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Section 4: Appendix A SPCC Cost Information Section 4 Appendix A-1 APPENDIX A: SPCC COST INFORMATION Preface. The following section contains a broad listing of items for which SPCC-related cost information can be researched and developed through local cost estimators, contractors, and vendors, or by performing internet searches, interviews, etc. The list was compiled by systematically (i.e., citation by citation) examining the requirements of 40 CFR 112, and noting any identified items, installations, or required tasks whose cost could conceivably be appraised. Additional items may also have come from the preamble portion of the regulation. Inclusion of an item in this appendix does not necessarily indicate it is a requirement; it may only be a recommendation or just one of a number of acceptable potential approaches. Refer to the respective citation for clarification. A listing of vendor, Navy, and federal- related web sites that contributed to the content of this appendix is included at the end of the appendix. The cost information for some of the items identified below may be difficult to approximate, even in general terms or broad price ranges. In many of these instances, approximations are largely dependent on site conditions that vary significantly from facility to facility, and development of general cost information may not provide meaningful or reliable data for the purposes of this guidance document. For each citation, identified items whose cost could conceivably be appraised are marked with a bullet symbol [ ], and any cost information that has been researched and developed for this guidance document immediately follows in blue font. The source of the respective cost information is provided at the end of the section in parentheses in blue italic font. As noted elsewhere in the guidance document, this cost information has been included merely to provide a ‘starting point’ from which installations may identify and begin to understand the relative costs of various options to improve their compliance stature. The illustrative cost estimates are rough approximations that could reasonably be expected to vary with respect to size, scope, vendor, location, mobilization, economy of scale, region, etc., sometimes quite significantly. Actual costs are subject to change and should be investigated prior to construction, equipment purchase, budget submissions, or committing resources to a project. Typical sources for funding environmental measures pertaining to SPCC planning include: Base operating funds (Operations and Maintenance, Navy (O&M,N)). Region environmental funds (O&M,N). Specialized sources of funds, such as Defense Energy Support Center (DESC) funding for the management of DESC fuel product, or Pollution Prevention Equipment Program (PPEP) funding for the installation of certain types of equipment (e.g., Bilge and Oily Wastewater Systems (BOWTS)). § 112.3 Requirement to Prepare and Implement an SPCC Plan. SPCC Plan Preparation SPCC Plans must be updated every 5 years or after any material change that would affect the facility’s potential to spill oil. The Navy Environmental Requirements Guidebook (i.e., the “Cookbook”) estimates the costs associated with SPCC Plan updates as follows: Very Small Activity (1 - 5 tanks): $5,000 to $10,000. Small Activity (5 - 20 tanks): $15,000 to $25,000. Medium Activity (20 - 50 tanks): $25,000 to $50,000. Large Activity (> 50 tanks): $50,000 to $75,000. (2002 Navy Environmental Requirements Guidebook – Chapter 9.)

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Page 1: APPENDIX A: SPCC COST INFORMATION

Section 4: Appendix A SPCC Cost Information

Section 4 Appendix A-1

APPENDIX A: SPCC COST INFORMATION

Preface.

The following section contains a broad listing of items for which SPCC-related cost information can beresearched and developed through local cost estimators, contractors, and vendors, or by performinginternet searches, interviews, etc. The list was compiled by systematically (i.e., citation by citation)examining the requirements of 40 CFR 112, and noting any identified items, installations, or requiredtasks whose cost could conceivably be appraised. Additional items may also have come from thepreamble portion of the regulation. Inclusion of an item in this appendix does not necessarily indicate it isa requirement; it may only be a recommendation or just one of a number of acceptable potentialapproaches. Refer to the respective citation for clarification. A listing of vendor, Navy, and federal-related web sites that contributed to the content of this appendix is included at the end of the appendix.

The cost information for some of the items identified below may be difficult to approximate, even ingeneral terms or broad price ranges. In many of these instances, approximations are largely dependenton site conditions that vary significantly from facility to facility, and development of general costinformation may not provide meaningful or reliable data for the purposes of this guidance document.

For each citation, identified items whose cost could conceivably be appraised are marked with a bulletsymbol [ Ø ], and any cost information that has been researched and developed for this guidancedocument immediately follows in blue font. The source of the respective cost information is provided atthe end of the section in parentheses in blue italic font. As noted elsewhere in the guidance document,this cost information has been included merely to provide a ‘starting point’ from which installations mayidentify and begin to understand the relative costs of various options to improve their compliance stature.The illustrative cost estimates are rough approximations that could reasonably be expected to vary withrespect to size, scope, vendor, location, mobilization, economy of scale, region, etc., sometimes quitesignificantly. Actual costs are subject to change and should be investigated prior to construction,equipment purchase, budget submissions, or committing resources to a project.

Typical sources for funding environmental measures pertaining to SPCC planning include:Ø Base operating funds (Operations and Maintenance, Navy (O&M,N)).Ø Region environmental funds (O&M,N).Ø Specialized sources of funds, such as Defense Energy Support Center (DESC) funding for the

management of DESC fuel product, or Pollution Prevention Equipment Program (PPEP) funding forthe installation of certain types of equipment (e.g., Bilge and Oily Wastewater Systems (BOWTS)).

§ 112.3 Requirement to Prepare and Implement an SPCC Plan.

Ø SPCC Plan Preparation

SPCC Plans must be updated every 5 years or after any material change that would affect thefacility’s potential to spill oil. The Navy Environmental Requirements Guidebook (i.e., the“Cookbook”) estimates the costs associated with SPCC Plan updates as follows:

• Very Small Activity (1 - 5 tanks): $5,000 to $10,000.• Small Activity (5 - 20 tanks): $15,000 to $25,000.• Medium Activity (20 - 50 tanks): $25,000 to $50,000.• Large Activity (> 50 tanks): $50,000 to $75,000.

(2002 Navy Environmental Requirements Guidebook – Chapter 9.)

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Note that the above estimates do not reflect any additional increase in estimated effort that may berequired as a result of the 17 July 2002 changes to the technical requirements of 40 CFR 112. Forexample, the following factors may influence the effort required to update an SPCC Plan to conformto the new requirements:

• Adopting the preferred 40 CFR 112 format for the Plan (or cross-referencing this format ifanother approach is taken).

• Updating the facility diagram to include all required information (e.g., 55 gal drums,transformers, operating equipment, animal and vegetable oil containers, UST locations, etc.)

• Providing more detailed inspection and testing details and schedules in the Plan.• Researching and providing industry standard information and citations in the Plan.• Reviewing and removing containers, such as USTs and tanks less than 55 gal in capacity,

that no longer require inclusion in the Plan.• Obtaining information on and incorporating containers, such as drums, electrical equipment,

operating equipment, and grease traps, that may have previously been omitted from the Plan.• Obtaining information on valves and piping infrastructure.

§ 112.7(c) Secondary Containment.

