V6 Sec4 Tank Terminals General Design

Energy East Pipeline Ltd. Consolidated Application Volume 6: Facility Design

Section 4 Tank Terminals – General Design

May 2016 Page 4-1

4.0 TANK TERMINALS – GENERAL DESIGN

This section describes the philosophies and information that will be generally applied to the design of the three tank terminals required for the Energy East Project. These terminals will be located at:

Hardisty, AB Moosomin, SK Saint John, NB

The terminals at Hardisty and Moosomin will be receipt locations where oil is accumulated in batches for delivery to the Energy East Pipeline. The Saint John tank terminal will be a delivery location where oil batches are delivered from the Energy East Pipeline.

The tank terminals include the following main components:

oil storage tanks with secondary containment

electric-driven pumps

custody transfer meters and meter prover (except Moosomin tank terminal)

interconnecting piping and valve manifolds

fire protection system

buildings that house petroleum quality measurement equipment, electrical equipment, materials, tools, and supplies

stormwater pond

4.1 SAFETY AND ENVIRONMENTAL PROTECTION

Safety and environmental protection measures will be incorporated into the tank terminals to reduce the risk of an incident such as an oil spill or fire from occurring and to reduce the potential effect of an incident should one occur. An overview of these measures is provided in this section, and further details are given in the descriptions of the individual components.

4.1.1 Oil Spill Prevention and Mitigation Measures

The components used to store and convey oil in the tank terminals will provide the primary protection in preventing oil spills. These components include the tanks and the pressure-containing components such as pumps, meters, pipes, and valves. The components will be made of carbon steel designed and manufactured in accordance with industry standards for the service conditions expected.

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When installed, the pressure-containing components will form a closed system. Pressure containment will be achieved by a combination of the thickness and strength of steel selected for each component, designed for the maximum operating pressure of the system. The design will comply with CSA Z662-15.

The integrity of the tanks and pressure containing components will be verified during fabrication and construction and will be maintained during operation by measures such as:

implementing TransCanada’s quality management program for verifying material and fabrication methods

coating surfaces and installing cathodic protection systems to prevent corrosion

hydrotesting piping during construction

leak testing tanks

operating within the approved pressures

implementing TransCanada’s integrity management program

Oil storage tanks will be equipped with an automated overfill protection system that uses redundant instruments. In addition, a leak detection system, an impermeable flexible membrane liner, and a cathodic protection system designed in accordance with API RP 651 will be provided for the tanks. A drain piping system will capture seal leakage from pumps and allow for the pumps and piping to be drained to a sump tank, reducing the potential for oil spills.

Secondary containment to control a product spill will be provided for the oil storage tanks and power transformers.

Meters and booster pumps will have isolation valves that would limit the size of an oil spill. These valves are operated with electric motors that can be closed with the push of a button, either from within the tank terminal or remotely from the TransCanada Operations Control Center (OCC). In addition, there will be isolation valves located at the inlet of the terminal and valves in the valve manifold that can isolate the flow of oil.

4.1.2 Fire Prevention and Mitigation Measures

Fire prevention is primarily achieved by the reduction of vapour release from oil-containing components and the elimination of potential ignition sources around them. The pressure-containing components form a closed system as described previously in Section 4.1.1, Oil Spill Prevention and Mitigation Measures. In addition, oil storage tanks will be equipped with floating roofs and rim seals that will be in contact with the oil, limiting the potential exposure to the air. Electrical equipment will be separated from oil-containing components or designed with protective features to operate safely when installed near oil-containing components.

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Tanks will be provided with electrical conductors for protection against lightning strikes. The conductors direct electricity into the ground where it is safely dissipated.

Sump vents will be equipped with a flame arrestor to prevent ignition of vapour in the sump tank.

A fire foam system will be installed to extinguish a potential fire in the rim seal area between the steel floating roof and the tank wall (see Section 4.5.1, Fire Foam System). Instrumentation will be installed on the tanks to detect fires and provide early warning. The control system will alarm and notify the OCC located in Calgary, Alberta. Upon confirmation of a fire, local personnel will activate the foam system to direct a foam concentrate solution to the fire.

