USER GUIDE & SAFETY MANUAL
Contents
1. equipment 8 Do not overfill the bladder tank and be certain all seals and valves are leak tight 9 Always fill the bladder tank slowly remove and replace the cap carefully open the discharge valve gradually and tighten the tie down straps uniformly Abrupt and careless handling can cause fuel spillage and a potential fire hazard Keep a Class BC Purple K fire extinguisher handy in case of ignition 10 To protect the ATL REB s bottom surface always position the bladder on a clean smooth surface or use ATL Underliner or Ground Cloth for chafe avoidance 11 When storing an ATL REB drain all fuel collapse the bladder flat to expel vapors wrap padding around all fittings fold up the bladder and wrap it in a polyethylene bag 12 For maximum bladder life minimize the tank s exposure to intense sunlight extreme heat and cold pressurization fungus abrasion and high humidity Avoid repeated folding along the same crease lines as this practice may cause unnecessary wear 13 Since fuel vapors are frequently flammable ATL REBs are to be used only in open well ventilated spaces Immediately clean up any fuel spills and preferably discharge fuel directly to the vehicles main tanks Use top quality hoses pumps valves and fittings when installing an ATL REB auxiliary fuel tank Keep the ATL REB exterior clean and dry 14 The fill and outlet fittings bosses on ATL REBs are of compos2. Y ATT USER GUIDE amp SAFETY MANUAL FOR RANGE EXTENSION FUEL BLADDERS ELEN PER TAAN NN Riri YELOCKER FUEJOCKER N a SEA LAND amp AIR AX 22K BLADDER TANKS ARE EVERYWHERE AERO TEC LABORATORIES AERO TEC LABORATORIES Spear Road Industrial Park ATL Technology Centre Denbigh Road Ramsey NJ 07446 1251 USA Bletchley Milton Keynes MK1 1DF England Tel 201 825 1400 Fax 201 825 1962 Tel 44 0 1908 351700 email atl atlinc com Fax 44 0 1908 351750 website www atlinc com email atl atlltd com 1 800 526 5330 website www ailltd com LAL gt 1 ATL REB Applications ATL REBs Are Intended For a Ferrying unpressurized aircraft under permit and sanction of the F A A or other jurisdictional body b Carrying reserve fuel on the open deck of U S C G compliant boats including commercial defense and pleasure craft c Extending the travel range of off road vehicles construction equipment open trucks and military equipment d Providing a fuel supply for power generators water pumps air compressors HVAC components cement mix ers and the like 1 ATL REB Compatibilit ATL REBs Should Be Used To Hold Hydrocarbon Fuels Only a Gasoline to 30 aromatics ASTM Fuel B b Diesel and Bio Diesel Fuel c Turbine Fuels JP4 5 8 10 JetA B etc d Heating Oils 2 4 e Collected
3. 1 800 526 5330 MK1 1DF UKTel 44 0 1908 351700 Fax 44 0 1908 351750 e Mail atl atiitd com PRODUCT SAFETY BULLETIN DS 370 Fax 201 825 1962 e Mail atl atlinc com D d iad f IMPORTANT SAFETY PRECAUTIONS IN USING ATL FLEXIBLE TANKS BLADDERS DRUMS PLUGS VALVES LINERS amp AIR CELLS 1 Compatibility Be certain your ATL product is designed to handle the temperature and fluid in question When in doubt contact ATL to discuss specific model numbers and material types Never subject any item to Ketones Chlorinated Solvents Concentrated Acids Alkalies Pure Aromatics or temperatures over 60 F unless specifically designed for that service and approved by ATL 2 Personnel Protection Be prepared for the unexpected All personnel handling fuels and hazardous chemicals must wear full protective clothing and equipment of an impervious non static and flame resistant type Specific information should be sought from your fuel chemical vendors industry associations and producers of personnel protection systems 3 Multiple Uses Some ATL tanks can be sufficiently cleaned to store or transport several different but similar liquids without contamination However never take this factor for granted Field and laboratory testing are always required before suitability can be assured ATL can frequently provide material samples and scale models to assist in your analysis Never switch a fuel or chemical container to a comest
