Hazards If The Safety Instructions Are Not ObservedMedium Vessels Loading vessels of volume between 6m³ and 20m³ is usually carried out using an independent or vehicle mounted crane

FOREWORD

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Tank Instruction Manual

This instruction manual is intended as an aid to

personnel installing Chem Resist Storage

Vessel(s).

This manual is intended as a source of important

information regarding the delivery and installation

of the vessel(s). Following the instructions given

will prolong the life of the vessel(s) and help

prevent hazards.

The location of this manual must be known at all

times by all personnel operating within the

confines of the plant at which the vessel(s) has

been installed.

This manual must be read by any personnel

appointed to work :

• in the vessel(s),

• on the vessel(s),

• on any equipment connected with the vessel(s)

OR

• in the surrounding vicinity of the vessel(s).

during any of the following duties :

1. transport, OR

2. installation.

Apart from the manual and those applicable

obligatory regulations for accident prevention in

the country of use and application location, the

standard technical regulations for safe and

professional operation must be observed.

This manual contains information which must be

observed during installation of the vessel(s) and

therefore must also be read by the Installation

Engineer / Supervisor.

Safety instructions in this manual are identified by

the general hazard symbol :

Non-observance of this safety symbol may lead

to personal injury.

Where damage to the vessel(s) may arise if the

instructions are not followed then the word

is inserted.

Hazards If The Safety Instructions Are Not

Observed

Non-observance of safety instructions may lead to

hazards to personnel as well as the environment

and vessel(s).

Non-observance of safety instructions may lead to

loss of any claims for damages.

Non-observance of safety instructions may lead in

particular to the following hazards,

(a) Failure of the vessel(s) in question,

(b) Personal hazard due to mechanical and / or

chemical influences,

(c) Environmental hazard due to leakage of

hazardous substances.

SAFETY

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In addition to the safety instructions named below, the safety instructions provided by any associated equipment manufacturer also apply.

General

Apart from the instruction manual and the

applicable obligatory regulations for accident

prevention in the country of use and application

location, the standard technical regulations for

safe and professional operation of the vessel(s)

and any associated equipment must be observed.

Not only the general safety instructions listed in

the chapter “Safety” but also the special safety

instructions added to the other main points must

be observed.

Do not attempt any operation which may be a

safety hazard.

Intended Use

Chem Resist storage vessels are fabricated

according to the latest technology and recognised

safety / design regulations. However improper

handling may lead to hazards for operating

personnel or other third party persons either in the

short term or the long term.

Chem Resist storage vessels should only be used

for the duty as designed by Chem Resist. Any

other duty or use beyond that of the designed duty

is not as intended. Chem Resist is not liable for

damages resulting from this, the user is solely

responsible. Intended use involves observance of

the instruction manual.

If a new duty or use lies outside the limits of use

defined by the vessel design or if the user is in

doubt regarding changes, the change must be

approved by Chem Resist.

Organisational Measures

Always keep the instruction manual in a

recognised location at all times.

Observe the general, legal, national and other

compulsory regulations on accident prevention

and environmental protection in addition to those

described in the instruction manual.

Any individual appointed to undertake work on

the vessel(s) must have read the instruction

manual before starting work, paying particular

attention to the chapter on safety instructions.

If changes are made to the vessel(s) applicable to

safety, then the vessel(s) must be emptied, (if they

still contain process liquids), isolated immediately

and the relevant authority / person must be

informed.

Changes on or additions to the vessel(s) which

could impair safety must not be undertaken unless

permission is received from the supplier.

SAFETY

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Personnel Selection

No work may be undertaken on any thermoplastic

vessel unless by a skilled plastic fabricator.

Information on Special Types of Hazard

Vessels containing hazardous and / or

environmentally dangerous material, the customer

/ user must inform appointed repair personnel

without being asked.

Environmentally hazardous media are:

• harmful substances

• toxic substances

• corrosive substances

• irritant substances

• combustible substances

• incendiary, highly, easily flammable

combustible substances

• carcinogenic substances

• substances changing hereditary factors

• substances which are dangerous to man in other

ways

If a leakage of hazardous substances occurs, then

the substance must be removed as safely and as

quickly as possible exercising due regard for the

methods stated in the hazard data sheet for that

substance.

Technical Measures

Ensure that following maximum permissible

operating parameters are not exceeded:

1. Pressure

2. Temperature

3. Stored Media Specific Gravity

Associated pipework and / or equipment must not exert excessive load upon the vessel(s) nozzles as this will result in failure and thus stored media leakage.

