ADDENDUM NO. 1 REQUEST FOR PROPOSAL NO. 9117-15-7154 ... · Copies Pre-design Report (70%, 95%,...
Transcript of ADDENDUM NO. 1 REQUEST FOR PROPOSAL NO. 9117-15-7154 ... · Copies Pre-design Report (70%, 95%,...
Michael Pacholok Director
Purchasing and Materials Management Division City Hall, 18th Floor, West Tower 100 Queen Street West Toronto, Ontario M5H 2N2
Allison Phillips Manager Professional Services
June 5, 2015 Sent via PDF – 240 pages
ADDENDUM NO. 1 REQUEST FOR PROPOSAL NO. 9117-15-7154
PROVISION OF ENGINEERING AND PLC/SCADA PROGRAMMING SERVICES FOR THE
PRELIMINARY DESIGN, DETAILED DESIGN, CONSTRUCTION ADMINISTRATION SERVICES, AND POST CONSTRUCTION SERVICES FOR REPLACING TWO AMMONIA
AND TWO DECHLORINATION CHEMICAL WOOD STAVE TANKS, INSTALLING A NEW AMMONIA SCRUBBER SYSTEM, AND IMPLEMENTING A PARTIALLY COMPLETED
DECHLORINATION SYSTEM AT THE R. C. HARRIS WATER TREATMENT PLANT
REVISED CLOSING DATE: JULY 8, 2014, 12:00 NOON (LOCAL TIME)
Please refer to the above Request for Proposal (RFP) document in your possession and be advised of the following: ATTACHMENTS
1. Revised Table 7.1 (Revised as per Addendum 1) – Deliverables.
Proponents must complete the attached revised Price Form (Addendum 1) and submit with their proposal. Failure to submit the revised form will results in your proposal being declared non-compliant.
2. Revised Table 7.3 (Revised as per Addendum 1) – Table of Provisional Allowance Items – All Phases. Proponents must complete the attached revised Price Form (Addendum 1) and submit with their proposal. Failure to submit the revised form will results in your proposal being declared non-compliant.
3. Air Dispersion Modelling Report (total of 79 pages)
4. Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at R. C. Harris Water
Treatment Plant Technical Memorandum (total of 152 pages)
REVISIONS A1-1 The closing date has been extended from June 17, 2015 to Wednesday, July 8, 2015 at
12:00 PM (local Toronto time). A1-2 The deadline for questions has been extended from June 10, 2015 to Tuesday, June 30,
2015.
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A1-3 Section 3.1 Scope of Work Overview, DELETE Item 3.1.1 in its entirety and
REPLACE with the following:
.1 The Consultant shall provide engineering services and PLC/SCADA programming for the full pre-design, detailed design, construction contract administration services including site supervision, and post construction services for replacing two (2) ammonia and two (2) dechlorination wood stave tanks, installing a new ammonia scrubber system, decommissioning of existing sodium bisulphite system with tanks, and implementing a partially completed drinking water dechlorination system at the R. C. Harris WTP. Note that responsibilities and deliverables described in the PCS guidelines for the System Integrator are to be included in the Consultants base scope of work since all PLC/SCADA programming will be done by the Consultant as part of this assignment.
A1-4 Section 3.1.2 Ammoniation and Dechlorination Storage Tank Replacement, DELETE
Item 3.1.2.c. in its entirety and REPLACE with the following:
.c The plant may consider structural modifications to the roof slab to drop in pre-fabricated tanks if determined to be a feasible option during design. The consultant shall investigate the feasibility of this option during the preliminary design phase of this assignment. In the event that this option is feasible, provisional allowances are included in Table 7.3 for the Proponent to price for
the complete detailed design effort and services during construction effort associated implementing this option for all the Ammonia and Dechlorination Chemical tanks.
A1-5 Section 3.1.2 Ammoniation and Dechlorination Storage Tank Replacement, DELETE
Item 3.1.2.d. in its entirety and REPLACE with the following:
d. Given the plant's experience with chemical fumes in the Ammonia and Dechlorination chemical storage rooms, review the existing chemical supply piping, vent piping, and discharge piping contained within the Ammonia and Dechlorination chemical storage rooms for leakage and make recommendations for improvement to be implemented as part of the design.
A1-6 Section 3.1.4 Drinking Water Dechlorination System Implementation, DELETE Item
3.1.4.o. in its entirety. A1-7 Section 3.1.4 Drinking Water Dechlorination System Implementation, DELETE Item
3.1.4.p. in its entirety and REPLACE with the following:
p. To enable the plant to operate all chemical systems in the LOCAL MANUAL mode, in the event the PLC is not available, the consultant must include in the design documentation the supply of a Eurotherm NANODAC Recorder/Controller, Model No. VH-C-X-LRD-XX-TS-WD-XXX-ENG-XXX-X-XXXX-XX-XX to be installed in the panel of each dechlorination chemical system. This device is to be configured and wired to display key process parameters related to the drinking water dechlorination process, which may include but are not limited to the plant's total treated water flow rate, treated water reservoir level, before Dechlorination Chemical addition chlorine residual, after Dechlorination Chemical addition chlorine residual, and other residual
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analyzer or flow information. Each Dechlorination Chemical System already has some of this information already hard wired to it.
In addition, loop isolators are to be installed in both of the dechlorination chemical system panels and the analogue signals from the chemical skid flow transmitter (FIT) and pressure transmitter (PIT) will be sent to the NANODAC Recorder/Controller and to the RPU-2022.
A1-8 Section 3.3 Preliminary Design Engineering Services, DELETE Item 3.3.5.f. in its
entirety and REPLACE with the following: .f A.4.9 – A Subsurface Utility Engineering study is not required. A1-9 Section 3.5 Services during Construction, DELETE Item 3.5.20 in its entirety and
REPLACE with the following:
.20 New/upgraded/altered equipment training for the plant staff is a joint responsibility of the Consultant, Contractor, sub-Contractor and vendors. Training shall also be included for SCADA/PLC programming modifications as specified in the PCS implementation manual. The Consultant is to ensure that all training materials that will be provided to plant staff are submitted to the City’s Project Manager four weeks prior to the scheduled training date for review and comments. Final training materials must be submitted in hardcopies (20 copies) and on CD to the City’s Project Manager 2 weeks prior to the training. The Consultant shall provide Five (5) training sessions focusing on SCADA/PLC (Remote) Operation and Local/ACP (Manual) Operation of the newly implemented Dechlorination System. Training sessions will be delivered between the hours of 7 am and 10 pm. All training is to be completed during the start-up/testing phase of the project.
A1-10 Section 3.8 Deliverables, DELETE Item 3.8.1. in its entirety and REPLACE with the
following:
.1 The following table summarizes the major project submissions, and provides general guidelines on the number of versions and quantities. The “number of versions” indicates, for the same document, the number of draft versions which will be submitted for review to the City, plus a final version (for example, if 3 versions are specified, this means a draft, second draft and a final version, assuming noted deficiencies are adequately addressed). The proponent should note that other deliverables are also required, as specified within this document.
Submission Number of
Versions Number of
Hard Copies
Pre-design Report (70%, 95%, 100%) 3 6 Designated Substances and Asbestos Survey Report 2 6 Tender Drawings (70%, 95%, 100%) 3 6 Contract Documents and Specifications (70%, 95%, 100%) 3 6 Completed WMS Datapilot Spreadsheet 2 0 Detailed construction cost estimate 2 6 PreStart Health & Safety Report at end of detailed design phase 2 6 Monthly Site Inspection Reports (provided monthly) 1 6 PreStart Health & Safety Report prior to commissioning 2 6 Updated Plant-wide Master Electrical Single Line Diagrams (SLD's), 2 6
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Master P&ID's, Master SCADA Architecture Drawings Equipment Calibration and Test Reports 1 6 ETMS Tagging List, WMS List, Physical Tag Lists and Tag Inspection Sheet
2 6
Equipment and Process Commissioning Reports 1 6 Consultant Process Operations & Maintenance Manual (75%, 90%, 100%)
3 6
SCADA Operation and Maintenance Manual (75%, 90%, 100%) 3 6 As-Built Drawings hard copy and 1 electronic copy on CD 2 6 A1-11 Section 7.3 Base Scope of Work and Provisional Allowances, DELETE Item 7.3.7. in its
entirety and REPLACE with the following:
.7 Provisional allowances have been provided in the cost breakdown Table in Section 7.3 for the Proponent to price for the engineering effort during Design and Construction to implement structural modifications and restoration of the Chemical Storage room roof slabs to drop in pre-fabricated tanks for the Ammonia and Dechlorination Chemicals.
A1-12 DELETE Table 7.1 - Costing Table and REPLACE with the one attached with this
Addendum. A1-13 DELETE Table 7.3 – Table of Provisional Allowances and REPLACE with the one
attached with this Addendum. A1-14 Appendix E – Project Reference Material, ADD the following attached Feasibility Study
for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum (Final) as E.13
A1-15 Appendix E – Project Reference Material, ADD the following attached Air Dispersion
Modelling for Emergency Release of Aqueous Ammonia at R. C. Harris Water Treatment Plant as E.14
QUESTIONS A1-Q1 Sections 2.1.7.d and 3.1.2.d discuss the chemical system piping. Please clarify which
piping is to be inspected for leakage. Answer: Please see Item A1-5 above. A1-Q2 Section 3.1.2.f indicates that a feasibility study for replacing the existing ammonia
tanks was completed in 2014. Can an electronic copy of this document be provided? Answer: Please see Item A1-14 above. A1-Q3 Please confirm if any equipment is to be pre-selected. In 6.3.9.b.ii) under ‘Detailed
Design’, “Pre-selection document and risk assessment” is required. However, 3.4.9.c indicates that no equipment is to be pre-selected or pre-purchased for this project. Please clarify.
Answer: Confirmed. No equipment is to be pre-selected or pre-purchased for this project. The list
provided in 6.3.9.b is a sample list. The actual tasks to be presented in the proponent's
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time task breakdown should reflect the necessary tasks specific to the Proponent's proposed approach for this assignment.
A1-Q4 Sections 3.5.10 and 3.5.11. Is the effort associated with the half day meeting with
City to review scope of job plan to be included within 40 hours carried or in addition to?
Answer: The half day meeting is in addition to the 40 hours. A1-Q5 Please clarify number of training sessions required per topic as well as number to be
held outside of normal working hours. There is conflicting information provided in 3.1.4.o and 3.5.20.
Answer: Please see Items A1-6 and A1-9 above. A1-Q6 Is it the City’s preference for the one workshop required in 3.4.8 to also cover the
topics identified in 3.4.5 and 3.4.6? Answer: No. The topics identified in 3.4.5 and 3.4.6 can be covered in design review meetings or
as part of regularly scheduled progress meetings. A1-Q7 Section 3.8, Deliverables Summary Table: Please confirm number of detailed design
packages. Under ‘Tender Drawings’ there are 4 versions required. Under ‘Contract Documents and Specifications’, there are 3 versions required.
Answer: Please see Item A1-10 above. A1-Q8 Section 3.8: Is a 50% detailed design package required? Answer: The items described in the appendices for the 50% detailed design should be completed,
however, the first package submitted for review and comment to the City will be at 70% detailed design.
A1-Q9 We request a copy of the Report referenced on Page 11 of the RFP Scope of Work,
Paragraph 3.1.2.f entitled Feasibility Study. Answer: Please see Item A1-14 above. A1-Q10 We request a copy of the Air Dispersion Modelling Report referenced on Page 12,
Scope of Work Para 3.3.h. Answer: Please see Item A1-15 above. A1-Q11 Reference Page 19, Section 3.4.8. Does the City require one workshop for all tasks
referenced, or one workshop for each task reference? Answer: One workshop for all tasks referenced. A1-Q12 As the City’s Project Manager mentioned during the voluntary site visit, there is
another City of Toronto Wastewater RFP that will be closing soon. Several of our resources are heavily involved with that proposal. In addition, multiple people in the water industry will be away attending the annual AWWA Water Conference in California from June 7 – 11, 2015. As such, can the City please consider extending the questions and closing deadline by at least two weeks?
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Answer: Please see Items A1-1 and A1-2 above. A1-Q13 The RFP states in Section 6 that the Project Manager must have at least 10 years of
experience in municipal water/ wastewater engineering including projects involving automated chemical systems. Provided that the RFP also calls for an experiences Design Lead with 8 years of experience and an experienced Process Controls Engineer/ Specialist with 10 years of experience, can the City please consider reducing the Project Manager’s experience to 6 years?
Answer: Proceed as per RFP requirements. No change. A1-Q14 Due to current workload, we are requesting a 2 week extension to the proposal
deadline. Answer: Please see Items A1-1 and A1-2bove. A1-Q15 Item 3.1.2.f (page 11) references a feasibility study for replacing the existing
aqueous ammonia tanks that was completed in 2014. Would it be possible to provide a copy of this study at this time?
Answer: Please see Item A1-14 above. A1-Q16 There appears to be a conflict between the number of training sessions required.
Item 3.1.4.o (Page 13) says “4 process and 4 SCADA training sessions,” while Item3.5.20 (Page 21) says “5 training sessions are to be provided for each training topic…” and Item 3.5.21 (Page 22) says “minimum of 5 sessions of each type with a breakdown between O&M training and process training.” Can you please confirm the number of sessions required?
Answer: Please see Items A1-6 and A1-9 above. A1-Q17 Item 3.1.4.n (page 13) identifies workshop(s) to identify and incorporate alarms
priority…. Can the City please confirm the number of workshops that will be required?
Answer: One workshop as per 3.4.8. A1-Q18 Item 3.3.5.f (page 18). Please confirm that as per item b, a sub-surface utility
engineering study is not required. Answer: Please see Item A1-8 above. A1-Q19 Item 3.1.2.c (page 11). The RFP identifies that the City may consider structural
modifications to the roof slab to drop in pre-fabricated tanks if determined to be a feasible option during design. Any major modifications to the roof slab will require a significant amount of time to complete the structural engineering design and detailed drawings and specifications. Can the City please confirm if this effort is to be included in the base proposal price?
Answer: Please see Items A1-4 and A1-11 above. A1-Q20 Section 3.1.2.f of the RFP states the successful proponent will receive a copy of the
2014 Feasibility Study Report. Would the City release a copy of that now, instead, to
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assist firms in understanding the alternatives that have been recommended for replacing the existing aqueous ammonia tanks?
Answer: Please see Item A1-14 above. A1-Q21 Given the many concurrent RFPs the City has issued over the past month, would it
consider extending the submission deadline to July 8, 2015 and extending the questions deadline to June 19, 2015?
Answer: Please see Items A1-1 and A1-2 above.
Should you have any questions regarding this addendum contact Patricia Vasquez, Senior Corporate Buyer at (416) 392-6808 or by email at [email protected]. Please attach this addendum to your RFP document and be governed accordingly. Proponents must acknowledge receipt of all addenda in their Proposal in the space provided on the Proposal Submission Form as per Appendix B, Section 4 – Addenda of the RFP document. All other aspects of the RFP remain the same.
Yours truly, Allison Phillips Manager Professional Services
RFP 9117-15-7154
Table 7.1 (Revised as per Addendum No. 1)
Provision of Engineering and PLC/SCADA Programming Services for the Preliminary Design, Detailed Design, Construction Administration Services, and Post Construction
Services for replacing Two Ammonia and Two Dechlorination Chemical Wood Stave Tanks, Installing a new Ammonia Scrubber System, and Implementing a Partially
Completed Dechlorination System at the R. C. Harris Water Treatment Plant
Deliverables Cost ($)
Audit Reports per Agreement Clause 3(6) $ Preliminary Design - Preliminary Design Labour $ - Preliminary Design Disbursements $ Detailed Design - Detailed Design Labour $ - Detailed Design Disbursements $ PLC/SCADA Programming - PLC/SCADA Programming Labour $ - PLC/SCADA Programming Disbursements $
Sub-total (A)
Services During Construction - All Engineering and Office Services Labour Inclusive of Resident Site Inspection Services
$
- Engineering / Office Services Labour Disbursements $ - Schedule of Provisional Weekly Rate Allowance (Value Carried from the Schedule of Provisional Weekly Rate Allowance – Construction Subtotal in Table 7.2)
$
Sub-total (B) $
Post Construction Services - Post-Construction Labour $ - Post-Construction Disbursements $
Sub-total (C) $
Provisional Items - Provisional Allowances Transferred from Table 7.3 $
Sub-total (D) $
TOTAL (A+B+C+D) $
13% HST $
TOTAL UPSET LIMIT PRICE (HST INCLUDED) $
RFP 9117-15-7154
Table 7.3 (Revised as per Addendum No. 1) Table of Provisional Allowance Items – All Phases
Item Description Amount (net
HST) Schedule of Allowance Items - Design
1. Health & Safety equipment $2,000.00
2. Completion of DSL Reports, Monitoring of asbestos abatement activities and reporting
$2,000.00
3.
All Detailed Design (including tendering) Effort required to Implement Structural Modifications and Restoration of the Chemical Storage Room Roof Slabs to Drop in Pre-Fabricated Tanks for the Ammonia and Dechlorination Chemicals
$___________
Subtotal – Design $___________
Schedule of Allowance Items – Construction
4. Preparation of asbestos abatement specifications, monitoring and clearance by an asbestos consultant during construction
$1,000.00
5.
All Engineering Effort required during Construction to Implement Structural Modifications and Restoration of the Chemical Storage Room Roof Slabs to Drop in Pre-Fabricated Tanks for the Ammonia and Dechlorination Chemicals
$___________
Subtotal – Construction $___________
(Transfer Total to Table 7.1) Total $___________
Air Dispersion Modelling for Emergency Release of Aqueous Ammonia at R. C. Harris Water Treatment Plant
Prepared for: City of Toronto 55 John St Station 1180 18th Floor, Metro Hall Toronto Ontario M5V 3C6 Prepared by:
February 2009
Executive Summary
The City of Toronto proposed to relocate existing hydrofluosilic acid (H2SiF6) and aqueous ammonia (NH4OH) dosing systems to separate, newly constructed storage rooms in the Residue Management Facility (RMF) at the R. C. Harris Water Treatment Plant (WTP) located on Lake Ontario at the foot of Victoria Park Avenue in the community area of Scarborough.
CH2M HILL was retained by the City of Toronto (the City) to conduct air dispersion modelling to predict the impacts of aqueous ammonia emergency spill inside the WTP ammonia storage room on the surrounding residential areas.
Ammonia emergency emission rates were estimated using a method provided in the United States Environmental Protection Agency (U.S. EPA), Chemical Emergency Preparedness and Prevention Office (CEPP) publication document “Risk Management Program Guidance for Offsite Consequence Analysis, EPA 550-B-99-009, April 1999”.
The maximum duration of ammonia release was assumed to be 6 hours, and each hour had decreasing emission rates. 24 Scenarios were selected to capture spills that might occur at any time of the day. For each scenario, the calculated hourly release rates for each of the six hours and zero (0) release for the rest of the day were used in the modelling.
The MOE 1996 - 2000 five-year meteorological data sets for Central Toronto area were used in the modelling. Multi-tier grid receptors were selected following the MOE guideline. In addition, eighteen sensitive residential receptors in the vicinity of the WTP were identified.
The results of AERMOD using the worst-case emission rates are summarized in Table E-1: Emission Summary. The results indicated that the maximum 24-hr POI concentrations at the property line and beyond under different ammonia release scenarios ranged from 175 μg/m3 to 820 μg/m3, which exceeded the O. Reg. 419/05 Schedule 3 standard of 100 μg/m3 for ammonia. As such, additional mitigation measures for ammonia emergency release are required to bring the WTP into compliance with the MOE guideline. An emergency ammonia scrubber is recommended to be added as part of the relocation project.
Table E-1 R.C. Harris Water Treatment Plant Ammonia Emergency Emission Summary
Contaminant CAS# Total Facility
Emission Rate Air
Dispersion Model Used
Maximum POI Concentration
Average Period
MOE POI Limit
Limiting Effect
Regulation Schedule #
Percent of POI Limit
Hour after
Spill (g/s) (μg/m3) (hours) (μg/m3) (%)
1st 33.1
2nd 32.4
Ammonia 7664-41-7 3rd 31.7 AERMOD 820 24 100 Health Schedule 3 820%
4th 30.9
5th 30.4
6th 29.8
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Table of Contents
Executive Summary and Emission Summary Table
1 Introduction ..................................................................................................................... 1 2 Project Description ......................................................................................................... 3
2.1 Ammoniation System................................................................................................. 3 2.1.1 Existing Ammoniation System ............................................................ 3 2.1.2 Aqua Ammonia Properties................................................................... 3 2.1.3 Aqua Ammonia Receiving and Storage ............................................. 4 2.1.4 Spill Containment .................................................................................. 5 2.1.5 Ammonia Gas Detector......................................................................... 5 2.1.6 Ventilation System................................................................................. 5
2.2 Operating Schedule .................................................................................................... 6 2.3 Site Plan........................................................................................................................ 6
3 Ammonia Emission Rate Estimate............................................................................... 7 3.1 Air Moving Speed inside the Chemical Room No. 3: ............................................ 7 3.2 Maximum 10-minutes Average Release Rate ......................................................... 8 3.3 Hourly Average Release Rate for First 6 Hours after Spill ................................... 9
4 Air Dispersion Modelling ........................................................................................... 10 4.1 Modelling Setting Information ............................................................................... 10
4.1.1 Coordinate System:.............................................................................. 10 4.1.2 Source: ................................................................................................... 10 4.1.3 Buildings: .............................................................................................. 12 4.1.4 Meteorological Data: ........................................................................... 12 4.1.5 Terrain: .................................................................................................. 12 4.1.6 Receptor Grids:..................................................................................... 12 4.1.7 Sensitive Receptors .............................................................................. 13 4.1.8 Averaging Period: ................................................................................ 13 4.1.9 Release Scenarios ................................................................................. 13
4.2 Air Dispersion Modelling Input and Output Files .............................................. 14 4.3 Elimination of Meteorological Anomalies ............................................................ 14
5 Impact at Sensitive Receptors..................................................................................... 17 5.1 Applicable Standard................................................................................................. 17 5.2 Predicted Maximum Concentrations at Sensitive Receptors.............................. 17
6 Conclusions and Recommendations ......................................................................... 19 6.1 Overall Emission Summary..................................................................................... 19 6.2 Conclusions and Recommendations...................................................................... 19
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Tables Table 2-1 Physical and Chemical Properties of 28 percent Aqua Ammonia Solution Table 2-2 Summary of Aqua Ammonia Flow Rate and On-site Storage Days Table 2-3 Ventilation Flow Rate through the Chimney Exhaust Table 3-1 10-Minute Average and Hourly Average Release Rate Summary Table 4-1 Source Summary Table Table 4-2 Sensitive Receptor summary Table 4-3 Emergency Release Scenarios Summary Table 4-4 AERMOD Predicted Result Summary Table 5-1 Sensitive Receptor Emission Summary Table 6-1 Overall Emission Summary Table
II
Figures Figure 1 R. C. Harris WTP Site Location Plan Figure 2 Aero-photo of the WTP On-Site Buildings and Surrounding Residential Dwellings Figure 3 R. C. Harris WTP Site Plan Figure 4 Chemical Rooms Layouts Figure 5 Chemical Room North-South Section Figure 6 3-Dimensional View of the Site and Building Layouts Figure 7 Station #61587, Toronto, Wind Rose (1996-2000) Figure 8 Terrain Contours Surrounding the Site Figure 9 Multi-Tiers Receptor Grid Figure 10-1 Maximum 24-hr Ammonia Concentration Contour Figure 10-2 Maximum 24-hr Ammonia Concentration Contour – Zoom In Figure 11 Station #61587, Toronto, Wind Rose (May 10, 1996)
III
Appendix Appendix A Calculation of Ammonia Release Rate Appendix B Ammonia Solution MSDS Appendix C Coordinates Conversion Appendix D Electronic Files of AERMOD
IV
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1 Introduction
The R. C. Harris Water Treatment Plant is one of the four water treatment plants operated by the Water Treatment & Supply section of Toronto Water. The WTP is a conventional treatment facility located on Lake Ontario at the foot of Victoria Park Avenue in the community area of Scarborough. The location of the WTP is presented in Figure 1 – Site Location Plan. The adjacent areas to the east, north and west of the WTP are developed residential apartment buildings and houses. Figure 2 shows an aero-photo of the onsite buildings and surrounding residential dwellings.
The R. C. Harris Water Treatment Plant is one of the four water treatment plants operated by the Water Treatment & Supply section of Toronto Water. The WTP is a conventional treatment facility located on Lake Ontario at the foot of Victoria Park Avenue in the community area of Scarborough. The location of the WTP is presented in Figure 1 – Site Location Plan. The adjacent areas to the east, north and west of the WTP are developed residential apartment buildings and houses. Figure 2 shows an aero-photo of the onsite buildings and surrounding residential dwellings.
FIGURE 1 FIGURE 1 R. C. Harris WTP Site Location Plan R. C. Harris WTP Site Location Plan
CH2M HILL was retained by the City of Toronto (the City) to conduct air dispersion modelling to predict the impact of emergency internal spill of aqueous ammonia at the R. C. Harris Water Treatment Plant (WTP) on the surrounding residential areas.
H2M HILL was retained by the City of Toronto (the City) to conduct air dispersion modelling to predict the impact of emergency internal spill of aqueous ammonia at the R. C. Harris Water Treatment Plant (WTP) on the surrounding residential areas.
R.C. Harris WTP
2
R2
Stack 1 – Exhaust Chimney
R3 R4
R11
R18
R1
FIGURE 2 Aero-photo of the WTP On-Site Buildings and Surrounding Residential Dwellings
R12
R5
R6
R13
R7
R14
R15
R8
R16
R10
R9
R17
2 Project Description
The WTP proposed to relocate existing hydrofluosilic acid (H2SiF6) and aqueous ammonia (NH4OH) dosing systems to separate newly constructed storage rooms in the Residue Management Facility (RMF) and to implement a new sodium bisulphite (SBS) dosing system. The purpose of this study is to identify the potential impacts of an aqueous ammonia spill in the ammonia storage room to the surrounding community.
2.1 Ammoniation System
stem
erties
2.1.1 Existing Ammoniation SyThe existing ammoniation system applies aqua ammonia to the plant treated water at the reservoir outlet downstream the SBS application point. After chloramination, process water flows into the treated water distribution conduit and is then pumped into the distribution system.
Currently the existing ammoniation system consists of the following main components:
• Four 8,500 L storage tanks; • Three metering pumps capable of providing appropriate dosage; one duty and two standby.
Two standby pumps are being proposed to mitigate ongoing operational issues with one of the existing skids, provide additional redundancy for the application of a critical chemical and to provide continuous backup capability during the transition period from the existing chemical storage location to the new location.
• Various accessories.
Under this contract, the four existing storage tanks will be decommissioned, and the two existing metering pumps and associated electrical and instrumentation and control equipment will be relocated to Chemical Room 3. The relocated metering pumps will be connected to the two existing aqua ammonia storage tanks in Chemical Room 3.
2.1.2 Aqua Ammonia PropTABLE 2-1 PHYSICAL AND CHEMICAL PROPERTIES OF 28 PERCENT AQUA AMMONIA SOLUTION
Properties Values
pH 12
Specific Gravity 0.90 at 16 °C
Freezing Point -71.5 °C
Boiling Point 30.5 °C
3
2.1.3 Aqua Ammonia Receiving and Storage Two wood stave tanks with PVC liner have been installed in Chemical Room 3 for bulk storage of aqua ammonia. Each tank has a height and diameter of 2.9 m and 3.9 m, respectively. Each tank has a net volume of 28,000 L to the invert elevation of the tank overflow pipe, and can provide 24,600 L available operating capacity.
Each storage tank is currently equipped with:
• A fill pipe, with a motorized valve and local control panel; • An access hatch; • An overflow line located about 0.3 m above the design maximum liquid level; • A sight gauge for visual confirmation; • A discharge line; • One vent line and a vapour recovery line.
A recirculation line, connecting to the fill line will be added.
Aqua ammonia is added to the treated water stream after the dechlorination process based on an ammonia to chlorine weight ratio. Typically, this ratio has been 1:3 (ammonia to chlorine) but will be an operator adjustable variable. The aqua ammonia dosing flow rate and the average on-site storage days are calculated and summarized in Table 2-2.
TABLE 2-2 SUMMARY OF AQUA AMMONIA FLOW RATE AND ON-SITE STORAGE DAYS
Flow rate Values
Total Treated Water Flow rate
Maximum
Average
Minimum
1000.0 ML/D
518.4 ML/D
345.6 ML/D
Aqua Ammonia Dosage
Maximum
Average
Minimum
0.50mg/L
0.33 mg/L
0.00 mg/L
Aqua Ammonia Characteristics
Effective Ammonia Concentration
Ammonia Specific Gravity:
28 percent
0.90
Aqua Ammonia Dosing Flow rate
Maximum
Average
Minimum
1.38 L/min (0.36 US GPM)
0.47 L/min (0.12 US GPM)
0.31 L/min (0.08 US GPM)
Storage Days
Average Daily Aqua Ammonia Usage
Average One Tank Storage Days
Average Two Tanks Storage Days
679 L
36 Days
72 Days
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2.1.4 Spill Containment
ector
stem
Chemical Room No. 3 is recessed to provide containment for any potential spills. The net spill containment area is approximately 97 m2 surrounding the tank area. The liquid level in the containment area corresponding to 110 percent of the volume of the largest storage tank placed in the room is approximately 0.35 m above the finished floor (El. 84.30 m). A sump is located in the south east corner of this room to accommodate a portable pump. A spill containment suction pipe is installed over the sump and runs to the fill hatch. The containment sump is monitored with a high level switch connected to the new RPU and the Central Backup Control Panel alarm annunciator. When there is spill, the level switch will trigger an alarm in SCADA, a vacuum truck will be called in to suck the spilled chemical out through the suction pipe.
2.1.5 Ammonia Gas DetChemical Room No. 3 is equipped with an existing ammonia gas detector. The system was set to the Immediate Danger to Life & Health (IDLH) value of 300 ppm. Once the ammonia concentration in the room reaches the set point (300 ppm), an alarm is annunciated at SCADA and also visually and audibly at local Control Panel. Upon gas leakage, the exhaust fan is commanded (via hardwired connection) to run at “high” speed or a flow rate of 2.356 m3/s.
2.1.6 Ventilation SyDuring normal operation, an exhaust fan runs at a “low” speed or a flow rate of 1.420 m3/s, which exchanges air in Chemical Room No. 3 with outdoor at a rate of 8.1 changes per hour. In the event of gas leakage and spill, the exhaust fan works at a “high” speed or a flow rate of 2.356 m3/s, which results in an increased air change rate to 13.5 times per hour for the same room.
The exhaust fan blows air inside Chemical Room No. 3 to the atmosphere through a rectangular chimney with exit dimensions of 0.6 meters by 1.4 meters, extending 32.4 meters above grade. This exhaust chimney is located on the roof of the service building attached to the Alum Tower on the west. The exhaust air from the other four Chemical Rooms (No. 1, 2, 4, & 5) is ducted to the same chimney as well. The total exhaust flow through the chimney is the sum of all the exhaust flows from Chemical Rooms No. 1 to 5. The flow rates of the exhaust air from each room are summarized below:
TABLE 2-3 VENTILATION FLOW RATE THROUGH THE CHIMNEY EXHAUST
Room Description Flow Rate
Chemical Room No. 1
Chemical Room No. 2
Chemical Room No. 4
Chemical Room No. 5
0.31 m3/s
0.71 m3/s
0.36 m3/s
0.31 m3/s
Chemical Room No. 3 (Aqua Ammonia Room) 1.42 m3/s (normal),
2.356 m3/s (emergency)
Total Exhaust Flow through the Chimney 3.11 m3/s (normal),
4.046 m3/s (emergency)
5
2.2 Operating Schedule
lan
The WTP operates 24 hours a day, 7 days a week and 52 weeks a year. The ammoniation system operates continuously.
2.3 Site PFigure 3 – R.C. Harris Water Treatment Plant Site Plan shows the existing site arrangement and building layout in the WTP. Structures and buildings include the existing Filtration and Administration Building, Service Building and Pumping Station. The new Residue Management Facility (RMF) is located underground between the Administration Building and the Service Building. The Chemical Rooms No. 1 to 5 are located under ground at the elevation of 85 meters in the RMF.
6
3 Ammonia Emission Rate Estimate
The United States Environmental Protection Agency (U.S. EPA), Chemical Emergency Preparedness and Prevention Office (CEPP) publication document “Risk Management Program Guidance for Offsite Consequence Analysis, EPA 550-B-99-009, April 1999) (the Guidance) was followed in the ammonia emission rate estimate during emergency spill.
n. If a concentrated water solution containing a volatile toxic
will decrease as the
elease, i.e. bed in Section 2.1,
the containment area is ng capacity of each tank is 24,600 L (24.6 m3). When a spill occurs, approximate 0.97 m3 of spilled ammonia or 4% of the
’s operating capacity can cover the entire containment with 1 cm in depth. The City has ending on when
rates for a ontinu us 6 h
This conservatively yielded the highest ammonia release rate of any spill or leakage that may occur in the room.
3.1 Air Moving Speed inside the Chemical Room No. 3 Figure 4 – Lay low rate of the air i rth-south section of the Chemical Rooms. The air exchange flow inside Chemical Room No. 3 is from south to north. During an emergency low the room air into the common exhaust chimney at a flow rate of 2.356 m3/s via two exhaust grills (total opening area: 1.08 m2) through north wall of Chemical Room No. 3.
During emerg the Chemical Room No. 3 over the containment area was estimated to be approximately 0.074 m/s assuming doors were closed. A rounded-up va d to the default air velocity value ce. Detailed calculations are provided in Appendix A.
Section 3.3 of the Guidance provides a method to estimate the release rates for common water solutions of toxic substances inside buildings.
The vapor pressure and evaporation rate of a substance in solution depends on this concentration in the solutiosubstance is spilled, the toxic substance initially will evaporate more quickly than water from the spilled solution, and the vapor pressure and evaporation rateconcentration of the toxic substance in the solution decreases.
The estimated ammonia emission rate in this section was based on the worst-case rspill inside the Chemical Room No. 3. According to the project design descri
approximately 97 m2 and the available operati
one tankadvised CH2M HILL that a spill may take as long as 6 hours to clean-up depthe spill occurs in a day and how fast the off-site vacuum truck responses. Emission c o ours after the entire containment is covered by spilled ammonia were estimated.
out and Ventilation System of Chemical Rooms shows the location, size and fntakes and exhausts in Chemical Rooms No. 1 to 5 and Figure 5 shows the no
spill, the exhaust fan will b
ency release, the average air velocity inside
lue of 0.1 m/s was used in emission estimates which equale(0.1 m/s) for indoor environment in the Guidan
7
3.2 Maximum 10-minutes Average Release Rate The maximum 10-minute average evaporation rate of aqueous ammonia at certain concentration was calculation using equation 3-10 in the Guidance:
QQRB ×= 1.0 R (Equation 3-10 of the Guidance)
Release Rate from the liquid pool (lb/min)
wind speed/worst-case weed speed)0.78
D-1 of the Guidance)
A = Surface area of liquid pool (ft )
Exhibit B-1 in Appendix B of Guidance), and
Where: QRB = Release rate from building (lb/min)
QR = Worst-case
0.1 = Mitigation factor, equal to (indoor
ALFAUQR ××= 78.0 (Equation
Where: U = worst-case wind speed, equal to 1.5 m/s.
2
LFA = Liquid Factor (given in
TVPMWLFA ××
=284.0 3/2
( ) ×05.82
Equation D-2 of the Guidance
Where:
)
VP = Vapour Pressure at released tempera
T o trati nge % - 3 ba n the
MW = Molecular weight (MWNH3 = 17.01
ture T (mm Hg)
T = Temperature of released substance (278 K)
he aqueous ammonia used at the WTP has a c ncen on ra of 20 1.5% sed oM tach Ap ix B). An ammonia concentration of 30% is SDS provided by the supplier (at ed in pendused in this study.
