Designing a Bulk Sodium Designing a Bulk Sodium Hypochlorite SystemHypochlorite System

Presented by Patrick H. Allman IIIPresented by Patrick H. Allman III

General ManagerGeneral Manager

Odyssey Manufacturing Co.Odyssey Manufacturing Co.

Disinfection Options – June Disinfection Options – June 19991999

Peninsular Florida WT & WWT Plant Disinfection Options

June 1999

97%

<1%<1%

3%<1%<1%

Chlorine Gas

Ozone

UltraViolet (UV)

NaOCl (Bulk)

NaOCl (On-SiteGeneration)

Chlorine Dioxide

Disinfection Options – June Disinfection Options – June 20032003

Peninsular Florida WT & WWT Plant Disinfection Options

June 2003

76%

<1%

<1%

23%<1%

<1%

Chlorine Gas

Ozone

UltraViolet (UV)

NaOCl (Bulk)

NaOCl (On-SiteGeneration)Chlorine Dioxide

Disinfection Options – June Disinfection Options – June 20052005

Peninsular Florida WT & WWT Plant Disinfection Options

Projected for June 2005

56%

<1%

<1%

42%1%<1%

Chlorine Gas

Ozone

UltraViolet (UV)

NaOCl (Bulk)

NaOCl (On-SiteGeneration)Chlorine Dioxide

Sodium HypochloriteSodium Hypochlorite

BleachBleach Liquid BleachLiquid Bleach Liquid ChlorineLiquid Chlorine Soda Bleach LiquorSoda Bleach Liquor ChlorineChlorine

CHEMICAL FORMULACHEMICAL FORMULA

NaOClNaOCl

Manufacturing ProcessManufacturing Process

2NaOH + Cl2NaOH + Cl22 => NaOCl + H => NaOCl + H220 0 + Heat+ Heat

Properties of Sodium Properties of Sodium HypochloriteHypochlorite

Mildly CorrosiveMildly Corrosive Has Free Sodium Hydroxide (Caustic Soda)Has Free Sodium Hydroxide (Caustic Soda) pH=12.5 to 13pH=12.5 to 13 Pale Yellow Solution, 12.5% By VolumePale Yellow Solution, 12.5% By Volume Non-FlammableNon-Flammable Incompatible with Many Other ChemicalsIncompatible with Many Other Chemicals Relatively Short Shelf Life - Contaminants, Relatively Short Shelf Life - Contaminants,

Heat And UV Cause DecompositionHeat And UV Cause Decomposition

Contrary to White’s Handbook of Contrary to White’s Handbook of ChlorinationChlorination

One Gallon of 120 GPL or 12 Trade One Gallon of 120 GPL or 12 Trade Percent Percent

EqualsEquals

1 lb of Cl gas1 lb of Cl gas

BLEACH DEGRADATIONBLEACH DEGRADATION

PrimaryPrimary

• 3NaOCl = 2NaCl + NaClO3NaOCl = 2NaCl + NaClO33 (Sodium Chlorate) (Sodium Chlorate) SecondarySecondary

• 2NaOCl = 2NaCl + O2NaOCl = 2NaCl + O22 (Gassing) (Gassing) Factors:Factors:

• Heat Heat • UV (e.g., Sunlight)UV (e.g., Sunlight)• Impurities (Primarily Heavy Metals)Impurities (Primarily Heavy Metals)• Strength (Rate = K (OClStrength (Rate = K (OCl--]]22

Sodium Hypochlorite Sodium Hypochlorite Degradation – Average Degradation – Average Manufacturer @ 70 Degrees FManufacturer @ 70 Degrees F

Time of Manufacture - 12.5 Trade Time of Manufacture - 12.5 Trade PercentPercent

2 Days Later – 12.43 Trade Percent2 Days Later – 12.43 Trade Percent 7 Days Later – 12.25 Trade Percent7 Days Later – 12.25 Trade Percent 14 Days Later – 12.01 Trade Percent14 Days Later – 12.01 Trade Percent 21 Days Later – 11.78 Trade Percent21 Days Later – 11.78 Trade Percent 28 Days Later – 11.55 Trade Percent28 Days Later – 11.55 Trade Percent 35 Days Later – 11.34 Trade Percent35 Days Later – 11.34 Trade Percent

