Bank on Your Tank;
HDPE Above Ground Treatment Tanks
100 Year Design Life
Infra Pipe Solutions Webinar
January 17, 2019
Todays Speakers
Grant Thornley
Working for over 25 years within the industrial
and municipal markets, Grant is known for his
expertise in mechanical, chemical and biological
treatment processes as well as pipe hydraulics.
He has written many papers, moderates the
Pipeline Condition Assessment Group and is a
regular speaker at many conferences. Grant is
the Director of Marketing and Product
Development for Infra Pipe Solutions.
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Webinar Agenda
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Introduction & Overview of HDPE Basics
Benefits of HDPE Tanks
Tank Design
Fabrication
QA/QC
Simple Life Cycle Cost Analysis
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Case Study
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Infra Pipe
Infra Pipe Solutions
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In 2013, KWH and Uponor merged under the name of Uponor allowing each company to leverage their
expertise
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Infra Pipe manufacturers PE Pipe and Fabricated HDPE Systems with the brand names of;
Sclairpipe®, Weholite®, Weholite® Modular
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Sclairpipe® (3/4” - 63” CTS,DIP,DIP)
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Weholite® Modular (up to 10’H x 45’L x 10’W per module)
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Weholite® Equalization Basins (up to 11’ dia. to depth >55’)
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ISO9001-2015 certified
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Certified to NSF, FM, BNQ, ASTM
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Multiple Manufacturing Plants in NA
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Engineered Systems
Infra Pipe manufactures (3) different types of products;
Solid Wall HDPE
Sclairpipe
Structural HDPE
Weholite Pipe
(Water & Wastewater)
Structural HDPE
Weholite Modular
(Pipe & Pump Stations)
(Tanks & Equalization Basins)
The various combinations and permutations of these products allows us to develop customizable
solutions to address unique or specific needs
What is Weholite?
Weholite® is a closed profile, Structural HDPE Beam Member which is extruded to long lengths
The Weholite® HDPE Structural beam member is configured into two unique configurations:
Weholite® Pipe (Equalization Basins & Wet Wells)
Long structural beams can be wound on-line into very, very
large pipe diameters (up to 11’ in diameter)
by winding the structural HDPE beam on a mandrel in a
helical rotation.
Weholite® Structural Panels
The extruded Weholite® structural beam is cut into linear
lengths and configured as a panel. The sides or wall of
each adjacent beam are then fused in which to create a
single structural panel.
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Weholite® Closed Profile Structural Beam
Structural HDPE Closed Profile Beam
Being Extruded
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Weholite® Closed Profile Structural Beam
“Pump Station”
HDPE
Fusion
Welds
Structural HDPE Closed Profile Beam
wound on an adjustable mandrel
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Round structural element can be used as
pipe or capped and used as a vessel
Weholite® Closed Profile Structural Beam
“WehoPanel”
Structural HDPE Closed Profile Beams
Cut into Specific Lengths
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Structural HDPE Closed Profile Beams being
fused together to create a panel
Wastewater Treatment Market
A Growing Need to Reduce Costs
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Wastewater Market
Global Market Revenue
Packaged water/wastewater systems will increase from $3.99 Billion in 2016 to $6.08 Billion in 2021 (CAGR of 6.2%).
Fastest growth is in the Asia Pacific region.
Centralized versus Decentralized
Wastewater management requires capital intensive investment with high operating and maintenance costs. Centralized
wastewater systems tends to be 2-4 times more expensive than drinking water systems. Decentralized offers substantial
savings
Market Acceptance
Communities between 30 to 1,000 families have better economics when installing their own decentralized treatment system
versus paying, to connect to centralized system, costing 2-4 times more. Decentralized treatment (point-of-source) saves on
capital, operations, distribution, maintenance and pumping costs.
Economics
The main driver influencing growth is Economics. Advanced technology such as SFBBR, MBR, MBBR, SBR, Fixed Film are
now lower in costs with improved efficiencies, allowing for smaller project foot prints to conventional treatment trains. Small
communities and land developers see packaged systems as more economic than centralized.
Weholite has a 100 year design life, offering one of the lowest life cycle costs in industry
Market Needs
Lower Costs/Better Economics
High Tank Maintenance Costs
Treatment tanks made of steel rust. Coating steel with epoxy to prevent corrosion commonly fail and require high annual
maintenance and inspection costs to maintain them. Tank inspections requires shutting down the WW treatment plant. Many
tank manufactures have conditional warranties, stipulating that tanks must be inspected annually and repaired or else the
warranty is voided. Many plants cannot shut down and as a result void their warranty.