A ted very inu ter t ill u he n average release rate was calcula for e 10 m tes af he sp sing t abovem lowethod. The steps are described be :
1) Calculate the 1st 10-min average release rate based on 30% a monia lution. After the m sofirst 10 minutes, ammonia concentration was redu to a l leve %) due to the ced ower l (X1
evaporation.
2) Calculate the 2nd 10-min average release rate based on X1% ammonia solution. After the second 10 minutes, ammonia concentration was reduced to an even lower level (X2%) due to the evaporation.
This process is repeated to cover a 6 hour period.
n Appendix A. Detailed calculations are provided i
8
3.3 Hourly Average Release Rate for First 6 Hours after Spill The hourly average release rate was estimated by adding the six 10-minutes total emissions (g/hr) and dividing it by 3600 (second/hr).
ed The summary of the calculated ammonia release rate for the first 6 hours after spill is providin Table 3-1.
TABLE 3-1 10-MINUTE AVERAGE AND HOURLY AVERAGE RELEASE RATE SUMMARY
Hours After Spill
1st 2nd 3rd 4th 5th 6th
1st 10-min average release rate (lb/min) 4.42 4.32 4.24 4.12 4.06 3.98
2nd 10-min average release rate (lb/min) 4.39 4.31 4.23 4.11 4.04 3.96
3rd 10-min average release rate (lb/min) 4.38 4.30 4.22 4.10 4.03 3.95
4th 10-min average release rate (lb/min) 4.37 4.28 4.19 4.08 4.02 3.94
5th 10-min average release rate (lb/min) 4.36 4.27 4.16 4.07 4.00 3.92
6th 10-min average release rate (lb/min) 4.34 4.26 4.14 4.06 3.99 3.91
Total emissions (lb/hr) 262 257 252 245 241 237
Total Emission (kg/hr) 119 117 114 111 109 107
Hourly Emission Rate (g/s) 33.1 32.4 31.7 30.9 30.4 29.8
9
10
4 Air Dispersion Modelling
Air dispersion modelling was conducted in accordance with the Ministry publication “Air Dispersion Modelling Guideline for Ontario” PIBS 5165e (The ADMGO).
The US EPA AERMOD v 07026 System was used to predict the maximum off-property Point of Impingeme t (PO
AERMOD as specially designed to support the US EPA’s regulatory modelling programs. It is the nex er n air s rsion model that incorporates concepts such as planetary layer theory and lex terrain. AERMOD requires two types of meteorological data files surface scalar parameters and a file containing vertical p iles. The model uses real hourly meteorological data to account for the atmospheric condition that affect the d bution of air pollution impacts on the modelling area.
4.1 Modelling Setting Information
4.1.1 Coordinate System: The local coordinate system used in Figure 3 was rotated 25.5 degrees counter clockwise to align the Y a is coordinate toward true north. The UTM (NAD 1983) coordinate system is presented in Local Coordinate to NAD 1983 UTM Coordinate for AERMOD dix C.
4.1.2 So : The rectang xhaust fans blow the air in the underground chemical r into the atmosphere, was tre ted as a point source (Stack 1) with the emission and source parameters listed in Table 4.1 – s an equivalen eters and ex nds 22.3 meters above the Service building and 32.4 m r ve ade. total exhaus w rate during the ammonia spill is 4.046 cubic meters per second.
n
w
a
rof
I) concentrations.
t-gen atio di
, a
pe
fildvanced method for handling comp
aining hourlye cont
istri
x
in Table C A
– Conversion of the ppen
urular chimney, through which the e
oo
ce
ms a Source Summary Table. The chimney ha
tet flo
t exs a
it diameter of 1.0 mboete gr The
11
TASOURCE SUMMARY TABLE
O
BLE 4-1
S URCE DATA EMISSION DATA
Stack Gta ig
i i teas S ck Stack He ht Stack Height Exhaust
Contam nant CAS # Variable Em ssion RaData
Quality EstimaTechni
tion que
Flo
Rat
w
e
Velocity Temperature Diam a t
ate
eter* Above Gr de Above Roof Outle
Coordin
Ho
afte
ur
r Spill
So
I
(m )
Percentage of Overall Emissions
urce D
(m3/s) (m/s) 0C ) (m) (m) (UTM (g/s)
1st hour 33.1
2nd hour 32.4
Sta 1.0 9, onia hour 100.00% ck-1 4.05 5.15 Ambient 32.38 22.25 (67873 Amm 7664-41-7 3rd 31.7 Above EC
2) hour A 483693 4th 30.9 verage
hour 5th 30.4
hour 6th 29.8
No
* iame ectangula
EC ulat
tes:
T
: E
he eq
ngin
uiv
eer
ale
ing
nt d
Calc
ter of a r
ions
r chimney outlet.
4.1.3 Buildings: The existing buildings at the WTP, i.e. Filtration and Administration Building, Service Building, and Pumping Station, were included in the modelling as the stacks are within the GEP 5L Area
gs. The UTM coordinates of the corners of the buildings and the – Local and UTM Coordinates of Sources, Buildings and
Property Line.
A three-dimensional view of the site including the buildings mentioned above and sources are shown in Figure 6.
.4 Mi ological Data (P 1 use he dell a within a 3 k s he fa source
om multi-family dwelliustr d as urban. Th ea 200 face ander a ronto, York-D H el wa cted an
d in
re 996 – 2000) wind rose in A
rio el Data (Tiles #087 & #92 do d from MOE
site n AERMAP. However th ut s wer re thanrs n shown in Figure 3 – Sit o e elev , eleva s ob ey agreed with on in F . As su0 m sion (SRTM3) D m were in the ell N43W080.hgt) er elling ain are
ere downloaded from Web GIS (www.webgis.com
of Influence of the buildinheights are presented in Table 3
4.1 Meteorological Data: The nistry’s Ontario Regional Meteor IBS 508 e01) were d for tmo ing. Since more than 50% of the are m radiu around t cility is accounted for by land use categories ranging frind
ng to commercial and rs (1996 –ial use, the site location is classifie e five y 0) sur
upp ir data for the Central Region - To urham, alton-Pe s sele d use the modelling.
Figu 7 shows the five-year (1 Toronto rea.
4.1.5 Terrain: Onta Digital Elevation Mod ) were wnloade theweb and initially used to ru e outp elevation e mo 30 mete lower than the elevatio e Plan. T verify th ation tionwere tained from Google Earth and th elevati s shown igure 3 ch, the 9 Shuttle Radar Topography Mis ata fro WebGIS usedmod ing. Two files (N43W079.hgt and that cov the mod dom a w ).
al terrain files were processed by AERMAP processor and elevation of d the stack were imported from the terrain file or the output file of
ds :
sed along the property line sed within 200 meters from Stack 1;
Figure 9 shows the property line, buildings, and the receptor grids.
The downloaded digitbuildings, receptors anAERMAP. Figure 8 shows the terrain contours surrounding the site. Electronic files are provided in attached CD.
4.1.6 Receptor Grids: As Stack 1 exhausts ammonia at ambient temperature, the maximum ammonia concentrations were not expected to occur beyond 1000 meters from the Stack. The following receptor griwere selected
• 10 m spacing was u• 20 m spacing was u• 50 m spacing was used from 200 m to 500 m from Stack 1; • 100 m spacing was used from 500 m to 1000 m from Stack 1.
12
4.1.7 Sensitive Receptors As the WTP is surrounding by residential dwellings, the windows/ f e 8) residential dw ed as sensitive receptors and are summarized in Table 4-2. Locations of sensi lso illustrated in Figure 2 and Figure 8.
T SENSITIVE RECEPTOR SUMMARY
DescUTM
Easting
(m)
UTM Northing
(m)
Height above Grade
(m)
balcony at the top level oighteen (1 ellings were identifi
tive receptors are a
ABLE 4-2
POI ID
ription
Elevation
(m)
R rey apartment buildi 638773 4837248 18 1 7-sto ng to the NE 107.9
R rey apartment buildi 638846 4837148 12
rey apartment buildi 638836 4837176 12
rey apartment buildi 638824 4837210 12
rey apartment buildi 638731 4837208 15
rey apartment buildi 638673 4837178 15
rey apartment buildi 638645 4837164 15
rey apartment buildi 638614 4837150 4.5
rey house to the we 638557 4837045 4.5
rey house to the we 638567 4837008 4.5
rey apartment buildi 638624 4836814 12
rey house to the we 638603 4836 4.5
rey house to the we 638606 4836 4.5
rey house to the we 638585 4836 4.5
rey house to the we 638577 4836 4.5
rey apartment buildi 638580 4837 15
rey apartment buildi 638543 4837 15
18 4-storey apartment building to the west 638609 4836852 84.4 12
2 4-sto ng to the east 99.0
R3 4-sto ng to the east 102.2
R4 4-sto ng to the east 105.0
R5 5-sto ng to the north 108.2
R6 5-sto ng to the north 106.3
R7 5-sto ng to the north 104.9
R8 5-sto ng to the north 102.4
R9 2-sto st 93.6
R10 2-sto st 92.7
R11 4-sto ng to the SW 79.3
R12 2-sto st 884 85.5
R13 2-sto st 901 86.0
R14 2-sto st 947 86.0
R15 2-sto st 975 89.7
R16 5-sto ng to the NW 140 100.0
R17 5-sto ng to the NW 119 97.3
R
4.1.8 Averaging Period: 3 standard for ammonia is a 24-hour average concentration limit based
on health effects, the predicted modelling results will be 24-hour average concentrations in
As discussed in Section 3.3, the maximum duration of ammonia release is expected to be d each hour has decreasing emission rates. Calculated hourly release
t y.
As O. Reg. 419 Schedule
order to compare to the applicable Schedule 3 standard.
approximately 6 hours, anrates for each of the six hours and zero (0) release for the rest of the day were used in the modelling.
4.1.9 Release Scenarios Since the spill may occur at anytime of a day and atmospheric condition during a day varies, twenty-four (24) release scenarios were modeled to capture potential spill impacts at differentimes of a day on the sensitive receptors due to different meteorological condition during a da
The modelled scenarios are summarized in Table 4-3.
13
TABLE 4-3 EMERGENCY RELEASE SCENARIOS SUMMARY
Scenario ID Description Maximum Duration of Spill
Scenario 1 Spill occurred at 1:00 1:00 - 7:00
Scenario 2 Spill occurred at 2:00 2:00 - 8:00
Scenario 3 Spill occurred at 3:00 3:00 - 9:00
Scenario 4 Spill occurred at 4:00 4:00 - 10:00
Scenario 5 Spill occurred at 5:00 5:00 - 11:00
Scenario 6 Spill occurred at 6:00 6:00 - 12:00
7 Spill occurred at 7:00 7:00 - 13:00
occurred at 8:00 8:00 - 14:00
Scenario 9 Spill occurred
Scenario 10 Spill occurred at 10
urred at 11:00 11:00 - 17:
S occurred at 12:00 12:00 - 18:00
S occurred at 13:00 13:00 - 19:00
S occurred at 14:00 14:00 - 20:00
S occurred at 15:00 15:00 - 21:00
S occurred at 16:00 16:00 - 22:00
S occurred at 17:00 17:00 - 23:00
S occurred at 18:00 18:00 - 24:00
S occurred at 19:00 19:00 - 1:0 ay)
S occurred at 20:00 20:00 - 2:0 ay)
occurred at 21:00 21:00 - 3:0 ay)
occurred at 22:00 22:00 - 4:0 ay)
occurred at 23:00 23:00 - 5:0 ay)
occurred at 24:00 24:00 - 6:0 ay)
Scenario
Scenario 8 Spill
at 9:00
:00
9:00 - 15:00
10:00 - 16:00
Scenario 11 Spill occ 00
cenario 12 Spill
cenario 13 Spill
cenario 14 Spill
cenario 15 Spill
cenario 16 Spill
cenario 17 Spill
cenario 18 Spill
cenario 19 Spill 0 (next d
cenario 20 Spill 0 (next d
Scenario 21 Spill 0 (next d
Scenario 22 Spill 0 (next d
Scenario 23 Spill 0 (next d
Scenario 24 Spill 0 (next d
4 isper delling Inpu d Output Files
M npu
T ic A (. INP) are p ed in a CD in Appendix
M utp
ic A (.ADO) are also provided in the CD in Appendix D.
wind
maximum 24-hour average concentrations over the five year period.
.2 Air D sion Mo t an
odelling I t Files
he electron ERMOD input files rovid D.
odelling O ut Files
The electron ERMOD output files
4.3 Elimination of Meteorological Anomalies As described early, the model estimated a full range of hourly meteorological data over 5 years(1996 to 2000) to account for the atmospheric conditions (e.g. atmospheric turbulence,speed, wind direction, etc.) that affect the distribution of air pollution impacts, and found the
14
However, certain extreme, rare and transient meteorological conditions may be present in the meteorological database that may be considered outliers. As such, Section 6.6 of the ADMGO
.
-ations for each scenario are extracted from the AERMOD output files and
AERMOD PREDICTED RESULT SUMMARY Maximum 24-hr Average O. Reg. 419 Highest 24-hr Average
Concentration
(μg/m3)
Document was followed to eliminate meteorological anomalies. The maximum 24-hour average predicted concentrations in each single meteorological year were discarded for each release scenario and then the highest remaining concentration was used for the compliance assessment
However, to be conservative, both the predicted maximum and the above described highest 24hour average concentrsummarized in Table 4-4.
TABLE 4-4
Scenario ID Release Duration
Concentration
(μg/m3)
Scenario 1 1:00 - 7:00 1079 820
Scenario 2 2:00 - 8:00 939 727
Scenario 3 3:00 - 9:00 760 672
818 618
673 498
308
Scenario 9 9:00 - 15:00 299 229
339 315
Scenario 14 14:00 - 20:00 398 398
15 15:00 - 21:00 608 426
0 805 579
io 17 17:00 - 23:00 565
enario 18:00 - 24:
Scenario 19 19:00 - 1:0 ay)
en - 2:00 day) 74
cen - 3:00 ay) 610
cen - 4:00 ay) 705
en - 5:00 day) 76
en - 6:00 day) 87
Scenario 4 4:00 - 10:00
Scenario 5 5:00 - 11:00
Scenario 6 6:00 - 12:00 692 449
Scenario 7 7:00 - 13:00 521 356
Scenario 8 8:00 - 14:00 431
Scenario 10 10:00 - 16:00 207 175
Scenario 11 11:00 - 17:00 225 176
Scenario 12 12:00 - 18:00 255 227
Scenario 13 13:00 - 19:00
Scenario
Scenario 16 16:00 - 22:0
Scenar
Sc
822
18 00
0 (next d
839
756
600
710
Sc ario 20 20:00 (next 1 705
S
S
ario 21 21:00
ario 22 22:00
(next d
(next d
601
606
Sc ario 23 23:00 (next 8 678
Sc ario 24 24:00 (next 6 700
The m s ind hat s h occur during the night time have higherimpacts than spills which occur during the day time on sensitive receptors. This is mainly
au ric t ence able during the night time and is more unstable in An unstable atm enhances turbule wher le
atmos echanical turbulence. A spill occurred between 1:00 – 7:00 has the highest
odelling result icate t pills whic
bec se the atmosphe urbul is more stdur g the day time.
s mosphere nce, eas a stab
phere inhibit
15
impacts and a spill occurred between 10:00 – 17:00 has the lowest impacts on the surrounding residential area.
The modelling results also indicate t g. 419 highest 2 erage POI concentrations μg/m urred level window of a 4 storey apartment building
e y bou y in 96, w the pre ng wind blew from SSW th levate eptor nd of the source, Refer to Figure 11 for the wind i .
r and 10-2 show the max our ch cenario pill o tween 1:00 – 7:00
hat the Re 4-hr avof ammonia (819.95 3) occ at the top(R3)and
ast of the facilite R3 was the e
ndard rec
May 10, 19 downwi
hen vaili
rose n May 10, 1996
Figu es 10-1 imum 24-h average concentration contours for ammoniawhi occurred in S 1 (s ccurred be ).
16
5 Impact at Sensitive Receptors
5.1 Applicable Standard s indicate in our proposal of t s study, e predicted highest 24-hour POI concentration of
mmonia at the sensitive receptors will be compared against the most stringent O. Reg. 419/05 ealth effect.
Maximum 24-hour Average Concentrations
Aa
d hi th
Schedule 3 Standard of 100 μg/m3 which is based on h
5.2 Predicted Maximum Concentrations at Sensitive Receptors Table 5-1 summarized the high end and low end maximum concentrations at each sensitive receptor and the associated scenarios.
TABLE 5-1 Sensitive Receptor Emission Summary
Low End High End POI ID
Description Concentration
(μg/m3) Scenario ID
Compliance (Yes/No)
Concentration (μg/m3)
Scenario ID Compliance
(Yes/No)
R1 7-storey apartment building t
92.4 Scenario 10 YES 423 Scenario 4 NO o the NE
R2 rtment
108.4 Scenario 11 NO 1079 Scenario 1 NO 4-storey apabuilding to the East
R3 4-storey apartment building to the East
151.0 Scenario 11 NO 820 Scenario 1 NO
R4 4-storey apartment building to the NE
143.6 Scenario 11 NO 754 Scenario 1 NO
R5 5-storey apartment building to the north
110.1 Scenario 11 NO 804 Scenario 2 NO
R6 121.4 Scenario 11 NO 705 Scenario 23 NO 5-storey apartment building to the north
R7 5-storey apartment building to the north
169.9 Scenario 11 NO 920 Scenario 1 NO
R8 5-storey apartment building to the north
161.8 Scenario 11 NO 790 Scenario 1 NO
R9 2-storey house to the NW
114.3 Scenario 11 NO 709 Scenario 1 NO
R10 2-storey house to the west
116.8 Scenario 11 NO 683 Scenario 22 NO
R11 4-storey apartment building to the SW
104.9 Scenario 19 NO 197 Scenario 4 NO
R12 2-storey house to the west
52.4 Scenario 22 YES 141 Scenario 7 NO
R13 2-storey house to the west
45.1 Scenario 22 YES 149 Scenario 10 NO
R14 2-storey house to the west
74.0 Scenario 22 YES 181 Scenario 7 NO
R15 2-storey house to the west
117.6 Scenario 13 NO 324 Scenario 18 NO
R16 5-storey apartment building to the NW
135.6 Scenario 10 NO 986 Scenario 1 NO
R17 5-storey apartment building to the NW
206.6 Scenario 10 NO 776 Scenario 24 NO
R18 4-storey apartment building to the west
113.4 Scenario 21 NO 271 Scenario 1 NO
17
18
The modelling results indicate that the high-end maximum 24-hour concentrations at all sensitive receptors exceeded the MOE criterion under all scenarios. Three receptors to the west of the facility had concentrations below the MOE criterion in some release scenarios. Overall, the event of internal ammonia spill in Chemical Room No. 3 has higher impacts on residential dwellings to the east, northeast and north of the WTP, and lower impacts on residential dwellings to the west and southwest of the WTP due to the prevailing wind nature in the area (Refer to Figure 7 for the 5-year wind rose).
19
6 5BConclusions and Recommendations
6.1 17BOverall Emission Summary The overall Emission Summary Table is provided in Table 6-1, which summarized the O. Reg. 419/05 highest off-property ammonia concentration and the required information by the Ministry.
TABLE 6-1 Overall Emission Summary Table
Variable
Emission Rate
Air
Dispersion
O. Reg. 419
Highest POI Averaging MOE POI Limiting Regulation Percentage
Contaminant CAS No. Hour after
Model Used Concentration Period Limit Effect Schedule #
of Limit
Spill
(g/s) (µg/m3) (hours) (µg/m3) (%)
1st hour 33.1
2nd hour 32.4
Ammonia 7664-41-7 3rd hour 31.7 AERMOD 820 24 100 Health Schedule 3 820%
4th hour 30.9
5th hour 30.4
6th hour 29.8
6.2 18BConclusions and Recommendations The modelling results indicate that spills which occur during the night time have higher impacts than spills which occur during the day time on sensitive receptors. This is mainly because the atmospheric turbulence is expected to be more stable during the night time than during the day time. An unstable atmosphere enhances turbulence, whereas a stable atmosphere inhibits mechanical turbulence. A spill occurred between 1:00 – 7:00 has the highest impacts and a spill occurred between 10:00 – 17:00 has the lowest impacts on the surrounding residential area.
The event of internal ammonia spill in the Chemical Room No. 3 has higher impacts on residential dwellings to the east, northeast and north of the WTP, and lower impacts on residential dwellings to the west and southwest of the WTP due to the prevailing wind nature in the area.
Under the current engineering design of the ammoniation system at the R. C. Harris WTP, i.e., no ammonia mitigation measures were employed for the ammonia emergency spill in Chemical Room No. 3, the predicted highest 24-hr ammonia concentrations at the property line and
20
beyond under different release scenarios ranged from 175 to 820 μg/m3, which exceeded the O. Reg. 419/05 Schedule 3 standard of 100 μg/m3 for ammonia.
As such, additional mitigation measures for ammonia emergency release are required in order to bring the R. C Harris Water Treatment Plant into compliance with the MOE criterion. An emergency ammonia scrubber is recommended to be added as part of the relocation project.
1:100
CHECKED
rch_h150ad_122339r.dgn
H J K L M N
1
2
3
4
5
1:100
MA
TC
HL
INE
, S
EE
DW
G H
150B
EL 84.300
EL 84.300
DN
DN
DN
DN
EL 85.390
EL
84.3
00
DN
EL 85.390
DECANT ACCESS RM
CORRIDOR No. 7
CHEMICAL
RM No. 1
CHEMICAL
RM No. 2
CHEMICAL
RM No. 3
CHEMICAL
RM No. 4
CHEMICAL
RM No. 5
PLAN AT EL 85 - AREA A
6
SW
2F-2003-105-211 H150A
SCALE 1:100
0 1.0 2.0 4.0m
A
250X200
154 l/s
TYP OF 2
350-SAD-AL
B
450X300
310 l/s
B
600X500
710 l/s
B
900X600
B
450X350
360 l/s
B
450X300
310 l/s
700-SAD-AL(SLOPING)
MATCH LINE SEE DWG. H150D
1420/2356 l/s
TYP OF 2
DAB/VS
A
A
1
2
AMMONIA
SENSOR
1 REVISED FOR ADDENDUM NO. 2
2
OCT 2004 CONTRACT DRAWINGS - ISSUED FOR CONSTRUCTION AM
REVISED FOR ADDENDUM NO. 6JUL 2004
JUN 2004
3
450X350-EAD-AL
BOD 88.05
650X500-EAD-AL
BOD 88.00 450X350-EAD-AL
BOD 87.40
450X300-EAD-AL
BOD 87.22
450X350-EAD-AL(SLOPING)
FIGURE 4 - CHEMICAL ROOMS LAYOUT
FIGURE 5
FIGURE 5
A
250X200
154 l/s
A
250X250
177 l/s
A
500X400
707 l/s
A
355X350
354 l/s
WATER & WASTEWATER SERVICES
REVISIONSNo. DATE INITIAL SIGNED
DRAFTING:
TECHNICAL SERVICES DIVISION
Engineering Services - Works Facilities & StructuresWORKS & EMERGENCY SERVICES
BARRY GUTTERIDGE,BARRY GUTTERIDGE,
WORKS and WORKS and
EMERGENCY SERVICESEMERGENCY SERVICES
COMMISSIONER COMMISSIONER
DIRECTOR,
DATE:
EXECUTIVE DIRECTOR,
WILLIAM G. CROWTHER, P. ENG.
WATER & WASTEWATER SERVICES
GENERAL MANAGER,
MIKE PRICE, P. ENG.
DESIGN:
SCALE:
CHECK: CONTRACT NO.
TECHNICAL SERVICES
RC HARRIS WATER FILTRATION PLANTRESIDUE MANAGEMENT FACILITY
WATER SUPPLY WATER SUPPLY
PATRICK NEWLAND
DRAWING
NUMBER:
CONSULT NO.
04FS-50WS
0 ISSUED FOR TENDER
MARCH, 2004
MAR 2004
KEY PLAN
A
D
B
C
1:100
EL. 69.190
1:100
123456789101112
EL. 74.390
EL. 77.190
EL. 84.300
EL. 85.390
EL 88.000
5660
1090
2610
1450
2800
5200
WY
1
7 PIPE GALLERY
DECANT TANK
ACCESS RM
LOWER
THICKENER
GALLERY
UPPER THICKENER
GALLERY
CENTRAL
THICKENER
GALLERYMACHINE SHOP
STORAGECORRIDOR NO. 6
07-5002
07-6006
07-7001
07-6001
07-1002
07-2002
07-300107-4010
07-4014
03-4006
07-5007
SECTION
A
A406
A410
2F-2003-105-077CONSULT No.
A203
GROUND LEVEL
EL. 78.640
0 1.0 2.0 4.0m
SIM
2A406
CHEMICAL RM
VESTIBULE NO. 5
DECANT TANK NO. 9
CHEMCIAL RM NO. 5
THICKENER NO. 4
WY
MEMBRANE WATERPROOFING
FIN GRADE
MONORAIL
MONORAIL
MONORAIL
WW
EXP JT
TYPE 4
A410
5
AL GUARD RAILS
FRP HANDRAIL
TO CHEM RM
A408
6 SIM
UPPER SERVICE
PLATFORM NO. 2
LOWER SERVICE
LEVEL NO. 2
1A407
SIM
MEMBRANE WATERPROOFING
FROM U/S SLAB DOWN TO
MIN 300mm BELOW EL. 69.190
EXTEND MEMBRANE
WATERPROOFING TO
MIN 300mm BELOW
EL. 84.300
MEMBRANE
WATERPROOFING
NOTE:
WATERPROOF MEMBRANE IS TO EXTEND DOWN THE
EXTERIOR FACE OF POURED IN PLACE WALLS
DOWN TO TOP OF CAISSONS.
WATERPROOF MEMBRANE NOT REQUIRED AT CAISSONS.
1
1 JUL 2004
2 OCT 2004
WY
WY
JMREVISED FOR ADDENDUM NO. 8
CONTRACT DRAWINGS - ISSUED FOR CONSTRUCTION
rch_a203d_122339r.dgn
FIGURE 4
FIGURE 5 - CHEMICAL ROOM NORTH-SOUTH SECTION
WATER & WASTEWATER SERVICES
REVISIONSNo. DATE INITIAL SIGNED
DRAFTING:
TECHNICAL SERVICES DIVISION
Engineering Services - Works Facilities & StructuresWORKS & EMERGENCY SERVICES
BARRY GUTTERIDGE,BARRY GUTTERIDGE,
WORKS and WORKS and
EMERGENCY SERVICESEMERGENCY SERVICES
COMMISSIONER COMMISSIONER
DIRECTOR,
DATE:
EXECUTIVE DIRECTOR,
WILLIAM G. CROWTHER, P. ENG.
WATER & WASTEWATER SERVICES
GENERAL MANAGER,
MIKE PRICE, P. ENG.
DESIGN:
SCALE:
CHECK: CONTRACT No.
TECHNICAL SERVICES
RC HARRIS WATER FILTRATION PLANTRESIDUE MANAGEMENT FACILITY
WATER SUPPLY WATER SUPPLY
PATRICK NEWLAND
DRAWING
NUMBER:
CONSULT No.
04FS-50WS
0 ISSUED FOR TENDERMAR 2004
MARCH, 2004
Appendix A
Calculation of Ammonia Release Rate
Table A-1 - Estimate of Wind Speed inside the Chemical Room 3Assumption: Room doors are closed.
Average Air Velocity Cross Section S
Free Area Cross Section S S ≤ (3.7 m * 11.7 m) - (3.937 m x 2.9 m)≤ 31.8727 m2
Emergency Room Exhaust Rate F = 2.356 m3/s
Average Air Velocity Cross Area S Vs ≥ F/S≥ 2.356 m3/s / 31.8727 m2≥ 0.074 m/s
A rolling up air velocity value of . 0.1 m/s was used for the Chemical Room No.3
11.7 m
S
Emergency exhaust flow rate: 2.356 m3/s
19.6 m
3.7 m
Normal exhaust flow rate: 1.420 m3/s
2.9 m
3.9 m
Table A-2 - Estimate of Ammonia Emission Rate
1. Calculation of Ammonia Emission Rate in 1st Hour after Spill.1.1 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the first 10 minutes
Assumption: Assuming a entire tank of ammonia hydrate spilled into the containment during spill.
Tank Volume: 24.6 m3Ammonia Concentration: 30%30% Ammonia Hydrate Specific Gravity: 0.86 kg/LAmmonia Hydrate Weight: 21156 kg = 46641 lbPure Ammonia Weight 6347 kg = 13992 lbPure Water Weight 14809 kg = 32648 lb
Maximum Area of pool for depth of 1 centimeter:: 2460 m2 = 26479 ft2Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 332 mm Hg
310 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 310 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 36.5 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.4 lb/min
After the 1st 10 minute 44 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13992 lb - 44 lb = 13948 lbAmmonia concentration decreased to : 13948 lb (ammonia) /[13948 lb (ammonia)+32648 lb (water)] = 29.93%
10-min average vapor pressure (mm Hg) of 30% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 30% ammonia solution at 1.5 m/s wind speed at 5 ºC
1.2 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the second 10 minutes
Ammonia Hydrate Weight: 46596 lbPure Ammonia Weight 13948 lbPure Water Weight 32648 lbAmmonia Concentration: 29.9%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 330 mm Hg
308 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 308 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 2088= 36.3 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.4 lb/min
After the 2nd 10 minute 44 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13948 lb - 44 lb = 13904 lbAmmonia concentration decreased to : 13904 lb (ammonia) /[13904 lb (ammonia)+32648 lb (water)] = 29.87%
10-min average vapor pressure (mm Hg) of 29.93% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 29.93% ammonia solution at 1.5 m/s wind speed at 5 ºC
1.3 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the third 10 minutes
Ammonia Hydrate Weight: 46552 lbPure Ammonia Weight 13904 lbPure Water Weight 32648 lbAmmonia Concentration: 29.9%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 329 mm Hg
307 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 307 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 36.2 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.4 lb/min
After the 3rd 10 minute 44 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13904 lb - 44 lb = 13860 lbAmmonia concentration decreased to : 13860 lb (ammonia) /[13860 lb (ammonia) + 32648 lb (water)] = 29.80%
10-min average vapor pressure (mm Hg) of 29.87% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 29.87% ammonia solution at 1.5 m/s wind speed at 5 ºC
1.4 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fourth 10 minutes
Ammonia Hydrate Weight: 46509 lbPure Ammonia Weight 13860 lbPure Water Weight 32648 lbAmmonia Concentration: 29.8%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 328.5 mm Hg
306 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 306 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 36.1 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.4 lb/min
After the 4th 10 minute 44 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13860 lb - 44 lb = 13817 lbAmmonia concentration decreased to : 13817 lb (ammonia) /[13817 lb (ammonia) + 32648 lb (water)] = 29.74%
10-min average vapor pressure (mm Hg) of 29.8% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 29.8% ammonia solution at 1.5 m/s wind speed at 5 ºC
1.5 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fifth 10 minutes
Ammonia Hydrate Weight: 46465 lbPure Ammonia Weight 13817 lbPure Water Weight 32648 lbAmmonia Concentration: 29.74%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 327.5 mm Hg
306 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 *306 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 36.0 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.4 lb/min
After the 5th 10 minute 44 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13817 lb - 44 lb = 13773 lbAmmonia concentration decreased to : 13773 lb (ammonia) /[13773 lb (ammonia) + 32648 lb (water)] = 29.67%
10-min average vapor pressure (mm Hg) of 29.74% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 29.74% ammonia solution at 1.5 m/s wind speed at 5 ºC
1.6 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the sixth 10 minutes
Ammonia Hydrate Weight: 46421 lbPure Ammonia Weight 13773 lbPure Water Weight 32648 lbAmmonia Concentration: 29.67%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 326 mm Hg
304 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 304 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 35.8 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.3 lb/min
After the 6th 10 minute 43 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13773 lb - 43 lb = 13730 lbAmmonia concentration decreased to : 13730 lb (ammonia) /[13730 lb (ammonia) + 32648 lb (water)] = 29.60%
10-min average vapor pressure (mm Hg) of 29.67% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 29.67% ammonia solution at 1.5 m/s wind speed at 5 ºC
2. Calculation of Ammonia Emission Rate in 2nd Hour after Spill.2.1 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the first 10 minutes
Assumption: Assuming a entire tank of ammonia hydrate spilled into the containment during spill.
Ammonia Hydrate Weight: 46378 lbPure Ammonia Weight 13730 lbPure Water Weight 32648 lbAmmonia Concentration: 29.6%
Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 325 mm Hg
303 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 303 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 35.7 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.3 lb/min
After the 1st 10 minute 43 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13730 lb - 43 lb = 13687 lbAmmonia concentration decreased to : 13687 lb (ammonia) /[13687 lb (ammonia)+32648 lb (water)] = 29.54%
10-min average vapor pressure (mm Hg) of 29.6% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 29.6% ammonia solution at 1.5 m/s wind speed at 5 ºC
2.2 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the second 10 minutes
Ammonia Hydrate Weight: 46335 lbPure Ammonia Weight 13687 lbPure Water Weight 32648 lbAmmonia Concentration: 29.54%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 324 mm Hg
302 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 302 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 35.6 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.3 lb/min
After the 2nd 10 minute 43 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13687 lb - 43 lb = 13643 lbAmmonia concentration decreased to : 13643 lb (ammonia) /[13643 lb (ammonia)+32648 lb (water)] = 29.47%
10-min average vapor pressure (mm Hg) of 29.54% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 29.54% ammonia solution at 1.5 m/s wind speed at 5 ºC
2.3 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the third 10 minutes
Ammonia Hydrate Weight: 46292 lbPure Ammonia Weight 13643 lbPure Water Weight 32648 lbAmmonia Concentration: 29.47%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 323 mm Hg
301 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 301 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 35.5 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.3 lb/min
After the 3rd 10 minute 43 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13643 lb - 43 lb = 13600 lbAmmonia concentration decreased to : 13600 lb (ammonia) /[13600 lb (ammonia) + 32648 lb (water)] = 29.41%
10-min average vapor pressure (mm Hg) of 29.47% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 29.47% ammonia solution at 1.5 m/s wind speed at 5 ºC
2.4 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fourth 10 minutes
Ammonia Hydrate Weight: 46249 lbPure Ammonia Weight 13600 lbPure Water Weight 32648 lbAmmonia Concentration: 29.41%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 322 mm Hg
300 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 300 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 35.4 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.3 lb/min
After the 4th 10 minute 43 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13600 lb - 43 lb = 13558 lbAmmonia concentration decreased to : 13558 lb (ammonia) /[13558 lb (ammonia) + 32648 lb (water)] = 29.34%
10-min average vapor pressure (mm Hg) of 29.41% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 29.41% ammonia solution at 1.5 m/s wind speed at 5 ºC
2.5 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fifth 10 minutes
Ammonia Hydrate Weight: 46206 lbPure Ammonia Weight 13558 lbPure Water Weight 32648 lbAmmonia Concentration: 29.34%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 321 mm Hg
299 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 299 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 35.3 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.3 lb/min
After the 5th 10 minute 43 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13558 lb - 43 lb = 13515 lbAmmonia concentration decreased to : 13515 lb (ammonia) /[13515 lb (ammonia) + 32648 lb (water)] = 29.28%
10-min average vapor pressure (mm Hg) of 29.34% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 29.34% ammonia solution at 1.5 m/s wind speed at 5 ºC
2.6 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the sixth 10 minutes
Ammonia Hydrate Weight: 46163 lbPure Ammonia Weight 13515 lbPure Water Weight 32648 lbAmmonia Concentration: 29.28%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 320 mm Hg
299 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 299 = 0.02582.25 * 278
QR = 1.50.78 *0.025 * 1044= 35.2 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.3 lb/min
After the 6th 10 minute 43 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13515 lb - 43 lb = 13472 lbAmmonia concentration decreased to : 13472 lb (ammonia) /[13472 lb (ammonia) + 32648 lb (water)] = 29.21%
10-min average vapor pressure (mm Hg) of 29.28% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 29.28% ammonia solution at 1.5 m/s wind speed at 5 ºC
3. Calculation of Ammonia Emission Rate in 3rd Hour after Spill.3.1 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the first 10 minutes
Assumption: Assuming a entire tank of ammonia hydrate spilled into the containment during spill.
