Installation, Operation, And Maintenance Manual (Revision 9-2023)

9/2023

GENERAL INFORMATION

•

Installation Videos: Please visit

https://www.polyprocessing.com/technical-

resources/video-library/

for installation videos and a current version of the Operation

and Maintenance Manual.

•

Installation: Hydro test (water test) tank system for 24 hours before introduction of

chemical. If necessary, remove all test water to prevent reaction with chemical stored.

Make sure all fittings are tightened using the factory recommended torque values and

techniques.

•

Heat Maintenance Systems: Two thermostats are furnished, one for control and one for

high limit; heating requirements vary depending on maintenance temperature, ambient

temperature, and wind conditions.

•

Polyurethane Insulation with Mastic Coating: 2-in nominal thickness, density range 2 – 2.8

lbs. /cubic foot, R value

≥

6.3 / inch, mastic coasting is white acrylic vinyl.

•

Nominal / Working Capacity: Calculated vertical tank capacity is to top of straight side-

wall.

•

ASTM D-1998 Standard: All vertical, IMFO

, and SAFE-Tank

systems greater than 500

gallons are manufactured in accordance with ASTM D-1998 standards.

•

Gallonage Markers: Approximate indicators are not intended for precise measuring or

metering. Fill vertical tanks and cones only to top of sidewall.

•

Support hoses, piping, and valves independent of tank sidewall and dome. Flexible

connections must be used to protect your tank warranty! (See page 26

) Shield all ﬁttings,

valves, and piping from physical impact and to protect personnel from chemical spray or

release.

•

Tank Foundation:

Place tank on a clean, smooth, and properly designed concrete foundation or in PPC

approved support assembly. Ensure NO trash of any kind is trapped between the tank

and its foundation or support.

IMFO

tank – use a PPC polyethylene PolyBase, a polyurethane PolyBase or a monolithic

concrete pad with ﬁnished edges to elevate bottom of tank above primary ﬂoor surface.

The pad must be at least 4”

in thick to provide full clearance for the IMFO® ﬂange. At

the IMFO® location, the straight wall of the tank must align with the straight wall of the

foundation with no more than 2” of projection under the IMFO neck at the cutout or

notch to prevent stress on the IMFO fitting. Use a polyurethane PolyBase or a concrete

pad

when storing ﬂuids with a speciﬁc

gravity greater than 1.65. (See 3D drawing on

next page)

9/2023

General guidelines to accommodate restraint clips and ladders:

−

Make foundation 2-ft larger in diameter than the diameter of the tank.

−

If using the IMFO

tank, provide a “notch” in the foundation to accommodate the

IMFO

outlet. Make sure the IMFO neck is supported and there are no valves or

heavy piping hanging off the IMFO.

−

If tank will have ﬁxed ladder, include adequate landing for the ladder to

prevent

injury.

WARNING:

Failure to provide proper foundation support constitutes a misuse of the tank and

will void your warranty!

9/2023

PRODUCT SPECIFICATIONS

•

Temperature:

Tank speciﬁc gravity ratings are based on continuous product operating

temperature of 100°F. For temperatures between 100°F and 150°F, please contact Customer

Support.

•

Pressure: Polyethylene tanks are designed and rated for atmospheric pressure only.

Proper venting alleviates pressure or vacuum from developing as the tank is ﬁlled and

emptied. See venting table below for proper

conﬁguration.

Two 2-inch vents DO NOT EQUAL 4-inch venting capacity.

For detailed venting guidelines, please visit:

www.polyprocessing.com/venting

•

Flexible Connections allow for tank expansion / contraction and reduce pump / piping

vibration stresses. Flexible connections

are required on any ﬁtting connection on

the lower

1/3 sidewall of the tank to preserve your warranty. (See page 25)

. Shield all ﬁttings, valves,

and piping from physical impact to protect personnel from chemical spray or release.

•

Tank Dome Loading: DO NOT stand or work on top of tank

. The tank surfaces are ﬂexible

and slippery and a dangerous fall could occur. There is no weight or load rating for the

domes of tanks.

9/2023

RECEIVING:

RECEIVING MERCHANDISE

•

Inspect immediately upon receipt for obvious damage, defects, or missing parts and

accessories.

•

Parts and accessories are often secured boxed and shipped loose from the tank. Locate

and open packages to account for all parts using the packing slip.

•

Note damage/discrepancies on the driver’s copy and the packing slip and have the driver

initial.

•

Immediately notify your Authorized Distributor or Poly Processing Company of any

problems.

•

DAMAGED/MISSING MERCHANDISE: Report damaged/missing merchandise within

THREE (3) working days to ensure your claim. Your authorized distributor and/or Poly

Processing Company can assist you with this process.

•

It’s common to store tanks for a period of time before installation. Often, loose or

boxed parts are misplaced or used for something else on site. We recommend clearly

marking any loose or boxed parts for the chemical storage tank only. Store boxes in a

safe location where they can be easily found and retrieved.

Tanks can sit in direct sunlight, but a tarp or cover will help keep them clean

Store tanks out of traffic areas, including forklift traffic, so they don’t get gouged

IMFO tanks or Sloped Bottom IMFO tanks need a 4 x 4 block under the IMFO

(molded outlet) so that it does not rest directly on the ground.

RETURNING MERCHANDISE

•

To return unused merchandise for proper credit:

Contact your authorized distributor or Poly Processing Customer Support and obtain a

PPC Return Merchandise Authorization (RMA) number. Have your packing slip available

for any needed information.

Use the RMA number on all return shipping paperwork and all correspondence.

Return the merchandise prepaid. Freight collect shipments will be refused.

Upon receipt, PPC will inspect the merchandise and issue appropriate credit. A

restocking fee may be assessed, particularly on products “made to order”.

•

To ensure employee safety, Poly Processing Company will not accept used tanks at its

facilities.

TANK LOCATION

•

Locate the Tank wisely:

Minimal employee and equipment traﬃc near

tank

Safe distance away from heat and

ﬂ

ames

Ease of future maintenance and inspection

Ability to remove and replace the tank cost eﬀectively in the future, i.e. Do not

trap/confine the tank(s) in a building or by other equipment

Provide

ﬂ

at, level and smooth monolithic foundation, adequate for the weight of the

chemical to be stored

Utilize secondary containment of proper size and chemical resistance to comply with

local, state, and federal regulations. The Safe Tank system is designed to provide a

minimum of 110% secondary containment

9/2023

OFF-LOADING INSTRUCTIONS

•

Keep personnel clear of tank, rigging, and lift equipment! Improper and unsafe

unloading can result in property damage, serious injury, or death.

