Document gEgEY9m9Kjr08EkBRyoNgebwa

rm>ty ___ FINAL PROJECT RETORT AHMCO STEEL CORPORATION POLLUTION ABATEMENT - PICKLING WASTE DISPOSAL PROJECT NO. 7186 MARCH 1, 1970 J DISTRIBUTION: ARMCO F. W. BARNES L. BOEHM R, L BRANNAMAN V. J. CURTIS T. R. FOLEY A. M. GRECO C. G. KRAMER W. K. LARSEN -- D. C. OSBORNE T. L. TAUBKEN J. M. THOMAS KAISER ENGINEERS D. A. DALY D. R. MCSPAHR1N K. D. THOMAS G. A. ZWISSLER B. P. FRANCESCHI E. D. LOWELL R. J < WOLF CENTRAL FILE BIG RED, YELLOW (W-A) FROM: D. B. WATSON APPROVED: S. G. IMHERR AKE-003801 KAISER ENGINEERS, INC. MIDDLETOWN, OHIO FINAL PROJECT REPORT ARMCO STEEL CORPORATION POLLUTION ABATEMENT - PICKLING WASTE DISPOSAL PROJECT NO. 7186 MARCH 1, 1970 CONTENTS I PROJECT SUMMARY GENERAL DESCRIPTION PROJECT AUTHORIZATION > PROJECT PERSONNEL PROJECT PROGRESS II PROJECT SCHEDULE III FINAL SUMMARY COST AND COMPARISON IV GENERAL ARRANGEMENT DRAWINGS V PHOTOGRAPHS BIG RED, YELLOW (W-A) AKE-003802 O FINAL PROJECT REPORT STEAM DISTRIBUTION SYSTEM PROJECT NO. 7186 I PROJECT SUMMARY 1.0 General Description Facilities provided by this project were designed to handle: (1) the unloading, storage and transfer of hydrochloric acid to be used in the pickling process at No. 4 and No. 5 Pickle Lines? (2) the collection, transfer, storage, filtration, and disposal of spent pickle liquor from the new Pickle Lines; and (3) the collection, transfer, treatment, and disposal of the rinse waters, including fume scrubber water, from the new Pickle Lines. j Three (3) Acid Unloading Pumps are provided to transfer fresh hydrochloric acid from two (2) tank car or truck unloading stations to two (2) 75,000 gallon tanks for storage. Two (2) acid transfer pumps are furnished to transfer the acid from the storage tanks to the pickle building for use in the pickling process. Spent pickle liquor overflows from the first tanks of No. 4 and No. 5 Pickle Lines and is piped to a 1,000 gallon collection tank at each line. Three (3) pumps are provided at the No. 4 Line collection tank area to transfer this spent pickle liquor to two (2) 75,000 gallon storage tanks located in the tank farm at the Pickle Waste Disposal Area. From storage, the spent liquor is pumped by BIG RED, YELLOW (W-A) 1- - AKE-003803 either one of two pumps through precoat filters for removal of suspended matter and then to one or the other of two disposal wells. At the disposal well, an injection pump housed inside a pump enclosure pumps the spent liquor into the disposal well for disposal into the Mount Simon sandstone strata located at a depth of approximately 3,000 feet below grade. Pick-le rinse waters from No. 4 and No. 5 pickle lines are collected in a 12,000 gallon tank at each line. Three (3) pumps are provided at the No. k pickle line collection area to pump the rinse water to two (2) elevated 45,000 gallon surge tanks located in the tank farm at the Pickle Waste Disposal Area from which it flows by gravity through the treatment facilities. Treatment includes neutralization, :) aeration, flocculation and clarification. Clarified effluent flovrs into a twenty million gallon holding lagoon before final discharge into Dicks Creek. Clarified slurry is pumped to vacuum filters, dewatered and the filter cake removed by gondola car for ultimate use in the blast furnaces. Design provides 100$ expansion capabilities for future pickle lines. A building is provided to house pumps, filtration equipment, limestone bins, air compressors and a control room. Approximately 6,450 square feet of floor space is under roof. A more detailed description of this project is included in Engineering Report 7186, dated July 15, 1967. J The need for this facility is required to meet State and Federal Restrictions for adequate lake and steam pollution control. 