Vessel Periodic Inspection

Chem Resist would recommend that all

thermoplastic storage vessels containing

aggressive / hazardous chemicals are placed

within a periodic inspection regime.

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INSTALLATION


General

Installation work may only be carried out by

specialist or appointed personnel.

All personnel involved with the installation of

Chem Resist storage vessels must read the

chapter regarding safety carefully.

All personnel involved with the installation of

Chem Resist storage vessels must be made aware

of hazards which arise in connection with these

activities.

Apart from the instruction manual and the

applicable obligatory regulations for accident

prevention in the country of use and application

location, the standard technical regulations for

safe and professional operation must be observed.

Protection of Vessel(s) During Transportation

Small vessels, (up to 6m³), can be packaged by

shrink wrapping onto a pallet to facilitate ease of

handling by fork lift truck.

Larger vessels are not normally packaged but

nozzles can be closed with simple flange blanks.

Keep at least one nozzle open to avoid over pressurisation of the vessel !

No thermoplastic vessel should not be loaded or transported in ambient temperatures below 7° Celsius without prior consultation with Chem Resist

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INSTALLATION


Loading

Different methods are used to load

thermoplastic vessels dependent upon the

size of the vessel.

Where tanks are lifted using the Lifting

Lugs, slings must be 30 mm wide. Any

wider slings will not fit snuggly into the

lug and may slip out during lifting

Small Vessels

Vessels of volume less than or equal to

6m³ are usually loaded by hand or fork lift

truck.

Lift Correctly Using Pallet

Do Not Lift Directly

These smaller vessels are normally

transported in a vertical position and

should be adequately secured to resist

horizontal and vertical movement.

Only Fibre Ropes or Strapping Should Be Used For This Purpose.

The Use Of Wire Ropes

Or Chains Is

Prohibited !

Medium Vessels

Loading vessels of volume between 6m³

and 20m³ is usually carried out using an

independent or vehicle mounted crane. The

lifting of the vessel will require the use of

a spreader beam, (see Figure 4.1 below).

Figure 4.1

Spreader Beam Lifting Arrangement

Do Not Push Vessel Along

Floor With Forks

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INSTALLATION


This weight tested horizontal beam has a central

crane attachment and two adjustable vessel lifting

points and therefore prevents damage which can

be caused to vessel covers by central lifting slings.

In cases where a lifting beam is not available a

single wide, (minimum 75mm), webbing strap

with a “choking” action positioned around the

tank cylinder approximately 1/3 rd of the vessels’

height down from the top can be used to lift the

vessel.

Care must be taken to avoid strain on the

connections and the strap must be kept tight

during the lifting operation.

Larger vessels are usually transported in the

horizontal position and extreme care should be

taken during the loading process if the rotation of

the vessel from vertical to horizontal plane uses

the tank base as a fulcrum, (see figure 4.2 below).

Figure 4.2

Loading A Vessel Using Base As Fulcrum

Large Vessels

Vessels of volume greater than 20m³ are normally

loaded using two cranes - in the following

example one crane is vehicle mounted and one

independent.

The independent crane uses the lifting beam

attached to the lifting lugs of the vessel. The

vehicle mounted crane is attached to the vessel

using a sling.

“Top and Tail” Vessel To Restrain Any Swinging Motion

Lift Clear Using Both Cranes

Do Not Drop The Vessel

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INSTALLATION


These vessels should be supported on felt or

carpet lined vessel support brackets arranged to

prevent deformation of the vessel during transport.

The following aspects should also be considered:-

i) Position of fittings on the vessel,

ii) Stability and shape of structure,

iii) Distribution of load,

iv) Other mechanical loading,

v) The mode of transport.

The vessel(s) shall be adequately secured to resist

horizontal and vertical movement during

transport.

The Use Of Wire Ropes Or Chains Is Prohibited !

Transportation

Once a thermoplastic vessel is correctly loaded

and secured the following guidelines should be

observed.

a) No vessel should be transported in

without prior consultation with Chem

Resist.

b) Shock loading of the vessel(s) due to

high speeds on poor road surfaces

must be avoided as stresses induced

by these actions can cause premature

failure of the vessel.

c) Attention must be paid to particular

requirements of modes of transport,

such as rail, as more stringent

packaging requirements may be

imposed.

d) Attention must be paid to particular

transport requirements of countries of

installation or countries of which the

vessel(s) pass through during

transportation, e.g. allowable vehicle

load widths.

