EVALUATION OF THIRTEEN SPILL RESPONSE TECHNOLOGIES
by
Mark L. Evans and Holly A. Carroll
Science Applications International Corporation
8400 Westpark Drive
McLean, Virginia 22102
Contract No. 68-03-3113
Project Officer
Mary K. Stlnson
Releases Control Branch
Land Pollution Control Division
Edison, New Jersey 08837
HAZARDOUS WASTE ENGINEERING RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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FOREWORD
Today's rapidly developing and changing technologies and Industrial
products and practices frequently carry with them the increased generation of
solid and hazardous wastes. These materials, when improperly dealt with, can
threaten both public health and the environment. Abandoned waste sites and
accidental releases of toxic and hazardous substances to the environment also
have important environmental and public health implications. The Hazardous
Waste Engineering Research Laboratory helps provide an authoritative and
defensible engineering basis for assessing and solving these problems. Its
product! support the policies, programs, and regulations of the Environmental
Protection Agency; the granting of permits and other responsibilities of
State and local governments; and the needs of both large and small businesses
in handling their wastes responsibly and economically.
This report describes assessment activities undertaken to evaluate and
stimulate the manufacture and use of thirteen spill response prototypes,
concepts, and devices. The information in this report 1s useful to those who
develop, select, or evaluate equipment for cleanup of spills or waste sites
or for the protection of response personnel and equipment.
For further information, please contacjt the Land Pollution Control
Division of the Hazardous Waste Engineering Research Laboratory.
Thomas R. Hauser, Director
Hazardous Waste Engineering Research Laboratory
111
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CONTENTS
Foreword ill
Abstract 1v
Figures vi
Tables vi
Acknowledgements ..... vil
1. Introduction 1
2. Conclusions 4
3. Recommendations 5
4. Methods and Results 6
Cholinesterase antagonist monitors 6
Hazardous materials identification kit 9
Insoluble sinkers detectors .... 10
Lactate dehydrogenase test method 10
Oxidation/reduction field test kit 11
Particle size analyzer 12
Foamed concrete 13
Leak plugger system 14
Vapor control coolants IB
Vapor control foams 16
Capture and containment bag 17
Emergency collection system 19
Sorbent oil recovery system 19
References 21
Appendices
A. One-page descriptions of prototypes 23
B. Contributors to assessment activities on
spill response systems 31
C. Evaluation of CAM-4 and the Emergency Collection System ... 35
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FIGURE
Number
1 Action of the leak plugger 14
TABLE
Number
1 General Assessment Activities for Prototypes,
Concepts, or Devices
vi
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ACKNOWLEDGEMENTS
Thanks and appreciation are extended to Michael D. Royer who served as
the USEPA Project Officer for the major part of this project and provided
many Important contacts. Thanks are also extended to Mr. Joshua Margolis
(SAIC) for his assistance with the capture and containment bag. The writers
would also like to thank all the individuals from trade associations, manu-
facturing firms, and spill response organizations who contributed information
for this document. The names and affiliations of these individuals appear in
Appendix B.
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SECTION 1
INTRODUCTION
During the 1970's, considerable.research was carried out by USEPA's
Office of Research and Development (ORD) under the authority of the Clean
Water Act (PL 92-500) to develop innovative technology to assist in the iden-
tification, control, and cleanup of spills of hazardous.materials. Passage
of more recent environmental laws such as the Resource Conservation and
Recovery Act (RCRA) of 1976 and the Comprehensive Environmental Response,
Compensation and Liability Act (CERCLA) of 1980 provided further incentive
for the development of specialized techniques and equipment to assess, facil-
itate, and accomplish hazardous materials cleanups. In addition, 1982 amend-
ments to'the Patent and Trademark Laws (PL 96-517) to encourage licensing of
Federally-owned inventions created an easier method by which private companies
could make use of USEPA-developed devices that show practical potential.
The primary purpose of this study was to Inform persons actively engaged
In hazardous waste management of thirteen devices, concepts, or prototypes
for detection, containment, and cleanup of hazardous chemicals that had been
developed over the earlier period of about ten years under authority of the
Clean Water Act with support of USEPA's Office of Research and Development.
All of the systems had practical uses and some had been successfully demon-
strated. Nevertheless, prior to the passage of more demanding environmental
laws, none of the systems had elicited sufficient interest for commercial
production to be undertaken. Therefore, a second objective was to conduct a
limited assessment of the practical application of these systems within the
context of current regulatory needs by documenting and analyzing comments by
persons who examined either the item or the literature on the Item.
The thirteen different devices, concepts, or prototypes capable of
detecting, containing, or cleaning up hazardous substances and selected for
this study were:
Detection
- Cholinesterase Antagonist Monitors (CAM-1 and CAN-4) - devices for detect-
ing organophosphate or carbamate pesticides in water by the inhibition of
cholinesterase enzyme activity.
- Hazardous Materials Identification Kit (HMIDK) - a portable test kit cap-
able of analyzing for 36 hazardous organic and Inorganic substances In the
field.
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- Insoluble Sinkers Detectors - two separate devices to detect and locate
denser-than-water organic pollutants in the bottoms of rivers, ponds,
lakes, and streams.
