Flexitank Operations Manual - FGN Global Logistics, Inc.

FGN Global Logistics, Inc.

Flexitank Operations Manual

FGN Global Logistics, Inc. 2

Contents

Introduction .................................................................................................................. 3 Container Selection .................................................................................................... 4 Criteria ................................................................................................................................ 4 Checklist ............................................................................................................................. 5 Installation / Fitting .................................................................................................. 6 Preparation ......................................................................................................................... 6 Fitting .................................................................................................................................. 8 Checklist ........................................................................................................................... 11 Flexitank Loading ...................................................................................................... 12 Requirements .................................................................................................................... 12 Procedure ......................................................................................................................... 12 Checklist ........................................................................................................................... 13 Flexitank Unloading/Discharge ........................................................................... 14 Requirements .................................................................................................................... 14 Procedure ......................................................................................................................... 14 Flexitank Disposal ..................................................................................................... 16 Incineration ....................................................................................................................... 16 Recycling .......................................................................................................................... 16 Landfill Disposal ................................................................................................................ 16 Incident Management .............................................................................................. 17 Information & Action ......................................................................................................... 17 Completion ........................................................................................................................ 17 Insurance .......................................................................................................................... 17 Appendix ....................................................................................................................... 19 Container Selection / Pre-Installation Checklist ................................................................ 19 Flexitank Installation Checklist .......................................................................................... 20 Flexitank Loading Checklist .............................................................................................. 21 Flexitank Technical Specifications .................................................................................... 22


Introduction The FGN Global Logistics, Inc. (FGN) Flexitank Operations Manual’s outlines the procedures for container selection, installation, loading/discharging, disposal, and incident response for the FGN Flexitank. The Flexitank Operations Manual also reviews the specific guidelines necessary to become an FGN Certified Flexitank Fitter.

FGN Certified Flexitank Fitters are able to install, train others to install, and approve the installation of an FGN Flexitank. FGN Certified Flexitank Fitters are authorized to sign off on the container selection and installation criteria/checklists required for each installed flexitank. FGN Global Logistics, Inc. - or our authorized representative - provides the initial training and certification necessary to become an FGN Certified Flexitank Fitter.

The four stages of the FGN Certified Flexitank Fitter training and certification process are:

1. Presentation and review of Flexitank Operations Manual

2. Container Selection/Flexitank Installation Training

3. Container Selection/Flexitank Installation Testing

4. Awarding of the Certified Fitter Certificate

Initial training and certification can be completed in 1-2 days. It is normally performed on-site at the fitting location. In addition to initial training and certification, FGN requires a semi-annual recertification. We offer quarterly continuous improvement webinars for all FGN Certified Flexitank Fitters in order to prepare for recertification.

With care and diligence, flexitanks are a safe and efficient form of bulk liquid shipping. And while the procedures described below can help ensure successful handling of flexitanks, they are only as effective as the operator responsible for performing them.

For any questions regarding items found within this manual or for additional details on how to become an FGN Certified Flexitank Fitter, please contact [email protected].


Container Selection Criteria The Flexitank Operator is responsible for selecting a container that meets quality requirements as outlined below. A “Container Selection Checklist” (see Appendix (1)) should be filled out during the selection process so that it is notated that each and every container meets FGN’s quality container guidelines.

Side Walls

• Weld seams at or on the container side walls should be smooth and free of sharp edges, weld splatter, and foreign objects.

• Repair seams should be covered with tape, cardboard, currogated paper, or other such “padding”.

• Container corrogations should be as consistent as at the time of manufacture and should not have irregularities.

Container Interior: Floor

• The container should be free from transferable or non-transferable dry dust, carbon dust, sand, dirt or depot yard dust.

• It should have no damp floor stains or burn marks.

• The container should be free from debris, dunnage, volcano ash and/or other kinds of previous cargo residue.

• Most importantly, the floor should be free from splinters and protruding nails, screws and other fixings.

Container Interior: Walls

• There should be no excessive scratches to the interior.

• The inside walls and roof should be free from large areas of rust or flaking paint.

• There should be no transferable stains.

Container Interior: General

• The container should be free from any types of residues and previous cargo odors.

• The shoring slots (in the door channel) should be straight and free from dents and obstructions.

Door Hardware

• Door gear fixing and bolt heads on the inside of the doors should be free of sharp points and edges.


Exterior: General

• The exterior should be free from hazardous cargo markings, markings relating to previous flexitank shipping, or any notations regarding other cargo moves.

