TUFFA TANKS 975PT Owner's manual

TUFFA
PETROL
TANKS
Installation, Operation and Servicing Manual Version 1.0.0
Models:
975PT | 1250PT | 1950PT | 2500PT | 3000PT

1
1. Introduction 2
2. Conditions of use 2
3. Safety 3
4. Product description 4
4.1 Productidentication 4
4.2 Productspecication 5
4.3 Product footprint 6
5. Transport & storage 11
6. Installation & commissioning 12
6.1 Installationguidelines 12
6.2 Systeminstallation 12
6.3 Systemlocation 12
6.4 Labelling        13
6.5 Riskassessment       14
  6.6 Electricalrequirements 15
6.7 Electricalwiringdiagram 15
7. Operation of the system 16
7.1 Usingthesystem 16
7.2 Summaryofmainparts   16
7.3 FillingTUFFApetroltank 18
7.4 Dispensingpetrolintovehicle 18
7.5 Levelcheck   19
8. Maintenance of the TUFFA TANKS 20
8.1Systemmaintenancetasks 21
8.2Inspectionbycompetentperson     21
8.3Internalexaminationandcleaning     21
8.4Troubleshooting 22
8.5Tankmaintenancerecord 24
8.6Petroldeliverylog 26
9. Warranty 28
10. Contact 29
11. Guarantee Registration 29
CONTENTS PAGE

2
1. Introduction
Thismanualcontainsspecicinstructionsandinformationrelatingtotheinstallation,
operationandmaintenanceofTu󰀨aTankssystems.
2. Conditions of use
• Readthismanualbeforeinstallingthissystem.
• Tu󰀨aTanksacceptsnoliabilityforpersonalinjuryorpropertydamageresultingfrom
workingonoradjustingtheequipmentincorrectlyorwithoutauthorisation.
• Tu󰀨aTanksacceptsnoliabilityfordirect,indirect,incidental,special,or
consequentialdamagesresultingfromfailuretofollowanywarnings,instructions,and
proceduressetoutinthismanual.
• Tu󰀨aTanksreservestherighttochangethespecicationsofitsproductsorthe
informationinthismanualwithoutnecessarilynotifyingitsusers.
• Variationsininstallationandoperatingconditionsmaya󰀨ecttheTu󰀨aTanksystems
performance.Tu󰀨aTanksmakesnorepresentationsorwarrantiesconcerningthe
performanceofthetanksystemundertheoperatingconditionsprevailingatthe
installation.
• OnlypartssuppliedbyorapprovedbyTu󰀨aTanksmustbeusedandno
unauthorisedmodicationstothehardwareorsoftwareshouldbemade.Theuseof
non-approvedpartsormodicationswillvoidallwarrantiesandapprovalsandcould
leadtohazardoussafetyconditions.
• Unlessotherwisenoted,referencestobrandnames,productnames,ortrademarks
constitutetheintellectualpropertyoftheownerthereof.
1. INTRODUCTION | 2. CONDITIONS OF USE

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3. Safety
PLEASE READ THIS MANUAL CAREFULLY BEFORE USE & COMPLY WITH ALL
INSTRUCTIONS BELOW.
THIS MANUAL SHOULD BE KEPT WITH THE EQUIPMENT AT ALL TIMES.
1.Themajorhazardinvolvedwithinstallingandoperatingtheunitiselectricalshock.
Thishazardcanbeavoidedifyouadheretotheproceduresinthismanualandexercise
allduecare.
2.Installationanduseofthisproductshouldonlybecarriedoutbyproperlytrainedand
approvedpersonnel.
3.PleaserefertostoragemediaMSDSwhichshouldbesuppliedbytheproprietorofthis
systemwhichwilldetailthePPErequiredforhandlingandemergencyprocedures.
4.Theuserofthisproductisresponsibleforthesafeandcorrectuseofthisproduct.
5.Thisproductisonlysuitableforstorageand/ordispensingoftheliquidmedia
referencedatthepointofsale.
3. SAFETY