- Lactate Dehydrogenase Test Method (LDH) - a field screening test for
detecting chlorinated hydrocarbons in water by the inhibition of lactate
dehydrogenase enzyme activity.
- Oxidation/Reduction Field Test Kit - a device for identifying chemically-
incompatible wastes in the field by measuring redox potentials.
- Particle Size Analyzer - a device that uses stop-action photography to
measure the size of oil droplets in oil/brine mixtures.
Containment
- Leak Plugger System - a rifle-like devijce^that injects polyurethane foam
to plug leaks in tanks, drums, pipes, and other vessels.
- Foamed Concrete - quick-setting, rigid, non-porous concrete to be used by
first responders to build self-supporting temporary dikes around spills.
- Vapor Control Coolants - the use of Dry Ice to inhibit the release to the
atmosphere of toxic and/or flammable fumes from spilled volatile chemicals.
- Vapor Control Foams - surface foams to Inhibit the release to the atmos-
phere of toxic and/or flammable fumes from spilled volatile chemicals.
Collection
- Capture and Containment Bag - a large polyethylene bag designed to be
attached to or placed against leaking tanks, drums, pipes, etc. to collect
leaking liquids.
- Emergency Collection System - a segmented 7,000-gal capacity polyurethane-
coated bag with suction hose and pumping unit to collect liquid chemical
spills.
- Sorbent Oil Recovery System - a mobile system to collect oil from the sur-
face of lakes, streams, and rivers In open-celled, flotable polyurethane
cubes that are then retrievable for recycle.
The approach used to inform potential users and manufacturers about the
above-mentioned prototypes, devices, and concepts included presentations,
publications In trade magazines, exhibits at conferences, mailings of USEPA
project summaries and technical reports, and exchanges of information and com-
ments by telephone. For eight of the thirteen items, one-page descriptions
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(see Appendix A) were developed because USEPA project summaries or reports
were either not available or were too lengthy for the initial needs of the
project. USEPA project summaries were distributed for the other five systems.
In addition to the review of the opinions of the participants in the
study on the various devices, additional activities were conducted for several
of them. These further activities included value engineering analyses on the
CAM-4 and the emergency collection system; design, construction, and testing
of the capture and containment bag; field testing of several prototypes by
interested parties; and the development of a handbook on the vapor control
foam concept.
Based on the interest exhibited by the respondents and review of their
comments on the practicality of each system, an appraisal was made of the
potential for practical application of each item.
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SECTION 2
CONCLUSIONS
Thirteen prototypes, devices, or concepts were evaluated to determine
their potentials for practical application. The evaluations were conducted
by summarizing the comments offered by potential users and manufacturers
after they were provided with Information and/or had an opportunity to test a
particular prototype, device, or concept. Of the thirteen Items, five were
determined to have immediate practical application In their present form;
four were expected to have apllcatlon after modification; the other four were
found to have a low potential for practical application at the present time.
The five prototypes, devices, or concepts found to have Immediate prac-
tical applications were: the oxidation/reduction field test kit; the particle
size analyzer; the leak plugger; the vapor control foams; and the capture and
containment bag. Of these, the capture and containment bags were subjected
to the most extensive evaluation. On the basis of this evaluation, the manu-
facturer of prototype bags, B.F. Goodrich, concluded that the bags were
"extremely viable" for spill response and would be an attractive product for
some manufacturer if priced at $300 to $400 each.
The spill response systems expected to be practical after modifications
were: the chollnesterase antagonist monitors (CAMs); the hazardous materials
Identification kit (HMIOK); vapor control coolants; and the emergency collec-
tion system. Review of the respondent's comments Indicated that the CAMs
needed increased sensitivity while the HMIDK required simplification for use
by technicians in the field. The use of Dry Ice as a vapor suppressant was
attractive, but sources of the coolant appeared to be a limiting factor for
actual use. The emergency collection system requires changes in design and
materials to reduce Its cost.
The systems found to have low potential for practical application based
on the responses of potential users and manufacturers Included: the Insoluble
sinkers detectors; the lactate dehydrogenase (LDH) test method; foamed con-
crete; and the sorbent oil recovery system. These systems either duplicated
existing hardware or had other disadvantages which made It unlikely that they
would find use.
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SECTION 3
RECOMMENDATIONS
Recommendations on some of the specific devices, concepts, or prototypes
included in this study are presented below.
CAMs - Modify CAM-4 to respond to a lower detection limit.
HMIDK - Simplify the kit so that it can be used by technicians with minimal
training; Also, reduce the cost of the kit and assure availability of
replacement parts, preferably from a single manufacturer.
Particle Size Analyzer - Pursue work started by two private firms to replace
manual photo-analysis with computer analysis of a photo-imaging display
function.
Foamed Concrete - Modify the prototype generator to increase portability and
reduce cost.
Vapor Control Foams - Publish the new handbook on foams, developed as a
result of this study, and distribute it to spill responders.
Capture and Containment Bag - Make the results of this study available to
small-to-medium manufacturing firms that may produce this equipment on a
commercial scale.
Emergency Collection System - Modify the collection bag so that it is less
costly or can be reused.