•

DO NOT STAND OR WORK ON TOP OF TANK.

The tank surfaces are ﬂexible and

slippery, which could cause a dangerous fall. The tank dome is not load rated, as it is not

required per ASTM D D1998-06; therefore, it cannot be guaranteed that the top of the

dome can support the weight of personnel.

•

Whether unloading or moving, the tank must be fully drained before lifting.

•

Poly Processing strongly recommends using a licensed and experienced construction rigger to offload

and set the tanks safely.

•

Use of Lifting Lugs: (If the tank doesn’t have molded in or bolted on lifting lugs refer to page 8

regarding using the manway to offload the tank)

Consult the tank drawing for the proper number of molded-in lifting lug sets to use

during a lift. Two molded lugs constitute a set. See picture below.

Position the boom of the crane directly over the centerline of the tank lying on its side

near the dome (top). Use all lifting lug sets as the lift points (the holes in the lifting lugs

have a 1-3/8-in diameter and are spaced 8-in from side to side). Use a shackle with a

threaded pin to connect through each eyelet of the lifting lug. Make sure the shackle

with pin is large enough to take up as much of the hole as possible to improve lifting

control. Ensure each shackle with bolt and cable have a lifting capacity of a minimum

3000 pounds. (INSULATED TANKS: Extreme care should be taken to ensure that during

the attachment of the bolts and cables from the boom position to the lifting lugs, none

come in contact with the tank, causing damage to the foam surface. To prevent this from

happening, attach pieces of cardboard to the dome, near the lifting lug positions to

protect the sensitive surface area from any contact during the lifting process. Once you

have

conﬁrmed that all Lifting Lugs are properly attached and the slack in the cables

have been removed, it is now an appropriate time to cut away the protective wrap and

wooden cradle before starting the lifting process)

Slowly begin to raise the tank into an upright position. Take extreme care in balancing

the weight of the tank. (INSULATED TANKS: The bottom portion of the foam area of the

tank base will be crushed if it is allowed to tilt and sit on its own weight)

Once the tank is positioned in its upright position, lift it up and lower the tank back onto

the bed of the trailer. This will remove the tension from the cables temporarily to

provide the opportunity to reposition the clamps and cables and ﬁnd the true balance

point positions. (INSULATED TANKS: Remove protective wrap and wooden cradle and

discard)

Raise the boom slowly until all slack has been removed from all lifting cables and you are

assured the weight of the tank is now balanced. Lift the tank high enough to clear the

trailer. You

are now positioned to transport the tank to its ﬁnal

position.

IMPORTANT NOTE: If the tank has an IMFO,

before it is allowed to sit ﬂat on its own

weight at any point during the oﬀ

-loading process, a block (preferably a 12-in 4x4) must

be set underneath the IMFO base to keep it oﬀ the ground. This is necessary to keep

the IMFO from being damaged (by design,

it sits lower than the ﬂat bottom of the

tank).

2 LUGS = 1 SET

9/2023

•

Use of Manway: Poly Processing strongly recommends the use of lifting lugs or truck

straps underneath the tank to lift the tank. We also If those are not available, then the

following applies.

Use a lifting device as shown below. The bar should be a minimum 3-in in diameter, have

adequate strength for the load, and range in length from 42-in to 46-in.

•

Use of Forklift:

Ensure the forklift tines are smooth and free from burrs.

Use extended tines if handling a large tank.

Tie the tank to the forklift mast to prevent rolling or sliding.

Insert the forklift tines into the long side of the tank (either from the

dome or ﬂoor)

to achieve a balance point Lift the tank

oﬀ the bed of the truck. Back away from the

truck slowly, as the weight of the tank and the cradle are both very heavy. Be

prepared to stop and adjust your load if need be.

Slowly set the tank onto the ﬂoor in an unobstructed, ﬂat area that allows for the

forklifts to move around as needed.

Set (3) or (4) 4x4 blocks on the ﬂoor in a pattern of the outside radius of the tank.

This will aid in temporarily allowing the tank to be elevated oﬀ the

ground to allow

the forks to get underneath for transporting the tank to its ﬁnal

position.

Station another forklift on the opposite side of the tank. This forklift is used so the tank

will not tip forward or rock back and forth and is used as a safety measure to catch the

tank as it is stood up. Using cardboard sleeves or other protective methods, wrap the

ends of the forks to prevent the tank from being gouged in the event the forks touch

the tank as it is being stood up. Raise and widen the fork spacing to straddle the

outside radius of the tank.

Set tank upright over the blocks so the tank is positioned, and the weight is equally

distributed. Insert the forks of one of the lifts under the bottom of the tank and lift the

tank slowly, just enough to clear the blocks, and transport the tank to the desired

location, slowly.

9/2023

SAFE-SURGE

EMERGENCY AIR SURGE PROTECTION

To install:

SAFE-Surge® lids are HEAVY. Use lifting equipment to place the SAFE-Surge® lid over

the tank manway.

Rotate the lid until the warning label is next to the edge of the tank.

Secure the lid with the polyethylene bolts provided.

Make certain the movement of the center cap of the lid is unrestricted and able to open

to relieve pressure build-up in the tank.

WARNING: SAFE-Surge® lids are heavy (22 lbs.) and awkward! DO NOT attempt to use a ladder for

installing the SAFE-Surge® lid. The ladder may become unstable and lead to a fall or injury! Use lift

equipment appropriate for work environment or use scaﬀolding and hoisting equipment.

DO NOT BIND OR

RESTRICT MOVEMENT OF

THIS ARM AND ASSEMBLY

MAKE SURE WARNING LABEL

IS SECURE AND VISIBLE ON LID

9/2023

RECOMMENDED TORQUE VALUES AND TECHNIQUES

ALWAYS:

•

Lubricate bolts with anti-seize compound prior to installing nuts.

•

Tighten the nuts in a crisscross pattern using a calibrated torque wrench.

Tighten in 5 ft. lb. increments.

Fitting

Torque

PVC Bolted Flange

15-20 ft.lbs.

CPVC Bolted Flange

15-20 ft.lbs.

PP Bolted Flange

15-20 ft.lbs.

