die

70. There are different pipe threading standards for

different applications. The standard thread for product
piping is National Pipe Taper, or NPT.
NPT dies come in different sizes to thread pipe of
different diameters

71, The dies fit into the head of the ratchet

72. The ratchet the dies around turns, moves, or

the pipe. rotates

73. Before you start threading, you need to apply a cutting

oil or fluid to the dies and pipe.
The cutting oil acts as a lubricant to reduce friction
and keep the work surfaces from getting
hot

74. Excessive heat buildup during threading can expand

the pipe, causing the dies to remove too much
metal, or material

75. After the threads cool, they may be ( under / over )-sized. under

76. If the threads are undersized and out of tolerance,

they probably won't make a good metal-to-metal
when the joint is assembled. seal, or contact

77. If the threads do not engage properly, the joint is very

likely to leak

65
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78. This drawing illustrates how to start threading the pipe.

POST CHAIN VISE

To begin threading, center the pipe in the die and

turn the ratchet in a ( clockwise / counter-clockwise ) clockwise
direction.

79. To reduce heat buildup, you should rotate the ratchet

( slowly / rapidly ). slowly

80. By rotating the ratchet slowly, you also make a cleaner

cut and ( increase / reduce ) the chances of damaging reduce
the threads.

81. As you thread the pipe, periodically add oil for

continued lubrication, cooling
or protection

82. Occasionally, back off the ratchet to clear out the

cuttings. metal

83. If you allow metal cuttings to accumulate around the

dies, they may get caught and damage, or ruin
the threads.

84. Continue threading until the end of the pipe is even

with the outer edge of the ( die / ratchet ). die

85. If you go beyond this point, you impair the thread taper
and the ability to make up a tight connection, or joint

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API PUBLIKLbb3C 95 0732270 05423b8 459

86. The last step is to back the threader completely off the
pipe and the quality of the threads. inspect, or examine

87. The threads should be ( sharp and uniform / sharp and uniform
rounded and varied ).

88. Here are a couple of examples of threaded piping.

The pipe on the ( left / right ) has damaged threads. right

89. The bad threads are probably caused by a ( dirty or

dull die / flaw in the metal ). dirty or dull die

90. Before you cut any new threads, you should clean or
the die. replace

91. The threads alone will not make a leak-proof seal.

The first step in installing threaded pipe is to apply a

to the threads. sealant

67
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92. In petroleum service, the sealant should be a

pipe compound that is compatible with the
that will flow through the pipe. product, or liquid

93. The sealant should be a type that does not become

brittle, or , with time. hard, or harden

94. Make sure that the sealant completely

the threads. covers

95. Next, hand tighten the pipe into the fitting.

Be sure it makes up easily, and isn't
-threaded. cross

96. Then, you fully tighten the joint using a pipe

wrench

97. When the piping run is complete from the pump sump
to the dispenser sump, it must be pressure tested for
possible leaks

98. Use compressed air to the piping. test, or pressurize

(WARNING: Never Use Compressed Air On
Pipe That Has Contained Combustible
FIuids!)

99. Components that are subject to the pressure test

include all the piping, the shear valves, and the swing
joints or connectors flex, or flexible

100. The test pressure recommended by the API is 150

percent of the maximum system operating pressure (or
a minimum of 50 psig) for 1 hour.

But states and localities may vary, so be sure

you know the test requirements of your local
code, or jurisdiction

101. While the piping is under pressure, coat all valves,

fittings, and surfaces with a soap solution.

Leaks are indicated by the presence of

bubbles

102. If you find a leak, depressurize the system and

it. repair, or fix

103. Then repressurize the system and test

it again.

104. When the leak test is complete, relieve the

on the system. pressure

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API PUBLnLbb3C 95 0732290 0542370 007

105. Metallic piping and fittings that routinely contain

product and are in contact with the ground must be
protected by a professionally designed, properly
installed cathodic protection system.

- SACRIFICIAL
ANODES
A-
r"-"
I I

IR

NOTE: Siope ail piping to tankS. i,,,,,;

The piping runs in this system are protected by several
sacrificial anodes

106. The anode material is an active or "ignoble" metal that

corrodes away before the of the pipe. metal

107. For the cathodic protection to be effective, each anode

must be electrically to the piping. bonded or connected

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108. This drawing illustrates how the anode wires may be

attached to the piping.

I Anodes three to five I

ATTACHMENT OF ANODE WIRES

One method uses a mechanical clamp

109. The other method is a weld. thermite

110. When thermite welding is being done, be sure there

are no vapors present. flammable

111. The anode leads are made of wire. copper

112. Both the clamp and the weld must be covered with a
coating. dielectric

113. The anodes should be located between three and

from the pipe. five, or 5

114. The anodes should be buried between two and

feet deep. three, or 3

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115. After testing the piping and having a cathodic

protection technician install the sacrificial anodes,
inspect each joint and component for damage to its
coating/wrapping.