4. Covers 3 Metal Containers 2 Ground Cloths amp Geotextiles 4 Fire Shield Covers This equipment in conjunction with reasonable care and maintenance will significantly improve the retention of physical properties and hence product longevity 10 Flex Fatigue Like most materials the polymers laminates and flexible composites used in most ATL products can weaken from severe pinching creasing folding and flex cycling Normal collapsing and distending produce no ill effects but compaction inversion and crushing will decrease physical properties Some materials comprised of high performance filaments are especially susceptible to flex fatigue and require diligent care to avoid abuse during packing operating storing and unfolding 11 Set Up and Installation ATL provides User Manuals and or installation instructions for most standard products However specialty items and custom made products require the user to formulate his own procedures or draw on established standards such as ASTM ASME SAE ISO etc 12 Cleaning and Storing All products should be periodically cleaned especially if they are to be stored for extended periods Follow the User Manual procedures or contact ATL for assistance 13 Leak Testing Prior to use all tank and container type products should be leak tested This procedure can generally be done with 1 8 psi air pressure and a standard bubble type leak detector solution Follow the User Manual procedure o
5. PILOTS ON FILL FLANGE CHAFE PAD DISCHARGE VALVE NYLON CLOSED STRAP 4 ATL TIE DOWN DECKING KIT COLLAR AND 4 STRAPS SELURING THE PETRU FLEX NOT SUPPLIED BY ATL FIG 1 ATL Tie Down Collar with ratchet straps at 4 equally spaced points Bladders can also be secured with cargo nets and harness webs If a partial discharge of fuel is made re tighten the straps or cargo net to restrain the bladder IV ATL Range Extension Bladders General Safety 1 ATL REBs generally contain flammable or combustible liquids and all relevant fire safety precautions apply 2 Keep the fuel bladder tightly restrained to prevent shifting and rolling On abrasive surfaces protect the ATL REB with a rubberized Underliner 3 Keep flame heat spark and static charges away from all ATL REB tanks A static ground strap from the outlet fitting to neutral earth is recommended 4 Before filling any bladder tank check the entire installation for cuts abrasions leaks or other potential hazards 5 Transfer fuel only when the vehicle is at rest or in a thoroughly stable mode Wear protective clothing as described in attached Bulletin DS 370 6 It is recommended to carry ATL REBs either full or empty Partial loads are more prone to surge roll and shift and therefore require regular adjustment to the restraint straps 7 Transfer fuel by pump or siphon only in a well ventilated area with non sparking
6. valve Gradually extract the siphon hose and close the vehicle s fuel fill port See Figure 4 Diagram Refers to BOTH Petro Flex and FueLocker FOUT PRESSURE TO START FLOW DISCHARGE VALVE OPEN CAP y DISCHARGE HOSE 142 FUEL FILL PURT HIGHER THAN PETRO FLEX MAIN TANK SLPRUN DISCHARGE NOT SUPPLIED BY ATL 4 e Fuel Discharge by Pump When gravity or siphon flow is not practical an electric or manual fuel pump may be employed to lift and discharge fuel to a main tank above the bladder Ascertain that the pump is an explosion proof variety designed for the type of fuel and flow rate required Watch the vehicle s fuel level gauge and when the main tank is near full turn off the pump and close the ATL REB discharge valve See Figure 5 Diagram Refers to BOTH Petro Flex and FueLocker MAIN TANK _ HIGHER THAN PETRU FLEX FUEL DISCHARGE DISCHARGE ELECTRIC FUEL PUMP PUMP DISCHARGE NOT SUPPLIED BY ATL FIG 5 V Contact Us ATL is available by mail phone fax and e Mail to answer questions lend advice and supply accessories for its Petro Flex and FueLocker bladder tanks Feel free to contact the factory ATL Fuel Cells UK ATL Technology Centre ATL Fuel Cells USA Aero Tec Laboratories Inc Spear Road Industrial Park Denbigh Road Ramsey New Jersey 07446 1251 USA Bletchley Tel 201 825 1400 Milton Keynes Toll Free
7. vapors and condensates of fossil fuels FUEJGCKER f Kerosene mineral spirits and isooctane g Gasoline alcohol hybrids to 15 homogenious volume methanol or ethanol M15 E15 h Vegetable oil type bio fuels and combustible plant extracts i Bio Butanol pi j High octane leaded race fuels 7 Hi ATL REB Dynamic Restraint ATL REBs Used In Mobile Applications Must Be Secured Or Restrained By One Of The Following Methods a Within a ventilated rigid container compartment locker or nacelle b Under a fastened cargo net or nylon web harness c Within 4 ratchet tie down straps one in each direction d Or another active restraint means able to absorb 3 g loadings along all axis CAUTION ATL s Tie Down Kits KS 198 and KS 199 are designed to stabilize your Petro Flex or Fue Locker on deck during routine excursions and outings They are very sturdy restraints but are NOT designed for rough seas and nasty weather Under storm and wake conditions cargo nets belts and or additional cross strapping to durable cleats is very important Otherwise if possible drain the bladder into your main tanks before engaging weather extremes or serious swells Diagram Refers to BOTH Petro Flex and FueLocker CLEAT HOOK RAIL OR OTHER ATTACHMENT POINT SAFETY VENT RELIEF VALVE RATCHET lt 4 TIE DOWN COLLAR UNDERL INER