Stainless Steel Bulkhead

25 ft.lbs.

B.O.S.S.® Fitting

15-20 ft. lbs.

Bellows Transition Fitting

15-20 ft.lbs.

IMFO® Flange Fitting

15-20 ft.lbs.

Flexible Connections

15-20 ft. lbs.

PVC Bulkhead Fitting

1/4 turn beyond hand tight

(This may vary slightly)

External Pipe Support

Bolt

15-20 ft. lbs.

Method for applying thread sealant to

threaded ﬁttings:

The following tightening sequence

is suggested for the

ﬂ

ange bolts.

ILLUSTRATION

thread sealant

9/2023

IMFO® FLANGE FITTING ASSEMBLY

•

The IMFO® (Integrally Molded Flanged Outlet) is assembled at the PPC plant sites and

hydro tested to ensure proper seal.

•

There are two types of IMFO® back up rings.

Tapered IMFO® w/ Stainless Steel Back-up Ring

Original IMFO® w/ PVC Back-up Ring

•

DO NOT disassemble the factory installation. If

ﬁ

eld replacement is necessary, use

picture and exploded view on the next page as a guide. Make sure the fittings are

tightened using the factory recommended torque values and techniques.

•

Protect the IMFO® ﬂanged nozzle when storing and installing. When storing, the tank

can be stood upright with adequate blocking or laid on its side and chocked to prevent

rolling.

•

Make sure the IMFO neck is supported and there are no valves or heavy piping

hanging off the IMFO. See Tank Foundation under General Information.

•

Note: Installing a butterfly valve on the IMFO fitting may require a spool

assembly for a proper seal. Contact the factory for more information.

CORRECT STORAGE: Notice clearance of tank above the ﬂoor

4” Minimum Clearance Between Tank

Bottom and Floor

9/2023

B.O.S.S. FITTING

(Bolted One-Piece Sure Seal)

ASSEMBLY

Using the gasket as a template, mark the bolt holes on the outside of the tank.

Drill the center hole and stud holes with a 1/4-in pilot bit. Be precise with the layout and

drilling of the tank as the ﬁtting requires close tolerances.

Drill out the pipe ﬁtting hole using a hole saw. Please note that the hole to be drilled into

the tank may be smaller than the hole in the outer plate that was used as a template. The

hole drilled should be only slightly larger than the outside diameter of the pipe

ﬁ

tting.

Next drill out the stud bolt holes using a 9/16-in drill bit for the 1/2-in diameter studs.

Clean and bevel all drilled and cut holes on the inside and outside of tank surfaces.

Install the ﬁtting and gasket from the inside of the tank. Inside of tank must be ﬂat and

smooth. If the inner surface is uneven or lumpy, the inner wall must be faced smooth

using a drill with sandpaper attached to a steel plate. All surfacing must be done in a

circular manner.

Slide the ﬂange onto the stud bolts that are protruding on the outside of the

tank.

Place the washers and nuts on the stud bolts. Tighten the nuts in a crisscross pattern using a

torque wrench. Tighten until the gasket is fully compressed (approximately 15-20 ft. lbs. on

a torque wrench).

Inspect the ﬁtting. The gasket should be compressed and the ﬂange should conform to

the

wall of the tank.

10.

Hydro test the tank for at least 24 hours prior to loading with chemical.

11.

These fittings will require a thicker Teflon tape and should be wrapped around threads

several times

Ring

Fitting

Tank

Wall

Flat

Lock

Fitting size

Hole saw

1”

1 1/2”

2”

2 5/8”

3”

3 5/8”

9/2023

BULKHEAD FITTINGS

Slide the gasket over the body of the

ﬁ

tting.

From inside the tank, insert ﬁtting body into hole in tank

sidewall.

Lubricate threads on ﬁtting

body with thread sealant and install large nut on the

outside of the tank.

Hand tighten

plus 1/4 turn with a wrench. This may vary slightly. Most Bulkhead ﬁttings use left

hand threads.

Do not allow ﬁtting body to slip or spin when tightening to prevent the gasket from

creeping between the ﬁtting and the tank

wall.

Inspect gasket for creep. If found, loosen nut and perform steps 4 & 5 again.

When installing a pipe or ﬂange adapter into the BHF, do not allow BHF to slip and

not over tighten.

Hydro test the tank for a minimum of 24 hours before placing into chemical service.

Bulkhead ﬁttings and tank sidewall

restrictions: Should not be used on the bottom sidewall of tanks

greater than 3,000 gallons or tanks greater than 6’ in height.

BHF size

Hole saw size

1/2”

1 3/8”

3/4”

1 5/8”

1”

1 7/8”

1 1/4”

2 3/8”

11/2”

2 5/8”

2”

3 1/4”

3”

4 1/2”

4”

5 3/4”

9/2023

BOLTED FLANGE FITTINGS

Flanges for pipe sizes 4-in and larger should be curved to match the outside diameter

of the tank.

Disassemble the ﬁttings as shipped. If the holes are not drilled, place the ﬂange

against the

tank in the desired location and use as a template for drilling the holes. Use a hole saw the

same size as the ﬁtting’s

port.

Clean and bevel all drilled and cut holes on the inside and outside of tank surfaces.

With the gaskets installed, place the stud bolts through the holes with the plastic head on the

inside of the tank; threads on the outside.

Place the full face ﬂange gasket over the bolts on the outside surface of the

tank.

Place the ﬂange over the gasket and stud threads with the hub of the ﬂange facing

out.

Put a washer and nut on each stud bolt. Be sure to lubricate the threads of the bolts with

anti-seize compound.

Tighten the nuts in a crisscross pattern using a torque wrench. Tighten in 5 ft. lb.

increments to 20 ft. lb.

Inspect ﬁtting. Gasket must be compressed and the outer ﬂange drawn down

evenly.

10.

Piping such as a ﬂange adapter should now be threaded into the ﬁtting.

Thread sealant or

Teflon tape is recommended

should be applied to all pipe threads. Do not over tighten.

11.

Hydro test the tank for a minimum of 24 hours before placing into chemical service.

Bolted Flange size

Hole saw size

1”

1 5/8”

11/2”

2”

2 1/2”

3”

3 5/8”

4”

4 1/2”

6”

150#

Flat

Lock

Assembly

Inside

CAUTION:

Over torquing will damage the ﬂange and gaskets.