Ø Portable Containment Berms

Portable or collapsible containment berms or pools can be taken to any level surface and set uprelatively quickly. Configurations typically include foam sidewalls and/or snap-up stays. Portablecontainment berms provide effective temporary containment for mobile oil storage containers, suchas drums and tank trucks that pose a risk of leaking. However, portable containment berms are noteffective long-term alternatives to conventional secondary containment for trucks or otherequipment receiving frequent use, since regular entry and exit will induce wear on the material, andweathering may also degrade the condition of the material. Portable containment berms rangefrom $200 to $1,400 for containment areas smaller than a vehicle, to from $3,000 to $7,000 forberms designed to accommodate trucks or large vehicles. (GSA, Bowhead, New Pig.)

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Ø Drum Containment Pallets and Pallet Inserts

Polyethylene drum containment pallets are designed to capture spills or leaks from drums in thesump of the pallet. Pallets may be modular, low or high profile, or have an internal bladder thatexpands outward to accommodate the spilled liquid. Prices range from $150 to $600 for pallets thataccommodate 2 to 4 drums, depending on design, vendor, configuration, etc. Steel pallet insertscontain from 55 to 80 gal can be retrofitted into exiting pallet racks, and cost from $450 to $600.(GSA, Bowhead, New Pig, Denios.)

Ø Spill Kits

Conveniently located and adequately stocked spill kits provide materials that can be utilized forimmediate response to cleanup a discharge upon discovery. Spill kits can be universal in nature,designed to absorb all liquids such as oils, coolants, solvents, antifreeze, acids, bases, and water,or be designed to selectively absorb petroleum, hydrocarbons, and other oil-based liquids. Spill kitscan be purchased complete, or components (e.g., mats, pillows, booms, disposal bags, gloves,goggles, etc.) can be purchased separately and placed into drums that are marked as spill kits toreduce the overall cost. Complete spill kits range from $100 to $1,000 depending on vendor,contents, size, container configuration, etc. (GSA, Bowhead, New Pig, Imbibitive Technologies.)

Ø Drain Covers

Drain covers (a.k.a. drain protectors, drain blockers, plug rugs) are made with mesh sandwichedbetween heavy layers of polyurethane that deform and seal off drains temporarily. A typical use ofa drain protector would be to temporarily seal off a nearby drain during fuel delivery from a tanktruck to an AST. Drain protectors range from $100 to $500 depending on vendor, size, andconfiguration. (Bowhead, New Pig, PSI Urethanes.)

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Ø Concrete Berm Design and Construction

Design of the following concrete berms are based on RS Means construction book software,incorporating the following assumptions: concrete berms incorporate 6” thick walls and a 6” thickslab with #4 steel reinforcing bars spaced at 12” on-center both ways. The concrete berms areassumed to set aboveground on a level surface (i.e., no excavation required), and are poured in amonolithic pour. Forming, placement of steel reinforcing bars, concrete finishing, and onedischarge ball valve are included in the project. The cost estimate includes material, equipment,labor, overhead, and profit, plus 20% contingency.

Tank Size Berm Dimensions (L × W × H) Containment Volume Cost Estimate500 gal 10’ × 5’ × 2’ 748 gal $ 3,1301,000 gal 14’ × 7’ × 2’ 1,466 gal $ 3,2702,500 gal 20’ × 10’ × 2’ 2,992 gal $ 6,5785,000 gal 28’ × 14’ × 2’ 5,864 gal $ 10,239

(PWD Port Hueneme / 2003 RS Means.)

Ø Masonry Berm Design and Construction

Design of the following masonry berms are based on RS Means construction book software,incorporating the following assumptions: masonry berm walls are constructed of 8” × 8” × 16”masonry blocks whose cores are filled with concrete and #4 steel reinforcing bars. The masonryberm walls are placed atop a 6” thick slab with #4 steel reinforcing bars spaced at 12” on-centerboth ways. The masonry berms are assumed to set aboveground on a level surface (i.e., noexcavation required). Forming, placement of steel reinforcing bars, concrete finishing, block laying,coating of the inside walls with petroleum resistant coating to seal the mortar joints, and onedischarge ball valve are included in the project. The cost estimate includes material, equipment,labor, overhead, and profit, plus 20% contingency.

Tank Size Berm Dimensions (L × W × H) Containment Volume Cost Estimate250 gal 8’ × 4’ × 2’ 479 gal $ 1,547500 gal 10’ × 5’ × 2’ 748 gal $ 2,1121,000 gal 14’ × 7’ × 2’ 1,466 gal $ 2,686

(PWD Port Hueneme / 2003 RS Means.)

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Ø Rollover (Drivable) Berm Design for Loading/Unloading Areas

Design of the following rollover berms for loading/unloading areas (e.g., for vehicles, tank trucks,etc.) are based on RS Means construction book software, incorporating the following assumptions:concrete slab is 8” thick with #4 steel reinforcing bars, designed to bear typical vehicle andequipment loads. The concrete slab is assumed to set aboveground on a level surface (i.e., noexcavation required), and the 6” high concrete rollover berm (speed bump type) is constructed ontop of the slab. The outer perimeter of the berm is backfilled from the top of the berm and slopesdown to grade with class II aggregate, to facilitate vehicle access. Forming, placement of steelreinforcing bars, and concrete finishing are included in the project. The cost estimate includesmaterial, equipment, labor, overhead, and profit, plus 20% contingency.

Tank Size Berm Dimensions (L × W × H) Containment Volume Cost Estimate1,000 gal 26’ × 12’ × 6” 1,167 gal $ 3,7755,000 gal 62’ × 24’ × 6” 5,565 gal $ 11,713

(PWD Port Hueneme / 2003 RS Means.)

Ø Earth Berm Design

Note that earthen berms or dikes are more commonly used at large oil storage facilities; the smalldesigns have been included here for comparative purposes. Design of the following earthen bermsor dikes are based on RS Means construction book software, incorporating the followingassumptions: compacted earthen berms are trapezoidal in cross-section with a 2:3 vertical-to-horizontal wall slope; listed dimensions are for the top interior of the dike.

Earthen berms may offer a lower cost alternative, or a temporary solution, to secondarycontainment requirements. However, unlike concrete or sealed masonry berms, earthen bermsare not impervious, and therefore must be lined or sealed to prevent infiltration into the soil. Theyare also subject to erosion and may require occasional rebuilding.

Where space allows, lined earth dikes are preferred over concrete or masonry berms, per DesignManual 22. Earth berms commonly have sloped walls so that the base of the dike is much widerthan the crown or top. The slopes of earth dikes should not be steeper than 2 feet vertical to 3 feethorizontal. On average, dikes are not to exceed an interior height of 6 feet. In addition, it is goodpractice to construct dikes with a level, three-foot wide surface on the crown to provide a walking

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surface for inspections. Dikes are typically constructed of well-compacted earth and coated withreinforced concrete, asphalt with rubberized coal tar sealer, or bentonite for erosion control and toprovide an impervious surface. Costs reflect construction and compaction of the dike; costsassociated with coating or lining to make the berm impervious are not included.