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SECTION 4
METHODS AND RESULTS
The thirteen spill response prototypes, concepts, or devices selected
for this program were subjected to a variety of assessment activities,
including:
- Contacting selected potential users or manufacturers of the response
systems to learn of their interest in one or more of the subject items;
- Providing information to the contacted groups and individuals by presen-
tations, publications, mailings, exhibits, and phone calls; and
- Documenting and analyzing comments offered by the contacted groups and
individuals on the items reviewed.
Table I lists the activities used to provide Information to users and
manufacturers for each technology.
The selection of initial contacts for the study was based on SAIC's
knowledge of the manufacturers, research and development staff, experts, and
special Interest groups who would most be likely to have an interest in learn-
ing more about these prototypes, concepts, or devices and would have the
experience and expertise to provide critical evaluations of the potential for
application of the systems to actual field situations. Those who showed
interest after their initial exposure to the Information on the prototype,
concept, or device were provided with more detailed information through mail-
ings of one-page descriptions, or by being referred to the USEPA project
summaries and technical reports. Those who wanted to examine or test certain
items, such as the CAMs, the hazardous materials identification kit (HMIDK),
or the capture and containment bag, were provided with the device on loan.
One page descriptions (with photography) of the devices (see Appendix A)
were developed for eight of the thirteen prototypes where brief documents
were not available. Descriptions were not prepared for the insoluble sinkers
detectors or the leak plugger because assessment activities were completed
before the Idea for these abbreviated summaries had been developed. The USEPA
project summaries for the vapor control coll ants and the vapor control foams
were sufficiently concise to serve the purposes of this project and were used
Instead of developing new one-page descriptions. The lactate dehydrogenase
(LDH) test method was added to the program too late to develop a descriptive
sheet; the existing project summary was used.
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TABLE I. GENERAL ASSESSMENT ACTIVITIES FOR PROTOTYPES, CONCEPTS, OR DEVICES
Chollnesteratc Antagonist
Monitors
Hazardous Haterlala
Identification Kit
Insoluble Sinkers
Detector
Lactate Dehydrogenasc
Test Method
Out da t Ion/Reduction
Field Test Kit
Particle Size Analyxer
Foaoed Concrete
Leak P lugger
Vapor Control Coolants
Vapor Control Foaas
Capture & Containment Bag
Emergency Collection System
Sorbent Oil Recovery Syaten
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After presenting Information on each prototype, concept, or device to a
wide range of potential users and manufacturers, the authors received,
reviewed, and analyzed the comments from all sources. Commentors who made
significant contributions to the assessment of particular devices are listed
in Appendix B.
Further assessment activities were conducted for the prototypes, concepts,
or devices that received high interest. For example, the capture and contain-
ment bag was redesigned and fabricated by a major manufacturing company for
field testing by five spfll response groups. These additional activities were
intended to encourage potential users and manufacturers to commercialize the
spill response systems.
The following subsections describe the methods and summarize the results
and analysis of the assessment activities for each prototype, including the
additional activities that were conducted for a few. Presentation follows
the order: detection, containment, and collection. Extensive description of
the device is provided only where a one-page summary is not included in
Appendix A.
CHOLINESTERASE ANTAGONIST MONITORS
The cholinesterase antagonist monitors (CAHs) were originally developed
for the U.S. Army to detect nerve gases in the atmosphere. Later, they were
modified to detect organophosphate and carbamate pesticides in water by Mid-
west Research Institute under contract to the USEPA [1,2]. Both a laboratory
model (CAM-1), and a newer field model (CAM-4) capable of detecting 0.1 to
0.26 ppm depending on the pesticide, were developed. Both units operate by
inhibiting enzyme activity. See Appendix A for a more complete description
of these devices.
Assessment Activities for the CAHs
A number of Industrial and governmental agencies expressed preliminary
Interest in the CAM devices for a wide range of uses, Including monitoring of
ground and drinking water quality (USEPA's Toxic Substances Division and the
Drinking Water Research Division); tracing of pesticides (USEPA's Office of
Pesticide Programs, USDA's National Monitoring and Residues Analysis Labora-
tory, U.S. Forest Service, Society of American Foresters, the Association of
Consulting Foresters, and the Tennessee Valley Authority); and monitoring of
Industrial health and safety (NIOSH and OSHA).
The opinion was expressed that the high detection levels (i.e., low sen-
sitivity) for tese devices preclude their use for drinking water monitoring
and reduce their effectiveness as spill monitoring devices where detection in
the low parts per billion level 1s needed. It was suggested by some of the
reviewers that these devices may be useful for monitoring pesticide overspray
during application and for spills in waterways, where higher concentrations
may be expected.
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A value engineering analysis on both the CAMs by a subcontractor, BiM
Technologies Service, Inc., concluded that while the CAM-1 is obsolete, the
CAM-4, with a few modifications, is a well-built, cost-effective analytical
instrument that compares favorably with other commercial monitoring instru-
ments in cost, ease of manufacture, and expected serviceability (see Appendix
C). On the basis of these observations and further discussion with Midwest
Research Institute, all further study was limited to the CAM-4 device.