8. an help either directly or by referral to a source of safety information for your particular problem Please refer to page 7 for ways to contact Aero Tec Laboratories We love it when our customers share with us photos videos of their ATL Bladders in use on the decks of their vessels If you would like to have your photos videos Oog featured on our website simply send them via email to jheotzler atlinc com ALSO FROM ATL PRIMARY INTEGRAL MARINE FUEL BLADDER TANKS SUPERCELL MATERIAL FLUOROCELL MATERIAL Lignt vveignt amp Supe Shock Vibration amp impact immune Foam Filled for Explosion Suppression Tolerant to Gasolines Diesel amp Bio Fuels Specially Tailored to Custome Dir mensions CALL OR VISIT OUR WEBSITE FOR MORE INFORMATION AERO TEC LABORATORIES AERO TEC LABORATORIES Spear Road Industrial Park ATL Technology Centre Denbigh Road Ramsey NJ 07446 1251 USA Bletchley Milton Keynes MK1 1DF England Tel 201 825 1400 Fax 201 825 1962 Tel 44 0 1908 351700 email atl atlinc com Fax 44 0 1908 351750 website www atlinc com email atl atlltd com 1 800 526 5330 website www atlltd com
9. d fuel expansion If internal pressure becomes extreme a safety relief valve in the fill cap is designed to exhaust this over pressure It is always best to keep the bladder in a well ventilated area away from intense sunlight or other heat sources However should the fill cap be removed from a bladder with internal vapor pressure an automatic flapper valve will help prevent rapid back flow of fuel up the fill neck A small relief passage will generally permit the slow bleed off of pressure again automatically Do not store any fuel for longer than 90 days as petroleum products can polymerize and become sour Deteriorated fuels may be harmful to the ATL REB as well as to fuel systems and engines Do not mix any additives with the fuel in an ATL REB tank Some fuel additives may be harmful to the bladder and its fittings or to fuel transfer hose All rubberized materials experience a small amount of vapor transmission or diffusion when they separate two fluids or gasses in this case a hydrocarbon fuel and air This permeation effect is normally unnoticed but in cases of over pressurization abuse or over filling there may be a fuel odor detectable Again ATL REB tanks should be located in a well ventilated area and inspected regularly Do not use a direct connection hook up for an diesel engine or for any other engine employing a fuel return line back to the tank ATL REBs are not equipped to accommodate a return line unless s
10. ibles use 4 Pressure Most ATL products are designed for use at ambient pressure Unless specifically designated Do Not subject any container valve or connection to pressure differential Do Not restrict venting Do Not overfill or exceed maximum height Do Not exceed normal flow rates during filling or discharging and Do Not pressurize any inflatable unless fully restrained and enclosed Always allow a 10 volume factor ullage to compensate for vapor expansion thermal expansion and overfill Those products designed for pressurization should be fully contained or restrained in an engineered rigid structure before filling 5 Fire amp Explosion Always exercise the utmost care in containing transferring venting or processing flammable and combustible materials Keep away from fire flame heat spark static charge oxygen lightning focusing lenses friction turbulence or any combustible materials that could spontaneously ignite Refer to your industry specialists and publications such as The National Fire Prevention Association Code for proper avoidance of fire and explosion hazards 6 Accessories Fittings flanges piping hoses valves vents meters pumps etc used in conjunction with ATL products must be designed selected and maintained for leak tightness galvanic compatibility chemical compatibility thread and seal compatibility as well as appropriate grounding electrical bonding vibration tolerance tamper resistance fle
11. ite plastic construction so as to be corrosion resistant non sparking and impact resistant However these threaded bosses are not intended to be connected to metallic pipe Do not alter the fitting arrangements on ATL REBs and if a replacement part in needed use only threaded nylon and not metal V ATL REB Operation a Fuel Filling An ATL REB will accommodate standard gas station nozzles Slowly remove the cam lock type fill to relieve pressure and then fill the bladder slowly with fuel When the bladder is taut and the fuel is 1 inch 2 3cm high in the fill neck stop filling and secure the cap with both levers carefully latched See Figure 2 Diagram Refers to BOTH Petro Flex and FueLocker HULU GROUNDED NOZZLE WITH ONE HAND x HOLO FILL NECK WITH OTHER HAND DISCHARGE VALVE CAP l OUTLET REMOVED CLOSED TY RECOMMENDED oor CLAMP AND STATIC GROUND FLAP VAL STRAP TO EARTH PETRO FLEXY 897 3 FILLING THE PETROU FLEX BLADDER NOT SUPPLIED BY ATL FIG 2 UNDERL INER It is a good idea to mark the bladder with its intended fuel type so as not to mix diesel leaded gas unleaded gas or other fuels b Fuel Storage When fuel is stored in an ATL REB tank be certain the fill cap is affixed tightly the outlet valve is closed and the bladder is well secured No venting is required as the bladder can grow slightly to accommodate normal vapors an
