general instructions for gfrp equipments · pdf filegeneral instructions for gfrp equipments...

Rev 0 – January 2016

R ‐ INSTALLATION GUIDELINES ‐

Contact: Tlf: +34 918700015 / Fax: +34 918700518 Email: [email protected] / www.salher.com

January 2016

GENERAL INSTRUCTIONS FOR GFRP EQUIPMENTS INSTALLATION

IMPORTANT:

THIS DOCUMENT EXPLAINS THE INSTALLATION PROCEDURE OF THE GFRP EQUIPMENT SALHER BRAND. IT WILL BE NECESSARY TO MAKE A CIVIL WORK SIGNED BY A COMPETENT TECHNICIAN SUPERVISOR. THE RESPONSIBILITY OF THE INSTALLATION IS ALWAYS OF THE INSTALLATION COMPANY. SALHER COULD GIVE TECHNICAL SUPPORT TO SUPERVISE THE DIFERENT STAGES OF THE INSTALLATION.

THE NON‐FULFILMENT OF THE NORMS PRESCRIBED MEANS THE FAILURE TO COMPLY WITH THE BASIC NORMS AND EXEMPTS SALHER FROM THE RESPONSIBILITY IN CASE OF ACCIDENTS OR DAMAGE TO THE EQUIPMENTS, AND ALSO CAUSES THE LOSS OF THE WARRANTY.

ANY INSTALLATION DEFECT IS RESPONSABILITY OF THE INSTALLER. FOR INSTALLATIONS OTHER THAN THOSE CONTAINED IN THIS MANUAL, PLEASE CONSULT SALHER TECHNICAL DEPARTMENT.



R‐ INSTALLATION GUIDELINES ‐ January 2016

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INDEX

1. TRANSPORT............................................................................................................ 2 2. LOADING, UNLOADING AND STORAGE ................................................................... 3 3. ORDER REVIEW....................................................................................................... 4 4. WATER FILLING AND EMPTYING OF THE TANKS...................................................... 5 ANNEX I: ABOVEGROUND INSTALLATION OF GFRP VERTICAL EQUIPMENTS............... 6 ANNEX II: ABOVEGROUND INSTALLATION OF GFRP HORIZONTAL EQUIPMENTS........ 9 ANNEX III: UNDERGROUND INSTALLATION OF GFRP EQUIPMENTS .......................... 11 ANNEX III.a: STABLE GROUNDS .................................................................................. 11 ANNEX III.b: UNSTABLE GROUNDS ............................................................................. 13

ANNEX IV: UNDERGROUND GFRP EQUIPMENTS INSTALLATION PROCEDURE........... 14 ANNEX IV.a: STABLE GROUNDS OPTION 1 ................................................................ 14 ANNEX IV.b: STABLE GROUNDS OPTION 2 ................................................................. 15 ANNEX IV.c: UNESTABLE GROUNDS ........................................................................... 16 ANNEX IV.d: PUMPING STATION IN STABLE GROUNDS ............................................ 17 ANNEX IV.e: PUMPING STATION IN UNSTABLE GROUNDS OR WITH PHREATIC LEVEL.................................................................................................................................... 18

ANNEX V: ABOVE GROUND GFRP EQUIPMENTS INSTALLATION PROCEDURE ........... 19 ANNEX V.a: VERTICAL ................................................................................................. 19 ANNEX V.b: HORIZONTAL ........................................................................................... 20


R‐ INSTALLATION GUIDELINES ‐


January 2016

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1. TRANSPORT

The necessary safety conditions should be taken for transport.

The shipper will be responsible for any non‐fulfilment of the basic norms, as well as any

loss, damage, alteration, deformation occurred during the shipment of the equipments,

as well as loading and unloading.

The non‐fulfilment of the prescribed norms implies the failure to comply with the basic

norms and exempts SALHER from any liability in the event of accidents or damages on

equipments; this will also cause the loss of the warranty.