Potential for Practical Application of the CAM
Based on a consensus of opinions expressed by the reviewers, there is a
moderate level of Interest among potential users and manufacturers for the
application of the CAM instruments. The major limitations of these devices
are their relatively poor sensitivity, their limited quantitative abilities,
and the short shelf-life of their pads and reagents. In addition, most gov-
ernment agencies judged that the frequency of use of the devices would not
benefit from the reduced cost/analysis offered while other commercial instru-
ments met their lower detection limit requirements. The potential for CAM-1
is further inhibited by Its outmoded circuitry. Based on the comments offered,
if the detection level of the CAM could be lowered to the low to middle parts
per 51 Iff on range without a substantial increase in unit cost, these devices
would be in high demand among most of the groups contacted during this study.
HAZARDOUS MATERIALS IDENTIFICATION KIT
In 1978, the LI SEP A and the U.S. Army Chemical Systems Laboratory (CSL)
developed a kit to test for water quality indicator parameters that could
detect (not necessarily identify) the presence of hazardous materials in
water [3]. Under an Interagency agreement between the USEPA and the U.S.
Army, a hazardous materials identification kit (HMIDK) was subsequently devel-
oped [4]. The kit, capable of Identifying 36 hazardous substances in water
and soil, 1s described in more detail in Appendix A.
Assessment Activities for the HHIDK
Attendees at the HAZMAT '83 Conference expressed considerable interest in
the HMIDK and 50 requests for more Information were received. However, after
receiving additional literature and a letter offering a possible loan of a
kit, none of the recipients showed further interest. Mailing of the one-page
description of the HMIDK to spill response/cleanup organizations resulted in
limited response. Military representatives expressed interest in the kit for
field identification of pesticides and chemical warfare agents. Other comments
from recipients of information indicated that the kit was too complex for field
use by relatively unskilled technicians, did not analyze a sufficiently wide
range of compounds, required frequent use to assure proficient operation and
reliability of the reagents, and, in general, was too costly. Repackaging of
the reagents in vfals and providing assurance that all replacement reagents
could be obtained from a single source, rather than requiring a series of
vendors or manufacturers, were suggested as modifications that would make the
kit more attractive.
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Potential for Practical Application of the HMIDK
The hazardous materials identification kit has a moderate potential for
application if its cost and complexity can be reduced. Because there presently
is a strong demand for chemical identification kits, some markets may exist
for the kit in its current form among well-funded groups with good chemical
backgrounds. Potential markets include the U.S. Army and Navy, spill response
organizations, and government agencies involved in spill response and enforce-
ment. No potential manufacturers were identified in this study.
INSOLUBLE SINKERS DETECTORS
The insoluble sinkers detectors are two separate devices developed by
Rockwell International Corporation, under contract to the USEPA [5], to detect
the presence of denser-than-water chemical pools or globules in lakes, rivers,
and streams. One of the detectors is designed to be anchored to the bottom
of a watercourse. When a heavy organic chemical such as carbon tetrachloride
contacts the device, a large drop in conductivity occurs and activates a radio
transmitter to an on-shore receiver that in turn activates the recorder, an
alarm system, or both.
The other insoluble sinkers detector consists of a mapping system based
on the principles of underwater acoustics. United States Patents 4,410,966
and 4,507,762 on the device have been assigned to the USEPA. This system,
which functions by measuring the reflection of emitted sound waves from the
bottom of a watercourse, can detect an insoluble layer as little as one centi-
meter 1n thickness by the difference in echo patterns. Currently, the echoes
are measured by oscilloscope.
Potential for Practical Application of the Insoluble Sinkers Detectors
Soon after the beginning of this study, both of these prototypes were elim-
inated from further assessment activities when it was determined that neither
had a high probability of becoming available for use. The conductivity-based
unit was never developed beyond the bench scale and Rockwell International
advised SAIC that a private company had subsequently developed, patented, and
was selling a device similar but superior to the acoustic device at lower cost.
The commercial device is an upgraded "fish finder."
LACTATE DEHYDROGENASE TEST METHOD FOR DETECTING CHLORINATED HYDROCARBONS
The lactate dehydrogenase (LDH) test method was developed as an easy and
rapid assay for chlorinated hydrocarbons 1n water. It can be used for field
screening, compliance testing, and for meeting emergency response needs [6].
The test, based on the oxidation of nicotinamide adenine dinucleotide 1n the
presence of inhibited lactate dehydrogenase enzyme, can be monitored by the
change 1n pH. It is sensitive to most classes of high molecular weight chlor-
inated hydrocarbons but will not detect low molecular weight compounds such
10
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as trichloroethylene and carbon tetrachloMde. Interfering compounds include
cyanide, heavy metals, alkylating agents, and other hydrocarbons.
Assessment Activities for the LDH Test
Potential users and manufacturers of the LDH test identified several
existing methods that provide better ways to detect chlorinated hydrocarbons,
including other enzyme tests and gas chromatography. It was noted that false
negatives are possible because of the rather high detection limit (500 to
1000 ppb) and that interfering agents frequently encountered in common waste
waters could produce false positives.
While some commentors felt that the detection limits, sensitivity, and
uniqueness of the test were good, an approximately equal number of respondents
suggested that sensitivity (detection limit) needed to be increased by as much
as two orders of magnitude. One potential manufacturer believed that increas-
ing sensitivity would also reduce interference by heavy metals and alkylating
agents. While comments on expected cost were few, one potential manufacturer
estimated that a kit containing 20 tests should cost between $75 and $150 per
test. Respondents felt that the test could be used to screen industrial influ-
ent and effluent waters, various hazardous wastes, and chlorinated municipal
water supplies, as well as to screen for PCBs and chlordane in emergency
situations.