9/2023

STAINLESS STEEL FITTINGS

Disassemble the stainless steel ﬁtting by removing the nuts from the stud bolts. Remove

the 1/8-in thick stainless-steel

outer plate. Set the remainder of the ﬁtting aside along with

the nuts and washers.

Using the outer plate as a template, mark the bolt holes on the outside of the tank.

Find the center of the large “pipe ﬁtting” hole by drawing an “X” through the center

of the

bolt holes.

Drill out the pipe ﬁtting hole using a hole saw. Please note that the hole to be drilled into

the tank may be smaller than the hole in the outer plate that was used as a template. The

hole drilled should be only slightly larger than the outside diameter of the pipe

ﬁ

tting.

Next drill out the stud bolt holes using a 9/16-in drill bit for the 1/2-in diameter studs.

Clean and bevel all drilled and cut holes on the inside and outside of tank surfaces.

Install the ﬁtting and gasket from the inside of the

tank.

Slide the outer plate onto the stud bolts that are protruding on the outside of the tank.

Replace the washers and nuts on the stud bolts. Tighten the nuts in a crisscross pattern

using a torque wrench. Tighten until the gasket is fully compressed (approximately 25-ft.

lbs. on a torque wrench).

10.

Inspect the ﬁtting. The gasket should be

compressed, and the outer stainless-steel plate

should conform to the wall of the tank.

11.

Hydro test the tank for a minimum of 24 hours before placing into chemical service.

STAINLESS STEEL Coupler

STAINLESS STEEL Full Nipple

Tank Wall

Inside

Lock

Rhino SS

BHF size

(Coupler Style)

Hole saw

size

1/2”

1 3/8”

3/4”

1 5/8”

1”

1 7/8”

1 1/2”

2 1/4”

2”

2 5/8”

3”

4 1/2”

4”

5”

Rhino SS

BHF size

(Nipple Style)

Hole saw

size

1/2”

1 3/8”

3/4”

1 5/8”

1”

1 7/8”

1 1/2”

2”

2 1/2”

3”

3 5/8”

4”

4 3/4”

9/2023

FILL LINE ASSEMBLIES

•

Fill line assemblies are available in 3 styles: internal, external and combination (see example

drawings below, number of pipe supports may vary).

•

Your tank system may be equipped with a drop pipe stabilizer bracket which is typically shipped

loose and requires simple installation. The internal pipe support is typically preinstalled at the

manufacturing facility.

Internal

Pipe

Support

Combo Fill Line

Adjustable

Nut for

Positioning

9/2023

SELF ALIGNING UNIVERSAL BALL DOME FITTING

The Self Aligning Universal Ball Dome ﬁttings are designed for

use only on tank domes. DO NOT

USE ON THE SIDEWALL OF THE TANK! There are two styles of Ball Dome ﬁttings: Bulkhead

Fitting Style and Bolted Flange Style.

Do not stand on tank dome when installing dome

ﬁ

ttings.

Use portable ladders, scaﬀold

ing, or personnel lifts with proper fall protection.

Install the bulkhead

ﬁ

tting or

ﬂ

ange portion of the ball dome

ﬁ

tting according to instructions

found on page 13 or page 14.

Thread piping into the threaded ball of the ﬁtting. Use thread

sealant.

Adjust vertical alignment:

Gently loosen the ball retainer ring located on top of the ﬁtting ball using a

large

blunt screwdriver or punch and hammer.

Adjust piping to desired angle.

Tighten retainer ring with blunt screwdriver or punch and hammer taking care not to

over-tighten!

WARNING:

Do not stand or work on top of tank. The tank surfaces are ﬂexible and

slippery and could

cause a dangerous fall to occur. There is no weight or load rating for the domes of the tanks.

BHF Style

Ball

Flat

Lock

Ring

Flange Style

UBD size

(BHF Style)

Hole saw

size

1”

3 1/4”

2”

4 1/2”

3”

5 3/4”

UBD size

(Flange Style)

Hole saw

size

2”

3 1/2”

3”

4 1/2”

4”

5 3/4”

9/2023

REVERSE FLOAT LIQUID LEVEL GAUGE

REVERSE FLOAT SYSTEM MAY NOT INCLUDE INTERNAL DOWNPIPE AND PIPE SUPPORT IF ORDERED

WITHOUT IT. CHECK WITH YOUR SALES CONTACT TO SEE IF IT WAS INCLUDED IN THE ORDER.

DO NOT USE GLUE FOR ANY OF THE FOLLOWING STEPS!

Retrieve exterior portion of gauge that is shipped loose.

Thread rope through:

Threaded nipple (for the tank dome

ﬁ

tting)

Over the top of the rollers in the

ﬁrst

90 degrees elbow

Short horizontal pipe

Over the top of the rollers in the second 90 degrees elbow

Attach rope to level indicator (note: length of rope must be determined during installation).

Install threaded nipple into dome

ﬁ

tting.

Attach

ﬁ

rst 90-degree elbow.

Attach short pipe.

Attach second 90- degree elbow.

Place level indicator into clear pipe.

Attach clear pipe to 90- degree elbow.

10.

Attach clear pipe to external pipe stabilizer.

11.

If using calibration tape, install from the bottom of the tank working

towards the top.

Periodically lubricate rollers to ensure proper operation!

See

www.polyprocessing.com/reversefloat

for more information

1/8-in Dia Yellow

Polypropylene

Rope

Fitting as

req’d

2-in Sch 80 Pipe

Th’d (1) End

2-in x 4-in Sch

80 Th’d Adpt

2-in Sch 40

Elbow W/

Roller Pulley

2-in Sch 40

Clear Tube

Float

4-in Perforated

Sewer Pipe

Pipe Stabilizer

2-in Sch 40

Pipe Cap

4-in x 4-in

Sewer Bushing

Level

Indicator

9/2023

Once the dome connection is made, pull the bottom section of the pre-cut piping to one side while angling the base until
the slip by slip connection can be made. Note: All connections are “glued connections”. As the piping is slipping into the
base bring the entire system back to a vertical position aligned with the dome fitting.

❹

Photo showing the base installed to the piping and aligned vertically with the dome fitting.

NOTE: At this point, re- tighten the dome fitting.

❺

After tightening the dome fitting, hand, tighten the plastic thumb screws (5) until they

touch

the bottom of the tank.