Sodium Hypochlorite Sodium Hypochlorite Degradation – Average Degradation – Average Manufacturer @ 80 Degrees FManufacturer @ 80 Degrees F

Time of Manufacture - 12.5 Trade Time of Manufacture - 12.5 Trade PercentPercent

2 Days Later – 12.34 Trade Percent2 Days Later – 12.34 Trade Percent 7 Days Later – 11.96 Trade Percent7 Days Later – 11.96 Trade Percent 14 Days Later – 11.47 Trade Percent14 Days Later – 11.47 Trade Percent 21 Days Later – 11.01 Trade Percent21 Days Later – 11.01 Trade Percent 28 Days Later – 10.59 Trade Percent28 Days Later – 10.59 Trade Percent 35 Days Later – 10.21 Trade Percent35 Days Later – 10.21 Trade Percent

Use of Pilot or Temporary Use of Pilot or Temporary SystemsSystems

To Maintain Continuous Disinfection To Maintain Continuous Disinfection During Conversion Construction During Conversion Construction

To size pumps and bulk storage tanksTo size pumps and bulk storage tanks To Determine Finished Water QualityTo Determine Finished Water Quality To Test different types of EquipmentTo Test different types of Equipment Familiarize Operations Personnel with Familiarize Operations Personnel with

Sodium HypochloriteSodium Hypochlorite Verify Operations in Unusual Verify Operations in Unusual

SituationsSituations

Sodium Hypochlorite System Sodium Hypochlorite System DesignDesign

DeliveryDelivery Bulk StorageBulk Storage Chemical Feed EquipmentChemical Feed Equipment PipingPiping

Delivery to End-UserDelivery to End-User

Bulk Delivery in 5,000-gallon tanker truckBulk Delivery in 5,000-gallon tanker truck ““Poured” from Small Delivery 26’ Flat-Bed Poured” from Small Delivery 26’ Flat-Bed

Truck w/installed HDLPE totes or tanksTruck w/installed HDLPE totes or tanks 300-gallon totes (forklift)300-gallon totes (forklift) 55 gallon drums55 gallon drums 15, 30 gallon totes15, 30 gallon totes 2.5 gallon “jugs”2.5 gallon “jugs”

Bulk Delivery by Tanker Truck

FRP Tanker Trailer

Bulk Delivery Site Should Bulk Delivery Site Should Have . . . Have . . .

2” Supported Male Connection w/Cap2” Supported Male Connection w/Cap Bag Filter – 1 micronBag Filter – 1 micron Safety Shower/Eye Wash/Running WaterSafety Shower/Eye Wash/Running Water Security/LightsSecurity/Lights Hook Up Protection / Labeled LinesHook Up Protection / Labeled Lines Proper Venting for Blow OffProper Venting for Blow Off ““Catch Bucket”Catch Bucket” Accessible Roadway and Turn AroundAccessible Roadway and Turn Around

Fill LineFill Line

Air Pressure – 15 to 25 psiAir Pressure – 15 to 25 psi Trucks Carry Up to 60’ HoseTrucks Carry Up to 60’ Hose Long Length – Consider Upsizing to 3”Long Length – Consider Upsizing to 3” Length Proportional to Offload Time Length Proportional to Offload Time Maximum Length – 200’Maximum Length – 200’ Proper supports – 45 Degree DownProper supports – 45 Degree Down Keep Line Vented Keep Line Vented

Bulk Storage TanksBulk Storage Tanks

Location – Covered vs. Non-Covered / Location – Covered vs. Non-Covered / Other Chemicals On-siteOther Chemicals On-site

Air Conditioning Storage SpacesAir Conditioning Storage Spaces Dilution of Stored Material – Use Soft Dilution of Stored Material – Use Soft

WaterWater Type (FRP vs. Bulk)Type (FRP vs. Bulk) Size or Volume and Number (10 to 40 Size or Volume and Number (10 to 40

days)days) Use of Day Tanks (F.S. 62-555)Use of Day Tanks (F.S. 62-555) Measuring Daily Usage (F.S. 62-555)Measuring Daily Usage (F.S. 62-555) Tie DownsTie Downs