\
DAMAGED BARE’
METAL METAL
COATING
(Wrench Cut)

At each joint, bare metal is exposed where the

were cut. threads

116. And the coating/wrapping may have been damaged

during threading and tightening by the jaws of the vise
and the pipe wrench

1 17. You restore protection to these areas by using

approved material to all exposed coat, wrap, or
metal surfaces. cover

118. For the cathodic protection system to be effective, the

piping must be electrically isolated from the tanks and
dispensers.

FLEX
NPT FEMALE

ISOLATION ADAPTER

You can isolate each piping run by attaching it to the

tank and dispensers with a dielectric union or, as
shown here, an isolation adapter

71
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 A P I PUBL*i<Lbb3C 75 0 7 3 2 2 9 0 0 5 4 2 3 7 3 BLb

119. The isolation adapter is made of strong dielectric

matenai, such as reinforced fiberglass
plastic.

120. Aside from strength, the other major requirement for

the dielectric material of an adapter or union is that it
must be with the product. compatible

121, The isolation adapter threads onto the flex connector

at one end and the valve at the isolation, or shear
other.

122. At the other end of the run, an adapter or dielectric

union fits between a flex connector and the discharge
of the

Fiberglass Reinforced Plastic (FRP) Piping

123. When purchased in quantity, FRP piping usually comes
factory-palletized, and packaged in bundles for ease of
handling.

The ends of the pipe are protected by special end

caps

124. Cardboard boxes store the adhesive kits and the

fittings

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A P I PUBL*Lbb3C 95 0 7 3 2 2 9 0 0 5 4 2 3 7 4 752

125. This drawing shows how FRP pipe should be stored if

it is not on a pallet.

4 IN.
MIN.

The maximum support spacing is feet. 1O, or ten

126. The minimum width of the bearing surfaces of the

supports is inches. 4, or four

127. A narrower bearing surface would ( increase / increase

decrease ) the pressure on the pipe resting on it.

128. The increased pressure might cause the pipe to

crack, or break

129. You can help protect pipe stored outside from the sun
and weather by covering it with an opaque
tarp, cover, or sheet

130. The ultraviolet rays in sunlight can result in loss of

bonding strength to machined surfaces of pipe and
fittings.

In order to block out the ultraviolet, you want to use

covering material that is dark, black, or opaque

131. Point loads can damage FRP pipe.

You want to avoid point loads caused by setting

the pipe on rocks or other objects that are
hard, or sharp

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 API PUBL*libb3C 95 m 0732290 0542375 699 m

132. Be careful when transporting FRP pipe.

.
4
-+t 1 0 4
(3M MAX)

Don't let the pipe bundles extend more than

feet beyond the end of the truck or 10, or ten
trailer bed.

133. Otherwise, bending stress could subject the pipe to a

load. point

134. Tie the pipe down securely to prevent it from bouncing

around.

Bouncing or other abnormal movement subjects the

pipe to point loads

135. Use nylon or hemp rope to the secure, or tie

pipe.

136. If you have to use chains to tie down the pipe, be sure
to use to cushion and protect the padding
pipe.

137. Also, if the truck or trailer bed has sharp edges, they
should be padded

138. When unloading pipe and fittings, handle them

carefully, lifting and setting them in place.

Never drop or pipe and fittings to throw

the ground.

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 A P I PUBL+Lbb3C 95 0732270 0 5 4 2 3 7 6 525

139. This drawing shows a correctly assembled FRP pipe

joint.

SPIGOT BELL

ADHESIVE y

BELL X SPIGIT JOINT I I

I U

The pipe ends are joined by wedging the spigot end of

one piece into the end of the other. bell

140. The bell and spigot fit closely because of the matching
taper

141. The matching surfaces are joined and sealed by a thin

layer of adhesive
142. FRP pipe can be cut to length in the field.

32 TEETH
PER INCH
BLADE

You can use a fine-toothed hacksaw with 32, or thirty-two

teeth / inch.

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API PUBLXLbb3C 95 0732290 0542377 4 b l

143. Or you can use a circular saw with a(n)

blade. abrasive

144. Or you can use a saber saw with a fine-toothed or

carbide grit blade. abrasive

145. When you cut fiberglass pipe, you generate dust and
chips that are irritating to the skin, eyes, and upper
respiratory tract.

You can reduce your exposure to this dust by making

sure the working area is well ventilated

146. Also, you should wear a nuisance dust breathing

filter, mask, or
respirator

147. Protect your skin by wearing a shirt with long

sleeves

148. And, the person doing the cutting should protect his
eyes by wearing safety ( goggles / glasses ).

149. You can taper pipe in the field using a tapering tool
sold by the pipe manufacturer or distributor.

CUTTING HEAD
ADJUSTMENT
HANDLE

BLADE
RETA INING

' COLLET

Hold the pipe steady by putting it in a vise

76
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150. Don't tighten the vise too far or you may

the pipe. damage, break, or
rack

151. Let the pipe extend at least 12 inches beyond the jaws
of the vise, so that it is not compressed into a slightly
shape. oval

152. When properly assembled, the tapering tool makes

tapers that match those of factory-made
spigots, or bells

153. This drawing illustrates how to measure the length of

FRP pipe to cut.