Several modifications were suggested for the test. These included
extending the shelf life by packaging the reagents in sealed samples and
including blanks and standards with the test to assure its reliability. One
reviewer suggested that evaporation of water from the samples would concentrate
the chlorinated compound and allow improved sensitivity. Another recommended
the use of an air impinger and inclusion of a pH test liquid to broaden the
scope of the test to include oils and soils.
Potential for Practical Application of the LDH Test Method
For the test to be useful at the levels recomended for protection of
aquatic life (1-3 ppb) or for protection of human health (less than 1 ppt),
modification to function at much lower detection limits is required. In its
current form, the test 1s only useful for analyzing for gross contamination,
tracking and locating large spills, and determining the source of spills. On
the basis of the comments offered, SAIC recommends that other available test
methods be considered for field use.
OXIDATION/REDUCTION FIELD TEST KIT
The oxidation/reduction field test kit was developed under contract to
the USEPA by Princeton Testing Laboratory [7] to assist in the rapid segrega-
tion of containers of strong oxidizing agents from containers of strong
reducing agents when the identities of the materials are unknown. A one-page
description of the technique and apparatus is given in Appendix A.
11
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Assessment Activities for the Oxidation/Reduction Field Test Kit
Activities for the oxidation/reduction test kit resulted in high interest
in the kit. Demonstration at the HAZMAT '83 Conference produced many comments
that the kit had a high potential for practical application. The kit has been
used successfully and with advantage during cleanup at several hazardous waste
sites. While one potential problem noted was than an inexperienced operator
could misclassify certain volatile, flammable organics (e.g., styrene and acry-
lonitrile) as oxldizers, thus creating a dangerous situation, another commented
that it was unlikely that incompatible spills would occur in the same area
simultaneously.
There was also considerable interest by potential manufacturers of the
kit. One manufacturer has continued to request Information on the kit and has
produced and successfully tested six kits. This firm will soon produce and
market the kits as dictated by the demand. Another manufacturer also agreed
to manufacture the kit if the USEPA wrote a one-page description of the device
listing all suppliers or evaluated a device provided by the manufacturer and
included'that evaluation in a USEPA bulleting or similar technology transfer
medium. USEPA agreed to this request. A device manufactured by this firm
was successfully tested and is now in production. A third manufacturer indi-
cated they had developed an Idea for a device, but plans for manufacture had
not been made.
Potential for Practical Application of the Oxidation/Reduction Field Test Kit
The oxidatlon/reducton field test kit 1s presently available as a commer-
cially manufactured item and has been used at several cleanups of uncontrolled
hazardous waste sites. The kit continues to be specified 1n procurements for
cleanup actions to avoid accidental mlxing^f incompatible materials.
PARTICLE SIZE ANALYZER
The particle size analyzer (PSA), developed by Rockwell International Cor-
poration under contract to the USEPA [8] for use on off-shore oil platforms,
can analyze the oil droplet size distribution in oil/brine and other oil/water
mixtures. This provides valuable Information when selecting or seeking to
Improve the operation of oil/water separators. See Appendix A for a more com-
plete description of the analyzer.
Assessment Activities for the Particle Size Analyzer
Eight oil/water separator manufacturers showed a high degree of Interest
In the analyzer after reviewing the one-page description of the analyzer and
further information was provided to all. After extensive discussion with SAIC,
one firm 1s now Interested In developing an Improved particle.size analyzer in
collaboration with a major optical equipment company.. The latter firm 1s
attempting to adapt an image analyzing computer to the particle size analyzer,
12
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which will eliminate the need for a photographic technique and provide much
faster analyses. This firm believes the particle size analyzer may have
important medical applications as well.
Most respondents (potential users and manufacturers) agreed that the use-
fulness of the analyzer in research, in waste treatment, or for industrial
processes was dependent on keeping the cost down or reducing it further. The
representative of one major oil company expressed the opinion that no compar-
able instrument existed and that capital cost would not be a deterrent to use,
while the need for a specially trained technician would be. This person also
suggested that the PSA should be adapted to analyze mixtures under pressure
since existing separators use pressurized systems.
Other commentors reiterated the need to reduce the cost of the equipment,
particularly the photographic portion, and expressed concern over the need
for a technically-oriented person to develop and analyze the photos. Never-
theless, the opinion was expressed that the PSA would be an excellent tool to
use on a,drilling platform as an aid in deciding when to take oil/water
separators out of service.
Potential for Practical Application of the Particle Size Analyzer
The particle size analyzer has high potential for practical application,
particularly 1f it can be Improved to provide results more rapidly. Applica-
tion in the medical profession would Increase its potential further.
FOAMED CONCRETE
Rapidly setting foamed concrete was developed by MSA Research Corporation
under a contract with the USEPA [9] to contain hazardous chemical spills by
the rapid formation of a free-form dike or diversion structure. The technique
1s described in Appendix A.