Ammonia Hydrate Weight: 46121 lbPure Ammonia Weight 13472 lbPure Water Weight 32648 lbAmmonia Concentration: 29.2%
Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 319 mm Hg
298 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 298 = 0.02482.25 * 283
QR = 1.50.78 *0.024 * 1044= 35.1 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.2 lb/min
After the 1st 10 minute 42 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13472 lb -42 lb = 13430 lbAmmonia concentration decreased to : 13430 lb (ammonia) /[13430 lb (ammonia)+32648 lb (water)] = 29.15%
10-min average vapor pressure (mm Hg) of 29.2% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 29.2% ammonia solution at 1.5 m/s wind speed at 5 ºC
3.2 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the second 10 minutes
Ammonia Hydrate Weight: 46078 lbPure Ammonia Weight 13430 lbPure Water Weight 32648 lbAmmonia Concentration: 29.15%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 318 mm Hg
297 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 297 = 0.02482.25 * 278
QR = 1.50.78 *0.024 * 1044= 35.0 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.2 lb/min
After the 2nd 10 minute 42 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13430 lb - 42 lb = 13388 lbAmmonia concentration decreased to : 13388 lb (ammonia) /[13388 lb (ammonia)+32648 lb (water)] = 29.08%
10-min average vapor pressure (mm Hg) of 29.15% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 29.15% ammonia solution at 1.5 m/s wind speed at 5 ºC
3.3 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the third 10 minutes
Ammonia Hydrate Weight: 46036 lbPure Ammonia Weight 13388 lbPure Water Weight 32648 lbAmmonia Concentration: 29.08%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 317 mm Hg
296 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 296 = 0.02482.25 * 278
QR = 1.50.78 *0.024 * 1044= 34.9 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.2 lb/min
After the 3rd 10 minute 42 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13388 lb - 42 lb = 13346 lbAmmonia concentration decreased to : 13346 lb (ammonia) /[13346 lb (ammonia) + 32648 lb (water)] = 29.02%
10-min average vapor pressure (mm Hg) of 29.08% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 29.08% ammonia solution at 1.5 m/s wind speed at 5 ºC
3.4 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fourth 10 minutes
Ammonia Hydrate Weight: 45994 lbPure Ammonia Weight 13346 lbPure Water Weight 32648 lbAmmonia Concentration: 29.02%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 315 mm Hg
294 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 294 = 0.02482.25 * 278
QR = 1.50.78 *0.024 * 1044= 34.6 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.2 lb/min
After the 4th 10 minute 42 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13346 lb - 42 lb = 13304 lbAmmonia concentration decreased to : 13304 lb (ammonia) /[123304 lb (ammonia) + 32648 lb (water)] = 28.95%
10-min average vapor pressure (mm Hg) of 29.02% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 29.02% ammonia solution at 1.5 m/s wind speed at 5 ºC
3.5 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fifth 10 minutes
Ammonia Hydrate Weight: 45952 lbPure Ammonia Weight 13304 lbPure Water Weight 32648 lbAmmonia Concentration: 28.95%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 313 mm Hg
292 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 292 = 0.02482.25 * 278
QR = 1.50.78 *0.024 * 1044= 34.4 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.2 lb/min
After the 5th 10 minute 42 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13304 lb - 42 lb = 13262 lbAmmonia concentration decreased to : 13262 lb (ammonia) /[13262 lb (ammonia) + 32648 lb (water)] = 28.89%
10-min average vapor pressure (mm Hg) of 28.95.8% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 28.95% ammonia solution at 1.5 m/s wind speed at 5 ºC
3.6 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the sixth 10 minutes
Ammonia Hydrate Weight: 45910 lbPure Ammonia Weight 13262 lbPure Water Weight 32648 lbAmmonia Concentration: 28.89%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 311 mm Hg
290 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 290 = 0.02482.25 * 278
QR = 1.50.78 *0.024 * 1044= 34.2 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.1 lb/min
After the 6th 10 minute 41 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13262 lb - 41 lb = 13221 lbAmmonia concentration decreased to : 13221 lb (ammonia) /[13221 lb (ammonia) + 32648 lb (water)] = 28.82%
10-min average vapor pressure (mm Hg) of 28.89% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 28.89% ammonia solution at 1.5 m/s wind speed at 5 ºC
4. Calculation of Ammonia Emission Rate in 4th Hour after Spill.4.1 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the first 10 minutes
Assumption: Assuming a entire tank of ammonia hydrate spilled into the containment during spill.
Ammonia Hydrate Weight: 45869 lbPure Ammonia Weight 13221 lbPure Water Weight 32648 lbAmmonia Concentration: 28.82%
Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 310 mm Hg
289 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 289 = 0.02482.25 * 278
QR = 1.50.78 *0.024 * 1044= 34.1 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.1 lb/min
After the 1st 10 minute 41 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13221 lb - 41 lb = 13179 lbAmmonia concentration decreased to : 13179 lb (ammonia) /[13179 lb (ammonia)+32648 lb (water)] = 28.76%
10-min average vapor pressure (mm Hg) of 28.82% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 28.82% ammonia solution at 1.5 m/s wind speed at 5 ºC
4.2 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the second 10 minutes
Ammonia Hydrate Weight: 45828 lbPure Ammonia Weight 13179 lbPure Water Weight 32648 lbAmmonia Concentration: 28.8%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 309 mm Hg
288 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 288 = 0.02482.25 * 278
QR = 1.50.78 *0.024 * 1044= 34.0 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.1 lb/min
After the 2nd 10 minute 41 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13179 lb - 41 lb = 13138 lbAmmonia concentration decreased to : 13138 lb (ammonia) /[13138 lb (ammonia)+32648 lb (water)] = 28.69%
10-min average vapor pressure (mm Hg) of 28.76% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 28.76% ammonia solution at 1.5 m/s wind speed at 5 ºC
4.3 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the third 10 minutes
Ammonia Hydrate Weight: 45787 lbPure Ammonia Weight 13138 lbPure Water Weight 32648 lbAmmonia Concentration: 28.69%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 308 mm Hg
287 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 287 = 0.02482.25 * 286
QR = 1.50.78 *0.024 * 1044= 33.9 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.1 lb/min
After the 3rd 10 minute 41 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13138 lb - 41 lb = 13097 lbAmmonia concentration decreased to : 13097 lb (ammonia) /[13097 lb (ammonia) + 32648 lb (water)] = 28.63%
10-min average vapor pressure (mm Hg) of 28.69% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 28.69% ammonia solution at 1.5 m/s wind speed at 5 ºC
4.4 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fourth 10 minutes
Ammonia Hydrate Weight: 45746 lbPure Ammonia Weight 13097 lbPure Water Weight 32648 lbAmmonia Concentration: 28.63%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 307 mm Hg
286 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 286 = 0.02482.25 * 278
QR = 1.50.78 *0.024 * 1044= 33.8 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.1 lb/min
After the 4th 10 minute 41 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13097 lb - 41 lb = 13056 lbAmmonia concentration decreased to : 13056 lb (ammonia) /[13056 lb (ammonia) + 32648 lb (water)] = 28.57%
10-min average vapor pressure (mm Hg) of 28.63% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 28.63% ammonia solution at 1.5 m/s wind speed at 5 ºC
4.5 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fifth 10 minutes
Ammonia Hydrate Weight: 45705 lbPure Ammonia Weight 13056 lbPure Water Weight 32648 lbAmmonia Concentration: 28.57%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 306 mm Hg
285 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 285 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 33.6 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.1 lb/min
After the 5th 10 minute 41 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13056 lb - 41 lb = 13016 lbAmmonia concentration decreased to : 13016 lb (ammonia) /[13016 lb (ammonia) + 32648 lb (water)] = 28.50%
10-min average vapor pressure (mm Hg) of 28.57% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 28.57% ammonia solution at 1.5 m/s wind speed at 5 ºC
4.6 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the sixth 10 minutes
Ammonia Hydrate Weight: 45664 lbPure Ammonia Weight 13016 lbPure Water Weight 32648 lbAmmonia Concentration: 28.50%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 305 mm Hg
285 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 285 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 33.5 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.1 lb/min
After the 6th 10 minute 41 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 13016 lb - 41 lb = 12975 lbAmmonia concentration decreased to : 12975 lb (ammonia) /[12975 lb (ammonia) + 32648 lb (water)] = 28.44%
10-min average vapor pressure (mm Hg) of 28.5% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 28.5% ammonia solution at 1.5 m/s wind speed at 5 ºC
5. Calculation of Ammonia Emission Rate in 5th Hour after Spill.5.1 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the first 10 minutes
Assumption: Assuming a entire tank of ammonia hydrate spilled into the containment during spill.
Ammonia Hydrate Weight: 45624 lbPure Ammonia Weight 12975 lbPure Water Weight 32648 lbAmmonia Concentration: 28.44%
Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 305 mm Hg
285 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 285 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 33.5 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.1 lb/min
After the 1st 10 minute 41 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12975 lb - 41 lb = 12935 lbAmmonia concentration decreased to : 12935 lb (ammonia) /[12935 lb (ammonia)+32648 lb (water)] = 28.38%
10-min average vapor pressure (mm Hg) of 28.44% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 28.44% ammonia solution at 1.5 m/s wind speed at 5 ºC
5.2 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the second 10 minutes
Ammonia Hydrate Weight: 45583 lbPure Ammonia Weight 12935 lbPure Water Weight 32648 lbAmmonia Concentration: 28.38%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 304 mm Hg
284 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 284 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 33.4 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.0 lb/min
After the 2nd 10 minute 40 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12935 lb - 40 lb = 12894 lbAmmonia concentration decreased to : 12894 lb (ammonia) /[12894 lb (ammonia)+32648 lb (water)] = 28.31%
10-min average vapor pressure (mm Hg) of 28.38% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 28.38% ammonia solution at 1.5 m/s wind speed at 5 ºC
5.3 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the third 10 minutes
Ammonia Hydrate Weight: 45543 lbPure Ammonia Weight 12894 lbPure Water Weight 32648 lbAmmonia Concentration: 28.31%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 303 mm Hg
283 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 283 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 33.3 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.0 lb/min
After the 3rd 10 minute 40 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12894 lb - 40 lb = 12854 lbAmmonia concentration decreased to : 12854 lb (ammonia) /[12854 lb (ammonia) + 32648 lb (water)] = 28.25%
10-min average vapor pressure (mm Hg) of 28.31% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 28.31% ammonia solution at 1.5 m/s wind speed at 5 ºC
5.4 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fourth 10 minutes
Ammonia Hydrate Weight: 45502 lbPure Ammonia Weight 12854 lbPure Water Weight 32648 lbAmmonia Concentration: 28.25%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 302 mm Hg
282 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 282 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 33.2 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.0 lb/min
After the 4th 10 minute 40 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12854 lb - 40 lb = 12814 lbAmmonia concentration decreased to : 12814 lb (ammonia) /[12814 lb (ammonia) + 32648 lb (water)] = 28.19%
10-min average vapor pressure (mm Hg) of 28.25% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 28.25% ammonia solution at 1.5 m/s wind speed at 5 ºC
5.5 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fifth 10 minutes
Ammonia Hydrate Weight: 45462 lbPure Ammonia Weight 12814 lbPure Water Weight 32648 lbAmmonia Concentration: 28.19%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 301 mm Hg
281 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 281 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 33.1 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.0 lb/min
After the 5th 10 minute 40 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12814 lb - 40 lb = 12774 lbAmmonia concentration decreased to : 12774 lb (ammonia) /[12774 lb (ammonia) + 32648 lb (water)] = 28.12%
10-min average vapor pressure (mm Hg) of 28.19% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 28.19% ammonia solution at 1.5 m/s wind speed at 5 ºC
5.6 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the sixth 10 minutes
Ammonia Hydrate Weight: 45422 lbPure Ammonia Weight 12774 lbPure Water Weight 32648 lbAmmonia Concentration: 28.12%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 300 mm Hg
280 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 280 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 33.0 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.0 lb/min
After the 6th 10 minute 40 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12774 lb - 40 lb = 12734 lbAmmonia concentration decreased to : 12734 lb (ammonia) /[12734 lb (ammonia) + 32648 lb (water)] = 28.06%
10-min average vapor pressure (mm Hg) of 28.12% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 28.12% ammonia solution at 1.5 m/s wind speed at 5 ºC
6. Calculation of Ammonia Emission Rate in 6th Hour after Spill.6.1 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the first 10 minutes
Assumption: Assuming a entire tank of ammonia hydrate spilled into the containment during spill.
Ammonia Hydrate Weight: 45382 lbPure Ammonia Weight 12734 lbPure Water Weight 32648 lbAmmonia Concentration: 28.06%
Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 299 mm Hg
279 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 279 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 32.9 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.0 lb/min
After the 1st 10 minute 40 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12734 lb - 40 lb = 12694 lbAmmonia concentration decreased to : 12694 lb (ammonia) /[12694 lb (ammonia)+32648 lb (water)] = 28.00%
10-min average vapor pressure (mm Hg) of 28.06% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 28.06% ammonia solution at 1.5 m/s wind speed at 5 ºC
6.2 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the second 10 minutes
Ammonia Hydrate Weight: 45342 lbPure Ammonia Weight 12694 lbPure Water Weight 32648 lbAmmonia Concentration: 28.0%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 298 mm Hg
278 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 278 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 32.8 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.0 lb/min
After the 2nd 10 minute 40 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12694 lb - 40 lb = 12654 lbAmmonia concentration decreased to : 12654 lb (ammonia) /[12654 (ammonia)+32648 lb (water)] = 27.93%
10-min average vapor pressure (mm Hg) of 28% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 28% ammonia solution at 1.5 m/s wind speed at 5 ºC
6.3 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the third 10 minutes
Ammonia Hydrate Weight: 45303 lbPure Ammonia Weight 12654 lbPure Water Weight 32648 lbAmmonia Concentration: 27.93%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 297 mm Hg
277 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 277 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 32.7 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 4.0 lb/min
After the 3rd 10 minute 40 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12654 lb - 40 lb = 12615 lbAmmonia concentration decreased to : 12615 lb (ammonia) /[12615 lb (ammonia) + 32648 lb (water)] = 27.87%
10-min average vapor pressure (mm Hg) of 27.93% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 27.93% ammonia solution at 1.5 m/s wind speed at 5 ºC
6.4 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fourth 10 minutes
Ammonia Hydrate Weight: 45263 lbPure Ammonia Weight 12615 lbPure Water Weight 32648 lbAmmonia Concentration: 27.87%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 296 mm Hg
276 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 276 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 32.5 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 3.9 lb/min
After the 4th 10 minute 39 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12615 lb - 39 lb = 12576 lbAmmonia concentration decreased to : 12576 lb (ammonia) /[12576 lb (ammonia) + 32648 lb (water)] = 27.81%
10-min average vapor pressure (mm Hg) of 27.87% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 27.87% ammonia solution at 1.5 m/s wind speed at 5 ºC
6.5 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fifth 10 minutes
Ammonia Hydrate Weight: 45224 lbPure Ammonia Weight 12576 lbPure Water Weight 32648 lbAmmonia Concentration: 27.81%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 295 mm Hg
275 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 275 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 32.4 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 3.9 lb/min
After the 5th 10 minute 39 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12576 lb - 39 lb = 12536 lbAmmonia concentration decreased to : 12536 lb (ammonia) /[12536 lb (ammonia) + 32648 lb (water)] = 27.74%
10-min average vapor pressure (mm Hg) of 27.81% ammonia solution at 1.5 m/s wind speed at 25 ºC10-min average vapor pressure (mm Hg) of 27.81% ammonia solution at 1.5 m/s wind speed at 5 ºC
6.6 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the sixth 10 minutes
Ammonia Hydrate Weight: 45185 lbPure Ammonia Weight 12536 lbPure Water Weight 32648 lbAmmonia Concentration: 27.74%Diked Area (containment area): 97 m2 = 1044 ft3Since the diked area is smaller than the maximum area, the following equation is used:
QR = U0.78 * LFA * AValue
QR: Worst -Case release rate (lb/min)U: Worst Case Wind Speed (m/s) 1.5LFA: Liquid Factor Ambient
LFA = 0.284 * MW2/3 * VP (Equation D-2)82.25 * T
=MW: Ammonia Molecular Weight 17.05VP: 294 mm Hg
274 mm Hg
T: Temperature of released substance (Kelvin (K)) 278 K
A: Diked Area (square feet) 1044 ft2
LFA = 0.284 * 172/3 * 274 = 0.02382.25 * 278
QR = 1.50.78 *0.023 * 1044= 32.3 lb/min
Calculation of Indoor Release Rate:QRB = (0.1/1.5)0.78 *QR
= 3.9 lb/min
After the 6th 10 minute 39 lb ammonia has releases to the atmosphere. The pure ammonia amount in the liquid pool become: 12536 lb - 39 lb = 12497 lbAmmonia concentration decreased to : 12497 lb (ammonia) /[12497 lb (ammonia) + 32648 lb (water)] = 27.68%
10-min average vapor pressure (mm Hg) of 27.74% ammonia solution at 1.5 m/s wind speed at 25 ºC
10-min average vapor pressure (mm Hg) of 27.74% ammonia solution at 1.5 m/s wind speed at 5 ºC
Table A-3Emission Rate Summary
Hours after Spill1st 2nd 3rd 4th 5th 6th
1st 10-min A Emission Rate (lb/min) 4.42 4.32 4.24 4.12 4.06 3.982nd 10-min A Emission Rate (lb/min) 4.39 4.31 4.23 4.11 4.04 3.963rd 10-min A Emission Rate (lb/min) 4.38 4.30 4.22 4.10 4.03 3.954th 10-min A Emission Rate (lb/min) 4.37 4.28 4.19 4.08 4.02 3.945th 10-min A Emission Rate (lb/min) 4.36 4.27 4.16 4.07 4.00 3.926th 10-min A Emission Rate (lb/min) 4.34 4.26 4.14 4.06 3.99 3.91Total Emission (lb/hr) 262 257 252 245 241 237
Total Emission (kg/hr) 119 117 114 111 109 107Hourly Emission Rate (g/s) 33.1 32.4 31.7 30.9 30.4 29.8
Hourly Emission Factor 1.0000 0.9807 0.9595 0.9351 0.9199 0.9017
10-min Emision RateMinutes after Spill (lb/min)
10 4.420 4.430 4.440 4.450 4.460 4.370 4.380 4.390 4.3
100 4.3110 4.3120 4.3130 4.2140 4.2150 4.2160 4.2170 4.2180 4.1190 4.1200 4.1210 4.1220 4.1230 4.1240 4.1250 4.1260 4.0270 4.0280 4.0290 4.0300 4.0310 4.0320 4.0330 4.0340 3.9350 3.9360 3.9
Hourly Emission Factor
0.8500
0.8700
0.8900
0.9100
0.9300
0.9500
0.9700
0.9900
1.0100
1st 2nd 3rd 4th 5th 6th
10-Min Average Emission Rate
3.0
3.5
4.0
4.5
5.0
10 30 50 70 90 110 130 150 170 190 210 230 250 270 290 310 330 350
Minutes After Spill
Em
iss
ion
Rat
e (l
b/m
in)
Appendix B
Material Safety Data Sheet
Appendix C
Coordinates Conversion
Table C - R.C. Harris WTP Local and UTM Coordinates of Sources, Buildings and Property Line.Rotated Deg: 25 degree
Local Local - Rotated to True North 0.44 radian UTM (NAD 83)Corner/Point X (m) Y (m) Height Corner/Point Easting (m) Northing (m) Corner/Point Easting (m) Northing (m)
Property Boundary Property Boundary Property Boundary1 1 1 638570.09 4837090.552 2 2 638624.79 4836946.213 3 3 638622.12 4836921.034 4 4 638664.41 4836779.115 5 5 638703.22 4836683.66 6 6 638925.91 4836922.737 7 7 638898.21 4837053.628 8 8 638846.78 4837125.119 9 9 638814.29 4837210.5510 10 10 638794.15 4837205.5211 11 11 638758.07 4837179.512 12 12 638720.3 4837156.01
Reference PointSW corner of Admin 0 0 7.1 SW corner 0.00 0.00 SW corner 638643.2 4836962.02
Admin Bldg Tier 1 40.0 0.0 1 0.00 0.00 1 638643.20 4836962.02
108.0 0.0 2 97.88 45.64 2 638741.08 4837007.66108.0 -5.4 3 100.16 40.75 3 638743.36 4837002.77111.4 -5.4 4 103.24 42.19 4 638746.44 4837004.21111.4 -10.4 5 105.36 37.65 5 638748.56 4836999.67125.0 -10.4 6 117.68 43.40 6 638760.88 4837005.42125.0 -5.4 7 115.57 47.93 7 638758.77 4837009.95128.4 -5.4 8 118.65 49.37 8 638761.85 4837011.39128.4 0.0 9 116.37 54.26 9 638759.57 4837016.28240.0 0.0 10 217.51 101.43 10 638860.71 4837063.45240.0 50.0 11 196.38 146.74 11 638839.58 4837108.76
0.0 50.0 12 -21.13 45.32 12 638622.07 4837007.34Tier 2 6
0.0 22.0 1 -9.30 19.94 1 638633.90 4836981.96240.0 22.0 2 208.22 121.37 2 638851.42 4837083.39240.0 28.0 3 205.68 126.81 3 638848.88 4837088.83
0.0 28.0 4 -11.83 25.38 4 638631.37 4836987.40Tier 3 8.08
111.4 -10.4 1 105.36 37.65 1 638748.56 4836999.67125.0 -10.4 2 117.68 43.40 2 638760.88 4837005.42125.0 50.0 3 92.16 98.14 3 638735.36 4837060.16111.4 50.0 4 79.83 92.40 4 638723.03 4837054.42
Tier 4 10.5111.4 18.2 1 93.27 63.57 1 638736.47 4837025.59125.0 18.2 2 105.60 69.32 2 638748.80 4837031.34125.0 31.8 3 99.85 81.65 3 638743.05 4837043.67111.4 31.8 4 87.52 75.90 4 638730.72 4837037.92
Tier 5 14.39108.0 -5.4 1 100.16 40.75 1 638743.36 4837002.77111.4 -5.4 2 103.24 42.19 2 638746.44 4837004.21111.4 0.0 3 100.96 47.08 3 638744.16 4837009.10108.0 0.0 4 97.88 45.64 4 638741.08 4837007.66
Tier 6 14.39125.0 -5.4 1 115.57 47.93 1 638758.77 4837009.95128.4 -5.4 2 118.65 49.37 2 638761.85 4837011.39128.4 0.0 3 116.37 54.26 3 638759.57 4837016.28125.0 0.0 4 113.29 52.83 4 638756.49 4837014.85
Service Building Tier 1 5.189.3 -76.0 1 40.55 -64.95 1 638683.75 4836897.07
21.3 -76.0 2 51.42 -59.88 2 638694.62 4836902.1421.3 -75.4 3 51.17 -59.33 3 638694.37 4836902.6927.4 -75.4 4 56.70 -56.76 4 638699.90 4836905.2627.4 -70.0 5 54.42 -51.86 5 638697.62 4836910.1674.1 -70.0 6 96.74 -32.13 6 638739.94 4836929.8974.1 -70.4 7 96.91 -32.49 7 638740.11 4836929.5389.4 -70.4 8 110.78 -26.02 8 638753.98 4836936.0089.4 -64.3 9 108.20 -20.49 9 638751.40 4836941.5392.6 -64.3 10 111.10 -19.14 10 638754.30 4836942.8892.6 -60.2 11 109.37 -15.43 11 638752.57 4836946.5977.1 -60.2 12 95.32 -21.98 12 638738.52 4836940.0477.1 -62.5 13 96.29 -24.06 13 638739.49 4836937.9621.3 -62.5 14 45.72 -47.64 14 638688.92 4836914.3821.3 -60.8 15 45.00 -46.10 15 638688.20 4836915.929.3 -60.8 16 34.12 -51.17 16 638677.32 4836910.85
Corner/Point X (m) Y (m) Height Corner/Point Easting (m) Northing (m) Corner/Point Easting (m) Northing (m)Tier 2 10.13
9.3 -76.0 1 40.55 -64.95 1 638683.75 4836897.0721.3 -76.0 2 51.42 -59.88 2 638694.62 4836902.1421.3 -75.4 3 51.17 -59.33 3 638694.37 4836902.6927.4 -75.4 4 56.70 -56.76 4 638699.90 4836905.2627.4 -70.0 5 54.42 -51.86 5 638697.62 4836910.1674.1 -70.0 6 96.74 -32.13 6 638739.94 4836929.8974.1 -70.4 7 96.91 -32.49 7 638740.11 4836929.5389.4 -70.4 8 110.78 -26.02 8 638753.98 4836936.0089.4 -60.2 9 106.47 -16.78 9 638749.67 4836945.2477.1 -60.2 10 95.32 -21.98 10 638738.52 4836940.0477.1 -62.5 11 96.29 -24.06 11 638739.49 4836937.9621.3 -62.5 12 45.72 -47.64 12 638688.92 4836914.3821.3 -60.8 13 45.00 -46.10 13 638688.20 4836915.929.3 -60.8 14 34.12 -51.17 14 638677.32 4836910.85
Transformer Station Tier 3 11.869.3 -76.0 1 40.55 -64.95 1 638683.75 4836897.07
21.3 -76.0 2 51.42 -59.88 2 638694.62 4836902.1421.3 -60.8 3 45.00 -46.10 3 638688.20 4836915.929.3 -60.8 4 34.12 -51.17 4 638677.32 4836910.85
Tier 4 12.4312.3 -73.0 1 42.00 -60.96 1 638685.20 4836901.0618.3 -73.0 2 47.44 -58.43 2 638690.64 4836903.5918.3 -63.8 3 43.55 -50.09 3 638686.75 4836911.9312.3 -63.8 4 38.11 -52.62 4 638681.31 4836909.40
Tier 5 1313.3 -72.0 1 42.48 -59.63 1 638685.68 4836902.3917.3 -72.0 2 46.11 -57.94 2 638689.31 4836904.0817.3 -64.8 3 43.06 -51.42 3 638686.26 4836910.6013.3 -64.8 4 39.44 -53.11 4 638682.64 4836908.91
Tier 6 13.5914.3 -71.0 1 42.97 -58.30 1 638686.17 4836903.7216.3 -71.0 2 44.78 -57.46 2 638687.98 4836904.5616.3 -65.8 3 42.58 -52.75 3 638685.78 4836909.2714.3 -65.8 4 40.77 -53.59 4 638683.97 4836908.43
Alum Tower Tier 7 22.3974.1 -70.4 1 96.91 -32.49 1 638740.11 4836929.5385.4 -70.4 2 107.15 -27.71 2 638750.35 4836934.3185.4 -64.2 3 104.53 -22.09 3 638747.73 4836939.9382.5 -64.2 4 101.90 -23.32 4 638745.10 4836938.7082.5 -60.2 5 100.21 -19.69 5 638743.41 4836942.3377.1 -60.2 6 95.32 -21.98 6 638738.52 4836940.0477.1 -64.2 7 97.01 -25.60 7 638740.21 4836936.4274.1 -64.2 8 94.29 -26.87 8 638737.49 4836935.1574.1 -66.1 9 95.09 -28.59 9 638738.29 4836933.4373.3 -66.1 10 94.37 -28.93 10 638737.57 4836933.0973.3 -68.5 11 95.38 -31.10 11 638738.58 4836930.9274.1 -68.5 12 96.11 -30.77 12 638739.31 4836931.25
Tier 8 26.7474.1 -70.4 1 96.91 -32.49 1 638740.11 4836929.5385.4 -70.4 2 107.15 -27.71 2 638750.35 4836934.3185.4 -64.2 3 104.53 -22.09 3 638747.73 4836939.9382.5 -64.2 4 101.90 -23.32 4 638745.10 4836938.7082.5 -63.6 5 101.65 -22.78 5 638744.85 4836939.2477.1 -63.6 6 96.75 -25.06 6 638739.95 4836936.9677.1 -64.2 7 97.01 -25.60 7 638740.21 4836936.4274.1 -64.2 8 94.29 -26.87 8 638737.49 4836935.1574.1 -66.1 9 95.09 -28.59 9 638738.29 4836933.4373.3 -66.1 10 94.37 -28.93 10 638737.57 4836933.0973.3 -68.5 11 95.38 -31.10 11 638738.58 4836930.9274.1 -68.5 12 96.11 -30.77 12 638739.31 4836931.25
Exhaust Stack Tier 9 32.3873.3 -68.5 1 95.38 -31.10 1 638738.58 4836930.9274.1 -68.5 2 96.11 -30.77 2 638739.31 4836931.2574.1 -66.1 3 95.09 -28.59 3 638738.29 4836933.4373.3 -66.1 4 94.37 -28.93 4 638737.57 4836933.09
Corner/Point X (m) Y (m) Height Corner/Point Easting (m) Northing (m) Corner/Point Easting (m) Northing (m)
Pumping Station Tier 10.0 -113.0 8.8 1 47.76 -102.41 1 638690.96 4836859.61
90.8 -113.0 2 130.05 -64.04 2 638773.25 4836897.9890.8 -86.6 3 118.89 -40.11 3 638762.09 4836921.910.0 -86.6 4 36.60 -78.49 4 638679.80 4836883.53
Tier 25.0 -113.0 11.6 1 52.29 -100.30 1 638695.49 4836861.72
90.8 -113.0 2 130.05 -64.04 2 638773.25 4836897.9890.8 -86.6 3 118.89 -40.11 3 638762.09 4836921.915.0 -86.6 4 41.13 -76.37 4 638684.33 4836885.65
Tier 312.3 -113.0 13.1 1 58.90 -97.21 1 638702.10 4836864.8183.5 -113.0 2 123.43 -67.12 2 638766.63 4836894.9083.5 -86.6 3 112.28 -43.20 3 638755.48 4836918.8212.3 -86.6 4 47.75 -73.29 4 638690.95 4836888.73
Tier 419.6 -105.7 14.1 1 62.43 -87.51 1 638705.63 4836874.5176.2 -105.7 2 113.73 -63.59 2 638756.93 4836898.4376.2 -93.9 3 108.74 -52.90 3 638751.94 4836909.1219.6 -93.9 4 57.45 -76.82 4 638700.65 4836885.20
Tier 5 14.420.1 -103.7 1 62.04 -85.49 1 638705.24 4836876.5375.7 -103.7 2 112.43 -61.99 2 638755.63 4836900.0375.7 -95.9 3 109.14 -54.92 3 638752.34 4836907.1020.1 -95.9 4 58.75 -78.42 4 638701.95 4836883.60
Tier 6 14.720.6 -101.7 1 61.65 -83.47 1 638704.85 4836878.5575.2 -101.7 2 111.13 -60.39 2 638754.33 4836901.6375.2 -97.9 3 109.53 -56.95 3 638752.73 4836905.0720.6 -97.9 4 60.04 -80.02 4 638703.24 4836882.00
Tier 7 15.121.1 -99.7 1 61.26 -81.44 1 638704.46 4836880.5874.7 -99.7 2 109.84 -58.79 2 638753.04 4836903.2374.7 -99.9 3 109.92 -58.97 3 638753.12 4836903.0521.1 -99.9 4 61.34 -81.62 4 638704.54 4836880.40
Stack: Stack-1 73.8 -67.3 13.5 1 95.33 -29.81 1 638738.53 4836932.21
Sensitive ReceptorsPOI ID Description X (m) Y (m) Elevation (m) Height (m)R1 7-storey apartment building to the NE 638773 4837247.93 107.9 18
R2 4-storey apartment building to the east 638846 4837148.47 99.0 12R3 4-storey apartment building to the east 638836 4837176.32 102.2 12R4 4-storey apartment building to the east 638824 4837210.13 105.0 12R5 5-storey apartment building to the north 638731 4837208.14 108.2 15R6 5-storey apartment building to the north 638673 4837178.31 106.3 15R7 5-storey apartment building to the north 638645 4837164.38 104.9 15R8 5-storey apartment building to the north 638614 4837150.46 102.4 4.5R9 2-storey house to the west 638557 4837044.57 93.6 4.5R10 2-storey house to the west 638567 4837008.04 92.7 4.5R11 4-storey apartment building to the SW 638624 4836813.54 79.3 12R12 2-storey house to the west 638603 4836883.64 85.5 4.5R13 2-storey house to the west 638606 4836901.41 86.0 4.5R14 2-storey house to the west 638585 4836946.82 86.0 4.5R15 2-storey house to the west 638577 4836975.46 89.7 4.5R16 5-storey apartment building to the NW 638580 4837140.25 100.0 15R17 5-storey apartment building to the NW 638543 4837118.69 97.3 15R18 4-storey apartment building to the west 638609 4836852.47 84.4 12
Appendix D
Electronic Files of AERMOD
`
FEASIBILITY STUDY FOR REPLACING EXISTING AQUEOUS AMMONIA TANKS AT R.C. HARRIS WATER TREATMENT PLANT TECHNICAL MEMORANDUM
APRIL 2015
Project no: 141-21256-00 Date: April 2015 – WSP Canada Inc. 600 Cochrane Drive, 5th Floor Markham, Ontario L3R 5K3 Phone: +1 905-475-7270 Fax: +1 905-475-5994 www.wspgroup.com
FEASIBILITY STUDY FOR REPLACING EXISTING AQUEOUS AMMONIA TANKS AT R.C. HARRIS WATER TREATMENT PLANT
TECHNICAL MEMORANDUM CITY OF TORONTO.
600 Cochrane Drive, 5th Floor, Markham, Ontario L3R 5K3 Telephone: 905.475.7270 Fax: 905.475.5994 www.wspgroup.com
141-21256-00 April 14, 2015 Mr. Zackary Sayevich City of Toronto Metro Hall 55 John Street, 21st floor Toronto, ON M5V 3C6 Re: Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water
Treatment Plant Techanical Memorandum (Final)
Dear Zack:
We are pleased to submit a copy of our Final Technical Memorandum (TM) for Replacing the Existing Aqueous Ammonia Tanks at RC Harris WTP for your review and comment.
Should you have any questions, please do not hesitate to contact the undersigned.