INSERTION LENGTH

1 @NTER:: F A C M

CENTERLINE

CENTERLINE

The length of the tapered section of the pipe is called

the length. insertion

154. For FRP pipe of a given diameter, the pipe

manufacturer detemines the insertion
length

155. The length of the pipe between the faces of the fittings
(shaded) is equal to the centerline-to-centerline
distance between the fittings ( plus / minus ) twice minus
the center-to-face dimension of the fittings.

156. To this length, add twice the length. insertion

157. In measuring pipe for a straight run, you have to add,

for each joint, the insertion length, that is,the length of
the section. tapered, or spigot

158. Before making up a pipe joint, you must first clean the
bell and spigot bonding surfaces

77
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 A P I P U B L * L b b 3 C 95 = 0732290 0542379 234
159. Use only the cleaning fluid provided with the adhesive
kit supplied by the manufacturer

160. If the bonding surfaces are really dirty, wash them with
a solution of and water. soap

161. Then, let them dry

162. After the bonding surfaces are dry, clean them
with a paper towel that you have wetted with
cleaning fluid

163. Be sure that you clean all the bonding

surfaces

164. While using the cleaner, wear eye protection, and

make sure the work area is well-ventilated to reduce
your exposure to the fumes

165. Now, you're ready to prepare the adhesive.

HARDE NE R

Most manufacturers produce adhesives that have

two components that must be mixed
together.

166. The components are a base adhesive, and a

hardener

167. To get good results, be sure to mix

the components thoroughly.

168. Follow the manufacturer's directions and observe all

precautions. safety

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A P I PUBLaLbb3C 95 0732290 0542380 T5b m

169. Empty the bottle of hardener into the can of base

adhesive, and begin to them. stir, or mix

170. Never use only part of an adhesive kit.

Mix all the base adhesive, and all the

hardener

171. Keep stirring until the mixture has a uniform color and
consistent flow off the mixing stirrer, or stick

172. The working life (also called 'pot life") of an adhesive is

the time it takes to harden in the can, measured from
the time that it was first mixed

173. This graph shows how the working life of a typical

adhesive varies with temperature.

AMBIENT TEMPERATURE VS.

TIME TO PRESSURE
2

!- _________-___--------
!-
z
!!i NORMAL WORKING RANGE
rn
I
a

O 2 4 6 8 10 12 14 16 18 20
TIME (HOURS)

As the temperature increases, the working life

( increases / decreases ). decreases

174. At temperatures below 70°F, the curing time is very

( long / short ). long

175. If the adhesive begins to set up in the container,

discard it at once.

Do not bond a pipe joint with adhesive that is partially

set, or hardened

176. If you stir the adhesive occasionally, you can help

extend its life. working , or pot

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 A P I PUBL*KLbb3C 95 0732290 0542383 992

177. Before applying the adhesive, double check to make

sure that the bonding surfaces are clean, and all
the has cleaning fluid
evaporated.

i 78. Take care never to mix cleaning fluid with the

adhesive

179. At temperatures below about 70°F,you can help

reduce the curing time by warming the adhesive with a
blow dryer or heat gun.

I - n

L
BLOW
'DRYER

~~
SPIGOT
BELL END
END I
You also want to warm the bonding
surfaces

180. Warm ( the bell /the spigot / both ). both

80
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 API PUBLXlbb3C 75 0732270 0542382 829

181. Then, apply the adhesive as shown.

Apply a thin, uniform coating of adhesive to ( the bell /

the spigot / both ). both

182. Make sure the bonding surfaces are completely

with adhesive. covered, or coated

183. Now, align and lock the joint.

Insert the spigot into the bell, and push and turn at the
same time until the pieces together. lock

184. Turning the joint helps to spread the adhesive

evenly

185. This drawing shows a properly made joint.

ADHESIVE
BEAD \

Around the edge of the bell, there is a small

of adhesive. bead

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 A P I PUBL+Lbb3C 95 = O732290 0542383 7 b 5 =
186. The pieces of pipe are aligned with each other and are
( on / off ) center. on

187. This joint is cocked.

NO ADHESIVE

ADHESIVE’
BEAD

The pieces of pipe are at a(n) to angle

each other.

188. On one side of the joint, there is no adhesive

bead

189. This joint is backed out.

The spigot is not all the way into inserted, or pushed

the bell.

190. When the joint backs out, the adhesive

is disturbed. bead

191. In either condition, re-align the pipe pieces and

use additional pressure to force the joint together
until the adhesive squeezes out and forms a
bead

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 API PUBL*Lbb3C 75 0732270 O542384 b T L

192. To reduce the adhesive cure time in cool conditions, it

may be necessary to supply heat to the joint.

An electrical heat collar, or blanket, is centered over

the joint and secured by straps

193. Avoid the possibility of electric shock.

Before installing the collar, check to be sure there are

no loose or bare wires

194. When the collar is in place, simply plug it into a 120

VAC source. power, or electrical

195. Don't plug the collar into a live power source while
you're standing in water or on a wet surface.

Be sure that you and your equipment are

196. The length of time that you must apply heat (the cure
time) depends on whether you are curing a piping joint
or a fitting.
When applying heat to a joint or fitting, be sure to
follow the manufacturer's instructions for temperature
and time. cure

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A P I PUBLxLbb3C 95

197. Chemical heat packs are also available.

'INSULATION ' TIE '

WRAP WIRES

Use one heat pack per joint

198. A coupling (as shown) requires ( 1 heat pack /

2 heat packs ). 2 heat packs
199. The pack is secured to the pipe with
tie wires

200. Then, cut a 1-inch in the top of slot, or slit

the pack.

