INSATALLATIONAND REQUIREMENS

Transcription

1 SECTION FIBERGLASS REINFORCED PLASTIC STORAGE TANKS PART 1 --GENERAL INSATALLATIONAND REQUIREMENS The Contractor shall furnish/ deliver, INSTALL, test and place in satisfactory operation offiberglass reinforced plastic storage tanks, complete with all necessary accessories at the locations shown on the attached sketches and as specified herein and accord with the manufactures recommendations. The CONTRACTOR shall be responsible for removal and disposal of existing tanks. ANY REFFERENCE IN SPECIFICATIONS TO "REMOVED OR FURNISHED BY OTHERS" SHALL BE THE RESPONISIBLIITY OF THE CONTACOTR. 1,02 CONDITIONS OF SERVICE/STORAGE TANK SCHEDULE A. Ferric Chlorjde Storage Tanks 1, The ferrio chlorlde storage tanks shall be designed for storing ferric chloride solutions per the table below. Max Solution Concentration Specific Gravity Freezing Point 'ph' Number of Tanks TVP9 Bottom. Configuration _ Top Configuration Nominal Capacity Nominal Diameter Nominal Height Cbnneotton Opsnlngs: 1) FIH Line 2) Metering/Transfer Pump Suction Line 3) Transfer Pump Dfscharae Line 4) Drain Line 6) Overffow Line 6) Vent with 180"_Retyrn Bend and Insect screen 7} _Manway Dlameter_(Top) 8) Manway Diameter (Side) 9) Ullrasohlc Level Instrument.HsatinfLPanels and Insulation Materials of Construction for Metal Parts Containment Wall Height Ferric Chloride 37% 40% -15dG@37% Two (2» _Vertlcal, Cytfndrica) Flat Bottom Dome Top _20,000 gallons 12'-0" 26i-6tr ~y~ _3" 3" 3" _4"_ 4" 2'.b" 2'-0" * Yes Titanlum 0'** Coordinate with existing Instrumehtation relocated from existing tanks Bottom of tanks will be Installed flush with top of containment wall : ROANOKE WPCP

2 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. ASTM C Chemical Resistance of Thermosetting Reslns Used in Glass Fiber Reinforced Structures B. ASTM C 582-Contact-Molded Reinforced Thermosetting Plastic Laminates for Corroslon- Resistant Equipment C. ASTM D 3299-OOa - Filament-Wound Gtass-Fiber-Relnforced Thermoset Resin Corrosion- Resistant Tanks D. ASTM D a - Contact-Molded Glass-Fiber-Relnforced Thermoset Resin Corrosion - Resistant Tanks E. ASME RTP-1 - Reinforced Thermoset Plastic Corrosion Resistant Equipment F. All reference specifications, codes, and standards shall be the current version available at the time of Bid SUBMITTALS A. Tank Supplier shall provide a minimum of three (3) separate submittals to the Owner for this purchase order as follows; five (5) paper copies and one electronic copy of all submittal documents shall be included with each of the three submittals: 1. Initial submittal within 30 days after a purchase order is issued which must be approved prior to start of fabrication. 2. Results of factory testing which must be approved prior to shipment. 3. Supplier field representative startup reports and installation certification as well as results of onsite mechanical integrity test using Acoustical Emission Test. All reports and test reports must be approved by Owner prior to final payment and certification of final installation. B. Initial submittal shall include Shop Drawings, Operation and Maintenance Instructions. Shop Drawings shall include complete erection, installation and adjustment instructions and recommendations. Installation instructions shall Include unloading, check-out following shipment, storage, handling, assembly, anchorage, and start-up instructions and shall be submitted prior to delivery of the tanks. C. Shop Drawings shall Include full descriptive information of materials used, method of fabrication, sizes, enclosures, ratings and layout dimensions, etc. to demonstrate full compliance with the Contract Documents. D, Shop Drawings shall include weights of all system components and total weight of each tank including insulation and heat trace jacketing. E. A complete description of the protective coating system to be used for all components, prior to shipment and after installation, shall be submitted with the shop drawings : ROANOKE WPCP