Yours truly, WSP Canada Inc. Negin Salamati, M.A.Sc., EIT Project Manager
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. ES-1
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. i
Table of Contents
Transmittal Letter Table of Contents
1. INTRODUCTION ......................................................................................................................... 1-1
1.1 Background .............................................................................................................................. 1-1 1.2 Feasibility Study – Scope of Work ........................................................................................... 1-1
2. BACKGROUND REVIEW AND NEEDS ASSESSMENTS ......................................................... 2-1
2.1 Existing Ammonia System ....................................................................................................... 2-1 2.2 Existing RMF Structural/Mechanical Review ........................................................................... 2-2
3. ALTERNATIVE OPTIONS FOR AQEOUS AMMONIA TANKS .................................................. 3-6
3.1 General Considerations ........................................................................................................... 3-6 3.2 Alternative Material for the Tanks ............................................................................................ 3-6
3.2.1 Option 1 Stainless Steel ........................................................................................... 3-6 3.2.2 Option 2 Fiberglass Reinforced Plastics (FRP) ....................................................... 3-7 3.2.3 Option 3 High-Density Polyethylene (HDPE) ......................................................... 3-10 3.2.4 Option 4: Cast-in-Place Concrete Tank ................................................................. 3-12 3.2.5 Option 5: Steel Tank .............................................................................................. 3-13
3.3 Constructability ...................................................................................................................... 3-15 3.3.1 Field Assembled Tanks .......................................................................................... 3-15 3.3.2 Shop Fabricated Tanks .......................................................................................... 3-15
4. EVALUATION OF OPTIONS .................................................................................................... 4-16
5. AMMONIA SCRUBBER .............................................................................................................. 5-1
5.1 Option 1: Wet Scrubber ........................................................................................................... 5-1 5.2 Option 2: Dry Scrubber ............................................................................................................ 5-2
6. PROCESS PIPING MODIFICATION .......................................................................................... 6-4
7. VENTILATION REQUIREMENTS ............................................................................................... 7-5
7.1 Existing Ventilation ................................................................................................................... 7-5 7.2 Future Ventilation Requirements ............................................................................................. 7-5
8. CONCLUSIONS AND RECOMMENDATIONS ........................................................................... 8-5
9. SUMMARY .................................................................................................................................. 9-6
List of Tables Table 2-1 Wood stave tank specification ................................................................................................... 2-1 Table 3-1 Stainless Steel Tank Specifications ........................................................................................... 3-6 Table 3-2 Capital cost for SS tanks ........................................................................................................... 3-7 Table 3-3 Bolted FRP tanks description .................................................................................................... 3-7 Table 3-4 Prefabricated FRP tanks description ......................................................................................... 3-8 Table 3-5 Smaller FRP tanks description .................................................................................................. 3-8 Table 3-6 Capital cost for FRP tanks ......................................................................................................... 3-9 Table 3-7 Description of HDPE tanks (Quantity: 2) ................................................................................. 3-10 Table 3-8 Description of HDPE tanks (Quantity: 6 or 9)1 ......................................................................... 3-11 Table 3-9 Capital cost for HDPE tanks1 ................................................................................................... 3-12 Table 3-10 Description of Cast in place Concrete tanks .......................................................................... 3-12
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Table 3-11 Capital cost for Cast-in Place Concrete1 ............................................................................... 3-13 Table 3-12 Description of Glass Fused Steel Tanks ............................................................................... 3-14 Table 3-13 Capital cost for Steel tanks .................................................................................................... 3-14 Table 4-1 Evaluation of different tank materials, fabrication, constructability and their associated costs 4-1 Table 5-1 Capital cost for wet packed tower scrubber ............................................................................... 5-2 Table 5-2 Capital cost for passive NH3 dry scrubber system .................................................................... 5-3 Table 5-3 Capital cosy for Purafil Inc., Model DS-500 Drum Scrubber ..................................................... 5-4
List of Figures Figure 1-1 R.C. Harris WTP ....................................................................................................................... 1-1 Figure 2-1 Existing Ammonia Storage System .......................................................................................... 2-1 Figure 2-2 Existing Ammonia Dosing System ............................................................................................ 2-2 Figure 3-1 Pre-Fabricated FRP tank .......................................................................................................... 3-8 Figure 3-2 HDPE tanks ............................................................................................................................ 3-11 Figure 3-3 Glass Fused to Steel Tanks with Roofs, Disco Road Facility, Toronto, ON .......................... 3-14 Figure 5-1 Wet Scrubber description ......................................................................................................... 5-1 Figure 5-2 Passive NH3 Dry Scrubber system ........................................................................................... 5-3 Figure 5-3 Purafil Inc., Model DS-500 Drum Scrubber .............................................................................. 5-4
Appendices Appendix A Equipment Technical Data
Appendix B Cost Estimate for the Recommended Option
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1. INTRODUCTION 1.1 Background R.C. Harris water treatment plant (WTP) is Toronto’s largest WTP and it was opened in 1941. It is located at 2701 Queen Street East, Toronto, next to Victoria Park Avenue along the shore of Lake Ontario in the Beach neighborhood. It has an average total treated water flow rate of 520 MLD and a maximum capacity of 950 MLD.
The existing chemical storage rooms at R.C. Harris WTP are located at the Residue Management Facility (RMF). Their previous location was at the plant’s terrace building where the aqueous ammonia was stored in four steel tanks. However, during a relocation project, they were transferred to two new wood stave tanks located at the RMF.
The existing system has experienced high concentration of ammonia fumes during the filling operations and during normal operations of the ammonia system. There is also a possibility of ammonia leakage from the tank liner and the existing flanges. Furthermore, the existing ammonia system does not have a vapor control system (for example, transferring the fumes back to the truck during the filling operation). Therefore, the City of Toronto conducted a feasibility study in order to resolve these issues. The plant should be fully operational during the period at which the tanks are being replaced.
This Feasibility Study assesses different options to replace the existing wood stave tanks with other material for the tanks. It also investigates the type the scrubber system to be used during the filling operation and in the event of ammonia spill.
Figure 1-1 R.C. Harris WTP
1.2 Feasibility Study – Scope of Work The purpose of this Feasibility Study was to:
- Conduct Field Review/Audit of the existing Ammonia System – Mechanical and Structural aspect of tanks, valving and associated piping
- Review the existing drawings
- Identify and propose alternative tank material
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- Identify and define scrubbing system
- Identify the constructability for each of the discussed options
- Prepare detailed cost estimate for each options
- Evaluate and compare different options
- Recommend the preferable option.
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2. BACKGROUND REVIEW AND NEEDS ASSESSMENTS
2.1 Existing Ammonia System The existing ammonia storage system is located at the RMF (Chemical Room 3). The system is comprised of two wood stave tanks for storage of aqua ammonia (% 30 NH4OH) with 40 mils (1mm) PVC # 328 closed top liner. Table 2-1 presents the technical data of the existing wood stave tanks:
Table 2-1 Wood stave tank specification
Tank Specifications Values
Overall Height (including the vents, etc.) (m) 3.289
Stave Height (m) 3.086
Inside Height (m) 2.896
Outside Diameter (DIA) (m) 3.937
Inside Diameter (m) 3.810
Net Volume (L) 28 000
Available Operating Capacity (L) 24 600
Overflow Height (m) 2.515
Figure 2-1 Existing Ammonia Storage System
The tanks have 610 mm DIA side flanged access ports and the liner is inserted into these access ports and they are water tight. There is another 610 mm DIA flanged port on top of the tank which is screwed from the top and the bottom. Each tank is equipped with 75 mm DIA discharge/equalization/drain lower level indicator port, 50 mm DIA upper level indicator port, 100 mm DIA overflow port (located about 3 m
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above the tank floor), 610 mm DIA side manway, 75 mm DIA fill, 150 mm DIA vent, 75 mm DIA ultrasonic level transmitter, high level switch and a leak detection system. There is also a sight gauge for visual confirmation of the chemical level in the tank. Figure 2-1 and Figure 2-2 show the existing wood stave tanks and the ammonia dosing system. Furthermore, there is an existing fiberglass reinforced plastic (FRP) platform along the west wall, adjacent to the tanks, which provide access to the top level of the tanks.
Figure 2-2 Existing Ammonia Dosing System
The tanks are filled by gravity through the 75 DIA fill line once per month. There is an existing return air line that is connected to the tanker truck but currently it is not in use. The tanks are connected to three (3) chemical dosing skids (by Morrflo Inc.) which currently, only one (1) is in operation and the other two (2) are on stand-by mode. The average and maximum ammonia dosage is 0.33 and 0.50 mg/l respectively. RC Harris WTP is adding aqueous ammonia to drinking water for disinfection purposes through chloramination.
With the existing system, RC Harris WTP is experiencing high concentration of ammonia fumes in the chemical storage room. This occurs during filling operation and normal operation of this system, which is potentially due to leakage from the top and side flanges. Furthermore, it appears that the existing plastic liners (flexible PVC, 40 mils (1 mm) thick sheets) are leaking. Although PVC is compatible with aqueous ammonia, there might be some cracks at the welded seams in the liner which can result in leakage.
2.2 Existing RMF Structural/Mechanical Review According to record drawings, the existing RMF was constructed in 2009 as an underground cast-in-place concrete structure situated between the Administration & Filter Building and the Service Building. The subjected ammonia storage tanks are located in Chemical Room 3, which is built directly above Decant Tanks No. 5 and No.6.
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Chemical Room 3 has plan dimensions of approximately 11.7m wide x 20m long. Access could be made from the corridor on the north side through two man doors and a vestibule, or via a man door from the upper thickener gallery on the south side. (Figures 2-3 and 2-4).
Figure 2-3 Existing North Access Vestibule and Stairs
Figure 2-4 Existing South Access Man Door and Stairs
The floor slab of Chemical Room 3 was constructed as a suspended reinforced concrete slab, capable of sustaining maximum of 25kPa/m2 live load. The two subjected ammonia storage tanks are placed on the
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top of the concrete housekeeping pads on floor. A FRP access platform was also built beside these tanks for easy access to the top of the tanks (Figures 2-5 and 2-6).
The ceiling above Chemical Room 3 was constructed as a buried cast-in-place concrete roof slab, which has various slopes for positive drainage and is supported by concrete beams and columns below.
Figure 2-5 Existing Ammonia Storage Tanks and FRP Access Platform
Figure 2-6 Existing Ammonia Storage Tanks and FRP Access Platform
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An approximate 1m x 1m overhead roof hatch opening was designed in the Chemical Room to allow for filling the existing ammonia storage tanks (Figures 2-7 and 2-8).
Figure 2-7 Underside of Existing Overhead Roof Hatch
(Including 75 DIA fill pipe, 75 DIA vapour return pipe and 100 DIA spill containment suction pipe;
Insulated fire water supply)
Figure 2-8 Top View of Existing Overhead Roof Hatch (Near One)
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3. ALTERNATIVE OPTIONS FOR AQEOUS AMMONIA TANKS
3.1 General Considerations The following options (materials compatible with the discussed chemical) are proposed for replacing the existing wood stave tanks currently used to store aqueous ammonia along with their constructability.
3.2 Alternative Material for the Tanks 3.2.1 Option 1 Stainless Steel 3.2.1.1 Technical Specifications This option includes the installation of two (2) Stainless Steel tanks with a total volume of 60 m3 (each 30 m3). The following table describes the specification of this option:
Table 3-1 Stainless Steel Tank Specifications
Specification Value
Diameter (m) 4
Height (m) 3
Stainless Steel 316
Bottom plate mm (inch)1 6.4 (1/4)
Side plates mm (inch)1 6.4 (1/4)
Top plates mm (inch) 3.2 (1/8)
Rolled angle outer support at 1.5m high mm (inch)
76x76x6.4 (3 x 3 x ¼) - top supports
Man way, mm (inch) 1 only 610 (24") gasketed stainless steel
Flanges mm (inch) 7 only 100 (4") pipes approx. 205 (8") long
Access ladder current access system to be reused 1 If required, plate thickness could be increased to e.g. 9.5 mm (3/8”), to be confirmed during the design
3.2.1.2 Constructability Due to limited accessibility to the ammonia storage room, all materials would be shop prepared and shipped to the site. The tanks would be 100 % welded (to CWB standards) and installed on site in the chemical storage room. Please refer to section 3.3.1 for further details. The power requirement for the site fabrication would be 120 volts 1 phase and 600 volt 3 phase. Tank testing would be radiographic or ultrasonic testing of randomly selected welds. After successful ultrasonic or radiographic testing, additional hydrostatic pressure testing would be provided. It should be noted that Stainless Steel tanks can also be pre-fabricated. However, to install the tanks, the celling of the ammonia storage room would need to be demolished to provide accessibility to this room. Please refer to section 3.3.2 for more details.
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3.2.1.3 Capital Cost The following table summarises the costs of on-site construction of stainless steel (SS) tanks and prefabricated SS tanks. For stainless steel tanks, internal liner is not required.
Table 3-2 Capital cost for SS tanks
Tank Material Capital Cost
316 Stainless Steel – welded on site $ 62 500.00/tank1
Pre- fabricated 316 Stainless Steel – excluding the cost of demolishing the roof
$ 76 800.00/tank2
- Add 4m x 4m opening above Chemical Room 3 (engineering cost included)
$ 125 000.00
- Delivery Cost (4-6 weeks) $ 11 000.00
- Modification to existing tank FRP access structure pipes and valves (assumed cost)
$ 5 000.003
1 Includes the mobilization/ demobilisation, material delivery and tank installation cost. 2 The cost of delivery and installation is not included 3 The existing access structure would be re-used (some minor modification may be required).
3.2.2 Option 2 Fiberglass Reinforced Plastics (FRP) 3.2.2.1 Technical Specifications This option includes the installation Fiberglass Reinforced Plastics (FRP) tanks with an approximate total volume of 56 to 60 m3. FRP is a corrosion resistant material compatible with aqueous ammonia, and therefore the RFP tanks would not require any liners. The following options are proposed for the installation of FRP tanks in the chemical storage room:
Bolted FRP tanks:
This option includes the installation of two FRP tanks with a total volume of 60 m3. The material for this type of tank would be shipped to the site and bolted inside the ammonia storage room. Since this type of tank is assembled on site, there is a possibility for leakage. Although several gaskets would be used during the bolting process, the tanks are not fully sealed and therefore it will not be discussed further.
Table 3-3 Bolted FRP tanks description
Specification Value
Diameter 4 m
Height 3 m
Construction Bolted on site
Top and bottom Flat
Manway 1
Ports All required ports to be provided
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Pre-fabricated FRP tanks:
This option includes the installation of two (2) or six (6) FRP tanks with a total volume of 56 to 60 m3. The following table is the technical description of two (30 m3 each) prefabricated FRP tanks:
Figure 3-1 Pre-Fabricated FRP tank
Table 3-4 Prefabricated FRP tanks description
Specification Value
Description 2 tanks
Diameter 4 m
Height 3 m
Construction Pre-fabricated
Top and bottom Flat
Manway mm (inch) 1 x 610 (24”) side manway
Nozzles mm (inch) 4 x 100 (4”)
Other Lift lugs and Hold down lugs
Examples of Installations - Aqueous Ammonia Storage, Great North Chemicals, Maple ON
- Aqueous Ammonia Storage, Anco Chemicals, Maple, ON
Please refer to section 3.3.2 for more details on the constructability of these types of tanks.
The following table provides details on six (6) smaller pre-fabricated FRP tanks:
Table 3-5 Smaller FRP tanks description
Specification
Description 6 tanks
Diameter 2 m
Height 3 m
Construction Pre-fabricated
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Top and bottom Flat
Manway mm (inch) 1 x 450 (18”) side manway
Nozzles mm (inch) 4 x 100 (4”)
Other Lift lugs and Hold down lugs
Please refer to section 3.3.2 for more details on the constructability of these types of tanks
3.2.2.2 Constructability Installation of two (2) FRP tanks (each 30 m3): Due to limited accessibility to the ammonia storage room, the celling of the ammonia storage room would be demolished to provide accessibility to this room. After the installation of the tanks, roof should be reconstructed. However, if required, this option will not allow any future possible tank replacement. Please refer to section 3.3.2 for more details. Installation of six (6) FRP tanks (approximate volume of 7.6 m3 each): there are two feasible ways to bring these pre-fabricated FRP tanks to the ammonia storage room: 1) expanding the existing hatch located in the ammonia storage room to provide permanent access to the chemical storage area 2) using the north corridor and overhead monorails in the existing Decant Tank Service room. Please refer to section 3.2.2 for more details. It should be noted that installation of six (6) tanks will result in a more complicated operation and maintenance process. 3.2.2.3 Capital Cost The following table presents the capital cost associated with different FRP tank options:
Table 3-6 Capital cost for FRP tanks
Tank Material – Construction Capital cost
Pre-Fabricated FRP tanks (2 tanks, each 30 m3) $ 40 000.00/tank1
- Add 4m x 4m opening above Chemical Room 3 (engineering cost included)
$ 125 000.00
- Modification to existing tank FRP access structure, pipes and valves (assumed cost)
$ 5 000.002
Pre-Fabricated FRP tanks (6 tanks) $ 12 500.00/tank1
- Add 2.5m x 2.5m opening above Chemical room 3 (engineering included)
$ 85 000.00
- OR: Transport tanks using monorail (engineering included)
$ 50 000.00
- New FRP access structure, pipes and valves (assumed cost)
$ 25 000.003
Delivery Cost for 2 or 6 tanks $ 8 000.00 1 The cost of delivery, craning, rigging, offloading, installation, piping, level instruments or vapor recovery systems are not included 2 Existing FRP access structure would be reused (some minor modification may be required) 3 New FRP access structure would be required
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3.2.3 Option 3 High-Density Polyethylene (HDPE)
3.2.3.1 Technical Specifications This option includes the installation of High-density polyethylene (HDPE) tanks with an approximate total volume of 56 to 60 m3. These types of tanks are corrosion resistant and compatible with almost all chemicals used in water treatment including aqueous ammonia; therefore they do not require any liner. Figure 3-1 is an indication of this type of tank. The following tanks can be installed at the chemical storage room:
Two (2) 30 m3 HDPE tanks:
Table 3-7 Description of HDPE tanks (Quantity: 2)
Specification Value
Diameter 3.63 m
Height 3.60 m
Construction Pre-fabricated, Rotationally-molded tank, one-piece seamless construction
Bottom Flat
Lid size, mm (inch) 610 (24)
Fittings, mm (inch) 100 (4”) flanged style inlet at top, 100 (4”) flanged style fitting for level on dome, 100 (4”) flanged overflow fitting, 2 x 100 (4”) spare flange style
fittings at top, 100 (4”) flanged outlet, 150 (6”) U-vent, 50 (2”) flanged fitting for reverse float level gauge, Reverse float level gauge included with
vertical support assembly
Ladder, m (ft) FRP ladder, height 4 (12)
Examples of Installations - Sarnia WWTP Alum Building – 2 x 6500 gal tanks for alum
- Alvinston WTP - 1000 gal tank for alum - Brigden PS – 5300 gal tank for alum - Owen Sound -5100 gal tank for sodium
hypochlorite - Tottenham WWTP – 2 x 8700 gal tanks for
alum and caustic - Sudbury Biosolids – 8050 gal tank for
ammonium hydroxide - Muskoka – Bracebridge WTP – 475 gal
tank for fluoride - Springwater Vespra WWTP – 3 x 4150 gal
tanks for alum
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Six (6) or nine (9) smaller tanks:
Table 3-8 Description of HDPE tanks (Quantity: 6 or 9)1
Specification Value
Description 6 tanks 9 tanks
Diameter, m (ft-inch) 2.16 (7’-1”) 1.85 (6’-1”)
Height, m (ft-inch) 3.15 (10’-4”) 2.92 (9’-7”)
Construction Pre-Fabricated Pre-Fabricated
Bottom Flat Flat
Volume, m3 (gallons) 9.65 (2550) 6.43 (1700)
Fittings 100 (4”) flanged style inlet at top, 100 (4”) flanged style fitting for level on dome, 100 (4”) flanged overflow fitting, 2 x 100 (4”) spare flange style fittings at top, 100 (4”) flanged outlet, 150 (6”) U-vent, 50 (2”) flanged fitting for reverse float level gauge, Reverse float level gauge included with vertical support assembly
100 (4”) flanged style inlet at top, 100 (4”) flanged style fitting for level on dome, 100 (4”) flanged overflow fitting, 2 x 100 (4”) spare flange style fittings at top, 100 (4”) flanged outlet, 150 (6”) U-vent, 50 (2”) flanged fitting for reverse float level gauge, Reverse float level gauge included with vertical support assembly
Ladder, m (ft) FRP ladder included, height 3.05 (10)
FRP ladder included, height2.74 (9)
1 New FRP access structure and piping would be required.
3.2.3.2 Constructability Installation of two (2) HDPE tanks (each 30 m3): Due to limited accessibility to the ammonia storage room, the celling of the ammonia storage room would be demolished to provide accessibility to this room. After the installation of the tanks, roof should be reconstructed. However, if required, this option does not allow any future possible tank replacement. Please refer to section 3.3.2 for more details. Installation of six (6) or nine (9) HDPE tanks (each 9.65 m3 or 6.43 m3 respectively): there are two feasible ways to bring these pre-fabricated FRP tanks to the ammonia storage room: 1) Expanding the existing hatch located in the ammonia storage room to provide permanent access to the chemical storage area 2) Using the north corridor and overhead monorails in the existing Decant Tank Service room. Please refer to section 3.2.2 for more details. It should be noted installation of six (6) or nine (9) tanks would require a more complicated operation and maintenance process.
Figure 3-2 HDPE tanks
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3.2.3.3 Capital Cost The following table presents the capital cost associated with different HDPE tanks:
Table 3-9 Capital cost for HDPE tanks1
Tank Material – Construction Capital cost
Pre-Fabricated HDPE tanks (2 tanks, each 30 m3) $ 20 400.00/tank2
- Optional adder for IMFO3 $ 7300.00 (for 2 tanks)
- Add 4m x 4m opening above Chemical Room 3 (engineering cost included)
$ 125 000.00
Pre-Fabricated HDPE tanks (6 smaller tanks) $ 11 150.00/tank2
- Optional adder for IMFO $ 11 500.00 (for 6 tanks)
Pre-Fabricated HDPE tanks (9 smaller tanks) – IMFO not available for this option
$ 8 100.00/tank2
- Add 2.5m x 2.5m opening above Chemical room 3 (engineering included)
$ 85 000.00
- OR: Transport tanks using monorail (engineering included)
$ 50 000.00
New FRP access structure, pipes and valves (assumed cost)
$ 25 000.00
Delivery Cost for 2, 6 or 9 tanks $ 7 500.00 1 All option would require provision for new FRP access structure, pipes and valves. 2 Installation and delivery cost is not included 3 Integrally Molded Flanged Outlet
3.2.4 Option 4: Cast-in-Place Concrete Tank
3.2.4.1 Technical Specifications With the existing hatch opening in the ceiling of Chemical Room 3, new cast-in-place concrete tanks would be constructed on site. A liner system is required inside the concrete tank for ammonia storage. Two (2) concrete tanks with a total volume of 60 m3:
Table 3-10 Description of Cast in place Concrete tanks
Specification Value
Width x Length 3.6m x 5m
Height 2m
Construction Cast-in-place
Bottom 400 mm thick
Wall 350 mm thick
Ladder 2m high FRP access ladder
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3.2.4.2 Constructability According to record drawings, the floor slab is capable of sustaining 25kPa/m2 of live load. The self-weight of reinforced concrete tanks is much higher than that of stainless steel or FRP tanks. For holding a same amount of ammonia liquid, the footprint of the new concrete tanks will need to be greater than the existing tank footprints in order to lower the liquid level inside the tanks to compensate for the increased self-weight. A liner system is also required inside the concrete tank for ammonia storage. 3.2.4.3 Capital Cost Table 3-11 Capital cost for Cast-in Place Concrete
1
Concrete Tank $ 85 000.00/tank2
Option 1: Flexible PVC closed top liner (Pre-fabricted)
Option 2: Chemical Resistant Coating (installed in-situ)
$ 16 000.00/tank
$ 25 000.00/ tank3
New FRP access structure, pipes and valves (assumed cost)
$ 25 000.00
1 Option would require provision for new FRP access structure, pipes and valves 2 Installation and delivery costs are included 3 Material and installation cost. Safety setup and travelling expenses would be additional.
3.2.5 Option 5: Steel Tank
3.2.5.1 Technical Specifications This option includes the installation of two (2) Steel tanks with a total volume of 60 m3 (each 30 m3). These types of tanks are made of Glass Fused Steel panels which would be bolted on site. The arrangements of the bolts are different from other types of tanks which allow the steel panels to overlap each other and ensure complete seal. After the construction, they would be water tested on site to ensure there is no leakage. This type of tanks has been used for several applications e.g. in anaerobic digestion at Disco Road and Vanley Crescent Green Bin Facility (Ontario); Table 3-12 describes the specification of this option.
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Figure 3-3 Glass Fused to Steel Tanks with Roofs, Disco Road Facility, Toronto, ON
Table 3-12 Description of Glass Fused Steel Tanks
Specification Value
Diameter 4.27 m
Height 3.1 m
Material Permastore Model 1410 Glass-Fused-to-steel1
Construction Bolted on site
Other Inclusive of ancillaries as required
Examples of Installations
- Anaerobic Digesters & Sequencing Batch Reactors, Disco Road Facility, Toronto, ON
- Reverse Osmosis Water Storage, Bienfait Activated Carbon, Estevan, SK
- Moving Bed Bioreactor & Other Tanks, British Columbia
- Process/Fire Water Tank, Northland Power, North Battleford, SK
1 Refer to Appendix A for technical data and material specification.
3.2.5.2 Constructability This tank would be constructed on site at the ammonia storage room. The glass-fused steel panels (each 1.52 m x 2.44 m) would be delivered to the site and assembled (bolted) in the ammonia storage room. Please refer to section 3.3.1 for further details.
3.2.5.3 Capital Cost Table 3-13 Capital cost for Steel tanks
Tank Material – Construction Capital cost
Glass-Fused-to-steel bolted steel tank (2 tanks, each 30 m3)
$ 66 000.00 /tank1
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Total Delivery Cost for two tanks $ 22 000.00
Flexible PVC closed top liner $ 16 000.00/tank
Modification to existing tank FRP access structure pipes and valves (assumed cost)
$ 5 000.00 2
1 Installation cost is included 2 Option requires p some modification to the existing FRP access structure (platform), piping and valves.
3.3 Constructability 3.3.1 Field Assembled Tanks Due to limited accessibility to the ammonia storage room, small tank parts would be produced at shop and transported into the chemical room through access man doors (1m wide x 2.2m high). The small parts would then be assembled using either field welding (e.g. stainless steel tanks) or bolted connections (e.g. FRP tanks and glass-fuse steel tanks). The welded tanks provide higher joint quality than those bolted. The costs of field assembled tanks would be higher than the shop fabricated tanks because field assembled tanks would need a customized design. The field welded tanks would require more thorough and extensive quality control and testing of welded joints.
3.3.2 Shop Fabricated Tanks Shop fabricated tanks (all discussed materials) could be purchased at a lower price. However, tanks cannot be delivered into the chemical storage room without provision of some modifications to the existing structure.
Option 1 A large opening in the ceiling of Chemical Room 3 would be added to allow for transportation of the tanks into the room. Addition of this new opening would compromise the integrity of the roof structure; therefore a detailed review of the existing underground structure and a structural analysis of the existing roof slab with the new opening would be required. Depending on the size of the new opening, it is likely that the existing roof would require reinforcing around the opening. Considerations should be given to install some steel beams under the existing roof slab to transfer loadings to existing roof beams and columns prior to cutting the new opening. New concrete curbs around the opening and a top cover with proper roof waterproofing and insulation would also be required since the existing roof slab is buried below grade. With this option, the new opening could be utilized to add or remove tanks in the future. Option 2
Another option is to transport the tanks through the north corridor using the existing 2.0-tonne overhead monorails inside the Decant Tank Service Room. The tanks would be transported through the Service Building into the RMF recycle area, then being picked up by the existing overhead monorails through an existing floor opening (2.825m wide x 4.18m long) at the Decant Tank Service Platform. The existing wall openings (1.5m wide x 2.31m high) in the dividing walls (1.1m thick) between the Decant Tank Access Room and the recycle area have to be enlarged to allow the passage of the tanks. A new opening would be added in the dividing wall (300 mm thick) located between the Decant Tank Access Room and Chemical Room no. 3. This opening is to be sealed and covered for
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future use. Some of the existing guard railings along the north corridor would be temporarily removed to allow the passage of the tanks; they would be reinstalled after the tanks have been installed. A new monorail system would be needed to transport the new tanks from the Decant Tank Access Room to the chemical room.
Both of the above options provide permanent access to the chemical storage area Therefore, any future maintenance and replacement could be performed through the expanded hatch or the openings provided in the north corridor.
4. EVALUATION OF OPTIONS The Table 4-1 is a summary of all the options of tanks along with their specifications and capital cost.
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Table 4-1 Evaluation of different tank materials, fabrication, constructability and their associated costs 5,6
Evaluation Criteria Qty. Liner Constructability Filing
Protocol Future
Removal/ Replacement
Maintenance Level and Operation
Life Expectancy Warranty Leakage Platform
Modifications Liner Cost per tank
Cost per each Tank
Total Delivery Cost
Estimated Total
Installation Cost
Constructability Cost
Estimated Capital Cost Supplier
Stainless Steel 1
2 No
Welded on site/access man doors or existing
openings
Same as existing
conditions Not possible Low 40-50 years 2 years No
Minor
Cost: $ 5 000.00
N/A 316 SS: $ 62 500.00 included Included N/A $ 130 000.00 10-Tech Industrial
Inc.
2 No Pre-Fabricated/
opening the ceiling
Same as existing
conditions Not possible Low 40-50 years 2 years No
Minor
Cost: $ 5 000.00
N/A 316 SS: $ 76 800.00 11 000.00 $ 46 000.00 $125 000.00 $ 340 600.00 Can-AM Instrument
FRP4
2 No Pre-Fabricated/
opening the ceiling
Same as existing
conditions Not possible Low 25 years 1 year No
Minor
Cost: $ 5 000.00
N/A $ 40 000.00 $ 8 000.00 $ 25 000.00 $ 125 000.00 $ 243 000.00 Can-AM Instrument
6 No
Pre-Fabricated/ expansion of the existing hatch or
north corridor
Require additional piping and
connections
Possible Moderate 25 years 1 year No
New Platform
Cost: $ 25 000.00
N/A $ 12 500.00 $ 8 000.00 $ 25 000.00 Option 1: $ 85 000.00 Option 2: $ 50 000.00
Option 1: $ 218 000.00 Option 2: $ 183 000.00
Can-AM Instrument
HDPE
2 No Pre-Fabricated/
opening the ceiling
Same as existing
conditions Not possible Low 20 years 5 years No
New Platform
Cost: $ 25 000.00
N/A $ 20 400.00 $ 7 500.00 $ 12 500.00 $ 125 000.00 $ 210 800.00
ACO Container Systems
Ltd.
Metcon sales &
engineering Ltd.
6 No
Pre-Fabricated/ expansion of the existing hatch or
north corridor
Require additional piping and
connections
Possible Moderate 20 years 5 years No
New Platform
Cost: $ 25 000.00
N/A $ 11 150.00 $ 7 500.00 $ 20 000.00 Option 1: $ 85 000.00 Option 2: $ 50 000.00
Option 1: $ 204 400.00 Option 2: $ 169 400.00
Metcon sales &
engineering Ltd.
9 No
Pre-Fabricated/ expansion of the existing hatch or
north corridor
Require additional piping and
connections
Possible High 20 years 5 years No
New Platform
Cost: $ 25 000.00
N/A $ 8 100.00 $ 7 500.00 $ 22 000.00 Option 1: $ 85 000.00 Option 2: $ 50 000.00
Option 1: $ 212 400.00 Option 2: $ 177 400.00
Metcon sales &
engineering Ltd.
Concrete 2 Yes
On site access man doors or
existing openings
Same as existing
conditions Not possible Low 50 years8 - Possible 3
New Platform
Cost: $ 25 000.00
$ 16 000.00 $85 000.007 Included Included N/A $ 227 000.00 -
Steel (Glass-Fused)
2 Yes
Bolted on site/ access man
doors or existing openings
Same as existing
conditions Possible Low 30 years 5 years Possible2
Minor
Cost: $ 5 000.00
$ 16 000.00 $ 66 000.00 $ 22 000.00 $ 66 000.00 N/A $ 257 000.00 H2flow
1 Field testing would be required for SS tanks 2 Steel tanks are bolted therefore there is a possibility for leakage. 3 Concrete tanks require a liner. Liners are susceptible to corrosion. 4 Extended Warranty can be provided at an extra cost – To be confirmed during the detailed design phase. 5 For the complete cost of the preferred option, please refer to Appendix B – Please note that all cost estimates have an accuracy of -15% to +25% 6 Please note that the cost of the following items has not been included in this table: modification to pipes and valves, scrubber, emergency scrubber, electrical & control, programming and updating PCN, general requirements, etc. Please refer to Appendix B 7 Including engineering fee 8 This is the life expectancy of the concrete tanks.
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. 5-1
5. Ammonia Scrubber The existing ammonia storage room does not have any ammonia scrubbing system in place to prevent any chemical leakage or to control the ammonia fumes in the storage room during filling and normal operation. Therefore, in this section we have proposed two types of scrubbers:
5.1 Option 1: Wet Scrubber Figure 5-1 is an indication of this type of scrubber which uses water as for scrubbing liquid. Ammonia fumes are forced counter current upwards through the water irrigated 1.8 m (6 ft.) deep packed bed. Meanwhile, scrubbing liquid is distributed at the top section of the packed bed and trickles downward through the bed where contaminants get separated from the gas phase. The clean gas passes through a mist eliminator as it exits upward from the scrubber and the scrubbing liquid is collected at the bottom of the unit in the recirculation sump.
Figure 5-1 Wet Scrubber description
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. 5-2
The unit has a passive operation with a nominal capacity of 20 L/s (40 cfm) (dimensions: diameter of 150 mm (6”) and height of 3.76 m (148”)). The tower is made from FRP with polypro internals such as spray nozzles, mist eliminator pas and packing. Water demand is 0.05 L/s (0.75 gpm) fresh water at 70 kPa (10 psig) or higher once through the waste. To install the system, a mounting rubber pad is required to be placed at the bottom section of the FRP tank. Hold-down lug anchors are also required.
The tank vent pipes would be connected to the scrubber inlet port. While the tanks are filled with ammonia, the fumes would be discharged to the scrubber for ammonia stripping. The generated ammonia-water solution would be pumped out to the water treatment process. A new pump, fan, basin, water service, process discharge, electrical and control equipment would be provided for the facility operation. The entire process would be controlled by PLC.
The following table indicates the cost of a wet packed tower scrubber.
Table 5-1 Capital cost for wet packed tower scrubber
Scrubber Type Cost
Wet Packed Tower Scrubber – Type 955 $ 37 000.001
Delivery Cost (included) Included ($ 525.00)
House Keeping Pad $ 2 000.00
Air Ducts $ 2 500.00
Micsellanous (pump, fan, valves, pipes, controls, assumed)
$ 10 000.00
Estimated Installation Cost $ 7 500.00
Total Cost $ 59 000.00 1 Installation cost not included, the supplier has confirmed the cost of this supply which does include the delivery cost and the system requirements
5.2 Option 2: Dry Scrubber Figure 5-2 is an indication of VEGA-PA dry scrubber (by Severn Trent) with dry carbon media (by Purafil Inc.) impregnated with phosphoric acid. This unit has a diameter of 34” and a height of 65.02” with an ammonia vapor capacity of 200 days, which can be installed indoor. Ammonia gasses enter from the bottom part of the system through a 38 DIA (1.5”) vapor line and pass through the dry carbon media impregnated with phosphoric acid. Clean gas exits from the top 75 DIA (3”) vapor outlet.
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. 5-3
Figure 5-2 Passive NH3 Dry Scrubber system
Table 5-2 indicated the cost for this type of dry scrubber.
Table 5-2 Capital cost for passive NH3 dry scrubber system
1 Installation cost not included, the supplier has confirmed the cost of this supplier which does include the delivery cost and the system requirements
Another type of media which can be used for ammonia gas scrubbing is Puracarb AM media. This unit contains 0.5 m3 (17 cu ft), of this media for the removal of ammonia gas through adsorption, absorption and chemical reactions and it is sized for airflows up to 0.24 m3/s (500 cfm) with a 1.5 horsepower motor (inlet diameter: 200 mm (8“)). As ammonia gas passes through the media, it gets trapped within the pellets where chemical reactions prevents them from desorption. This type of media has a 5.8% removal capacity (by weight) of ammonia with an overall media performance of minimum 99.5% initial removal efficiency. Figure 5-3 indicated DS-500 Drum Scrubber for this application.
Scrubber Type Cost
VEGA-PA dry scrubber $ 37 000.001
Delivery Cost (included) Included ($ 575.00)
House Keeping Pad $ 2 000.00
Air Ducts $ 2 500.00
Micsellanous (assumed) $ 2 000.00
Estimated Installation Cost $ 5 000.00
Total Cost $ 48 500.00
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. 6-4
Figure 5-3 Purafil Inc., Model DS-500 Drum Scrubber
If this system is exposed to water droplets, the media performance will diminish. Therefore this system would be accompanied with a mist eliminator on the air inlet to prevent the entry of water to the system. The following table indicates the cost of this type of scrubbers.
Table 5-3 Capital cosy for Purafil Inc., Model DS-500 Drum Scrubber
1 Price includes freight charges. Installation cost is not included.
6. PROCESS PIPING MODIFICATION Existing pipes, valves and fittings would need to be modified or replaced to suit new tank layout. This includes the connection to the existing chemical dosing system, fill line, vent line, overflow, drain, new scrubber, etc. These modifications would be completed after the tank layout is confirmed.