A copy of these guidelines should be given to the driver of the particular transporting vehicle.

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INSTALLATION


Offloading

On arrival at the installation site it is

recommended that a representative of the client

carry out a short inspection of the vessel(s) prior

to offloading to ascertain any damage or

movement of the vessel(s) during transportation.

Any damage or signs of movement should be

reported to Chem Resist immediately.

The unloading sequence is the reverse of the

loading sequence and therefore all guidelines

observed in the loading of the vessel(s) also apply

in the offloading of the vessel(s).

Intermediate Storage

Vessel(s) should be stored in a vertical position, on flat level ground and secured to prevent wind damage.

Installation

Care should be taken to ensure all rainwater which has entered the vessel(s) during storage is completely drained prior to lifting the vessel(s).

The vessel(s) should be sited on a continuous flat surface, e.g. concrete plinth.

If the installation surface is rough or uneven, e.g. broken stone, then siting of the vessel(s) cannot take place.

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INSTALLATION


There should be no other material placed between the vessel(s) base and the installation surface, e.g. sand, as the gradual loss of this layer will cause uneven stressing of the tank base.

Pipe Work

Allowance must be made for expansion of the vessel(s) and connected pipes to reduce the stress build up in the pipe work.

Ensure that pipe work and vessel connections are aligned properly to avoid unnecessary strain on the connections.

All valves and pipe work running to and from the vessel(s) should be correctly supported.

Important Notes

DO USE THE PROPER

EQUIPMENT WHEN OFFLOADING

DO NOT ROLL VESSELS OFF THE

TRANSPORT VEHICLES

DO NOT LIFT VESSELS BY THEIR

FITTINGS

DO PROVIDE A SOLID FLAT

BASE TO SIT THE VESSELS UPON

All Bulk Storage Vessels Should Be

Bunded

If the vessel is fitted with a side manway, all bolts must be tightened to 95 Nm in case they came loose during transport.

A full hydrostatic test with water must be carried out after installation and all bolts should be re-tightened within 24 – 48h following the first fill.

.

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BUND INSTALLATION

PROCEDURE Tank Instruction Manual

General

All bulk storage vessels should have a safety bund

in case of any leaks from the vessel. The two best

known methods to create a bund around the

storage vessel(s) are:

1. Protective Coated Concrete Bund

2. Thermoplastic Integral Bund

Concrete bunds are best used for large numbers of

vessels where the bund can be placed around all of

the vessels.

Thermoplastic integral bunds are ideal for small

numbers of vessels where the cost of a concrete

bund would be prohibitive.

Bund capacities MUST be 110% of the maximum

contents of the vessel. Of course where two or

more vessels are linked in a “balanced” fashion,

the bund volume will be 110% of the combined

maximum contents.

Chem Resist supplies a number of thermoplastic

integral bunds. Sizes are linked to the Chem

Resist range of thermoplastic storage vessels of

which they are designed to accompany.

The following are important points which should

be adhered to in order for the bund to be installed

safely and correctly.

Installation

The bund must be installed prior to storage vessel

installation.

The bund should be sited on a continuous flat surface, e.g. concrete plinth.

If the installation surface is rough or uneven, e.g. broken stone, then siting of the bund cannot take place.

There should be no other material placed between the bund base and the installation surface, e.g. sand, as gradual loss of this layer will cause uneven stressing of the bund base, (compounded by the weight of the vessel).

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BUND INSTALLATION

PROCEDURE Tank Instruction Manual

When installing the vessel into the bund, the

Emergency Valve, (in between the vessel and

bund), must be removed.

Failure to remove the Emergency Valve may cause damage to the valve and / or fitting.

After the tank has been installed into the bund,

ensuring that the outlets are aligned properly, the

Emergency Valve can be fitted. Correct fitting of

the Emergency Valve is shown below.

Water Testing

The vessel and bund connection must be water

tested after installation in the bund by the

following method:

(a) Isolating the bund outlet valve, (optional),

(b) Opening the Emergency Valve,

(c) Filling the vessel to the maximum fill level,

(prior to overflow).

Failure to perform this Water Test may result in unnecessary and dangerous Chemical Spillages.

Bund Emptying

If the bund is situated external to any buildings,

then regular monitoring for fluid build up within

the bund must be performed.

This is due to the possible ingress of rainwater

into the bund, especially if the bund is not fitted

with the optional rain skirt.

