WASTEWATER STILLING TANKS

DECEMBER 1994

PAGE 1 OF 14

EGE 26-B-5 1994

TABLE OF CONTENTS 1. 2. 3. 4. 5. Scope References General Performance Design 5.1 5.2 Process Mechanical Design and Materials

History of Change EGE 26-D-5 Stilling Tank Data Sheet

1. SCOPE This Guide covers basic requirements for the design, materials, and fabrication of stilling tanks and associated equipment used in wastewater treatment for refinery, marketing, and chemical facilities. 2. REFERENCES The following publications form a part of this Guide. The references cited with dates in this Guide were used in its development. For all references which have been superseded, revised, and/or corrected, the user of this Guide is obligated to determine if the latest versions of the cited references have any impact on the content of this Guide or its use. Mobil Technology Company (MTC) Guide Sponsor should be consulted if there are any concerns or questions.
Mobil Engineering Guides EGE 00-C-4 EGE 14-B-1 EGE 14-S-8 EGE 31-B-1 EGE 35-B-2 EGE 45-B-61 EGE 45-B-62 EGE 45-B-63 EGS 626 EGS 629 (1993) (1993) (1993) (1989) (1993) (1993) (1992) (1991) (1986) (1991) Equipment and Packaged Units General Purchasing Requirements Aboveground Welded Steel Storage Tanks (Low-Strength Steel and Stainless Steel) Design and Construction Storage Tanks Foam Connections Steel Structures Design and Fabrication Painting Coating and Lining of Storage Tanks Fixed and Portable Fire Fighting Monitors Live Hose Reels for Fire Protection Portable Fire Extinguishers and Fire Blankets Fire Protection Storage Tanks Fire Protection and Loss Prevention Refineries and Petrochemical Plants

API (American Petroleum Institute) Standard 650 (1993) Welded Steel Tanks for Oil Storage

3. GENERAL 3.1 The stilling tank and its components shall be designed and fabricated as a complete unit for service in an industrial wastewater treatment plant. Components of a stilling tank include:

MOBIL ENGINEERING GUIDE EGE 26-B-5 1994 (a) (b) (c) (d) (e) (f) (g) Tank. Cover. Inlet chamber with inner wall and reaction jets. Oil removal system. Slotted outlet header and associated piping. Outlet weir box. Sediment removal system.
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Typical stilling tank arrangements are shown in Figures 1 and 2. The dimensions of appurtenances such as inlet pipe diameter, for larger tanks will differ from those shown in Figure 2. The number of reaction jets will differ from Figure 2 in accordance with Table 1. 3.2 Equipment shall be purchased in conformance with EGE 00-C-4, except as modified for specific equipment by the project instructions, specifications, and terms and conditions stated in Mobils request for quotation. 3.3 The design and fabrication of the complete unit and its components shall conform to all applicable national and local laws and regulations. 3.4 Stilling tank facilities shall comply with the fire protection requirements of EGS 629. One 14 kg (30 lb) dry chemical extinguisher meeting the requirements of EGE 45-B-63 shall be located within 15 m (50 ft) of the tank in a fire-safe and easily accessible location. Fixed firewater monitor coverage in accordance with EGE 45-B-61, or a live hose reel meeting the requirements of EGE 45-B-62, shall be available for fire protection of the tank. One hydrant shall also be located in the vicinity of the tank.

FIGURE 1 STILLING TANK GENERAL ARRANGEMENT

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EGE 26-B-5 1994

FIGURE 2 STILLING TANK GENERAL ARRANGEMENT Diameter 12.2 m (40 ft)

MOBIL ENGINEERING GUIDE EGE 26-B-5 1994

PAGE 4 OF 14 DECEMBER 1994

For covered stilling tanks, a semifixed foam protection system, in accordance with EGS 626 and EGE 14-S-8, shall be installed to extinguish fires inside the tank. 4. PERFORMANCE 4.1 The stilling tank shall be sized to remove all oil globules having a diameter of 0.15 mm (0.006 in. or 150 microns) or larger within the entire range of the design flowrate. The unit shall be designed to provide a quality of effluent with both free oil and suspended solids concentrations of 100 mg/liter or as listed in EGE 26-D-5. 5. DESIGN 5.1 Process