12. pecially fitted at the Aero Tec Laboratories ATL factory Fuel Discharge by Gravity When draining fuel to a lower main tank from an ATL REB simple down hill gravity flow is very convenient Insert a 1 2 inch inside diameter I D hose into the vehicle s fuel fill port and slowly open the ATL REB discharge valve If needed step lightly on the bladder to initiate fuel flow Watch the vehicle s fuel level gauge and when near full close the discharge valve remove the hose slowly and re cap the vehicle s main fuel tank See Figure 3 Diagram Refers to BOTH Petro Flex and FueLocker CAP FOOT PRESSURE 00 NOT TO START FLOW REMOVE DISCHARGE VALVE i 1 2 FUEL DISCHARGE HOSE FILL PORT LOWER THAN PETRU FLEA MAIN TANK GRAVITY DISCHARGE NOT SUPPLIED BY ATL FIG d Fuel Discharge by Siphon When transferring to a lower tank but through a higher fill port the siphon technique is helpful Run a siphon hose 1 2 inch I D into the vehicle s fuel port extending to a level below the bottom of the bladder at least 6 inches as shown Open the ATL REB discharge outlet valve and step on the bladder to initiate flow Fuel will siphon to the main tank To remove all residual bladder fuel roll up the nearly empty bladder toward its discharge fitting squeezing fuel out Watch the vehicle s level gauge and when the main tank is near full close the bladder discharge
13. r contact ATL for help Always rinse and dry the surface after testing 14 Intended Purpose Never use an ATL product for an application other than that intended unless specifically authorized For example don t use a static storage tank for dynamic operations don t use an air inflatable to contain nitric acid or a berm liner as a field cover Be methodical order precisely what you need and avoid adaptations 15 Abrasion Plastics rubber and fabrics can deteriorate from excessive abrasion or chafing ATL s compounds minimize this wearing effect but all efforts should be made to avoid dragging rubbing cutting and scuffing of flexible materials Poly slip sheets talc light oil and doubler patches frequently help ward off abrasion but the best protection is reasonable care in handling and use 16 Repairs All repairs to ATL products should be performed at the factory When this is not practicable and where field repairs are authorized a reasonably skilled technician can patch and seal most ATL flexible containers Be certain to use only the appropriate ATL repair kit and perform the repair in a clean well equipped facility following the repair instructions precisely Remember not all damage is repairable Do Not attempt to repair a tank drum air cell etc that has been broadly weakened by chemical attack ozone effect UV exposure etc 17 When in Doubt Do Not take chances Please contact ATL for assistance We c
14. xibility flow capacity and mounting methods Get professional assistance to assure total system functionality and safety 7 Personnel Training ATL products are of a technical nature and are frequently used in conjunction with hazardous materials All operating and support personnel must be trained in the user s specific application of these ATL items A full familiarity with the important safety precautions and procedures is essential before any such devices are placed in service Each user must establish his own training program geared to his particular industry and specific application 7 8 Environmental Considerations ATL products are engineered so as not to endanger the water air and land environments Many ATL devices are in fact employed specifically for pollution abatement purposes Nevertheless wherever fuels and potentially hazardous substances are stored ATL recommends the simultaneous use of its secondary containment products such as 1 Permanent Berm Liners 4 Tank Envelopes Wrappers 2 Inflatable Berm and Liner Systems 5 Portable Dikes 3 Pit and Pond Liners 6 2 ply Flex Tanks 9 Weathering Undue exposure to the natural elements may adversely affect ATL products Minimize exposure to sunlight ultraviolet ozone severe hail ice loading freeze thaw cycling water immersion and extremes of temperature ATL offers these protective accessories to help guard against adverse weathering effects 1 Sun Shield
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