Replacement Costs
Most tank or package plant manufactures provides a 10 year warranty on their tanks. Perforations in the epoxy coating,
covering steel is common. Leaks can develop in tanks within 1-2 years. If annual tank inspections were not conducted, then
eventually the tank will need be replaced. Tank replace is not uncommon and adds to life cycle costs.
Stainless Steel Alternative-Too costly
Some companies recognize the weakness in steel tanks and offer stainless steel as an alternative. Stainless steel tanks are
4-5 times more expensive than epoxy coated steel tank.
There is now another option …HDPE Tanks with a 100 year design life!
Weholite® Modular Tanks & Equalization Basins
Weholite® Tanks - Advantages
Durability and Sustainability
Immune to pH, H2S, Corrosion, MicroBio
100-Yr Design Life
Versatility in Design
Customizable to any design need
100% Watertight
Factory tested
Double Wall Containment
Fast Installation
Drop-in-Place
No form construction, no concrete cure time
Lower Project Cost
Lower project management cost
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Weholite® Tank – Applications
Stormwater HDS and Filtration
Stormwater Detention
CSO Storage and Pumping
Rainwater Harvest
Pump Station Wet Wells
Geothermal Vaults
Wastewater Treatment
Below Ground Structures
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Engineered Systems
HDPE
Characteristic & Properties
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HDPE Resin Properties
Discover in 1933, PE has become one of the most widely used piping
materials in the world due to its unique properties and robustness.
High Density Polyethylene (HDPE) is very robust, durable, non-corroding
and chemically inert. HDPE is defined by its three main characteristics;
ASTM D3350 Example: PE4710
1. Density
2. Molecular Weight (MW)
3. Molecular Weight Distribution
(tensile and stiffness)
(durability)
(environmental stress crack resistance)
“PE”=polyethylene
“4”=high density resin
“7” = SCG resistance >500 hours
10 = 1000 psi, HDS for water @ 73F
Resin types are defined by their cell classification per ASTM D3350
HDPE Strength & Flexibility
CreepStress Relaxation -
(t=1 min) (t=50 yr)
(t=100 yr)
2000 lb
0 lb
2000 lb
CREEP
(temporary stress)
(t=1 min)
(t=50 yr)
12,270 lb
3,150 lb
Constant Stress
Removed Stress
Applied Stress
Applied Stress
(t=0)
Increasing strain under constant load
Decreasing load under fixed strain
STRESS RELAXATION
(stress decays over time)
Ductility & Toughness
HDPE Tolerates freezing without cracking or splitting
Remains ductile to temperatures of –170F
High impact strength
Highly resistant to pressure surges
500% Elongation before break at+73.4 F
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High Tensile Strength
WELD
PROFILE
SECTION
WELD
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> 2900 psi
High Compressive Strength
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High Abrasion Resistance
HDPE
Taber Abrasion Testing
Chemical, Chlorine and Corrosion Resistant
Chlorine Resistant
Unaffected by Hydrogen Sulfide
Unaffected by Corrosion
(structural deterioration of concrete/steel)
(pipe wall loss or pitting)
Unaffected by acids & bases
(low pH dissolves concrete)
Tank Design Offering
Weholite® Tank- Membrane Cassette Use
Most packaged WW treatment systems use
membrane technology mounted within modular
cassettes. Cassettes can be easily installed into
Weholite® tanks, providing better economics than
steel with a 100 year design life.
Weholite® Customizable Treatment Tank
In some cases, clients require tanks to not only house
membrane cassettes but also additional treatment
processes; settling tank, chlorine contact tank, sludge
holding tank. Weholite® is easily configurable to provide
additional treatment processes for treatment operations.
Tank Design Considerations
I.