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4. Product description
TheTu󰀨aPetrolTankrangeisabundedreproofedsteelfabricatedtankdesignedforthe
safestaticstorageandlocaldispensingofPetrol.Theintendeduseforthissystemisforend
userswhowishtostoreandlocallydispensepetrolattheirfacilityfromaxedpoint(non-
mobile).Tu󰀨apetroltankshavebeendesignedinaccordancewiththeBluebookguidelines
andapplysafetydesignfeaturesinaccordancewithDSEAR(Dangeroussubstances&
ExplosiveAtmospheresRegulations2002SecondEdition).
Tu󰀨apetroldispensingtanksareo󰀨eredinavarietyofpumpingspecicationsinorderto
meetend-userrequirements,dispensingoptionsvarybetweenamanualhandpump,12V,&
240Vpumpswhichcarrytheappropriatecerticationforthesafedispensingofpetrol.Tu󰀨a
petroltanksaredesignedtotakedeliveryfromapetroltankerthroughthemeansofagravity
llanddonotcontaintransferpumpstoo󰀪oadapetroltanker.Thesetanksarenotdesigned
orcertiedfortheresaleofpetroleumspirit.
4.1 Productidentication
Theidenticationplateislocatedexternallyoneachsystemandwilldetailthecapacity,serial
number,modelnumberandyearofmanufacture.
4. PRODUCT DESCRIPTION

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4.2Productspecication
975PT 1250PT 1950PT 2500PT 3000PT
Capacity 975litres 1250litres 1950litres 2500litres 3000litres
Length 1540mm 1710mm 2860mm 3040mm 3040mm
Width 1460mm 1485mm 1460mm 1800mm 2000mm
Height 4500mm 4500mm 4500mm 4500mm 4500mm
Weight (approx.) 585kgs 795kgs 940kgs 1160kgs 1275kgs
Bund material Mildsteelconstruction
Inner tank
material
Mildsteelconstruction
Description Bundedpetroltank
Fill point 4”BSP
Voltage 12V/240V
Ventilation 2”sparkarrestorvent
Flow rate Upto70LPM
Flowmeter Mechanicalmeter(accuracy+/-1%)
ATEXpulsemeter(accuracy+/-1%)
Delivery hose 4 metres
Nozzle Automaticshuto󰀨nozzle/manualspout(handpumponly)
Filtration Inlinestrainer
4. PRODUCT DESCRIPTION

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4.3 Product Footprint
4. PRODUCT DESCRIPTION

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4. PRODUCT DESCRIPTION

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4. PRODUCT DESCRIPTION

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4. PRODUCT DESCRIPTION

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4. PRODUCT DESCRIPTION

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5. Transport & storage
DO NOT TRANSPORT WITH LIQUID INSIDE THE TANK
1. Ensureallequipmentissecuredpriortotransportation.
2. Loadingando󰀨-loadingmustbecarriedoutbyacompetentpersonusingsuitable
ratedandmaintainedequipment,eitheraforkliftwithextendedforks/tinesoracrane.Iflifting
slingsareused,theymustbeattachedtotheliftingpointsasshowninthepicturesbelow
usingasteelliftingeyeinsert.Ifliftingfrombelowuseasuitableratedforkliftwithextended
forks.Ifliftingfromaboveuseasuitableratingliftingslings/chains.
3. Liftwithforkliftfromonesideorwithx2slingsfromtheundersideofthetank.
5. TRANSPORT & STORAGE