3 F. Structural calculations for each tank showing that the tanks are designed for all wind and snow loads regardless of whether the tank is full, empty or at level between the tank drain and overflow. G. Tank Supplier shall coordinate with Engineer during presubmittal coordination site visit to assist the Engineer's determine as to whether the existing tank anchors can be reused. If existing anchors cannot be reused, Tank Supplier shall provide proposed size, quantity, location and max load for all tank anchors. Anchors shall be spaced to not interfere with existing anchors. Engineer shall determine required anchor bolt embedment based upon Tank Suppliers load information. H. Heat trace wiring diagrams and field wiring requirements shall be submitted with the shop drawings WARRANTY AND GUARANTEE A. The equipment furnished under this Contract shall be guaranteed to be free from defects in workmanship? design and/or materials for a period of five (5) years. The period of such warranties shall start on the date the particular equipment is placed in use by the Owner with corresponding start-up certification provided by the manufacturer's technical representative as specified herein, provided that the equipment demonstrates satisfactory performance during the thirty day operational period after the equipment startup. If the equipment does not perform satisfactorily during the thirty day operational period, the start of the warranty period will be delayed until the equipment demonstrates proper operation. The Equipment Supplier shall repair or replace without charge to the Owner any part of equipment which is defective or showing undue wear within the guarantee period, or replace the equipment with new equipment If the mechanical performance is unsatisfactory; furnishing all parts. materials, labor, etc., necessary to return the equipment to its specified performance level. B. The Contractor shall provide an equipment warranty log book prepared specifically for this project and submit two (2) copies of the document to the Engineer prior to final payment. The equipment warranty log book shall include a summary listing of all equipmentwarranties provided, date received, and start date and end date of warranty period. A copy of each equipment warranty and equipment start-up certification shall also be provided in the document. C. The Equipment Supplier shall guarantee to the Owner that all equipment offered under these specifications, or that any process resulting from the use of such equipment In the manner stated is not the subject of patent litigation, and that he has not knowingly offered equipment, the installation or use of which is likely to result in a patent controversy, in which the Owner as user is likely to be made the defendant. Where patent infringements are likely to occur, each Equipment Supplier shall submit, as a part of his bid, license arrangements between himself, or the manufacturer of ths equipment offered, and the patent owner or the controller of the patent, which will permit the use in the specified manner of such mechanical equipment as he may be bidding. Each EquipmentSupplier, by submitting his bid, agrees to hold and save the Owner and Engineer or Its officers, agents, servants, and employees harmless from liability of any nature or kind, including cost and expenses for, or on account of, any patented or unpatented invention, process, article, or appliance manufactured or used in the performance of the work under this contract, including the use of the same by the Owner : ROANOKE WPCP

4 D. Warranty service and response by manufacturers is of utmost importance to the Owner. A response within 2 business days is required for all warranty Issues and claims. Liquidated damages as specified in the Agreement will be assessed for each additional day that a warranty issue is not addressed with a good faith effort to remedy the issue. PART 2 " PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS A. The flberglass reinforced plastic storage tanks shall be as manufactured by Justin. Belco, or Plas-Tanks. No other manufacturers will be accepted. B. The fiberglass reinforced plastic tank manufacturer shall specialize in manufacture, assembly, and field service of FRP chemical storage tanks with a minimum of ten years experience. The manufacturer shall have at least five (5) U.S. installations of the type, approximate size, and chemical service being proposed, each with a minimum of five (5) years of satisfactory service. The manufacturer shall submit references for the existing installations with shop drawings MATERIALS AND CONSTRUCTION A. The Contractor is responsible for the coordination and selection of corrosion resistant materials for the chemical solutions specified below. The fiberglass reinforced plastic storage tank manufacturers shall inform themselves of the characteristics of the specified chemical solutions and guarantee the suitability of the materials used in manufacturing of the tank and appurtenances. The Contractor and manufacturer shall include all features as necessary for satisfactory operation of the tank system for all specified chemical solutions. B. All tank capacities (volumes) specified shall Include only that volume in the straight shell below the overflow pipe invert elevation and above the top of the outlet pipe. At least four inches offreeboard shall be provided between the invert elevation of the overflow pipe and the top of the straight shell. C. Resin 1. The resin forfiberglass reinforced plastic storage tanks shall be a commercial-grade, corros ion-resistant thermoset that has either been evaluated in a laminate by testing in accordance with ASTM C-581 or that has been determined by previous documented service to be acceptable for the service conditions. 2. The resin used shall not contain any fillers, plgments, dyes, orcolorants, which may interfere with visual inspection of lamlnate quality, except as required for viscosity control. The limit of filler shall be 5 percent by weight. No fjllers or bulking agents shall be used in the exterior structural layer to decrease the glass loading ratio. Resin pastes used to fill crevices before overlay are permitted. Ultraviolet absorbers shall be added to the exterior surface for improved weather resistance. Insulated tanks, where specified, shall have a light gray pigmented exterior gelcoat layer. 3. The initiators used will be of the type, manufacturing origin, and amounts specified by the resin manufacturer : ROANOKEWPCP

