FIBERGLASS STORAGE TANK INSTALLATION INSTRUCTIONS & OPERATING GUIDELINES PETROLEUM TANKS FLOWTITE ®...

FIBERGLASS STORAGE TANKINSTALLATION INSTRUCTIONS & OPERATING GUIDELINES

PETROLEUM TANKSFLOWTITE® WATER TANKS

OIL / WATER SEPARATORSCHEMICAL TANKS

Agenda

• Introductions• Review Key Installation Procedures (PPT)• Written Exam• Contractor Documentation• Submit signed Attachment E

as a record of training• Review Missed Questions• 2-Year Renewal

Generally Used Terms

Important Documentation

PRE INSTALLATION PREPARATIONSections 1 & 2

Safety Reminders

• Pay close attention to the important safety comments throughout the Installation Instructions

• Remember to follow all OSHA, EPA and local regulations which apply

• Remember to barricade tank area.

• Complete installation checklist.

• Review shipping packet contents.

Handling/Preparation


The Installation Checklist:• Is included in the installation

instructions.• MUST be filled out for

each tank on every project.• MUST be retained by the

tank owner and provided to CSI to validate any future warranty claim.

Section A

Handling/Preparation:• All tanks must be mechanically unloaded.• Carefully unload all accessories to prevent damage.

For temporary job site storage:• Use provided shipping pads or approved tank

backfill.• Chock tanks with sandbags.• Place on smooth ground.• Tie down tank in anticipation of high winds.• Protect collars from freezing conditions.



Upon arrival• When tanks arrive at the job

site, they should always be mechanically unloaded.

Tanks• There are different tank

orientations for unloading or lifting into the excavation.

• Identify the tank lift lug orientation and use the appropriate method to lift the tank.

Handling / Preparation

BED & BACKFILLSection 3

Bed & Backfill

Approved Backfill• Always use approved pea gravel or

crushed stone.• Require sieve analysis from your

backfill supplier.• Do not use sand or native soil.• Alternative materials must be

approved in writing by CSI Tech Support prior to installation.

• Clean and washed backfill material only.

• Crushed Stone no larger than 1/2”.

• Rounded Pea Gravel no larger than 3/4”.

• No more than 5% passing #8 sieve.

Bed & Backfill

Section B 14

Backfill calculator on CSI website to confirm sieve analysis

Bed & Backfill

• If backfill materials that meet CSI’s requirements are not available, alternative materials can ONLY be used if written permission is obtained from CSI prior to installation.

Section B 15

TANK TESTING PROCEDURESSection 5

Testing All Fiberglass Tanks

Important Warning For all TestsNever pressurize tank over 5 psig or 3 psig for 12’ diameter tanks


• Connect a “Tank Test Manifold” to a primary fitting.

• Use pressure gauge of 15 psig or less (max ¼ psig increments).

• Use pressure relief device to ensure tank pressure does not exceed 5psig (3 psig for 12’ tanks).

Tank Test Manifold(Contractor Supplied)


• For any tank model with a dry interstitial space (including a double-wall bulkhead) connect an “Annular Space Gauge and Valve” to an annular space fitting.

Annular Space Gauge and Valve(Contractor Supplied)


• Soap entire tank and inspect for air bubbles.

• Soap all fittings and manways.• Contact CSI Field service

immediately in the unlikely event a leak is discovered.


• Double-Wall Tank Tests are only in Sections 5.2 – 5.6.

• Determine which section is appropriate.• Follow each step of the instructions provided in the Tank

Installation Instructions.

Only four (4) of the possible seven (7) testing procedures are discussed in this presentation and only the critical steps

are highlighted.You are responsible for all the steps in any of the seven (7)

possibilities when installing CSI tanks.

SINGLE-WALL TANK TESTING PROCEDURESSection 5.1

Section 5.1 - Testing Single-Wall Tanks

Steps 5.1.1-5.1.3: follow Installation Instructions5.1.4 Pressurize tank to

5 psig maximum (3 psig for 12’ tanks).

5.1.5 Close the air supplyvalve to the primary tank.

5.1.6 Disconnect the air supply.5.1.7 Monitor the pressure readings for 30 minutes for

any loss in pressure from the initial reading which may indicate a leak.

