MEKSIS A.Ş. INSTALLATION GUIDE Prismatic Sectional Water Tank MEKSIS Mekanik Sistemler İmalat ve Müh. San. A.Ş. ASO 2.SANAYİ BÖLGESİ 2009.CAD.NO:6 TEMELLİ TÜRKOBASI KÖYÜ SİNCAN ANKARA Telefon : +90 312 271 43 05 Faks : +90 312 271 43 04 E-Posta : MEKSIS@MEKSIS.com.tr
TABLE OF CONTENTS 1. INTRODUCTION... 1 2. IMPORTANT NOTICES BEFORE ASSEMBLY... 2 3. PRISMATIC SECTIONAL WATER TANK ASSEMBLY... 3 3.1. CONCRETE BASEMENT... 3 3.1. ASSEMBLY OF BASES... 4 3.2. SIDE PANELS ASSEMBLY... 6 3.3. INSTALLATION OF REINFORCING RIBS... 7 3.4. ASSEMBLY OF ROOF... 8 3.5. ASSEMBLY OF THE ACCESSORIES... 10 4. TEST AND TIGHTENING... 11 4.1. BOTTOM LEAKAGE TEST:... 11 4.2. TANK SIDE PANELS TEST:... 11 4.3. FINAL TEST:... 11 5. IMPORTANT NOTICES AFTER ASSEMBLY... 12 6. MAINTENANCE... 12 7. SUMMARY OF SECTIONAL WATER TANK ASSEMBLY... 13 8. MEKSIS AFTER SALES SERVICE... 14 8.1. MAKING A SERVICE AGREEMENT:... 14 8.2. TECHNICAL SUPPORT... 14 8.3. UPGRADE AND REFURBISHMENT... 14 8.4. REPAIR AND MAINTENANCE... 14 1. INTRODUCTION Thank you for buying our sectional water tanks. Please follow these instructions carefully. The Prismatic Sectional Bolted Tank is a modular, constructed from separated panels which are pressed steel sheets (Figure 1) and bolted together on site to create a larger water tank. There is no welding operation used during the panels manufacturing (Figure 2). Figure 1. Star type prismatic sectional tanks panel MEKSIS A.Ş. Page 1
Modular design provides ease of transport and flexibility. Panels are rigidly supported by an internal combination of horizontal and vertical reinforcing ribs and supports. Figure 2. Graphical view of a prismatic sectional water tank 2. IMPORTANT NOTICES BEFORE ASSEMBLY Before assembly, please notice the following procedures: a. Analyze the water prior to store and chose the correct material or coating system for your tank. b. Utmost care shall be taken during assembly not to damage the panel surfaces, and proper and clean shoes should be worn to avoid damage to the tank base or walls. c. Provide 220V electricity supply and adequate construction site lighting. d. To allow access to bolts, minimum space of 350 mm shall be provided all around the tank. Detailed space range is shown in Figure 3. Figure 3. Minimum space requirements around sectional tank e. Tank foundation must be at the same dimensions which were provided to the customer by MEKSIS. MEKSIS A.Ş. Page 2
f. Check the all required components (tank sections, nuts, bolts, washers, sealant and other requested accessories shown in Figure 4). Figure 4. Summary of a prismatic sectional water tank s accessories g. There must be enough water for leakage test after the installation. h. Provide all necessary test equipments such as valves, flanges, blind flange and etc. i. For the tanks which are aimed to be filled with oil or gasoline, water can also be used for leakage test. 3. PRISMATIC SECTIONAL WATER TANK ASSEMBLY 3.1. Concrete Basement NOT: The foundation should be done by the construction project owner. Tank must be assembled on a flat and level concrete basement and it must exceed the nominal tank dimensions by a minimum of 700 mm. Concrete basement shall have the following specifications: a. Concrete quality should be at least C25. Other specifications and mixture ratio are as bellow: Cement: 340 kg/m 3 Water: 200 kg/m 3 Small Aggregate: 757 kg/m 3 Thick Aggregate: 1,135 kg/m 3 Concrete Strong: 300 kg/m 2 b. Concrete thickness must be minimum 50 mm. If it possible 100 mm is recommended. c. Under normal ambient conditions (20ºC), the concrete curing time is 28 hours. If you have the opportunity to steam the concrete, curing time MEKSIS A.Ş. Page 3
