Erection Manual
Erection Manual
Erection Manual
INSTALLATION MANUAL
ALUMINIUM VERSION n
Issue: 08/2011
Email: vacono@vacono.com
Website: www.vacono.com
Contents
1 PRELIMINARIES 1
1.1 SAFETY REGULATIONS, FORMALITIES ................................................................ 1
1.2 Material STORAGE .......................................................................................... 1
1.3 MATERIAL CONTROL ........................................................................................ 1
1.4 TANK CONTROL............................................................................................... 1
1.5 TORCH-CUTTING AND WELDING ON TANK ........................................................... 1
2 FREE VENTILATION 1
2.1 PERIPHERAL SCOOPS ...................................................................................... 1
2.2 SIDE OVERFLOW ............................................................................................. 1
2.3 CENTRE ROOF VENT ........................................................................................ 2
3 INSTALLING THE VACONODECK 2
3.1 FINDING THE CENTRE-LINE ............................................................................... 2
3.2 DISTRIBUTION OF PERIPHERAL ELEMENTS ......................................................... 2
3.3 PERIPHERAL LEGS .......................................................................................... 2
3.4 FITTING SPACING ELEMENTS ............................................................................ 2
3.5 PREPARATION OF FIRST PERIPHERAL ELEMENT .................................................. 3
3.6 PRE-FITTING OF PERIPHERAL ELEMENTS ........................................................... 3
3.7 ERECTION OF PERIPHERAL RING ....................................................................... 3
3.8 DISPLACEMENT OF LEGS WITH OBSTACLES ........................................................ 3
3.9 POSITIONING AND ASSEMBLY OF FRAMEWORK ................................................... 3
3.10 CONNECTING THE FIRST CHANNELS .................................................................. 4
3.11 COMPLETION OF FIRST ROW OF FLOATS ............................................................ 4
3.12 COMPLETION OF FRAMEWORK .......................................................................... 5
3.13 DIFFICULTIES WITH UNEVEN TANK FLOOR .......................................................... 5
3.14 LEVELLING ..................................................................................................... 5
3.15 FIXING THE FIXED LEGS ................................................................................... 7
3.16 FIXING THE UPPER POSITION WITH ADJUSTABLE LEGS ......................................... 7
3.17 FIXING THE LOWER OPERATING POSITION WITH ADJUSTABLE LEGS....................... 7
3.18 BOLTING THE PERIPHERAL ELEMENTS ............................................................... 8
3.19 BOLTING THE PERIPHERAL ELEMENTS ............................................................... 8
3.20 BOLTING THE FLOATS WITH LEGS ...................................................................... 9
3.21 RE-CENTERING OF LEVELLED FRAMEWORK........................................................ 9
3.22 FITTING OF SOCKETS AND BOTTOM ANGLES FOR ANTIROTATION CABLES .............. 9
3.23 ALIGNING THE FRAMING SPACER ...................................................................... 9
3.24 FITTING THE ASSEMBLY SPACERS ....................................................................10
3.25 ALIGNING THE FIRST CHANNEL LINE .................................................................10
3.26 POSITIONING THE FIRST COVER SHEET .............................................................10
3.27 DRILLING THE BUTT STRAPS ............................................................................11
3.28 TRANSFER OF ASSEMBLY SPACERS .................................................................12
3.29 POSITIONING THE FIRST COVER SHEET .............................................................12
3.30 BOLTING THE SHEETS TO PERIPHERY AND POSITIONING THE FOLLOWING SHEETS 13
3.31 METHOD OF MOUNTING SHEET FOR DIFFERENT VACONODECK DIAMETERS .....13
3.32 TIGHTENING THE BUTT STRAPS ON THE CHANNELS ............................................15
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3.33 COMBINATION AIR VALVE-MANHOLE .................................................................15
4 FITTING THE NEGOTIATING DEVICES 15
4.1 PLUMBING THE FITTING POSITIONS IN THE VACONODECK ..............................15
4.2 ANTIROTATION SYSTEM ..................................................................................15
4.3 FUNNELS ......................................................................................................16
4.4 PIPE-,ROOF COLUMN- AND LADDER NEGOTIATING DEVICES ................................16
4.5 NEGOTIATING DEVICES FOR AUTOMATIC GAUGING.............................................17
5 FITTING THE SEAL 18
6 FITTING THE ANTISTATIC SYSTEM 18
7 FITTING FLOATS ON PERIPHERY 18
8 ANTISTATIC PAINT 18
9 DRAIN PIPES 18
10 TOOL AND PROTECTIVE CLOTHING LIST FOR INSTALLATION 19
11 VACONODECK - INSTALLATION CHECKLIST- 20
II Issue: 08/2011
1 Preliminaries
2 Free ventilation
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2.3 Centre roof vent
The centre roof vent can be fitted by welding the steel sockets directly to the tank roof,
see drawing SGB-3090-4 or by mounting it on an existing roof socket no longer required.