5.1.8 While under pressure, cover tank outer surface including fittings and manways, with soap solution and inspect.

Steps 7-10: follow Installation Instructions

DOUBLE-WALL TANK TESTING PROCEDURES

Section 5.2SHIPPED UNDER VACUUM

Testing Tanks Under Vacuum

Steps 5.2.1.1-5.2.1.3: follow Installation Instructions5.2.1.4 A tank shipped under vacuum can be installed and

backfilled with the vacuum intact if both of the following conditions are met:• The vacuum date precedes the tank installation by

at least 7 days.• The vacuum gauge reads at least 10”Hg (34kPa).

Testing Tanks Under Vacuum

5.2.2. After backfilling to tank top5.2.2.1 Pressurize only the primary tank and all

compartments while maintaining vacuum on the annular space. Cover fittings and manway(s) with soap solution and inspect.

5.2.2.2 In the unlikely event a tank leak is discovered, discontinue the installation and immediately callCSI Field Services to schedule a repair.

5.2.2.4 If the vacuum level is ever less than 10” Hg, immediately call CSI Field Services.


Section 5.3TANKS WITH DRY ANNULAR SPACE

Section 5.3 - Testing Double-Wall Tankswith Dry Annular Space

Steps 5.3.1-5.3.5: follow Installation Instructions

5.3.6 Pressurize tank to 5 psig maximum (3 psig for 12’ tanks).

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5.3.9 Open valve between primary tank and annular space in order to pressurize the annular space using the existing pressure in the primary tank (pressure in the primary tank may drop slightly).

5.3.10 While under pressure, cover fittings and manway(s)with soap solution and inspect.


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Steps 5.3.11-5.3.12: follow Installation Instructions5.3.13Maintain pressure on the annular space

(see Figure D4-3).5.3.14Observe and monitor the gauge on the annular space

for 30 minutes for any loss of pressure which may indicate a leak.

5.3.15While under pressure, cover tank outer surface, including fittings and manway(s), with soap solution and inspect.



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Section 5.5

TANKS WITH HYDROSTATICALLYMONITORED ANNULAR SPACE

Section 5.5 - Testing Double-Wall Tanksw/ Hydrostatically Monitored Space

Step 5.5.1-5.5.2: follow Installation Instructions5.5.3 If monitoring fluid is found on the tank

inner or outer surface during any test, discontinue the installation and immediately contact Containment Solutions Field Services.

Steps 5.5.4-5.5.8: follow Installation Instructions5.5.9 With a light, look inside for

any monitoring fluid.5.5.10Replace and tighten fitting

plug(s).

5.5.11 Connect “Tank Test Manifold” to a primary tank fitting.

5.5.12 Connect the pressure source to the “Tank Test Manifold.”



5.5.13 Pressurize primary tank to 5 psig maximum (3 psig for 12' tanks) (see Figure D7-2).

5.5.14 Close valve on “TankTest Manifold.”Disconnect the air supply line.

5.5.15 Monitor the pressure for 30 minutes for any loss in pressure from the initial reading which may indicate a leak.

5.5.16 While under pressure, cover tank fittings and manway(s), with soap solution and inspect.


EXCAVATIONSection 6

Excavation

Sizing• Minimum spacing between tanks is

18” when no mechanical anchoring is required.

• Tank spacing depends on soil in the excavation as well as the choice of anchoring systems.

Excavation Size – Stable Soil

Stable Soil• Minimum spacing between

tanks and excavation walls, in stable soils.

• Example: with no mechanical anchoring, a 10’ diameter tank will need a minimum 18” spacing between tanks and 24” spacing between the tank and the excavation walls.

Excavation Size

Unstable Soil• Minimum spacing between

tanks and excavation walls, in unstable soils.

• In unstable excavations the spacing between the excavation walls and the tank should always be a minimum of ½ the diameter of the tank.

Excavation

When job site conditions require an oversized hole, fill the entire excavation

with approved backfill.

GEOTEXTILE FABRIC(FILTER FABRIC)Section 7

Geotextile Fabric

Usage• Geotextile fabric is required between backfill and

native soils for certain installations such as unstable soils, swampy areas and landfills to prevent backfill from migrating and thereby undermining support of the tank, piping or paving.