Place the equipment in the middle of the vehicle, on a flat base or a system which

ensures its stability, avoiding any contact with other equipments / materials, and

ensuring it will not move. If necessary, use straps to fix / tie up the equipments to avoid

any damage / blow during the transport.

Never use metallic straps, only plastic material, to ensure the equipment safety and

avoid any deformation.

Safety measures should be taken during loading, unloading and storage operations,

besides the measures required by the construction manager, safety and health Officer.

During the transport, GFRP equipments must not contain water.




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2. LOADING, UNLOADING AND STORAGE

Safety measures should be taken during loading, unloading, and storage operations.

The appropriate resources should be used during loading and unloading operations,

according to the equipment weight and dimensions, ensuring all the time its stability, a

safe handling and avoiding any kind of sudden movement. If necessary tie up with straps.

GFRP equipment loading and unloading from the truck or in the construction site will be

performed only if the equipment is empty, and with non‐metallic straps, harness through

hoisting devices available on the equipment (eyebolts).

The equipments should be stored on a flat base to avoid any kind of distortion / damage /

breaking due to external conditions.

GFRP equipments must be empty during loading, unloading, and storage operations,

therefore the user should take care to avoid any external water entry.




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3. ORDER REVIEW At the reception of the order at the construction site, check the delivery note, specially

bulks and equipments mentioned in the order. Check the GFRP equipments, accessories

and electromechanical equipments supplied.

At the same time, check externally the equipments to detect any blow / deformation/

breaking / damage, caused during the transport.

Equipments have been submitted to an internal quality control, in accordance with the

Standard ISO 9001:2008.

ANY JUSTIFIED COMPLAINT RECEIVED THE DAY OF DELIVERY WILL BE IMMEDIATELY

ADDRESSED.




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4. WATER FILLING AND EMPTYING OF THE TANKS

If equipments have compartments, they can be vertical or horizontal, please follow these guidelines

during filling and emptying.

To equalise the hydrostatic pressure on both sides of the separation deflector between

chambers, the first filling of the equipment and complete emptying will be done

simultaneously in all compartments.

For the first filling, it is recommended to use a hose or a pipe in each compartment through

the corresponding manholes. Check visually the evolution of level in each of them, ensuring a

balance during the whole process.

To empty, use the hose or suction pipe in each compartment, the access should be done

through the corresponding manholes. Check visually the evolution of level in each of them,

ensuring a balance during the whole process.




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ANNEX I: ABOVEGROUND INSTALLATION OF GFRP VERTICAL EQUIPMENTS

The installation will be performed on a solid ground (with enough resistance to support the

equipment weight when it is full of water), flat, levelled, and must support all the base of the

tank.

If it is necessary to build a concrete slab (minimum HA25): depending on the type of ground, it

will be necessary to calculate a thickness and a specific framework according to the

specifications of the construction manager, to provide a stable and levelled surface.

The surface will be free of rough elements (rocks or sharps items) which could damage the

tank base when full or empty.

The appropriate safety measure should be taken to avoid any kind of alteration, deformation

or breaking of the equipments and accessories, as well as movements caused by external

agents (wind, etc.) or unfavourable conditions on the installation site.

If necessary, fasten the equipment at the installation base with framing squares or fixing

elements.

The tank connections (inlet, outlet, overflow, etc.) to other elements of the installation can be

performed with PVC or flexible material pipes and / or flanges. Do not make any METAL‐PVC

rigid connections.

Before making the hydraulic connections, the equipment must be filled up with water at the

2/3 parts of its total capacity. All levelling operations will be preformed once the hydraulic

connections are disconnected to avoid damages. Once the equipment is full of water, check

the correct levelling, and if necessary, level it again always without water.

If equipments are installed in grounds with slope or hillside, the appropriate safety measures

should be taken to avoid any alteration / deformation / breaking of the equipments and

accessories, as well as movements caused by external agents (wind, etc.) or unfavourable

conditions on the installation site.




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The picture above shows the hoisting and aboveground installation process recommended for

GFRP vertical tanks:

Firstly, fasten with no metallic straps both sides, surrounding completely the tank.