5 4, Resln shall be as manufactured and recommended by Ashland. A letter of recommendation shall be provided for each type of chemical service that is to be provided under this Contract. D. Reinforcement 1. The reinforcing material shall be a commercial grade glass fiber having a coupling agent which shall provide a suitable bond between the glass reinforcement and the resln and shall be suitable for the fabrication method used. The reinforcing material shall be comparable to that used to generate corrosion resistance. 2. Chopped Strand Mat - Chopped strand mat shall be constructed from chopped commercial-grade E-type glass strands bonded together using a binder. The strands should be treated with a sizing that is chemically compatible with the resin system used. 3. Continuous Roving - Continuous roving shall be a commerclal-grade E-type glass fiber with a sizing that is chemically compatible with the resin system used. 4. Woven Roving - Woven roving shall be in accordance with ASTM Specification D Surface Mat - The reinforcement used for the inner surface shall be either a commercial-grade chemical resistant glass surface mat as recommended by the resin manufacturer for the intended service. E. Laminate Construction 1. The faminate comprising the structural tank (bottom, cylindrical shell, top head) shall consist of a corrosion-resistant barrier comprised of an inner surface, interior layer, and a structural layer. 2. The inner surface exposed to the chemical environment shall be resin-rich, not less than 0.02-inch thick, and reinforced with chemically resistant surfacing material. The surface shall be smooth, glossy, and free of pits. Material used as reinforcing on the surface exposed to chemical attack shall be a commercial grade chemical resistant glass fiber having a coupling agent. 3. The interior layer shall be not less than 0.1-inch thick and composed of resln, reinforced only with noncontinuous glass strands applied in a minimum of two plies of chopped strand mat or in a minimum of two passes by the spray-up process. Glass strands shall not be shorter than 1.0 inch or longer than 2.0 inches. Glass content of the inner liner and interior layer combined shall be 27% +/- 5% by weight. 4. Before the reinforcement of the exterior layer is applied, the interior layer shall be allowed to cure completely so that the thickness of the corrosion barrier, consisting of the inner surface and interior layer, will not be reduced. MEKP cure system shall be used. The degree of cure of the iaminate, after post cure, shall be such as to exhibit a Barcol hardness on the inner surface of at least 90% of the resin manufacturer's minimum specified hardness for the cured laminate : ROANOKE WPCP