Scrubber Type Cost
Purafil Inc., Model DS-500 Drum Scrubber - c/w 1.5 HP TEFC motor, 6 ft. power cord
$ 13 695.001
Explosion proof fan motor (Optional) $ 1 125.00
Delivery Cost (included) Included
Mist eliminator (Optional) $ 2 434.00
House Keeping Pad $ 2 000.00
Air Ducts $ 2 500.00
Miscellaneous (assumed) $ 2 000.00
Estimated Installation Cost $ 5 000.00
Total Cost $ 28 754.00
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. 8-5
7. VENTILATION REQUIREMENTS 7.1 Existing Ventilation The existing ventilation system in the ammonia storage room consists of an air supply and exhaust systems.
The air supplied through an air handling unit (AHU-6801) located above the clarifier thickener tank area. The AHU is servicing all chemical rooms by providing pre-heated air through a common duct header. Air is discharged to the ammonia room via two (2) horizontal diffusers with a dimension of 500 x 400 mm (W x H) which are installed in the duct. The diffusers are located on the south wall of the room.
The air from the room is exhausted via two (2) exhaust louvers with a dimension of 900 x 600 mm (W x H) located on the north wall. The exhaust louver ducts are connected to a common 700 x 450 mm exhaust duct, which is, in turn, connected to a suction side of the exhaust fan (EF-6815).
During the normal operation of the system, air is supplied at a rate of 1,414 L/s (or 6.6 air changes per hour – ACH) to the ammonia storage room and exhausted at a rate of 1,420 L/s. Since the rate of air exhaustion is greater than the rate of air supply, the pressure of the room is maintained at a negative level. This prevents ammonia vapors escaping to the adjacent premises.
In case of an emergency, EF-6815 has been designed to run at a high speed, providing 2,356 L/s (11 ACH).
7.2 Future Ventilation Requirements The existing ventilation system discharges air to outdoors without any pre-treatment. In case of an emergency, EF-6815 switches to a high speed.
For future, it is recommended to install a dry activated carbon scrubber at the exhaust side of EF-6815 for ammonia sorption.
8. CONCLUSIONS AND RECOMMENDATIONS As confirmed by the City, structural modifications to the existing ammonia storage room would not be an acceptable option. Three of the main reasons are as follow: structural modifications would compromise the load capacity of the roof system, the new structural joints would be prone to potential leaks in the future and it is not a cost effective approach. Since installation of pre-fabricated tanks requires modifications to the existing structure, they would not be considered for upgrading the existing wood stave ammonia tanks.
The other three (3) remaining options (e.g. concrete tank, glass-fused tank and stainless steel tank) are discussed and summarized as follows:
- Concrete tank is a very heavy structure and requires an internal liner or a chemically resistant coating on the concrete, therefore, it would be a similar arrangement as the existing tanks – this option is declined.
- Glass-fused tank, assembled on site (by bolting and gasketing), may have leakage through the gaskets, requires an internal liner and it is relatively expensive - this option is also declined.
- Site-fabricated stainless steel tank does meet major City’s requirements; the welded joints of the tank provide a high degree of chemical isolation and an internal liner is not required.
The following recommendations are provided:
- In order to maintain the operation of the facility, the existing tanks would be removed one-by-one. Therefore, at all times one of the tanks would be in operation.
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. 9-6
- Two (2) identical tanks (28 m3 each) would be supplied and fabricated in the ammonia storage room (one-by-one). Construction material of the tanks would be 316L stainless steel.
- The new tank configuration would be the same as the existing tanks (diameter, height, nozzles layout, instrument layout, etc.).
- The existing RFP access structure (platform) would be re-used (some minor modification may be needed and is to be confirmed during design phase).
- A new wet scrubber would be provided in the ammonia storage room; the scrubber would be connected to the tank vent pipes and used during filling and discharging operations.
- For emergency situations, a new dry scrubber would be provided and connected to the exhaust of EF-6815.
- Modifications to existing pipes and re-commissioning controls and provisions for new controls would be required.
9. SUMMARY This technical memorandum discusses five (5) different types of martial for aqueous ammonia storage tanks. The new tanks are required for replacing the existing wood stave tanks, currently used for the storage of aqueous ammonia.
Based on the City’s requirement (provisions for the facility upgrading without structural modification and a cost effective option), on-site fabrication of two (2) new stainless steel tanks with similar dimensions and capacity as the existing ones is recommended. These tanks should be supplied and fabricated one-by-one to maintain the continuous operation of the ammonia facility.
In order to control the ammonia fumes during the filling and regular operations, two (2) types of ammonia scrubber systems (wet and dry scrubbers) are discussed. The dry-type scrubber is recommended.
In the event of a chemical leakage at the RC Harris WTP ammonia storage room, a new dry scrubber is recommended to be installed in the EF-6815 exhaust duct.
The preliminary construction cost estimate for the Replacement of Existing Aqueous Ammonia Tanks project would be $ 484 000.00 including engineering (20%), Contractor’s overhead (10%) and contingency (10%). Please refer to Appendix B for the associated cost breakdown.
The cost estimate has been prepared using cost data from similar recent projects. The cost estimates were prepared to be between -15% and +25% accuracy.
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. 9-7
APPENDIX A EQUIPMENT TECHNICAL DATA
575.0900.0Formerly 575.0040
Severn Trent Services
3000 Advance Lane Colmar, PA 18915
Tel: 215-997-4000 • Fax: 215-997-4062
Web: www.severntrentservices.com
E-mail: [email protected]
Copyright 2006 Severn Trent Services08/06
Represented by:
Design improvements may be made without notice.
575.0900.0 - 2 -
Technical Information
Properties
NCSH-06-05-05-11
Product Disclaimer Dyno Nobel Inc. and its subsidiaries disclaim any warranties with respect to this product, the safety or suitability thereof, or the results to be obtained, whether express or implied, INCLUDING WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND/OR OTHER WARRANTY. Buyers and users assume all risk, responsibility and liability whatsoever from any and all injuries (including death), losses, or damages to persons or property arising from the use of this product. Under no circumstances shall Dyno Nobel Inc. or any of its subsidiaries be liable for special, consequential or incidental damages or for anticipated loss of profits.
Dyno Nobel Inc.2795 East Cottonwood Parkway, Suite 500, Salt Lake City, Utah 84121 USAPhone 800-732-7534 Fax 801-328-6452 Web www.dynonobel.com
AQUA AMMONIAAmmonium Hydroxide
Product DescriptionAQUA AMMONIA, aqueous ammonia and ammonium hydroxide are synonymous terms referring to a solution of ammonia in water. Aqua is a high purity solution produced using demineralized water and is suitable for applications that require low levels of trace minerals. This product is used in stack emission control systems to neutralize sulfur oxides from combustion of sulfur-containing fuels and as a method of NOx control in both catalytic and non-catalytic applications. It is also used for pH control, nutrient for waste disposal systems and wood treating.
Application Recommendations• AQUA AMMONIA is used as a source of ammonia and is the preferred form for
users who need to avoid the storage of the compressed gas, which is considered to be more hazardous.
• AQUA AMMONIA can be injected as a liquid into various process streams and quickly vaporized with the addition of heat into water vapor and gaseous ammonia. It also is used as a base to neutralize acidic conditions in various chemical processes.
Transportation, Storage and Handling• AQUA AMMONIA is transported in tanker trucks suitable for hauling corrosive
materials. The trailers are constructed of stainless steel since AQUA AMMONIA is corrosive to carbon steel.
• Storage containers must ALWAYS conform to all applicable requirements for the locale and generally have some type of vapor recovery system for the ammonia fumes. Tanks are most generally constructed of stainless steel or carbon steel with a non-corrosive liner.
• When handling, ALWAYS use approved personal protective equipment, gloves goggles, face shield, boots and water impervious clothing.
MSDS#1130
Total Ammonia by weight typical 19% 30%
Total Ammonia, % by weight minimum 18.5 29.4
Chloride, ppm typical <1 ppm <1 ppm
Sodium, ppm typical <1 ppm <1 ppm
Phosphate, ppm typical <1 ppm <1 ppm
Sulfate, ppm typical <1 ppm <1 ppm
Nitrate, ppm typical N/A <1 ppm
Heavy Metals, ppm typical <1ppm <1ppm
Iron, ppm typical N/A <1 ppm
Specific Gravity, @ 60oF 0.9293 0.896
Approximately Density, @ 60oF (lbs/gal) 7.74 7.47
Boiling Temperature, °F 120.6oF 83.5oF
Freezing Temperature, °F -28oF -119oF
Vapor Pressure, @ 100oF (psia) 9.0 22.0
Physical Form Liquid Liquid
Color Clear Clear
Hazardous Shipping Description• AQUA AMMONIA is defined as DOT hazard class 8, corrosive. The trailers must be
placarded with the corrosive label and also display the international transportation number UN2672.
• A spill of 1,000 pounds or more is a reportable quantity (RQ) pursuant to CERCLA Section 311 of the Clean Water Act.
• Consult MSDS #1130 for more specific and comprehensive information about chemical hazards.
Chemical Storage Tank Systems And AccessoriesProduct and Resource Guide
Pre-Purchase Guide 35
chemical resistance Guide 36
limited Warranty 37
tank sPecifications 38
our tank offerinGs 39
safe-tank® system 41
Vertical tanks With imfo® 42
Vertical tanks 43
cone-Bottom tanks 44
oPen-toP tanks 45
secondary containment Basins 46
horizontal tanks 47
fittinGs and accessories 48
fittinGs 49
PlumBinG 53
manWays/lids 58
accessories 60
restraints 62
Vents 63
deliVery 64
introduction 1
Who is Poly ProcessinG? 2
aBout XlPe 4
nsf certification 5
our innoVations 6
or-1000™ 6
imfo® 7
safe-tank® 8
the B.o.s.s.™ 9
safe-surge™ manWay coVers 9
enhanced BelloWs transition fittinGs 9
our tank systems 10
sodium hyPochlorite 11
sulfuric acid 15
hydrochloric acid 19
additional chemicals oVerVieW 23
sodium hydroXide 25
hydrofluoric acid 27
hydrofluosilicic acid 29
ferrics, alums and Polymers 31
hydroGen PeroXide 33
Table Of Contents
1
IntroductionWhen chemical storage solutions are smarter, your job is easier.
INTRODUCTION
That is our goal at Poly Processing – to bring you safer, smarter tanks and fittings that make chemical storage easy for you.
We do this by basing our systems on your processing needs. At Poly, each storage system is designed specifically for the chemical it will contain. So issues like fuming, temperature sensitivity, weight and chemical reaction are all used to create the ideal storage situation, at drawing-board level.
We’ve been pioneers in rotational molding – and that has led to one of the most durable and affordable solutions for chemical storage: high-density crosslinked polyethylene, or XLPE. This thermoset resin gives you 20 times the environmental stress crack resistance, 10 times the molecular weight and 5 times the impact and tensile strength of standard high-density linear polyethylene.
Our IMFO® (Integrally Molded Flanged Outlet) tanks give you the capability for full drainage, which makes sludge buildup easier to control. Our B.O.S.S.™ fitting is designed for a sure seal, with a simplified structure that prevents leakage. Our SAFE-Tank® double-wall tanks provide containment with a minimal footprint. And our OR-1000™ engineered system gives you 4 times the antioxidant strength of a standard polyethylene.
Combine those innovations with bend-over-backwards service, and you get a true partner in advanced chemical storage.
Who Is Poly Processing?
Known as a leader in crosslinked polyethylene chemical tanks, Poly Processing is a company dedicated to storage safety, as well as operational- and cost-effectiveness. This national company has worked to raise the standards of the industry and continually develops new and better storage concepts that are based on client feedback.
Formerly known as the Abell Company, Poly was founded in 1955 as an agricultural distribution service. In 1970, the Abell family recognized a need for better storage solutions for corrosive chemicals. They developed a process for rotomolded, crosslinked plastic storage as an alternative to FRP, stainless steel and lined steel. Today, Poly Processing has manufacturing facilities in Louisiana, California and Virginia.
Poly Processing works with industry professionals and major educational facilities to research and develop further advances in chemical storage.
While Poly is known for its technological innovations, it is also known for its human approach to business and service. Here, every phone call is answered by a person, not a machine – and customer service is at the heart of all we do.
2
3
WHY POLY PROCESSING
4
About XLPE
High-density crosslinked polyethylene, or XLPE, is a thermoset resin that is specifically designed for critical applications like chemical storage. During the XLPE manufacturing process, a catalyst (peroxide) is built into the resin, which creates a free radical. The free radical generates the crosslinking of the polymer chain, so the tank essentially becomes one giant molecule. The result is a resin that is specifically designed for critical chemical applications.
XLPE versus Linear Polyethylene
• XLPE has 20 times the environmental stress crack resistance of HDPE.• It has 10 times the molecular weight of HDPE.• It has 5 times the impact and tensile strength of HDPE.
XLPE versus Fiberglass-Reinforced Plastic (FRP)
• XLPE offers seamless construction for greater strength.• With FRP, chemicals can wick into the fiber, compromising tank life.• XLPE can have a lower cost of ownership, due to the low amount of required maintenance compared to FRP.• FRP often requires special handling to avoid cracking.
XLPE versus Carbon and Stainless Steel
• XLPE has seamless one-piece construction, which eliminates the potential for chemical attack points and bad welds.
• Unlike carbon and stainless steel, XLPE has very broad chemical resistance capabilities without the need for high-cost coatings.
• XLPE does not require ongoing maintenance and inspection.• XLPE is a cost-effective solution to high-priced alloys.
5
NSF/ANSI Standard 61 addresses crucial aspects of drinking water system components – and Poly Processing is the ONLY company offering storage tanks certified to NSF/ANSI 61 standards for chemical storage. Most products are tested under NSF-61 with the pH 5, pH 8 and pH 10 exposure waters defined in the standard. These exposure waters were designed to simulate the wide variety of potable water chemistries encountered across North America. However, these exposure waters were not designed to predict leaching of materials in chemical storage tanks. Poly Processing’s OR-1000™ products have been tested with the NSF-61 exposure waters, as well as with corrosive chemicals, to ensure they are safe for potable water use.
Poly Processing offers NSF-certified solutions for the storage of:
Talk to your Poly Processing representative to find out more – or visit our website, www.polyprocessing.com, to review our NSF white paper.
We’re The Only Companywith chemical tanks certified to NSF/ANSI 61 standards!
WHY POLY PROCESSING
Acetic Acid ≤ 80%
Aluminum Sulfate ≤ 50% (Alum)
Calcium Carbonate 60–100%
Calcium Chloride ≤ 30%
Chlorine Dioxide ≤ 38%
Citric Acid ≤ 100%
Copper Sulfate ≤ 25%
Deionized Water
Ferric Chloride ≤ 50%
Ferric Sulfate ≤ 60%
Ferrous Chloride ≤ 37%
Ferrous Sulfate ≤ 30%
Hydrochloric Acid ≤ 37%
Hydrofluoric Acid ≤ 52%
Hydrofluosilicic Acid ≤ 30%
Liquid Ammonium Sulfate 35–45%
Magnesium Chloride ≤ 35%
Phosphoric Acid ≤ 75%
Poly Aluminum Chloride ≤ 100%
Polyorthophosphate ≤ 100%
Potable Water
Potassium Hydroxide ≤ 50%
Sodium Aluminate ≤ 100%
Sodium Bisulfite ≤ 40%
Sodium Carbonate ≤ 85%
Sodium Chlorite ≤ 34%
Sodium Hydroxide ≤ 50%
Sodium Hypochlorite ≤ 0.08%
Sodium Hypochlorite ≤ 15%
Sodium Permanganate ≤ 40%
Sodium Silicate ≤ 100%
Sulfuric Acid ≤ 98%
Zinc Orthophosphate ≤ 100%
6
OR-1000™An inner-surface technology for four times the antioxidant power.
Poly Processing’s exclusive OR-1000™ system was specifically designed to address the aggressive oxidation effects of sodium hypochlorite, sulfuric acid and hydrochloric acid by adding an additional chemical barrier between XLPE and the chemical. OR-1000’s engineered inner surface is made of medium-density polyethylene, specifically formulated to resist oxidation. Its outer surface is made of XLPE for superior strength. The 2 surfaces are molecularly bound together during the rotomolding process, creating a truly seamless bond between the XLPE and the inner surface.
The advantages of OR-1000™:
• The result gives you 4 times the antioxidant strength of any polyethylene on the market today!
• All wetted surfaces are covered by OR-1000™, eliminating the opportunity for a chemical attack on the structural portion of the tank.
• OR-1000™ can be used on any of our tanks, including SAFE-Tank® and IMFO® tank systems.
7
OUR INNOVATIONS
Innovative Tank SolutionsIMFO®: integrally molded for major hazard control.
Traditional tank maintenance can be a challenge with many chemicals – so Poly has developed a unique system that helps minimize the hazards associated with traditional vertical tank maintenance. With Poly’s Integrally Molded Flanged Outlet, or IMFO® system, the flange is molded while the tank is processing, making it a stress-free part of the tank. The flange is created from the same material as the tank – it’s not an insert introduced during or at post-production.
The IMFO’s advantages are many:
• Since the flange is at the bottom of the tank, full drainage is achieved below the tank knuckle radius, which can eliminate the need to enter the tank for cleaning.
• One-piece construction enhances long-term performance of the tank, since it doesn’t compromise the tank hoop’s integrity or structural design.
• In aggressive applications, the complete flange face is protected by the antioxidant OR-1000™ system.
• The IMFO’s design brings you the highest amount of static head pressure, which contributes to the highest net positive suction head (NPSH) of any vertical non-coned tank.
Innovative Tank SolutionsSAFE-Tank®: a complete system for secondary containment.
Poly Processing’s SAFE-Tank® is a “tank-within-a-tank” system that keeps contaminants from entering the interstitial area. These tanks provide secondary containment to avoid the damaging of equipment or property, loss of chemical, or injury to employees in the event of a spill.
The SAFE-Tank®:
• Provides 110% secondary containment.
• Will equalize the liquid and allow the chemical to be continually used until it is convenient to repair the tank.
• Is ideal for chemicals like sulfuric acid that can have dangerous exothermic reactions to water.
• Eliminates the expense, cost and maintenance of secondary concrete containment.
• Minimizes the system’s footprint by providing secondary containment in a more compact way.
• Adding and enhanced bellows transition fitting will maximize your SAFE-Tank® system's performance.
SAFE-Tank® systems (see page 41 for details) are also available with OR-1000™ for superior antioxidant resistance.
8
9
Our Other Innovations
THE B.O.S.S.™: A Simple Design For Better Leak Protection.
With its streamlined one-piece design, the B.O.S.S.™ (bolted one-piece sure seal) reduces the seal point to a single gasket to greatly reduce chances for leakage. This unique fitting:
• Is constructed of polyethylene for chemical compatibility with your tank.
• Has an innovative backing ring design to reduce stress on the fitting and make it three times stronger than plastic fittings.
• Is easy to maintain and troubleshoot since the pipe connection is extended beyond the sidewall of the tank.
• Is available in 1, 2 and 3 inches I.D.
The B.O.S.S.™ is available in three alloy options: 316 stainless steel, titanium and C-276. It comes fully assembled and pressure tested and can be installed through the tank wall as with any other standard bulkhead fitting. See page 49 to find out more.
SAFE-Surge™ MANWAY COVERS: Emergency Air Surge Protection For Pneumatic-Filled Tanks.
Poly’s SAFE-Surge™ manway covers ensure that your tank maintains the proper ACFM at all times – even in the event of air surges that can’t be handled by primary venting. This system was designed specifically for pneumatic-filled tanks. SAFE-Surge™:
• Is never to be considered part of your primary venting.
• Releases at a 6-inch water column to prevent over-pressurization.
• Features an easy inspection port.
• Is available for 19- and 24-inch manways.
This cover is REQUIRED in pneumatic filling operations excluding scrubbers. For detailed venting requirements, please refer to the chart on page 63.
ENHANCED BELLOWS TRANSITION FITTINGS: A Secure Yet Flexible Fully Contained SAFE-Tank® Bottom Discharge.
By incorporating an expansion joint, the tank expands freely during loading and unloading, and it also virtually eliminates damage from piping vibrations caused by pumps. With this performance-maximizing fitting:
• Containment of the expansion joint eliminates the threat of uncontained chemical leaks and dangerous “spurts.”
• Piping layouts can be fully contained by connecting a dual-wall piping system onto the fitting. This can mean a safer workplace and less threat to the environment.
• Unsurpassed containment of discharge is allowed on a SAFE-Tank®.
The pressure-tested internal components of the fitting come to you pre-assembled and ready to install.
OUR INNOVATIONS
Poly Processing understands the very specific storage requirements for every chemical – so we have developed systems that meet the unique requirements of each product. The following systems have been designed to optimize your system’s safety, longevity and compatibility, based on the properties of the stored chemical. Please note that each of these systems can be adapted to suit your particular needs.
10
H2SO4SULFURIC ACID
HClHYDROCHLORIC ACID
NaOHSODIUM HYDROXIDE
HFHYDROFLUORIC ACID
H2SiF6HYDROFLUOSILICIC ACID
H2O2HYDROGEN PEROXIDE
Our Tank Systems
Fe+Al+()nFERRICS, ALUMS, POLYMERS
NaOClSODIUM HYPOCHLORITE
NaOClSODIUM HYPOCHLORITE
Commonly known as bleach, sodium hypochlorite is used in a variety of applications, particularly for the disinfection of drinking water and wastewater. When it comes to storage of this chemical, three factors must be considered:
• UV can degrade sodium hypochlorite, so special precautions must be taken to reduce this effect.
• Sodium hypochlorite typically contains transition metals such as nickel, iron and copper, which can buildup in a storage tank creating off-gassing.
• “Hypo” is a potent oxidizer, so all materials in the chemical’s storage tank must be up to the task.
By addressing all three of these issues, this caustic chemical can be contained in a more secure and effective manner, with a tank system that meets NSF/ANSI Standard 61 for chemical storage.
Sodium Hypochlorite. An aggressive oxidizer that presents a major storage challenge.
OUR TANK SYSTEMS
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Poly’s OR-1000™ system is another key component of the Hypo System. OR-1000™ is the result of our exclusive rotomolding process, which creates a seamless bond between an inner surface of medium-density polyethylene and an outer surface of high-density crosslinked polyethylene. OR-1000™ allows four times the antioxidant strength of a normal polyethylene. In any application where OR-1000™ is used, all wetted surfaces – including covering the face of the IMFO® drain – are completely covered by the material, eliminating any opportunity for a chemical attack on the structural portion of the tank.
Poly Processing’s Sodium Hypochlorite Storage Systems are specifically designed for containment of this challenging chemical. By using carbon black, white or gray compound XLPE resin, UV degradation of the chemical can be dramatically reduced. Mastic coatings and insulation are other ways to reduce UV’s effect on the chemical.
To prevent the potential buildup of transition metals in the tank, Poly has developed the IMFO® system. This special design allows for full drainage of the tank, which can greatly increase the half-life of the chemical*.
The Poly Processing Hypo System
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Sodium Hypochlorite 9%–15% XLPE with OR-1000™ 1.9 PVC EPDM/Viton® Titanium
»» See our website for a complete Chemical Resistance Chart.
NaOClSODIUM HYPOCHLORITE
NOTE: To meet NSF-61 certification, use EPDM or Viton® GF.
*Natural tanks are available for indoor use.
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Tank Specifications
OUR TANK SYSTEMS
• High-density crosslinked polyethylene (XLPE) outer surface ensures maximum corrosion protection through molecular bonding.
• OR-1000™ molecularly bonds XLPE with an antioxidant inner surface that resists the heavily oxidizing nature of sodium hypochlorite.
• Integrally Molded Flanged Outlet (IMFO®) constructed as part of tank ensures complete drainage. Non-IMFO® options also available
• UV protection for the chemical is achieved by using compounded black, white or gray resin or insulation coating to help maximize the half-life of the chemical for outdoor applications.
Recommended System Components
Plumbing:Requires flexible, Hypo-resistant connections [see page 54] to allow for lateral and vertical tank contraction and expansion, and to reduce vibration stress
NOTE: Do NOT use stainless steel or Alloy C-276 due to nickel content reaction.
Secondary containment: Recommended. Alternative: PPC secondary containment basin of XLPE, or SAFE-Tank® if concrete containment is not available.
Venting:SAFE-Surge™ manway cover is recommended on pneumatically loaded systems to support tank longevity.
Fittings:IMFO® to prevent transition metal buildup
The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
NaOClSODIUM HYPOCHLORITE
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FITTINGS
Sidewall: Recommend 3˝ maximum B.O.S.S.™ fitting
Dome: No restrictions
PLUMBING TO THE TANK
• Required use of flexible connections with fittings on lower third of sidewall
» Allows for lateral and vertical expansion and contraction of the tank
» Reduces pump and piping vibration stress on the tank
• Expansion joints must meet the following minimum requirements:
» Axial Compression ≥ 1.5˝ » Axial Extension ≥ 0.625˝ » Lateral Deflection ≥ 0.750˝ » Angular Deflection ≥ 14° » Torsional Rotation ≥ 4°
VENTING
See chart on page 63.
FOUNDATION AND RESTRAINTS
• PPC IMFO® tank pad or smooth concrete, asphalt or steel foundation designed to accommodate IMFO®, SAFE-Tank® or vertical tank
• No restraint or ladder attachment bands circumscribing the tank are allowed. Cable restraint systems must pass cables over the top of the tank.
TEMPERATURE
Product should not exceed 100°F at delivery or during storage to reduce the decomposition of the chemical and maintain ASTM D1998 design parameters.
LID
SAFE-Surge™ manway cover for pneumatically loaded tanks; bolted manway cover for all other applications
OPTIONS
Restraint systems for wind and seismic, level gauges, ladders, heating pads, insulation, fume-tight manway cover, NSF-61 certification and engineering stamp
TANK
IMFO® Vertical Flat Bottom of XLPE with OR-1000™:
• 1,000–13,650 gallons
• 1.9 spg rating
NOTE: 230–1,000 gallons do not require OR-1000™.
Non-IMFO® alternative*:
Standard Vertical Flat Bottom XLPE with OR-1000™:
• 1,000–13,650 gallons
• 1.9 spg rating
NOTE: 30–1,000 gallons do not require OR-1000™.
*Three-year warranty offered on Non-IMFO® alternatives.
*On-site generation (.08%) max size : 4000 gallons (without engineering review)
SAFE-Tank® XLPE:
• 1,500–8,700 gallons
• 1.9 spg rating for primary tank with OR-1000™
• Spg ratings for secondary tanks ≥ 3,000 gallons may be equal to or 1 less spg than primary tank.
• All other tank sizes must equal primary tank spg rating.
NOTE: 55–1,000 gallons do not require OR-1000™.
Black, white or gray color or insulation with mastic coating required in outdoor applications to minimize bleach degradation and maximize chemical half-life.
SECONDARY CONTAINMENT
Recommend SAFE-Tank® secondary XLPE as shown above.
Non-SAFE-Tank® Alternatives:
• PPC secondary containment basin
• Other secondary containment suitable for sodium hypochlorite, of adequate size for use
Technical Overview:Sodium Hypochlorite Storage Tanks
CAUTION! The life of a Sodium Hypochlorite Storage System is greatly affected by the quality of the chemical itself. Tank owners are cautioned to use high-quality sodium hypo with low iron, nickel and copper content, to avoid decomposition of the chemical and acceleration of the oxidization and degradation of the tank.
NaOClSODIUM HYPO-
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H2SO4SULFURIC ACID
Sulfuric acid is used in a huge array of industrial applications, for everything from water and wastewater treatment to the manufacture of chemicals, fertilizer and car batteries. But this highly exothermic acid presents serious storage challenges, for a number of reasons.
• Sulfuric acid is an extremely heavy chemical that will test the mechanical integrity of any material.
• The addition of water to concentrated sulfuric acid leads to the dispersal of a sulfuric acid aerosol – or worse yet, an explosion.
• If sulfuric acid is spilled on metals, it can create highly flammable hydrogen gas.
• Skin and other bodily burns from sulfuric acid are potentially more serious than burns from other strong acids. Sulfuric acid dehydrates whatever it touches, and the heat caused by that reaction with water can create secondary thermal damage.
Poly Processing’s tanks and fittings can be combined specifically to contain sulfuric acid, reducing the risks presented by this highly acidic chemical.
Sulfuric Acid.Challenging a storage tank’s strength and design safety.
OUR TANK SYSTEMS
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greatly lowers the risk for hazardous contact of sulfuric acid with water. SAFE-Tank® systems are designed with OR-1000™.
If secondary containment* is present, the IMFO® tank is recommended. With the use of an IMFO® system instead of mechanical fittings, the tank’s structural integrity is maximized. Combine this tank design with the OR-1000™ system, and oxidation is reduced dramatically.
All of these features lead to a safer tank – designed to reduce safety risks and improve the longevity of the system.
Through a combination of innovative features, Poly Processing creates the ideal system for sulfuric acid storage. With their robust load tolerance, crosslinked polyethylene tanks can more than handle the chemical’s heavy weight. The molecular bonding of XLPE and tank wall thickness is particularly important in the bottom third of the tank, where high levels of load are concentrated.
If secondary containment is not present, the Poly Processing SAFE-Tank® is a smart choice. Along with containing the chemical from its surrounding environment, this double-walled tank
The Poly Processing Sulfuric Acid System
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Sulfuric Acid ≥ 93% XLPE with OR-1000™ 2.2 PVC Viton® 316SS
Sulfuric Acid 80%–92% XLPE with OR-1000™ 2.2 PVC Viton® C-276
Sulfuric Acid < 80% XLPE 1.9 PVC Viton® C-276
H2SO4SULFURIC ACID
»» See our website for a complete Chemical Resistance Chart.
NOTE: To meet NSF-61 certification, use Viton® GF.
*Containment tank is required with this chemical in all applications.
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OUR TANK SYSTEMS
• High-density crosslinked polyethylene (XLPE) accommodates the heavy weight of sulfuric acid.
• OR-1000™ bonds the XLPE with an antioxidant inner surface, minimizing oxidation, reducing the potential for fault and maximizing life span.
• SAFE-Tank® design creates a “tank within a tank,” ensuring that water will not enter the containment area. (Recommended where secondary containment is not available)
• IMFO® tank is molded as a single unit. This maintains hoop stress rating, adding to the strength of the tank. (Recommended for situations with existing secondary containment)
• B.O.S.S.™ fitting provides bolted one-piece sure-seal design, limiting the seal point to a single gasket for major leak prevention.
Recommended System Components
Plumbing: Reverse float gauge recommended to ensure proper tank leveling.See page 55.
NOTE: For concentrations less then 93%, DO NOT use stainless steel.
Venting:SAFE-Surge™ manway cover is recommended on pneumatically loaded systems to support tank longevity.
Fittings:Recommend enhanced bellows transition fitting for bottom sidewall discharge
Fittings:B.O.S.S.™ fitting also recommended to prevent leaks
The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
Tank Specifications
The Poly Processing Sulfuric Acid System
*Containment tank is required with this chemical in all applications.
H2SO4SULFURIC ACID
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TANK
SAFE-Tank® of XLPE with OR-1000™:
• 3,150–8,700 gallons » 2.2 spg rating with OR-1000™ for primary tank » 1.9 spg rating for secondary tank
• 1,550–2,500 gallons » 2.2 spg rating with OR-1000™ for primary tank » 2.2 spg rating for secondary tank
• 55–1,000 gallons » 1.9 spg primary and secondary tanks
NOTE: 55–1,000 gallons do not require OR-1000™.* ≥ 94% concentration max tank size: 4,400 gallons (without engineering review)
Non-SAFE-Tank® alternatives:
IMFO® Vertical Flat Bottom of XLPE with OR-1000™:
• 1,150–6,600 gallons• 2.2 spg rating
IMFO® Vertical Flat Bottom of XLPE:
• 230–905 gallons• 1.9 spg ratingNOTE: Limit one IMFO® per tank
Standard Vertical Flat Bottom of XLPE with OR-1000™:
• 1,050–6,600 gallons• 2.2 spg rating
Standard Vertical Flat Bottom of XLPE:
• 30–1,000 gallons• 1.9 spg ratingNOTE: ≥ 94% concentration max tank size: 4,000 gallons (without engineering review)
SECONDARY CONTAINMENT
Non-SAFE-Tank® alternatives:
• PPC secondary containment basin
• Other secondary containment suitable for sulfuric acid, of adequate size for use
FITTINGS
Sidewall: Recommend 3˝ maximum B.O.S.S.™ fitting
Dome: No restrictions
PLUMBING TO THE TANK
• Required use of flexible connections with fittings on lower third of sidewall
» Allows for lateral and vertical expansion and contraction of the tank
» Reduces pump and piping vibration stress on the tank
• Expansion joints must meet the following minimum requirements:
» Axial Compression ≥ 1.5˝ » Axial Extension ≥ 0.625˝ » Lateral Deflection ≥ 0.750˝ » Angular Deflection ≥ 14° » Torsional Rotation ≥ 4°
VENTING
See chart on page 63.
FOUNDATION AND RESTRAINTS
• Smooth concrete, asphalt or steel foundation designed to accommodate IMFO®, SAFE-Tank® or vertical tank
• No restraint or ladder attachment bands circumscribing the tank are allowed. Cable restraint systems must pass cables over the top of the tank.
TEMPERATURE
Product should not exceed 100°F at delivery or during storage to maintain ASTM D1998 design parameters.
LID
SAFE-Surge™ manway cover for pneumatically loaded tanks; bolted manway cover for all other applications
OPTIONS
Restraint systems for wind and seismic, level gauges, ladders, heating pads, insulation, fume-tight manway cover, NSF-61 certification and engineering stamp
Technical Overview:Sulfuric Acid Storage Tanks
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H2SO4SULFURIC ACID
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HClHYDROCHLORIC ACID
Also known as muriatic acid, hydrochloric acid is used to acidize petroleum wells, remove scales from boilers, aid in ore reduction and serve as a chemical intermediate, among other applications. This pungent liquid is a strong, highly corrosive acid, and it presents serious storage challenges.
• Hydrochloric acid has an extremely low pH, making it highly corrosive.
• The chemical creates toxic fumes that can deteriorate equipment – and these fumes can be fatal to employees. To control the chemical’s fumes, the tank’s venting system must be exact.
• Tank maintenance can also be an issue because of fuming. Entering the tank must be avoided at all costs, and part replacement must be minimized.
By creating a strong, corrosion-resistant tank system that ties into a scrubber system, all of these issues can be addressed.
Hydrochloric Acid.Controlling a chemical – and its fumes.
OUR TANK SYSTEMS
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Poly Processing’s OR-1000™ surface is ideal for HCl storage. OR-1000™ has proven so effective in containing HCl that systems using it have a 5-year warranty. These tanks bring you the strength of high-density crosslinked polyethylene with an antioxidant surface.
Poly also incorporates airtight lids and customized scrubbers to accommodate the fuming of HCl.
Storing a chemical as corrosive and fuming as HCl takes a truly specialized system. Poly Processing resolves these issues with its tank, venting and fittings solutions. An Integrally Molded Flanged Outlet, or IMFO®, allows for complete drainage of the tank, which eliminates the need to enter the tank for cleaning. This is imperative when dealing with such a strongly fuming chemical. The IMFO® design also reduces chances of having to replace parts, as the drainage system is part of the tank’s mold.
The Poly Processing Hydrochloric Acid SystemHCl
HYDROCHLORIC ACID
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Hydrochloric Acid ≤ 37% XLPE with OR-1000™ 1.9 PVC EPDM C-276
»» See our website for a complete Chemical Resistance Chart.
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OUR TANK SYSTEMS
• OR-1000™ binds the XLPE with an antioxidant inner surface, which is vital when storing such a corrosive chemical.
• IMFO® construction eliminates the need to enter the tank for cleaning, helping employees avoid HCl’s toxic fumes.
• High-density crosslinked polyethylene (XLPE) ensures the strength of the tank.
Tank Specifications Recommended System Components
Secondary containment: SAFE-Tank® is recommended where secondary containment is not available.
Fittings:B.O.S.S.™ fitting is also recommended to prevent leaks.