Tank Size Interior Berm Dimensions (L × W × H) at Top Containment Volume Cost Estimate250 gal 10’ × 5’ × 2’ 299 gal $ 857500 gal 12’ × 6’ × 2’ 539 gal $ 1,1771,000 gal 16’ × 8’ × 2’ 1,107 gal $ 1,322

(PWD Port Hueneme / 2003 RS Means.)Ø Repair or Sealing of Cracks and Fissures

Diked areas must prevent discharges and precipitation from leaking out into the surrounding area orinfiltrating into the soil beneath the containment area. Cracks or holes that develop must beproperly repaired and sealed. Sealing ¼” to ½” cracks that have formed in concrete or masonryberms will cost $30 to $35 per linear foot. (PWD Port Hueneme / 2003 RS Means).

Ø Doorway Spill Barriers

For indoor oil storage facilities, especially those with frequent personnel or vehicle (e.g., forklifts,trucks, etc.) traffic, doorway spill barriers can provide secondary containment. When installed infacilities where the floor and lowermost portions of the wall surfaces are sealed and areimpermeable, doorway spill barriers may provide viable alternatives to costly or operationally lessconvenient secondary containment approaches such as: concrete berms surrounding containers;containment pallets beneath containers; ramps installed at doorways; rollover (drivable) bermsinstalled at doorways; trench drains installed in the floor; sumps excavated beneath the floor, etc.An additional benefit of doorway spill barriers is that they typically contain not only of the capacity ofthe largest oil storage container within the building, but also contain [the required amount of] waterreleased from a fire sprinkler system in the event of a fire.

There are manual and automatic doorway spill barriers. Manual barriers require an operator toposition the barrier in place and secure it in the event of a spill. Though this is a task that can beaccomplished in seconds, the fact that someone must be present to carry it out is an obviousdrawback the manual method. An automatic barrier manufactured by Denios functions without theneed for an operator. When a spill occurs, the liquid flows into a shallow 4” to 6” sump inside thedoorway entrance, where the barrier is resting flush with the floor surface. When enough liquid hasentered the sump, the barrier is displaced from the sump and activated into a upright position whereit secures itself.

Doorway Barrier Type 3’ x 1’ 4’ x 1’ 6’ x 1’ 8’ x 1’ 10’ x 1’Manual $ 2,985 $ 3,696 $ 4,873 $ 6,392 $ 7,737Automatic $ 4,632 --- $ 7,318 $ 9,256 $ 10,909

(Denios.)

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Ø Oil-Swellable Absorbent Polymer Storm Drain Inserts

Oil-swellable (i.e., oleophillic, or ‘oil loving’) absorbent polymer storm drain inserts may be a viablelow-cost alternative for secondary containment in locations where berm-type containment is costlyor not practicable, but where the risk of release must be addressed in accordance with SPCCregulations (e.g., transformer sub stations, other operating equipment, fuel truck parking areas,etc.) Oil-swellable absorbent polymers are engineered to allow water to pass through, whilehydrocarbons are absorbed (i.e., imbibed) into the material. Oleophillic spheres, or Imbiber Beads,can swell up to 3 times their original diameter, or 27 times the original volume of the Bead, whenabsorbing hydrocarbons. The Beads are packaged into blankets, pillows, boom, packets, blends,bulk, and specially designed drain protection systems. These can be configured in various sizesand are suitable for various locations, including drain and curb inlets, allowing for the free passageof water while preventing the passage of oil. Drain protection shut-off systems, allow water topercolate through the void spaces between the spherical Beads. The physical expansion (i.e.,swelling) of Imbiber Beads within the system closes off the void space between the spheres in theevent a large slug of oil were to be released. This would cause the inlet chamber to physically plug,thereby sealing the leak path, and thus preventing the draining or release of any oil.

Drain protection shut-off systems, with Imbiber Bead packets or pillows, inlet fixtures (single ormultiple chambers), and ancillary parts, range from $800 to $10,000 depending upon the size andcomplexity of the system required. DoD costs for individual Imbiber Bead products (e.g., forcustomized installations and/or spill response) are listed below.

Product NSN Unit Size DoD CostImbiber Beads® Packets 4235-01-434-6845 7” x 7” - 36/ctn $86 / ctnImbiber Beads® Pillows 4235-01-434-6847 14” x 21” - 6/ctn $81 / ctnImbiber Beads® Blankets 4235-01-434-6853 21” x 42” - 4/ctn $168 / ctnImbiber Beads® Mini-Booms 4235-01-434-6857 7” x 42” - 12/ctn $168 / ctnImbiber Beads® Floating Booms 4235-01-472-6400 9’ x 4.5” - 2/ctn $227 / ctnImbiber Beads® Bulk Form 4235-01-434-6863 40 lb drum $340 / drImbiber Beads® Military Blankets(weighted with sand to combat wind-sheer)

4235-01-452-7294 21” x 42” - 4/ctn $168 / ctn

Imbiber Beads® Military Boom (weightedwith sand to combat wind shear)

4235-01-452-7290 9’ x 4.5” - 2/ctn $227 / ctn

Imbiber Beads® Bulk Beads/Sand Blend 4235-01-434-6827 25 lb cubitainer $89 / jug(Imbibitive Technologies.)

Refer to Chapter 7 of the Spill Prevention Guidance Document (NFESC, 1998) for further information onspill containment [http://enviro.nfesc.navy.mil/ps/spillprev].

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§ 112.7(d) Deviation from Secondary Containment Requirement (Contingency Planning).

Ø Integrity Testing of Tanks

Refer to the discussion for § 112.8(c)(6) below.

Ø Leak Testing of Valves and Piping

The Navy Environmental Requirements Guidebook (i.e., the “Cookbook”) provides guidance onpressure testing of piping (under ‘Recurring SPCC Requirements’). Estimated costs for pressuretesting of piping ranges from $200 to $1,000 per pipe segment, depending on the length and thecomplexity of the piping segment. (2002 Navy Environmental Requirements Guidebook – Chapter 9.)

The Cookbook also notes (under ‘Release Detection for Large Underground Piping Systems’) thatinstallation of permanent release detection systems for large underground piping systems will costbetween $40,000 to $1M depending on the length of the piping system and the type of leakdetection system used. Alternately, annual testing will cost between $2,000 to $20,000 dependingon the length of the piping system and the type of release detection method used. (2002 NavyEnvironmental Requirements Guidebook – Chapter 7.)

§ 112.7(g) Security.

Ø Fencing

It may be appropriate or necessary to provide individual site fencing (i.e., in addition to theperimeter fencing surrounding the installation). For example, site fencing should be considered forcritical or large oil storage locations, and oil-filled electrical equipment. Enhanced measures, suchas taller fencing, barbed wire, or security cameras may also be employed where security concernsare paramount. Estimated costs associated with fencing are listed below.

Item Cost UnitSteel galvanized chain link fencing (height of 6 - 10 feet) $20 - $25 LFVinyl coating (additional cost) $4 - $6 LFFence posts $60 - $80 EAPersonnel swing gates $300 - $400 EALarge swing gates $10 - $12 SFLarge rolling gates $7 - $9 SFVinyl coating (additional cost) $4 - $6 SF

(PWD Port Hueneme / IDQ Contract.)