201. Inject the activating fluid (usually water) into the pack,
using the activator syringe

202. When a chemical heat pack is spent, be sure to

of it properly. dispose

203. The procedure to follow in installing an FRP piping

system is to "dry fit" it together, with all pieces of pipe,
fittings, and couplings in roughly their final position in
the trench.

This way you can make sure that each piece is where it
belongs, and that it in place. fits

204. In many UST installations, current practice is to install

secondary containment piping at the same time as the
primary piping goes in.

The reason for this is that the primary piping runs

inside the piping. secondary, or
Containment

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 API PUBL*:Lbb3C 95 0732290 0542386 474

205. Also, most jurisdictions require that 100% of the

primary piping be soaped during the pressure test.

This secondary containment piping system uses

sections of pipe that have slightly different
diameters

206. The secondary piping sections telescope, or "nest,"

within each other.

Together, they can move or slide over the primary

piping to allow access for testing, or inspection

207. When the primary piping system is assembled, it must

be tested. pressure

208. The API recommends a test pressure of at least 150%

of the maximum system working pressure, and a
minimum pressure of 50 psig. Local jurisdictions vary,
so be sure to check with yours to determine what their
test requirements are.

Remember to be extremely careful when you are

around FRP piping that is under pressure

209. Stay away from the ends of piping runs, and places
where the piping changes direction

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 A P I PUBLXlbb3C 95 D 0732290 0542387 300 D

21 O. This drawing shows how the secondary containment

piping fits together.

SCARF
AREA.

LBOLT
HOLES

First you have to use a special tool, or sandpaper to

"scarf" the ends of the pipe, that is, remove the gloss
from its surface

21 1. For three inch secondary containment pipe, the pipe

must be scarfed a minimum of inches 3in
from the end.

212. The secondary containment fittings come in two half-

sections which are held together by adhesive and
bolts

21 3. These fittings require more adhesive than primary bell

and spigot joints, a minimum of inch. 1/16

Flexible Piping Systems

214. Please refer to Exhibit 4, which shows the basic com-
ponents of a typical flexibe piping system that can be
used for underground petroleum delivety.

Secondary containment is provided by an outer flexible

( continuous /jointed ) pipe. continuous

215. The secondary pipe connects the dispenser pan and

the pump at the tank. sump

21 6. Containment isolation is provided at each sump

penetration cuff by a flexible seal boot

217. A metal clamp compresses the boot around the

( primary / secondary ) pipe. secondary

218. The boot makes a liquid-tight seal on the secondary

pipe ( inside / outside ) the sump or dispenser pan. inside

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 A P I P U B L X L b b 3 C 75 O732270 0542388 247

219. Unless it is required by the local jurisdiction, there is no

backfill of rock or soil inside the sump.

So, corrosion of the clamp due to soil contact ( is /

is not ) likely. is not

220. At each end of the primary pipe, there is a full-

female NPT threaded coupting. swivel

221. In the pump sump, the primary hose couples to a fitting

on the pump outlet. discharge

222. Because the primary pipe itself is flexible, a flexible

connector ( is / is not ) necessary. is not

223. In the intermediate dispenser sump, the primary pipe

connects to a threaded coupling. tee

224. A riser pipe connects the tee to the

shear valve

225. The bolts shear valve

rigidly to a bracket on the dispenser island.

226. Another length of primary pipe connects from the

intermediate tee to a 90 degree elbow, riser, and the
shear valve in the dispenser terminating
sump.

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 API PUBL*Lbb3C 95 0732290 0 5 4 2 3 8 9 183

227. This drawing shows the construction of one type of

primary and secondary piping.

SMOOTH REINFORCING
FINISH \BRAIDS1 INNER
BORE -,
\ 1 I

SECONDARY
CONTAINMENT I NTERMEDIAT E LAYER S
PIPE OF POLYURETHANE
FORADDEDSTRENGTH

The inner bore of the primary pipe is product-compatible,

and is corrugated so that it can bend, or flex

228. Strength and puncture resistance are added by two

layers of polyurethane

229. Additional strength is provided by a layer of polyester

braid

230. An outer layer of smooth polyurethane provides

resistance to abrasion

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 A P I PUBLXLbb3C 95 = 0732290 0542390 9T5

231. This drawing shows another type of flexible piping

system.

PRODUCT-CO MPATIBLE
INNER PIPE

It is similar in construction to the system we discussed

previously, with the major difference that the secondary
pipe is co- around the primary. extruded

232. As a result, you install the primary and secondary

( separately, at different times /together, at the same
time ). together, at the same
time

233. If it should become necessary to remove a section of

this type of piping for any reason, you would have to
remove ( the primary only / both primary and
secondary ). both primary and
secondary

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 A P I PUBL*3bb3C 95 0732290 0542393 833 W

234. This drawing shows how to install a typical flexible

piping system in its trench.