Fume-tight manway cover:17 ,̋ 19˝ or 24˝ with EPDM gaskets
Scrubbers: Individually designed to support the reduction of dangerous fumes into the environment
Fittings: IMFO® system is recommended.
Plumbing:Requires flexible connections with fittings on lower third of sidewall to accommodate expansion and contraction and reduce vibration stress on the tank
The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
The Poly Processing Hydrochloric Acid System
HClHYDROCHLORIC ACID
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PLUMBING TO THE TANK
• Required use of flexible connections with fittings on lower third of sidewall
» Allows for lateral and vertical expansion and contraction of the tank
» Reduces pump and piping vibration stress on the tank
• Expansion joints must meet the following minimum requirements:
» Axial Compression ≥ 1.5˝ » Axial Extension ≥ 0.625˝ » Lateral Deflection ≥ 0.750˝ » Angular Deflection ≥ 14° » Torsional Rotation ≥ 4°
VENTING
See chart on page 63.
FOUNDATION AND RESTRAINTS
• PPC IMFO® tank pad or smooth concrete, asphalt or steel foundation designed to accommodate IMFO®, SAFE-Tank® or vertical tank
• No restraint or ladder attachment bands circumscribing the tank are allowed. Cable restraint systems must pass cables over the top of the tank.
TEMPERATURE
Product should not exceed 100°F at delivery or during storage to maintain ASTM D1998 design parameters.
LID
Fume-tight manway cover to manage release of chemical gases
OPTIONS
Restraint systems for wind and seismic, level gauges, ladders, heating pads, insulation and engineering stamp
TANK
IMFO® Vertical Flat Bottom of XLPE with OR-1000™:
• 1,000–13,650 gallons
• 1.9 spg rating
NOTE: 230–1,000 gallons do not require OR-1000™.
Non-IMFO® alternative:
Standard Vertical Flat Bottom XLPE with OR-1000™:
• 1,000–13,650 gallons
• 1.9 spg rating
NOTE: 30–1,000 gallons do not require OR-1000™.
SAFE-Tank® XLPE:
• 1,500–8,700 gallons
• 1.9 spg rating for primary tank with OR-1000™
• Spg ratings for secondary tanks ≥ 3,000 gallons may be equal to or 1 less spg than primary tank.
• All other tank sizes must equal primary tank spg rating.
NOTE: 55–1,000 gallons do not require OR-1000™.
SECONDARY CONTAINMENT
Recommend SAFE-Tank® secondary XLPE as shown above
Non-SAFE-Tank® Alternatives:
• PPC secondary containment basin
• Other secondary containment suitable for hydrochloric acid, of adequate size for use
FITTINGS
Sidewall: Recommend 3˝ maximum B.O.S.S.™ fitting
Dome: No restrictions
Technical Overview:Hydrochloric Acid Storage Tanks
HClHYDROCHLORIC ACID
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OUR TANK SYSTEMS
Additional Chemicals Overview:Solutions for storage of more popular chemicals.
NaOHSODIUM HYDROXIDE
HFHYDROFLUORIC ACID
H2SiF6HYDROFLUOSILICIC ACID
H2O2HYDROGEN PEROXIDE
Each chemical has its own specific properties, so Poly Processing makes it easy to adapt our tanks with the type of gaskets, venting, fittings and other features necessary for that chemical. The following are just a few of the many chemicals that can be stored safely with a Poly Processing tank system. For details on those chemicals not listed here, talk to your Poly Processing representative.
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Tank Specifications Recommended System Components
The Poly ProcessingSystem Recommendation.
Tank options include:
• High-density crosslinked polyethylene (XLPE) construction for maximum strength
• OR-1000™ antioxidant inner surface
• Integrally Molded Flanged Outlet (IMFO®) for complete drainage
• SAFE-Tank® design for “tank-within-a-tank” protection
NaOHSODIUM HYDROXIDE
HFHYDROFLUORIC ACID
H2SiF6HYDROFLUOSILICIC ACID
H2O2HYDROGEN PEROXIDE
Plumbing:Requires flexible connections [see page 54] to allow for lateral and vertical tank contraction and expansion and to reduce vibration stress
Secondary containment: SAFE-Tank® if concrete containment is not availableAlternative: PPC secondary containment basin or other secondary containment suitable for chemical, of adequate size for use
Venting:SAFE-Surge™ manway cover is recommended on pneumatically loaded systems to support tank longevity.
Fittings:IMFO® eliminates the need for confined space entry.
The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
NaOHSODIUM HYDROXIDE
Also known as caustic soda or liquid lye, sodium hydroxide is used to adjust pH in water and wastewater treatment and in the manufacture of chemicals, rayon, cellophane, pulp and paper, aluminum, detergents, soaps and a wide range of other products. As for storage:
• Sodium hydroxide is a “slippery” chemical that tries to find leak paths.
• This chemical is extremely corrosive to tissue. It is also highly toxic if ingested.
• If sodium hydroxide is not kept at a specific temperature, it will crystallize and go solid.
A tank system and proper fittings from Poly Processing can reduce your risk with this hazardous chemical.
Sodium Hydroxide.Defying a chemical that “finds” leaks.
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OUR TANK SYSTEMS
The key to storing sodium hydroxide properly is strong, safe containment. Since the chemical is so corrosive, secondary containment is an absolute.
If secondary containment is already available, the IMFO® tank is recommended. IMFO® systems are ideal for Sodium Hydroxide Systems, since their flange is actually a molded part of the tank, not an insert that could leak or fail. The IMFO® also ensures long-term performance of the overall system, since it eliminates the need to drill into the sidewall of the tank and install a mechanical fitting, which can create a maintenance issue for this chemical.
When secondary containment is not available, a SAFE-Tank® can meet this requirement. This “tank within a tank” extends the margin of safety by providing a system with 110% secondary containment.
The tank’s high-density crosslinked polyethylene construction means greater strength. It is so strong, in fact, that Poly offers a warranty of five full years on all tanks.
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Sodium Hydroxide 50% XLPE 1.65 PVC EPDM 316SS
»» See our website for a complete Chemical Resistance Chart.
The Poly ProcessingSodium Hydroxide System.
Alternative secondary containment: PPC secondary containment basin or other secondary containment suitable for sodium hydroxide, of adequate size for use
Plumbing: Requires use of flexible connections with fittings on lower third of sidewall. See page 54 for flexible connections options.
Venting: See chart on page 63.
Foundation: PPC IMFO® tank pad or smooth concrete, asphalt or steel foundation designed to accommodate IMFO®, SAFE-Tank® or vertical tank
Temperature: Product should not exceed 100°F at delivery or during storage or drop below 50°F to prevent damage to the chemical. Contact Customer Support if chemical is to exceed 100°F.
Lid: SAFE-Surge™ manway cover for pneumatically loaded tanks; bolted manway cover for all other applications
Options: Restraint systems for wind and seismic, level gauges, ladders, heating pads, insulation, mixer mounts, OR-1000™ for NSF-61 certification and engineering stamp
Tank Specifications & Technical Overview
NaOHSODIUM HYDROXIDE
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NOTE: To meet NSF-61 certification, use OR-1000™.
NOTE: Heating pad and insulation are highly recommended to prevent crystallization of the chemical.
IMFO® VERTICAL FLAT BOTTOM OF XLPE:
• 230–13,650 gallons
• 1.65 spg rating
NON-IMFO® ALTERNATIVES:
SAFE-Tank® XLPE:
• 55–8,700 gallons
• 1.65 spg rating for primary tank
• Spg ratings for secondary tanks must be equal to primary tank.
• All other tank sizes must equal primary tank spg rating.
Standard Vertical Flat Bottom XLPE:
• 30–13,650 gallons
• 1.65 spg rating
The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
1527
HFHYDROFLUORIC ACID
Hydrofluoric Acid. Reducing the risk of human exposure.
Used in the production of aluminum, fluorocarbons and gasoline and for applications like glass etching and uranium processing, hydrofluoric acid is an extremely dangerous chemical that must be handled with the utmost care.
• This corrosive liquid penetrates tissue more quickly than typical acids. Toxicity can occur through dermal, ocular, inhalation and oral routes.
• Since HF alters nerve function, accidental exposure can go unnoticed by the victim, delaying treatment and increasing the extent of injury.
• It can also be absorbed by the blood through the skin, reacting with blood calcium and potentially causing a heart attack.
The extreme nature of this chemical calls for superior structural integrity – the level of integrity Poly Processing is known for.
OUR TANK SYSTEMS
When people’s lives are at risk, you can take no chances. You need a system that goes above and beyond to prevent contact with this corrosive acid. That system starts with a crosslinked polyethylene tank. XLPE is a thermoset resin that gives customers 20 times the environmental stress-crack resistance, 10 times the molecular weight and 5 times the impact and tensile strength of HDPE. This system carries a warranty for a full five years.
A SAFE-Tank® can help reduce health and environmental concerns due to closed containment of hydrofluoric acid. If a SAFE-Tank® is not a possibility, an IMFO® flange can be used to reduce hands-on maintenance, thereby reducing the risk to your employees.
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Hydrofluoric Acid XLPE 1.9 PP Viton® C-276
»» See our website for a complete Chemical Resistance Chart.
HFHYDROFLUORIC ACID
The Poly ProcessingHydrofluoric Acid System.
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Alternative secondary containment: PPC secondary containment basin or other secondary containment suitable for hydrofluoric acid, of adequate size for use
Plumbing: Requires use of flexible connections with fittings on lower third of sidewall. See page 54 for flexible connections options.
Venting: See chart on page 63.
Foundation: PPC IMFO® tank pad or smooth concrete, asphalt or steel foundation designed to accommodate IMFO®, SAFE-Tank® or vertical tank
Temperature: Product should not exceed 100°F at delivery or during storage to maintain ASTM D1998 design parameters.
Lid: Fume-tight manway cover to manage release of chemical gases
Options: Restraint systems for wind and seismic, level gauges, ladders, heating pads, insulation, mixer mounts and engineering stamp
Tank Specifications & Technical Overview
IMFO® VERTICAL FLAT BOTTOM OF XLPE:
• 230–13,650 gallons
• 1.9 spg rating
NON-IMFO® ALTERNATIVES:
SAFE-Tank® XLPE:
• 55–8,700 gallons
• 1.9 spg rating for primary tank
• Spg ratings for secondary tanks ≥ 3,000 gallons may be equal to or 1 less spg than primary tank.
• All other tank sizes must equal primary tank spg rating.
Standard Vertical Flat Bottom XLPE:
• 30–13,650 gallons
• 1.9 spg rating
The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
1529
H2SiF6HYDROFLUOSILICIC ACID
Hydrofluosilicic Acid.Controlling heat to avoid hazardous reactions.
Hydrofluosilicic acid is used in water fluoridation, ceramic production, electroplating, bottle sterilizing, brewing and many other applications. This colorless, fuming liquid presents a host of challenges in storage:
• It decomposes in heat, giving off toxic fluoride compounds, which may react violently with alkaline materials.
• Hydrofluosilicic acid is corrosive to most metals – and it attacks glass and stoneware.
• Like lye and sodium hypo, hydrofluosilicic acid has a tendency to find leak paths.
• The chemical is incompatible with strong alkalis and strong concentrated acids. It reacts with oxidizing agents, combustible solids and organic peroxides.
• Its reaction with metals produces flammable hydrogen gas.
A complete system equipped with specialized features can reduce the risks associated with this toxic chemical.
OUR TANK SYSTEMS
Hydrofluosilicic acid is an extremely dangerous chemical. Human contact with it can result in severe injury or fatality. But when the chemical is controlled in a stable environment, risk can be dramatically reduced. XLPE tanks are ideal in this situation. The thermosetting of XLPE’s polymer chains acts as a netting to prevent permeation, leakage or seepage.
With its full drain design, a built-in IMFO® flange can help eliminate any buildup of sediment, lessening the potential for lead and arsenic deposits over time. The IMFO® system’s design also keeps the tank intact, which is important for chemicals that try to find leak paths. If an IMFO® isn’t an option, wetted fittings should be kept to an absolute minimum to avoid failure.
If secondary containment is not available, a SAFE-Tank® is recommended instead of an IMFO® tank. This tank within a tank greatly reduces the chance for leaks.
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Hydrofluosilicic Acid XLPE 1.9 PVC EPDM C-276
»» See our website for a complete Chemical Resistance Chart
The Poly ProcessingHydrofluosilicic Acid System.
NOTE: We recommend always venting this chemical outside a confined environment due to health risks from the fumes and to the damage it will cause to glass and metals.
H2SiF6HYDROFLUOSILICIC ACID
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NOTE: To meet NSF-61 certification, use OR-1000™, EPDM or Viton® GF.
Alternative secondary containment: PPC secondary containment basin or other secondary containment suitable for hydrofluosilicic acid, of adequate size for use
Plumbing: Requires use of flexible connections with fittings on lower third of sidewall. See page 54 for flexible connections options.
Venting: See chart on page 63.
Foundation: PPC IMFO® tank pad or smooth concrete, asphalt or steel foundation designed to accommodate IMFO®, SAFE-Tank® or vertical tank
Temperature: Product should not exceed 100°F at delivery or during storage to maintain ASTM D1998 design parameters.
Lid: Fume-tight manway cover to manage release of chemical gases
Options: Restraint systems for wind and seismic, level gauges, ladders, heating pads, insulation, mixer mounts, OR-1000™ for NSF-61 certification and engineering stamp
Tank Specifications & Technical Overview
IMFO® VERTICAL FLAT BOTTOM OF XLPE:
• 230–13,650 gallons
• 1.9 spg rating
NON-IMFO® ALTERNATIVES:
SAFE-Tank® XLPE:
• 55–8,700 gallons
• 1.9 spg rating for primary tank
• Spg ratings for secondary tanks ≥ 3,000 gallons may be equal to or 1 less spg than primary tank.
• All other tank sizes must equal primary tank spg rating.
Standard Vertical Flat Bottom XLPE:
• 30–13,650 gallons
• 1.9 spg rating
The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
1531
Fe+Al+()nFERRICS, ALUMS, POLYMERS
Ferrics, Alums and Polymers.Containing chemicals that react to their environment.
Ferrics, alums and polymers are commonly used to treat water and wastewater. There are several reasons why these substances require specialized storage:
• Separation, settling and coagulation are major issues with these chemicals – and those conditions can be compounded by temperature variations.
• Settling and separation issues can lead to difficulty in pumping the chemicals.
• The chemicals are often delivered at elevated temperatures, testing the expansion and contraction capabilities of a tank.
• Ferrics create fumes that can defoliate surrounding trees and plants.
• Polymers can act as an environmental stress-cracking agent.
By providing the right kind of storage for these chemicals, safety can be maintained – and the integrity of the product can be preserved.
OUR TANK SYSTEMS
Several of Poly Processing’s features can make your storage system work for handling ferrics, alums and polymers. An IMFO® system is ideal for sludge control and ease of cleaning, since the tank drains at its true bottom. Heat pads and insulation can help keep the chemicals at the optimal temperature, greatly reducing the chance of separation and settling.
A mixing system can also be installed to keep the chemicals from separating – and a scrubber can help reduce the effects on foliage if you’re venting outdoors. As for handling elevated temperatures – this is where the strength of the XLPE tank comes in. The crosslinked construction of these tanks allows for greater expansion and contraction, while maintaining structural integrity, lessening your risk for tank failure.
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Aluminum Sulfate XLPE 1.65 PVC EPDM 316SS
Ferric Chloride XLPE 1.65 PVC EPDM Titanium
Ferric Sulfate XLPE 1.65 PVC EPDM Titanium
Ferrous Chloride XLPE 1.9 PVC EPDM Titanium
Ferrous Sulfate XLPE 1.65 PVC EPDM Titanium
Polymers XLPE 1.35–1.9* PVC EPDM 316SS
The Poly Processing SystemFor Ferrics, Alums And Polymers.
32
NOTE: To meet NSF-61 certification, use OR-1000™.
Alternative secondary containment: PPC secondary containment basin or other secondary containment suitable for ferrics, alums and polymers, of adequate size for use
Plumbing: Requires use of flexible connections with fittings on lower third of sidewall. See page 54 for flexible connections options.
Venting: See chart on page 63.
Foundation: PPC IMFO® tank pad or smooth concrete, asphalt or solid steel foundation designed to accommodate IMFO®, SAFE-Tank® or vertical tank
Temperature: Product should not exceed 100°F at delivery or during storage to maintain ASTM D1998 design parameters. Contact Customer Support if chemical is to exceed 100°F.
Lid: SAFE-Surge™ manway cover for pneumatically loaded tanks; bolted manway cover for all other applications
Options: Restraint systems for wind and seismic, level gauges, ladders, heating pads, insulation, fume-tight manway cover, mixer mounts, OR-1000™ for NSF-61 certification and engineering stamp
Tank Specifications & Technical Overview
IMFO® VERTICAL FLAT BOTTOM OF XLPE:
• 230–13,650 gallons
• Appropriate spg rating for chemical as shown in Chemical Resistance Chart
NON-IMFO® ALTERNATIVES:
Standard Vertical Flat Bottom XLPE:
• 30–13,650 gallons
• Appropriate spg rating for chemical as shown in Chemical Resistance Chart
SAFE-Tank® XLPE:
• 55–8,700 gallons
• Appropriate spg rating for chemical as shown in Chemical Resistance Chart
• Spg ratings for secondary tanks ≥ 3,000 gallons may be equal to or 1 less spg than primary tank.
• All other tank sizes must equal primary tank spg rating.
The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
*Based on type of polymer, amount of solids, etc., specific gravities can vary. Consult the specific MSDS for correct weight.»» See our website for a complete Chemical Resistance Chart.
1533
Hydrogen Peroxide.Accommodating a potentially explosive chemical.
Available in a variety of concentrations, hydrogen peroxide is used as an oxidizing agent in textile, paper and fur processing. It is also used as a plasticizer, a polymerization catalyst and a water and sewage treatment chemical. It poses a number of challenges when it comes to storage:
• Concentrated solutions are highly toxic and are strong irritants.
• Hydrogen peroxide is relatively unstable and decomposes into water and oxygen when exposed to the environment. The primary danger of this composition is fire and/or explosion.
For concentrations of hydrogen peroxide that are below 50%, high-density crosslinked polyethylene is a smart option.
OUR TANK SYSTEMS
H2O2HYDROGEN PEROXIDE
If there is a chance that hydrogen peroxide has escaped from its storage system, evacuation is mandatory, since explosion could occur. Therefore, it’s imperative that an environment be made as leak-free as possible. Poly Processing’s crosslinked polyethylene helps ensure that, by providing a high-strength storage option for hydrogen peroxide. The SAFE-Tank® system offers tank-within-a-tank protection for secondary containment. And if secondary containment is already provided for the tank, Poly Processing recommends the IMFO® tank system to provide complete drainage without entering the vessel shell, helping personnel avoid contact with this strong irritant.
The Poly ProcessingHydrogen Peroxide System.
H2O2HYDROGEN PEROXIDE
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Hydrogen Peroxide XLPE 1.9 PVC/CPVC Viton® 316SS
»» See our website for complete Chemical Resistance Chart.
34 The above components are just a few of the many options offered by Poly Processing. See pages 38–63 for additional information and products, or talk to your Poly Processing representative.
NOTE: Use only flanged connections with hydrogen peroxide. Threaded fittings should be avoided!
Alternative secondary containment: PPC secondary containment basin or other secondary containment suitable for hydrogen peroxide, of adequate size for use
Plumbing: Requires use of flexible connections with fittings on lower third of sidewall. See page 54 for flexible connections options.
Venting: See chart on page 63.
Foundation: PPC IMFO® tank pad or smooth concrete, asphalt or steel foundation designed to accommodate IMFO®, SAFE-Tank® or vertical tank
Temperature: Product should not exceed 100°F at delivery or during storage to maintain ASTM D1998 design parameters.
Lid: A hinged, weighted manway to prevent over-pressurization due to rapid decomposition
Options: Restraint systems for wind and seismic, level gauges, ladders, heating pads, insulation, mixer mounts, OR-1000™ and engineering stamp
Tank Specifications & Technical Overview
IMFO® VERTICAL FLAT BOTTOM OF XLPE:
• 230–13,650 gallons
• 1.9 spg rating
NON-IMFO® ALTERNATIVES:
SAFE-Tank® XLPE:
• 55–8,700 gallons
• 1.9 spg rating for primary tank
• Spg ratings for secondary tanks ≥ 3,000 gallons may be equal to or 1 less spg than primary tank.
• All other tank sizes must equal primary tank spg rating.
Standard Vertical Flat Bottom XLPE:
• 30–13,650 gallons
• 1.9 spg rating
Pre-Purchase Guide
TEMPERATURE
• Tank specific gravity ratings are based on a product temperature of 100 degrees F.
• For tank designs for temperatures up to 150 degrees F, contact Customer Service.
PRESSURE
Atmospheric pressure must be maintained in the tank at all times; vacuum must equal zero.
VENTING
See chart on page 63.
PLUMBING
Requires use of flexible connections with fittings on lower third of sidewall
HEAT MAINTENANCE CONTROLS
Two thermostats are furnished, one for control and one for redundancy; heating requirements vary depending on mainte-nance temperature, ambient temperature and wind conditions.
POLYURETHANE INSULATION WITH MASTIC COATING
• 2-inch nominal thickness
• R-value = 8.33/inch
• Density = 2 lbs./cubic foot
• Mastic coating is white acrylic vinyl.
Before Ordering:1. Determine capacity and location restrictions: gallons, maximum height and diameter, and indoor or outdoor installation.
2. Conduct a chemical review: name, concentration, specific gravity and temperature.
3. See the chemical resistance guide (page 36) for tank and fittings materials, specific gravity rating, and full-drain and secondary containment requirements.
4. Use the complete 8-digit stock number when placing orders. Note: the first digit of each stock number indicates the manufacturing location: 4 = Monroe, LA; 7 = Winchester, VA; 1 = French Camp, CA.
5. Download a tank schematic from polyprocessing.com and use this drawing to specify the fitting locations.
6. Contact a Poly Processing distributor for details.
Operating Parameters
1535
ORDER INFORMATION
TANK COLOR
• High-density crosslinked polyethylene (XLPE) – natural, black, white, gray.
• Linear polyethylene (HDPE) – natural, black.
NOTE: For additional colors, contact Customer Service.
TANK DOME LOAD RATING
DO NOT stand or work on tank domes. The surface is flexible and slippery. There is no weight or load rating for the dome.
GENERAL INFORMATION
• Nominal capacity = Calculated tank capacity to top of straight sidewall
• All vertical, IMFO® and SAFE-Tank® systems greater than 500 gallons are manufactured in accordance with ASTM D1998 standards.
• Gallonage markers are approximate; not for precise measuring or metering
LOGISTICS
Delivery and shipping information is provided on page 64.
36
CHEMICAL RESINTYPE
SPECIFIC GRAVITY RATING
FITTINGMATERIAL
GASKETMATERIAL
BOLTMATERIAL
Acetic Acid ≤ 80% XLPE 1.9 PP EPDM 316SSAluminum Sulfate XLPE 1.65 PVC/CPVC EPDM 316SS
Calcium Carbonate XLPE 1.9 PVC/CPVC EPDM 316SSCalcium Chloride XLPE 1.65 PVC/CPVC EPDM Titanium
Citric Acid XLPE 1.65 PVC/CPVC EPDM 316SSDeionized Water XLPE 1.65 PVC/CPVC EPDM 316SSEthylene Glycol XLPE 1.35 PVC/CPVC EPDM 316SSFerric Chloride XLPE 1.65 PVC/CPVC EPDM TitaniumFerric Sulfate XLPE 1.65 PVC/CPVC EPDM Titanium
Ferrous Chloride XLPE 1.9 PVC/CPVC EPDM TitaniumFerrous Sulfate XLPE 1.65 PVC/CPVC EPDM Titanium
Hydrochloric Acid ≤ 37% XLPE with OR-1000™ 1.9 PVC/CPVC EPDM C-276Hydrofluoric Acid XLPE 1.9 PP Viton® C-276
Hydrofluosilicic Acid XLPE 1.9 PVC/CPVC EPDM C-276Hydrogen Peroxide XLPE 1.9 PVC/CPVC Viton® 316SS
Magnesium Chloride 30% XLPE 1.65 PVC/CPVC EPDM TitaniumPhosphoric Acid > 50% XLPE 1.9 PVC/CPVC Viton® C-276Phosphoric Acid ≤ 50% XLPE 1.9 PVC/CPVC Viton® 316SS
Potable Water HDPE 1.35 PVC/CPVC EPDM 316SSPotassium Hydroxide XLPE 1.9 PVC/CPVC EPDM C-276
Sodium Bisulfite XLPE 1.65 PVC/CPVC EPDM 316SSSodium Carbonate XLPE 1.35 PVC/CPVC EPDM Titanium
Sodium Chlorite XLPE 1.9 PVC/CPVC Viton® GF 316SSSodium Hydroxide 50% XLPE 1.65 PVC/CPVC EPDM 316SS
Sodium Hypochlorite 9%–15% XLPE with OR-1000™ 1.9 PVC/CPVC EPDM/Viton® TitaniumSulfuric Acid ≥ 93% XLPE with OR-1000™ 2.2 PVC/CPVC Viton® 316SS
Sulfuric Acid 80%–92% XLPE with OR-1000™ 2.2 PVC/CPVC Viton® C-276Sulfuric Acid < 80% XLPE 1.9 PVC/CPVC Viton® C-276
»» For more resistance information, including details on other chemicals, visit www.polyprocessing.com and access our Chemical Resistance Online Guide.
Chemical Resistance Guide
Temperature: Product temperature is limited to 100 degrees F. For temperatures from 100 to 150 degrees F, contact Customer Service.
MATERIAL DESCRIPTIONS
Fitting materials:
• PP (Polypropylene) – light, durable pipe or fitting material with outstanding chemical resistance
• PVC (Polyvinyl Chloride) – stronger, more rigid pipe or fitting material with excellent chemical resistance
• CPVC (Chlorinated Polyvinyl Chloride) – stronger, more rigid pipe or fitting material with higher temperature rating
Gasket materials:
• EPDM (ethylene propylene diene monomer) – good abrasion and tear resistance with excellent chemical resistance
• Viton® (fluorocarbon) – broader temperature and chemical resistance
• Viton® GF/GORE-TEX® – highest temperature resistance
Bolt materials:
• 316SS (stainless steel type 316) – common alloy used in many storage applications
• Titanium – strong as steel, but half the weight
• C-276 (Alloy C-276) – broader chemical resistance for more difficult storage applications
37
POLY PROCESSING COMPANY PRODUCT WARRANTY PERIOD
CROSSLINKED POLYETHYLENE TANKS for all suitable applications except those listed below 5 yrs.
IMFO® tanks storing SODIUM HYPOCHLORITE 9–15 wt%XLPE w/ OR-1000™, 1.9 spg rating 5 yrs.
NON-IMFO® tanks storing SODIUM HYPOCHLORITE 9–15 wt%1,000 gallons and larger: XLPE w/ OR-1000™, 1.9 spg ratingLess than 1,000 gallons: XLPE 1.9 spg rating
3 yrs.
Tanks storing SULFURIC ACID ≥ 80% concentrationSAFE-Tank® to 8,700 gallons: XLPE w/ OR-1000™, 2.2 spg ratingVertical tanks 1,000–6,600 gallons: XLPE w/ OR-1000™, 2.2 spg ratingVertical tanks less than 1,000 gallons: XLPE 1.9 spg rating
3 yrs.
Tanks storing HYDROCHLORIC ACID ≤ 37% concentrationXLPE w/ OR-1000™, 1.9 spg rating 5 yrs.
Tanks storing HYDROCHLORIC ACID ≤ 37% concentrationXLPE 1.9 spg rating 3 yrs.
LINEAR POLYETHYLENE TANKS for all suitable applications except Sodium Hypochlorite 9–15%; Sulfuric Acid and Hydrochloric Acid of any concentration 3 yrs.
Limited Warranty
Poly Processing Company’s warranty consists of repair or replacement of defective product. Owner and/or user may be requested to provide a cleaned section of the product in question for evaluation. Product disposal or alternate use is the owner’s and/or user’s responsibility. Warranty begins at date of shipment from PPC plant. Parts and ancillary items are warranted for ninety (90) days.
Poly Processing Company’s liability is limited to either repair or replacement of its product. By accepting delivery of the product, owner and/or user waives any claim against PPC for incidental or consequential damages as they relate to lost profits or sales or to injury of persons or property, including secondary containment. Owner and/or user accepts full responsibility for providing secondary containment appropriate and adequate for the stored material.
This warranty will be nullified if:
1. Product has been used in manner other than its originally declared purpose or if PPC tank recommendations have not been followed.
2. Product has not been installed, used and maintained in accordance with a) all federal, state and local laws and regulations; b) generally accepted best practices within the applicable industry; and c) guidelines set forth in the PPC Installation Manual and/or in PPC Technical Overviews.
3. Product has been altered or repaired by unauthorized personnel.
4. Notification of the defect has not been made in writing within the warranty period.
5. Invoice for product has not been paid.
6. Product has been subjected to misuse, negligence, fire, accident, act of war or act of God.
ORDER INFORMATION
The limited warranty described herein is Poly Processing Company’s sole warranty and the complete, final and exclusive statement of the terms of the warranty. Owner and/or user may not rely on any oral statement or representations. This warranty is neither assignable nor transferable.
Tank Specifications
38
39
Our Tank Offerings
TANK SPECIFICATIONS
VERTICAL TANKS WITH IMFO®
Tanks with drainage at the true base, allowing for minimal sludge buildup and easier maintenance
CONE-BOTTOM TANKS
Generally used in a process environment, where the tank has to be 100% drained, and to address concerns about vortexing
SAFE-Tank® SYSTEMS
A “tank-within-a-tank” that creates secondary containment with a minimal footprint. Available with or without OR-1000™ surfacing
VERTICAL TANKS
Standard-sized chemical storage tanks in crosslinked polyethylene for superior strength. Available with OR-1000™ antioxidant surface
40
Our Tank Offerings
Visit www.polyprocessing.com for easy, intuitive ordering!
SECONDARY CONTAINMENT BASINS
Used for the nesting of traditional vertical or vertical IMFO® tanks to meet secondary containment requirements
OPEN-TOP TANKS
Process-oriented tanks that are typically used for blending or for containment. Open-top tanks often incorporate the use of mixer bridges.
HORIZONTAL TANKS
Primarily used in the agricultural industry for application processes
41
TANK SPECIFICATIONS
SAFE-Tank® System
• = Molded-in lifting lugsL = Molded-in ladder attachment lugs
T1SAFE-Tank® SYSTEMS – STORAGE & CONTAINMENT
F.O.B.Stock Number Nominal Capacity Approx. O.D. Approx. Overall
Height Lid Size Ladder HeightLA VA CA4 1 20087004 1 2110150
L • Assembly 8,700 11'-11" 14'-6" 24" 15'
4 1 20066504 1 2107450
L • Assembly 6,650 10'-3" 14'-3" 24" 14'
4 20054004 2106300
L • Assembly 5,400 11'-11" 9'-9" 24" 10'
7 1 20044007 1 2104950
L • Assembly 4,400 10'-3" 10'-3" 24" 10'
4 20031504 2103550
L • Assembly 3,150 10'-2" 7'-7" 24" 7'
4 20025004 2103100
L • Assembly 2,500 8'-0" 9'-11" 17" 10'
7 20015507 2101950
• Assembly 1,550 8'-0" 6'-11" 17" 7'
7 1 20010007 1 2101200
• Assembly 1,000 6'-5" 6'-7" 17" 6'
4 20005404 2100655
• Assembly 540 6'-5" 4'-0" 17"
7 1 20004057 1 2100445
Assembly 405 4'-0" 5'-9" 7"
4 7 1 20001604 7 1 2100220
Assembly 160 3'-0" 4'-11" 7"
4 7 1 20001054 7 1 2100150
Assembly 105 3'-0" 3'-6" 7"
4 20000554 2100085
Assembly 55 3'-0" 2'-5" 7"
42
Vertical Tanks With IMFO®
T2VERTICAL TANKS WITH IMFO®
F.O.B. Stock Number
Nominal Capacity
Approx. O.D.
Approx. Overall Height
Lid Size
IMFO® Size
Ladder HeightLA VA CA
• 1 1113650 13,650 13'-9" 16'-10" 24" 4" 13'• 1 1112150 12,150 12'-0" 16'-8" 24" 4" 17'• 4 1112150 12,150 12'-0" 17'-1" 24" 4"D 17'• 1 1110300 10,300 12'-0" 14'-4" 24" 4" 14'
L • 4 1110150 10,150 11'-11" 14'-5" 24" 4" 14'L • 4 1108500 8,500 10'-0" 16'-9" 24" 4" 17'L • 4 1108100 8,100 11'-11" 11'-10" 24" 4" 12'L • 1 1108050 8,050 10'-0" 15'-6" 24" 4" 15'L • 4 1107300 7,300 10'-2" 14'-2" 24" 4" 14'L • 1 1106600 6,600 10'-0" 13'-7" 24" 4" 13'L • 4 7 1106150 6,150 10'-2" 12'-5" 24" 4" 12'L • 4 1106100 6,100 8'-6" 16'-4" 24" 4"D 16'
• 1 1106100 6,100 10'-0" 12'-7" 24" 4" 12'• 4 1105050 5,050 7'-10" 16'-0" 24" 4"D 16'• 1 1104600 4,600 10'-2" 9'-7" 24" 4" 9'
L • 4 1104300 4,300 11'-11" 7'-1" 24" 4" 7'L • 7 1104150 4,150 8'-6" 12'-6" 24" 3" 12'
• 1 1104050 4,050 8'-2" 12'-10" 24" 3" 12'L • 4 1103900 3,900 7'-10" 12'-6" 24" 4"D 12'L • 4 7 1103000 3,000 7'-1" 12'-0" 24" 3" 12'L V 7 1102550 2,550 7'-1" 10'-4" 24" 3" 10'L V 4 7 1102000 2,000 7'-1" 8'-6" 24" 3" 8'
1 1101600 1,600 6'-1" 9'-1" 17" 3" 9'4 7 1101400 1,400 5'-4" 9'-11" 17" 3"
1 1101250 1,250 5'-0" 9'-10" 17" 3"7 1101150 1,150 5'-4" 8'-3" 17" 3"7 1100905 905 5'-4" 6'-7" 17" 2"
4 1100545 545 4'-0" 6'-11" 17" 2"F 7 1100475 475 4'-0" 6'-4" 17" 3"F 7 1100325 325 4'-0" 4'-8" 17" 3"F 7 1100230 230 3'-2" 4'-11" 17" 3"
T3SLOPED BOTTOM VERTICAL TANK WITH IMFO®
F.O.B. Stock Number
Nominal Capacity
Approx. O.D.