5.1.1 The design methodology for a stilling tank follows that used for a conventional oil-water separator. However, the design procedure which relates Stokes Law to the various design parameters is modified herein because of the circular configuration of the stilling tank. The stilling tank design shall be based on Stokes law applied to the rate of rise of oil globules in water as:

<t

'C

Sw ! S o

Where:
vt C = rate of rise of 0.15 mm (0.006 in.) diameter oil globule in wastewater mm/sec (ft/min). = constant = 0.00122 si, 0.0241 customary.

Sw = specific gravity of wastewater at design temperature of wastewater. So = specific gravity of oil in wastewater at design temperature of wastewater. = absolute viscosity of the wastewater at design temperature (poises).

5.1.2 The design mean horizontal velocity (of the 0.15 mm diameter oil globule), vH, shall be the smaller of 15 vt or 0.3 m/min (1 ft/min). For circular tanks, vH is calculated at the center of the tank. If the operating water level is set, the tank diameter can be calculated by using the following equation.

D '

Q H vH

Where:
vH Q H D = horizontal velocity of the 0.15 mm (0.006 in.) diameter, oil globule at the center of the tank m/min (ft/min). = flowrate m /min (ft /min). = operating water level m (ft). = tank diameter m (ft).
3 3

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EGE 26-B-5 1994

5.1.3

The retention time, assuming full utilization of the tank volume shall be three to five hours.

R'

V Q

Where:
R V Q H D = = = = = retention time (minimum).

B D 2 H = volume of stilling tank m3 (ft3).

4

flowrate m /min (ft /min). operating water level m (ft). tank diameter m (ft).

5.1.4 The most cost effective stilling tank height for all tank diameters has been determined to be 7.3 m (24 ft). This provides an operating water level of 6.1 m (20 ft). Deviation from this standard height should be subject to Mobil approval. Higher operating levels are not recommended because the influence of increased depth on oil rise may limit the ability of the oil globule to reach the surface before the water exits the tank. The normal water level shall be a minimum of 610 mm (24 in.) below the top of the tank wall. 5.1.5 Table 1 lists a range of sizes of stilling tanks which meet these design criteria. Stilling tanks are not 3 recommended for flowrates greater than 11.5 m /min (3000 gpm).
TABLE 1 TYPICAL SIZES AT DIFFERENT FLOWRATES AND OPERATING CAPACITIES
Tank Operating Capacity m3 397 715 1115 1430 1750 2065 bbl 2500 4500 7000 9000 11000 13000 Length of Inlet Chamber Inner Wall m 5.00 7.04 8.66 10.18 11.06 12.41 ft 16.4 23.1 28.4 33.4 36.3 40.7 3 4 5 6 7 8 Reaction Jet (Orifice) Diameter mm 127.0 152.4 152.4 177.8 177.8 177.8 in 5 6 6 7 7 7

Flowrate m3 per min 1.9 3.8 5.7 7.6 9.5 11.5 US gpm 500 1000 1500 2000 2500 3000

Tank Diameter m 9.1 12.2 14.6 16.5 18.3 21.3 ft 30 40 48 54 60 70

Inlet Chamber Radius m 1.8 2.6 3.2 3.8 4.1 4.6 ft 6 8.5 10.5 12.5 13.5 15

No. Reaction Jets in Inlet Chamber

NOTE: 7.3 m (24 ft) high tank; 6.1 m (20 ft) operating water level based on inlet chamber retention time of 15 minutes and tank retention time of approximately three hours.