6 5. The structural layer shall provide additional strength necessary to meet the tensile and flexural requirements. The reinforcement shall be fllament wound, contact molded or a combination of both and may consist of continuous roving, woven roving, chopped strand mat or chopped strands. Where separate layers of reinforcement are used, all layers shall be lapped a minimum of 1.0 inch. Laps shall be staggered as much as possible. If woven roving or cloth Is used in successive layers, it shall be alternated with a layer of chopped strand glass. Glass content of the filament-wound structural layer shall be 50 to 80 percent by weight. The thickness of the filament wound portion of the tank shell may vary with tank height, provided that all stress and other requirements are met at any height level. All reinforcement used shall be resistant to corrosion by the particular chemical stored In the tank. 6. The outer surface shall consist of chopped strands or surfacing mat, or both, over which shall be applied a resln-rich coating. The outer surface shall not be plgmented, painted or dyed except to prevent ultraviolet degradation of the tank contents. This surface shall be at least 0.02 inch thick. 7. Tanks shall be dry heat post cured in accordance with resin manufacturer's guidelines. 8. The tank top shall be domed with openings and connections as shown and specified. The tank top shall be able to support a 250-pound load on a 4"!nch by 4-inch area. Tank bottom shall be seamless and shall have a seamless attachment to the tank wall. No joints shall be allowed within the bottom 7'0" of the tank wall. F. Insulation 1. Chemical storage tanks shall be provided with insulation. Tank top and sidewalls shall be Insulated with 2 inches of 2 Ib/ft3 poiyurethane foam board insulation. The insulation shall be overwrapped with a minimum mil thick glass-fiberresln laminate with a brown plgmented exterior gel coat weatherproof protective coating 10 mils thick. 2. During Tank Supplier presubmittal site visit, tank supplier shall field verify color of existing tanks to ensure that the color of the new and existing tanks match. 3. Chemical storage tanks shall be provided with heating panels. Location of panels shall be coordinated with location of existing power supplies. Provide a 1" diameter opening in the insulation located near the temperature sensor for the tank heating panels for manual checking of tank sk!n temperature. Opening shall be plugged when not in use CONNECTIONS AND ACCESSORIES A. All flanged nozzles shall be of hand lay-up construction with pipe stub molded integrallywith the pipe flange. Al! connections/openings shall be flanged in accordance with ANSI B pounds and provided with flanged gasket Hanged connections, nozzles, and openings shall be FRP gusseted and flat face : ROANOKEWPCP

7 B. Each tank shall be provided with a flexible connector resistant to the specified chemical to allow for expansion and contraction of the tank and to isolate the tank from vibration. Flexible connectors shall be provided by the tank manufacturer. C. Tank drain connections shall be siphon drain connections. Each tank drain line shall be provided with a ball vatve. D. Vent lines shall be top-mounted. Each vent shall be extended to the atmosphere and shall have a 180 degree return and a fiberglass vent insect screen. Vent lines shall be supplied and furnished by the Contractor as required or as directed by the Engineer. E. The Owner shall provide each tank with an existing relocated level sensor as indicated on the Drawings. The Tank Supplier shall coordinate the mounting and connecting requirements with the Owner. F. Each tank shall be provided with flat-faced flanged manways with gaskets and blind flanges that are chemically resistant as shown in the Tank Schedule. G. Each tank shall be provided wllh a minimum of four lifting lugs, three of them around the top edge of the tank and one at the base of the tanks. Lifting lugs shall be capable of withstanding weight of an empty tank with a safety factor of 3 to 1. H. Each tank shall be provided with a minimum of six tie-down lugs and all necessary anchor bolts. The tank shall withstand horizontal loadings of 40 pounds per square foot or the maximum wind load at the location in accordance with the latest building code for the area under the worst condition, whichever is greater. The bottom of the existing tank mounting pad is flush with the top of the surrounding chemical containment area wall, so It Is not necessary to design the tie-down lugs shall be capable of withstanding buoyancy of empty tank in a flooded containment area. The tank manufacturer shall submit calculations to verify that tie-down lugs can withstand wind load. I. The tank shall be provided with a permanently attached label providing the following information: 1. Type of material stored 2. Concentration of material stored 3. Specific gravity 4. Maximum temperature 5. Type of liner resin and reinforcement 6. Type of surface veil 7. Tank capacity 8. Manufacturer 9. Date of manufacture J. All metallic parts, fasteners, brackets, mounting hardware, and accessories provided by the tank manufacturer shall be constructed ofcorroslon resistant metals as specified in the Tank Schedule : ROANOKEWPCP