To avoid kinking the pipe, trench turns should be

( sharp / sweeping ). sweeping

235. After the sumps are in place, measure the length of the
secondary from fitting to fitting.

In measuring you want to be sure to follow the contour

of the trench, or your measurement won't be
accurate

236. Add about 1 foot to your measurement, and cut the

pipe to length for that section of the run.

Lay the pipe in the trench, letting the excess protrude

into the sump through the flexible boot

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 API PUBLXLbb3C 95 m 0732290 0542392 7 7 8 m

237. Check the pipe runs in the trenches.

4" 6"
MIN MIN
I l

The runs should be centered in each trench, with a

minimum separation of about inches 4, or four
between them.

238. The minimum distance from the outer runs to the

trench walls should be about inches. 6, or six

239. This drawing shows one method of sealing the

penetration of the secondary piping into the secondary
containment sump.

I
CLAMP

The gasket ribs lock into the ( high / low ) points of the low
corrugations on the secondary.

240. The outside of the gasket is lubricated by non-hardening,

product-compatible, compound. silicone

241. The gasket fits tightly into the penetration sleeve,

and is compressed by tightening a stainless steel
clamp

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 API P U B L x L b b 3 C 95 H O732290 0542393 6 0 4

242. This drawing shows how a sump penetration might be

sealed using a flexible entry boot.

The fastener studs of the boot fit through holes drilled

through the of the sump. wall

243. The boot is sealed around the sump penetration

opening by nuts that tighten down on a
ring. compression

244. The boot is sealed on the outside of the

secondary piping by tightening a stainless steel
clamp

245. Please refer to Exhibit 5A, which shows how one type
of flexible secondary can be set up for soap testing.

In the secondary line at the pump sump, you place a

assembly. test gage

246. The assembly is sealed in place with a stainless

steel clamp on the outside of the gasket
seal. compression

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 A P I PUBL*Lbb3C 95 w 0732290 05q2394 5 4 0 H

247. Then, bridge the secondary lines in the intermediate

dispenser sump using rigid plastic test lines.

At the penetration gaskets, the bridging lines are

sealed with stainless steel clamps

248. At the final dispenser sump, the secondary is plugged

with a terminating test cap

249. When the test components are assembled, pressurize

the secondary line to about 3 psig, and soap test all
pipe-to-sump seals. compression, or
penetration

250. Also, soap test the entire length of the

piping. secondary

251. Now, please refer to Exhibit SB, which shows a method

for testing the secondary interstice of a different flexible
piping system.

In this and similar systems, the secondary piping

interstice is isolated by use of flexible rubber test
at the ends of each piping section. boots

252. The test boot is sealed at each end by a stainless steel

clamp

253. In a given piping run, one secondary piping section

may be connected to the next using a connector
tube

254. The ends of the connector tubes attach to

barbed fittings on each boot. test

255. In the terminating dispenser sump, install a terminating

on the barbed fitting. cap
256. The test gage assembly connects to the flexible test
boot in the sump. Pump
257. When the test components are assembled, pressurize
the secondary to the manufacturer's requirements
(usually about 3 psig), and soap test all the
seals. compression, or boot

258. If the seals hold, then you soap test the entire
of the secondary pipe. length

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259. Please refer to Exhibit 6, which shows how several

basic flexible primary systems fit together.

The completed primary consists of two major

assemblies: first, pipe-to- coupling

260. And, second, coupling-to- fitting

261. For Type A and B assemblies, the coupling is

mechanically onto the pipe. crimped, or expanded

262. The Type C coupling, either male or female, is held in

place and sealed by a clamp. split

263. Tightening four nuts on the clamp presses the Type C

primary piping onto the coupling 9 shank
making a tight seal.

264. The Type A coupling-to-fitting connection is

( threaded / clamped ). threaded

265. In this example, the fitting threads are ( male / female ). male

266. The coupling-to-fitting seal is made by compressing a

soft metal (usually copper or brass) washer onto the
of the fitting. cone seat

267. Tightening the threaded female coupling provides the

to make the joint liquid-tight. pressure, or
compression

268. The Type B coupling-to-ftting connection is

( threaded / clamped ). clamped

269. The joint seal is provided by compressing a product-

compatible plastic gasket

270. Pressure to compress the gasket is provided by

tightening a stainless steel clamp

271. The Type C coupling-to-fitting connection is NPT

threaded

272. To help assure a liquid-tight joint with this type of

connection, apply a non-hardening, product-compatible
to the threads before tightening. sealant, or compound

273. In making up any of the pipe coupling-to-fitting connec-

tions that we've discussed, tighten the fastener to the
specified by the manufacturer. torque, or pressure

94
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 A P I PUBL*1bb3C 95 m 0732290 0542396 313 m

274. With flexible piping systems in which the secondary

and primary piping are installed separately (as in Type
A and C above), each secondary and primary run is
tested separately.