MOBIL ENGINEERING GUIDE EGE 26-B-5 1994 5.2 5.2.1 Mechanical Design and Materials Tank
PAGE 6 OF 14 DECEMBER 1994

The stilling tank shall be designed and constructed of carbon steel in accordance with API 650 and EGE 14-B-1. Exterior painting and interior lining, including shell and internals, shall be in accordance with EGE 35-B-2. 5.2.2 Cover

Environmental regulations may require stilling tanks to be covered to reduce odors or hydrocarbon emissions. Fixed covers are preferred and shall be of lightweight construction and made of aluminum or other suitable material. Access panels for servicing of grease fittings and similar items shall be included on the covers. Fixed covers shall be provided with chain or cable-restrained explosion vents. Suitable gas blanketing shall be provided between fixed covers and the liquid surface to avoid formation of an explosive mixture. Gas blanket pressure can be maintained as low as 2.8 mm Hg (1.5 in. water) with special regulation valves. Access/view hatches shall be provided at the slotted pipe skimmer. The design of floating covers shall be subject to Mobil approval. 5.2.3 Inlet Chamber

The inlet chamber shall be designed to reduce inlet velocities and to obtain a uniform flow distribution throughout the tank. The inlet chamber shall be sized for a retention time of not less than 15 minutes. The influent shall leave the inlet chamber and enter the center portion of the stilling tank through a series of reaction jets. The reaction jets shall be positioned in a single row on the inner wall of the inlet chamber at an elevation of one half of the operating water level (Figure 2). The horizontal spacing between adjacent reaction jets shall be 1.68 m (5.5 ft) for 9.1 m (30 ft), 12.2 m (40 ft), 14.6 m (48 ft), and 16.5 m (54 ft) diameter tanks and 1.52 m (5 ft) for 18.3 m (60 ft) and 21.3 m (70 ft) diameter tanks. The remaining space available in the length of the inlet chamber inner wall shall be divided equally between the two outside jets and the tank wall. Figure 3 shows the reaction jet spacing for a 12.2 m (40 ft) diameter stilling tank. The reaction jets consist of an orifice and a dished target baffle. The orifice shall consist of a circular opening cut into the inlet chamber inner wall. The orifice shall have smooth, right-angle edges. The concave surface of the baffle faces the orifice. The flow of water from the orifice is reversed by the baffle, so it impinges on the inlet wall of the tank. In this manner, the velocity head is dissipated, and the flow is effectively and uniformly distributed over the cross-sectional area of the tank. Reaction jet design (see Figure 4) shall be based on the following criteria: (a) Radius of curvature of the baffle, R mm (in.), is equal to orifice diameter, D mm (in.).

(b) Selection of orifice diameter to maintain design flow velocity of 36.58 m/min (2 fps) to 54.86 m/min (3 fps) in the orifice. (c) Baffle diameter, D + 1, is 25.4 mm (1 in.) larger than orifice diameter.

(d) Baffle is located 63.5 mm (2.5 in.) downstream from the orifice (inlet chamber inner wall). This distance is required in order to avoid clogging. (e) A hole in the center of the baffle shall be provided to improve distribution. The diameter, d, mm (in.) of this hole shall be six percent of the plane area of the baffle; d ' 0.06 (D % 1) .

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EGE 26-B-5 1994

FIGURE 3 INLET CHAMBER Tank Diameter 12.2 m (40 ft) Tank Height 7.3 m (24 ft)