Secondly, hoist simultaneously from both sides to a height which enables the

straightening manoeuvres.

Then, hoist progressively the upper bottom of the tank. It is important to perform

this operation, maintaining carefully stable the tank.

Once the tank stands vertically, slowly lower it until it is in contact with the support

surface.

It is recommended to hold the equipment until it is completely settled and fastened.

The company in charge of the installation will be liable in the event of non‐fulfilment of the

norms, as well as any other safety norm not taken into account during the installation. The

non‐fulfilment of the prescribed norms shall exempt SALHER from any liability in the event of

accidents or equipment damage, causing also the loss of the warranty.




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ANNEX II: ABOVEGROUND INSTALLATION OF GFRP HORIZONTAL EQUIPMENTS

Equipments placed on GFRP / Metallic supports SALHER brand.

o For tanks with diameter ≤2.250mm, supports will be of GFRP and will be fixed to the

equipment.

o For tanks with diameter >2.250mm, supports will be of GFRP or metallic.

The installation will be performed on a solid surface (with enough resistance to support the

weight of the equipment full of water), flat, levelled, the whole base of the equipment in

contact with ground.

If it is necessary to build a concrete slab (minimum HA25): depending on the type of ground, it

will be necessary to calculate a thickness and a specific framework according to the

specifications of the construction manager, to provide a stable and levelled surface.

The surface will be free of rough elements (rocks or sharps items) which could damage the

tank base when full or empty.

The appropriate safety measure should be taken to avoid any kind of alteration, deformation

or breaking of the equipments and accessories, as well as movements caused by external

agents (wind, etc.) or unfavourable conditions on the installation site.

If necessary, fasten the equipment at the installation base with framing squares or fixing

elements.

For the installation of equipments on metallic supports (diameter >2500mm), first lower the

supports, aligning them on the flat base, checking its levelling, with equal separation along the

whole length of the separator. Then a crane will lower the equipment, so that the base of the

equipment can be in contact with the whole length of the ferrule or cylindrical part. Finally,

fasten the supports to the tank with the supplied straps; tighten them to avoid any movement

of the tank. Straps should be of GFRP, nylon or similar plastic material, not metallic, for a safe

fastening.




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The tank connections (inlet, outlet, overflow, etc.) to other elements of the installation can be

performed with PVC or flexible material pipes and / or flanges. Do not make any METAL‐PVC

rigid connections.

All levelling operations will be performed once the hydraulic connections are disconnected to

avoid damages.




conditions on the installation site.




January 2016

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ANNEX III: UNDERGROUND INSTALLATION OF GFRP EQUIPMENTS

ANNEX III.a: STABLE GROUNDS

OPTION 1: Mechanical compaction equipments and perimetral space ≥1m between

equipments are required.

o Base: Formed by a mechanically compacted levelled sand bed in the entire excavation

perimeter, with minimum of 95% of the normal Proctor density and thickness ≥200mm.

o FILLING MATERIAL: Fine, clean, sieved, dust‐free and clay‐free, free of organic matter

and coarse solids (ρmín.1500 Kg/m3).

o FILLING UP: fill the perimeter up to the 2/3 parts of the equipment height with layers of

20cm, mechanically compacted, then fill up with water the ¼ parts height of the tank.

Continue to fill the perimeter with layers of 30cm up to the pipes level, connect the

pipes and finish filling up the tank.

OPTION 2:

o BASE: Composed of fresh concrete ≥30cm and place the tank on the fresh concrete.

o FILLING MATERIAL: Concrete HM‐20 and filling of fine sand, clean, sieved, dust‐free and

clay‐free, free of organic matter and coarse solids (ρmín.1500 Kg/m3).

o FILLING UP: Fill up with vibrated concrete (HM‐20) in layers of 30cm, let it harden

between coats up to 2/3 of the equipment alternating with water up to the same

height. Upper filling with compact sand at 97%.

When performing the excavation, please consider the depth, material and diameter of the

inlet collector.

