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.

2

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

4

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

I

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

I

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

4

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



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 638614 4837150 4.5

rey house to the we 638557 4837045 4.5









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




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






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




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


R5 5-storey apartment building to the north


R6 121.4 Scenario 11 NO 705 Scenario 23 NO 5-storey apartment building to the north





R9 2-storey house to the NW


R10 2-storey house to the west


R11 4-storey apartment building to the SW



52.4 Scenario 22 YES 141 Scenario 7 NO







R16 5-storey apartment building to the NW


R17 5-storey apartment building to the NW


R18 4-storey apartment building to the west


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

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150B

EL 84.300

EL 84.300

DN

DN

DN

DN

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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.


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


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.


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:





308 mm Hg



LFA = 0.284 * 172/3 * 308 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 2088= 36.3 lb/min


= 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


1.3 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the third 10 minutes






307 mm Hg



LFA = 0.284 * 172/3 * 307 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 36.2 lb/min


= 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%



1.4 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the fourth 10 minutes





=MW: Ammonia Molecular Weight 17.05VP: 328.5 mm Hg

306 mm Hg



LFA = 0.284 * 172/3 * 306 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 36.1 lb/min


= 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





=MW: Ammonia Molecular Weight 17.05VP: 327.5 mm Hg

306 mm Hg



LFA = 0.284 * 172/3 *306 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 36.0 lb/min


= 4.4 lb/min



1.6 Evaporation Rate Estimate for Mitigated Ammonia Solution Release at the sixth 10 minutes






304 mm Hg



LFA = 0.284 * 172/3 * 304 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 35.8 lb/min


= 4.3 lb/min




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


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:





303 mm Hg



LFA = 0.284 * 172/3 * 303 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 35.7 lb/min


= 4.3 lb/min









302 mm Hg



LFA = 0.284 * 172/3 * 302 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 35.6 lb/min


= 4.3 lb/min










301 mm Hg



LFA = 0.284 * 172/3 * 301 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 35.5 lb/min


= 4.3 lb/min










300 mm Hg



LFA = 0.284 * 172/3 * 300 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 35.4 lb/min


= 4.3 lb/min









299 mm Hg



LFA = 0.284 * 172/3 * 299 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 35.3 lb/min