Heat and smoke detectors will be installed in the electrical equipment shelters. These instruments will be monitored by the control system and an alarm will be sent to the OCC if heat or smoke is detected. If a fire is confirmed, the emergency shutdown system (ESD) can be initiated remotely by the OCC or locally.

Isolation valves will have a certified fire-safe design.

4.2 OIL CONTAINING COMPONENTS

4.2.1 Oil Storage Tanks

Oil storage tanks are industry standard, designed and fabricated to API 650. The tanks will have a vertical cylindrical steel shell and steel plate floor and will be equipped with external floating roofs as shown in Figure 4-1.1

The tanks will have an external floating roof, which will be a pontoon-style steel floating roof that covers the surface of the oil. This design allows the roof to be in direct contact with the oil, which reduces vapour emissions to the atmosphere.

The space between the edge of the floating roof and the fixed sidewall of the tank (the rim) is designed with primary and secondary seals to further reduce vapour emissions and the risk of a fire. Tank seals will be specified in accordance with Canadian Council of Ministers of the Environment PN 1180. Wipers mounted on the rim seal will work as a squeegee to wipe the tank walls when the roof is lowered to reduce the amount of oil that might cling to the sidewalls.

Geodesic domes or cone roofs might be added to some tanks to address climatic loads such as rain and snow. This determination will be made during detailed design.

1 This figure was provided courtesy of Matrix Service Company.

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Figure 4-1: External Floating Roof Tank Cross-Section (CA Rev.0)

4.2.2 Preliminary Tank Specifications

Preliminary tank specifications are provided on Table 4-1.

Table 4-1: Preliminary Tank Specifications (CA Rev.0)

Description 350,000 Barrel Tanks1 600,000 Barrel Tanks1

Nominal Capacity2 55,600 m3 (350,000 bbl) 95,400m3 (600,000 bbl)

Working Capacity3 49,400 m3 (311,000 bbl) 87,400 m3 (550,000 bbl)

Tank Diameter 65.5 m 78.6 m

Tank Height 18.2 m 21.3 m

Roof Type External floating roof External floating roof

Maximum Injection and Takeaway Flow Rate4

370,000 m3/day (2,330,000 bbl/day) 530,000 m3/day (3,310,000 bbl/day)

Note: 1. Tank specifications will evolve as project planning progresses through detailed design. 2. Nominal capacity is the volume from the floor of the tank to the design liquid level. 3. Working Capacity is the volume between the minimum and maximum operating levels of the tank. 4. The maximum and injection takeaway flow rates are based on a maximum roof drop speed of 4.6 m/h. The

flow rate will be lower due to hydraulic restrictions.

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4.2.3 Tank Overfill Protection

The tank level gauging system and an independent level switch will provide overfill protection. An alarm will be initiated by the gauging system if the level exceeds the normal operating level, providing time for the OCC to respond. If the gauging system or level switch detects a level that exceeds the maximum operating level, the tank’s inlet isolation valves will automatically close to prevent an overfill condition. The tank foundations and operating levels will be designed to account for the seismic zones at each location.

4.2.4 Tank Corrosion Protection

An industrial epoxy coating will be applied to the tank floor and the bottom (1 m) of the interior vertical wall. This will protect against corrosion resulting from water that might settle at the bottom. In addition, the bottom (1 m) of the exterior vertical wall will be coated with an epoxy to protect against corrosion resulting from water that might accumulate at the base. The remaining tank exterior, including the roof, will be painted.

Corrosion protection will be provided for the tank underside by a cathodic protection system.

4.2.5 Pumps

Major pumps (booster, marine loading and transfer pumps) will be vertical deep well centrifugal units designed and manufactured in accordance with API STD 610. Each pump will be driven by an electric motor started and controlled by a dedicated variable frequency drive (VFD). Instruments will be mounted on pumps and motors to monitor their operation, including temperature and vibration. A deviation from the normal operating range will cause the control system to alarm and, if required, shut down the pump.

Each pump will be equipped with a mechanical seal between the pump’s shaft and casing. Leakage from the seal will be directed to the oil drain system and stored in the sump tank. Leakage will be monitored and, in the event of a seal failure, the control system will alarm and shut down the pump.