The ditch dimensions where the equipment will be placed must be ≥ 1.000mm in OPTION 1

and ≥500mm in OPTION 2.

The distance between equipments in series and parallelly must be ≥500mm.

The ditch dimensions will be so that the equipment could lie on a concrete or sand slab.

It is necessary to install an above ground viewfinder and a perimeter draining system to avoid

water storage in the installation area.




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UPPER FILLING UP LEVEL (above the upper line of equipments).

o The upper filling should have a minimum height of 500mm from the upper line of the

equipment. Equipments are manufactured to resist to a maximum filling height of

1.000mm, in the event of upper heights (>1.000mm) equipment will be reinforced

(consult Salher).

o No machinery will circulate on and around the equipments (a minimum horizontal

distance of 4 meters from the equipment).

o In the event of road traffic, a concrete slab should be placed. This slab must not transmit

load to the walls of the equipment, it must lay on firm ground.

MANHOLE:

o Equipment have upper manholes to enable the access inside the equipment. If

equipments are installed at a specific depth and manhole cannot be reached, manhole

or access chambers should be built to check the manholes and work inside. Access

chambers must be waterproof and must not transmit traffic load to from the surface to

the tank.

The company in charge of the installation will be liable in the event of non‐fulfilment of the

norms, as well as any other safety norm not taken into account during the installation. The

non‐fulfilment of the prescribed norms shall exempt SALHER from any liability in the event of

accidents or equipment damage, causing also the loss of the warranty.

STABLES GROUNDS RESISTANCE TO COMPRESSION > 3700 kg/m2




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ANNEX III.b: UNSTABLE GROUNDS

Build a skin reinforcement with a distance separation of ≥ 200mm from the tank.

Fill up the inner part of the skin reinforcement with concrete (HM‐20).

Fill up the exterior of skin reinforcement with sand.

When making a deeper excavation, the material and the inlet collector diameter should be

taken into consideration.

The ditch dimensions where the equipment is placed must include a distance of ≥ 500mm

between the equipment and the wall of the ditch.

Take into consideration the need to use timber formwork or steel plates to ensure the walls of

the excavation.

Distance between equipments in series and in parallel must be ≥ 500mm.




conditions on the installation site

LEVEL OF UPPER FILLING UP

In the event of road traffic, a concrete slab should be placed. This slab must not transmit load

to the walls of the equipment, it must lay on firm ground, not on the equipment.

MANHOLE:

Equipments have upper manholes to enable the access inside the equipment. If equipments

are installed at a specific depth and manhole cannot be reached, manhole or access chambers

should be built to check the manholes and work inside. Access chambers must be waterproof

and must not transmit traffic load to from the surface to the tank.

* UNSTABLE GROUNDS Compression resistance < 3700 Kg/m2. Marshy or muddy areas, limp grounds expansive clays, or any ground which would not support the equipment weight when full of water in resistance conditions.


Rev 0 – January 2016 Contact: Tlf: +34 918700015 / Fax: +34 918700518 Email: [email protected] / www.salher.com

January 2016

Page 14 of 21

ANNEX IV: UNDERGROUND GFRP EQUIPMENTS INSTALLATION PROCEDURE

ANNEX IV.a: STABLE GROUNDS OPTION 1



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ANNEX IV.b: STABLE GROUNDS OPTION 2



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ANNEX IV.c: UNESTABLE GROUNDS



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ANNEX IV.d: PUMPING STATION IN STABLE GROUNDS



January 2016

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ANNEX IV.e: PUMPING STATION IN UNSTABLE GROUNDS OR WITH PHREATIC LEVEL



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ANNEX V: ABOVE GROUND GFRP EQUIPMENTS INSTALLATION PROCEDURE

ANNEX V.a: VERTICAL



January 2016

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ANNEX V.b: HORIZONTAL



January 2016

Page 21 of 21

ANNEX VI: INSTALLATION OF UNDERGROUND GFRP EQUIPMENT PROCEDURE (FRANCE)

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