= 4.3 lb/min









299 mm Hg



LFA = 0.284 * 172/3 * 299 = 0.02582.25 * 278

QR = 1.50.78 *0.025 * 1044= 35.2 lb/min


= 4.3 lb/min




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








298 mm Hg



LFA = 0.284 * 172/3 * 298 = 0.02482.25 * 283

QR = 1.50.78 *0.024 * 1044= 35.1 lb/min


= 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%








297 mm Hg



LFA = 0.284 * 172/3 * 297 = 0.02482.25 * 278

QR = 1.50.78 *0.024 * 1044= 35.0 lb/min


= 4.2 lb/min










296 mm Hg



LFA = 0.284 * 172/3 * 296 = 0.02482.25 * 278

QR = 1.50.78 *0.024 * 1044= 34.9 lb/min


= 4.2 lb/min










294 mm Hg



LFA = 0.284 * 172/3 * 294 = 0.02482.25 * 278

QR = 1.50.78 *0.024 * 1044= 34.6 lb/min


= 4.2 lb/min









292 mm Hg



LFA = 0.284 * 172/3 * 292 = 0.02482.25 * 278

QR = 1.50.78 *0.024 * 1044= 34.4 lb/min


= 4.2 lb/min


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







290 mm Hg



LFA = 0.284 * 172/3 * 290 = 0.02482.25 * 278

QR = 1.50.78 *0.024 * 1044= 34.2 lb/min


= 4.1 lb/min




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








289 mm Hg



LFA = 0.284 * 172/3 * 289 = 0.02482.25 * 278

QR = 1.50.78 *0.024 * 1044= 34.1 lb/min


= 4.1 lb/min









288 mm Hg



LFA = 0.284 * 172/3 * 288 = 0.02482.25 * 278

QR = 1.50.78 *0.024 * 1044= 34.0 lb/min


= 4.1 lb/min










287 mm Hg



LFA = 0.284 * 172/3 * 287 = 0.02482.25 * 286

QR = 1.50.78 *0.024 * 1044= 33.9 lb/min


= 4.1 lb/min










286 mm Hg



LFA = 0.284 * 172/3 * 286 = 0.02482.25 * 278

QR = 1.50.78 *0.024 * 1044= 33.8 lb/min


= 4.1 lb/min









285 mm Hg



LFA = 0.284 * 172/3 * 285 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 33.6 lb/min


= 4.1 lb/min









285 mm Hg



LFA = 0.284 * 172/3 * 285 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 33.5 lb/min


= 4.1 lb/min










284 mm Hg



LFA = 0.284 * 172/3 * 284 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 33.4 lb/min


= 4.0 lb/min










283 mm Hg



LFA = 0.284 * 172/3 * 283 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 33.3 lb/min


= 4.0 lb/min










282 mm Hg



LFA = 0.284 * 172/3 * 282 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 33.2 lb/min


= 4.0 lb/min









281 mm Hg



LFA = 0.284 * 172/3 * 281 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 33.1 lb/min


= 4.0 lb/min









280 mm Hg



LFA = 0.284 * 172/3 * 280 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 33.0 lb/min


= 4.0 lb/min












279 mm Hg



LFA = 0.284 * 172/3 * 279 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 32.9 lb/min


= 4.0 lb/min









278 mm Hg



LFA = 0.284 * 172/3 * 278 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 32.8 lb/min


= 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







277 mm Hg



LFA = 0.284 * 172/3 * 277 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 32.7 lb/min


= 4.0 lb/min










276 mm Hg



LFA = 0.284 * 172/3 * 276 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 32.5 lb/min


= 3.9 lb/min









275 mm Hg



LFA = 0.284 * 172/3 * 275 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 32.4 lb/min


= 3.9 lb/min









274 mm Hg



LFA = 0.284 * 172/3 * 274 = 0.02382.25 * 278

QR = 1.50.78 *0.023 * 1044= 32.3 lb/min


= 3.9 lb/min




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


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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

Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Final Table of Contents

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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

Feasibility Study for Replacing Existing Aqueous Ammonia Tanks at RC Harris Water Treatment Plant Technical Memorandum – Draft Final

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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


$ 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



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



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


Pre-Fabricated HDPE tanks (2 tanks, each 30 m3) $ 20 400.00/tank2

- Optional adder for IMFO3 $ 7300.00 (for 2 tanks)


$ 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



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.



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


Glass-Fused-to-steel bolted steel tank (2 tanks, each 30 m3)

$ 66 000.00 /tank1



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



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.


WSP Canada Inc. 4-1

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


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


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


north corridor


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


north corridor


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.


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


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.


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)



Micsellanous (assumed) $ 2 000.00


Total Cost $ 48 500.00


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



Miscellaneous (assumed) $ 2 000.00


Total Cost $ 28 754.00


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.


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.


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.

smythp

Line

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


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

11

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.


NOTE: To meet NSF-61 certification, use EPDM or Viton® GF.

*Natural tanks are available for indoor use.

12

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.


13

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


*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.


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-

14

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

15

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


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


NOTE: To meet NSF-61 certification, use Viton® GF.

*Containment tank is required with this chemical in all applications.

16

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.


Fittings:Recommend enhanced bellows transition fitting for bottom sidewall discharge

Fittings:B.O.S.S.™ fitting also recommended to prevent leaks


Tank Specifications

The Poly Processing Sulfuric Acid System

*Containment tank is required with this chemical in all applications.