8 2.04 PIPING SUPPORT A. All existing vertical and horizontal runs of piping supported by the existing tanks shall be supported by Ihe new tanks. During the presubmittal site visit, Tank Supplier shall field verify the location of existing piping and provide new supports on the new tanks at a maximum spacing of 5-ft on center. B. External piping shall be not less than 6 inches from the outer face of the tank wall insulation. Support locations for piping installed within the tank shall be coordinated with equipmentto be installed within the tank. All piping into the tanks shall be supported such that no weight is placed on the tank or its connections ELECTRICAL AND CONTROL REQUIREMENTS A. Chemica! storage tanks shall be provided with heating panels. A minimum of three (3) 500- watt. 110 volt fully grounded electrical heating panels shall be provided for each tank to maintain the temperature of the tank contents at 400F at an outside temperature of -10 F. The system shall be provided with 2 NEMA 4X thermostats. Provide primary thermostat to control tank heat and backup thermostat to control tank heat if primary fails. The heat panels shall be low watt density heat panels that shall operate without damage to the tank when the tank is empty. B. During the Tank Supplier presubmittal coordination and field verification site visit, the location of new heat trace termination panel shall be coordinated with the location of existing power supply stub ups to minimize length of new conduit that has to be installed by others to connect the existing stub ups to the new heat race panel. PART 3 -- EXECUTION 3.01 MANUFACTURER'S FIELD SERVICES A. The services of a qualified manufacturer's technical representative shall be included in the price for tanks and shall be provided as detailed herein and shall include the following site visits: Service Presubmittal field verification Delivery and tank setting Installation and Testing Startup and Training Services after Startup Number of Trips 1 1 T 1 1 Number of Days/Trip 1 1 T 1 1 B. The Thanks Supplier shall arrange for the services of a qualified manufacturer's service person, with at least five years of experience, who is regularly involved in the inspection, operation, and maintenance of FRP tanks systems of the size and type being furnished. The service persons shall: 1. Inspect the installed equipment to verify that installation is in accordance with the tank manufacturer's requirements. 2. Witness and check final adjustments and alignments : ROANOKE WPCP

9 3. Witness and check start-up of each tank. 4. Assist the Owner in performing field testing and prepare a written report as specified below. 5. Troubleshoot and correct any tank problems which are noted during initial operation. 6. Submit written certification signed by the service person that the system has been properly installed, tested, and adjusted; that the system operates as specified or as required, including date of field test, as well as a listing of all persons present during the tests. 7. Investigate and supervise correction of any operating problems which may arise during the guarantee period of the equipment C. The Supplier shall arrange for the services of a qualified service person, with at least five years of experience in FRP tank installation, testing and maintenance, to provide training to Owner staff. Owner staff shall be trained on tank rigging for offloading, installation and maintenance. D. Training shall be Included In the price for the tank accessories and shall entail a period of not less than three training events: 1) rigging and handling, 2) installation, and 3) maintenance. E. The manufacturer's service person shall sign in and out every day on-slte and shall comply with all Owner requirements for visiting the site INSTALLATION A. The Contractor shall furnish and Install the Fiberglass Reinforced Plastic storage tanks, and related Items in accordance with the manufacturers' recommendations. B. All piping, valves, fittings, conduit, wiring, etc., required to interconnect system components shall be furnished and Installed by the Contractor. Unless otherwise noted, piping shall be Schedule 80 CPVC. C. All metallic fasteners, brackets, mounting hardware, and accessories located!n chemical storage and feed areas shall be constructed of corrosion-resistant metals as specified in the Tank Schedule. D. Two layers of roofing paper shall be installed between each concrete pad and storage tank. The tanks shall be installed on existing concrete pads INSPECTION AND TESTING A. A 3-stage inspection process shall be performed on the tank during various stages in the construction process. The first inspection shall be performed at the completion of the corrosion barrier and before structural winding occurs. The second inspection wllf be performed after the tank is removed from the mandrel and before any nozzles are attached. The third Inspection shall be a final inspection prior to shipment of the tank. These : ROANOKEWPCP

