Handling & Installation Manual

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: AGF/11920 – Handling & Installation

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G R P / FIBREGLASS TANKS HANDLING, INSTALLATION & SAFETY INSTRUCTIONS

0 Revision Project Client Consultant

August 1, 2009 For reference Date Description Saadiyat Link Project. M/s. Tourism Development & Investment Co. M/s. Parsons International Ltd. AMBUSH FIBREGLASS WORKS L.L.C.

Tel: Tel: 0971 0971 2 55520 552098 98

P O Box – 4256, Abu Dhabi, United Arab Emirates Fax Fax: 0971 0971 2 5552 555210 106 6 E mail: ail: ambu ambus sh@em h@emir irat ates es.n .net et.a .ae e

Webs ebsite: ite: www.a ww.am mbus bushfib hfibrre.c e.com

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Contractor M/s. Leighton Contracting (Abu Dhabi) L.L.C. Supplier M/s. ADMMI. Tel: +971 2 5552098 Fax: +971 2 5552106 E mail: [email protected]

Tank Description

Capacity Overall Size Material of Construction Approximate Weight

Product Tanks 52 m 3 4150 mm(ID) x 6264mm (High) Glass Reinforced Plastic 2.2 Tons

Salt Saturators 19 Tons Ø3200mm(ID) x 4866mm (High) Glass Reinforced Plastic 1.5 Tons

General This manual is intended as a procedural guidance for the Handling & installation of vertical chemical tanks. . If any questions in the related field are not answered in this manual or the instructions / procedures are not clear to understand contact Ambush Fibreglass Works L.L.C for clarifications prior to proceeding. This manual is considered as a portion of the equipment and should accompany the equipment. Installation and service of the tanks is the responsibility of the owner/operator and not the manufacturer. Since the flexural, impact and shear properties of Glass Reinforced Plastic are lower than those of steel tanks, special consideration must be given to the load distribution and contact points during the handling and installation process of the tanks. It is the responsibility of the purchaser to convey and supervise these guidelines / recommendations to those personnel responsible for the handling and installation of the tanks. Note: Since the tanks are designed and built to meet the customer requirement the instructions furnished may not be same for other tanks and thereby these instructions shall not be practiced for any other

Transport - Positioning The tanks shall be transported to site in low bed trailer. Normally tanks shall be placed on the trailer bed surface in horizontal position. If the height of the tank, when placed over the trailer bed is less than the locally allowable height, the tank shall be placed on the trailer bed surface in vertical position.

Before Unloading Upon arrival at site the purchaser or his agent / representative shall inspect the tanks for any structural damages such as crack or break, which can be occurred as a result of severe physical shock / impact encountered in transit. If any damage has occurred, the purchaser shall inform the person in charge of the delivery and notify the manufacturer prior to putting the tank into service. Key areas to Inspect: Breakage of any nozzles and accessories. Projections / projected areas. Areas where the tanks has been in contact with packings, blocks and bands. • • •

Note: Any damages / scratches / patches for the external coating shall not be considered significant, since touch up is required and shall be provided after installation.

Handling Instructions

AMBUSH FIBREGLASS WORKS L.L.C.

Tel: 0971 2 5552098

P O Box – 4256, Abu Dhabi, United Arab Emirates Fax: 0971 2 5552106 E mail: [email protected]

Website: www.ambushfibre.com

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The following instruction shall be practiced during the offloading the tanks. Please note that the lifting lugs provided on the tank shall be used only for vertical lifting. When lifting use all the lugs at the top end simultaneously in order to disperse the load uniformly. If the tanks are placed vertically over the trailer bed, with crane utilizing the lifting lugs provided on the tank carefully offload the tank and place it over a firm surface. To unload Horizontally Placed Tank

Tanks should be moved / unloaded in a horizontal position with a crane and two slings of appropriate capacity / size and suitably positioned on the tank. Lift off the tanks with (Nylon or Fabric) slings around the tank. Spreader bar in order to separate the slings and hold the slings at a distance is recommended. The tanks shall be offloaded and placed over a firm surface horizontally. Notes: 1. 2. 3. 4. 5. 6. 7.

Proper rigging practices shall be observed at all times. Prevent the tank from swinging out of control Do not drop the tank or allow falling. Do not roll or slide down the tank. Do not pull or lift using any Nozzles or attachment. Avoid contact of chains / cables / wire ropes with the tank during handling. Do not use lifting lugs on the tanks to unload the tank from trailer.

To Upright Horizontally Placed Tank • •

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•

•

•

Notes: 1. 2. 3. 4. 5. 6.