❻

Pre-cut internal
piping, Top is
connected to the
dome fitting.

Pipe support
base

9/2023

SIGHT GLASS LIQUID LEVEL GAUGE

DO NOT USE SIGHT GLASS GAUGES IN SULFURIC ACID OR OTHER DANGEROUS

CHEMICAL SERVICE! Use only in benign applications such as water.

Sight glass assemblies are completed at the factory and shipped separate of the tank to pre-

vent damage.

Separate the unions on either end of the assembly.

Screw the two short

nipples, with 1/2 of the union, into the sight glass ﬁttings at the top

and

bottom of the tank.

Rejoin the unions on the assembly and tighten carefully.

If necessary, install additional valves and/or piping.

HYDRO TEST FOR 24 HOURS before placing into chemical service!

Special Notes:

•

The clear tubing will discolor over time due to chemical and UV attack.

•

WARNING: In the event the liquid level gauge is damaged or leaks, it is very likely the entire

contents of the tank will be lost! Use only in benign applications such as water.

WARNING: Do not use sight gauges in sulfuric acid or other dangerous chemical service. Loosening of

any ﬁttings associated with a sight glass liquid level gauge, may result in a chemical spill and/or

property damage, bodily injury, or death.

9/2023

INSTALLATION GUIDELINES

ENHANCED BELLOWS TRANSITION FITTING

Before crane or boom truck leaves, make sure step 1-3 are completed and see videos at

https://www.polyprocessing.com/safetankinstall

for SAFE-Tank Installation Instructions

Tightening/torque criteria:

•

Steel bolts/stud bolts --- tighten in crisscross pattern to 20 ft lbs. max.

•

PVC BHF Nut --- Hand tight plus ¼ turn with a wrench

TESTING:

Following assembly, fill tank with water to the top knuckle, allow it to set for 24 hours, check to ensure no leaks

STEP 1!

CRITICAL STEP:

ENSURE THE LINE ON

THE ALIGNMENT SLEEVE LINES UP WITH THE

OUTSIDE EDGE OF THE TANK.

THE ALIGNMENT

SLEEVE MUST BE CENTERED AND THE GAP

MUST BE EQUIDISTANT AROUND THE SLEEVE.

THIS MUST BE DONE WHILE CRANE OR BOOM

TRUCK IS STILL AVAILABLE. THIS WILL ENSURE
PROPER SPACING BETWEEN THE TWO TANKS.

STEP 3

STEP 4

STEP 2

AFTER ALIGNMENT IS CONFIRMED

(THE

ALIGNMENT SLEEVE IS CENTERED)

REMOVE (2)

NUTS AND REMOVE AND DISPOSE OF THE

ALLIGNMENT SLEEVE. WITH ALIGNMENT SLEEVE

REMOVED MEASURE TO ENSURE INNER TANK

FITTING IS CENTERED IN OUTER TANK HOLE.

INVENTORY:

•

(1) BELLOWS HOUSING

•

(3) SS SPLIT RINGS

(

(2) 6”/(1)8”

)

•

(1) PIPE/FLEX JOINT/BHF

ASSEMBLY

•

(1) PLASTIC PE PLATE

•

(2) GASKETS

(

(1) 6”/(1)8”

)

•

HARDWARE

WITH ALIGNMENT SLEEVE REMOVED

, REMOVE NUT

FROM BHF/PIPE ASSEMBLY AND SET ASIDE FOR LATER

USE.

MAKE SURE ALL BOLTS OF THE PIPING

ASSEMBLY ARE TORQUED CORRECTLY INCLUDING

TANK FITTING, EXPANSION JOINT CONNECTIONS AND

(COUPLER IF B.O.S.S. FITTING IS INSTALLED)

. GLUE

PIPE ASSEMBLY INTO THE INNER TANK FITTING.

9/2023

3-15-19

WITH ALIGNMENT SLEEVE REMOVED

REMOVE NUT FROM BHF/PIPE ASSEMBLY

AND SET ASIDE FOR LATER USE. GLUE PIPE

ASSEMBLY INTO THE INNER TANK FITTING.

STEP 7 (BACK SIDE VIEW)

STEP 7 (FRONT SIDE VIEW)

RE-INSTALL GASKET ON BHF THEN INSTALL; 6” GASKET, BLACK PE PLATE, AND 6” SPLIT RING’s USING

THE PROVIDED HARDWARE. TIGHTEN NUT ONTO BHF. CONNECT PLUMBING TO
FEMALE THREADED BULKHEAD FITTING.

HYDRO TEST TANK

SECTIONED VIEW

ENTIRE ASSEMBLY

QUESTIONS CALL: 1-866-765-9957

STEP 6

INSTALL BELLOWS HOUSING AND 8” SPLIT RING USING THE

PROVIDED HARDWARE.

NOTE:

AFTER ASSEMBLY IS GLUED

REMOVE GASKET FROM BHF AND CHECK WITH A STRAIGHT EDGE

TO ENSURE ALL SEALING SURFACES ARE ON THE SAME PLANE.

CHECK
SEALING
SURFACES
WITH
STRAIGHT
EDGE.

STEP 5

INSTALL 8” GASKET ON OUTER TANK

9/2023

Butterﬂy

Polyethylene

Flexible connection

Stud Bolts

Flexible connection

FLEXIBLE CONNECTIONS

PPC requires that fittings and connecting pipes installed on the lower 1/3

of the sidewall of a tank have flexible

connections with the lowest spring rates possible to mitigate nozzle loading and to allow the tank to expand and

contract and to protect the tank from pump vibrations.

The Ethylene Flex-

Joint and the

Proco 261R and 262R EPDM expansion joints have the lowest spring rates with

the largest range of movements and are best suited for polyethylene and other plastic tank materials and piping

systems. Poly Processing Company has experience with these expansion joints installed on our tanks in the field.

When properly installed between the tank nozzle and the independently supported piping, the nozzle loads are

reduced to the maximum spring rate of the flexible connection.

Do not use expansion joints that are designed

for steel piping on a plastic tank. Using the wrong expansion joint or system will void the warranty. Expansion

joints should not be attached directly to the tank wall or IMFO. A full face flange must be installed on the tank

first. Contact our factory with any questions.

Pipes connecting to dome fittings should also be independently supported eliminating nozzle load and do not

require flexible connections as there is little to no movement on the tank dome when the tank is filled and

emptied.