FIGURE 4 REACTION JET

MOBIL ENGINEERING GUIDE EGE 26-B-5 1994 5.2.4 Oil Removal System
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A slotted pipe skimmer oil removal system permitting manual operation shall be provided (see Figure 5). The rotatable slotted pipe skimmer shall be mounted so that the slots can be rotated 75 degrees in either direction. Carbon steel pipe, a minimum of NPS 12 (NPS = nominal pipe size, inches) in outside diameter and 9.5 mm (0.375 in.) in wall thickness, shall be used. A 60 degree slot shall be cut symmetrically about the vertical axis of the pipe, with the edges of the slot serving as a weir which the oil flows over when the pipe is rotated. The edges of the slot shall be parallel to the longitudinal axis of the pipe. At regular intervals a maximum of 760 mm (30 in.), 50 mm (2 in.) wide bands of the full pipe periphery shall be left in the pipe to act as stiffeners. The rotatable slotted pipe skimmer shall be supported at each end to allow it to be adjusted to the water level. The pipe shall be supported by and revolve in a rolled steel collar which shall be welded to an adjustable steel plate. A viton seal shall be furnished on the open end pipe support to provide a watertight connection to the tank wall without grouting. This seal shall be constructed so that it remains tight even with a slight misalignment of the pipe and collar. The seal shall be readily renewable without removing the pipe from the supporting brackets and shall not bind or impede the smooth action of the revolving pipe. The rotatable pipe shall be manually operated by means of a cast iron handwheel with handle and rack-and-pinion assembly. The handwheel shall be fitted to a structural steel floor stand of welded construction having a nonrising stem. The stem shall be threaded brass and shall turn inside a standard pipe lifting stem which raises and lowers the sliding rack assembly. The rack assembly shall consist of two angles fastened together by two connecting pins and welded to a plate which is welded to the lifting stem. The rack assembly shall move in a cast iron guide bracket to assure positive contact of the connecting pins with a steel pinion segment welded to the pipe. The pinion segment shall rotate on the rack connecting pins to permit an easy and accurate means of adjusting the pipe through a 75 degree angle in either direction, for a total of 150 degrees. 5.2.5 Slotted Outlet Header

The outlet header shall be a single pipe configuration as shown in Figure 6 for a 12.2 m (40 ft) or less diameter tank and a dual configuration as shown in Figure 7 for tanks greater than 12.2 m (40 ft) diameter. In either case, the header discharges to a single weir. The dual-outlet header is preferred because it minimizes short-circuiting and permits more efficient use of stilling tank capacity. A detailed piping plan for dual-outlet headers is shown in Figure 8 for a 12.2 m (40 ft) diameter tank. 5.2.6 Outlet Weir Box

A detailed weir design for a 12.2 m (40 ft) diameter stilling tank is shown in Figure 9. The primary function of the outlet weir is to hydraulically regulate the operating level in the tank. Efficient operation of the rotatable slotted pipe skimmer depends on a controlled liquid level, from a lower limit of approximately 63.5 mm (2.5 in.) below the center line of the pipe skimmer to an upper limit of approximately 101.6 mm (4 in.) above the center line of the pipe skimmer. This establishes an operating range of 165 mm (6.5 in.). The weir height variation is determined by two components: (a) (b) Pressure drop caused by 6.1 m (20 ft) of outlet header (plus equivalent lengths of fittings). Operating level above weir, or weir crest, to give desired rate of flow.

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EGE 26-B-5 1994

FRONT VIEW

FIGURE 5 DETAIL OF ROTATABLE SLOTTED PIPE SKIMMER INSTALLATION

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NOTE: Plate thicknesses shown are minimums. Pipe dimensions are in inches NPS (nominal pipe size). All pipe Schedule 40 except 2 in. Schedule 80.

FIGURE 6 SINGLE-OUTLET HEADER Tank Diameter 12.2 m (40 ft) or Less

FIGURE 7 DUAL-OUTLET HEADER Tank Diameter Greater than 12.2 m (40 ft) (Two Required)

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EGE 26-B-5 1994

NOTE:

Pipe dimensions are in inches NPS (nominal pipe size). All pipe Schedule 40 except 2 in. Schedule 80.

FIGURE 8 PIPING PLAN FOR DUAL OUTLET

The height of the weir crest, in mm (in.), shall be calculated from the Francis formula:

Q = Where:
Q C L H = = = = flowrate, m /m (US gpm).
3

C LH

3/2

constant = 2.433 si, 36.084 customary. length of weir, m (ft). height of weir crest (operating level above weir), mm (in.).

The necessary weir length for design flowrates shall be calculated so as to operate within the skimmer operating constraints. In all cases, the combined pressure drop in the vertical outlet pipe and the weir crest should not total more than 165 mm (6.5 in.) water for the maximum flow.