Checklist See Appendix – ”Container Selection / Pre-Installation Checklist”:

Complete, sign, send .pdf copy to [email protected] and retain a copy for your records.


Installation / Fitting Preparation Container Positioning

• Position the container at a dock high door for easy access and exit.

• Light the container with projection lamps so that the inside of the container is brighly illuminated.

Floors and Walls

• Carefully sweep the container floor, checking visually and by hand for any rough edges, projections, splinters, screw heads, poor welding, stones, or any other projections inside the container.

• Flip a push broom over so that the broom head lies against the container floor and gently run the broom head along the container floor, feeling and listening for protrusions or projections that may not have been caught during the visual inspection.

• Cover any troubled spots with heavy duty masking tape (duct tape), cardboard, or similar “padding”.

Container Preparation


Lining the Container

• To protect the flexitank during transport, suitable corrugated paper should be taped to the container walls and floor area; the paper should be a minimum of 60” or 1,500 mm high/wide.

• Ensure there is a 6” overlap where the corrugated paper liner on the floor meets the corrugated paper on the container side.

• High strength polypropylene felt liner with moisture proof polyethylene backing may be used to line container walls and floor area; FGN provides such material at the customer’s request.

Container Lining

Door Warning Labels

• Remove old labels and stickers on the outside of the container.

• Affix the FGN Door Warning Label on the outside of left side door (provideded in flexitank shipping box).

• Secure the red warning tag to the left hand door handle using the zip/cable ties (provideded in flexitank shipping box).


Fitting Flexitank / Flexitank Placement Procedures

• Ensure the container has been properly inspected and prepared.

• Place the shipping box in the center of the container floor prior to bulkhead installation.

• Remove the flexitank from its shipping carton, place the flexitank along right side of container, and roll the flexitank open to the front and rear of the container.

• Unfold the flexitank to the full length of the right side of the container; then unfold to the left, so that the flexitank is centered in the container and covers the whole floor area.

Flexitank Placement


Cage Bar Soft Bulkhead Installation Procedures

• Install the bottom two-bar “cage unit” (the two bars that are connected by two short vertical bars) into the channel at the bottom of the contianer.

• Place the cage unit firmly into the right side door channel (the groove just on the inside of the door frame) and then slide the inserts firmly into the channel slot on the left side.

• Secure the inserts by tightening the bolts provided and the left side of the cage unit. • Insert the provided spacers into the side channel above the botton cage unit and

place a single bar above the spacer; repeat with second and third single bars.

o The length of the spacers can be altered, if necessary.

• Fit the polypropylene backing board on the inside of the fitted bulkhead bars and string the zip ties through the appropriate pre-drilled holes.

o Backing board height may need to be slightly adjusted so that the holes are properly aligned with bulkhead bars.

o The valve window in the backing board should fit against the valve window of the bottom cage unit.

• Using zip ties provided in the shipping box, attach the single vertical bar (the “short bar”) to the outside of the bulkhead as shown in the photo below.

• Cover the inside of the backing board with corrugated liner.

• Carefully cut away the corrugation from the valve window and pull the valve through the valve window.

o Ensure the valve is positioned correctly in valve window, as shown in the photo below.

• Secure the valve plate to the two vertical bars with the zip ties provided in the shipping box, as shown in the photo below.

Extension Rod and PVC Spacers


Bulkhead Backing Board

Proper Valve Placement


Secured Valve Plate

Checklist See Appendix – ”Flexitank Installation Checklist”:



Flexitank Loading Requirements Site

• Allow a minimum height of 16 Feet (5 Meters) and minimum width of 10 Feet (3 Meters) for each container loading operation.

• The hose connection should fit the flexitank valve, which is a 3" butterfly valve with a 3" male cam fitting.

Equipment

• Self-priming, positive displacement pumps are recommended for fast and efficient loading of flexitanks.

o When handling food grade products, pumps should be food grade approved and carry the proper cleaning/inspection paperwork.

o Loading facilities are responsible for power.

• In order to assess the correct pump for the desired application, the following information is required:

o Diameter and layout of the customers pipe works.

o Total head or height product has to be pumped.

o Distance from the pump to the flexitank valve.

o Viscosity of the product.

Loading Guidelines

• FGN flexitanks have the following loading guidelines:

o Maximum allowable load over/under load capacity: +/- 5% of stated capacity

o Maximum temperature allowable during loading: +140°F (60°C)

o Minimum temperature allowable during loading: +14°F (-10° C)

o Maximum valve flow rate: 210 Gallons (400 Liters) per minute

• A properly calibrated flow meter is required to ensure loading loading capacity guidelines are met.

