Polymaster AVM Standard Agitators Vessels Instruction Manual

AVM Standard Agitators Vessels
Instruction Manual

About Polymaster

A TRUSTED PARTNER
After a quarter of a century, Polymaster now stands as the industry standard in liquid storage. Why? Because we deliver more than a product. We deliver a promise. We are relied upon to store, secure, and safeguard on behalf of our customers.
SOLUTIONS ARE DELIVERED AT EVERY SCALE.
Whether it’s a humble backyard water tank, complex chemical storage, or vital firefighting equipment, we take on the responsibility our customers put in us because we know we have the unrivaled experience to deliver.
WE MAY BE KNOWN FOR OUR TANKS. WHAT WE PROVIDE IS ENGINEERED PERFECTION.
Our holistic solutions are creative, considered, and customized. Integrated, state-of-the-art, and end to end to meet specific problems. Best of all ­ they work. We have thousands of customers, businesses, government departments, and entire communities to prove it.
Today, we continue to be proactive, investing time and energy into the role our technology will play in years to come. We’re proud to be at the forefront of the industry, ahead of the curve, and leading the way.
At Polymaster, together, we hold the future.
WE’RE AUTHENTIC
A proud Australian business since 1994, we’ve earned an industry-leading reputation through reliable products and honest, trusted, dependable service. We listen to our clients, and we respond with quality solutions that will help them to thrive. Because at the end of the day, their business is our business.
WE’RE PRECISE
From our meticulous process to our extensive distribution network and after- sales support, every part of the Polymaster experience is carefully considered. The result? Precision-designed products manufactured to perfection to do the job, and holistic end-to-end service with complete care for guaranteed satisfaction.
WE’RE INNOVATIVE
We embrace each new challenge as a way to improve our products and our services. Known for thinking outside the square, we bring our collective creative smarts to every opportunity, disrupting conventional wisdom and delivering with energy and expertise. Every day, in every way, we go above and beyond.

QUALITY ASSURANCE

Our tanks undergo rigorous testing to ensure quality. This includes hydrostatic testing, and ultrasonic thickness testing to ensure the material we’re using is the correct thickness. For our impact testing, a sample from each tank is frozen and impact is applied from a specified height.
RESEARCH & DEVELOPMENT
We’re always innovating, with a range of polymers designed to store any type of chemical or liquid. Our polymer chemists are here to help you determine which type of material to use.
ENGINEERING
Working closely with your engineering teams, our own highly skilled engineering personnel are ready to assist with all mechanical, polymer, and chemical-related requirements.
PROJECT MANAGEMENT
Our dedicated project managers take full control of all our industrial projects to ensure they stay on time and within budget, as well as provide you with the convenience of a single point of contact. At Polymaster our highly experienced project managers have an in-depth knowledge of industrial projects.
MANUFACTURING CAPABILITIES
From processing our raw materials through to the finished product’s final fit- out, we have control over the entire manufacturing process to ensure absolute quality is upheld at every stage.
DELIVERY
Polymaster tanks can be delivered directly to the site. We arrange specific delivery times to suit your timetable and on-site requirements.
SERVICE
Supplying the complete package from design and engineering right through to manufacturing. We arrange the fit-out of dosing systems and much more, so you don’t need to deal with multiple suppliers. We offer on-site maintenance and inspections post-installation to ensure everything continues to run as smoothly as possible.

AUSTRALIAN STANDARDS

Polymaster is certified to ISO9001 International Standards and undertakes regular audits from third-party auditors.
Our tanks are certified to the Polyethylene tank standard for water & chemicals, AS/NZS 4766:2006 for a range of chemical-specific gravities. This means that every tank is independently tested & certified to SAI Global’s AS/NZS 4766 standard and labeled to display manufacturing details and serial numbers for complete traceability.
ABOUT PRODUCT
Polymaster supplies a wide range of chemical storage solutions with storage capacities up to 50,000 liters. Our Industrial grade tanks are Australian-made and certified to provide safe storage of diesel, oil, solvents, chemicals, and other hazardous liquids.
Polymaster’s range of standard agitator and supports stands have been developed to provide customers with an engineered solution to their mixing and agitation applications, features include:

• Durable steel fabricated support structure
• Agitators are available to suit a wide range of applications. By following the installation requirements, this tank will give you many years of trouble-free service.

