DC PRO ENGINEERING

SECTION 13205
THERMAL STORAGE TANK

PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Chilled water thermal storage tank performance requirements
2. Chilled water thermal storage tank construction and insulation
3. Related accessories
B. Related Items:
1. General Provisions: Section 15050.
2. Pipes and Pipe Fittings: Section 15060.
3. Temperature Sensing, chilled water Level and Alarm Systems: Controls.
1.2 REFERENCES
A. American Society of Mechanical Engineers (ASME)
1. ASME B31.1, Code for Pressure Piping - Power Piping.
B. American Water Works Association (AWWA):
1. AWWA D100, Welded Steel Tanks for Water Storage.
2. AWWA D102, Painting Steel Water Storage Tanks.
C. American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE):
1. ASHRAE Applications Handbook, Chapter 34, Thermal Storage.
2. ASHRAE Design Guide for Cool Thermal Storage, 1993 Edition.
D. Air Conditioning, Heating & Refrigerant Institute (AHRI):
1. Guideline T - Specifying the Thermal Performance of Cool Storage Equipment.
E. National Fire Protection Association (NFPA):
1. NFPA 780, Lightning Protection Code.
F. Steel Structures Painting Council (SSPC):
1. SSPC SP-10, Near White Blast Cleaning.
1.3 DEFINITIONS
A. Charging: Directing all or part flow from chillers into the bottom of storage tank at low velocity to
prevent mixing of cool and warm chilled water inside storage tank and simultaneously directing equal
flow from top of storage tank into chilled water return to chillers.
B. Discharging: Directing all or part flow from bottom of storage tank into chilled water supply to building
and simultaneously directing equal flow from chilled water return into top of storage tank at low velocity
to prevent mixing of warm and cool chilled water inside storage tank.
C. Off-Peak: Period of the working day during which an electrical utility does not foresee high electrical
demand, generally resulting in reduced electrical consumption and demand rates.
D. On-Peak: Period of the working day during which an electrical utility foresees high electrical demand,
generally resulting in increased electrical consumption and demand rates.
E. Thermal Energy Storage (TES): The thermal storage tank installed, connected and operational.
1.4 SUBMITTALS
A. Product Data: (PD)
1. Extent of Product Data:
a. Manufacturer's specifications and technical data.
b. Detailed specification of construction and fabrication.
c. Manufacturer's installation instructions.
d. Certified test reports indicating compliance with specified performance requirements.
2. Submit Product Data for each factory-manufactured component specified.
B. Shop Drawings: (SD)
1. Extent of Shop Drawings:

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a. Dimensions.
b. Description of materials and finishes.
c. Specific modifications.
d. Component connections.
e. Anchorage methods.
f. Hardware.
g. Installation procedures.
h. Project-specific wiring diagrams. (WD)
2. Submit Shop Drawings for each of the following assemblies of shop-fabricated, field-fabricated and
manufactured components:
a. Tank, including penetrations for personnel access and control system instrumentation,
insulation, coverings and protective coatings.
b. Structural support system for shell and roof, Certified by Professional Engineer (Structural).
c. Internal flow distributors and header piping.
3. A Professional Engineer must certify Shop Drawings.
C. Samples: (S) Submit 2 sets each of the following for selection or verification.
1. Color samples for exterior shell jacket and roof finish.
D. Quality Control:
1. Test reports: (TR)
a. Mill certified test reports for steel plate.
b. Soil in-place densities.
c. Concrete compressive strengths.
d. Welding non-destructive examination.
e. Paint thickness readings.
f. Performance test as indicated in Part 3.
2. Professional certifications.
3. Manufacturer's field reports with field samples specified below.
4. Written report-certifying inspection.
5. Certification that painting meets AWWA D102 Specification.
6. Pre-qualification of welders.
E. Contract Closeout Submittals:
1. Project Record Documents. (PRD)
2. Operating and Maintenance Manuals. (OMM)
a. Testing, Cleaning and Maintenance Instructions.
b. Maintenance Materials List.
c. Parts List/Diagram.
F. System Responsibility:
1. Manufacturer to be responsible for design and construction of complete tank system specified
herein including tank, foundation system, tank fittings, accessories, nozzles for gauging system,
internal flow distribution piping, chilled water sampling system, insulation, coatings, testing, etc., as
required for a complete installation ready for service.
2. Controls by Division 15. Piping outside tank beyond outlet connections by Division 15.
3. Grounding by Division 16.