2- - BIG RED, YELLOW (W-A) AKE-003804 BIG RED, YELLOW (W-A) AKE-003805 BIG RED, YELLOW (W-A) AKE-003806 Is *1 ' * 4.0 Pro.lect Progress The issuance of the Engineering Report, Request for Appropriation, and approval of the Request for Appropriation are as outlined in Section 2.0. Detail design was started August 1, 1967 and was primarily the responsibility of Kaiser Engineers* Chicago Office, except for that portion of the project which falls inside the battery limits of the Pickle Line and was accomplished by Kaiser Engineers' Pittsburgh Office. The efforts of both Design Offices were augmented by the Project Technical Staff. Detail design was essentially complete on November 1, 1968. The following drawings and specifications were prepared by the Middletown Technical Staff for the Pickling Waste Disposal Project: Drawings Scoping 5 Civil 3 Piping 4 Electrical 23 Instrument 2 Specifications Performance 5 Subcontract k Equipment 18 In addition to the above, a Test and Start-Up Manual was also prepared by the Project Technical Staff. -5- BIG RED, YELLOW (W-A) AKE-003807 } Total design effort of the two Kaiser Engineers' Design Offices is summarized as follows: } j CHICAGO OFFICE Manhours Actual Budget Drawings Actual Budget Hrs/Dwg Structural 4, 435 4,940 30 38 148 Architectural 774 1,100 5 11 155 Civil 1,226 300 14 3 88 Piping 8,423 4,900 35 36 241 Instrun ent 2,597 2,240 23 16 113 Electrical 5,663. 6,180 54 95 105 Follow-Up (included) 2,800 -- -- -- Supervision 1,157 1,000 -- -- -- ) Steno-Clerical 1.983 1,500 . . -. TOTAL 26,258 24,960 161 199 155 Structural Piping Electrical Supervision Steno-Clerical TOTAL PITTSBURGH OFFICE Manhours Actual Budget 212 780 1,488 1,690 386 570 143 150 268 225 2,497 3,415 Drawings Actual Budget Hrs/Dwg 3 6 71 13 13 114 76 ---- 55 -- --w 23 25 109 Detail design was completed in April 1969* 6- - BIG RED, YELLOW (W-A) AKE-003808 Major procurement activity for engineered equipment began in July 1967 and was essentially complete in February 1969* A total of approximately forty (40) purchase orders (excluding field purchase orders) were processed and no major delays in delivery were encountered to affect construction progress. Construction activity by Kaiser Engineers' Field Forces commenced in August 1969, although there had been some subcontract activity prior to that. A preliminary safety inspection was made on February 25, 1969 and a final inspection was conducted April 28, 1969* Subcontract involvement covered the following areas of construction activity: Subcontract Subcontractor 1. Furnish and install clarifier thickener Walker Process 2. Drill and test No. 1 Injection Well American Industrial Disposal System 3* Furnish storage and surge tanks Justi.n Enterprises 4. Pollution abatement structure masonry Bilbrey Masonry Construction 5. Heating and ventilating Norm Woolley Company 6. Furnish structural steel Dave Steel 7* Drill and test No. 2 Injection Well and hang tubing in No. 1 and No. 2 Well International Pollution Control o BIG RED, YELLOW (W-A) -7 - AKE-003809 II PROJECT SCHEDULE The schedule outlining the proposed and actual progress of the Project is shown on the following page. The extension of the project schedule beyond the original completion date was caused partially by a craft strike during the summer of 1968. Also, in some instances it was necessary to delay tests until the system was complete rather than to test by increments. r> iII*; I I i i f BIG RED, YELLOW (W-A) 8- - I I AKE-003810 AKE-003811 -9- i. BIG RED, YELLOW (W-A) PROJECT NO, 7186KAISER ENGINEERS, INC. L'l REPORT DATE FINAL IO F 2 AKE-003812 BIG RED, YELLOW (W-A) I 10 - PROJECT NO. 7186 ______ KAISER ENGINEERS, INC. REPORT DATE FINAL 2 OF 2 AKE-003813 BIG RED, YELLOW (W-A) PROJECT NO. __________________________ KAISER ENCIHEERSi IMC T {'/) Ill FINAL SUMMARY COST AND COMPARISON A tabulation of final cost compared with the official budget is shown on the following page. Following is a list of the accounts with expenditures $5i000 greater or less than the appropriated budget and the reasons for the variations: Project Section 201 - A cost in excess of the budget in this project section reflects the decision to extend the height of the structure for the full length of the north bay to totally enclose the limestone bins under roof. Project Section 202 - A final, savings in cost below the original budgeted figure reflects a lower cost for the Annco enclosures than was provided for in the estimate. Project Section 401 - Costs less