Approx. Overall Height
Lid Size
IMFO® Size
Ladder HeightLA VA CA
• 1 1211800 11,800 12'-0" 16'-6" 24" 4" 15'L • 4 1206350 6,350 10'-2" 12'-7" 24" 4" 13'L • 1 1206250 6,250 10'-0" 13'-1" 24" 4" 12'L • 7 1204100 4,100 8'-6" 12'-11" 24" 3" 13'
PADS FOR TANKS WITH IMFO®
F.O.B. Stock Number Diameter Height
LA VA CA7 8000004 4'-0" 4"
1 8000005 5'-0" 6"7 8000054 5'-4" 4"
1 8000006 6'-0" 6"7 8000071 7'-1" 4"
4 1 8000008 8'-2" 4"4 8000086 8'-6" 4"
1 8000010 10'-0" 4"4 7 8000102 10'-2" 4"4 1 8000012 12'-0" 4"
1 8000014 14'-0" 4"4 8100086 8'-6" Slope 12" x 6"
1 8100010 10'-0" Slope 12" x 6"4 8100102 10'-2" Slope 16" x 6"
1 8100012 12'-0" Slope 10" x 4"
• = Molded-in lifting lugsL = Molded-in ladder attachment lugsV = Molded-in lifting lugs – Virginia onlyD = Double IMFO® availableF = Flat backing ring required
T4
43
Vertical Tanks
T5VERTICAL TANKS
F.O.B.Stock Number Nominal Capacity Approx. O.D. Approx. Overall
Height Lid Size Ladder HeightLA VA CA
• 1 1013650 13,650 13'-9" 16'-10" 24" 13'L • 4 1012250 12,250 11'-11" 17'-1" 24" 17'
• 1 1012150 12,150 12'-0" 16'-8" 24" 16'L • 4 1010300 10,300 11'-11" 14'-6" 24" 14'L • 1 1010300 10,300 11'-11" 14'-6" 24" 14'
• 1 1009100 9,100 12'-0" 12'-11" 24" 12'L • 4 1008500 8,500 10'-0" 16'-9" 24" 16'L • 1 1008050 8,050 10'-0" 15'-8" 24" 15'L • 4 1 1007300 7,300 10'-2" 14'-2" 24" 14'L • 4 7 1006150 6,150 10'-2" 12'-4" 24" 12'L • 4 1006100 6,100 8'-6" 16'-4" 24" 16'
• 1 1006100 6,100 10'-0" 12'-8" 24" 12'L • 4 7 1005300 5,300 9'-2" 12'-10" 24" 13'
• 1 1005100 5,100 10'-2" 10'-7" 24" 10'L • 4 1005050 5,050 7'-10" 16'-0" 24" 16'
1 1004925 4,925 9'-0" 11'-11" 24" 11'• 1 1004900 4,900 12'-0" 8'-1" 24" 6'
L • 4 1004250 4,250 11'-11" 7'-0" 24" 7'L • 7 1004150 4,150 8'-6" 12'-6" 24" 12'L • 4 7 1003900 3,900 7'-10" 12'-9" 24" 12'L • 7 1003850 3,850 10'-2" 8'-6" 24" 8'
• 1 1003650 3,650 10'-2" 8'-5" 24" 6'L • 4 7 1003000 3,000 7'-1" 11'-8" 24" 12'L 4 7 1002650 2,650 8'-0" 8'-9" 24" 8'L V 4 7 1002550 2,550 7'-1" 10'-4" 24" 10'
1 1002500 2,500 8'-0" 8'-2" 24" 8'L 4 7 1002250 2,250 8'-0" 7'-9" 24" 7'
1 1002000 2,000 7'-5" 7'-5" 17" 7'L V 4 7 1002000 2,000 7'-1" 8'-6" 24" 8'
7 1001950 1,950 5'-4" 13'-5" 17"1 1001700 1,700 6'-1" 9'-7" 17" 9'1 1001550 1,550 5'-1" 11'-9" 17"
• = Molded-in lifting lugsL = Molded-in ladder attachment lugsV = Molded-in lifting lugs – Virginia only
TANK SPECIFICATIONS
VERTICAL TANKS CONTINUED »»
44
Vertical Tanks (continued)
Cone-Bottom Tanks
VERTICAL TANKS (continued)
F.O.B.Stock Number Nominal Capacity Approx. O.D. Approx. Overall
Height Lid Size Ladder HeightLA VA CA4 1001450 1,450 7'-2" 6'-2" 17"4 7 1001400 1,400 5'-4" 10'-0" 17"4 7 1001150 1,150 5'-4" 8'-2" 17" 8'
1 1001090 1,090 5'-1" 8'-6" 17" 8'7 1001050 1,050 5'-1" 8'-6" 17" 7'
4 1001000 1,000 7'-2" 4'-8" 17"4 7 1000905 905 5'-4" 6'-9" 17" 6'
7 1000805 805 4'-0" 9'-11" 17"4 1000755 755 5'-4" 5'-9" 24"
1 1000685 685 5'-1" 5'-4" 17"7 1000615 615 4'-0" 7'-9" 17"
1 1000540 540 4'-0" 7'-0" 17"4 7 1000540 540 4'-0" 6'-9" 17"
1 1000475 475 4'-0" 6'-3" 17"7 1000400 400 3'-9" 5'-3" 7"
1 1000325 325 4'-0" 4'-8" 17"1 1000300 300 3'-6" 4'-11" 7"
4 1000295 295 3'-10" 4'-5" 7"7 1000281 281 2'-10" 7'-0" 7"
1 1000280 280 2'-10" 7'-0" 7"1 1000230 230 3'-2" 4'-11" 17"
4 1000205 205 2'-7" 6'-2" 7"4 1000155 155 2'-7" 4'-9" 7"
1 1000115 115 2'-6" 3'-11" 7"4 1000100 100 1'-11" 5'-7" 7"
1 1000055 55 1'-11" 3'-5" 7"
CONE-BOTTOM TANKS
F.O.B.Stock Number Nominal Capacity Slope Degrees Approx. O.D. Overall Height
with Stand Lid Size Ladder HeightLA VA CA
1 4006850 6,850 60 10'-1" 20'-3" 24" 19'4 4006500 6,500 45 9'-3" 19'-3" 24" 19'
1 4105550 5,550 30 10'-0" 15'-4" 24" 15'4 4005350 5,350 45 9'-3" 16'-11" 24" 16'4 1 4002300 2,300 30 7'-11" 9'-9" 16"/24" 9'
1 4001400 1,400 30 7'-11" 7'-2" 16"/24" 7'1 4001070 1,070 45 5'-1" 11'-2" 17" 10'1 4000735 735 48 5'-1" 8'-11" 17" 8'1 4000615 615 44 4'-0" 9'-9" 17" 9'1 4000335 335 44 4'-0" 6'-9" 17" 6'
T6
T7
45
Open-Top Tanks
TANK SPECIFICATIONS
OPEN-TOP / CONTAINMENT TANKS
F.O.B.Stock Number Nominal Capacity Approx. O.D. Approx. Overall
Height Flange Type Cover TypeLA VA CA
1 1514650 14,650 14'-0" 13'-1" Internal 1 1512300 12,300 12'-0" 15'-0" Internal 1 1506900 6,900 12'-0" 8'-4" Internal 1 1505000 5,000 12'-0" 6'-0" Internal 1 1504000 4,000 10'-0" 6'-11" Internal
7 1503650 3,650 8'-6" 9'-0" Internal 4 1503050 3,050 8'-0" 8'-5" External Domed Cover
1 1502890 2,890 10'-0" 5'-0" Internal4 1502650 2,650 8'-0" 7'-3" External Domed Cover
1 1502400 2,400 7'-5" 7'-7" Internal 4 1502000 2,000 8'-0" 5'-7" External Domed Cover
7 1501800 1,800 6'-1" 8'-6" Internal 1 1501800 1,800 6'-1" 8'-7" Internal
7 1501750 1,750 7'-9" 5'-1" Internal 7 1501200 1,200 7'-8" 3'-8" Internal 1 1501200 1,200 6'-1" 5'-7" Internal 7 1501150 1,150 6'-1" 5'-7" Internal 7 1500960 960 5'-4" 6'-0" Internal
1 1500760 760 6'-1" 3'-7" Internal 7 1500715 715 6'-1" 3'-9" Internal
1 1500710 710 5'-1" 4'-9" Internal 7 1500700 700 5'-1" 4'-9" Internal
1 1500515 515 4'-0" 5'-7" Internal 4 1500470 470 3'-10" 5'-8" External Mod. Shoe Box
1 1500370 370 4'-0" 4'-0" Internal7 1500360 360 4'-0" 4'-0" Internal
4 1500330 330 3'-10" 4'-0" External Mod. Shoe Box4 1500160 160 2'-7" 4'-4" External Mod. Shoe Box
1 1500160 160 3'-1" 3'-0" Internal7 1500155 155 3'-1" 3'-0" Internal
T8
46
Secondary Containment Basins
SECONDARY CONTAINMENT – CYLINDRICAL – NESTABLE
F.O.B.Stock Number Nominal Capacity Approx. O.D. Top* Approx. O.D. Bottom Approx. Overall
Height Flange WidthLA VA CA4 1501500 1500 11'-9" 11'-6" 2'-0" 2"
7 1500935 935 6'-7" 6'-3" 4'-0" 2"7 1500570 570 6'-6" 6'-4" 2'-7" 2"
SECONDARY CONTAINMENT – RECTANGULAR
F.O.B.Stock Number Nominal Capacity Approx. I.D. Length Approx. I.D.
WidthApprox. Overall
Height Flange WidthLA VA CA4 5101850 1,850 9'-11" 8'-11" 2'-11" 3"4 5101500 1,500 6'-3" 5'-3" 7'-2" 4"4 5101150 1,150 5'-9" 4'-9" 6'-2" 3"
1 5101000 1,000 12'-7" 7'-7" 2'-4" N/A1 5100730 730 8'-6" 4'-10" 3'-0" N/A
4 5100700 700 8'-0" 6'-0" 2'-1" 3"4 5100635 635 9'-2" 3'-1" 3'-2" 4"
1 5100555 555 6'-6" 4'-10" 3'-0" N/A4 7 5100440 440** 5'-8" 4'-8" 2'-6" 2"4 5100385 385 5'-6" 3'-7" 2'-10" 2"
7 5100320 320 5'-6" 3'-5" 2'-8" 3"4 5100225 225** 4'-10" 3'-2" 2'-1" 4"
1 5300175 175 10'-5" 5'-0" 8" 3"4 1 5300135 135 3'-5" 3'-5" 2'-2" N/A4 5100080 80 3'-1" 2'-1" 2'-1" 2"
T9
T10
* Diameter does not include flange.** Support stand with grating is available.NOTE: External support is required to maintain calculated volume on rectangular tanks.
47
Horizontal Tanks
TANK SPECIFICATIONS
HORIZONTAL TANKS
F.O.B.Stock Number Nominal
Capacity Approx. O.D. Approx. Length Lid Size SaddleStock #
4' StandStock #
6' StandStock #LA VA CA
1 3002600 2,600 5'-10" 13'-8" 16" 63194 3001950 1,950 5'-4" 13'-2" 19" 3464 3475 3486
1 3001050 1,050 4'-0" 11'-11" 17" 63164 3001000 1,000 5'-4" 7'-3" 10"/19" 3459 3472 3483
1 3000610 610 3'-11" 7'-9" 7" 66784 3000520 520 4'-0" 6'-4" 10" 3456 3470 3481
1 3000400 400 3'-6" 6'-0" 17" 63121 3000170 170 2'-8" 4'-7" 12" 6306
HORIZONTAL LEG TANKS
F.O.B.Stock Number Nominal Capacity Approx. O.D. Approx. Length Lid Size Stock # for
MetalworkLA VA CA4 3502500 2,500 5'-5" x 6'-10" 13'-0" 22" 5307
1 3402500 2,500 5'-10" 14'-11" 17" 63291 3401750 1,750 5'-0" 12'-11" 17" 6328
4 3401600 1,600 4'-8" 13'-3" 22" 53031 3401060 1,060 5'-4" 7'-3" 17" 6327
4 3401050 1,050 4'-0" 12'-9" 16" 52991 3401030 1,030 4'-0" 11'-11" 17" 6326
4 3400700 700 4'-6" 6'-9" 16" 76144 1 3400515 515 4'-0" 6'-4" 12" 63254 3400410 410 3'-7" 5'-11" 12" 63244 3400330 330 3'-3" 6'-2" 12" 63234 1 3400220 220 3'-3" 4'-2" 12" 63224 1 3400135 135 2'-7" 3'-10" 12" 63214 3400065 65 1'-11" 3'-6" 7"
T11
T12
48
Fittings and Accessories Poly Processing carries hundreds of fittings and accessories for chemical storage. The following pages give an overview of our more popular products. For a complete list of our inventory, with prices, please contact your Poly Processing representative. This representative can also help you determine which products are most suitable for the chemical you are storing.
49
FITTINGS AND ACCESSORIES
Fittings
BOLTED FLANGE FITTINGS
Available in PVC and CPVC. With these fittings, all aspects of fitting maintenance can be done externally, with no tank entry required. These can be installed on sidewall or dome. Bolt heads are encapsulated in polyethylene, providing chemical resistance.
Bolts: 316 stainless steel, titanium, C-276 and Alloy 400
Body: standard PVC and CPVC
Connections: socketed or threaded
Sizes: 1̋ , 11/2̋ , 2 ,̋ 3˝ and 4˝ threaded;1̋ , 11/2̋ , 2 ,̋ 3 ,̋ 4˝ and 6̋ socketed
Gaskets: EPDM, Viton® and Viton® GF
Options: flange adapter, siphon leg
THE B.O.S.S.™ FITTING
This one-piece sure-seal fitting prevents leaks and adds value to your tank installation. Its one-piece design reduces the seal point to a single gasket, and its polyethylene construction ensures chemical compatibility. Its back ring design reduces stress on the fitting and makes it three times stronger than similar plastic fittings.
Bolts: 316 stainless steel, titanium and C-276
Body: Polyethylene
Connections: socketed
Size: 1̋ , 2˝ and 3˝
Gaskets: EPDM, Viton® and Viton® GF
Options: flange adapter, siphon leg
50
Fittings
BOLTED SPOOL FITTINGS
The Bolted Spool Fitting is fabricated per the customer’s requirements and is typically used for larger dome and sidewall connections. Use a Van Stone flange to connect piping. Bolted Spool Fittings 8 inches or greater are manufactured with gussets.
Bolts: 316 stainless steel, titanium, C-276 and Alloy 400
Body: standard PVC, CPVC and polypropylene
Connections: flanged
Size: 1̋ to 12˝
Gaskets: EPDM, Viton® and Viton® GF
Options: siphon leg
BULKHEAD FITTINGS
An economical fitting best used on small tanks in mild applications. Can be installed on sidewall, overflow or dome. May be used as a overflow fitting with all chemicals, since it’s non-wetted. Bulkhead Fittings must be installed from the inside of the tank, requiring tank entry for repairs and maintenance. They should not be used on tanks greater than 3,000 gallons or tanks greater than 6 feet in height.
Body: standard PVC, CPVC and polypropylene
Connections: socketed or threaded
Size: 1/2̋ to 6̋
Gaskets: EPDM, Viton® and Viton® GF
Options: flange adapter, siphon leg
NOTE: Over time, this fitting “creeps,” causing the nut to loosen. Regular monitoring for drips is critical.
NOTE: These fittings are for top-use only.
51
FITTINGS AND ACCESSORIES
Fittings
UNIVERSAL BALL DOME FLANGES
These flanges are “self-aligning,” which allows for vertical plumbing on the dome of the tank up to 22 degrees. The fitting can be repaired and maintained externally without tank entry. Available with Ryton® bolts, an economical alternative to titanium, C-276, and Alloy 400.
Bolts: 316 stainless steel, titanium, C-276, Alloy 400, Ryton®
Body: standard PVC or CPVC
Connections: threaded
Size: 1̋ to 4˝
Gaskets: EPDM, Viton® and Viton® GF
Options: flange adapter
UNIVERSAL BALL DOME BULKHEADS
Our Universal Ball Dome Bulkheads are also “self-aligning,” which allows for vertical plumbing on the dome of the tank. An economical alternative to UBD flange-style bulkheads, since no additional bolts are required.
Body: standard PVC or CPVC
Connections: threaded
Size: 1̋ to 3˝
Gaskets: EPDM, Viton® and Viton® GF
Options: flange adapter
52
Fittings
MADE-VERTICAL FITTINGS
Made-Vertical Fittings are fabricated per the customer’s requirements. They are typically used for larger domes that require a fitting to be above 4 inches and in those few cases where our domes are extremely steep. They may need to be supported independently of the tank. For optimal support, install it on a tank runway or as close to the edge as possible.
Bolts: 316 stainless steel, titanium, C-276, Alloy 400, Ryton®
Body: standard PVC or CPVC
Size: 6̋ to 10˝
Gaskets: EPDM, Viton® and Viton® GF
Options: flange adapter socketed or threaded
FLANGE ADAPTERS
Includes a nipple and flange for connection to plumbing system
Body: standard PVC and CPVC
Connections: socketed or threaded
Sizes: 1̋ , 11/2̋ , 2 ,̋ 3˝ and 4˝ threaded; 1̋ , 11/2̋ , 2 ,̋ 3 ,̋ 4 ,̋ and 6̋ socketed
NOTE: This fitting is for top-use only.
Plumbing
BUTTERFLY VALVES
Being slim and light weight yet robust, makes this the ideal shutoff valve for IMFO® drain.
Bolts: 316 stainless steel, titanium, C-276, Alloy 400
Body: standard PVC, CPVC and polypropylene
Size: 2˝ to 6̋
Seals: EPDM, Viton® and Viton® GF
Options: flange adapter
BALL VALVES
Complete line of high-performance Ball Valves to meet varying needs
Body: standard PVC, CPVC and polypropylene
Connections: socketed, threaded or true union
Size: 1/2̋ to 6̋
Seals: EPDM, Viton® and Teflon®
Options: flange adapter
53
FITTINGS AND ACCESSORIES
NOTE: Can also be used on mechanical fittings by using a flange adapter.
54
Plumbing
FLEXIBLE HOSE CONNECTIONS
Flexible Hose Connections isolate the tank from the stresses and forces associated with pumps and piping. This connection is manufactured from ultra high molecular weight hose, which offers tremendous chemical resistance; two King nipples (barbed); and mechanically attached stainless steel bands securing the hose to the nipple. These connections are also a great solution for transitioning through secondary containment.
Connections: threaded
Sizes: 1̋ to 4˝
FLEXIJOINT® EXPANSION JOINT
These flexible PTFE connectors and tremor barriers are designed to compensate for misalignment, absorb expansion and contraction, and isolate the vibration and shock that could damage a tank. Their low spring rate protects stress-sensitive connections. Can be installed directly to the dome of the tank to overcome piping misalignment
• Made of pure 100% virgin PTFE resin
• Ethylene’s exclusive Fluorforming™ process guarantees multiple convolution walls of consistently uniform thickness for any size.
• Features T-Band™ root and sidewall support and protection from over-compression
• LimitLinks™ stainless steel cables protect from over-expansion.
Bolts: 316 stainless steel, titanium, C-276, Alloy 400
Gaskets: EPDM, Viton® and Viton® GF
Performance specifications:
» Axial Compression ≥ 1.5˝ » Axial Extension ≥ 0.625˝ » Lateral Deflection ≥ 0.750˝ » Angular Deflection ≥ 14° » Torsional Rotation ≥ 4°
55
Plumbing
PVC LIQUID LEVEL GAUGES
PVC Liquid Level Gauges are made from 3/4 inches clear PVC tubing for a level indicator with up to three optional valves. Please note that one pipe support should be used for every 6 feet of sidewall height to maintain alignment.
REVERSE FLOAT LEVEL GAUGES
The Reverse Float Level Gauges offer a safe and reliable means of determining the chemical level in your tank and especially in the SAFE-Tank®. Available in PVC as standard.
Advantages:
• No sidewall tank penetrations or chemical exposure
• All joints are dry fit for easier part replacement.
• Internal float now weighted to chemical specific gravity
• Polypropylene rope used for indicator
• Calibration tape can be added for tank capacity.
• Standard or freestanding pipe supports available
NOTE: These gauges are NOT intended to be used for metering purposes.
56
Plumbing
COMBINATION INTERNAL & EXTERNAL FILL/DISCHARGE DROP PIPES
Fill Line assemblies are available in PVC and CPVC with sizes ranging from 1 to 3 inches and include a true union for quick assembly. When choosing a fitting, be sure to consider if the fill will be placed on the flat of the dome; otherwise it will require a self-leveling fitting.
For dome fittings installed +/- 12 inches from the sidewall, standard pipe supports can be used. If the dome fitting is more than 12 inches from the sidewall or if the fitting size is greater than 4 inches, you must use a non-invasive internal pipe support (our “promo tank”) to support the internal piping. Customer installation of the internal drop pipe assembly is required. Use a universal ball dome fitting for easier installation. Pipe supports should be used one for every 6 inches of sidewall height.
Optional fittings: ball valve, quick adapter and cap and 45° elbow as shown
FILL EXTERNAL DROP PIPES
Fill Line assemblies are available in PVC and CPVC with sizes ranging from 1 to 3 inches and include a true union connection for easy assembly. When choosing a fitting, be sure to consider if the fill will be placed on the flat of the dome; otherwise it will require a self-leveling fitting.
Optional fittings: ball valve, quick adapter and cap (as shown). 45° elbow also available
57
FITTINGS AND ACCESSORIES
Plumbing
FILL/DISCHARGE INTERNAL DROP PIPES
Fill Line assemblies are available in PVC and CPVC with sizes ranging from 1 to 3 inches and include a true union for quick assembly. For dome fittings installed +/- 12 inches from the sidewall, standard pipe supports can be used. If the dome fitting is more than 12 inches from the sidewall or if the fitting size is greater than 4 inches, you must use a non-invasive internal pipe support (our “promo tank”) to support the internal piping. Customer installation of the internal drop pipe assembly is required. Use a universal ball dome fitting for easier installation. Pipe supports should be used one for every 6 feet of sidewall height.
58
Manways/Lids
FUME-TIGHT MANWAY COVER
Available in two sizes, 17 and 24 inches, with bolts of stainless steel, Alloy C-276 and titanium. Gasket materials available include EPDM, Viton®, Viton® GF, XLPE or Buna. The 17-inch model is often used on 19-inch manways as well.
BOLTED (8/16) MANWAY COVER
These are the most popular covers we provide. They are available in 24 inches. Please note that if you plan on visually inspecting the interior of the tank with some frequency, our SAFE-Surge™ manway cover may be a better alternative.
59
Manways/Lids
FITTINGS AND ACCESSORIES
THREADED LID
Available in two sizes, 7 and 17 inches, coarse threaded. Gasket materials available include EPDM, Viton®, Viton® GF, XLPE or Buna.
SAFE-Surge™ MANWAY COVER
Designed specifically for pneumatic-filled tanks. Releases at a 6-inch water column to prevent over-pressurization, ensuring that the tank maintains proper ACFM at all times – even in the event of air surges that cannot be handled by primary venting. Available in 19 and 24 inches. For detailed venting requirements, please refer to the chart on page 63.
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Accessories
LADDER ASSEMBLIES
Poly Processing’s tank ladders are available in heights from 6 to 20 feet, depending on the tank application. To determine height, ladder height equals height to top of manway rounded to the nearest foot. If height of ladder exceeds the height of the manway, subtract 1 foot.
• Ladders are available in mild steel as well as FRP construction.
• All ladders meet OSHA requirements.
• Ladders are not offered on all tanks due to safety requirements. Approved systems are noted with the appropriate ladder height in the distributor price list.
• Cages range from 7 to 8 feet and extend 4 feet above the top rung of the ladder.
Tanks with a center manway will have the additional cost of a platform to reach the ladder.
HEAT PADS AND INSULATION
Poly Processing’s tank heating systems are specifically designed for temperature maintenance of polyethylene tanks. SilcoPad® tank heating systems maintain a desired product temperature, not to exceed 100 degrees F.
• Each heating system consists of tank heating pad(s) and a temperature controller. The quantity and type of SilcoPad® tank heating pads required is determined by the size of the tank, the desired temperature maintenance and environmental conditions.
• Tanks are available with standard heating systems with a Delta T of 30, 60 and 100 degrees F.
• Tanks are typically supplied with the heating panels and a controller installed by Poly Processing. The only field connection required is a power supply to the heating system.
Please contact our customer support staff if HT & I is required on a 14-foot-diameter tank.
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FITTINGS AND ACCESSORIES
Accessories
OPTIC LEAK DETECTION SWITCH
This switch is an excellent choice for leak detection in secondary containment tanks. The submersible sensor is mounted in the interstitial space of the tank. The internal 1A relay provides a reliable switch interface with indicators, PLCs, SCADAs and alarms.
• Fail-safe leak sensor inverts wet to alert user for maintenance.
• Rugged PP or PFA Teflon® probe and cable rated NEMA 6
• 1A relay selectable NO or NC via power supply wiring polarity
• Compatible with MicroPoint™ multi-channel indicator
ULTRASONIC LEVEL SWITCH
This CSA-approved switch is intrinsically safe for use in hazardous-area locations. The Ultrasonic Level Switch is broadly used in chemical liquids. Its 1A relay provides a reliable switch interface with remote devices such as a PLC, SCADA or alarm. This submersible sensor is universally mounted through the wall inside the tank.
• CSA-approved intrinsically safe for use in hazardous-area locations
• Rugged PP or PFA Teflon® probe and cable rated NEMA 6
• 1A relay selectable NO or NC via power supply wiring polarity
• Compatible with MicroPoint™ multi-channel indicator
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Restraints
SEISMIC RESTRAINTS
Used to protect against seismic events, these clip systems are available for location- and site-specific information areas.
• PE wet stamps will be provided by request for a fee. Contact Poly Processing’s customer support staff.
• If the tank will be placed on a concrete pad, it is critical to allow at least 8 inches of space between the tanks and the edge of the pad to accommodate the proper anchoring of the clips.
For all other design considerations, please contact our customer support team and ask to talk to our engineering department. For Monroe, LA, call 866.590.6845; for French Camp, CA, call 877.325.3142.
WIND RESTRAINTS
Poly Processing offers cable systems to help stabilize tank systems that are challenged by wind.
• Standard systems are designed for wind speeds of 130 mph.
• PE wet stamps will be provided by request for a fee.
For all other design considerations, please contact our customer support team and ask to talk to our engineering department. For Monroe, LA, call 866.590.6845; for French Camp, CA, call 877.325.3142.
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FITTINGS AND ACCESSORIES
Vents
MUSHROOM VENT
For day tanks, an economical alternative to traditional U-vents or fittings. Made of polypropylene, in sizes 1 to 3 inches
U-VENT
Standard venting for outdoor tanks or for storing chemicals that create fumes. In PVC, in sizes 2 to 6 inches
VENTING REQUIREMENTS FOR POLYETHYLENE TANKS
Mechanical Pump Fill Pneumatic Fill
IF ≤ 1,000 gallons IF – Vent length ≤ 3' IF – Vent length > 3' and ≤ 30' IF – Scrubber application
Vent size should equal size of largest fill or
discharge fitting
AND – Vent screen mesh size ≥ ¼" or no screen used
AND – 3 or less 90° elbows with no other restrictions or reduction in pipe size
Vent pipe size throughout scrubber system CANNOT be reduced!
Centerline of dispersion pipe not to be submersed > 6"
IF > 1,000 gallons Emergency Pressure Relief Cover Required
Emergency Pressure Relief Cover Required
Perforated dispersion pipe must be same diameter as vent or larger. Sum of
perforations ≥ cross-sectional area of pipe
Vent size should exceed the largest fill or
discharge fitting by 1"
Tanker Discharge
Inlet/Fitting Size
Minimum Vent Size
Tanker Discharge
Inlet/Fitting Size
Minimum Vent Size
Tanker Discharge
Inlet/Fitting Size
Minimum Vent Size
2" 2" 4" 2" 2" 6" 2" 2" 6"3" 2" 6" 3" 2" 6" 3" 2" 8"3" 3" 6" 3" 3" 8" 3" 3" 10"
»» See our website for Detailed Venting Guidelines.
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Delivery:Getting it to you at the right time, in the right condition.
At Poly Processing, we do our best to keep you informed and on track. Once you place your order with us, you’ll have full access to daily order tracking, and we’ll give you 24 to 48 hours’ notice of tank delivery as well. We’ll gladly work with you to accommodate special needs, coordinating with issues such as crane delivery.
Your order will ship directly from one of our three strategically located plant sites: Louisiana, California or Virginia. We make all the arrangements for wide loads, escort-permitted loads, flatbeds, vans, less-than-truckloads, and common carriers and hot shots. We also ship via UPS and Fed Ex, when it makes sense to do so. We have the ability to handle overseas shipments, too.
All of our tanks are washed, cleaned, protective-wrapped and final inspected before shipment, and common carrier shipments are wrapped and palletized.
For extra security, fitting and thread protectors are added, and all loose parts are boxed and labeled.
www.polyprocessing.com
California8055 S. Ash St.
French Camp, CA 95231Tel: 877.325.3142
virginia161 McGhee Rd.
Winchester, VA 22603Tel: 866.590.6845
louisianaP. O. Box 4150
2201 Old Sterlington Rd.Monroe, LA 71203Tel: 866.590.6845
smarter storage means a safer environment
At Poly Processing, we know that chemical storage isn’t just about business processes. It’s about protecting our environment from harm. So our company constantly strives to create smarter, safer ways to contain, maintain and transfer chemicals. By bringing new and better ideas to the industry, we’re safeguarding our planet. It is part of our commitment to continually seek better solutions to chemical storage challenges.
Doc Ref: P106 Rev 13 01/10/14 Page 1 of 4
QUALITY STANDARD FOR
TRIFUSION® PLUS
GLASS COATINGS
FOR USE IN
INDUSTRIAL LIQUID STORAGE TANKS 1. SCOPE
This Standard specifies the quality requirements for the TRIFUSION® PLUS process for glass coating by vitreous enamelling of panels intended for use in the construction of storage tanks for uses such as the storage or treatment of industrial effluent, where a wider variability of liquor concentrations exists and the more aggressive environment demands a superior quality.
This Standard applies to the enamelling elements of the TRIFUSION® PLUS process, however, the quality criteria in Section 5.2 should apply to the tank as built. The TRIFUSION® PLUS glass coating has been developed with reference to International Standard specifications for glass coatings on bolted steel panels and conforms to EN ISO 28765(1).
2. DEFINITIONS
For the purposes of this Standard, the following definitions shall apply.
Glass coating: Any coating, commonly also referred to as vitreous enamel, based on silica Glass-Fused-to-Steel sheets by the TRIFUSION® PLUS process at temperatures sufficient to cause glass melting and chemical bonding to the steel substrate so as to form a composite glass/steel panel.
Supplier: Any company supplying Permastore with any materials for use in the TRIFUSION® PLUS process.
Defect: Any void, break, crack, thin spot, blister, foreign inclusion or contamination of the glass coating.
Discontinuity: Any defect which allows an electric current to pass through the glass coating when testing using the specified instrument operated in accordance with Section 5.2.2 of this Standard.
3. GENERAL
The inspection procedures specified in this Standard and the TRIFUSION® PLUS enamelling process shall be carried
out under quality management systems accredited to ISO 9001(2).
4. RAW MATERIALS
4.1 The steel used shall have a specification as agreed between Permastore and the steel supplier having due regard to the requirements of the enamelling process.
4.2 All other raw materials used in the production of the glass coated panels shall be inspected on receipt at Permastore’s premises to ensure that they meet Permastore’s specifications.
4.3 Where Permastore is not able to inspect raw material against any aspect of Permastore’s specification or the specification according to Clause 5.1.1 (for example, chemical composition of steels, flow bead tests of glass etc.), Permastore shall require the supplier to carry out such inspections at the supplier’s premises and provide Permastore with authorised copies of certificates for such inspections and record conformity of the raw materials in accordance with the Quality Specification, and make certified copies of those records available.
5. QUALITY
5.1 Glass Coating
Glass coated test samples shall be regularly tested to ensure that the properties of the glass coating meet the requirements of this Standard and Permastore’s specification.
5.1.1 Quality Specification
Tests shall be carried out to ensure that the glass coating on the contact enamel surface meets the chemical resistance and physical properties specifications set out in Table 1.
Doc Ref: P106 Rev 13 01/10/14 Page 2 of 4
TABLE 1 – CHEMICAL RESISTANCE AND PHYSICAL PROPERTIES
TEST
STANDARD QUALITY
SPECIFICATION
MINIMUM TEST
FREQUENCY
CHEMICAL RESISTANCE (Inside Surface)
Citric acid at room temperature
EN ISO 28706-1:2011 (3) Clause 9
Class AA Monthly
Boiling citric acid EN ISO 28706-2:2011 (4) Clause 10
Maximum weight loss 0.75g/m2 after 2½ hours
Annually
Boiling distilled or demineralized water Liquid phase - Vapour phase -
EN ISO 28706-2:2011 Clause 13
Maximum weight loss 1.5g/ m2 after 48 hours 5g/m2 after 48 hours
Annually
Hot sodium hydroxide
EN ISO 28706-4:2011 (5) Clause 9
Maximum weight loss 6g/ m2 after 24 hours
Annually
Sulphuric acid at room temperature
EN ISO 28706-1:2011 Clause 10
Class AA Monthly
Hydrochloric acid at room temperature
EN ISO 28706-1:2011 Clause 11
Class AA Monthly
Boiling hydrochloric acid Vapour phase
EN ISO 28706-2:2011 Clause 12
Maximum weight loss 7g/m2 after 7 days
Annually
Standard detergent solutions
EN ISO 28706-3:2011 (6) Clause 9
Maximum weight loss 2.5g/m2 in 24 hours
Annually
PHYSICAL PROPERTIES (Inside Surface)
Impact ISO 4532(7), 40N force.
Maximum cracking 2mm after 24 hours
Monthly
Adherence level EN 10209: Annex C(8)
Class 2 Monthly
Resistance to abrasion
ISO 6370-2(9) Maximum weight loss 45g/m2
Annually
Resistance to thermal shock
EN ISO 28763:Annex A (10)
No Damage Annually
Scratch hardness EN 15771(11) Mohs 5 Monthly
Doc Ref: P106 Rev 13 01/10/14 Page 3 of 4
5.2 Finished Panels
Finished panels shall be inspected following the enamelling process, prior to packing and despatch from Permastore’s premises. Permastore shall carry out inspections on both the inside and the outside surfaces. In cases where both the inside and the outside surfaces of the panel are in contact with the stored liquid both surfaces shall be treated as inside surfaces for the purposes of this Standard.
5.2.1 Inspection of the Outside Surface
The outside surface of all panels shall be inspected visually under good daylight or equivalent lighting for defects in the glass coating. Any panel having visible defects larger than 1mm shall be rejected. Any panel having more than three visible defects per m2 of the total panel area shall be rejected. All visible defects on the outside surface of accepted panels shall be repaired using a repair material approved by Permastore for this purpose and applied according to the repair material manufacturer's instructions.
5.2.2 Inspection of the Inside Surface
The inside panel surface shall be inspected using a high voltage tester approved by Permastore for this purpose and used in accordance with Test A of EN 14430(12) and Clause 5.2.2.1. Inspection shall be carried out on every panel and any panel having any discontinuities shall be rejected.
5.2.2.1 The tester shall have an accuracy of ±1% and a test voltage of 1500 volts shall be used. The tester shall have a valid calibration record.
5.2.3 Inspection of the Glass Thickness
The thickness of the glass shall be measured using an approved instrument suitable for a measurement
range of 0-500m and used in accordance with EN ISO 2178(13). Inspection shall be carried out using a sampling procedure complying with ISO 2859: Part 1(14).
The thickness of the glass on the inside surface of every panel shall be maintained in the range from 340µm to 500µm. The thickness of the glass on the outside surface of every panel shall be maintained in the range from 250µm to 500µm. Panels having a glass
thickness outside these ranges shall be rejected.
5.2.4 Inspection of Glass Colour
The outside panel surface shall be inspected using a colour comparator instrument and the colour checked against standard limits set by Permastore. Inspection shall be carried out using a sampling procedure complying with ISO 2859: Part 1. Panels of a colour outside these limits shall be rejected.
6. HANDLING AND PACKING
Prior to storage or packing panel edges shall be protected using a material approved by Permastore for this purpose and applied according to the edge protection material manufacturer's instructions. All panels shall be packed using a suitable membrane between the panels.
7. GUIDANCE NOTES FOR INSTALLATION AND USE
7.1 Care in Handling
Recommendations for the correct methods of handling outside the enamelling premises are given in the Permastore Construction Guide.
7.2 Inspection at the Construction Site
During tank installation, the use of an approved low voltage wet swab tester on the inside panel surface is recommended. Permastore can advise on the use of the low voltage wet swab test equipment. Guidance is also given in the Permastore Construction Guide.
7.3 Change of Use
Owners and users of industrial storage tanks should be aware that changes in the use or structure of a tank can result in dramatic changes to the operating environment and affect the coating and design limitations of the tank. Permastore will offer advice on request.
PERMASTORE® and TRIFUSION® are Registered Trade Names
of Permastore Limited of the United Kingdom.
Copyright PERMASTORE Limited 2014
Doc Ref: P106 Rev 13 01/10/14 Page 4 of 4
8. REFERENCES
1. EN ISO 28765:2011
Vitreous and porcelain enamels – Design of vitreous enamel coated bolted steel tanks for the storage or treatment of water or municipal or industrial effluents and sludges.