PART 2 - PRODUCTS
2.1 APROVED SUPPLIERS
A. AMANA PIPELINES
B. CBI
C. AL JABER / ENE SYSTEMS
D. OR EQUIVALENT OTHERS

2.2 THERMALLY STRATIFIED CHILLED WATER STORAGE TANKS

A. Foundation System Design:
1. The tank shall be installed above underground water tank with arrangement as shown on
drawings.

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2. Coordinate foundation size, location, elevation, soil report requirements, mechanical and electrical
connections etc., with the Architect’s Representative.
3. The foundation, shall be meeting the construction tolerances and design requirements of AWWA
D100 and ACI 318. Manufacturer to design the foundation to a net allowable bearing value based
on tank dimensions.
4. The foundation will be sloped to prevent the accumulation of rainwater with 1/100 slope. For
unanchored tanks, the shell will be supported by an asphalt- impregnated fiberboard as specified
in AWWA D100.
B. Tank Design: Vertical, cylindrical all-welded steel type with flat bottom and low conical fixed roof.
Bolted construction is not acceptable.
1. Bottom and roof plates joined to cylinder using lap joints welded from topside only.
2. Designed, constructed and tested per AWWA D100 by tank manufacturer.
a. Wind load: 128.7 km/h (80 mph) when filled with chilled water.
b. Seismic design: per AWWA D100 and verify with local seismic zone requirements for entire
tank including roof framing and columns. Manufacturer's design shall account for a proper
sloshing wave height allowance to prevent roof damage.
3. Roof live load: Minimum 1.2 kPa. Verify with local code requirements.
4. Corrosion allowance: 3.175 mm (1/8 inch) corrosion allowance for tank bottom.
C. Tank Connections and Openings: See Part 3 for sizes not listed below.
1. Two shell access manholes: (One 600 mm (24 inch) and one 1000 mm (40 inch) diameter.):
a. Flanged and gasketed blankoff plates.
b. Install on opposite sides of tank, centered 36 inches above tank bottom.
2. Two roof access manholes: (One 600 mm (24 inch) diameter and one 900 mm (36 inch) square
hatch.):
a. Flanged and gasketed blankoff plates.
b. Install one in center of tank and one centered 60 inches from shell.
3. One 1.22 meter (4 ft) diameter by 0.91 meter (3 ft) drain sump, located inside the tank near the
shell manway.
4. One 600 mm ( 24 inch) diameter roof vent opening with 900 mm (36 inch) diameter mushroom
type roof vent and No. 4 aluminum bird screen. Locate at tank center.
5. All piping connections to be ANSI Class 150 welded flanges.
a. One 700 mm (28 inch) chilled water supply inlet/outlet connection
b. One 700 mm (28 inch) chilled water supply inlet/outlet connection
c. One 250 mm (10 inch) interior mounted overflow piping system with a flap valve mounted at
the point of discharge exterior to the tank.
d. 4 – 25mm (1 inch) chilled water sample connections.
e. Center column clean-out nozzle.
f. 150 mm (6 inch) drain nozzle piped to a minimum of 50 mm above tank base level.
D. Tank Fittings and Accessories:
a. Provide exterior galvanized steel OSHA approved ladder and handrail around the tank
periphery as shown on drawings.
2. Provide interior galvanized steel OSHA approved vertical ladder and safety climb device.
a. Bottom rung of ladder to start 30.5 cm above bottom of tank.
3. One temperature transmitter insertion well coupling welded to shell at each 300mm of tank shell
height. (approx. 70 total). First coupling starts at 300 mm from bottom of tank. Transmitters shall
be located along the ladder for ease of maintenance and servicing.
a. For sensing internal chilled water temperature.
b. Locate immediately adjacent to exterior ladder.
c. Size to accept standard RTD or thermistor temperature sensor and thermowell. Refer to
Controls for temperature sensing device.
4. Tank grounding system. Provide shell clips for electrical bond to electrical grounding system.
Refer to Division 16.
E. Chilled water Level Gauging System: (By Controls Contractor)
1. All connections to be provided by tank manufacturer. Locate on top of tank.
2. Provide 100 mm 68 kg (4 inch 150 lb). flanged steel pipe connection.
3. Provide a Magnetrol 801-2031-N40 analog chilled water level transmitter with a Magnetrol 41-
5093-120 probe having a 3.05 m long rigid sensor on the top of the tank. Transmitter to output a 4
to 20 milliamp or 0 to 10 volt signal for connection to the control automation system. Transmitter
housing and probe housing shall be weather proof for installation outdoors. Suspend floats inside
tank within a 100 mm (4 inch) perforated, protective pipe extended 3.05 m from top of tank.