Above Ground (AGM) Tanks
II. Below Ground (BGM) Tanks
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Above Ground Applications (AGM)
Design Considerations
Wind Load
Ambient Temperature
Solar Exposure
Hydrostatic Head
Soil Bearing
Equipment Loading
Internal Component Support
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Above Ground-Standard Tank Design
Design Options
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MBBR, MBR, SBR
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Single or Multiple tank design
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Can provide aerobic, anaerobic,
anoxic zones
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Settling tanks with hopper bottoms
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Disinfection/chlorine contact tanks/
UV
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and more…
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Engineered Systems
Above Ground-Customizable Tank Design
Membrane
Tank
Settling Tank
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(hopper bottom)
Engineered Systems
Membrane
Tank
Chlorine Contact
Tank
Above Ground Tank- Options
Hopper Bottom
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Clarification tank with hopper bottom
Helps with sludge dewatering
Higher solids/lower disposal costs
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Engineered Systems
Above Ground Tank- Options
V-Notch Weir
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Control flow
Scum trough catches carry over
HDPE will not corrode
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Engineered Systems
Above Ground Tank- Options
Skimmer with V-Notch
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Improves clarification
Reduces carry over
Reduces chlorine dosing
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Engineered Systems
Weholite® Tank-Below Ground
Design Considerations
Existing Soil Bearing and Modulus
Existing and Proposed Utilities
Emergency Vehicular Load
Pedestrian Loading
Internal Configuration
Water table
Depth of Cover
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Engineered Systems
Weholite® Tank-Below Ground
Vehicular or Pedestrian
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Designed for HS20/CL625
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Designed for pedestrian traffic
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Engineered Systems
Weholite® Tank Design & Modelling
CANDE
2D Planar - Analysis and Design’
INVENTOR 3D FEA Analysis
• Material Testing
• Live Full Scale Load Testing
• Empirical Data Calibrated Design
• Third Party Validated Design
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Weholite® Tank Design & Modelling
Design Modeling
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In depth FEA analysis ensures
robust designs, and successful
applications
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Stress analysis verifies if
reinforcement is required
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Engineering Update and Review
Weholite® Tank-Fabrication
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Hot Gas (Air) Fusion and Extrusion Welding
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A fusion gun heats up all surfaces to be welded (A&B) and filler material.
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Filler material is applied between surfaces A&B (joint) forming pool of molten material.
Once cooled, joint is stronger than the base material.
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Fusion gun are heated from 480°F to 1022°F, depending upon material thickness and
type.
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Hot Gas (Air) Fusion Welding is not the same technique as gluing, brazing and
soldering, which do not melt the base metal.
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Engineered Systems
Hot Gas (Air) Fusion and Extrusion Welding
Hand Fusion Weld
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Engineered Systems
Extrusion Weld
Fusion Welding (Hand)
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Extrusion Welding
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Engineered Systems
Extrusion Welding-Hand Held Units
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Thermoplastic Welding Standards
AWS B2.4:2012
Standard Welding Procedure Specification for
Welding Procedure and Performance Qualification
for Thermoplastics
Approved American National Standards Institute
Specifies the Qualifications of Personnel and
Procedures
Qualifications specify welding position and
equipment
Self Regulated Certification Process
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Engineered Systems
DVS 2205
Design Calculations for Thermoplastic Tanks
DVS 2231:2008
Quality Assurance for Above Ground Tanks
DVS 2207
Welding Guidelines for Fusion and Extrusion
(Hot Gas)
Thermoplastic Welding Standards
ASTM F2487
Standard Practice for Infiltration and Exfiltration Acceptance Testing
ASTM D3261
Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Pipe
ASTM D3350
Standard Specification for Polyethylene Plastic Pipes and Fittings Materials.
ASTM F714
Standard Specification for Polyethylene (PE) Plastic Pipe
ASTM F1759
Standard Practice for Design of High Density Polyethylene Manholes
ASTM C1147
Standard Practice for Determining Weld Strength of Thermoplastics
ASTM F2620
Standard Practice for Heat Fusion Joining of Polyethylene Pipe and Fittings
ASTM D2321
Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers
ASTM F894
As applicable to Uponor Weholite Profile Wall PE Pipe.
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Engineered Systems
Quality Assurance Testing
Visual
Distortion and wash along the edge of the welding rod indicating proper welding heat and pressure.
Surface appearance of the base material right next to the weld indicates proper preheat temperature.
Referred to as HAZE (heat affected zone).
Properly Welded PE will have a dull appearing HAZE
Overheated PP and PE will look very shiny and small splashes of material seem to spray away from the
bead.
Pressure Test of Internal Voids
Weholite internal void can be pressurized to check overall weld integrity.
In Field Leak Testing
ASTM F2487 Standard Practice for Infiltration and Exfiltration Acceptance Testing.
(15 US Gallons per inch of pipe diameter per mile of pipe per day)
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Engineered Systems
System Pressure Test
In-Plant Testing
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Engineered Systems
In-Field Testing
Life CycleHDPE
Costs (LCC)
LCC is the TOTAL cost of ownership. It takes into account all costs of acquiring,
maintaining, operating, and disposing of a system.
Source: Alliance for PE Pipe
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Life Cycle Cost Calculation Example
$ per Year
Initial
Purchase $
LCCA
Maintenance
Design Life
(Years)
Operations
HDPE
110,000
1
1
100
110,200
Steel
100,000
5
5
50
201,000
82%
Purchasing on capital cost alone does not capture the true cost of ownership
In this example, HDPE is priced higher than steel and assumes that steel on
averages is (5) times higher in operations and maintenance cost than HDPE
The result is that steel is 82% higher in LLC than HDPE is over its design life
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Thank You