WARNING: OVER- OR UNDER-LOADING FLEXITANKS WILL VOID THE MANUFACTURERS WARRANTY.

Procedure • Open the right side door only and confirm that the flexitank and bulkhead have not

shifted in transit and are positioned in the container.

WARNING: LEFT SIDE CONTAINER DOOR MUST REMAIN CLOSED AT ALL TIMES.


• Remove the dust cap and screw plug from the flexitank valve.

• Connect the female cam quick-release coupling to the flexitank valve male cam lock and ensure a proper seal is achieved.

WARNING: IF EXCESSIVE FORCE IS REQUIRED TO CLOSE CAM ARMS, CHECK AND/OR ADJUST THE SIZE OF THE GASKET INSIDE FEMALE COUPLING.

• Carefully turn the flexitank valve handle to the open position, turn on the loading pump, and commence loading.

WARNING: IF EXCESSIVE FORCE IS REQUIRED TO OPEN THE FLEXITANK VALVE HANDLE, ENSURE THE SCREW PLUG HAS BEEN REMOVED.*

• After the flexitank has safely loaded to the approved allowable capacity, turn off the loading pump and close the valve handle.

• Replace the dust cap and screw plug.*

• Ensure the connector arms of the dust cap are in the proper locked position.

• Close and lock right side container door.

• Ensure any residual material that may have dripped from the hose is thoroughly cleaned so there is no appearance of leakage.

Checklist See Appendix – ”Flexitank Loading Checklist”


* If provided with particular flexitank model.


Flexitank Unloading/Discharge

Requirements Site

• Allow height of 16 Feet (5 Meters) and width of 10 feet (3 Meters) for each container loading operation.

• If site the location allows, position the container on slight incline with the door end of container in a lower position than the “nose” (front) of the container.

Equipment

• FGN recommends self-priming, positive displacement pumps for fast and efficient unloading of flexitanks.

• When handling food grade products, the pump supplier should certify that the pump is food grade approved.

• In order to assess the correct pump for the desired application, the following information should be available:

o The diameter and layout of the pipe works.

o The total head or height that the product has to be pumped.

o The distance from the pump to the flexitank valve.

Guidelines

• The receiver of the flexitank loaded container should closely follow the handling guidelines for unloading in order that the manufacturer’s warranty remains valid.

• FGN flexitanks have the following guidelines for unloading:

o Maximum temperature allowable unduring unloading: +140°F (60°C).

o Minimum temperature allowable during unloading: +14°F (-10° C).

o Maximum valve flow rate during unloading: 210 Gallons (400 Liters) per minute.

Procedure

WARNING: BEFORE PROCEEDING WITH FLEXITANK DISCHARGE, CHECK THE LOCKING HANDLES ON THE LEFT HAND CONTAINER DOOR TO ENSURE THAT THEY ARE SECURE AND IN A LOCKED POSITION.

• Remove dust cap and/or screw plug* from flexitank valve.

• Connect the female cam quick-release coupling to the flexitank valve male cam fitting and adjust the cam arms to ensure a proper seal has been achieved.

* If provided with particular flexitank model.


WARNING: IF EXCESSIVE FORCE IS REQUIRED TO CLOSE THE CAM ARMS, CHECK AND/OR ADJUST THE SIZE OF GASKET INSIDE THE FEMALE COUPLING.

• Turn the flexitank valve handle to the open position, engage pump operations, and commence with unloading/discharge.

• When approximately 75% of the product is dischareged, reduce the pump rate to half speed.

• When the liquid in the flexitank is lowered to approximately 4 inches (10 cm) from floor level, two attendants should enter the container, and:

o Begin rolling the mosty emptied flexitank from the “nose” end of the container.

o As the flexitank is being rolled, lift the outside edges of the flexitank so material flows toward the center of the flexitank.

o Continue rolling the flexitank until the it takes the shape of a cylander just behind the bulkhead.

o Lift the ends of the cylander until the all the residual material is removed by the suction pump.

• Close the valve and turn off the suction pump.

• Remove the coupling from the flexitank valve and replace the dust cap / screw plug.*

• If required (due to the conditions of the Terms of Transport**):

o Open the left container door and dismantle the bulkhead.

o Remove the bulkhead assembly, flexitank, and container liner and arrange for disposal.

o Close the container doors.

o Remove the bulk liquid caution labels/decals from the container.

* If provided with particular flexitank model. ** Necessary if unloading party is responsible for disposal.