Fig. 1
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Refer to drawing SGB-03060-4.
External Float
TYP 21
Centre Float TYP 3
TYP 21
TYP 3
T1
1000/1500
F/C M1
2000
M2
T2
Framing Spacer
TYP 4
TYP 4
Fig. 2
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Points M1 and M2 are marked at the centres of the peripheral elements, Type1, (Pos.2)
and then a cord stretched tightly from M1 to M2. Points T1 and T2 are then marked on the
peripheral ring. The centre is marked on the centre float, Type 21, and a leg sleeve fitted
hand tight at both ends with leg. The float length can be obtained from installation
drawing.
T1
T2
Frame
Screw Clamps
Fig. 3
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=
= Framing Spacer
ca.1,5m
L1
Fig. 4
If it found that the R-channels- Type 3+4, cannot be connected to peripheral elements,
Type 1, it must be checked whether they are really too short or whether they are not
parallel. The actual length must then be compared with the value specified in the list of
material. In the event of complaints, the differences should be reported to Rheinfelden.
Fig. 5
3.14 Levelling
Before levelling, the cover height shown in the assembly drawing must be marked on a
leg at the tank manhole. The marking is suitably made on the lower edge of the P-sleeve.
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190
34 for 10“Float
59 for 8“Float
Deck height
Marking
Hose Leveling Instrument
Fig. 6
For fixed legs, the difference of the lower edges of sleeves between the legs at the
periphery and the legs in the inner area is 59mm, for 8“ floats, and 34mm for 10“ floats, as
shown in Fig.6.
For adjustable legs, the lower edges are at the same level.
Staring from the selected leg, the height marked is then transferred with the hose levelling
instrument or laser unit to all other legs.
Levelling with the hose levelling instrument is performed as shown in Fig.6.
Levelling with a laser unit is performed as indicated in Fig.7.
Fig. 7
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The bracket is placed on the wall of the tank, where it is held by magnets. The rotary table
is set horizontal with the three adjusting screws. The mark on the first leg is transferred to
all the others by turning the laser – as for the hose levelling instrument. It must be
ensured that none of the legs stands in the shadow of another.
When all legs have been marked, they must then be fixed at the correct height.
Fig. 8
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190
Assembly Position
Service Position
Tank wall
Diffuser
Fig. 9
The service height determined is measured from the lower edge of the leg sleeve
downwards. The leg is drilled at that point and an M8x55 screw, Type 33, inserted and
tightened.
B
250
= =
Connection butt strap 300
Type 23
A-B
90 ° turned
Fig. 10
It should be noted here that the upper edges of the channels must lie in one plane, that
the bolt spacing is 250mm and that the centreline of the framing spacers is aligned, as
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shown in Fig.10. A connection butt strap 300, Type 23, is used as an aid to installation. A
start is made at the centre. After tightening, the diameter is measured again over the
outer edges of the peripheral elements, to check whether its coincides with assembly
drawing. If it is too large, the end-framing spacers, Type 5, must be shortened evenly. If
too small, the length of the other centreline must be established later.
All channel connections and – if present- all other framing spacers are tightened in the
same way.
The R-channel connections and – if present- all other framing spacers are tightened in the
same way.
When marking, alignment is taken either from the assembly drawing or – if the points
have to be newly selected- according to the framework channels, i.e. it must be ensured
that the plumb-bob passes as nearly as possible through the centre of a panel and
therefore does not meet a channel or float.
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Connecting Screws
Spacer
Centreline
Fig. 11 1
A B
Sheet
1
Centreline-Deck
Fig. 12
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of the slotted holes should coincide as closely as possible with the centres of the screws.
If the layout is as shown in Fig.13 channel line a, the sheet can be unrolled without
difficulty. If the screws of channel line B are in the position shown in b or c, however, the
entire channel line must be moved so that the screws lie at the centre of the hole.
If the framing spacer, Type 5, is displaced to one side or the other in the direction of the
width, so that the screws do not fit the slotted holes, it must be loosened again at the
periphery and set to the correct position.
The sheet is then completely unrolled. If it lies satisfactorily, the channel lines A and B are
screwed tightly at the ends with the peripheral section.
Cutt off
Screwed tightly
Fig. 14
The projecting end of the sheet is cut off flush at the outside edge of the peripheral
section.
With continuous sheets, a start is made in the same way at one end of the centre panel.
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Starting mark
ca.50mm A
A-A
90° turned
A
Panel
1
Fig. 15
The pre-drilled and pre-bent PE-butt strap, Type 10, is clamped with screw clamps on the
outer flange of the peripheral element and acts as a drilling template. The start of the first
PE-butt strap, Type 10, is made on the flange of the peripheral element. The PE-butt
straps, Type 10, are drilled successively in the clockwise direction.