Assessment Activities for Foamed Concrete
Definitive interest 1n the foamed concrete system was not indicated. A
representative from a spill response company stated that a foamed concrete
system would be very expensive, Infrequently used, and, consequently, not
justifiable.
Potential for Practical Application of Foamed Concrete
This prototype is relatively expensive and has a limited area of appli-
cation. In addition, a less costly, more mobile, and commercially available
polyurethane foam dike pack substantially reduces the market potential for
the foamed concrete.
13
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LEAK PLUGGER
The leak plugger was developed for the USEPA by Rockwell International
Corporation [10] to temporarily stop leakage from punctured or slashed tanks
or other containers. The prototype is a rifle-like device attached to a back-
pack with canisters of the polyol and diisocyanate precursors of the urethane
foam (Figure 1). The two foam ingredients are mixed in the chamber of the
"rifle" and forced from the applicator tip to form a mushroom-like foam on
both the inside and outside of the leaking container.
, rsr:
1 * *
^.Quick-
Oisconnect
Chemical
Tank Wall — ""
^
v\\\»,
>>
X
-I
Liquid
Chemical
rr^--r^-——
8 I »«^ • • ••" —^^=~
Pressurized Foam
Compound Cylinders
Foam
Supply
Expendable
Tube Section
Step 1. Foam Composite Applicator Tip
Inserted Through Hole in
Damaged Chemical Tank
Rubber
Bladder
Step 2. Applicator Tip. Filled with Foam.
Expanding In Hole
Step 3. Fully Expanded and Cured
Composite Foam Plug
Securely in Hole
Figure 1. Action of the Leak Plugger.
14
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Assessment Activities for the Leak Plugger
A number of comments were received regarding the leak plugger prototype.
A potential manufacturer was Interested In working with the USEPA to produce
a leak plugger similar to the prototype but the proposed system was rejected
by the agency as Inferior to the prototype. During this study, SAIC was
advised that Rockwell had developed and patented (U.S. Patent 4,329,132) an
Improved model of the plugger using styrofoam Instead of polyurethane.
Representatives of the National F1re Academy did not believe that fire
companies could justify the leak plugger because of its high cost, short
shelf life (approximately one year) and anticipated infrequent use. On the
other hand, representatives of the Association of American Railroads felt the
device could be useful 1n controlling small leaks at train derailments or In
switching yards. Oil company representatives thought the unit would be useful
to fire companies and cleanup contractors.
Potential for Practical Application of the Leak Plugger
A modified leak plugger currently is being used by U.S. Coast Guard
Strike Team divers to plug leaks in boats and prevent sinking. However,
because of the high price, low shelf life (about two years), and the special
equipment needed to refill it, even the modified plugger has only a moderate
potential for practical applications.
VAPOR CONTROL COOLANTS
This concept was developed by MSA Research Corporation with support from
the USEPA. The report [11] describes the successful control of vapors from
spilled hazardous liquids, but the technique for distributing Dry Ice over a
spill area Is not efficient.
Assessment Activities for Vapor Control Coolants
Limited interest resulted in comments that the approach seems to be of no
practical use for general response preparedness and planning, nor for discrete
spills.
.Communication with a Dry Ice equipment manufacturer revealed that Dry Ice
1s not used widely nor in large quantities in most industries and would not
normally be available In proximity to spilled volatile chemicals. A repre-
sentative of the Compressed Gas Association pointed out that liquid carbon
dioxide Is more widely used and that a machine 1s available for conversion of
liquid carbon dioxide to a spray of solid carbon dioxide snow. This machine,
used to cool non-refrigerated railroad cars, could possibly be available for
use on spilled volatile liquids. Howe vejv»-mod1f1 cat Ions would be necessary
to increase the throw range to more than the 20 feet now achievable.
15
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Potential for Practical Application of Vapor Control Coolants
Vapor control coolants have a low potential for practical application.
Few industrial plants meet the criteria of storing hazardous volatile liquids
and having large quantities of Dry Ice available to make this concept practical,
Both logistics and equipment issues would need to be resolved before the use
of liquid carbon dioxide in a snow conversion machine could become practical
for controlling hazardous vapors.
VAPOR CONTROL FOAMS
The vapor control foams concept was developed by MSA Research Corporation
(MSAR) under contract to the USEPA [12] by testing the ability of various com-
mercial firefighting foams to suppress vapors from 17 different volatile
liquids. Based on these tests and a review of the literature, MSAR developed
a table indicating the proper foam types to use for controlling vapors from
spills of 36 volatile materials. The USEPA also has prepared a motion picture
film of tests conducted by MSAR.
It should be noted that the technology for vapor control foams is expand-
ing rapidly, ranging from reducing volatilization of toxicants at a spill site
to preventing and suppressing fires from spills of highly explosive fuels.
Foams vary greatly In their chemical makeup, compatibility with spilled com-
pounds, quarter-drainage times, expansion ratios, and methods of application.
Assessment Activities for Vapor Control Foams
The National Fire Academy 1s now training firefighters on the use of
foams for vapor control. Part of this training involves viewing of the USEPA
film. Based on activities at the HAZMAT '83 Conference, an instructor for a
commercial course on oil and hazardous materials spills also promoted the use
of the film and several fire companies requested Information about manuals on
the use of foams.