2. ISO 9001
Quality management systems - Requirements for design, manufacture and installation of vitreous enamelled tanks and silos for storage and processing of liquid and dry product and associated equipment.
3. EN ISO 28706-1:2011
Vitreous and porcelain enamels – Determination of resistance to chemical corrosion – Part 1: Determination of resistance to chemical corrosion by acids at room temperature.
4. EN ISO 28706-2:2011
Vitreous and porcelain enamels – Determination of resistance to chemical corrosion – Part 2: Determination of resistance to chemical corrosion by boiling acids, neutral liquids and/or their vapours.
5. EN ISO 28706-4:2011
Vitreous and porcelain enamels – Determination of resistance to chemical corrosion – Part 4: Determination of resistance to chemical corrosion by alkaline liquids using a cylindrical vessel.
6. EN ISO 28706-3:2011
Vitreous and porcelain enamels – Determination of resistance to chemical corrosion – Part 3: Determination of resistance to chemical corrosion by alkaline liquids using a hexagonal vessel.
7. ISO 4532:1991
Determination of the resistance of enamelled articles to impact: Pistol test.
8. EN 10209:2013
Annex C: Cold-rolled low carbon steel flat products for vitreous enamelling – Technical delivery conditions.
9. ISO 6370-2:2011
Vitreous and porcelain enamels – Determination of resistance to abrasion – Part 2: Loss in mass after sub-surface abrasion.
10. EN ISO 28763:2011
Vitreous and porcelain enamels - Regenerative, enamelled and packed panels for air-gas and gas-gas heat exchangers – specifications.
11. EN 15771:2010
Vitreous and porcelain enamels – Determination of surface scratch hardness according to the Mohs scale.
12. EN 14430:2004
Vitreous and porcelain enamels – High voltage test.
13. EN ISO 2178:1995
Non-magnetic coatings on magnetic substrates – Measurement of coating thickness – Magnetic method.
14. ISO 2859:1999
Sampling procedure for inspection by attributes - Part 1: Sampling schemes indexed by Acceptance quality limits (AQL) for lot-by-lot inspection.
worldwidecontainmentsolutions
. . . . . . . . . . . ... .... .... .... ...
Permastore is the market leader in themanufacture and supply of Glass-Fused-to-SteelTanks and Silos. Since 1959 the Company has beenproviding durable and cost effectively engineeredcontainment solutions in Municipal, Industrial andAgricultural environments worldwide. Permastoreexports to over 110 countries and in excess of300,000 structures have been installed worldwide,each with the ability to withstand localenvironmental extremes, from the cold of thearctic to the heat of the desert. Permastore offersa complete range of diameter and height optionswith storage capacity solutions exceeding50,000m3 (13,200,000 US Gallons).
• ISO 9001:2008 – Accreditation of qualitystandards to guarantee Customer satisfaction.
• International Standards – Permastore’s qualitysystems ensure that products meet or exceed therequirements of AWWA D103-09, EEA 7.20 andEN ISO 28765:2011 amongst others.PERMASTORE® structures are engineered with apredicted minimum 30 year design life inaccordance with the requirements ofISO 15686-1:2011, ISO 15686-2:2012 andISO 15686-3:2002 which provide the frameworkfor determining and planning a service life of upto 50 years.
• International Bodies – Permastore QualityStandards are verified by MPA NRW. Certified toNSF/ANSI 61. Approved by the UK Secretary ofState under Regulation 31 for drinking water andlisted by DWI (Drinking Water Inspectorate) in itsList of Approved Products.
• In-house Engineering Design and ContractManagement – This provides reassurance thatall structures arrive on schedule and are fit forpurpose.
• Production – All controlled at one manufacturingsite, thereby simplifying the supply chain andproviding a seamless service to meet Customers’requirements.
• Technical Support – An experienced team thatinteracts with our Customer base to ensureCustomer demand is met.
• Modern Manufacturing Facility – A state of theart factory dedicated solely to the production ofGlass-Fused-to-Steel product.
• Advanced Glass-Fused-to-Steel Technology– This provides the ultimate in corrosionresistance for the life of the structure.
What is Glass-Fused-to-Steel?
Glass-Fused-to-Steel is a unique tank finish. Two materialsare fused together to achieve the best of both materials –the strength and flexibility of steel combined with thecorrosion resistance of glass. Applied to both interior andexterior surfaces, Glass-Fused-to-Steel is able to providemany years of trouble free service in harsh environments.
• High performance and hard wearing
• As strong and flexible as steel
• Inert silica glass
• Colour fast / UV stable
The Solution
FEATURE BENEFIT TO THECUSTOMER
Modular Design Site fabrication is not requiredsimplifying build
Factory applied coating Consistent quality notdependent on site conditions
Strong adhesion Strength of steel withcorrosion resistance of glass
Abrasion & UVresistance
Ensuring long term aestheticsand reduced maintenancecosts
Lifetime coating,re-application notrequired
Reduced operational costsand downtime, improving thereturn on capital investment
Corrosion allowance notrequired
Reduced capital expenditure
Potable water compliant Versatility at no extra cost
Features and Benefits of Glass-Fused-to-Steel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .The Company
STEEL
ENAMEL
The modular tank systemallows very rapidinstallation when comparedto traditional concrete orwelded tank construction.The structures supplied andinstalled by Permastore’sDistributors are constructedin accordance with detailedconstruction guides bytrained crews to give rapidand high qualitycompletion on-site.
Tanks and silos are each supplied as a complete kit ofcomponents ready for assembly. The kit design includesfeatures to ensure that the build can take place in theoptimum time and be “right first time”.
Tanks are usually designed to be mounted on preparedconcrete foundations. However PERMASTORE® structurescan include Glass-Fused-to-Steel floors or cones whererequired.
This modular bolted system gives the flexibility ofconstruction techniques to suit local conditions. Forexample, tanks and silos can be built with a jacking systemwhich allows the build work to be carried out at groundlevel, giving build time benefits and crew safety benefits.
InstallationIs independently Certified and meets or exceedsInternational Quality Standards
A philosophy enshrined in Permastore’s procedures, whichexceed the requirements of International EnamellingStandards. All industrial grade finishes are subject to 100%inspection and electrical testing of the contact surface. Anypanel having a discontinuity is rejected. Permastore hasearned this reputation by dedication to the highest qualityand commitment to ZERO DISCONTINUITY (defect free attest voltage) glass fusion.
The Quality
MPA NRW – Fully independentauditing of Permastore QualityStandards and product testingsince 1986.
NSF/ANSI 61 – Certification forproduct quality and suitability forpotable water storage.
ISO 9001:2008 – Accreditation ofQuality Management Systemssince 1996 to guarantee consistentcustomer satisfaction.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .
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Potable Water
PERMASTORE® tanks are globally accepted for potablewater applications.
The Company’s Glass-Fused-to-Steel tank system hasNSF/ANSI 61 certification and is approved by the UKSecretary of State under Regulation 31 for drinking waterand listed by DWI (Drinking Water Inspectorate) in its List ofApproved Products.
The hard, inert and hygienic surface of the Glass-Fused-to-Steel finish makes it simple to clean and disinfect watertanks.
A large range of water treatment processes can beaccommodated within PERMASTORE® tanks, includingborehole water, seawater desalination tanks, reverseosmosis (RO), permeate tanks, settling tanks, filtrationtanks, disinfection tanks, coagulation/flocculation tanks,aeration tanks, activated sludge tanks, filter tanks,sedimentation tanks, chlorine contact tanks and dosingtanks, amongst others.
The bolted tank and silo system allows structural designs tobe used in various configurations including water storagereservoirs, water standpipes, and elevated waterdistribution tanks.
Designs can accommodate secure tank storage for localenvironmental conditions, such as high wind speeds, snowor seismic loads. Permastore offers a complete range ofdiameter and height options with storage capacity solutionsexceeding 50,000m3 (13,200,000 US Gallons).
The Market Sectors
MunicipalSewage Treatment
Glass-Fused-to-Steel tanks have a very high resistance tochemical corrosion and have excellent abrasion resistanceproperties, making them a suitable consideration in yoursewage treatment application. PERMASTORE® tanks havebeen successfully used for an extensive range of sewagetreatment applications. Just some of the uses include:
• Clarifiers
• Aeration
• Membrane batch reactors (MBR)
• Sequential batch reactors (SBR)
• Thickener tanks
• Sludge holding
• Sludge mixing
• Sludge treatment
• Equalisation tanks
• Trickling/filter media tanks
• Settlement
• Grey water
• Storm water
• Sludge cake silos
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .
Industrial Effluent
There can be a high degree of variability in the effluentfrom industrial sources. This can place a challenge on theprocess designer to select suitable storage and processtanks to withstand a range of aggressive liquids.
The PERMASTORE® Glass-Fused-to-Steel solution providesa high degree of protection for the tank for a large range ofindustrial processes from food waste to tannery effluent andleachate amongst others.
The advantages of the high corrosion resistance of Glass-Fused-to-Steel together with the modular nature of the tankbuild give customers significant benefits in containmentsecurity, project build times and life-time costs.
Process Water
Process water tanks take advantageof the inert properties of the Glass-Fused-to-Steel finish and the factthat it does not require recoating,giving users the re-assurance theyrequire for these critical applications.
With existing certification for potable water storage toNSF/ANSI 61 and approval by the UK Secretary of Stateunder Regulation 31 for drinking water and listed by DWI(Drinking Water Inspectorate) in its List of ApprovedProducts, PERMASTORE® tanks are proven to be ideal forprocess water applications.
For example, these can include food and beverage waterrequirements, or alternative water applications such as fishfarms, or demineralised water storage for industry such aspower plants.
Industrial
Bulk Solid Storage
PERMASTORE® silos with the hard, inert finish offered byGlass-Fused-to-Steel have exceptional resistance to abrasionand present a hygienic, low friction surface to the storedproduct. Some of the bulk storage applications include:
• Food production
• Coal
• Carbon black
• Fishmeal
• Limestone
• Powders
• Plastics
• Road salt
• Soya meal
• Grains or other whole or milled food stuffs
The designs of the silos are tailored to suit specific materialproperties and allow for a range of loading (filling) andunloading (discharge) systems. They also can incorporateroofs, cones and connections for pipework or sensors.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .The Market Sectors
Biogas/Anaerobic Digestion
FEATURE BENEFIT
Long life span Reduced replacement costsand improved return oninvestment
Modular bolted tankconstruction
Rapid and cost effective siteinstallation – Reducing projecttimescales, costs andrequirement for on-siteequipment
Flexibility to remodel andrelocate
Tanks can be extended,dismantled and resited givinglong-term asset value
Optimum corrosion resistanceof Glass-Fused-to-Steel
Safe and secure storage withminimal maintenance costs
Complete range of diameterand height options withstorage capacity solutionsexceeding 50,000m3
(13,200,000 US Gallons)
Most cost effective solution tomeet customers’ needs
Permastore’s history of anaerobic digestion (AD) tanksexceeds 40 years, and the Company’s experience hasexpanded considerably over the decades. Glass-Fused-to-Steel tanks are utilised for mesophilic digesters,thermophilic digesters, pasteurising digesters andenhanced enzymic hydrolysis (EEH) digesters amongstvarious other processes and applications.
In the industrial sector using anaerobic digestion to createbiogas is increasingly recognised as a valuable method toutilise waste streams to create renewable energy.
Almost any organic waste can be digested, opportunitieshave developed to utilise food processing waste, domesticwaste and restaurant waste. Increasingly combinations ofwaste streams are being processed along with co-digestionof municipal sludge effluent and farm waste such as animalslurry to generate “green” renewable energy.
Biogas produced can be cleaned and introduced directlyinto the grid, or converted into electricity in combined heatand power engines (CHP). This also gives the opportunityto generate heat energy in the form of hot water.
At the end of the process the digested material can beconsidered for use as fertilizer, which increases the potentialrevenue streams.
Modular design allows the flexibility to accommodatevarious aspect ratios, process pressures and temperaturesto suit a variety of AD processes, designs and applicationsas specified by your process designer.
Glass-Fused-to-Steel is not only utilised for the tank wallsbut also in the roofs on tanks such as digesters. This givesthe high degree of protection of Glass-Fused-to-Steelthroughout a digester, especially in the highly aggressivegaseous zone.
These roofs are structurally designed to allow for localenvironmental loading and can also support centrallymounted mixer systems.
Additionally, Glass-Fused-to-Steel tanks can also be usedfor biogas storage by incorporation of
double membrane covers.
The combination of Permastore’s inert Glass-Fused-to-Steelfinishes, combined with the strength of steel and theflexibility of modular construction give significant benefitsover other types of digester structures. These include:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .
Slurry
Farm pollution control has become important and effectiveand secure slurry storage is a critical part of the solution.
Local environmental agencies around the world are usinglegislation and support schemes to encourage farmers toupgrade their slurry management systems. This includesdrivers such as the European Commission Nitrates Directiveand the US Natural Resources Conservation ServiceEnvironmental Quality Incentives Programme (EQIP).
To safeguard the environment, slurry is required to bestored at certain times of the year. This is where the highlevel of security of the PERMASTORE® Glass-Fused-to-Steeltank system is particularly suited. Permastore have beensuccessfully supplying slurry tanks since the late 1960’s,demonstrating the durability and longevity of the product inthis harsh environment.
Complete range of diameter and height options areavailable with storage capacity solutions exceeding50,000m3 (13,200,000 US Gallons).
Silos
With a history dating back to 1948, PERMASTORE® Glass-Fused-to-Steel silos provide clean and efficient storage ofgrains and forage. The secure sealed system of storage withcapacities from 250 to 1400 metric tonnes (275 to 1540 UStons), gives significant benefits to livestock producers:
• High quality feed grain
• Maximised nutrient value of the feed with lowermoisture loss
• Natural conservation without use of chemicals
• No drying costs
• Exclusion of vermin and birds
• Natural suppression of diseases and weeds by the dark,oxygen limiting environment
• Suitability for organically grown produce
• Traceability of inputs for accreditation schemes
• Permits earlier harvesting to eliminate drying costs
• Harvesting flexibility and buffer storage for existinggrain storage systems
• Greater palatabilityfor livestock
• High digestibility forlivestock
• High animal growthrates and feedconversion efficiency
Agricultural
The ECOFUSION® agricultural gradefinish is subject to Permastore’sstringent manufacturing, inspectionand testing regimes in accordancewith BS and EN ISO standards.
ECOFUSION® is used for:
• Livestock effluent tanks
• Moist grain silos
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The biofuel industry is growing around the world as anenvironmentally acceptable renewable energy sourcegenerated from biomass. Biofuel use can reduce emissionsof green house gases, lower the demand for fossil fuels andis often supported by government subsidies.
The main biofuels are, bio-ethanol or alcohol made fromfermentation and bio-diesel produced by transesterifi -cation. They are both derived from organic biomass. Theplants manufacturing these biofuels therefore haverequirements for tanks and silos for the input ingredients,
from sugar and starch crops such as sugar cane tovegetable oils or animal fats. Also storage is required forthe finished product as well as for feed water and fire watertanks on-site. BIOTANQ® modular tanks and silos can beutilised in these areas giving significant benefits overtraditional welded structures.
International Standards – For biofuels storage, Biotanq’squality systems provide a credible alternative to the API 650standard for welded tanks and to the 12B specification forbolted tanks.
Benefits For The End User:
The BIOTANQ® Glass-Fused-to-Steel finish combined withits modular design and build concept, offers an array ofbenefits to contractors and end users.
• Long Life
• Low Capital Cost
• Low Maintenance Costs
• Rapid more economical Site Installation Times whencompared to welded structures
• Economic Worldwide Shipments
• Flexible to Remodel, Extend, Dismantle and Resite
• Optimum Corrosion Resistance
The Market Sectors
Mining
Biofuels
The mining industry requires treatment tanks which mustresist the highly abrasive nature of the contents and thecorrosive environment of mining processes.
PERMASTORE® Glass-Fused-to-Steel tanks are ideal for thisapplication. PERMASTORE® tanks are suited to toughenvironments where dependability is a vital characteristic.They can withstand the extremes of the environment inthese remote locations, and the modular design principle ofthe tank kits offers ease of transport and assembly at site.
The bolted nature of the tanks allow them to be built veryquickly when compared to welded structures. It also allowsthe existing tanks to be unbolted and moved on to newlocations when required, significantly increasing asset value.
Both process and effluent treatment can be carried out inPERMASTORE® tanks in most applications which caninclude mines for gold, silver, coal, copper, diamonds, ironore, cobalt, nickel, platinum, potash, rare earth metals,uranium, zinc and many other minerals.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .Roofs, Covers and Ancillaries
Viewports
PVC Cover
Ladders & Platforms
Glass-Fused-to-Steel Floors
Cones
Level Indicators
Connections
Manways
Launders
Walkways
Dome Roof
Trough Deck Roof
Comprehensive Ancillary Range and otheravailable options
Comprehensive Roof andCover Range
Double Membrane Cover
Glass-Fused-to-Steel Roof
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ISOFUSION® V700 is the primary industrial contact surfacefinish generally used for bulk solids, storm water, filter tanksand sludge storage. An established low cost solutiondelivering security and protection through Permastore’s100% inspection, high voltage zero discontinuity coatingspecification which is defect free at test voltage.
• Application: pH 3-9
• Type: 2 coat, 1 fire
• Thickness: 200-360 microns
• Test Regime: Zero discontinuities at 700V
• Exceeds quality requirements of EEA 7.20
• Meets or exceeds the glass coating requirements ofAWWA D103-09 – Section 12.4
• Meets or exceeds quality requirements ofEN ISO 28765:2011*
TRIFUSION® has rightfully become the standard by whichall other finishes are assessed. This proven high qualitycontact surface finish sets the benchmark for use in themore demanding areas of industrial effluent treatment andsludge digestion. An additional protective layer, togetherwith the zero discontinuity finish tested at an exacting 1100Volts, provides exceptional security and continuousprotection.
• Application: pH 2-11
• Type: 3 coat, 2 fire
• Thickness: 280-460 microns
• Test Regime: Zero discontinuities at 1100V
• Exceeds quality requirements of EEA 7.20
• Meets or exceeds the glass coating requirements ofAWWA D103-09 – Section 12.4
• Meets or exceeds quality requirements ofEN ISO 28765:2011*
HV ISOFUSION® is the premium grade of the ISOFUSION®
range. Combining the commercial benefits of ISOFUSION®
glass and the established confidence associated with highvoltage testing. Delivering a high grade zero discontinuitycoating for optimum protection in specific areas ofapplication which is defect free at test voltage.
• Application: pH 3-10
• Type: 2 coat, 1 fire
• Thickness: 200-360 microns
• Test Regime: Zero discontinuities at 900V
• Exceeds quality requirements of EEA 7.20
• Meets or exceeds the glass coating requirements ofAWWA D103-09 – Section 12.4
• Meets or exceeds quality requirements ofEN ISO 28765:2011*
TRIFUSION® PLUS finish takes Permastore’s acclaimedTRIFUSION® standard to an even higher level, for use inthe most extreme of environments. Aggressive chemicaland high temperature processes can be considered withthis high quality contact surface finish, offering zerodiscontinuity when tested to 1500 Volts.
• Application: pH 1-14
• Type: 3 coat, 2 fire
• Thickness: 340-500 microns
• Test Regime: Zero discontinuities at 1500V
• Exceeds quality requirements of EEA 7.20
• Meets or exceeds the glass coating requirements ofAWWA D103-09 – Section 12.4
• Meets or exceeds quality requirements ofEN ISO 28765:2011*
* Note: EN ISO 28765:2011 Vitreous and porcelain enamels – Design of bolted steel tanks for the storage or treatment of water or municipal orindustrial effluents and sludges, covers both the glass coating requirement and the tank structure design and as such is the first dedicated international
standard specifically created for the Glass-Fused-to-Steel product applicable for water and waste water applications.
A Zero Discontinuity policy applies to ISOFUSION® V700,HV ISOFUSION®, TRIFUSION® and TRIFUSION® PLUS for the tests shown.
All applications are subject to concentration and temperature considerations. All specifications relate to the contact surfaces only.
A detailed specification is available on request.
Industrial Glass Grades
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APPLICATION ISOFUSION®
V700HV
ISOFUSION® TRIFUSION® TRIFUSION®
PLUS INTERNAL COLOURS
Edible / Vegetable Oils 3Dry Bulk Solids 3Farm Digesters (Liquid Zone) 3Storm / Fire Water 3Potable Water (NSF / ANSI 61) 3Filter Tanks 3Municipal Sludge Storage (Open Topped) 3Municipal Sludge Treatment (Open Topped) 3Municipal Mesophilic Digester (Liquid Zone) 3Drinking Water (DWI, Reg 31 Approved) 3Municipal Backwash Effluent 3Municipal Sludge Cake Storage 3Farm Digesters(Roof & Rings Exposed to Gaseous Zone) 3
Municipal Sludge Storage (Tanks with Roof) 3Municipal Sludge Treatment (Tanks with Roof) 3Industrial Effluent and/or Aeration Process 3Food Process Washings 3Liquid Leachates 3Municipal Mesophilic Digester(Roof & Rings Exposed to Gaseous Zone) 3
Thermophilic Digester (Liquid Zone) 3Thermophilic Digester(Roof & Rings Exposed to Gaseous Zone) 3High Temperature Applications 3Aggressive / Chemical Industrial Effluent 3
MUNSELL7.5YR 7/4
00 - A - 05(RAL 7004)
14 - C - 39(RAL 6028)
20 - C - 40(RAL 5013)
12 - B - 29(RAL 6006)
Standard External Colours
Optional External Colours
Further external colours are available on request. All colouridentification numbers are the closest visual match only. Allpanel exteriors are Glass-Fused-to-Steel environmentalspecification. Optional colours at additional cost.
20 - C - 40(RAL 5013)
20 - C - 40(RAL 5013)
14 - C - 40(RAL 7009)
14 - C - 40(RAL 7009)
Application Guide
Distributor:
Permastore LimitedEye, Suffolk, IP23 7HS, England
T: +44 1379 870723F: +44 1379 870530
E: [email protected]: www.permastore.com
Only products bearing the NSF mark are Certified.
PERMASTORE®, TRIFUSION®, ISOFUSION®, ECOFUSION® and BIOTANQ® are Registered Trade Names ofPermastore Limited of the United Kingdom.
Because Permastore Limited is constantly improving products, it reserves the right to change designand/or specification without notice. This brochure reflects the general presentation of product only
and any application is subject to limitations of data made available at time of purchase.
©Copyright 2014 Permastore Limited
Passive Dry Scrubber Model: VEGA–PA Vent Exhaust Gas Arrestor – Phosphoric Acid Media Installation, Operation, and Maintenance Instructions
Page 2 of 10
INSTALLATION CONSIDERATIONS
• EMPTY STORAGE TANK:
o The unit should be installed in a shaded or protected area and not be installed directly in the
sun.
o Install a 1/4" thk Neoprene pad under tank or (2) two layers of 30# roofing felt.
o Water should not be permitted to enter the gas outlet connection. A rain cap or other suitable
prevention mechanism should be used.
o A good way to install this unit outdoors would be to install it under a roof, with the exhaust
duct run through the roof, with a rain cap installed.
o Cables and anchor bolt to hold down tank are not supplied by Severn Trent. Please consult
detailed tank installation instructions.
o Consult detailed tank installation instructions, starting on page 5, for further information
Passive Dry Scrubber Model: VEGA–PA Vent Exhaust Gas Arrestor – Phosphoric Acid Media Installation, Operation, and Maintenance Instructions
Page 3 of 10
• VAPOR DISTRIBUTION SYSTEM / DRY SCRUBBING MEDIA
o Verify the gas diffuser pipe is installed in bottom of tank by opening the plug on lower 3” bulk
head fitting. The diffuser should be oriented with the holes pointing down, and to the sides. If not
properly installed, proceed to make corrections. If properly installed, reinstall plug, and proceed
to install the support gravel.
o The media support gravel should not be
dropped from the manway, it should be
carefully lowered to the bottom of the tank,
and be evenly distributed to cover the vapor
distribution pipe. It may be beneficial to install
the gravel with a chute, perhaps made of
cardboard, or a bucket. The gravel should be
approximately 10” deep, level, and totally
cover the gas diffuser pipe.
o Installing the PA scrubbing media should
be done with care, and the necessary
safety measures should be taken. Irritating
dust will be present. Safety goggles, dust
mask, and other protective covering, such
as a disposable jump suit are
recommended to be worn when handling
the media. For further information consult
the MSDS sheet for other handling
instructions. It may be useful to run a shop-
vac to the gas outlet of the tank in an
attempt to control the dust. The type ‘PA’
scrubbing media should be raked level to no more than 12” from the top of the manway. Do not
overfill the tank with media.
Passive Dry Scrubber Model: VEGA–PA Vent Exhaust Gas Arrestor – Phosphoric Acid Media Installation, Operation, and Maintenance Instructions
Page 4 of 10
• PASSIVE DRY SCRUBBER INSTALLATION SCHEMATIC
• PERFORMANCE CHARACTERISTICS
The passive dry scrubber system has been designed to handle releases from the customer
supplied PRV mounted on top of a tank containing 19 percent (by weight) aqueous ammonia.
The valve has an orifice diameter of 0.34” and a 4 psig set-point.
Based upon the above, and a release occurring at 70° F, the vapor rate will be a nominal 100
lbs/hour, and will contain 0.25 lbs/minute of NH3. The media bed is capable of treating a total of
100 lbs of Ammonia vapors. Assuming that there will be 1 release event per day, and that each
release event will last for 1 minute, the passive dry scrubber will be able to operate for 400 days.
This system has the ability to treat approximately 10 percent of the 40,000 gallon tank volume,
while exhausting from 4 psig to 2 psig, while having a 50° F increase in temperature from 70° F to
120° F in the media bed. During this event the scrubber will absorb approximately 7 lbs NH3.
The total media bed capacity is 100 lbs NH3. The 40,000 gallon storage tank of 19 percent NH3
(aq) can hold a maximum of 68 lbs NH3 in the vapor phase at 70° F. The relief time from 4 psig
to 2 psig should take less than 4 minutes thru the 0.34” diameter relief valve orifice.
Note: The VEGA could cause an undue back pressure on the relief line should the temperature
rise exceed 50° F or temperature go above 120° F for an extended period of time, therefore it is
recommended that a 1 psi relief be used in the vent line connecting the 40,000 gallon tank and
the VEGA.
Note: A pH test could be performed to test if the PA media is exhausted.
Passive Dry Scrubber Model: VEGA–PA Vent Exhaust Gas Arrestor – Phosphoric Acid Media Installation, Operation, and Maintenance Instructions
Page 5 of 10
1. SAFETY CHECKLIST
1.1. Do not rigidly pipe tanks. Refer to section 5.3.2 for additional information.
1.2. All tanks must be properly vented. These tanks are not pressure vessels and must be vented to
atmosphere. Venting equipment should be sized to limit pressure or vacuum in the tank to a
maximum of 1/2" of water.
1.3. WARNING: It is the installer's responsibility to follow all appropriate NFPA, OSHA, and
governmental safety precautions. The following information has been provided as guidelines for
tank use and installation. It does not address safety issues which may be present at specific tank
installation sites. Use appropriate safety practices when handling any tank and/or using heavy
equipment.
1.4. Prevent excessive heat near or inside the tank. Install out of direct sunlight. The maximum
recommended service temperature is 120° F.
1.5. Consider tank entry as a confined space entry. Follow proper entry procedures.
1.6. Do not stand or work on top of a tank. Remember - Safety First!
1.7. Read all warning labels on the tank prior to use and installation.
1.8. Record all warranty information as per section 2 while all information is available at time of tank
receipt. Please refer to section 10 for warranty and policy statements.
2. RECEIVING AND INSPECTING YOUR TANK
2.1. Upon arrival at the destination, the purchaser and/or his agent shall be responsible for inspection
for damage in transit. If damage has occurred or parts are missing, the purchaser should
document this on the bill of lading, file a claim with the carrier, and notify the manufacturer prior
to putting the tank into service.
2.2. Do not drop a tank off a truck onto the ground. Please see section 4 for proper unloading
instructions.
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3. TANK LOADING, UNLOADING, AND POSITIONING
3.1. Tanks should only be moved when empty. They should be hand carried, moved with a handling
cart, or moved with a forklift with protected or rounded fork extensions (to prevent sharp forks
from damaging tanks and to provide adequate support for the tank as it is being moved). Under
no circumstances move a tank loaded with media.
3.2. Tanks should be loaded and unloaded from a horizontal or vertical position in the truck with a
minimal amount of sliding. The tank shall be hand carried, moved with a handling cart, or moved
with a forklift with protected or rounded fork extensions to minimize sliding.
3.3. Tanks should be loaded or unloaded from a dock of proper height or with a forklift with protected
or rounded fork extensions. NEVER drop a tank off of a truck onto the ground since this
may damage the tank and void the warranty.
4. PRE-INSTALLATION NOTES
4.1. TANK OPERATING CRITERIA
4.1.1. TEMPERATURE - All standard tanks are designed for a maximum continuous service
temperature of 100° F. Service temperatures greater than 100° F reduce the strength of the
tank. If exposed to a high temperature for an extended time, inspect tank for damage.
4.1.2. PRESSURE - All standard SII tanks are designed for use at atmospheric pressure.
Pressure or vacuum situations can cause excessive deformation or damage to the
tanks and void warranty.
4.1.3. LOCATION REQUIREMENTS - There may be location requirements which should be
considered prior to placing the tank into service. Some items to consider are: secondary
containment; locating the tank in a flood plain; locating the tank so it is easy to install and
access for service; locating a tank in an area where seismic or wind forces may be
experienced; and heat from surrounding equipment. It is the responsibility of the end user to
ensure that all location requirements have been taken into consideration. Check for all
federal, state, and local regulations that may apply to the tank installation. A thorough
evaluation of the proposed tank location prior to tank installation is recommended.
4.1.4. TANK ENTRY PRECAUTIONS - If entry into the tank is necessary, be sure to take all
necessary precautions and follow all applicable regulations. Entry into a tank should be
considered a "CONFINED SPACE ENTRY with appropriate OSHA safety precautions
required. There are many safety practices which should be considered depending on the
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specific conditions at the site. Please follow all local, state, and Federal rules and
regulations.
4.2. FOUNDATIONS AND SUPPORTS
4.2.1. Vertical flat bottom tanks should be positioned on a concrete pad providing adequate
support and a method to attach a tank restraint system (see Section 5 for restraint system
pad placement criteria). The pad should be clean, smooth, and level so it fully supports the
entire tank bottom with no deflection. The construction site engineer must design an
appropriate concrete pad based on the specific application. It is recommended to install a
1/4" thk Neoprene Pad, or two layers of 30 lb roofing felt under the tank.
4.3. TANK FITTINGS AND CONNECTIONS
4.3.1. Most tank fittings are typically left installed in the tank. Some fittings are not installed due
to damage potential or customer request. Customer job site fitting installation insures proper
gasket compression and minimizes fitting damage potential. Some distributors sell or install
their own tank fittings or accessories. These fittings or accessories are not warranted.
4.3.2. All tank connections must have adequate provisions for tank expansion/contraction due
to temperature and load changes. See Figure below.
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4.3.3. These provisions should allow 4 percent dimensional movement. Rigid piping must not
be directly connected to tank outlets. STWP strongly recommends using expansion joints or
other provisions for all tank connections. Please see the hose connection example in Figure
5.4. The use of rigid piping or the failure to provide for the expansion of the tank will
void all warranties.
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4.4. TESTING AND FINAL INSPECTION
4.4.1. After all fittings are installed and all connections to the tank have been made, fill the tank
with water and hold for at least 5 hours to identify any leaks. A record of the water pre-
test must be submitted to STWP to validate the tank warranty.
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5. WlND/SElSMlC TANK RESTRAINT SYSTEM (FLAT BOTTOM TANKS)
5.1. The wind/seismic tank restraint system is designed for tank restraint on an appropriate concrete
pad under 110 MPH wind or seismic zone 4 conditions. Using the assembly drawing and table
sent with the assembly, verify that all parts are present. Please see Figure 8.2 for a restraint
system installation and assembly information.
5.2. Locate the tank, on the rubber pad, on the concrete pad as desired. Lay out all anchors required
(4 or 8) equally spaced, (4 anchors must be directly below the tank tie down locations). Make
sure all anchors are located next to the tank with the front face of the anchor weldment located
next to the tank. Mark all the anchor bolt locations, remove the anchors and install the required
Hilti adhesive model HVA anchor bolts as specified in the assembly drawing and table sent with
the assembly. These anchor bolts are not provided by the manufacturer and must be purchased
by the customer. Customer must follow all Hilti anchor bolt installation instructions.
5.3. Replace the anchors and secure the anchors to the concrete. Fasten the tank to the concrete
pad with the required cable (make sure the cable sheath is on the cable and located around the
lug locations) as shown by the assembly drawing utilizing the cable thimbles and clamps
provided. Tension the cable before filling the tank to remove cable looseness. Do not over-
tension the cables as this may cause tank damage. The cable tension will change with tank
loading and temperature changes - DO NOT re-tension the cables.
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6. TANK MAINTENANCE
6.1. TANK INSPECTION
6.1.1. Simple periodic inspections of the tank installation can prevent problems and chemical
loss from occurring. Inspection intervals should be consistent with site usage (the more
release events/loading cycles, the more frequent the inspections). The checking procedure
should be as follows:
6.1.2. Inspect the tank for physical damage such as cuts, impacts, cracks, swelling, softening of
tank walls, and stress cracks (caused by long term exposure to environmental conditions
and stress). NOTE: A tank inspection guide is located in the appendix.
6.1.3. Inspect the fittings for broken parts, cracks, wear marks, or other signs of potential leaks.
6.1.4. Inspect gaskets for deterioration. Look for discoloration, bulges, checking or crazing. All
of these symptoms could indicate potential failure.
6.1.5. Inspect any valves and/or pumps that may be connected to the tank. Also inspect the
hoses and connections for any signs of wear.
Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final
WSP Canada Inc. 9-8
APPENDIX B
COST ESTIMATE OF RECOMMENDED OPTION
CITY OF TORONTOR.C. HARRIS WTP - REPLACEMNT AQUEOUS AMMONIA TANKS
PRELIMINARY CONSTRUCTION COST ESTIMATE(FEASIBILITY STUDY REPORT)
No. Work or Item Description Units Unit Unit Cost Install. Total Installed CategoryQty $ Factor Cost, $ Subtotal
1 MECHANICAL & PROCESS WORK & EQUIPMENT 297,500
SS Tank (supplied and fabricated at site) * EA 2 65,000 1.00 130,000Scrubber (in Vent Duct) * LS 1 30,000 1.00 30,000Wet Scrubber Additional Services (pump, pipes, valves, electrical, I&C, etc.) LS 1 22,000 1.00 22,000Modification to Tank Access Structure LS 1 7,500 1.00 7,500Modifications to Pipes and Valves LS 1 7,500 1.00 7,500Emergency Scrubber (including concrete work and ducting) EA 1 35,000 1.30 45,500Electrical and Control (Instrument re-commissioning, emergency scrubber) LS 1 35,000 1.00 35,000Programming and Updating PCN LS 1 10,000 1.00 10,000Misc.: Restoration, cleaning up, removals, etc. LS 1 10,000 1.00 10,000
2 GENERAL REQUIREMENTS 36,000Mobilization/Demobilization L.S. 1 5,000 1.00 5,000Bonding/Insurance L.S. 1 15,000 1.00 15,000Trailers/Temp Facilities (assumed for 2 mon. duration) mo 2 1,600 1.00 3,200Project Superintendant (assumed for 2 mon. duration) wk 8 1,600 1.00 12,800
Sub-Total 333,500Engineering (20%) 66,700Sub Total 400,200General Contractor Overhead & Profit and Markups (10%) 40,020Sub-Total Construction Cost 440,220Contingency (10%) 44,022TOTAL CONSTRUCTION COST(Excluding HST) 484,242
Notes: *- Represents rounded up numbersAccuacy is -20% to +30%
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