4.2.6 Piping

Piping will be designed, manufactured, installed, and tested in accordance with CSA Z662-15.

Corrosion control for belowground piping will be provided through pipe coatings and cathodic protection. The primary coating for the external surface of the belowground pipe will be fusion bonded epoxy. Field girth welds will be protected with a field applied epoxy coating.

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Aboveground piping will be coated using paint products that are suitable for the environmental conditions in which the piping is installed.

Buried piping will have access points for instrumented tool insertion to allow for periodic assessment of the pipe condition, including measurement of metal wall thickness.

4.2.7 Custody Transfer Metering

For details of the custody transfer metering for the Project, refer to Section 8, Custody Transfer Metering – General Design.

4.2.8 Pressure Control and Overpressure Protection

Each tank terminal will be controlled by the local control system to operate within specified pressure ranges. Oil pressure inside the terminal will be continuously monitored using pressure-sensing instruments mounted to the pipe. Discharge pressure of the terminal booster pumps will be controlled by the terminal PLC via a variable frequency drive.

Facilities upstream of the Hardisty D tank terminal, which will also be owned and operated by TransCanada, will provide pressure control for the Hardisty D terminal inlet lines. At the Moosomin and Saint John tank terminals pressure control valves at the terminal inlet will be used to control the pressure in the inlet lines.

Overpressure protection requirements due to transient events such as hydraulic surge will be defined during detailed design. Pipe rated for higher pressures, relief valves, and/or surge accumulators will be used where necessary to prevent overpressure. If relief valves are used, they will direct the flow to a tank.

Pressure safety valves will be installed on the piping for thermal relief of blocked-in sections. The pressure safety valves will discharge into the oil drain system.

4.2.9 Leak Detection System

Tank leak detection will be provided by a subsurface weeping tile detection system comprised of an impermeable liner and slotted pipes beneath the tank. Any leakage will be directed to the tank perimeter and into inspection wells through the slotted pipes. The inspection wells extend aboveground and will be inspected visually by Operations personnel for the presence of leaks in accordance with the applicable TOPs.

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Oil flowing into and leaving the tank terminals will be measured by leak detection meters or custody transfer meters. In addition, a radar-based level gauging system will continuously monitor oil levels in the storage tanks. This information will be used by the OCC to monitor for leaks.

4.2.10 Secondary Oil Containment

Oil storage tanks will be grouped in bermed lots up to a maximum of six tanks. A tank lot perimeter berm and underground impermeable liner will provide secondary containment in the event of a tank failure. The secondary containment can hold the volume of the largest tank plus 10% of the total volume of the remaining tanks. The perimeter berms will be earthen berms. In cases where there are space constraints, the perimeter berms will be concrete walls. A shallower intermediate berm will be constructed between tanks to capture smaller spills (up to 10% of each tank’s volume). These intermediate berms are constructed of granular material.

4.2.11 Oil Drain System

An oil drain system will be provided to collect pump seal leaks and to drain the terminal equipment and piping for maintenance. Drain pipe will be connected to the drain system header, which will be routed to one or more sump tanks.

The sump tank will have a double-walled design with corrosion-resistant fiberglass where the inner shell provides primary containment while the outer shell provides secondary containment. The space between the two walls will be monitored for leakage, allowing for detection. The tank will be provided with two independent level instruments that are monitored by the control system. If the oil in the sump tank reaches the high-level setpoint, an alarm will be activated. If the oil rises further to the “high-high” level, an ESD will be activated shutting down all connected systems.

The sump tank will be equipped with a sump pump to pump accumulated oil into the valve manifold.

The location, number of sump tanks, and tank sizes will be determined during detailed design.

4.2.12 Onsite Batch Detection System

A batch detection system will be installed at the inlets to the following tank terminals immediately upstream of the receiver trap:

Moosomin tank terminal (Energy East Pipeline inlet and Cromer Lateral inlet) Saint John tank terminal (Energy East Pipeline inlet)

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The batch detection system is a skid-mounted shelter that contains a small pump and densitometer. It is used to detect the interface between two batches of oil in the pipeline by measuring density and viscosity. This information is provided to the OCC through the SCADA system.