First, install and test the ( primary / secondary ). secondary

275. You test the secondary by pressurizing it according

to the manufacturer's instructions (usually to about
3 psig), then check for leaks at all seals and along its
complete length using a(n) solution. soap

276. When the soap test is complete, release or bleed

the pressure.

277. Then after installing the couplings on each section of

primary piping, but before installing the section into the
seconúary, use equipment provided by the manufac-
turer to pressurize it to the necessary test pressure
(usually 50 to 60 psig).

Allow the pressure to stabilize, and then soap test each

section along its length and at each coupling

278. Next, depressurize the primary, pull it through the

secondary, and make up the couplings to the
in each sump. fittings

279. When you have installed all sections of the run,

close the valve on the pump discharge, and cap the
valves in each dispenser sump. shear, safety, or
emergency

280. Then pressurize the complete primary run to

the necessary pressure, and soap test each
-to- coupling; fitting
connection.

281. If the primary does not leak, it is ready for

service, use, or product

282. In co-extruded flexible systems, the primary and

secondary section are installed ( together / together
separately ).

283. After all sections are installed, connect the flexible test
boots, and pressurize the piping to secondary
the manufacturer's specifications.

284. Then soap test the entire length of the run, including
the seals on every test boot

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285. Next, release pressure on the secondary, and close it

off again. Now you're ready to test the primary.

Cap the shear valves in the dispenser sumps, and

close the valve on the pump discharge, or outlet

286. Pressurize the primary to the manufacturer's specifi-

cations, and soap test the pipe-to-coupling and
coupling-to- connections at the fitting
ends of each section.

287. Soap testing the entire length of the primary pipe ( is /

is not ) possible. is not

288. But if there is a leak in the primary, the pressure in the

interstice (which is closed off) will ( increase / increase
decrease ).

289. Most manufacturers recommend that, after you have

made up and tested the primary and secondary runs,
you repressurize the interstice to about 3 psig.
Then, during backfilling and paving, you
the pressure. monitor, or check

290. When you are finished backfilling and paving, you can
pressure on the interstice. release

Stage 111 Vapor Recovery Piping

291. Please refer to Exhibit 7, which shows a typical piping
arrangement for a multiple US1installation that
includes Stage II vapor recovery piping.

The aboveground vapor return piping at the dispensers

is made of ( FRP / copper ). copper

292. The vapor return lines connect to the 3-inch vapor

return manifold by corrosion-protected 2-inch
connectors. flex, or flexible

293. The diameter of the vapor retum line is larger than

that of the primary product delivery piping, to allow
for the simultaneous return of vapor from several
dispensers

294. In this particular arrangement, the product piping and

vapor retum line ( share / do not share ) the same trench. do not share

295. The vapor recovery piping is made of material that is

( the same as / different from ) the product delivery the same as
piping.

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A P I PUBLXLbb3C 75

296. Because it normally contains only product vapors, the

vapor return piping ( may be singlewalled / must be may be single-walled
double-walled ).

297. The vapor return piping must slope continuously

downward to the tanks at the rate of at least
of an inch per foot of run.

298. Low spots are not allowed because they provide

pockets where condensed product vapors may collect
and the return of vapor. block

299. At the tanks, the 3-inch vapor recovery piping connects

to a 3-inch manifold. vent

300. Across the tanks, you should ( hold the manifold level /
slope it downward to the middle tank ), hold the manifold level

301. At each tank, the vapor return line connects via a tee
fitting directly to the extractor/ I vent
vapor return fitting.

302, Another flex connector attaches the underground vent

manifold to the 3-inch steel vent
riser

303. If it has metal parts that come into contact with the
backfill, this flex connector ( must / need not ) be must
corrosion-protected.

L i

NOW l " T 0 THE " i 'PAGE AND

WORK THOSE REVIEW lTJ3MS.
I I

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REVIEW
WORKBOOK PERIOD
NUMBER 4

1. The key(s) to a good product piping system design

is(are):
A. shortmns.
B. minimum number of crossovers.
C. minimum number of joints.
D. All of the above
E. None of the above

2. Where a piping run changes direction or attaches to a

relatively rigid object, it is preferable to use:
A. a swing joint.
B. a threaded elbow or adapter fitting.
C. a flex connector.
3. Metallic (iron) product piping is usually 2 inch schedule:
A. 40.
B. 60.
C. 80.

4. The weakest points of a metal piping system are the:

A. threaded connections.
B. piping joints.
C. fittings.
5. Probably the most important point to remember when
you are assembling a threaded metallic product piping
system is to make sure that:
A. your pipe wrench doesn't slip.
B. you don't overtighten a connection.
C. your thread dies aren't dull or dirty.

TURN "0 THE BACK OF THIS PAGE

FORTETE ANSWERS TOTHESE l!i'EMS.
I
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ANSWERS
ITEMS 1 THROUGH 5

1. [Link] of the above

2. C.a flex connector.

3. A. 40.

4. A. threaded connections.

5. [Link] thread dies aren't dull or ditty.

I TURNTO THE NEFT PAGE AND WORK

THE REST OFTHEREVIEW ITEMS.