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6. Installation & commissioning
6.1 Installation guidelines
TheproprietoroftheTu󰀨apetroltankisresponsibleforcomplyingwithalllegalrequirements
relatingtotheinstallationanduseofthisproduct,aswellastheguidelinesissuedbylocal
reghtingauthoritiesandenvironmentalauthorities.
Oncethepetroltankhasbeenreceivedonsite,checkthatnodamagehasoccurredwhilein
transit.Locatethetankinthedesiredlocationusingeitheracrane,forkliftorrollers.
6.2 System installation
Systemfoundation
Thesystemmustbeinstalledandfullysupportedonasmoothlevelledconcretebasebuiltin
accordancewithgoodbuildingstandardsandengineeringprinciples.Itisrecommendedthat
tanksbeinstalledonaconcretebaseatleast100mmthick.Pleaserefertodiagrambelow:
6.3 System location
Thelocationofthesystemshouldbepositionedbyaroadoraccesswithenoughwidthand
loadingcapacitytoaccommodateapetroltanker.ProvisionfortheU-turnofatankershould
beconsideredandanyobstaclesforatankerintheformoftreebranches,electricalcabling
orparkedvehiclesmustbeminimised.
Ifnecessaryadditionalimpactprotectionaroundthetankmayberequiredintheformof
bollardsorbarriers.Suitableclearanceforthesafedeliveryofpetrolfromatankermustbe
consideredbeforedecidingthelocationofaTu󰀨apetroltank.
6. INSTALLATION & COMMISSIONING

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Tanksabovegroundshouldbesitedinawell-ventilatedpositionseparatedfromthesite
boundary,occupiedbuildings,additionaltanks,sourcesofignitionandprocessareas.Tanks
shouldbelocatedatleast4metresfromsiteboundaries,adjacentbuildings&building
escaperoutesincludingwindowsanddoors,processareas,xedsourcesofignitionand
additionaltanks.
Thelayoutoftanksshouldalwaysconsidertheaccessibilityneededfortheemergency
services.Ifaseriousredevelopsinvolvingonetankinagroupoftanksthenitisunlikely
thatthesebetween-tankseparationdistanceswillpreventdamageorevendestructionofthe
adjacenttanks.However,theyshouldallowenoughtimeforemergencyprocedurestobe
implementedandforpeopletobeevacuatedfromareasthreatenedbytheincident.Itisnot
recommendedthatgroupsofpetroltanksarepositioneddirectlynexttooneanotherwithout
asu󰀩cientseparationdistance,failuretodosoincreasesyouraggregatepetrolstorageina
localisedareawhichcouldleadtoagreaterpotentialhazardintheeventofignition.
6.4 Labelling
Itisrecommendedadequatehazardandwarninglabellingisusedaroundanypetroltank
installationnotifyinganypersonsofthedangersinvolvedwithstoringpetrolaboveground.
6. INSTALLATION & COMMISSIONING

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6. INSTALLATION & COMMISSIONING
ThebelowgraphicshowsaselectionoflabellingusedwithanyTu󰀨apetroltank,we
recommendthatthesewarninglabelsorsimilarbeusedintheareasurroundingthetankto
adviseanypersonsonthesafeprocedurethatmusttakeplacewithinthehazardousarea.
6.5 Risk Assessment
Itisrecommendedthatanappropriatesiteriskassessmentiscarriedoutbeforeanypetrol
tankinstallationtoidentifythehazardsthattheproductandenvironmentcanpose.Arisk
assessmentshouldatbestidentifythehazardsandquantifytherisksassociatedwiththe
following:
• Thescaleandanticipatede󰀨ectofreandexplosion
• Hazardousareas&ignitionsources
• Environmentalpollution
• Spillcontainment
• Leaks
• Fueldeliveries
• Security&attemptedtheft
• Impactormaliciousdamage
• Maintenance,repairandreplacementofancillaryequipment
• Dailyoperationanduseoftheproduct
• Firedetection&reprevention
• Emergency&evacuation
• COSHHassessmentofPetroleum