H2SO4SULFURIC ACID

17

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:


• 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)


Non-SAFE-Tank® alternatives:


• Other secondary containment suitable for sulfuric acid, of adequate size for use

FITTINGS









VENTING



• 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

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

18

H2SO4SULFURIC ACID

19


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

20

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


FITTINGMATERIAL

GASKETMATERIAL

BOLTMATERIAL

Hydrochloric Acid ≤ 37% XLPE with OR-1000™ 1.9 PVC EPDM C-276


21

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 Poly Processing Hydrochloric Acid System


22







VENTING



• 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 and engineering stamp

TANK


• 1,000–13,650 gallons

• 1.9 spg rating


Non-IMFO® alternative:

Standard Vertical Flat Bottom XLPE with OR-1000™:

• 1,000–13,650 gallons

• 1.9 spg rating


SAFE-Tank® XLPE:

• 1,500–8,700 gallons

• 1.9 spg rating for primary tank with OR-1000™





Recommend SAFE-Tank® secondary XLPE as shown above

Non-SAFE-Tank® Alternatives:


• Other secondary containment suitable for hydrochloric acid, of adequate size for use

FITTINGS



Technical Overview:Hydrochloric Acid Storage Tanks


23

OUR TANK SYSTEMS

Additional Chemicals Overview:Solutions for storage of more popular chemicals.


HFHYDROFLUORIC ACID



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.

24

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


HFHYDROFLUORIC ACID



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


Fittings:IMFO® eliminates the need for confined space entry.



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.

25

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


FITTINGMATERIAL

GASKETMATERIAL

BOLTMATERIAL

Sodium Hydroxide 50% XLPE 1.65 PVC EPDM 316SS


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


26

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.


Standard Vertical Flat Bottom XLPE:

• 30–13,650 gallons

• 1.65 spg rating


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


FITTINGMATERIAL

GASKETMATERIAL

BOLTMATERIAL

Hydrofluoric Acid XLPE 1.9 PP Viton® C-276


HFHYDROFLUORIC ACID

The Poly ProcessingHydrofluoric Acid System.

28

Alternative secondary containment: PPC secondary containment basin or other secondary containment suitable for hydrofluoric acid, of adequate size for use




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



• 230–13,650 gallons

• 1.9 spg rating


SAFE-Tank® XLPE:

• 55–8,700 gallons





• 30–13,650 gallons

• 1.9 spg rating


1529


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


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.


30

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





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



• 230–13,650 gallons

• 1.9 spg rating


SAFE-Tank® XLPE:

• 55–8,700 gallons





• 30–13,650 gallons

• 1.9 spg rating


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


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



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



• 230–13,650 gallons

• Appropriate spg rating for chemical as shown in Chemical Resistance Chart



• 30–13,650 gallons


SAFE-Tank® XLPE:

• 55–8,700 gallons





*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


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.


CHEMICAL RESINTYPE


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





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



• 230–13,650 gallons

• 1.9 spg rating


SAFE-Tank® XLPE:

• 55–8,700 gallons





• 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


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


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


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)


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


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˝



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˝


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.



Size: 1/2̋ to 6̋



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

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˝


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.



Size: 1̋ to 3˝



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®


Size: 6̋ to 10˝


Options: flange adapter socketed or threaded

FLANGE ADAPTERS

Includes a nipple and flange for connection to plumbing system

Body: standard PVC and CPVC


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


Size: 2˝ to 6̋

Seals: EPDM, Viton® and Viton® GF


BALL VALVES

Complete line of high-performance Ball Valves to meet varying needs


Connections: socketed, threaded or true union

Size: 1/2̋ to 6̋

Seals: EPDM, Viton® and Teflon®


53


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.


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


Performance specifications:


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


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.

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Manways/Lids


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.

60

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.

61


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.

63


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.

64

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

[email protected]

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.


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


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


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.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .

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.








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.








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.








* 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


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.


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.


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.


Page 6 of 10

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.


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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