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6. Metallic underground piping and fittings that normally

contain product and are subject to corrosion must be:
A. coated.
B. wrapped.
C. cathodically protected.
D. coated or wrapped, and cathodically protected.

[Link] API-recommended test pressure for underground

product piping systems is 150% of the maximum
system working pressure, or a minimum of:
A. 25 psig.
B. 50 psig.
c. 100 psig.
8. An important thing to remember when you are making
up joints of FRP pipe is to be sure that:
A. the temperature is not too high.
B. the temperature is not too low.
C. the adhesive cures properly.
9. Fewer, more accessible connections are a feature of:
A. metallic piping systems.
B. FRP piping systems.
C. flexible piping systems.
1O. Stage II vapor recovery piping must slope down toward
the tank by at least:
A. 1/8 inch per foot of run.
B. Vi inch per foot of run.
C. % inch per foot of run.

T" TO THE BACK OF THIS PAGE

FORTHE ANSWERS TO THESE ITEMS.

1o1
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ANSWERS
ITEMS 6 THROUGH 10

6. D. coated or wrapped, and cathodically protected.

7. B. 50 psig.

8. [Link] adhesive cures properly.

9. [Link] piping systems.

1O. A. 1/8 inch per foot of run.

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WORKBOOK PERIOD
NUMBER 5
SECONDARY CONTAINMENT, SPILL CONTAINMENT AND OVERFILL
PREVENTION, AND RELEASE DETECTION

VOCABULARY Read over these definitions until you are familiar with them.

SPILL CONTAINMENT - Any of a number of systems designed to prevent a release

of product by accidental spillage during product delivery.

OVERFILL PREVENTION - Any of a number of devices designed to prevent the

overfilling of a tank, with subsequent product release,
during product delivery.

RELEASE DETECTION - Any of a number of devices designed to detect product

that may be released into the environment.

NEW LEARNING MATERIAL

This part of the program discusses typical methods of providing and installing product containment,
spill prevention, and release detection equipment.

TURN TO THE NEXT PAGE.

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A P I P U B L * l b b 3 C 95 0542404 2 L T

SELF-TEACHING FRAMES Use the cardboard mask to cover the response column.

1. This drawing shows how manufacturers typically install

fittings on FRP tanks, and how the installer might
attach the STP sump to them.

COMPRESSION
RING $
SUMP
J BOTTOM

BY
INSTALLER Jf
BY GASKET/ RING
TANK MFR (Shown Compressed)

NK

I r

FRpA FILLET COMPRESSION

OVERLAY WELD CLOSE-OFF FITTING
W/4'# INT. NPT THREADS
8 5' O EXT. 8NPSM THREADS

The fittings are a type of close-off fitting. compression

2. The fitting rests on a circular steel plate

3. The fitting is attached rigidly to the steel plate by a

weld. fillet

4. Both the fitting and plate are held in place by a(n)

of FRP. overlay

5. Sitting on the FRP shoulder around the fitting, there is

an O-ring, or gasket

6. The bottom of the sump rests directly on the ( O-ring / o-ring

FRP shoulder ).

7. You compress the O-ring by tightening down on a(n)

inside the sump. compression ring

8. The seal between the inside of the sump and the

outside backfill is made by the O-ring, or gasket

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9. Please refer to Exhibit 8, which presents a section

through one type of pump sump, showing details of
typical equipment arrangement.
If there is space underneath it, and the bottom of the
sump needs support, place gravel backfill under the
sump by hand

1O. The sump monitor is housed in a 4-inch diameter,

schedule 40 PVC riser that is factory-
slotted

11. Support straps hold the sump monitor housing to the

housing of the annular space
monitor.

12. The pump is equipped with a line leak

detector

13. For maintenance or repair, you can isolate the pump

from the product piping by closing a ball
valve

14. The rigid electrical power conduit for the monitors and
the pump feeds into the sump through grommets

15. Use a silicone caulking compound, inside and out, to

the grommets. seal

16. Inside the sump, the power lines terminate in

explosion-proof junction boxes

17. To isolate the electrical connections from any flam-

mable vapors which may be present in the sump, the
pump power lines pass from the junction box through a
Class 1 flexible conduit coupling

18. The lines from the low-voltage junction box tie to the
monitors through a low-voltage splice
barrel

19. An O-ring seals the joint between the sump and the
sump riser

20. The sump riser is corrugated so that it can

flex, give, or move

21. The flexibility of the riser helps prevent surface loads

from transferring to the of the tank. top, or surface

22. A clamp attachment secures the sump

to the sump riser. top, or lid

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23. Please refer to Exhibit 9, which shows an alternative

method of fitting a sump onto a tank.
The tanks are FRP or FRP-coated steel

24. In the first example shown, the tank comes with a

manufacturer-installed containment collar

25. The joint between the sump base and the collar is
made by an adhesive inside the bead
sump base.

26. The sump assembly is made of product

compatible material, such as polyethylene.