Storage Tank FittingsStorage Tank Fittings

Vents – (2” or 3”) Use Vinyl Bug ScreenVents – (2” or 3”) Use Vinyl Bug Screen Drains – Minimize # of Tank PenetrationsDrains – Minimize # of Tank Penetrations Fill Line – Fill from Top not Side or BottomFill Line – Fill from Top not Side or Bottom Overflow Line – Maximize Use of TankOverflow Line – Maximize Use of Tank Sight glasses – Type/Operational NecessitySight glasses – Type/Operational Necessity Tanks Squat - Flexible Connection at BottomTanks Squat - Flexible Connection at Bottom Feed Line - Pulling Out of the Top or BottomFeed Line - Pulling Out of the Top or Bottom Bottom Fittings – Types/Titanium is only Bottom Fittings – Types/Titanium is only

acceptable Metalacceptable Metal Gaskets – Viton Only; No EPDMGaskets – Viton Only; No EPDM

ContainmentContainment

Requirements – Florida Statues/RQ Requirements – Florida Statues/RQ HDLPE TubsHDLPE Tubs Poured Wall / Concrete Block WallPoured Wall / Concrete Block Wall CoatingsCoatings Wall PenetrationsWall Penetrations

Types of PipingTypes of Piping

Schedule 80 PVC – Most Commonly Schedule 80 PVC – Most Commonly UsedUsed

Schedule 80 CPVC – PlasticizationSchedule 80 CPVC – Plasticization Schedule 40 – Should Not Be UsedSchedule 40 – Should Not Be Used Kynar – Expensive/Workmanship IssuesKynar – Expensive/Workmanship Issues Carbon Steel Lined with Teflon or Carbon Steel Lined with Teflon or

Kynar – Typically used in Power Plants; Kynar – Typically used in Power Plants; Beware of Sizing IssuesBeware of Sizing Issues

PVC Applications: Socket PVC Applications: Socket Welding vs. Threaded Welding vs. Threaded ConnectionsConnections

Minimize the Use of Threaded ConnectionsMinimize the Use of Threaded Connections Use Stainless Steel Re-inforced Fittings on Use Stainless Steel Re-inforced Fittings on

Threaded Joints When Possible – Pump Discharge Threaded Joints When Possible – Pump Discharge FittingsFittings

If you must use a threaded connection, two If you must use a threaded connection, two wraps of Teflon Tape onlywraps of Teflon Tape only

Use proper glue procedure – 45-Degree Bevel, Use proper glue procedure – 45-Degree Bevel, Debur, Clean/Prime, and Glue Each End.Debur, Clean/Prime, and Glue Each End.

Use proper Glue:Use proper Glue:• IPS WELDON CPVC 724 – 24 to 48 hrs setup time (grey)IPS WELDON CPVC 724 – 24 to 48 hrs setup time (grey)• IPS EZ WELDON WET R’ DRY PVC 725 – 10 minutes IPS EZ WELDON WET R’ DRY PVC 725 – 10 minutes

under low pressure (blue) under low pressure (blue)

ValvesValves

Use the same model of Valve Use the same model of Valve throughout the entire project; throughout the entire project; Standardize!Standardize!

True Union with Viton o-rings – No True Union with Viton o-rings – No EPDMEPDM

Bleed Hole for Pressure BuildupBleed Hole for Pressure Buildup Socket Weld Ends, No Threaded Socket Weld Ends, No Threaded

ConnectionsConnections

Piping to Chemical Feed Piping to Chemical Feed EquipmentEquipment

Purpose – Minimize Off-GassingPurpose – Minimize Off-Gassing Pipe Sizing – Optimize velocityPipe Sizing – Optimize velocity Minimize Length – Maximum 50’Minimize Length – Maximum 50’ Stack Vents/Sightglasses – Carry Off GasesStack Vents/Sightglasses – Carry Off Gases Minimize Bends – Keep Gases in SolutionMinimize Bends – Keep Gases in Solution Use of Flexible Piping/TubingUse of Flexible Piping/Tubing Eliminate “High Spots” – Piping Pitch Eliminate “High Spots” – Piping Pitch Use of Strainers – “Catch” PVC shavingsUse of Strainers – “Catch” PVC shavings