Contacts at H111 Air Force Base revealed that MSAR, under a U.S. Air
Force contract [13], has developed a portable foam vapor suppression system
for responding to spills of hydrazine and nitrogen tetroxlde using foams mixed
with either a polyacrylic additive (for hydrazine) or a pectin additive (for
nitrogen tetroxlde). This system, also equipped with a pump and bag system
for collection of spilled material, will be available during the downloading
of Titan missiles.
A presentation to the American Petroleum Institute resulted in comments
that the MSAR report contained Information useful in preplanning response
activities and procedures. However, It was also noted that assuring avail-
ability of the correct foam would be a logistics problem.
16
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After review of the USEPA report by MSAR, the use of vapor control foams
1s being considered (November 1985) for recommendation by the ASTM. Also, as
a result of reading the report, the Ohio State Fire Marshal offered test burn
pits and firefighters for further testing by USEPA. In his opinion, the
report contains Information that would be useful in the training courses that
Ohio provides to some 12,000 firefighters.
Potential for Practical Application'of Vapor Control Foams
Since the Initial USEPA report on foams for vapor control, use of this
technology has grown Immensely and 1s currently widespread. The USEPA will
soon provide a handbook on the selection and use of foams for vapor control
[14].
CAPTURE AND CONTAINMENT BAG
The capture and containment bag was first developed by MSA Research Cor-
poration under a contract with the USEPA [15] to collect spills from ruptured
tanktrucks and railroad cars. Appendix A presents a one-page description of
the equipment and its use.
Assessment Activities for the Capture and Containment Bag
The initial assessment activities for the bag system generated consider-
able Interest, most of which was overwhelmingly positive. Based on this
reaction, the USEPA sought a manufacturing firm to produce additional bags
for field testing by potential users. (All the bags fabricated in the original
study had been destroyed during testing to failure.) A competitive procurement
sent to 11 manufacturers resulted in 3 proposals (even though the financial
incentive was only $2500 to produce at least 5 bags). Award was made to B.F.
Goodrich Company, who proposed a 1000-gal capacity polyethylene bag weighing
about 25 Ibs and fitted with a 30-ft long, 4-1n. diameter transfer tube.
Approximately thirty firms had expressed an Interest in field testing the
bags. Of the thirty, twelve submitted proposals describing tests they would
perform on bags loaned to them. Proposals were accepted for the specific
testing noted from five organizations:
- Association of American Railroads
0 Leaking bottom outlet in the center of a tank car (wild car)
0 Puncture leak 1n the lower end of a tank car (typically caused by the
linkage knuckle of a trailing car)
0 Dome leak on an overturned tank car
0 Leaking locomotive fuel tank.
17
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- Fairfax County Fire Department
0 Tank truck leak
0 Tank car gash
0 Leak on a grassy slope.
- Houston Fire Department
0 Collection of wastewater from ° Leak on roadway
a safety shower ° Leak in grassy ditch
0 Gash in tank car ° . Leak from stationary tanks
0 Dome leak on tank truck ° Pressurized valve flange leaks.
0 Wild car leak
- Spill Recovery of Indiana, Inc.
0 Leaking drop valve on an upright tank in a flat grassy area, onto a
flat paved area, and near a ditch
0 Exposure of a bag to sub-freezing temperatures
0 Leaking drums.
- Texas A&M University, Engineering Extension Service
0 Repetitive filling on a flat concrete surface
Other tests proposed but not completed.
o
A total of approximately 250 individuals from fire and police departments,
privatre manufacturing and spill response firms, and state and federal agen-
cies conducted or observed the various tests. Of these, about 72% believed
that the bag is a feasible method for responding to spills.
Encouraged by the positive results of the bag tests, by the interest in
them, and by the numerous suggestions offered for improvement of the prototype,
B.F. Goodrich performed a market research study at its own cost to determine
whether the bag should be commercialized. Analysis of comments solicited from
fire chiefs, state fire marshals, chemical manufacturers, and cleanup contrac-
tors in this survey indicated that 66% of the 63 respondents (out of 439 con-
tacted) felt the bag had some potential. The observed 6% of weepage rate over
24 hours was not considered excessive by 85% of the respondents. Half of
those providing expected cost information were willing to pay over $200 and
28% were willing to pay over $400.
B.F. Goodrich concluded that the bag concept, with bags priced at $300
to $400 each, was "extremely viable" but that the weepage would have to be
eliminated in a final design. The company's investigators also pointed out
that compatibility with the spilled material could not be overlooked when
using the bag. Ultimately, Goodrich decided that fabrication was best accom-
plished by another company where the liability/benefit ratio would be more
attractive.
18
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Potential for Practical Application of the Capture and Containment Bag
The capture and containment bag received more Interest than any of the
other prototypes. Most of the comments were positive and Indicated the bag
would fill a real need in the trucking industry, 1n the railroad industry,
for fireflghtlng, and in private and government spill response.
EMERGENCY COLLECTION SYSTEM
The emergency collection system was developed for the USEPA under con-
tract by MSA Research Corporation [16] for the collection and temporary
containment of hazardous and non-hazardou's~'1and spills. A more complete
one-page description of the system Is given in Appendix A.