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4. Liquid level controller shall monitor high and low chilled water levels, reporting abnormal chilled
water level to the control automation system. Set the high level at 7.6 cm below overflow. Set the
low level at 30.5 cm below overflow. Wiring to the building automation system is by Controls
contractor.
5. Liquid level controller shall also monitor the operating chilled water level and maintain the level
15.2 cm below overflow of the tank. When the chilled water level drops below the setpoint, make-
up chilled water valve shall open to supply chilled water to the tank. Valve shall close when chilled
water level reaches setpoint. Remote make-up chilled water valve will be specified in Controls
Section.
F. Chilled Water Sample Tubing for Thermal Storage Tank: (By Plant Contractor)
1. Provide 4 independent 25 mm (1 inch) stainless steel tubing water sample lines as shown on the
Drawings. The tubing shall be annealed passive type 304 stainless steel with wall thickness of
1.651mm. All bends for changes in direction shall be made in accordance with the tubing and
fitting manufacturer's recommendations. All fittings shall be compression type Swagelok or equal.
Provide threaded adapters for ball valve shutoff valves at tank. All tubing inside tank and above
ground shall be supported at minimum distance recommended by tubing manufacturer. All tubing
inside the thermal storage tank to be furnished and installed by the tank manufacturer. All tubing
and valves outside the tank and heat tracing and insulation to be furnished and installed by the
contractor.
2. Chilled water solution sample tubing shall be routed and supported near the perimeter of the tank
shell. Each tube shall terminate at 30.5 cm away from the tank shell and within 30.5 cm off the
tank bottom for each of 4 equal distance circumference locations beginning at the nozzle
connection location with tubing exit point shown on the drawings. The other 3 terminal points for
water sample tubing shall be from the other quadrants inside the tank.
G. Internal Flow Distributors:
Designed and constructed per ASHRAE Applications Handbook, 2007 Edition, and Chapter 34. The
Froude number shall be less than 0.5 to minimize the height of thermal cline.
Construction with carbon steel supports and fiberglass reinforced polyester structural channels, GRP
or HDPE or 2 mm thick reinforced stainless steel channels of grade SST 304 shall be removable for
painting of the tank. Head loss:
The total hydraulic head loss from the tank inlet flange to the tank outlet flange at the maximum
design flow rate will be a maximum of 13.79 kPa (2.0 psi) .
H. Coatings:
1. In addition to standard AWWA weld clean up procedures, provide welds as welded samples for
machine and hand welds.
2. Slag shall be cleaned from all welds. Welding joints shall not be painted until after the work has
been completed and accepted. The surfaces to be painted shall be cleaned of splatter, rust, loose
scale, oil and dirt.
3. Blast clean outside surfaces prior to application of coatings per SSPC SP-6 and inside surfaces as
per SSPC SP-10.
4. Apply coatings during temperature, humidity and cleanliness conditions within coating
manufacturer recommended limits.
5. Outside (under bottom): heat resistant paint. 1 shop coat of Carbon Zinc 11.
6. For Outside un-insulated areas, the exterior paint shall be of the same material as used for AWWA
D102 ICS-1, or of the same generic classification without ANSI/NSF Standard 61 certification
(Certification to ANSI/NSF Standard 61 is not mandatory for the exterior surface). Surfaces
exposed to the atmosphere shall receive a primer coat and a second coat of the same generic
material as AWWA D102 ICS-1, where the second coat is of a specific or special color to match
the insulation jacket color (or to otherwise suit the owner's color requirement). The two coat
system for surfaces exposed to the atmosphere shall have a total minimum dry film thickness of
7.0 mils.
7. For Outside surfaces that will be under insulation, the exterior paint shall be of the same material
as used for AWWA D102 ICS-1, or of the same generic classification without ANSI/NSF Standard
61 certification (Certification to ANSI/NSF Standard 61 is not mandatory for the exterior surface).
Surfaces under insulation shall receive one coat only, applied for a minimum dry film thickness of
5.0 mils.
8. Inside: AWWA D102 system ICS-1-W.
I. Insulation: As required to meet the thermal performance specifications.