4.3 CIVIL INFRASTRUCTURE

4.3.1 Stormwater Management

Stormwater and snow melt collected inside the lined tank lots will be contained. Stormwater and snow melt runoff from the pump, meter, and valve manifold area will be directed to a stormwater pond by sloped grading. The pond will have an impermeable liner. Stormwater runoff from other areas in the terminal will be directed to natural drainage areas.

Collected stormwater from the stormwater pond and tank lot area will be tested. If it is found to be within limits specified by applicable regulations, it will be released to natural drainage areas. If the water is not within the specified limits, it will be removed and transported offsite for treatment or disposal.

4.3.2 Water and Wastewater Management

Where practical, municipal potable water will be supplied to the tank terminals. If this is not feasible, ground water from wells will be used to supply potable water. If ground water is not suitable for consumption, potable water will be trucked to site and stored in a cistern.

Where practical, sanitary wastewater for each site will be disposed of in the municipal system. If this is not feasible, sanitary waste will be stored onsite using septic tanks and will be trucked away and transported for disposal.

4.3.3 Security

A security fence will be installed around each tank terminal. It will include personnel egress gates and locked vehicle entrance gates to restrict access to the site.

Other security measures at the tank terminals include intrusion alarms, surveillance systems, and lighting. Specific measures will be determined during detailed design.

4.3.4 Foundations

Energy East anticipates that storage tanks will be supported by gravel granular pad foundations. Equipment, buildings, and structures will be supported by steel or concrete piles or reinforced concrete foundations. The fenced area in the terminals will be finished with crushed gravel. Foundation types will be confirmed during detailed design.

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4.3.5 Geotechnical Considerations

Site-specific geotechnical investigations performed in accordance with CSA Z662-15 and the National Building Code of Canada have started and will continue through detailed design for each tank terminal. If the geotechnical investigations indicate there are conditions not addressed in CSA Z662-15, Energy East will provide a report from a qualified professional engineer and a description of the designs and measures required to safeguard the terminal.

The geotechnical investigations will be focused on the following key design components:

Subsurface Soil Conditions: Borehole information and soil samples will be assessed to determine the nature of the subsurface soil, the presence of unfavourable material such as permafrost or acid rock, and determine its suitability for foundation design.

Slope Stability: Significant slopes will be reviewed to identify areas of active landslides, mudflows and slumping or historic events that may have the potential of being reactivated due to construction.

Faults and Seismicity: Records of historic earthquakes will be analyzed and available geological information reviewed to assess the possible intensity of future seismic events and potential of adverse impacts to the terminals.

Ground Subsidence and Other Geohazards: The potential of ground subsidence, due to natural causes as well as human activities, will be evaluated through the combination of historic record review and aerial reconnaissance.

Measures to mitigate potential geohazards that may impact the integrity of the tank terminals will be implemented, as required, during design, construction and operation of the terminals.

4.4 ELECTRICAL INFRASTRUCTURE

4.4.1 Electric Power Supply

Power for the Hardisty D and Moosomin tank terminals will be supplied from the substations located in the adjacent pump stations. At the Saint John tank terminal, power will be supplied through a substation in the Saint John tank terminal. The power lines supplying the tank terminals will be constructed and owned by independent, third-party regulated utility companies.

Power will be supplied from the substations through redundant transformers, medium voltage buses, and feeder cables. Two electrical equipment shelters will distribute 6.9 kV power to the 600V powered equipment at the terminals. The power will be

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equally split so that if, for example, one electrical equipment shelter is out of service, about 50% of power will be available through the other electrical equipment shelter.

The tank terminals will be have an alternative source of power to supply critical loads in the event of a utility power supply outage. Critical loads will include isolation valves, the uninteruptible power supply system, and the heating, ventilation and air conditioning units. This will allow the tank terminal to be safely shutdown and isolated from the pipeline in the event of a utility power supply outage.