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Ø Valve Lockouts

Valve lockouts prevent unauthorized persons from turning valves by riding atop the handwheelwithout engaging it. The lockout must be removed to turn the handwheel to open the drain valve.Valve lockouts cost $15 to $50 apiece depending on vendor and handwheel diameter:

Item Cost UnitBall Valve Lockouts (small – large) $18 - $25 EAGate Valve Lockouts (1” - 2.5”) $12 - $15 EAGate Valve Lockouts (2.5” - 5”) $19 - $23 EAGate Valve Lockouts (5” - 6.5”) $23 - $27 EAGate Valve Lockouts (6.5” - 10”) $29 - $37 EAGate Valve Lockouts (10” - 13”) $51 - $70 EA

(GSA, Allstate, New Pig.)

Ø Padlocks

Padlocks used to secure pump starter controls, lock boxes, drain valves, gates, and starter controlscost $5 to $20 apiece depending on vendor, brand, type (e.g., combination, resettable combination,or key), shackle length, etc. Multiple locks opened by the same key or combination are available,which could help ensure keys won’t be misplaced or combinations forgotten. (GSA, Home Depot,Ace Hardware, New Pig.)

Ø Lighting

Exterior lighting assists in the discovery of spills at night and in the prevention of spills occurringthrough acts of vandalism. The two types of security lighting most commonly used areincandescent (i.e., filament) or high-intensity discharge lamps (e.g., mercury vapor, metal halide, orhigh-pressure sodium.

The estimated cost of a 150-watt high-pressure sodium exterior light fixture, attached to a 10’ highaluminum pole, mounted on 2’ diameter by 3’ deep concrete base, including trenching ofunderground power from a source 20 feet away is $2,243. A similar wall-mounted exterior fixture,with a surface mount electrical panel box located 20 feet away will cost $390. (PWD Port Hueneme/ 2003 RS Means.)

Estimated costs for installation of various lighting fixtures, provided in pages 600 - 604 of the 2003National Construction Estimator, are summarized below.

⇒ High Intensity Discharge Fixtures (all types):[Commercial and architectural grade fixtures with ballasts (no lamps, wire, conduit, orconcrete)]70 - 400 watts, various mountings, shapes, and configurations: $200 - $650 installed.

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⇒ High Intensity Discharge Lamps (all types):[For commercial and architectural grade luminaries]35 - 400 watts: $30 - $65.

⇒ Incandescent Lighting:[Commercial and architectural grade fixtures and lamps (no wire, conduit, or concrete)]150 watts, various mountings, shapes, and configurations: $35 - $165 installed.

⇒ Vandal Resistant High Intensity Discharge Lighting (high-pressure sodium):[Commercial and architectural grade fixtures and lamps (no wire, conduit, or concrete)]35 - 70 watts, various mountings, shapes, and configurations: $270 - $305 installed.

⇒ Vandal Resistant Incandescent Lighting:[Commercial and architectural grade fixtures and lamps (no wire, conduit, or concrete)]35 - 70 watts, various mountings, shapes, and configurations: $75 - $105 installed.

⇒ High Intensity Discharge Yard and Street Light Fixtures (all types):[Fixtures with ballasts (no pole, concrete work, excavation, wire, lamps, or conduit)]70 - 400 watts, various mountings, shapes, and configurations: $400 - $530 installed.

⇒ Yard and Street Light Poles:[Aluminum poles (no excavation, pole, concrete work, excavation, wire, lamps, or conduit)]12’ - 30’ in height, single arm, various shapes: $480 - $1,335 installed.

⇒ Area Lighting Installed on Poles:[Excavation for pole, pole foundation (2' x 2' x 3' deep), 150' of 2" PVC conduit run with 40'of RSC, 600' of #8 copper wire and terminations, 35' x 8" square steel pole and one armand 480 volt mercury vapor 1,000 watt luminaire with lamp for each fixture. Equipment is aflatbed truck with a boom & auger]

Fixture Cost Person Time Labor Equipment Total1 fixture per pole $ 2,860 Ea E1 30.4 hrs $ 1,240 $ 295 $ 4,3952 fixtures per pole $ 3,510 Ea E1 32.5 hrs $ 1,320 $ 316 $ 5,146

(2003 National Construction Estimator.)

Refer to Chapter 9 of the Spill Prevention Guidance Document (NFESC, 1998) for further information onsecurity [http://enviro.nfesc.navy.mil/ps/spillprev].

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§ 112.7(h) Loading/Unloading.

Ø Overfill Prevention

Scully Signal systems provide overfill prevention at most Navy fuel farm loading/unloading racks.Scully Signal systems provide high level shutoff overfill prevention for tank trucks and refuelingvehicles. The system consists of an all-electronic, continuously self-checking system thatautomatically shuts off the bottom loading fuel flow at the fillstand when the tank truck is full. TheGroundhog vehicle static grounding system provides grounding protection against static electricity,a source of considerable concern for high flow rate dispensing systems used at theloading/unloading racks of large fuel farms. The estimated cost of a Scully Signal system with aGroundhog system is $18,000 without installation. (NAS North Island Fuel Department.)

Ø Vehicle Brake Interlock System

Brake interlock systems prevent the tank truck from departing while the tank truck is engaged ornozzle interlocks are activated. Systems may be equipped with an electric brake interlock overrideto allow movement of the refueler during emergencies. For cost information, provide vendors withthe specifics of the loading/unloading operation.

Ø Wheel Chocks

Wheel chocks also prevent early departure of vehicles from loading/unloading racks beforecomplete disconnection of transfer lines has occurred. Wheel chocks placed in front of and behindthe tires of tank trucks at the fillstand (or simply parked on an incline) serve as a reliable backup incase the vehicle parking brakes fail or the operator forgets to engage them. Wheel chocks can befabricated of urethane, plastic, or rubber, and may be extruded or molded. Chocks come in avariety of sizes and durability to accommodate all types of mobile vehicles and equipment and costfrom $10 to $80 apiece for non-aviation wheel chocks. (GSA, HammersPlastic, Checkers IndustrialProducts.)

Ø Warning Signs

Warning signs are identified in § 112.7(h)(2) as one of several measures that can help preventvehicles from departing before complete disconnection of transfer lines has occurred. Well-placed,

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clearly worded signage will remind and alert operators to verify all connections have been secured.Signs may cost up to $150 apiece, depending on mounting and placement. (PWD Port Hueneme /IDQ Contract.)

Refer to Chapter 5 of the Spill Prevention Guidance Document (NFESC, 1998) for further information ontransfer areas [http://enviro.nfesc.navy.mil/ps/spillprev].

Refer also to the following sections of the Spill Prevention Resource Guide [NFESC, 2003] in Section 3Tab B: Overfill Prevention; Loading Rack Devices (for Spill Prevention).

§ 112.7(i) Brittle Fracture Evaluation.