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FIGURE 9 WEIR BOX Tank Diameter 12.2 m (40 ft)

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EGE 26-B-5 1994

5.2.7

Sediment Removal System

Periodic removal of sediment from the bottom of the stilling tank is essential to prevent the resuspension of settleable solids into the outlet header. This operation can be performed without taking the tank out of service. As indicated in Figures 1 and 2, removal may be achieved by means of a sludge suction line with a bellmouth attachment. The tank bottom should be sloped to a sludge hopper. Sediments should be removed from the following two locations: (a) From the inlet chamber, to permit continuous operation without plugging.

(b) From the bottom of the main body of the stilling tank, to permit longer periods of continuous operation without tank dewatering. In both the inlet chamber and the main body of the stilling tank, the line size shall be a minimum of NPS 6. To facilitate periodic manual cleaning, the tank shall be equipped with a 1.2 m x 1.2 m (4 ft x 4 ft) flush-type cleanout fitting. The fitting shall be sized to permit the use of power-driven cleaning equipment. 5.2.8 External Appurtenances

The stilling tank shall be furnished with walkways in accordance with EGE 31-B-1 and as follows: (a) The walkways and handrails shall extend across the entire width of the stilling tank adjacent to the skimmer pipe. (b) All grease fittings, rotatable skimmer, gear mechanism, and valve operators shall be readily accessible from the top of the walkway without heavy covers or floorplates being raised.

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HISTORY OF CHANGE

The history of change contained herein does not constitute a complete listing of revisions and changes made to this document. Only revisions and changes of significant technical content (per sponsor and Steering Committee) are listed. EGE 26-B-5 1994 EGE 26-B-5 1994 (formerly EGS 722) supersedes the 1988 version with the following significant technical changes: 1. 2. Design basis added for oil droplet rise (Stoke's Law as modified), mean horizontal velocity of oil globule, and tank retention time. Table 1 has been revised to include:
C C

Inlet chamber radius and length of inner wall. Number of reaction jets and reaction jet orifice diameter.

3.

Reaction jet and baffle design has been clarified.

MOBIL ENGINEERING GUIDE WASTEWATER STILLING TANK DATA SHEET

ISSUE 1 2 Number of Units Tank Diameter Tank Wall Height Tank Freeboard Tank Construction In accordance with API 650? (If no, attach list of exceptions.) Yes No Model No.* APPROVED 4 5 ISSUE APPROVED JOB NAME ITEM NAME LOCATION Manufacturer JOB NO. ITEM NO.

EGE 26-D-5 1994

Page 1 of 2

PERFORMANCE DATA Minimum Design Flowrate liters/h (US gpm) Minimum Oil Droplet Size to be Removed mm (in.) Ambient Temperature C (F) Influent Wastewater Temperature C (F) Influent SS Concentration (mg/l) Influent Oil Concentration (mg/l) Influent Wastewater Specific Gravity Influent Oil Specific Gravity Influent Wastewater Absolute Viscosity (poise) Effluent SS Concentration (mg/l) Effluent Oil Concentration (mg/l) PROCESS DESIGN AT DESIGN FLOW Rate of Rise of Oil Globule mm/min (ft/min) Horizontal Flowrate mm/min (ft/min) Tank Retention Time (Hr) Inlet Chamber Retention Time (min) Oil Layer Thickness mm (in.) MECHANICAL COMPONENTS Corrosion Allowance: Corrosion Allowance for Internal Parts: Coatings: External: By Tank Contractor Internal: Covers:* Type: Material of Construction: By Tank Contractor By Others By Others Yes Fixed Specify: Specify: No Floating 1.27 mm (0.5 in.) No Other: Yes, Specify: max min Normal Maximum

Gas Blanket: Type Off-Gas Control System:

*Items designated by an asterisk shall be completed by supplier.

Yes Source

No

MOBIL ENGINEERING GUIDE WASTEWATER STILLING TANK DATA SHEET

MECHANICAL COMPONENTS (Contd) Sediment Removal System:* Type: Inlet Chamber:* No. Reaction Jets Outlet Header:* Single Outlet Outlet Weir:* Length m (ft) Height of Weir Crest m (ft)
*Items designated by an asterisk shall be completed by supplier.

EGE 26-D-5 1994

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No. of Jets

Pipe Size

Design Velocity mm/min (ft/min)

Dual Outlet