will decrease to 8 hours. Chemical materials shall also be used at cold winter conditions. NOT: Do not assembly tank before this time. d. If a higher strength is needed Dramix steel fibers with dosage o 35 kg/m³ can also be added to the concrete. e. Foundation surface shall be flat and without slope. If the base is sloping, it should be flatted using the concrete. f. Be noted that the concrete basement alone may not provide the sufficient resistance and soil mechanics are also needed to be considered. Foundation should be sited on firm/solid ground. Sites on made up ground, i.e. filled ground should be avoided. g. Dimensions of the foundation shall be as given information in drawings. Foundation with larger or smaller dimensions may lead to miss-assemblies. NOT: The space between the tank and walls must be definitely filled with concrete. 3.1. Assembly of Bases If you have ordered the plastic footings, first place them on concrete basement and then lay the bottom panels on them as shown in the Figure 5. Figure 5. Placing plastic footings If there is no plastic footing, first place the reinforcement plates and their sealing gasket on the concrete basement, then place and push the EPDM sealant strip around the flange of bottom panels and then lay out them with drilled flange uppermost. You can use a podger for cutting bolt holes on sealant and align the panels, then insert bolts you maybe push the bolts through the sealant strip when bolting the panels together (Figure 6 and 7). NOT: Don t forget to wipe clean the faces, such that, the sealant strip can t come into contact with dust from the floor area. MEKSIS A.Ş. Page 4
Figure 6. Assembly of bases Figure 7. Aligning the bottom panels using a podger MEKSIS A.Ş. Page 5
3.2. Side Panels Assembly The next stage in the tank assembly is the installation of side panels. First, like previous stage, place and push the EPDM around the periphery of assembled bottom panels and similarly apply EPDM sealant to the horizontal and vertical faces of the side panels (Figure 8). NOT: Ensure that all side faces of the panel are covered by sealant strips. Figure 8. Applying sealant strip around the side panels Then, place the Star Sealant Gasket (T shape) between the panels at the cross joints. Place 2 stars, back to back, where the 4 panels are connected (Figure 9). Don t forget to put a star seal between two side panels and bottom panel (Figure 10). Then bolt the row panels together with M10 bolts and nuts, and finish the side walls assembling. Figure 9. Placing the star seals between panels MEKSIS A.Ş. Page 6
Figure 10. Placing one star seals between side panels and bottom panel After assembly of the side panels, commence installation of 4 corner angels and ensure that the corner sealant gasket to be placed properly, as shown in Figure 11. Figure 11. Placing the corner sealant gasket 3.3. Installation of Reinforcing Ribs Proper installation of the reinforcing ribs is the most critical step in the tank assembly. Connect the reinforcing ribs to the side panels by bolting to the special end stiffener plates which are inserted between two side panels (Figure11 and 12). NOT: Use the same M10 bolts for reinforcing parts, and use washers for both sides. Also, ensure that the bolts and nuts are connected as shown in Figure 11 and. MEKSIS A.Ş. Page 7
Figure 11. Reinforcing ribs and end stiffener plates connections-inside view Figure 12. Reinforcing ribs and end stiffener plates connections-outside view 3.4. Assembly of Roof After the side panels assembly is completed, commence the installation of the roof panels. But before that, ensure that vertical supports are installed and tightened to the bottom panels (Figure14). Like bottom and side panels, first place and push the sealant strips to the flange faces of the top panels. Then, commence the assembly from side panels and proceed to the center. Finally, tighten the vertical support top to the roof (Figure15). MEKSIS A.Ş. Page 8
Figure 14. Vertical support assembly Figure 15. Assembly of roof and vertical support IMPORTANT NOT: During the tightening please consider the following: 1. All bolts must be fitted hand tight only at first. After the whole tank assembly is complete, tighten the bolts mechanically. 2. For mechanical tightening, tighten the nut with a nut-runner (i.e. impact wrench) and keep the bolt from the opposite side by a box end wrench, and be sure that the bolt head does not turn while the nut is turned. Before the tightening, proper tightening torque must be measured with a torque wrench (Figure16). 3. Maximum tightening torque shall be as follow: M10 M12 M14 45 (Nm) 60 (Nm) 80 (Nm) MEKSIS A.Ş. Page 9