Geotextile Fabric

7.2.4 Geotextile fabric should be used in tidal conditions, area of frequently changing ground water, and unstable soils

7.5 Do not use plastic, or any other material that may tear or degrade, as a replacement for geotextile fabric

BURIAL DEPTH & COVERSection 8

Burial Depth and Cover

8.2 Minimum burial depth may not be sufficient to anchor the tank in buoyant conditions.

8.2.1 Traffic pad must extend at least 12” beyond tank perimeter in all directions.

8.2.2 The maximum burial depth is 7’ from the tank top to grade elevation.

8.2.3 Dry hole excavations must have a minimum of 12” and a maximum of 24” backfill between the bottom of the tank and either the bottom of the excavation or the top of the concrete anchor pad.

Burial Depth & Cover

8.3 No Traffic Loads:8.3.1 4’-10’ tanks need a minimum of 24” backfill

or 12” backfill and 4” reinforced concrete.8.3.2 12’ tanks need 42” backfill or 38” backfill and

4” reinforced concrete.

Burial Depth – Traffic Load

8.4 For Traffic Loads:8.4.3 4’-10’ tanks need a minimum of 36” backfill or

18” backfill and 6” reinforced concrete.8.4.4 12’ tanks need 48” backfill or 36” backfill and

6” reinforced concrete.

TANK ANCHORINGSection 9

Tank Anchoring

The three common methods are:1. Deadmen Anchors.2. Concrete Anchor Pad.3. Overburden (no mechanical anchoring).

For minimum burial depths refer to the Anchoring Chart in Installation Instructions INST 6001 (Appendix A)

Mechanical Tank Anchoring

• If water can enter the tank excavation, CSI recommends mechanical anchoring.

• Use only CSI fiberglass anchor straps.

• Deadmen or concrete anchor pads may be used.

• After installation, all exposed metal should be coated or galvanized to protect against corrosion.

Tank Anchoring – Anchor Straps

Anchor Straps• Use correct length anchor

straps for each diametertank.

• Anchor points must be aligned with designated anchor ribs (±1"). Do not use straps ►◄between ribs except on 4' tanks.

• Use one anchor point per strap end.

Tank Anchoring

Anchor Point Loads• Must have anchor points at the bottom of the hole

aligned within 1” of the designated rib.• Should be tightened with turnbuckles or come-a-longs to

give a “snug” fit.• Are available in a convenient man-out-of-hole split strap

option.

Unloading Deadmen:• Ensure lifting equipment is rated to handle the full load

before lifting.• Use a minimum of 2 equally spaced anchor points.

Tank Anchoring

Tank Anchoring - Deadmen

• Lay the deadmen in the excavation parallel to the tank and outside of the tank shadow.

• Each tank requires its own deadman on both sides, or if one deadman is used between adjacent tanks, it must be doubled in width.

• Place multiple deadmen, in contact, end to end.

Section H 53

Standard installation is bottom of deadman even

with bottom of tank

Tank Anchoring

Anchor Pad:• As a minimum the anchor pad for stable excavations

must be at least 8" thick, with #6 rebar on 12" centers each way.

• When a concrete anchor pad is used the tank and pad must be separated by at least 12” of approved pea gravel or crushed stone backfill.

• Embedded anchor points must be designed for the working loads.

Section H

BALLASTING TANKS

Section 10

55

(ADDING LIQUID)

56

BALLASTING TANKS10.3 Use water or fluid heavier than water as ballast. Be

sure the ballast will not contaminate the product being stored or clean the tank before product is added.

10.4 Do not make a direct (hard) connection of the ballast fill line to any tank fitting.

BALLASTING TANKS

10.5.1 At the moment the tank is full, the pressure in the fill line will result in an instant pressurization of the tank which will damage the tank.

10.5.2 This problem can be avoided by providing adequate tank venting or removing the fill line and manually bringing the tank to full capacity.

Ballasting Tanks• De-water hole as

much as possible• Place 18”- 24” backfill

bed under tank• Use only enough

water ballast in tankto sink tank

• Ballast level inside tank should not be more than 12” above ground water level outside of tank

• Fiberglass tanks installed in unstable soils such as peat, swamp or landfill type must have a hole size big enough to allow a minimum space equal to half the tank diameter from the ends and sides of the tank to the excavation walls.

VERTICAL DIAMETER MEASUREMENTSSection 11.2

59

Vertical Diameter Measurements

• Excessive Deflection (loss of vertical diameter) of any installed tank can create stress on the tank.