Flexitank Disposal Incineration

• Recycling and/or incineration are the preferred methods for flexitank disposal.

• The receiver should ensure that the flexitank is disposed at an authorized facility that complies with local environment regulations that apply to both the flexitank and the material being shipped.

Recycling • Un-dyed polyethylene and polypropylene are thermoplastic materials that can be

recylced in an economically advantageous way under certain circumstances.

• Recycling options should be reviewed prior be starting a flexitank program in order to minimize costs and provide for an envrionmentally friendly logistics program.

Landfill Disposal • Disposal in landfill facilities is considered to be a safe and approved method for

flexitank disposal in most countries.


Incident Management Information & Action

• Following the report of an incident anywhere in the transport process, the cargo owner or transport vendor should immediately notify FGN of the circumstances of the incident.

• The first responder should report:

o The container, seal, and flexitank ID numbers.

o The identity of the product via the Material Safety Data Sheet (MSDS).

o The circumstances of the incident and the contact information for any person or business entity that is on-site or handling incident management.

o Incident information should be collected and reported as quickly as possible.

• Once all relevant permissions have been obtained, FGN will dispatch a local team to inspect the container, the flexitank, and the status of the material being shipped.

• Depending on the nature of the incident, FGN will coordinate the following assets, as required:

o Independent cargo surveyors.

o Containment / Environmental teams.

o Companies experienced in container handling, repositioning, repair or other related activities.

o Insurance companies who have offered coverage on the particular shipment.

• An insurance company may issue a list of parties they require to be involved in the inspection and handling of the incident. FGN will ensure these parties are contacted and remain involved as per insurace company requirements.

• If product trans-loading is required, FGN will co-ordinate the sourcing and delivery of alternative packaging (new flexitank, IBC, Drums, ISO tank, etc.).

Completion • Once action has been taken, FGN will maintain communications with all parties

involved until the incident is resolved.

• Completion is defined as the time when the product being shipped is back into the contracted logistics process and any quarantined product or containment area is restored to the condition it was in prior to the incident.

Insurance • Shippers and/or Beneficial Cargo Owners (BCO’s) are responsible for carrying

suitable liability insurance.

• FGN maintains Manufacturer’s Liability Insurance through it’s flexitank manfuacturing partner, which assumes liability for damages that are the direct result of manufacturing defects (design/material/workmanship). This insurance:

o Covers to a limit of USD $5MM per single event in aggregate.

o Is offered under a Certificate of Insurance that are available upon request.


• Transport vendors and other parties who issue bills of lading or other documents that represent an acceptance of liability are responsible for carrying applicable insurances and must comply with all current flexitank codes of practice as set forth by the Containers Owners Association.


Appendix Container Selection / Pre-Installation Checklist

Container Selection / Pre-Installation Checklist

[email protected] 843.278.9225 www.fgn-net.com

Container Number FGN Reference Number Date Date of Container Manufacture

Container Data Max Gross

Allow Stack Wt Safety Approval Plate (Minimum 30,480 Kg) Side Wall ACEP 10 yrs old Maximum End Wall NED

Item Description Accepted Yes No

Side Walls

Weld seams to side walls have smooth weld seams and are free from sharp edges and objects

Repair seams have been covered with tape There are identical corrugations over the full length, there is no logo panel or flattened corrugations

Container Interior Floor

The container is free from transferable or non transferable dry dust, carbon dust, sand, dirt or depot yard dust

There are damp floor stains There are paint spills There are large areas of transferable burn marks The container is free from debris, dunnage and previous cargo residue. Floor is free from splinters and protruding nails, screws and other fixings.

Container Interior Walls

There are excessive accumulated scratches to the interior due to normal use of the container.

The inside walls and roof is free from large areas of rust or flaking paint. There are excessive non transferable stains. There are transferable stains.

Container Interior General

The container is free from taint and previous cargo odours. The container is watertight / light tight. The shoring slots (at door end) are straight and free from dents and obstructions There are lashing bars as required to all corners and top and bottom rails Interior is free from graffiti

Understructure Door Hardware Exterior General

The underside of the container has been inspected Door gear fixing and bolt heads on the inside of the doors are free from sharp points and edges.