than the original estimate in this project section reflect the nature of the entire project; namely research and development. Costs of actual equipment, as finally designed, were less than anticipated during development and scoping. Project Section 402 - Cost savings in this project section fall into the same category as those for Project Section 401. Project Section 404 - Costs less than the original budget reflects decision to change from unit substation concept to separate items and also of inexpensive overhead primary conductor routing to air breaker switches and transformers rather than underground routing. Project Section 405 - A cost saving in this project section is realized due to less outdoor lighting requirements than had been anticipated. * - 12 - BIG RED, YELLOW (W-A) AKE-003814 Project Section hOS - Cost savings in this project section result from lower costs on the second well due to intelligence gained from the drilling of the first well. Project Section L50 - Final design indicated less instrumentation requirements than had been anticipated and thus indicates a cost savings in this section. Project Section 460 - Costs exceeding the original estimate were recorded in this project section due to the change in foundation and trench concept from that which was originally scoped. The tanks were set on elevated pads rather than making trenches depressed. Project Section 461 - An overrun was experienced in this project section due to the need for additional pipe supports caused by the extensive use of fibercast and chemtite pipe. Project Section 462 - Considerable savings were incurred in this section due to the savings in excavation cost rea3.ized by using the existing borrow pit as the location of the final lagoon. Construction costs were also less than had been provided for. Project Section 463 - This project section was deleted due to the decision to proceed with the erection of the clarifier for the Cold Mill Waste Disposal Project at this time, thus making it available and eliminating the need for an emergency lagoon. BIG RED, YELLOW (W-A) - 33 - AKE-003815 Project Section hi5 - Development of detail design indicated much less miscellaneous steel requirement than had been provided for and reflects a cost less than the original budget for this project section. Project Section 625 - An overrun in this project section reflects the extended time required for start-up due to the nature of the schedule. Start-up and construction completion were being accomplished concurrently which minimized efficiency. Project Section 645 - Some equipment which was originally scoped under the Cold Mill Waste Project was integrated into the Pickling Waste Project and additional costs incurred are reflected in an overrun in this project section. Project Section 701 - Costs over and beyond those provided for in the original budget were incurred by the addition of the compressed air piping to the aeration tank to augment the aeration mixer. Project Section 704 - Addition of safety showers over and beyond those that were scoped and the addition at each pickle line collection area of a system for tempering Spent Pickle Liquor temperatures caused an overrun in this project section. Project Section 706 - Steam piping requirements exceeded those anticipated at the time the original estimate was made. This was partially attributable to the need to provide for the addition of the Cold Mill Waste Disposal at a later date. ) - 14 - BIG RED, YELLOW (W-A) AKE-003816 1 Project Section 710 - The use of fibercast pipe and envelope type gaskets created some construction problems and required considerable rework of this piping. Changes during the design period due to the research and development nature of this project also contributed to the cause of the costs in excess of the original budget in this project section. Project Section 711 - The cost in excess of the estimate for this project section is essentially attributable to the same causes as those for Project Section 710. Project Section 712 - Costs above the estimate reflect the use of polypropolene lined pipe and fittings for this service