Alternative sources of power may include an independent utility power supply or emergency generator which will be determined in detailed design. Emergency power will be activated through the automatic operation of a transfer switch and, if required, automatic start-up of the backup generator. Once the third-party power has returned to normal and remains stable for 30 minutes, the transfer switch will restore the normal supply to the critical loads and, if required, shut down the backup generator. A double-walled diesel storage tank will be part of the backup generator skid equipment, if required.

4.4.2 Uninterruptible Power Supply

A UPS system, that includes a battery backup, will maintain the operation of critical control, communication and electrical protection systems for up to eight hours in the event of loss of power. Each UPS will include:

a rectifier/charger a battery bank an inverter a static transfer switch a manual transfer switch

The inverter output will be synchronized to a station service power source at the terminal. Should the UPS experience a failure, the static transfer switch will instantly connect the UPS electrical load to the normal station service power source. Once personnel are onsite, the manual transfer switch can be operated to enable continued supply to UPS loads while troubleshooting, repairing and restoring the UPS to normal operation. The battery bank will consist of highly reliable absorbed glass mat (AGM) sealed batteries wherein the electrolyte is completely contained within the glass fibres thus making these batteries spill-proof.

Isolation valves will have emergency power or stored energy devices to close the valves in the event of a loss of utility power.

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4.4.3 Medium Voltage Protection and Control

Medium voltage feeder cables and buses will be protected by relays which will initiate a circuit breaker trip in the event of a fault condition. Fused vacuum contactors will be applied to the VFD supplies of the booster pump motors. The application of fused contactors will accommodate the increased switching duty for these motors.

4.4.4 Lighting

Outdoor light fixtures will be mounted on poles and shelters to provide lighting for security and maintenance activities. Battery powered emergency lighting will be supplied inside electrical shelters and in other buildings that will be occupied.

4.5 ANCILLARY SYSTEMS

4.5.1 Fire Foam System

A fire foam system designed to extinguish tank rim seal fires will consist of an onsite firewater pond, pumps, foam concentrate storage and mixing skid, foam distribution piping, and foam nozzles. The fire protection system will be finalized during detailed design in consultation with the local fire authority having jurisdiction.

A 425 kW electric motor driven pump (with backup) will transfer water from the firewater pond to the foam skid. The water is mixed with foam concentrate to create a foam concentrate solution. The solution is piped to the top of each oil storage tank and discharged through nozzles where it mixes with air and expands. The resulting foam will slide down the inside wall until it reaches the rim seal area and smothers the fire. The size of the electric pump (and backup) will be confirmed during detailed design.

4.5.2 Pressure Vessels and Heating Boilers

Surge vessels might be installed at some sites to accommodate surge events. The location and number of the surge vessels will be determined during detailed design. Vessels will be designed and constructed in accordance with ASME Boiler and Pressure Vessel Code (BPVC), Section VIII, Division 1.

The design and specification of pressure vessels will be registered with the authority having jurisdiction in the province in which they are installed. Pressure vessels will be inspected as specified in API STD 510 to determine that they are being properly maintained and calibrated, and in good working condition.

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4.5.3 Cathodic Protection

Impressed current cathodic protection systems will be installed for underground piping at tank terminals. The system will include ground beds and rectifiers as determined in detailed design. Other non-cathodic protection related infrastructure, such as civil or electrical, will be considered during detailed design to ensure adequate cathodic protection current and distribution.

Each tank floor exposed to soil will have an independent impressed current system to protect the tank bottom from corrosion.

Monitoring systems will be implemented to determine the effectiveness of the applied cathodic protection current.

4.5.4 Ancillary System Piping

As part of this Consolidated Application, Energy East is seeking exemption from Section 17 of the National Energy Board Onshore Pipeline Regulations for the ancillary piping systems listed in Table 4-2.