The exterior is free from hazardous or previous cargo marks

Declaration I have inspected the container and found that it complies with the Container Owners Associations’ Standard for the Safe Handling and Operation of Flexitanks – Container Selection as summarized above and find it acceptable for use

Yes No

Inspected by Inspected at FGN Certified Flexitank Fitter Number

Print Name


Flexitank Installation Checklist

Flexitank Installation Checklist


Item Description Yes No

Container Selection Verification

Is the container 30 ton rated Are container doors operable and easy to open and close Has the Container Selection Checklist been completed and signed by FGN Certified Fitter

Preparation

The container has been cleaned of debris, dunnage and previous cargo residue All weld seams have been checked for rough edges and taped over Container floor is free from splinters and protruding nails, screws and other fixings Corrugated paper liner has been used to cover container walls and floor and there is a 6” overlap of corrugated paper between container walls and container floor

Flexitank Load sticker installed on container door and warning label installed on left hand container door

Fitting

Flexitank has been carefully placed in container as per proper procedure Bulkhead backing sheet valve window is approximately 8” from center of container Zip/Cable ties have been used to secure bulkhead backer to bottom bulkhead bar Valve is positioned correctly in valve window cutout PVC Spacers have been secured with tape in container door channel Corrugated liner has been used to cover bulkhead backing board Flexitank straps have not been secured to the bulkhead Flexitank serial number and date of installation recorded

Declaration I have inspected the container and flexitank installation and found that it complies with the FGN Global Logistics, Inc. – Flexitank Operations Manual as summarized above and find it suitable for loading

Yes No

Inspected by Inspected at FGN Certified Flexitank Fitter Number

Print Name

Container Number FGN Reference Number Flexitank Serial Number Date


Flexitank Loading Checklist

Flexitank Loading Checklist


Item Description Yes No

Loading Site

The loading site is accessible by a 20’ ocean container mounted on a chassis The immediate area around the loading site is free from obstruction

Pre-load

Temperature of product during loading has been verified as less than 140°F and greater than 14°F

Appropriate length loading hose available and fitted with 3” female, cam fitting Flow rate of loading pump is verified as not exceeding 105 gallons per minute Capacity of the flexitank has been verified and will not be filled beyond or below +/- 132 gallons of capacity

Flexitank valve is secured against the bulkhead and positioned correctly Left hand container door confirmed closed and sealed Bung Cap or Dust Cover removed prior to connecting loading hose

Load Valve handle has been locked in the open position Loading hose with 3” female cam fitting is securely fixed to flexitank valve and loading hoses and hose fitting are supported to prevent downward pressure on the flexitank valve

Load was attended at all times by Material Handler or other qualified individual Load weight and volume recorded and confirmed within specification Valve handle has been locked in the closed position after disconnecting loading hose

Bung Cap or Dust Cover replaced and secured Right hand container door closed and sealed

Declaration I have attended or inspected the load in question and certify that it has been loaded according to procedure and is suitable for transport

Yes No

Loaded by Loading Company Time load started / Time load ended

Print Name

Container Number FGN Reference Number Flexitank Serial Number Date

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Flexitank Technical Specifications

FGN Global Logistics, Inc. 145 King Street, Suite 229 Charleston, SC 29449 FMC Number: 024107NF


FGN Flexitank Technical Specification

The FGN Flexitank is constructed from Multi-layered, High Tensile, Multi-ply, and Ethylene co-polymers appropriate for Foodstuffs, Pharmaceuticals,

Chemicals or Industrial products shipped in bulk.

Polyethylene)Film)

Thickness) 125±11.5micron,

Tensile)Strength)MD, ≥20N/15mm,

TD, ≥20N/15mm,

Elongation))MD, ≥600%,

TD, ≥600%,

Maximum)Load)) ≥90N,

Tensile)Strength)) ≥40N/15mm,

Elongation)Rate)) ≥300%,

Polypropylene)Cloth)

Weight) 170±5gsm,

Tensile)Strength)Warp, 2000N/5cm,

Weft, 2000N/5cm,

Elongation))Warp, 18.8%,

Weft, 18.8%,

Valve)Pressure) ≥0.4MPa,Loading)Temperature) D20℃"D,65℃,Minimum)Temperature) D20℃,

Maximum)Temperature) 80℃,


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FGN$Global$Logistics,$Inc.$145$King$Street,$Suite$229 Charleston,$SC$29401$$FMC$Number:$024107NF$$

FGN 3” Ball Valve

Description 3” Food Grade Ball Valve

Valve Body Polypropylene

Gaskets/Seal Silicone and Teflon

Securing Mechanism Threaded Screw Plug and Locking Bung Cap

Maximum pressure rating 8 Bar

Working Pressure 5 Bar

Temperature Rating 60 C

Flexitank Operations Manual - FGN Global Logistics, Inc.

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