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1. The insulation system shall meet or exceed the system performance requirements for ambient
heat gain to less than 1% of rated thermal storage capacity in a 24 hour period based on 43.33 °C
) ambient or based on 24 hours daily load profile.
2. The insulation system shall be designed to withstand a 160 km/h wind loading. Verify with local
code requirements.
3. Design for bottom insulation shall include the following:
a. Minimum of 10.2 cm foam glass insulation capable of handling the tank net bearing stress to
be installed above the underground tank.
b. Minimum of 10.2 cm sand cover above the insulation for protection from tank bottom welding.
c. Maximum U Value 0.426 W/m2.K.

4. Design for the shell and roof insulation shall include the following:
a. A rigid insulation board, of polyurethane or polisocyanurate, with pre-attached aluminum foil
3
vapor barriers. The board shall have a density of 32.04 kg/m having an aged thermal
conductivity value no more than 0.023 W/m.K (R=6.25/inch).

b. The insulating boards shall be installed as a single or multiple layer. The edges of the board
shall be tightly butted against each other. The joints of adjacent layers shall be offset a
minimum of 15.24 cm (6 inches) both vertically and horizontally, during installation.
c. The outermost layer of the insulation board shall be bonded (laminated) to an aluminum
jacket, of 0.6 mm (0.024 inch) minimum thickness, to provide weather and mechanical
protection. Alternatively, sandwich panel of minimum thickness of 38.1 mm (1½ inch) with
powder coated (Color subject to consultant approval) 0.6 mm (0.024 inch) aluminum external
panel and 0.6 mm (0.024 inch) galvanized steel internal jacket.

d. The metal jacket on both the shell and roof shall have a vertical standing closure seam. These
closure seams shall be made vapor tight with a sealant installed in the joint prior to closing the
seam. All seams shall be sealed mechanically (machine) at all accessible locations and hand
sealing shall be minimized. Alternatively, an interlocking sandwich panel with vapor tight
sealant is acceptable.

e. Horizontal seams between jacket sheets (if required) on the tank shell and the seams at the
top and bottom of the shell shall be sealed vapor tight with a non hardening, permanently
flexible sealant or other approved material. Any lapped seams shall be installed in the down
weather position to allow water run off.

f. Circumferential joints in the roof system (if required) shall consider expansion joints and a
down weather lap position. The roof panels can be placed in a radial pattern or a "Chevron"
pattern as required to best address the tank diameter.

g. The attachment system for the insulation panels shall be a concealed fastener system such as
tensioned cables and/or pencil rods.

h. The exposed insulation jacket shall have a smooth finish. The jacket will be factory coated
with a polyester resin. The color shall be PPG Bone White or requested alternative color
subject to consultant approval.

i. A reinforced corner flashing metal shall be installed at the transition of the roof to shell jackets.
This flashing section shall be a rolled section (as opposed to segmental strips). Care shall be
taken to minimize penetrations through this corner flashing.

j. The insulation system shall include removable insulated covers for the:
1) Manholes (shell and roof).
2) Anchor bolt chairs (when anchorage is required).

k. Penetrations through the metal jacket shall be sealed with a non-hardening flexible butyl
sealant (or approved equivalent) and penetrations on the roof shall be sealed using a "pitch
pot" detail.

l. The perimeter area where the tank shell meets the foundation shall be adequately sealed and
insulated to minimize condensation.

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PART 3 - EXECUTION
3.1 INSTALLATION
A. Provide 15.24 cm (6 inch) clean sand cushion under tank bottom.
B. Pipe, Fittings and Internal Flow Distributors: Per requirements of AWWA D100 and as indicated.
All piping, flanges, fittings, welding and welder qualifications shall be in accordance with applicable
standards.
C. Tank shall be constructed of steel in accordance with AWWA D100. Before any plate is welded and
before any new welding operator begins work on this project, manufacturer to provide copies of
welders certification per ASME Section IX QW-303. Qualified welding operators shall do all welding.
D. The following shall be welded by Automatic Machine:
1. All horizontal welds for shell plates by Submerged Metal Arc.
E. The following shall be welded by Automatic Machine or manually:
1. All vertical welds 1.59 cm (5/8 inch) and larger by Electrogas Arc.
2. All vertical welds less than 1.59 cm ( 5/8 inch )by Shield Metal Arc.
3. All rectangular floor plates by Submerged Metal Arc or Flux Core Arc.