Table 4-2: Ancillary Piping Systems Specifications, Design Pressure and Non-Destructive Examination Coverage (CA Rev.0)

Piping System TransCanada Specification Design Code

Design Pressure

(kPa)

NDE Coverage

(%)

Instrument Air TES-MATL-MD1, Table 12 ASME B31.3 1,035 15

Glycol/Water Heating TES-MATL-MD1, Table 11 ASME B31.3 1,100 15

Potable Water TES-MATL-MD1, Table 10 ASME B31.3 550 15

Non-Commodity Drainage TES-MATL-MD1, Table 13 ASME B31.3 550 15

Lube Oil TES-MATL-MD1, Table 7 ASME B31.3 1,035 15

Vents TES-MATL-MD1, Table 11 N/A N/A 15

Firewater TES-MATL-MD1-OIL, Table 4-6 ASME B31.3 1,900 15

Contact Water TES-MATL-MD1, Table 13 ASME B31.3 550 15

For additional information, refer to Section 2.5.5, Ancillary System Piping.

4.6 CONTROL SYSTEMS

4.6.1 Programmable Logic Controllers

Tank terminals will be remotely monitored and controlled by the OCC through the SCADA system. The SCADA system will communicate with programmable logic controllers (PLC) installed at the terminals.

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Each terminal will be monitored and controlled by a terminal PLC. The PLC will include features to operate safely and shut down the terminal. The primary functions of the PLC include:

process and equipment protection tank manifold and valve manifold operation booster pump operation and protection high and medium voltage switchgear monitoring communications and data exchange with the SCADA system sump operation

An emergency shutdown will be initiated in the event of a terminal PLC failure.

4.6.2 Human Machine Interface

A local human machine interface will provide the interface between field personnel and PLCs. It provides an alarm summary for all devices in the terminal and local control of equipment during maintenance and troubleshooting activities. The local human machine interface will have a graphic display of the operation that includes:

process and equipment operating information alarms and shutdowns TransCanada OCC and local commands

4.6.3 Emergency Shutdown System

A terminal emergency shutdown system will automatically shut down and isolate the terminal in the event of an unsafe condition such as:

confirmed fire in electrical shelter high sump tank level control system power failure

A terminal ESD can be initiated remotely by the OCC through the SCADA system or by field personnel through the human machine interface. There will also be manual pushbuttons located throughout the terminals.

The following actions will occur when a terminal ESD is initiated:

trip all operating pumps isolate the terminal by closing the inlet and outlet valves (equipped with stored

energy actuators that allow the valve to operate in the event of a power loss)

The ESD logic in the terminal PLC will be backed up by an independent hardwired relay-based ESD system. The hardwired system is designed to replicate the response provided by the PLC in the event of a PLC failure.

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Each booster pump will have a unit ESD. A unit ESD can be initiated by the OCC through the SCADA system or by field personnel through the human machine interface. There will also be manual pushbuttons located near the pumps.

The following actions will occur when a unit ESD is initiated:

trip the operating pump associated with the unit ESD isolate the pump by closing the pump’s inlet and outlet valves

A failure of an ESD initiator component will initiate an ESD.

4.6.4 System Communications

A telecommunications wide area network (WAN) will enable communication between the SCADA system and the tank terminals. Primary and backup WAN circuits will be available from both the OCC and its backup control centre to the terminals. Telecommunications services and infrastructure will be determined during detailed design and might include the following:

underground cable – fiber and/or copper, often provided by telephone companies satellite cellular

4.7 NOISE

Tank terminals will be designed to meet the noise standards identified on Table 4-3.

Table 4-3: Noise Standards (CA Rev.0)

Province Applied Standard

Alberta, Saskatchewan and New Brunswick1

The Alberta Energy Regulator, Directive 038

Note: 1. AER Directive 038 is being applied to Saskatchewan and New Bruncwick facilitites due to the absence of

applicable provincial requirements

Continuous noise sources will be the pumps, motors, piping, tank mixers and power transformers. Intermittent noise sources will be the emergency fire water pumps and generators. Noise from the tank terminals will be affected by the surrounding facilities and environmental conditions such as wind and terrain.

Additional noise assessments will be completed and mitigation measures will be implemented, as required, to ensure compliance with the applicable standards. Mitigating measures might include the following:

sound absorbing insulation on pipes and equipment sound reducing enclosures

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sound barrier berms or walls

4.8 DESIGNATED PROTECTED AREAS

There are no tank terminals in designated protected areas.

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V6 Sec4 Tank Terminals General Design

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