•

Install ﬂexible connection in accordance with the speciﬁc

manufacturer’s

installation guidelines:

The “breech opening” in the piping for the ﬂexible connection should be within

1/8-in of

the relaxed length of the ﬂexible connection.

Flexible connections are not to be used for correcting piping misalignment. The ﬂexible

connection and mating ﬂanges must be installed in a centered and neutral

position.

Attach only

FULL FACE ﬂanges to the ﬂexible connection. They are not designed

attach directly to the tank wall.

Ensure adequate clearance between bolt ends for full use of

ﬂ

exible connections.

Torque to 20 ft. lbs. using crisscross tightening pattern.

Provide pipe

support adjacent to the ﬂexible

connection.

Flexible connection

installed on IMFO

ﬂ

ange

(Optional Flange Mate Shown)

Flexible connection

installed near tank

sidewall

(Optional Flange Mate Shown)

9/2023

•

Flexible Connection Minimum

Speciﬁcations:

(For common size fittings and piping systems up to

6”) Contact Poly Processing for information on larger expansion joints.

Axial Compression

≥

0.67”

Axial Extension

≥

0.67”

Lateral Deﬂection

≥

0.51”

Angular Deﬂection

≥

14°

Torsional Rotation

≥

4°

•

Installation of ﬂexible hose

connections:

Use of thread sealant or Teflon tape is recommended for pipe thread preparation.

Support hose adequately but do not restrict its ability to move in horizontal directions.

FLEXIBLE CONNECTIONS

Proper Installation of Pipe Supports

Pipe supports positioned

CORRECTLY

: pipe support must be placed after

the ﬂexible connection to allow the tank to properly expand and contract.

9/2023

Pipe supports positioned

INCORRECTLY

: pipe support incorrectly placed

before the ﬂexible connection does not allow the tank to properly expand

and contract, which can cause the piping or tank to crack over time.

FLEXIBLE CONNECTIONS

Proper Installation of Expansion Joints

Flexible connections aligned

CORRECTLY

: pipe system with the expansion joint

is aligned in a straight manner, which allows for proper expansion and

contraction of the two connecting tanks.

Flexible connections aligned

INCORRECTLY

: the expansion joint should not be

used to accommodate misaligned piping. This will limit the ability of the

expansion joint to function correctly and possibly damage the joint itself.

9/2023

CUSTOMER INSTALLATION GUIDELINES FOR FRP LADDERS

Pre-Installation

Tank will arrive with

bracket attached

Ladders will arrive

packaged

Unpacking the ladder

components

To uncrate ladder,

remove end panel &

slide ladder out

FRP ladders are provided in a

variety heights and assemblies.

The example shown is a 15-foot

ladder with cage, return, and

adjustable support bracket.

EACH FRP “part” provided is

labeled for easy installation.

Hardware needed for each part is

packaged individually for the

speciﬁc use.

Vertical cage slats are

numbered as shown in the

photo and must be installed in

this sequence. Both of the

FS-1 slats will have additional

bolt holes for attachment to

the cage brackets

Feet and hardware

Main ladder span

Laying out the components of

your ladder will ensure you have

all the parts needed and make

installation simple.

Lower Cage Hoop (the

longest of the hoops)

Cage Attachment bracket for

both sides of the ladder span

Adjustable support bracket

Step 1

9/2023

Ladder assembly and installation WARNINGS:

Make certain there is an adequate, level landing where the ladder will be installed.

Ladder is heavy. Use mechanical lifting equipment to raise ladder to vertical position.

Do not climb ladder in any manner until it is fully attached both top and bottom.

Use portable ladders, scaﬀolding, or personnel lifts when installing ladder.

Do not stand or work on top of tank. The tank surfaces are

ﬂ

exible and slippery and a

dangerous fall could occur. There is no weight or load rating for the domes of tanks.

Attach feet to the

bottom of the

ladder legs

Support bracket bolted to

ladder rails

Install returns or walk through

if applicable at top of ladder

Use pre-drilled holes

approximately at the

midpoint of ladder.

Install bolts with bolt

head on the inside of

ladder railing and

nuts and washers on

the outside.

Flat side of support

bracket is to be

directed toward the

tank

There are 2 predrilled bolt

holes for the returns.

bolt, washer, and nut as

the bottom bolt holes will

be used to attach to the

ladder bracket (blue),

which comes already

attached to the tank.

Ladder bracket shown in

photo has been removed

from tank for clarity. DO

NOT remove bracket from

tank when making ﬁeld

installation.

Returns/walk through

sections are designed to

slide inside the ladder

railing

Step 3

Assemble and attach

adjustable support

bracket

Bolt the mounting bracket

to the adjustment plate

Completed assembly

9/2023

Detail showing cage attachment

bracket bolted to ladder railing

Finished assembly of cage

Review the layout to ensure it is

correct

***STOP*** Carefully check tightness, 5 ft. lbs., of all

nuts and bolts before proceeding.

Ladder assembly and installation WARNINGS:

Make certain there is an adequate, level landing where the ladder will be installed.

Ladder is heavy. Use mechanical lifting equipment to raise ladder to vertical position.

Do not climb ladder in any manner until it is fully attached at both top and bottom. Use portable ladders,

scaﬀolding, or personnel lifts when installing ladder.

Do not stand or work on top of tank. The tank surfaces are ﬂexible and slippery and a dangerous fall could

occur.

There is no weight or load rating for the domes of tanks.

In addition:

Make certain the four bolts associated with the metal ladder attachment bracket are tight before using ladder.

No ﬁeld drilling of holes in the ladder is required. Do not drill extra holes or enlarge factory drilled

holes.

When fully assembled, the ladder and accessories should have no unﬁlled bolt

holes.

Perform an annual routine inspection of the ladder tightening bolts and looking for signs of damage or

deterioration. Remove any suspect ladder from service and destroy.

Step 5

Install cage attachment brackets

Labeling and sequence of

installation is critical

Begin by laying both of

the FS-1 vertical slats

EDGE ways on the cage
attachment brackets

Install the hoops by

bolting one side and

then bending the hoop

to the other side,

install bolts

Note:

That Vertical slat

goes inside the hoop

Photo showing location for cage

attachment brackets to ladder

railing (8 total). Heads of bolts are

on climbers’ side of ladder.