27. Electrical conduit and product piping penetrations of

the sump walls are sealed by flexible, product-
compatible grommets

28. The grommets are caulked inside and out with a non-
hardening, product-compatible material such as
urethane or silicone

29. The sump extension riser fastens to the sump base by

a double seal. O-ring

30. Pressure to seal the o-ring is provided by tightening

nuts on a studded flange and a ring. compression

31. Structural ribs allow the riser to flex and help avoid
transferring surface to the top loads
of the tank.

32. The sump access cover joins to the top of the

extension riser by a(n) seal. o-ring

33. Please refer to Exhibit 70, which shows additional

variations of sump installation and sealing methods.
In this example, the containment collar has a(n)
flange

34. The sump's base seals to the collar flange with a

double gasket

35. The base-to-riser and riser-to-cover assemblies

are similar to those in Exhibit 9, but the piping and
conduit penetrations are sealed by flexible entry
boots

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36. Please refer to Exhibit I I , which shows a îypical spill

containment fillbox installation.
The primary fill riser is 4 inch, NPT threaded,
iron. galvanized

37. The fitting that the primary riser threads into is installed
by the ( manufacturer / installer ). manufacturer

38. The primary riser is isolated from the backfill by

a 6-inch (usually HDPE) NPT threaded
pipe. containment

39. The 6-inch axial fitting on the tank is NPT threaded

steel, coated by the factory with FRP

40. The &inch containment pipe is sealed at the bottom of

the fillbox by a flexible boot

41. The fillbox has ribs that allow it to flex to avoid trans-
femng loads to the top of the tank. surface

42. The fill riser extends to a hose connection

at the top. collar

43. When not in use, the truck hose connection is sealed

by a lockable cap
44. Product that may be accidentally spilled into the fillbox
opening will be caught by a hydrocarbon absorbent
II II
sausage

45. If the sausage becomes saturated with product, any

additional product on it may be into released, or leaked
the environment.

46. When saturated, a sausage must be properly disposed

of and replaced

47. This system accomplishes overfill prevention by

making an automatic valve part shutoff
of the fill tube.

48. The main valve closes when the product level reaches
about % of tank capacity. 95, or ninety five

49. Closure of the main valve reduces the fill flow rate to
5 gallons per minute through a valve. bypass

50. When the main valve closes, the product delivery

operator closes the truck valve, and drains the delivery
hose through the valve. bypass

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51. The bypass valve closes ifthe level in the tank reaches
% of capacity. 98, or ninety-eight

52. Closure of the bypass valve effectively prevents more

product from entering and causing the tank to
overfilI

53. Spill detection capability for the fillbox enclosure is

provided by a liquid at the bottom sensor
of the secondary containment riser.

54. Leads to the sensor run through 1-inch rigid conduit

threaded into the penetration stub

55. Please refer to Exhibit 72, which shows a typical

secondarily-contained Stage I vapor return assembly.
The bottom of the vapor return riser is fitted with a
valve. ball float

56. In tank systems where the vapor return lines are

manifolded together, an accidental tank overfill might
cause cross-contamination of products through the
lines. vapor return

57. The ball float valve helps prevent mixing of product due
to an accidental overfill

58. The ball float valve mounts into a(n)

assembly. extractor

59. The extractor assembly allows the ball float valve to be

for maintenance or inspection. removed, or accessed

60. The extractor assembly also provides a tee connection

to the tank vent

61. The vent line penetration through the secondary

containment riser is sealed by a product-compatible
tubber grommet

62. Release detection is provided at the bottom of the

secondary enclosure by a sensor. liquid

63. The secondary riser is sealed near the top of the vapor
return riser by a flexible boot

64. The flexible boot seals to the primary and secondary

risers by two stainless steel clamps

65. The vapor return riser terminates in a lockable, vapor-

tight cap and fitting that is incompatible with product
delivery hose nozzles, or fittings

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66. The containment liner around the top of the vapor

return riser is a boot. flexible

67. The containment boot’sflexibility allows the grade slab

to move up and down slightly without imposing a
on the top of the tank. load

NOW TURN To THE NEXT PAGE AND

WORBTHE RENIEwrrEMs.

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REVIEW
WORKBOOK PERIOD
NUMBER 5

1, Sumps, containers, and pans around tank openings

and under dispensers are used primarily to provide:
A. easy access.
B. release prevention.
C. product recovery.
D. All of the above

2. Sump and dispenser pan penetrations are commonly

sealed by:
A. grommets or flexible boots.
B. product-compatible, water-resistant caulking
compound.
C. flexible connectors and self-sealing terminations.
3. Most sumps and containers have ribs or corrugations
that allow them to flex, or yield, in response to:
A. movement of the tank.
B. changes in the surface load.
C. changes in the temperature.
4. If not isolated from the backfill by some form of
secondary containment, fill and vapor return risers
must be:
A. coated.
B. wrapped.
C. coated or wrapped, and cathodically protected.

I I
'i"TO THE BACK OF THIS PAGE
FOR TEE ANSWERS TO THESE l
T-
.

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ANSWERS
ITEMS 1 THROUGH 4

1. D. All of the above

2. A. grommets or flexible boots.

3. B. changes in the surface load.

4. [Link] or wrapped, and cathodically protected.

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