which necessitates shop fabrication of all pipe. Again, changes during design also caused additional expense due to the nature of the piping material. Project Section 730 - Cost savings in this project section over and beyond that which was provided for in the initial budget indicate less underground piping required than anticipated. Project Section 801 - Overrun in costs in this section indicate additional raceways required due to the addition of the Snergency Motor Control Center, adding one manhole and moving the Control Room and Outdoor Substation. BIG RED, YELLOW (W-A) - 15 - AKE-003817  \ Pro.iect Section 802 - Costs exceeding budgeted figures reflect the added costs incurred due to purchase of an emergency generator larger than the one that was scoped, plus auxiliary equipment for the generator. The purchase of the additional Emergency Motor Control Center, plus costs incurred due to the addition of one manhole, also contributed to an overrun in this project section. Pro.iect Section 603 - Costs in excess of those provided for in the original budget were incurred due to the integration of some of the Cold Mill Waste Disposal equipment into the Pickling Waste process at this time. Pro.iect; Section 880 - Cost savings for this project section reflect actual cost less than was provided for in the original estimate. Pro.iect Section 920 - The costs over and beyond the original budget for this section again reflect the nature of the entire project. Time dictated that detail design proceed even though the actual process was in the lab and later, the pilot plant stage. Continued refinements and changes were dictated by findings in research and development. Pro.iect Section 930 - Cost overrun in this project section reflects the extended schedule of the entire project. Due to rescheduling of the Pickle Line construction, the Pickle Waste Disposal Plant was rescheduled to concur with the Pickle Line completion. Additional costs in this project section were incurred due to the crafts' strike during the summer of 1963. - 16 - BIG RED, YELLOW (W-A) AKE-003818 ) o +V> B t E. & } ' J BIG RED, YELLOW (W-A) 8 VO ir\ t- ?x R VO *1. C\i t & VD OJs AKE-003819 4J ^ C *o Vc J 888 88 HH I3 cd aK t T3 O *r cPoc< A(<4*u g 3 O*o4< <JJ b*t<t*BL* a&O oi o rOWti tcotjji IS! -Ci?UVCOO* Qpi i-h ^ co S * r-t< CV *Ox v8o CO CO r*< UN c-< CO iikn -ea*i tncS $US iCnO 3 CO $ (na$ -5t 5 o in co in 8 CO H CO $ cv* i *d> * o*. -c; t, u? Pa. *da <r cq g'3?1 b- CO CO -=* r- 8 ro 2 sco *s t(3f oO eg US5$ 3 8 vo O SO *k > *s in VO CO rino CO r-t r-J CO CDs o Q* lr*t ow 8 i fi 3 g -0.o)> Co *-3 O Ci-r-5 4.5 b* c*o> p O CD cQG \c0o' QOS\ BIG RED, YELLOW (W-A) - 18 - AKE-003820 BIG RED, YELLOW (W-A) AKE-003821 11p r - t .iT. ; i im.W-,! b o OCt.'f & in -4 r\ -l BIG RED, YELLOW (W-A) I -I AKE-003822 BIG RED, YELLOW (W-A) AKE-003823 BIG RED, YELLOW (W-A) AKE-003824 BIG RED, YELLOW (W-A) AKE-003825 BIG RED, YELLOW (W-A) AKE-003826 1 V PHOTOGRAPHS <v BIG RED, YELLOW (W-A) - 26 - AKE-003827 PHOTO NO. 1 POLLUTION ABATEMENT - PICKLE WASTE DISPOSAL This photo taken October 1967, looking west, shows the Final Lagoon excavation with Bentonite and Rip--Rap in place. Also shown is plant site prior to start of construction. BIG RED, YELLOW (W-A) AKE-003828 PHOTO NO. 2 - POLLUTION ABATEMENT' - PICKLE WASTE DISPOSAL This photo taken March 1968, looking northwest, shows the building steel essentially complete. Pickle Building and Pickle Goil Storage Building can be seen in left foreground. BIG RED, YELLOW (W-A) AKE-003829 PHOTO NO. 3 - POLLUTION ABATEMENT - PICKLE WASTE DISPOSAL This photo .taken October 1968, looking west, shows the storage tanks in place in tank farm with Flocculator Tank and equipment in foreground. Pipe supports are being erected. BIG RED, YELLOW (W-A) AKE-003830 PHOTO NO. Z, - POLLUTION ABATEMENT - PICKLE WASTE DISPOSAL This aerial, view taken January 1969) looking east, shows the completed project. The two well enclosures are shown east and west of the main structure. Supports for pipe runs to and from the Pickle Line located in the right center of the <picture. i BIG RED, YELLOW (W-A) AKE-003831