Ø Brittle Fracture Evaluation

When there is a repair, alteration, or reconstruction of the AST that might affect the risk of adischarge or fracture due to brittle fracture, or there is a change to a more severe level of service(e.g., operating at a lower temperature, or handling a product with a higher specific gravity), thetank must be evaluated for brittle fracture. Evaluation may include following assessmentprocedures from industry standards (e.g. Section 5.3 of API 653) that may require hydrotesting orother non-destructive testing or considerations in order to assess the tank’s suitability for continuedservice.

An estimated cost for an authorized inspector (recommended, though not explicitly required by §112.7(i)) to conduct brittle fracture evaluation on a 20,000 gal steel AST is $3,500 to $6,000 plustravel expenses. Testing that may be required for brittle fracture evaluations could require severaldays to a week of the inspector’s time, plus several additional days to prepare a brief report of thefindings. Typically, the tank owner is responsible for the logistics and costs of supplying anddisposing of any water used in hydrotests. (NFESC.)

§ 112.8(b)(1) Diked Storage Area Drainage.

Ø Pumps and Ejectors

Diked storage areas that do not have valves or drain outlets can use pumps and ejectors to drainretained rainwater as long as the pumps are not automatically activated. Pumps with or withoutejectors range from $150 to $450. (GSA, Bowhead, New Pig.)

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Estimated costs of installing sump pumps, with no electrical work, submersible type are listed below:

Sump Pumps Cost Person Time Labor Total1/4 HP, 1-1/2" outlet, ABS plastic $ 99.40 Ea P6 0.200 hrs $ 81.80 $ 181.201/3 HP, 1-1/4" outlet, Cast iron $ 115.00 Ea P6 0.200 hrs $ 81.80 $ 196.801/3 HP, 1-1/4" outlet, ABS plastic* $ 118.00 Ea P6 0.200 hrs $ 81.80 $ 199.801/3 HP, 1-1/4" outlet, cast iron $ 114.00 Ea P6 0.200 hrs $ 81.80 $ 195.801/3 HP, 1-1/2" $ 84.80 Ea P6 0.200 hrs $ 81.80 $ 166.60

* Upright type (2003 National Construction Estimator.)

Refer to Sections 8.2 and 8.3 of the Spill Prevention Guidance Document (NFESC, 1998) for furtherinformation on collection and containment, and transfer, respectively[http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(b)(2) Diked Storage Area – Valves Used; Inspection of Retained Stormwater.

Ø Drain Outlets

Installation of drain outlets or drain holes in existing concrete or masonry berms may be desirable,to reduce the reliance on pumps, ejectors, or vacuum trucks for emptying captured rainwater fromthe berms. Note that drain outlets must have manual open-and-closed drain valves installed onthem to prevent rainwater from automatically draining before it can be inspected. Drilling a 3”diameter drain hole through 6” concrete or masonry costs $43 per hole, plus $3.31 per inch greaterthan 6” thick. (PWD Port Hueneme / 2003 RS Means.)

Ø Manual Open-and-Closed Valves

Manual open-and-closed valves are required for the drainage of diked areas to prevent theautomatic drainage of rainwater before it can be inspected for the presence of oil. Valves areavailable in a variety of sizes and materials such as PVC, steel, and bronze with typical costs ofranging from $5 to $70 for valves less than 3” in diameter. (GSA.)

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Estimated costs of installing ball valves, bronze, 150 lb threaded, Teflon seat are listed below:

Ball Valve Cost Person Time Labor Total1/2" $ 5.82 Ea P1 0.210 hrs $ 5.81 $ 11.633/4" $ 8.61 Ea P1 0.250 hrs $ 6.92 $ 15.531" $ 12.20 Ea P1 0.300 hrs $ 8.30 $ 20.501-1/4" $ 21.20 Ea P1 0.400 hrs $ 11.10 $ 32.201-1/2" $ 25.80 Ea P1 0.450 hrs $ 12.50 $ 38.302" $ 34.70 Ea P1 0.500 hrs $ 13.80 $ 48.50

(2003 National Construction Estimator.)

Refer to Sections 8.2 and 8.3 of the Spill Prevention Guidance Document (NFESC, 1998) for furtherinformation on collection and containment, and transfer, respectively[http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(b)(4) Diversion Systems.

Ø Boom

Containment boom permanently installed in drainage ditches or creeks could serve diversionarypurposes in the event of a spill, as could sorbent boom installed around operating equipment. Inpractice, boom is more commonly employed in response scenarios, rather than for pre-emptivediversionary purposes.

Navy installations can utilize NAVFAC’s Oil Spill Equipment Program to obtain containment boom,as well as oil skimmers, utility boats, vacuum trucks, and other equipment (including training) at nocost to the installation [http://enviro.nfesc.navy.mil/ps/oilspill/oilspill.htm]. Commercially availableboom costs are provided below:

Item Cost UnitContainment boom $7 - $16 LFOil sorbent boom (oil sorbent socks) $2 - $4 LF

(GSA, Bowhead, New Pig.)

Refer to Section 7.2.4 of the Spill Prevention Guidance Document (NFESC, 1998) for further informationon trenches, retention ponds, and surface impoundments [http://enviro.nfesc.navy.mil/ps/spillprev].

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§ 112.8(b)(5) Lift Pumps.

Ø Pumps.

Refer to the discussion for § 112.8(b)(1) above.

Refer to Sections 8.4 and 8.5 of the Spill Prevention Guidance Document (NFESC, 1998) for furtherinformation on treatment units, and flow between treatment units, respectively[http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(c)(2) Secondary Containment – Bulk Storage Containers.

Ø Bulk Storage Containment

Refer to the discussion for § 112.7(c) above.

Refer to section 4.2.9 of the Spill Prevention Guidance Document (NFESC, 1998) for further informationon secondary containment approaches for bulk storage tanks, or Chapter 7 for further information on spillcontainment [http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(c)(4) Completely Buried Tanks; Corrosion Protection.

Ø Cathodic Protection Retrofitting

Cathodic protection is often retrofitted on existing metallic buried or bunkered tanks and pipelines.The cost varies substantially based on the size, age, location, local environmental regulations, etc.A suggested range to base a cost estimate on is 5% to 20% of the cost of a similar new installation,although some retrofit installations may exceed this. Select a percentage from this range based oneconomy of scale and location. For example, use a lower percentage for large MILCON-sizedfacilities such as tank farms in generally lower cost or environmentally less strict areas; use ahigher percentage for a small project such as a 1,000 gal UST in a generally higher cost orenvironmentally more strict area (e.g., California). (NFESC.)