If the bund is fitted with an optional rain skirt,

then, due to the skirt obscuring the view of the

bund internals, a high level liquid alarm must be

fitted.

Caution MUST be used when emptying the bund contents. As the purpose of the bund is for chemical retention should the vessel skin fail, the bund could contain leaked or condensed chemical and could therefore be dangerous. Correct Personal Protective Equipment MUST be considered when emptying bund.

TEST BUND CONTENTS PRIOR TO DISCHARGE !!

Before tightening flange bolts ensure that the

joining faces are flush and positioned closely to

Bund

Outlet

Valve Emergency

Valve

Bund

Outlet

Valve

Emergency

Valve


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Bolt Tightening Torque

the gasket. Pulling pipes towards a flange will

create tensile stress which may cause failure in the

long term.

The length of the bolts should be such that the bolt

protrudes past the nut by two or three turns.

A washer should be placed under the bolt head

and the nut

Bolts should be covered with Copper grease or

Molybdenum Sulphide to ensure that they can be

removed after years of service.

Ensure that the bolts are tightened evenly, check

that the distance between the backing rings is the

same at each bolt.

The gasket material must be chemically

compatible with material stored or pumped.

We recommend using gasket materials with a

Shore A hardness of 70. Harder materials are

commonly used in steel piping and require

considerably higher tightening torque to ensure a

proper seals. The use of such gasket materials in

thermoplastic flanges is not recommended as this

may lead to deformation of the flange.

Nominal Diameter

Number of Bolts x Thread Diameter

Recommended Bolt Tightening Torque

Flat Gasket, 40 °C Profile Gasket, 16

bar max. O-ring, 16 bar

max.

15 4 x M12 10 Nm @ 10 bar 10 Nm 10 Nm

20 4 x M12 10 Nm @ 10 bar 10 Nm 10 Nm

25 4 x M12 15 Nm @ 10 bar 10 Nm 10 Nm

32 4 x M16 20 Nm @ 10 bar 15 Nm 15 Nm

40 4 x M16 25 Nm @ 10 bar 15 Nm 15 Nm

50 4 x M16 35 Nm @ 10 bar 20 Nm 20 Nm

65 4 x M16 50 Nm @ 10 bar 25 Nm 25 Nm

80 8 x M16 30 Nm @ 10 bar 15 Nm 15 Nm

100 8 x M16 35 Nm @ 10 bar 20 Nm 20 Nm

125 8 x M16 45 Nm @ 10 bar 25 Nm 25 Nm

150 8 x M20 60 Nm @ 10 bar 35 Nm 30 Nm

200 8 x M20 70 Nm @ 6 bar 45 Nm 35 Nm

250 12 x M20 65 Nm @ 6 bar 35 Nm 30 Nm

300 12 x M20 90 Nm @ 6 bar 50 Nm 40 Nm

350 16 x M20 90 Nm @ 6bar 40 Nm N/A

400 14 x M24 100 Nm @ 6bar 60 Nm N/A


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Bolt Tightening Torque

600 mm Tank Side Manway

28 x M12 90 Nm N/A N/A

900 mm Tank Side Manway

30 x M24 90 Nm N/A N/A

Bolt-on item without backing ring, for example

top manways and scrubber inspection ports

require considerably less torque. They should be

tightened comfortably with a spanner (hand tight).

Over tightening will deform the cover and cause

leakage.


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Tank Anchoring

All Chem Resist Vessel must be anchored using

the anchor and spacer plates provided. The

anchors should be evenly spaced around the tank

The anchor bolt PCD should be selected so that

the anchor and spacer plates have 5 mm gap

between respectively the tank weld and the tank

base, please see drawing below.

The gaps allow for the thermal expansion of the

tank without ‘hitting’ the plates which would

cause stress points.

Bolts should be hand tight, secure, without

compressing the tank base.

Bolt holes should be at least 5 diameters away

from an unsupported edge, for example the edge

of a plinth.

Bolts must be anchored with suitable plugs or

chemical anchors.

For further information on positioning the bolts

and the required depth of holes consult the

technical manual provided by the bolt or plug

manufacturer or stockist.

If it is not possible to anchor the tank, for example

during temporary storage, the tank should be filled

with water to at least 1 m fill height. This is to

prevent deforming the base during pressure uplift

of the barrel.

Documents

Hazards If The Safety Instructions Are Not ObservedMedium Vessels Loading vessels of volume between 6m³ and 20m³ is usually carried out using an independent or vehicle mounted crane