Step 6

Install the cage to the ladder

9/2023

Drawing Example

CAUTION

Lift the ladder by mechanical means

such as a forklift and align the pre-

drilled holes in the top of the ladder

railing with the holes in the tank’s metal

ladder bracket. The tabs of the ladder

bracket go inside the ladder rails.

Bolt the ladder and bracket to one

another using the 3/8” x 2 ½” bolts.

Torque to 5 ft. lbs.

Plumb the ladder. Mark the location for the

anchor bolts. Drill anchor holes and attach

ladder to foundation.

Step 8

Make Adjustments

After the ladder has been aligned and securely

attached at top and bottom, adjust to support

bracket so that the ﬂat side touches the outer wall

of the tank, tighten support bracket bolts.

Step 7

Attach the ladder to the tank using the

metal ladder bracket

9/2023

RESTRAINT SYSTEMS

Wind and seismic restraint systems are governed by state and local code. Consult your local code for

requirements. The drawings below show specific seismic systems. The material, type of clip, quantity

of clips, cables, etc. may vary. Please consult the calculations that were sent with your system or

contact Poly Processing with any questions.

Restraint Clips

Space equally around circumference of tank. If tank operating temperatures exceed 100° F,

contact Customer Support for proper clip placement.

Allow minimum of 1-in clearance between tank and back of clip to accommodate tank

expansion.

Attach the clips to the foundation with appropriate fasteners (customer supplied).

Cable Assembly

Place cable assembly over the tank with the cable sling or tension ring at the top center of

the dome.

Pass each cable leg over the upper shell knuckle.

Place the wire rope thimble in the eye-nut (Style A) or the hole provided in the restraint

clip (Style B) and loop the cable around the thimble.

Install the wire rope clips by forming a loop with the cable end. See instructions included

with wire rope clips.

After the cable is attached to the restraint clips, the excess cable slack must be removed. Cable

tension should only be hand tight. Excessive cable tension should be avoided as it may cause

undue stress and deformation to the tank.

After cable tension is properly adjusted, the wire rope clips should be checked for proper

tightening.

Periodic Inspection

Periodically check cables and wire rope clips to ensure proper but not excessive tension.

Adjust if necessary, following steps e and f above.

9/2023

HORIZONTAL TANK STANDS

NOTE: Horizontal tank stands are designed to be located on level concrete foundations or other

approved surfaces. Tank stands must be bolted to the foundation. Stands for larger horizontal tanks are

shipped “knocked down” to minimize freight. Small tank stands do not require assembly.
If working with a stand shipped “knocked down”:

Check to ensure that the following components have been received:

Vertical leg units

Side angle braces

One bag containing stainless steel tabs and bolts

Assemble vertical leg units to side angle braces. Square unit and tighten all bolts.

If working with any stand:

Place the stand on a level foundation.

Anchor stand to foundation with appropriate bolts. (customer supplied)

Center tank and skid on stand.

With a forklift, crane, or other lifting device, place the tank and skid onto the stand, being

careful not to damage the skid. Protect hands and ﬁngers from pinch points during this

step.

Locate holes in the top of the stand and center the tank and skid unit on the stand.

Install the stainless-steel tabs and bolts using the holes in the top of the stand per

photo below.

Hydro test the tank for at least 24 hours prior to loading with chemical.

Tank Size

No. Upright

Leg Units

No. Side Angle

Braces

No. of Bolt

Assemblies

No. of Tabs

520 gal.

stand is welded together

1,000 gal.

1,950 gal.

Note: These “knocked down” assembly instructions apply only to horizontal tank stands from Monroe, Louisiana.

Assemble Side Angle Braces

Position SS Tabs

Place Tank on Stand

Finished Assembly

9/2023

START-UP CHECKLIST

Hydro test (water test) tank system for 24 hours before introduction of chemical. Remove all

test water from tank to prevent reaction with chemical stored.

Make sure all fittings are tightened using the factory recommended torque values and

techniques.

Follow chemical manufacturer’s best practices for product being stored.

Conﬁrm compatibility of tank, ﬁttings, bolts and gaskets before ﬁlling tank with

chemical.

Obtain, utilize, and retain Material Safety Data Sheets (MSDS) for the chemical being stored.

Make sure vent size is not reduced. Inspect vent lines for obstruction. Verify vent size is

adequate to prevent over pressurization of the tank. Follow Poly Processing’s venting

guidelines. See page 4.

Ensure ﬂexible connections are installed on all lower sidewall ﬁttings and that they

are

installed correctly. See page 26.

Ensure there is adequate support of valves, piping and hoses and that support is installed

correctly. See page 26-29

Ensure valves are installed as close to the tank as possible. Be sure valves can be

easily accessed.

Check ladders at top and bottom for stability and safety.

Label tank with the appropriate warning label for the chemical being stored. Do not remove

Poly Processing’s general warning labels.

SAFETY TIPS

•

DO NOT STAND OR WALK ON TOP OF TANK.

The tank surfaces are ﬂexible and

slippery and a dangerous fall can occur. There is no weight or load rating for the domes of

tanks.

•

Tanks are conﬁned spaces. Follow proper entry procedures based on local,

state, and

federal regulations. Establish and adequate retrieval plan.

•

Maintain guards, shields, barriers,

and walkways to protect tank, ﬁttings and

piping

from impact and to protect personnel from chemical release.

WARNING: Failure to adequately support tank,

ﬁ

ttings, valves, piping, and hoses and to protect

them from impact can cause chemical release resulting in serious injury or death.

9/2023

MAINTENANCE ITEMS

Conduct annual inspections of the tank. See page 38 for inspection guidelines.

Inspect gaskets for signs of fatigue. Replace as necessary.

Check bolt torque on ﬁttings and adjust as

needed. Make sure all fittings are tightened using the

factory recommended torque values and techniques.

Look for signs of stress cracking on both the exterior and interior surfaces of the tank.

Look for crazing or a spider web type look.

Check ﬂexible connections to make sure they are functioning properly, are not in a

bind,

and are not worn or leaking.

Check threaded couplers to make sure they cannot be turned by hand.

Check for leaks at the threaded couplers. This can be caused by over tightening and can

take months or years to ﬁnally

give.

Inspect valves for leaks and make sure they are working properly.

Inspect vent lines for any restrictions or obstructions.

Inspect ladders, brackets, stabilizers and stands for signs of corrosion.