Ø Cathodic Protection Monitoring and Testing

Cathodic protection systems for metallic tanks and piping must be regularly monitored and tested toensure they are functioning correctly and thus minimizing the rate at which those surfaces thatcannot be visually inspected (e.g., surfaces that are buried, partially buried, bunkered, or sitting onthe ground) are corroding. First time or full (annual) cathodic protection surveys can cost up to$8,000 for large tank farms, or up to $7,000 for extensive piping systems. Regular maintenancemonitoring and testing must be performed more frequently. Monthly or bi-monthly rectifierinspections cost up to $760. Quarterly or semi-annual structure-to-electrode potential tests cancost up to $500 for large tank farms, or up to $7,000 for extensive piping systems. (The aboveestimates reflect survey time only; costs associated with report writing, project management, travelexpenses, etc. are additional.) Refer to Section 4 Appendix C for further detail on estimated costsof cathodic protection surveying. (NFESC.)

The Navy Environmental Requirements Guidebook (i.e., the “Cookbook”) also provides guidanceon UST corrosion protection testing and maintenance and repair. Estimated costs for USTcorrosion protection testing for impressed current systems are $1,800/year per tank. Estimated

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costs for magnesium anode systems are $600/year per tank or $1,800 every 3 years per tank.(2002 Navy Environmental Requirements Guidebook – Chapter 7.)

Ø Leak Testing USTs and Bunkered ASTs

The Navy Environmental Requirements Guidebook (i.e., the “Cookbook”) provides guidance ontank and pipe tightness testing. Estimated costs for UST tightness testing are $1,500/year per tankand $750/year per pipe run. Leak detection on large, field-constructed USTs is generally moredifficult and costly, with periodic tests costing between $5,000 and $50,000, depending on the sizeof the tank and the type of release detection method chosen. (2002 Navy EnvironmentalRequirements Guidebook – Chapter 7.)

For instance, tracer testing of USTs costs $15,000 per tank at the 567,000 gal USTs at the NASNorth Island Fuel Farm, and tracer testing of pipelines costs $3.76 per liner foot. (NAS North IslandFuel Department.)

Refer to Section 4.2.4 of the Spill Prevention Guidance Document (NFESC, 1998) for further informationon corrosion protection [http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(c)(5) Partially Buried or Bunkered Tanks; Corrosion Protection.

Ø Partially Buried or Bunkered tanks

Refer to the discussion for § 112.8(c)(4) above.

Refer to Section 4.2.4 of the Spill Prevention Guidance Document (NFESC, 1998) for further informationon corrosion protection [http://enviro.nfesc.navy.mil/ps/spillprev].

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§ 112.8(c)(6) Integrity Testing.

Ø Non-Destructive Shell Testing

Various non-destructive shell tests can be used to verify the integrity of tanks and piping.Ultrasonic testing is commonly employed for metallic tanks to establish baselines for comparisonduring future inspections. It is a quick, inexpensive, and useful method to monitor the shellconditions of metallic tanks and piping. Radiographic [X-ray] testing is commonly performed onnew piping systems (older piping will typically fall far short of today’s standards), but less commonlyperformed on tanks in service. Hydrostatic testing with water is commonly performed on new tanks,reconstructed tanks, and tanks that have undergone extensive repairs or modifications, to verify theintegrity of the tank. [For in-service tanks, testing similar to ‘Hydrostatic’ testing, only withpetroleum product, is often employed to simply verify the tanks are not leaking.] Acousticemissions and other non-destructive tests may also be utilized.

Tank inspections that combine visual inspection with the above techniques, conforming to API 653,cost $10,000 to $30,000 per tank for large tanks (e.g., fuel farm tanks), depending tank size, tankmaterial (steel or concrete), configuration (AST or UST), mobilization costs, personnel travel costs,etc. Tank cleaning, typically required to make the environment suitable for inspection of tankinteriors and bottoms, will add another $5,000 to $20,000 depending on similar variables. (Theabove costs are total project costs.) Note that while API 653 addresses ASTs and not USTs, thereis no widely accepted equivalent industry standard that addresses UST inspection. Consequently,UST inspections typically follow the guidelines of API 653 where practicable. (NFESC.)

The Navy Environmental Requirements Guidebook (i.e., the “Cookbook”) provides guidance onhydrostatic testing, non-destructive shell thickness testing, and other precision storage tank testing(under ‘Recurring SPCC Requirements’). Estimated costs for this testing ranges from $500 to$2,500 per tank. (2002 Navy Environmental Requirements Guidebook – Chapter 9.)

In 1991, the EPA estimated tank integrity testing and leak testing costs of buried piping to be to$465 per tank, $155 for equipment, and $310 for installation. Small facilities were assumed to haveno buried piping. Medium sized facilities were assumed to bear first year costs for tank installationand testing of $4,704 and subsequent year costs of $1,449. Large facilities were assumed to incura first year cost of $11,313, and subsequent year costs of $3,519. (EPA.)

Refer to Sections 4.2.10, 4.2.11, and 4.2.12 of the Spill Prevention Guidance Document (NFESC, 1998)for further information on tank system testing, tank inspections, and leak detection and monitoring,respectively [http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(c)(8) Alarm Systems.

Ø Automatic Tank Gauging Systems

The Automatic Fuel Handling Equipment (AFHE) program is a software-managed Automatic TankGauging (ATG) program that is centrally funded and managed by Defense Energy Support Center(DESC) Facilities Engineering Division. Under this program, Navy facilities such as fuel farms andlarge bulk storage facilities that store DESC owned petroleum product are equipped with ATGsystems that provide continuous monitoring of bulk petroleum products. Barton ATG systemsdesigned to interface with the Fuels Automated System (FAS) are used on tanks over 75,000 gal.Ronan and Veeder Root ATG systems also designed to interface with the FAS are used on smallertanks under 75,000 gal. New tanks planned to be installed in future that will store DESC productwill include ATG as part of the associated MILCON project (i.e., no cost to the Navy operator or

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installation). The ATG systems interface with the FAS Fuels Manager module to provide agraphical site and individual tank overview, as well as provide audible and visual alarms. (NavalPetroleum Office.)

ATG systems for non-DESC facilities must be funded by the installation.

Ø Liquid Level Sensing Device Testing and Maintenance.

The Navy Environmental Requirements Guidebook (i.e., the “Cookbook”) provides guidance ontesting and maintenance of liquid level sensing devices or other overfill protection devices (under‘Recurring SPCC Requirements’). Estimated costs for testing and maintenance ranges from $200to $1,000 per device. (2002 Navy Environmental Requirements Guidebook – Chapter 9)

Ø Level Sensors with Audible and/or Visual Overfill Alarms

Unlike USTs regulated under 40 CFR 280, aboveground oil containment systems are not requiredto have continuous fuel level monitoring systems, since leaks from the AST are visible. For someaboveground facilities, however, fuel level monitoring systems, such as magnetorestrictive systems,are effective (this is a type of system commonly employed at small neighborhood gas stations). Atypical complete fuel monitoring system utilizing magnetorestrictive technology for two tanks,consisting of various components such as tank probes with floats, interstitial sensors, productdispensers, underground sumps and conduit, overfill warning devices, user consoles, etc. costsbetween $7,500 to $10,000. Installation could add an estimated $5,000, depending on site factorssuch as distance to the electrical supply, amount of concrete that must be removed, extent ofconduit and sensors that must be installed, etc. Simplified, less automated magnetorestrictivesystems designed less for inventory purposes than for leak or overfill protection would cost less, aslow as $2,000 to $3,000 plus installation. (Western Pump.)