GENERAL HEALTH AND SAFETY

• Installation and use of this product should only be carried out by properly trained and approved personnel.
• This manual contains important information concerning the safe installation and use of this product. Read the manual carefully before installation and use, paying attention to all safety warnings.
• Users of this product are responsible for the safe and correct use of this product.
• Any changes to this product, which have been done without consulting the manufacturer, will invalidate all warranties and guarantees.
• The manufacturer will not be responsible for any accidents or damages caused by incorrect installation or use of this product.
• Polymaster recommends that customers assess the suitability of chemicals being stored with the materials used in the construction of this product.
• The components must not be altered or tampered with due to potential risks to personnel.
• Users of this product are responsible for the safe and correct use of this product.
• It is the responsibility of the end-user/customer to ensure appropriate PPE, health and safety measures, safe work practices are employed in conjunction with the use of this product.
• If present, control boards are not suited for use in areas where there may be a risk of explosion.

CHEMICAL RESISTANCE

As standard, Polymaster’s standard agitator range is supplied with 316 stainless steel wetted components. It is the customer’s responsibility to make a final assessment of the suitability of materials in their specific application.
A chemical resistance chart may be found on our website www.polymaster.com.au. It is recommended that you discuss your specific chemical storage requirements with a Polymaster consultant or study the comprehensive chemical chart to ensure compatibility.
A more comprehensive list is also available on request.
VISCOSITY & SG RATINGS
The viscosity, as well as specific gravity (SG) of the medium to be agitated, has a direct impact on the design of an agitator and its support structure. Attention must be given to the agitator system being selected for each specific application as the improper selection may lead to damage to equipment and/or poor system performance.
POLYETHYLENE MATERIALS
Polymaster uses a variety of Polyethylene resins that have been specially designed for the rotational molding process in the manufacturing of chemical and process tanks. These advanced materials exceed all requirements of the Australian standard AS/NZS 4766 Polyethylene Storage Tanks for Water and Chemicals. Key features of the mechanical properties include Excellent impact resistance, strength, and environmental crack resistance. These materials also carry a high level of UV and antioxidant stabilizer designed for the harsh outdoor Australian environment, minimum of UV 12 rating.
TEMPERATURE & SG RATINGS
The temperature of the chemical/liquid stored has different effects on the Polyethylene and can produce different effects within the same chemical range. Contact a Polymaster consultant if you are unsure about your application. A continuous liquid temperature above 40 degrees Celsius is not recommended for these tanks. Tanks are designed to a maximum Specific Gravity (SG) rating to suit the application and must not be exceeded.
VENTING
These tanks cannot be pressurized and are designed to operate at atmospheric pressure. Proper venting stops pressure or vacuums from developing as the tank is filled or emptied. It is recommended that the vent should always exceed the size of the largest fill or discharge. Check that the chemical you are using is able to be vented to the atmosphere without prior treatment.
GENERAL LOCATION
There are many aspects to consider when selecting the best location for your tank.
Some points to consider are

• Excessive wind or seismic forces
• areas subject to flooding
• A safe distance from any source/equipment generating heat or flames

Generally accessible location to ensure safe operation, maintenance, and distance from another chemical in line with authority storage requirements.

REGULATIONS

There may be local, state, or national regulations that apply to your proposed tank and agitator installation. Check with the relevant authorities concerned to ensure all requirements are complied with. A thorough evaluation of the proposed site is recommended prior to any placement or installation works being carried out.
Service access and safe egress paths away and around the tank and agitator system in line with Australian and local authority requirements to suit the specific chemical being stored is the responsibility of the installer and user of the tank. Do not block any service access or egress paths.
Position the tank and agitator system to allow for ease of regular inspection and maintenance. It is recommended that tanks are not installed adjacent to equipment or buildings that will impact cost-effective removal and or replacement of the tank in the future. Use guards and physical restraints to prevent tank fittings and piping from impact damage and protect personnel from potential chemical leakage.
TRANSPORT, HANDLING, AND STORAGE
These instructions should be read in their entirety before commencing installation of the Tank.
A. The agitator and frame system must be protected against mechanical damage during transport and storage.
B. Loading and off-loading must be carried out using only professional equipment. Craneage at the site is the responsibility of the customer/end-user to suit the installation location.
C. Agitator frames must never be pushed, pulled, dragged, or rolled.
D. Agitator frames may not be suitable for live loads, please discuss specific access requirements with Polymaster.