• The major cause of deflection is the loss of tank support because of improper backfill material or installation method.

• Compare all deflection measurements to the limits established by CSI on the Tank Installation Checklist.

• There are 5 total vertical diameter measurements.

Section I 60


11.3.4 Set tanks directly on backfill bed.

11.3.5 Tank the “First Vertical Diameter Measurement” and record the value on the Tank Installation Checklist.

Section I 61


Section I 62

11.3.6 If mechanical anchoring is used, after anchoring is completed, take the “Second Vertical Diameter Measurement” and record the value on the Tank Installation Checklist. If this value does not equal the “First Vertical Diameter Measurement”, loosen the anchor straps.


11.3.13 Backfill to tank top.

11.3.14 Take the Third Vertical Diameter Measurement and record the value on the Tank Installation Checklist and verify measurement A does not exceed the value inTable 11-1 in INST 6001 on page 19.


11.4.4 Once the tank has been backfilled to subgrade, before placement of concrete pad, take the fourth vertical diameter measurement.

11.4.5 Record the value on the Tank Installation Checklist.

Final Tank Deflection Measurement

11.4.6 Take the Fifth Vertical Diameter Measurement and record the value on the Tank Installation Checklist.

11.4.7 The inner diameter measurement is calculated by subtracting the “Fourth Vertical Diameter Measurement” and “Fifth Vertical Diameter Measurement”.

TANK INSTALLATION PROCEDURESSection 11

66

Installation Procedures

Basic Installation Steps Overview:1. Review all instructions and make sure you are compliant

with proper procedures2. Add Backfill Bed3. Place Tanks in excavation on Backfill bed4. Take First Vertical Diameter Measurement5. Complete Mechanical Anchoring6. Take Second Vertical Diameter Measurement7. Backfill Tank to tank top8. Take Third Vertical Diameter Measurement9. Backfill to subgrade10. Take Fourth and Fifth Vertical Diameter Measurements

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Installation Procedure – Dry Hole

11.3.7 Proper backfilling is required to provide necessary support for the tank.

11.3.8 Place the first 12” lift of approved backfill material evenly around the tank. Push the backfill in place by using a probe long enough to reach beneath the tank, eliminating all voids, so the tank is fully supported.

Installation Procedure – Dry Hole

11.3.9 Eliminate all voids by using a long handled probe to push backfill:

11.3.9.1 Completely beneath tank bottom.

11.3.9.2 Completely between the 5 o’clock and 7 o’clock positions along the entire length of the bank.

11.3.10 Repeat this process with a second 12” lift, eliminating all voids.

Ballast tank only AFTER backfill is to top of tank

INSTALLATION PROCEDURES – WET HOLE

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11.3.12.1 Water level in the excavation should be maintained at lowest practical level by using pumps.

11.3.12.2 Ballast the tank if ground water cannot be lowered (see Section 10).

Internal Piping Clearances

13.2.5 Internal piping should be a minimum 4” from bottom of tank (6” min. 12’ tanks).

Section K 71

External Piping Clearances13.2.1 Isolate external piping from the concrete pad.

13.2.2 A flexible Connector must be directly installed on all tangentially mounted fittings, nozzle or pipe.

Section K 72

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TANK VENTINGSection 14

Tank Venting

14.1 All primary tanks and compartments that contain product must be vented at all times, except as defined during pre-installation testing.

14.3 For tanks with inlet or outlet piping that will result in pressure at the tank top, the pressure should be limited to 1 psig.

14.4 The tank’s venting system must be adequately sized to ensure that the pressure or vacuum at the tank top will not exceed 1 psig at the tank top at all times, including when filling and emptying the tank.

Section L & Section M 74

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Filling TanksSection 15

Filling Tanks

15.1 If the delivery vehicle uses pumps to fill the tank:

15.1.1 Install positive shut-off equipment in the lines and on the truck to prevent the tank from being overfilled.

15.1.2 Pressurization from overfilling will damage the tank, even if the tank vent is unrestricted.

Section L & Section M 76

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MANWAYSSection 16

Manways

16.1 The load bearing capacity for a standard 22” manway installed is 1,200 lbs. for single-wall tanks and 2,400 lbs. for double wall tanks

16.2 All 30” and 36” manways have a load bearing capacity of 2,400 lbs.

16.3 Do not exceed 50 ft./lb. torque during bolt tightening or manway flange damage may occur.

CONTAINMENT COLLARS,TANK SUMPS & TANK RISERSSection 18

Tank Collars, SumpsInitial Jobsite Testing

• The installation contractor must test the tank sump to the secondary containment collar joint and the secondary containment collar to tank attachment before backfill is around the collar.