F. Coatings: per requirements of AWWA D102 and as indicated.

G. Overflow Drain: Internal pipe to indirect drain near tank bottom as indicated with flapper valve outlet.
H. Insulation: apply per manufacturers recommendations.
3.2 CLEANING, FLUSHING AND FILLING BY CONTRACTOR
A. Perform procedure following completion of coating inside tank:
1. Remove construction debris from inside tank and manways.
2. Pump or wet-dry vacuum inside of tank bottom and internals.
3. Owner will inspect tank for cleanliness prior to filling.
B. Fill tank with clean water and perform leak tests prior to start-up and operating tests in accordance with
supplier’s recommendations. Notify chemical treatment contractor prior to fill allowing sufficient time
for preparation and installation of treatment program. All water treatment and testing shall be
continuous from the initial fill of water. The tank shall not be allowed to be full of water without testing
and treatment as required to maintain water quality. Clean water shall be drained and replaced with
fresh water. All sampling and chemical treatment to be continuous throughout all testing and until final
acceptance by the Owner.

3.3 PERFORMANCE TEST (TR)

A. Requirements:
1. Perform test within 30 days from date of Substantial Completion of the chilled water refrigeration
and distribution system.
2. Supplier, Owner and Contractor to witness entire test.
B. Preparation:
1. Confirm the operation of the following permanent instrumentation:
a. Chilled water supply (low) inlet/outlet temperature sensor.
b. Chilled water supply (low) inlet/outlet flow sensor.
c. Chilled water return (high) inlet/outlet temperature sensor.
d. Chilled water return (high) inlet/outlet flow sensor.
e. Internal tank temperature sensors.
f. Tank level gauging system.
C. Test Procedure:
1. Requirements:
a. The Owner has the option of conducting a performance test of the TES system to verify its
ability to meet the performance requirements specified. The test will take place within 30 days
of Substantial Completion of the TES System. Prior to the test, Owner will have data
confirming that the chilled water supply system equipment is operational.

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b. If design cooling load is not available at the time of testing, the performance test shall be
based on recharging the TES System.
c. Supply and operation of all mechanical equipment, controls and data recording devices shall
be by the Owner. The tank manufacturer will provide a qualified engineer to monitor the test.
The tank manufacturer will review the test data and issue a written report to the Owner.
d. The TES System will have met the specified performance requirements if after the flow of one
complete tank volume, the stored capacity is equal to or greater than the design value as
specified.
2. Preparation:
a. Owner shall notify tank manufacturer at least 2 weeks prior to test date.
b. At least the lowest 2.44 meter of the chilled water in the storage tank will be chilled to the
design supply temperature and will be held for 3 days to confirm that the soil and foundation
have reached a steady state thermal condition.
c. The Owner will confirm that calibrated inlet/outlet flow meter, inlet/outlet temperature
instrumentation, the thermal charge instrumentation are operational.
3. Test procedure:
a. The TES system will be brought to a fully discharged condition (all chilled water at
approximately 16.7 °C.) to initiate the performance test.
b. Charge the tank at the maximum design rate:
1) Record inlet and outlet flow and temperature at fifteen (15) minute intervals.
2) Cooling capacity delivered into storage during the fifteen (15) minute intervals will be
calculated from the flow and temperature recordings; the total stored capacity will be
calculated from the sum of the capacities from all intervals.
3.4 SCHEDULES
A. Chilled Water Storage Tank
1. Storage capacity: 189,910 kW-h (54,000 ton-hours)
2. Tank diameter: 32.5 meters maximum
3. Tank height (straight side): 25 meters maximum
4. Chilled water supply temperature: 4.44 °C (40 deg. F)
5. Chilled water return temperature: 13.33 °C (56 deg. F)
6. Maximum design discharge flow rate: 946.35 l/s (15,000 gpm)
7. Maximum design charge flow rate: 946.35 l/s (15,000 gpm)
8. Maximum heat gain (@ 48.89 °C (120 °F. ambient) and 1% in 24 hours
Maximum soil temperature at 29.44 °C (85 Deg.F).
9. Maximum usable Chilled Water Supply temp. during 5 °C (41 deg. F).
Discharge.

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