10 Inspections shall be performed by an independent Inspector with at least 5 years of experience with FRP vessels. B. Upon completion of instahation of tank and prior to connecting piping, the Contractor shall provide blind flanges or other suitable plugs for all openings in the tank, fill tank with potable water from a source approved by the Engineer and conduct a leakage test. Tank shall be filled up to the top of the straight shell and left to sit over a 5 consecutive day test period. There shall be no leakage over the test period. Upon satisfactory completion of leakage test, Contractor shall drain the tank and dispose of water in a suitable manner. C. Quality control for visual defects shall be as shown in the following Table 1. Corrosion liners requiring rework in excess of 1 % of the surface area of the component shall be cause for rejection. D. After the tank has completed a successful hydrostatlc test, the tank shall undergo a mechanical integrity test using Acoustical Emission Test (AE Test) in accordance with the latest version of ASTM E The Contractor shall secure the services of Non-Desfructive Evaluation International (Davidson, NC) or an equally qualified firm to perform the AE testing. Firms shall be considered equally qualified by demonstrating the following: 1, The firm shall specialize in AE testing. 2. The firm shall have all necessary equipment to perform AE testing. 3. The firm shall have a minimum of five (5) years experience in AE testing and shall provide a list of AE tests performed to demonstrate experience. 4. The firm's testing staff shall have a minimum of five (5) years experience with AE testing. Contractor shall provide all labor and materials necessary for completing AE testing including water to fill tanks with during testing. After testing is completed, a final report shall be submitted to the Engineer. In the event the AE test results indicate repairs are required; the tank manufacturer shall promptly repair all faulty areas of the tank as identified by the test. The tank shall then be re-tesfed using the hydrostatic test and the AE test. The second AE test reportshall be submitted to the Engineer. Any tank failing the second hydrostafic test or the AE test shall be removed from the project site and replaced with a new tank at no cost to the Owner. The replacement tank shall undergo hydrostatlc and AE testing and shall be subject to the same acceptance criteria as the initial tank, This process shall be repeated until all tanks provided to the project pass the AE test. Visual Defect Air Bubbles - Bubbles trapped within, on, or between plies. (0.015" dia. and larger) Not to be confused with froth. Table 1 Maximum Allowable Visual Defects Quality Level 1 Corrosion Liner between veil and antiwicking barrier. (Test with pencil point) Max. 1/16" dia.. 2 per in2, averaged over 1 ft2 area. In no case, more Structural & Finish Layers Practically achievable but not larger than 1/4" dia. Total combined area of all air bubbles not to exceed 10 in2 per yd2 for laminates up to 1/2" thick, and increased proportionately for thicker laminates. In no case : ROANOKEWPCP

11 Blisters" Rounded surface elevations resembling a human skin blister. Burned Areas - Dark discoloration and distortion of the laminate from excessive curing temperature. Chips - Small pieces broken off an edge or surface of the lamlnate. Cracks - Material separation or fracture. Crazing - Fine cracks at or under the surface of the laminate. Delaminaflons - Separation of the layers of material In a laminate. Dry Spots" Area of surface where the reinforcement has not been wetted with resin. Not to be confused with glinting. Edge Delamlnation - Separation of the reinforcement layers at the edge of the laminate. Foreign Inclusions -Anything other than raw material components (visible with naked eye) Pits" Small craters In the surface of the laminate. Surface Pinholes - Numerous visible pinholes in the surface of the lam In ate. Scratches - Shallow marks or grooves caused by mishandling the laminate. Wrinkles " Linear, abrupt change in surface plane due to overlap in reinforcing layer, irregular mold surface, or wrinkled release film, resulting in a resin rich area that could be easily chipped. Waviness is allowed provided!t does not result in resin rich area. than 4 per in2. None exposed to surface. (must be covered with resln) 1/16" dia. 2 per yd2 1/32" deep No exposed surfacing veil. 1/8" but must not decrease the laminate thickness below allowable. more than 4 bubbles per in2. 3/16" dia 1/16" height 1 peryd2 1/8" dia. 1 per yd2 1/16" deep 1"dia. 1 peryd2 1/64" deep Practically achievable, but not more than 1/4" dia. and 3 per yd2. 1/8" dia. 4 per yd2 1/16" deep Not applicable 1/32" deep 3" long Mot applicable " END OF SECTION : ROANOKE WPCP

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14 Existing Tank Pad/ Ladder and conduits to level sensor Ferric Chloride Tank Replacement Roanoke WPCP, WVWA f': -.. '' ''^/. '.,' :^ ' '.. ' ll;lt. '.. ^^-J^^ ''.' '".-.-i

15 Existing Piping Ferric Chloride Tank Replacement Roanoke WPCP/ WVWA

16 Existing Conduit to Tank Level Sensor Ferric Chloride Tank Replacement Roanoke WPCP, WVWA