• All collars and tank sumps should be isolated from direct traffic loading

• All collars and tank sumps must be continuously monitored for leaks using an electronic monitoring sensor

Critical Installation Steps Review

1. Air/Soap test the tank

2. Use proper backfill material

3. Provide a proper bed for the tank

4. Evaluate if the tank will need to be anchored

5. Properly place and probe the first two 12” lifts of backfill under the haunches of the tank

6. DO NOT ballast the tank until backfill is to the top of the tank

7. Measure and Record all Vertical Diameter Measurements

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TANK SUMP INSTALLATION PROCEDURESSINGLE-WALL TANK SUMPSPublication INST 6030

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Tank Sump Terms

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Handling and Preparation

• Visually inspect the sump components for shipping damage. (If damage is found, contact CSI Field Service)

• Wear gloves.• Do not roll, drop, or bounce.• Set on smooth surface.• Secure sumps to prevent damage from high winds. Proper

precautions should be taken to protect adhesive channels.

INST 6030 84

Kit AD - Assembly Preparation

• Store kits indoors between 50° - 70° F.

• Dry fit all sump components.• Make necessary field cuts (+/- ¼”).• Remove rocks or debris from channel.• Sand and clean mating surfaces.• Wipe surfaces free of dust with a clean

cloth.

INST 6030 85

Kit AD - Instructions

• Check adhesive container for expiration date.• Thoroughly mix two part adhesive by hand or with a

powered mixer following the mixing instructions contained in the adhesive kit.

INST 6030 86


• Pour properly mixed adhesive into grout bag for easy installation into adhesive channel.

• Add supplemental heat to tank sump when temperatures are below 60° F.


• Fill channel with adhesive using the grout bag or application tool.

• Make two consecutive 360° passes with adhesive around each channel.

• Allow adhesive to cure at least 24 hours without moving the joined parts.

Layup Kit (Kit LK) - Instructions

• Optional Kit used in lieu of Kit AD• Thoroughly mix resin and

catalyst following the mixing instructions in the layup kit.

• Resin coat previously ground mating surfaces.

• Apply 3 layers of glass layup saturated with resin 360° around sump, centered on joint. All layup joints must overlap a minimum of 1" but not exceed 2” in circumferential direction.

• Roll layup until all air is removed.• Allow layup to cure at least 24 hours without

moving the joined parts.

INST 6030 89

Tank Sump Installation

• All joints must be sealed with either adhesive or layup material for a watertight sump.

• Always vent sumps.• All sumps must be continuously monitored for leaks using

an electronic leak monitoring sensor.• Isolate sumps from direct traffic loading.• Approved backfill is critical to long term

tank sump performance.

INST 6030 90

Tank Sump Installation - Concrete Slabs

• Properly backfill around sump.

• Place a 5' x 5' x 3/4" rigid board with appropriate cutout for access to sump top.

• Use grade access manhole large enough to allow sump lid removal after installation.

• Pour slab directly onto rigid board.

INST 6030 91

Tank Sump Installation Checklist

Tank Sump Installation Checklist:• Is included in the SW Sump

Installation Instructions, found in the shipping packet.

• MUST be properly filled out for each project.

• MUST be signed by both the installing contractor and tank owner’s representative.

• MUST be retained by the tankowner and provided at a latertime to CSI to validate anyfuture warranty claim.

For Additional Questions

Tank Technical Support(800) 537-4730(936) 756-7731

Field Service Department(800) 822-1997(814) 542-8520

FIBERGLASS STORAGE TANK INSTALLATION INSTRUCTIONS & OPERATING GUIDELINES PETROLEUM TANKS FLOWTITE ®...

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Transcript of FIBERGLASS STORAGE TANK INSTALLATION INSTRUCTIONS & OPERATING GUIDELINES PETROLEUM TANKS FLOWTITE ®...