NOT: During the tightening, ensure that the bolt holes are perfectly aligned (i.e. coaxial). Figure 16. Proper bolt tightening method 3.5. Assembly of the Accessories After the tank has been completely assembled, before filling, proceed to install the tank accessories which have been shown in Figure 4. Assemble of the inlet/outlet nipples and other connections shall be fitted to the positions, which have been agreed at the time of order (Figure 17). Figure 17. Inlet and outlet connection details Ensure that the manhole is fully sealed and cover is securely closed (Figure 18). MEKSIS A.Ş. Page 10
4. TEST AND TIGHTENING Figure 18. Manhole cover installation The final stage of sectional water tank assembly is leakage test. After filling, if any leakage occurs, carefully retighten bolts around the area until it stops. The following steps should be followed in the testing: 4.1. Bottom Leakage Test: First, fill the tank by test water up to 100 mm. After filling, tank shall be controlled for at least 4 hour. 4.2. Tank Side Panels Test: Tank shall be controlled from outside and inside by adding 500 mm water at each time. In case of any problem (e.g. Leakage, deformation, etc.), stop the filling and re-tension the bolts around the leaked area. After the solving the problem(s), test can be continued. 4.3. Final Step: Finally, tank shall be completely filled and left for at least 6 hours. If there is no sign of any leakage, tank test is completed. NOT: During the test, sometimes, it is needed to reduce the water level. In all water tank tests, there is a risk of discharging of averagely %25 of the tank capacity. In order to reusing the discharged water, it is recommended to provide another space (e.g. another small tank) to save the discharged water. MEKSIS A.Ş. Page 11
If there is no chance of such an extra space, the manufacturer is not responsible for cost of the discharged water. 5. IMPORTANT NOTICES AFTER ASSEMBLY Please consider the following note after the assembly of your tank: a. If possible, implement a filtration or a treatment system prior to the tank, for preventing unexpected corrosions. b. Depend on the stored water quality; corrosion may take place inside the tank, causing some health problems. For preventing this problem, it is strongly recommended that at least every one year, clean the tank. c. Do not clean your tank by unknown chemicals; they may cause damage at tank materials. d. Check bolts for unclench every one year and retighten any unclench bolts. e. All inlet/outlet connections shall be independently supported and shall not impose any point load on the tank body. f. Do not step or walk on the top of the tank. Also placing any heavy weights may result in deformations and leakages on the tanks. NOT: Entry into the tank should only be made by persons who are trained and equipped for entry into spaces. NOT: if the assembly of the tank has been made by untrained or unsupervised staff, no responsibility can be accepted by the MEKSIS for the installation. 6. MAINTENANCE Please review the related product Operations & Maintenance manuals for detailed information. MEKSIS A.Ş. Page 12
7. SUMMARY OF SECTIONAL WATER TANK ASSEMBLY MEKSIS A.Ş. Page 13
8. MEKSIS AFTER SALES SERVICE MEKSIS A.Ş. after sales service department provides comprehensive inspection, maintenance, cleaning and repair services on all its products. Our trained technical staffs are fully dedicated to ensure all works are carried out in compliance with relevant legislation and guidance. MEKSIS service includes the following: 8.1. Making a Service Agreement: Our service agreement includes monthly/annually preventive maintenances. 8.2. Technical Support Adding insulation in an existing tank Applying protective coating Implementation water treatment/softener Applying of electronic equipments for water level control or freeze alarm indicator. 8.3. Upgrade and Refurbishment Increasing or decreasing the tank capacities Complete removal and replacement tanks 8.4. Repair and Maintenance Tank cleaning Sealants and retightening the bolts Panel repairs or replacements Re-coating an existing tank MEKSIS Service Tel: +90 850 800 20 30 MEKSIS Service E-Posta: servis@meksis.com.tr MEKSIS A.Ş. Page 14