9/2023

ANNUAL TANK INSPECTION CHECKLIST

Even relatively new polyethylene tanks should receive routine and careful visual inspections. These

inspection guidelines should be followed at least annually to ensure the safety of personnel and the

preservation of the chemical stored. The tank should be replaced if it displays stress cracking,

crazing, or embrittlement.

Empty the tank. Neutralize any chemical remaining. Thoroughly clean the exterior and

interior of the tank. A dirty tank cannot be properly inspected.

Examine the exterior and the interior of the tank for cracking, crazing and brittle appearance.

Pay particular attention to areas around ﬁttings and where diﬀerent portions of the tank

converge into one another. In other words, give special attention to “corners” where sidewall

and dome meet and where sidewall and bottom meet.

If a conﬁned space entry is not feasible, use a bright light source to inspect the tank interior from

the manway opening. An interior inspection is essential because stress cracks normally show up

on the inside of a tank before appearing on the outside.

Don’t forget to inspect areas of the tank that never actually come in contact with the chemical

stored. With fume-emitting chemicals, oxidation and resulting embrittlement of the dome can

occur without any actual contact with the chemical stored.

Inspect ﬁttings, ﬂexible connection hoses, and gaskets for leaks and signs of general

corrosion or deterioration.

Inspect vents and fume scrubbers to ensure adequate venting for pressure and vacuum.

Ensure end of scrubber piping is never submerged in more than 6 inches of liquid.

Conﬁrm that ﬁlling of the tank from tanker trucks is not causing over pressurization and

not

ending with a line purge that “balloons” the tank. See “VENTING” on page 4.

Conﬁrm secondary containment is appropriate for chemical stored, adequate in size, and in

good repair.

WARNING: Failure to follow these inspection guidelines and take necessary corrective actions can

result in unintended chemical release causing serious property damage, injury, or death.
Chemical fumes may be present in the area of the manway opening.
A tank is a

conﬁned space.

Do not enter tank without a conﬁned space entry and retrieval plan.

Use lift equipment and/or fall protection to prevent fall into or away from tank.
DO NOT STAND OR WORK ON TOP OF TANK.

Dome surfaces are ﬂexible and slippery. The

dome may be embrittled. A dangerous fall could occur.

9/2023

LIMITED WARRANTY

Poly Processing Company

Poly Processing Company Product

Warranty Period

CROSSLINKED POLYETHYLENE TANKS

for all suitable applications except those listed below

Max tank size for on-site generation of low concentration sodium hypochlorite (.8%) is 4000 gal

unless larger size approved for specific application

5 yrs.

IMFO



TANKS STORING

SODIUM HYPOCHLORITE 9 – 15 wt.%

(refer to PPC Position Statement)

HDXLPE

w/ OR-1000



1.9 spg. rating

5 yrs.

-IMFO



TANKS STORING

SODIUM HYPOCHLORITE 9 –15 wt.%

(refer to PPC Position Statement

for System Requirements) 1000 gallons and larger: HDXLPE

w/ OR-1000



, 1.9 spg. rating

Less than 1000 gallons: HDXLPE 1.9 spg. rating

3 yrs.

ANKS STORING

SULFURIC ACID

≤

98%

CONCENTRATION

(refer to PPC Position Statement for System

Requirements)

Sulfuric Acid may be stored in tanks less than 11,000 gallons and less than 15’ tall. This includes

vertical, IMFO

, Sloped IMFO

, and SAFE-Tank

3 yrs.

ANKS STORING

HYDROCHLORIC ACID

≤

37%

CONCENTRATION

(refer to PPC Position Statement)

HDXLPE

w/ OR-1000



1.9 spg. rating

5 yrs.

ANKS STORING

HYDROCHLORIC ACID

≤

37%

CONCENTRATION

(refer to PPC Position Statement)

HDXLPE 1.9 spg. rating

3 yrs.

LINEAR POLYETHYLENE TANKS

- for all suitable applications except

Sodium Hypochlorite 9 –

15%; Sulfuric Acid and Hydrochloric Acid of any concentration

3 yrs.

Chemical manufacturing service, rental service, mobile service, and elevated temperature service are special applications.

Contact Poly

Processing Customer Service for warranty for these applications

Poly Processing Company’s warranty consists of repair or ONE-TIME replacement of defective product. Owner and/or user may be requested to provide

a cleaned section of the product in question for evaluation. Product disposal or alternate use is the owner and/or user’s responsibility. Warranty begins at

date of shipment from PPC plant.

Standard Poly Processing parts and ancillary items are warranted for ninety (90) days. Electrical heat tracing systems are warranted ONE YEAR. Non-

standard parts warranty is by manufacturer.

Poly Processing Company’s liability is limited to either repair or replacement of its product. By accepting delivery of the product, owner and/or user waives

any claim against PPC for incidental or consequential damages as they relate to lost profits or sales or to injury of persons or property, including secondary

containment. Owner and/or user accepts full responsibility for providing secondary containment appropriate and adequate for the stored material.

This warranty will be nullified if:
1. Product has been used in manner other than its originally declared purpose or if PPC tank recommendations have not been followed.

2. Product has not been installed, used, and maintained in accordance with a) all federal, state, and local laws and regulations; b) generally accepted

best practices within the applicable industry; c) guidelines set forth in the PPC Installation Manual and/or in PPC Position Statements.

3. Product has been altered or repaired by unauthorized personnel.

4. Notification of the defect has not been made in writing within the warranty period.

5. Invoice for product has not been paid.

6. Product has been subjected to misuse, negligence, fire, accident, act of war, or act of God.

The limited warranty described herein is Poly Processing Company’s sole warranty and the complete, final and exclusive statement of the terms

of the warranty. Owner and/or user may not rely on any oral statement or representations. This warranty is neither assignable nor transferable.

9/2023

Below are links to additional IOM information which you may find helpful:

SAFE-Tank and Enhanced Bellows Fitting Installation

PPC Heat Maintenance System User Manual

Repairing a Scratch in a Polyethylene Tank

Repairing a Gouge in a Foamed Tank

Installing a PVC Bolted Flange Fitting

Poly Processing’s Video Collection

Company Headquarters:

8055 S. Ash St.

French Camp, CA 95231

P.O. Box 4150 (71211)

2201 Old Sterlington Road

Monroe, Louisiana 71203

Tel: 866-765-9957

www.polyprocessing.com

161 McGhee Road

Winchester, VA 22603