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Itisrequiredthatallemployersandtheself-employedshouldassessallpotentialrisksto
employeesandotherswhosesafetymaybea󰀨ectedbytheuseorpresenceofadangerous
substanceattheworkplace.Athoroughandwellplannedriskassessmentcanhelpbest
locateyourTu󰀨apetroltanktothesafestandmostpracticallocation,identifyinganypotential
riskswillhelptoimplementtheappropriatecontrolmeasuresrequiredtoremoveorreduce
thatriskorhazard.
6.6 Electrical requirements
Onlyasuitablyqualiedelectricianaccordingtoapplicableregulationsmayworkontheelec-
tricwiringinstallation.Thesystemcomponentsunderservice,maintenance,andrepairwork
mustbedisconnectedfromthepowersupplybeforeanyworkinundertaken.
System power requirements:
• 220-240Volts,50Hz+/-10%
• 20ampcircuitbreakerrecommended
• Powercablerecommendation:3Core2.5mmexcable
6.7 Electrical wiring diagram
6. INSTALLATION & COMMISSIONING

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7. Operation of the system
Thesystemanditscomponentsareintendedforpetrolonlyandforthepurposesdescribed
below.Useofthissysteminameansotherthandescribedbelowisregardedasmis-use
ofthesystem,theuserofthesystemwillbeliableforanydefectsthatoccurduetoits
unintended use.
7.1 Using the system
Theoperationandmaintenancepersonnelmustbesuitablytrainedtousethesystem,the
usermustmakesuretheyfullyunderstandtheoperationandmaintenancesectionsofthis
manual.
7.2 Summary of main parts
12v pump
7. OPERATION OF THE SYSTEM

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Hand pump
240v pump
7. OPERATION OF THE SYSTEM

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7.3FillingTu󰀨apetroltank
1. Fillingshouldbeperformedonlyunderconstantsupervisionofanauthorisedperson.
2. Thistankcanonlybelledbyagravitylltankerequippedwitha4”femalecoupling.
3. Beforellingthepetroltanktakeadipreadingusingthedipsticktocalculatethe
 currentleveloffuelwithinthetank
4. Fittankerdeliveryhoseto4”BSPllcouplingontank.
5. Stopllingwhendesiredamounthasbeendispensedintotank.
6. Thetankerdrivermustobservethetankbeinglledatalltimesduringthisprocess.
7. Oncecompletedisconnectdeliveryhosefromtankcoupling.
7.4 Dispensing petrol in to vehicle
Piston hand pump
1. Placespoutintodesiredcontainer,vehicleorplantmachinery
2. Pullpumphandlebackwardsandforwardstostartow,becarefulnottooverll
3. Whenfullstoppumpinganddrainthespoutanddeliverypipeintothecontainer, 
 vehicleorplantmachinery
4. Returnspoutbackintoholster,containinganydrips.
12V pump
1. Ensure12vbatteryisaminimumof4metresawayfromtanksothatcrocodileclip
 cablesarefullyextended.
2. Connectclipstobattery,redpositiveandblacknegative
3. Resettheowmetertotalizerto0iftted
4. Removenozzlefromnozzleholsterandinsertthenozzlecompletelyintothecontainer,
 vehicleorplantmachinery
5. Turnonpumpmotorwithnozzleswitchonpumphousing
6. Pulltriggeronthenozzletoallowpetroltoowintothevehiclepetroltank
7. Atthistimetheowmetercounterwillstartrecordingtheow,continuerefuelinguntil
 thedesiredamountisreachedorwhenthecontainer,vehicleorplantmachinery
8. Whenthefueltankisfullthenozzlewillautomaticallyswitcho󰀨
9. Releasethetriggerofthenozzleandreplacebackintotheholstercontaininganydrips
10. Turno󰀨pumpmotor,removecableclipsandstowawayneatly
240V pump
1. Resettheowmetertotalizerto0iftted
2. Removenozzlefromnozzleholsterandinsertthenozzlecompletelyintothecontainer,
 vehicleorplantmachinery
3. Turnonpumpmotorwithnozzleswitchonpumphousing
7. OPERATION OF THE SYSTEM