To upright the tank into the vertical position a crane with 2 Nos hoist hooks shall be utilized. Slings shall wrapped circumferentially on the tank at an appropriate distance from the bottom and top end in a manner that the sling should not slide from the position. Hook each sling into separate lifting hooks of the crane. Lift the tank slightly maintaining in horizontal position itself. Provide support packing (Loose sand or used tyres will serve) at the tank bottom end side. Operate the hoist hooked on the tank top end sling slowly. Continue this until the tank comes to approximate angle of 45 0 to the horizontal. Position the whole tank with bottom knuckle over the support packing and slowly place the tank corner / knuckle over the packing. When stationary erect the tank into vertical position by operating both the crane hooks consecutively in stepwise until vertical and static. Proper rigging practices shall be observed at all times. Prevent the tank from swinging out of control Do not drop the tank or allow falling. Do not roll or slide down the tank. Do not pull or lift using any Nozzles or attachment. Avoid contact of chains / cables / wire ropes with the tank during handling.

Installation Instructions The tanks are intended to be installed over concrete pad with proper bedding. Proper fill soil conditions and pad design is the responsibility of the customer / installer.

1. Concrete pad thickness and reinforcement should be designed for minimal deflections under a fully 2.

loaded tank. Pad surface must be free of cracks, depressions and vertical projections so that the tank has AMBUSH FIBREGLASS WORKS L.L.C.

Tel: 0971 2 5552098



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4. 5. 6. 7.


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continuous bottom support. Special attention must be given to the bottom edge / knuckle of the tank. This edge / knuckle must be in complete contact with the pad. In order to provide continuous contact between the tank bottom and the foundation, and to compensate for surface irregularities in the foundation and the tank bottom, cushioning / bedding as proposed in the applied standard BS4994: 1987 (Page 152 – Appendix H, Recommended Supports and bedding material). Sweep the foundation before applying the bedding, and take care to prevent gravel or foreign objects from getting into the foundation when applying the bedding. Also inspect the bottom prior to setting it on the bedding to make certain that no gravel or foreign object is accidentally adhering to the tank bottom. When connecting pipings to the nozzles on the tank, consider that the tank may settle down when loaded / filled. So some flexibility must be ensured in the piping works since stiff mounting may transmit excessive force into the tank nozzles when filled. After fixing the connections and, before filling place shim packing under aech hold down lugs (any suitable hard, long lasting material such as steel or hard rubber should be used). Fill the tank with water up to 1/3 of the shell. Just after filling the void tighten the anchor bolts. Do not tighten the anchor bolts without shimming under the lugs to avoid damaging stresses on the tank. Please refer BS 4994: 1987 Page 69 - Figure 27 for installation details.

Follow the instructions as mentioned in the standard BS 4994: 1987. The reference pages of the Standard are here with attached. Page 67 - Section 22.2.1 Bottom support requirement. Page 69 - Figure 27 for installation details. Page 152 – Appendix H, Recommended Supports and bedding material.

Safety The tanks are used for many purposes and can be incorporated into larger storage or process systems. Therefore, other safety related guidelines, in addition to those presented in this section, may be appropriate shall be followed. Access to all tanks must be limited to authorize persons only. To avoid damage or tampering, the owner operator should implement appropriate security measures including, but not limited to: enclosing the tank area with a fence, providing lighting at tank ladders and platforms, installing an alarm system and/or a ladder gate. The man ways shall be kept locked. The man way should be opened by authorized personnel only. Tanks may be considered to be “confined spaces” under international regulations and standards. When entering a tank it is your responsibility to comply with the following safety precautions apart from the standing site / plant instructions.

1. Access to be restricted and allow only trained persons. 2. The use of various equipment and procedures to control the hazard presented by the confined space, i.e., the use of retrieval lines, respirators or special protective clothing; Failure may cause serious personal injury or death. 3. The presence of an attendant outside the tank to maintain contact with personnel inside the confined space and to monitor events; and 1. Access to properly trained rescue personnel and rescue equipment. 2. Flush with normal water, ventilate and monitor gases before entering the tank. No flames or sparks. Gases can cause loss of consciousness and death and can be explosive. Explosive gasses may be present in and around the tanks. Do not smoke or allow open flames or sparks in the tank area. Fire or explosion may result in explosion causing damage to tank.

Assure: • •

NO HOT SPARKS! NO WELDING! AMBUSH FIBREGLASS WORKS L.L.C.

Tel: 0971 2 5552098



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NO GRINDING!

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NO CUTTING!

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NO CUT OFF SAW! WITHIN 6.0m OF THE TANK. If working closer, you must protect the TANK from hot sparks with a welding blanket, plywood, or other adequate means. •

Do not cut any openings or mount any additional fixtures on the tanks without prior approval of the manufacturer.

End

AMBUSH FIBREGLASS WORKS L.L.C.

Tel: 0971 2 5552098



Handling & Installation Manual

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