• For all agitator installation and maintenance, please take into consideration Health & Safety and Local Building Regulations.
• For further advice, contact Polymaster on 1300 062 064

INSTALLATION

• A solid flat and horizontal plinth suitable for the anchorage requirement of the agitator is required. This plinth is to be engineered by the user and is to be compatible with the anchorage requirements detailed below. Engineering of any restraint or tethering system to suit specific local or chemical-specific storage requirements is the responsibility of the customer/end-user.
• Prior to installing, inspect for damage, if damaged do not install.
• In no cases should any modifications such as holes being drilled be implemented without consulting with Polymaster, doing so may void the warranty.
• Drawings of agitators and support structures are available and may contain information relating to freight and handling.
• Agitator installation is the end user’s responsibility, in most instances, the agitator shaft and hub need to be installed through the tank manway, this means that tank entry may be required as part of agitator installation.
• Addition equipment to be mounted/fitted to the agitator support structure at the end user’s own risk.

ANCHORAGE
Recommended: Ramset REO520 chemical anchors, M16x125. Refer to the OEM manual for detailed installation requirements.
Check agitator drawing for specific instructions, information on drawings overrides information within the installation guide.
USAGE
After installation, please ensure that this instruction booklet is left with the end-user for future reference. Agitator Sytems are warranted against faulty manufacture, provided that the following criteria are adhered to (applicable to all models):

• The agitator system is installed and commissioned in accordance with this installation guide.
• The agitator system is installed and commissioned by a suitably qualified engineer.
• The agitator system has not been subject to misuse, careless handling, faulty installation, or any repairs that have not been attempted or carried out other than by authorized, competent service staff.
• The agitator system has been purchased by the end-user and is not for hire purposes.
• The agitator system is installed above ground.
• The agitator system is inspected every 3 months. This is to be performed by a suitably qualified service engineer or technician.
• Agitators have a minimum liquid level which must be maintained during usage. Failure to meet this requirement will likely cause damage to the agitator system and tank. Please refer to the agitator drawing for minimum liquid level information or contact Polymaster for assistance.
• Immediately upon discovery of any defect you contact Polymaster and allow a representative to inspect the agitator system and its surroundings and where necessary carry out any repairs (before any attempts are made to move the system). Safe Chemical handling takes precedence over a representative inspecting the system.

Recommended Care Instructions

TABLE 1

original installation, Review changes for any influence on the safe use of the tank such as wind or distance to people and traffic| As Used / 12 Months
Tank Condition| Temperature & SG Ratings of the product. Review the product being stored in the tank and confirm that they match those intended for original tank use. Inspect abrasions or cuts on the tank. Assess tank for excessive weathering. Assess the tank for any swelling, bulging, or deformation of tank walls.| As Used / 3 Months
Chemical Degradation and Compatibility| Confirm the chemicals currently used are compliant with the original installation. Review any change with Polymaster and the Poimaster Chemical Compatibility Chart.| As Used / 12 Months
Valves| During normal operation, check the action of installed ball valve handles and/or Slide Gate.| As Used / 3 Months
Vent| Check and clean around the vent regularly to remove any buildup of dust/dirt. Check that there is nothing impeding the operation of the vent.| 3 Months
Seals| When the unit is completely empty, undo and remove the PVC-U ball valves. Check the condition of the seals within the ball valve. Replace if the seals have deteriorated.| 12 months
Gaskets| Visually inspect the condition of the flanges and connected fitting regularly for any changes or leaks. If any change is noted, completely drain the tank until empty then inspect and service the unit and replace gaskets as needed.| As Used / 3 Months
Screw Lids| Check that the screw lids are still tightly secured.| As Used/12 months.
Weld-on Fittings| Investigate any degradation of weld and/or excessive stress marks. Check for any leakage or surface cracks developing. Check fitting distortion including vertical horizontal alignment.| As Used/12 months
Flexible Connections| Check positioning and alignment of flexible connections. Assess the compatibility of the connector to the user’s systems. Review for excessive axial or lateral compression.| As Used / 3 Months
Electrical / Sensors| Visually inspect the condition of the power box and associated components.
Clean the power box with a damp cloth to remove any buildup of dust/dirt/chemical spillage.| 3 Months
Foundation/Base| Check the condition of the tank foundation for any erosion, cracking, or subsidence. Repair as required. Ensure any repair materials meet the Installation Guide requirements.| 3 Months
Moving| Refer to the Installation Handling section for information on moving the tank.|
Tank Restraints| Review all restraints, tie-down lugs, and associated fasteners to ensure they are secure, meet “As Installed” condition and performance, and are in good condition.| As Used / 3 Months