The following diagrams were included to illustrate devices and appurtenances associated of AST systems,including overfill protection valves, level sensors and gauges, fill catchments, and other devices. Theseand other images can be viewed at [ http://www.morbros.com/tank_diagrams.htm ]. (Morrision Bros.)

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Devices associated with a horizontal cylindrical AST Suction System with top fill and top mounted pump.

Devices associated with a rectangular double-wall AST Suction System with remote fill and remote pump.

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Devices associated with a horizontal cylindrical AST Pressure System with top fill and remote dispenser.

Devices associated with a rectangular double-wall AST Pressure System with remote fill and sidemounted dispenser.

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Refer to Sections 4.2.7, 4.2.8, and 5.9 of the Spill Prevention Guidance Document (NFESC, 1998) forfurther information on level controls, automatic controls, and overfill protection, respectively[http://enviro.nfesc.navy.mil/ps/spillprev].

Refer also to the following sections of the Spill Prevention Resource Guide [NFESC, 2003] in Section 3Tab B: Level Sensing; Overfill Prevention; Leak Detection (Double-Walled ASTs); Loading Rack Devices(for Spill Prevention).

§ 112.8(c)(11) Mobile Containers.

Ø Mobile Storage Containment

Refer to the discussion for § 112.7(c) above.

Refer to sections 4.3 and 5.13 and 7 of the Spill Prevention Guidance Document (NFESC, 1998) forfurther information on container storage, tank car and tank truck loading/unloading racks, and secondarycontainment, respectively [http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(d)(1) Buried Piping.

Ø Buried Piping Upgrade or Replacement.

It is recommended that new or replacement piping be placed aboveground whenever possiblebecause such placement makes it easier to detect discharges, and may avoid the need to providethe coating and cathodic protection otherwise required for buried piping. Note that safety or trafficconsiderations may influence the decision whether piping should be installed aboveground orunderground.

The Navy Environmental Requirements Guidebook (i.e., the “Cookbook”) provides guidance on thereplacement of piping that does not meet corrosion or secondary containment requirements. It issometimes feasible to upgrade unprotected steel piping by adding corrosion protection, but it isusually better to simply replace the piping, particularly if it is over 15 years old. It is often not costeffective to add secondary containment to existing single-walled piping. If secondary containmentis necessary, the single-walled piping is usually removed and replaced with double-walled piping.Piping is usually removed and replaced when a tank is replaced. Estimated costs for removal andreplacement of substandard piping are $200/foot for piping of 20 feet or less in length, or $150/footfor piping in excess of 20 feet in length. Costs are for construction only; add another 10% to 20%for design costs. (2002 Navy Environmental Requirements Guidebook – Chapter 7.)

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Ø Cathodic Protection of Buried Pipelines

Cathodic protection must be provided for buried metallic piping installed on or after 16 August 2002,as well as for previously installed buried metallic piping if soil conditions warrant (and the EPAbelieves all soil conditions warrant protection of buried piping).

The Navy Environmental Requirements Guidebook (i.e., the “Cookbook”) provides guidance oncathodic protection testing of pipelines (under ‘Recurring SPCC Requirements’). Estimated costsfor testing are $1,500 to $2,500/year per pipeline for impressed current systems or $300 to$800/year per pipeline for magnesium anode systems. (2002 Navy Environmental RequirementsGuidebook – Chapter 9.)

Also, refer to the discussion for § 112.8(c)(4) above.

Ø Pipe Wrapping or Coating

When properly applied, corrosion resistant pipe tape or pipe wrapping, or extruded pipe coating, willsignificantly reduce the likelihood of corrosion of buried metallic piping. These approacheseffectively create a barrier to moisture, oxygen, and electrical current, sealing the metal pipelinefrom the corrosive environment. According to the Navy’s Design Manual DM-22, the exteriorsurfaces of all underground steel piping systems should be protected by either an extrudedpolyethylene coating system or a coal tar double-wrapped felt system. Field joints and irregularshaped fittings can be protected with pressure-sensitive organic plastic tape. Note that § 112.8(d)(1)requires underground piping installed on or after August 16, 2002 to have protective wrapping andcoating. Pipe tape ranges from $20 to $75 for 30 yards of pipe tape 1” to 4” in width. (GSA.)

All exterior surfaces of aboveground steel piping systems should be protected by a coating of azinc-rich primer, one bond or tie coat, followed by two or more coats of vinyl paint. For recoating ofexisting piping under a pier, greased absorbed wrapping tape with 50% overlapping should beused. Estimated costs of wrapping or costing 200 feet of piping, excluding labor, are as follows:

Pipe Diameter Description Cost Count Total4” 4 x 50 930-35 Polyken Tape Roll $13.07 Ea 60 Ea 783.206” 6 x 50 930-35 Polyken Tape Roll $18.63 Ea 72 Ea $1,341.636” 1027 Polyken Primer Gal $30.06 Gal 10 Gal $300.60

(NFESC.)

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Refer to Section 5.3 of the Spill Prevention Guidance Document (NFESC, 1998) for further information onpipeline corrosion protection [http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(d)(3) Pipe Supports.

Ø Pipe Hangers and Supports

Piping must be designed to allow for contraction and expansion to reduce the possibility of ruptureresulting from changes in temperature or pressure. Pipe hangers and supports that allow forthermal expansion and contraction, as well as other physical movement of the piping, are availablein a variety of shapes and configurations. Piping supports such as brackets, clamps, bands,hangers, rolls, saddles, sockets, straps, and U-bolts can be used to affix piping to walls, ceilings,overhead beams, or to support the piping from beneath. Hangers or supports are typically placedevery 6’ to 10’. Estimated costs of pipe hangers and supports are listed below.

Support Type & Pipe Diam Cost Person Time Labor Total* Diagram1” $ 0.91 Ea Q-1 0.121 $ 4.08 $ 4.992” $ 1.27 Ea Q-1 0.129 $ 4.34 $ 5.614” $ 4.89 Ea Q-1 0.145 $ 4.89 $ 8.018” $ 8.20 Ea Q-1 0.160 $ 5.40 $ 13.60

Clevis Hanger

12” $ 27.50 Ea Q-1 0.180 $ 6.05 $ 33.552” $ 11.75 Ea Q-1 0.114 $ 3.84 $ 15.594” $ 17.65 Ea Q-1 0.137 $ 4.60 $ 22.258” $ 38.50 Ea Q-1 0.167 $ 5.60 $ 44.10

Roll,Adjustable Yoke

12” $ 67.00 Ea Q-1 0.235 $ 7.90 $ 74.902” $ 15.90 Ea 1 Plum 0.118 $ 4.39 $ 20.294” $ 25.00 Ea 1 Plum 0.138 $ 5.15 $ 30.158” $ 51.50 Ea 1 Plum 0.160 $ 6.00 $ 57.50