Please note:
A distance of 250mm form the last hole of the PE-butt strap to the 1st hole of the next PE-
butt strap, must be maintained. The PE-butt strap make-up section Type 10, has to be cut
to fit on site.
Fig. 16 A B C D E F
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Fig. 17
3.30 Bolting the sheets to periphery and positioning the following sheets
When three sheets are laid in he 1m-system, and two sheets in the 1,5m/2,0m system,
the first PE-butt strap is immediately placed, the sheets drilled through at the edge-with
the PE-butt strap again serving as a drilling template- and screwed tight. The tank wall
spacers must then immediately be securely fitted again.
Fig. 18
The spacers from panel 2 are moved to panel 4, Fig.16, after all float brackets of channel
lines C and D had been secured. The fourth sheet is then laid, the corresponding straight
S-butt strap secured hand-tight and the PE-butt strap section positioned and screwed
tight.
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Fig. 19
With through going sheets, a start is also made with panel 1, but from the edge and first
closing one half and then the other. If sufficient personnel are available, both sides can
also be worked here simultaneously, see Fig.20.
Fig. 20
With large diameters, i.e. over 30m, all 15m long S-sheets are first laid and then
installation continued – as for a cover with sheet panels divided in the middle, see Fig 21.
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Fig. 21
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A hole is cut in the sheet where the cover has been marked – of diameter slightly larger
than the guide pipe approx. 21mm. The cable guide, Type 64, is inserted and the square
base plate aligned, with a hole-free side parallel to a straight butt strap. The sheet is then
drilled on the pre-perforated sides of the square. The holes are trimmed from underneath.
The two frame sections are centred under the holes and drilled and screwed up with the
channels. The six holes already present in the sheet are also drilled from above through
the frame sections. The cable guide is replaced on the lower side, provided with sufficient
sealing paste, Type 130, secured with six screws and riveted along the transverse sides.
The antirotation cable, Type 66, is secured to the eyebold – as illustrated – which in turn
is attached to the 3“ cap, secured and lowered through the 3“ socket. The 3“ cap is
screwed as tightly as possible by hand. The cable is drawn through the cable guide in the
cover and then secured on the floor together with the spring. The spring is tensioned to
2/3 its unloaded length with loose lower cable clamp, the cable is then clamped, the
second cable clamp fitted and the remainder of the cable cut off or neatly coiled.
Fig. 22
4.3 Funnels
When providing gauging funnels, the upper funnel is laid centrally with the mark on the
cover and the internal diameter marked. The circle is neatly cut out, so that no excess
remains inside. The upper funnel is placed on again and aligned with one side of the
square flange parallel to the nearest butt strap. All pre-drilled holes are transferred to the
cover sheet. After drilling, the channels are fitted as described in 4.2 and drilled in a
similar way. Assembly of upper and lower funnels is performed as shown on drawings
SGB-03072-4 and SGB-03073-4. Where it is planned to include nylon membranes, it
must be ensured that the slots running at 60° do not overlap.
1040/1540/2040
Fig. 23 Sheet Pipe
The sheet is cut open on one side for negotiating devices near the wall of the tank and
sufficient material cut out around the pipe entering to permit the remaining sheet slot is
later sealed with waste sheet, sealing paste, Type 130, and pop rivets, Type 37. The
sheet is cut right through for roof supports inside the tank, in order to avoid deformation
when further unrolled, Fig.24.
Sheet cut
Sheet cut out
1040/1540/2040
Sheet
Fig. 24 Column
The seal firmly inserted in the sealing plate must be inspected before the two halves of
the plate are riveted together, to check whether it provides an efficient seal. Modify if
necessary. Ensure when riveting together that the rivet heads are on the underside of the
plate.
8 Antistatic paint
The painting work to TRbF 120 if necessary, the areas to be coated are specified on
assembly drawing. The areas indicated are marked and cleaned and then painted with
the green primer,Type 94, (mixing ratio paint to hardener 7:1). The black top coat (mixing
ratio paint o hardener 4:1) is applied when the undercoat has dried.
9 Drain pipes
The drain pipes are mounted as per drawing SGB-03093- 4, 1 pc. per sheet - in the
center of the sheets.
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10 TOOL AND PROTECTIVE CLOTHING LIST
FOR VACONODECK - INSTALLATION
PROTECTIVE CLOTHING :
1.) Overall
2.) Protective boots
3.) Gloves
4.) Dust mask
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11 VACONODECK - INSTALLATION CHECKLIST-
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Sealing correct
Nylon plug for opening rod inserted
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2. TANK BOTTOM Check Mark
2.2 Diffuser
Diffuser is installed pointing to tank centre
Diffuser horizontally installed
Support welded to diffusor
No welding between support and tank bottom
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3. DECK TOP SIDE Check Mark
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3.7 Gauging funnel, SGB-03072-4, SGB-03073- 4
Nylon diaphragm installed
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4. TANK ROOF Check Mark
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