CARE AND MAINTANENCE

Regular routine visual inspections of your agitator are important to ensure the safety of personnel and the preservation of stored chemical. Any sign of stress cracking, UV degradation, and/or other signs of tank failure should be immediately reported and a full inspection carried out by authorized Polymaster personnel.
A. Plan and initiate a maintenance regime for the agitator system. Aim to keep all system equipment in good working condition.
B. Spare parts must comply with the requirements of the manufacturer and be of like-for-like type.
C. Any faults or alarms should be reported to the user’s station manager/site manager or equivalent immediately.
D. Protect against unauthorized access.
E. Carry out a daily visual check of the tank and ancillary equipment. Any leaks are to be promptly recorded, reported, and repaired by a qualified service engineer or technician. If the liquid is detected by alarm or observed around the tank, promptly record, report, and arrange for corrective action. Corrective action may include locating the source of the liquid, possibly caused by an overfill event or leak. If the liquid source is not the result of an overfill event, contact Polymaster for additional advice. Further action may include emptying and isolating the tank.
F. Ensure that contamination not intended to be in the tank is prevented from entering at any time either by design or a managed maintenance regime. If the stored liquid or fumes are allowed to escape outside the tank, ensure you check local EPA, Australian standards,s and local Authority guidelines and requirements for compliance.
G. Metal items and control panels that could be affected by the fumes must be protected from corrosion by using good engineering practice. Additional corrosion protection to suit the chemical being stored is the responsibility of the customer/ end-user.
INTERNAL INSPECTION
It is recommended that an internal inspection is undertaken over regular intervals. Polymaster recommends this is done yearly. Empty the tank and neutralize any chemical remaining. All chemical handling must be safely performed in line with Australian Standards, EPA, and local authority requirements for the specific chemical being stored. Where a confined space entry is possible, thoroughly clean the inside of the tank, a dirty tank will potentially mask faults. Examine the tank surface for any cracking or surface degradation. Pay particular attention to fittings and the base in the radius where the cone meets the wall.
If a confined space entry is not possible, clean inside as well as possible from the inspection cover and use a light to inspect the internals.
WARNING: Do not enter a tank without confined space entry training and relevant personnel and permits. Use adequate approved ventilation equipment when inspecting the internals of a tank as fumes and vapors may be present. Use necessary fall protection equipment to prevent accidental falls relating to entry methods or slippery conditions. Failure to comply with these warnings could result in injury or death.

WARRANTY
This guarantee is not valid for the following defects:

• Mechanical damage caused by the user, dealer, or improper maintenance.
• Faults, damage, or premature wear caused by improper use.
• Damage caused by third parties.
• Repairs carried out by unauthorized service personnel.

Polymaster products are guaranteed against material or manufacturing defects and have the following guarantee period commencing from the date of the invoice:

• For polyethylene tanks: 5 years
• For accessories/components: 12 months (i.e. agitators and frames) – or as per the manufacturer’s warranty
• Excluding Hoses, Nozzles, and sensors which are 3 months

Together we hold the future.
➔ 1300 062 064
➔ polymaster.com.au
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Documents / Resources

| Polymaster AVM Standard Agitators Vessels [pdf] Instruction Manual
AVM, Standard Agitators Vessels, AVM Standard Agitators Vessels
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References

• Polymaster Group - Tanks and Liquid Storage Solutions

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