Roll,Chair

12” $ 94.00 Ea 1 Plum 0.174 $ 6.50 $ 100.501” $ 3.35 Ea Q-1 0.121 $ 4.08 $ 7.432” $ 5.75 Ea Q-1 0.129 $ 4.34 $ 10.094” $ 14.30 Ea Q-1 0.145 $ 4.89 $ 19.19Split Ring

8” $ 55.60 Ea Q-1 0.160 $ 5.40 $ 61.901” $ 2.48 Ea Q-1 0.117 $ 3.93 $ 6.412” $ 3.60 Ea Q-1 0.124 $ 4.17 $ 7.773” $ 6.90 Ea Q-1 0.131 $ 4.41 $ 11.31Strap

4” $ 12.90 Ea Q-1 0.140 $ 4.72 $ 17.621” $ 1.22 Ea 1 Plum 0.053 $ 1.97 $ 3.192” $ 1.44 Ea 1 Plum 0.058 $ 2.15 $ 3.594” $ 3.89 Ea 1 Plum 0.068 $ 2.55 $ 6.448” $ 5.05 Ea 1 Plum 0.073 $ 2.74 $ 7.79

U-bolt

12” $ 11.35 Ea 1 Plum 0.077 $ 2.87 $ 14.224” $ 195.00 Ea 1 Plum 0.118 $ 4.39 $ 199.396” $ 201.00 Ea 1 Plum 0.136 $ 5.05 $ 206.058” $ 213.00 Ea 1 Plum 0.151 $ 5.65 $ 218.65Saddle

12” $ 222.00 Ea 1 Plum 0.167 $ 6.25 $ 228.25 * Total cost does not include the installing contractors’ overhead and profit. (2003 RS Means.)

Ø Expansion Loops and Bellows

Expansion and contraction in piping can be accommodated by expansion loops and bellows, andother types of expansion joints or devices. Expansion loops and bellows are typically factored intopiping system design, rather than retrofitted on existing systems.

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Estimated costs of installing stainless steel bellows type expansion joints, 150 lb, are listed below:

Stainless Steel Bellows Cost Person Time Labor Total3” pipe, 6” travel $ 869 Ea M1 1.33 hrs $ 57.70 $ 926.704” pipe, 6” travel $ 1,040 Ea M1 1.78 hrs $ 77.20 $ 1,117.205” pipe, 7” travel $ 2,270 Ea M1 2.20 hrs $ 95.40 $ 2,365.406” pipe, 4” travel $ 2,340 Ea M1 2.67 hrs $ 116.00 $ 2.456.008” pipe, 8” travel $ 3,470 Ea M1 3.20 hrs $ 139.00 $ 3,609.00

(2003 National Construction Estimator.)

Estimated costs of installing flexible metal hose connectors, stainless steel braids over corrugatedstainless steel, 150 psi, are listed below:

Stainless Steel Bellows Cost Person Time Labor Total*3” pipe, 9” long $ 65 Ea 1 Stpi 0.889 hrs $ 33.50 $ 98.504” pipe, 9” long $ 80 Ea 1 Stpi 1.143 hrs $ 43.00 $ 153.004” pipe, 30” long $ 170 Ea 1 Stpi 1.600 hrs $ 60.00 $ 278.006” pipe, 11” long $ 132 Ea 1 Stpi 1.600 hrs $ 60.00 $ 192.006” pipe, 36” travel $ 251 Ea 1 Stpi 2.105 hrs $ 79.00 $ 330.008” pipe, 12” travel $ 264 Ea 1 Stpi 2.000 hrs $ 75.00 $ 339.00* Total cost does not include the installing contractors’ overhead and profit. (2003 RS Means.)

Refer to Section 5.2 of the Spill Prevention Guidance Document (NFESC, 1998) for further information onpipeline structural stability including support integrity, support spacing, and pipeline expansion andcontraction [http://enviro.nfesc.navy.mil/ps/spillprev].

§ 112.8(d)(5) Vehicular Traffic.

Ø Signs and Placards

Warning signs and placards are one method that may be used to warn vehicles entering the facilityabout aboveground piping or other oil transfer operations. Well-placed, clearly worded signage willremind and alert operators to be careful when maneuvering vehicles in the area. Signs may costup to $150 apiece, depending on mounting and placement. (PWD Port Hueneme / IDQ Contract.)

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Ø Traffic Bollards

Traffic bollards or posts are another method to protect aboveground piping and oil transferequipment. Effectively spaced and distinctively painted or colored traffic bollards are effectivebarriers between vehicles and sensitve oil equipment. Steel concrete-filled traffic bollards costapproximately $500 apiece. (PWD Port Hueneme / IDQ Contract.)

Refer to Sections 5.10 of the Spill Prevention Guidance Document (NFESC, 1998) for further informationon traffic collision protection [http://enviro.nfesc.navy.mil/ps/spillprev].

Refer also to the following section of the Spill Prevention Resource Guide [NFESC, 2003] in Section 3Tab B: Gas Station Devices (for Damage Mitigation).

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Web Site Listing.

Information from the following vendor, Navy, and federal-related web sites contributed to the content ofthis appendix. Many of the products and equipment highlighted above are common items sold bynumerous manufacturers or vendors. Consequently, inclusion of specific manufacturers or vendors in thefollowing list does not suggest endorsement of the company or products they sell, nor does exclusionimply other companies or products are inferior. This following list was merely compiled from sourcesused in the creation of this appendix, to help the reader rapidly locate sources where additionalinformation may be obtained.

Ø Ace Hardware[ http://www.acehardware.com ]

Ø Allstate Sign and Plaque Corporation[ http://www.allstatesign.com ]

Ø Bowhead Manufacturing Company, LLC[ http://www.bmccatalog.com ]

Ø Checkers Industrial Safety Products, Inc.[ http://www.checkersindustrial.com ]

Ø Denios, Inc.[ http://www.thehazmatpro.com ]

Ø General Services Administration (GSA) Advantage[ http://www.gsaadvantage.gov ]

Ø Hammers Plastic, Plastic Recycling of Iowa Falls, Inc.[ http://www.hammersplastic.com ]

Ø Home Depot[ http://www.homedepot.com ]

Ø Imbibitive Technologies Corporation[ http://www.imbiberbeads.com ]

Ø Morrison Bros. Co.[ http://www.morbros.com ]

Ø 2003 National Construction Estimator[ http://www.get-a-quote.net ]

Ø Naval Supply Systems Command (NAVSUP) Naval Petroleum Office[ http://www.navpetoff.navy.mil ]

Ø 2002 Navy Environmental Requirements Guidebook – Chapter 7[ http://155.252.252.6/wrs/guidebook/functional/CH_TOC.asp?CH=07 ]

Ø 2002 Navy Environmental Requirements Guidebook – Chapter 9[ http://155.252.252.6/wrs/guidebook/functional/CH_TOC.asp?CH=09 ]

Ø New Pig Corporation[ http://www.newpig.com ]

Ø PSI Urethanes, Inc.[ http://www.psiurethanes.com ]