Chemical Feed EquipmentChemical Feed Equipment

Eductors vs. Positive Displacement PumpsEductors vs. Positive Displacement Pumps PD Pumps – Peristaltic vs. DiaphragmPD Pumps – Peristaltic vs. Diaphragm Pump Skids vs. Wall /Floor MountingPump Skids vs. Wall /Floor Mounting Height of Equipment – Suction Lift IssuesHeight of Equipment – Suction Lift Issues Degasification Valves – When To UseDegasification Valves – When To Use Vapor Lock Issues – Bleed Valve or VentVapor Lock Issues – Bleed Valve or Vent Control Issues – Flow Meters / 4-20 maControl Issues – Flow Meters / 4-20 ma 99% of Most Operational Problems Come 99% of Most Operational Problems Come

from Over-sizing Pumps!from Over-sizing Pumps!

Chemical Injection PipingChemical Injection Piping

Proper Sizing of Pipe – Minimize Off-Proper Sizing of Pipe – Minimize Off-gassing and Provide Precision Control of gassing and Provide Precision Control of Feed RateFeed Rate

Backpressure Valves at End of Pipe – Backpressure Valves at End of Pipe – Improve Feed Rate ControlImprove Feed Rate Control

Maximum Length of Injection Point – 500’Maximum Length of Injection Point – 500’ Turnover Time – Less than 4 hoursTurnover Time – Less than 4 hours Use of Solution or “Carry” WaterUse of Solution or “Carry” Water Design of Injection PointsDesign of Injection Points Mixing IssuesMixing Issues Minimizing Calcification/ScalingMinimizing Calcification/Scaling

Water Quality IssuesWater Quality Issues

pH Boost - Typically .3 to .4 Units (.1 with OSG)pH Boost - Typically .3 to .4 Units (.1 with OSG) THM’s – Typically slight reduction (from Chlorine THM’s – Typically slight reduction (from Chlorine

Gas) Gas) Bromates – Can Be Problematic with Ozone and Bromates – Can Be Problematic with Ozone and

Some Salt Sources (OSG); Ensure Quality SupplierSome Salt Sources (OSG); Ensure Quality Supplier Chlorates – May Be Regulated in the Future; Ensure Chlorates – May Be Regulated in the Future; Ensure

Quality SupplierQuality Supplier Chlorides/Sodium – Ensure Quality SupplierChlorides/Sodium – Ensure Quality Supplier Alga Control – Bulk Strength as effective as Alga Control – Bulk Strength as effective as

Chlorine Gas Chlorine Gas Chloramine Formation – May be slightly more Chloramine Formation – May be slightly more

effective than Chlorine Gas because of pH shifteffective than Chlorine Gas because of pH shift

SYSTEM DESIGN SUMMARYSYSTEM DESIGN SUMMARY

Proper Engineering Design Essential To:Proper Engineering Design Essential To:• Eliminate Problems from Any Bleach GassingEliminate Problems from Any Bleach Gassing• Eliminate Calcium Carbonate BuildupEliminate Calcium Carbonate Buildup• Minimize Product DegradationMinimize Product Degradation• Improve Life of EquipmentImprove Life of Equipment• Minimize MaintenanceMinimize Maintenance• Ensure No Startup ProblemsEnsure No Startup Problems• Eliminate Problems from Using a Corrosive Eliminate Problems from Using a Corrosive

MaterialMaterial

Information Sources for Information Sources for BleachBleach

Chlorine Institute Pamphlet 96Chlorine Institute Pamphlet 96 AWWA Standard B300-99AWWA Standard B300-99 ANSI/NSF Standard 60ANSI/NSF Standard 60 AWWA Reference LibraryAWWA Reference Library Material Safety Data Sheet (MSDS)Material Safety Data Sheet (MSDS) Sodium Hypochlorite ManufacturerSodium Hypochlorite Manufacturer Equipment Fabricators (e.g. Pump Equipment Fabricators (e.g. Pump

Skids)Skids)