Assessment Activities for the Emergency Collection System
Little interest was expressed by potential users' for this prototype,
even after mailing the one-page description and exhibiting the device at the
HAZHAT '83 Conference. In spite of this low level of interest, it was learned
that a similar system was being built for the U.S. A1r Force to collect
potential propellant spills during downloading of Titan missiles.
The National Fire Academy commented that the estimated minimum cost of
$9000 for the system was too high for use by fire departments. Others com-
mented that the use of pillow bags with portable pumps and hoses was much
more cost-effective.
A value engineering analysis concluded that the application potential
was uncertain and that "additional design research to meet commercially accep-
table criteria of cost, manufactorability, and desired field performance" was
needed (Appendix C).
Potential for Practical Application of the Emergency Collection System
Aside from the interest by the U.S. A1r Force, the emergency collection
system currently Is not of high interest. Although it offers quick response
capabilities for spilled liquids, the high cost of the disposable bag
discouraged most potential users.
SORBENT OIL RECOVERY SYSTEM
The sorbent oil recovery system was developed under a USEPA contract to
Seaward International, Inc. [17]. The device distributes polyurethane cubes
over floating oil spills. The oil-saturated cubes are then recovered, squeezed
free of oil, and reused. A more complete description of the system is provided
in Appendix A.
19
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Assessment Activities for the Sorbent 011 Recovery System
A representative of Seaward confirmed the opinions of other respondents
that recovery of the oil-saturated cubes was inefficient and that the weight
of the system was too great. Others commented that superior equipment was
already on the market and that most spills occur on rivers that are too wide
for the sorbent oil recovery system. Nevertheless, as a result of a presenta-
tion to the American Petroleum Institute, a German researcher sought Informa-
tion, believing that the cubes could be effective (and less of a problem when
washed ashore) when storms delayed the cleanup of oil spills.
Potential for Practical Application of the Sorbent Oil Recovery System
There appears to be little current interest in this system in its present
form. Undefined improvements would be needed to transform the system into a
competitive prototype.
20
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REFERENCES
1. Goodson, L.H.. and W.B. Jacobs. Evaluation of "CAM-1," A Warning Device
for Organophosphate Hazardous Materials Spills. EPA-600/2-77-219, U.S.
Environmental Protection Agency, Cincinnati, Ohio, November 1977.
2. Goodson, L.H., and B.R. Cage. CAM-4, A Portable Warning Device for
Organophosphate Hazardous Materials Spills. EPA-600/2-80-033, U.S.
Environmental Protection Agency, Cincinnati, Ohio, January 1980.
3. Sllvestri, A., A. Gadman, L. McCormack, M. Razulls, A. Jones, Jr., and
M. Davis. Development of a Kit for Detecting Hazardous Material Spills
in Waterways. EPA-600/2-78-055, U.S. Environmental Protection Agency,
Cincinnati, Ohio. March 1978.
4. Silvestrl, A., M. Razulls, A. Goodman, A. Vasquez, and A.R. Jones, Jr.
Development of an Identification Kit for Spilled Hazardous Materials.
EPA-600/2-81-194, U.S. Environmental Protection Agency, Cincinnati,
Ohio, October 1981.
5. Meyer, R.A., M. Klrsch, and L.F. Marx. Detection and Mapping of Insoluble
Sinking Pollutants. EPA-600/2-81-198, U.S. Environmental Protection
Agency, Cincinnati, Ohio, October 198-k-
6. Offenhartz, B., and J. Lefko. Enzyme Based Detection of Chlorinated
Hydrocarbons 1n Water, U.S. Environmental Protection Agency, Cincinnati,
Ohio, June 1985.
7. Turpin, R. Oxidation/Reduction Potential Field Test Kit for Use at
Hazardous Material Spills. 1982 Hazardous Materials Spills Conference
Proceedings, April 19-22, 1982. pp. 225-227.
8. Meyer, R.A., and M. Kirsch. Apparatus and Procedure for Determining Oil
Droplet Size Distribution. EPA-600/2-82-032, U.S. Environmental Protec-
tion Agency, Cincinnati, Ohio, June 1982.
•v
9. Frlel. J.V., R.H. H1ltz, and M.D. Marshall. Control of Hazardous Chem-
ical Spills by Physical Barriers. EPA-R2-73-185, U.S. Environmental
Protection Agency, Cincinnati, Ohio, March 1973.
10. Vrolyk. J.J., R.C. Mitchell, and R.W. Mel void. Prototype System for
Plugging Leaks in Ruptured Containers. EPA-600/2-76-300. U.S. Environ-
mental Protection Agency, Cincinnati, Ohio, December 1976.
21
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11. Greet, J.S., S.S. Gross, R.H. Hlltz, and M.J. McGoff. Modification of
Spill Factors Affecting Air Pollution. Vol. I: An Evaluation of Cool-
Ing as a Vapor Mitigating Procedure for Spilled Volatile Chemicals.
EPA-600/2-81-214, U.S. Environmental Protection Agency, Cincinnati,
Ohio, September 1981.
12. Gross, S.S., and R.H. Hlltz. Evaluation of Foams for Mitigating Air
Pollution from Hazardous Spills. EPA-600/2-82-029, U.S. Environmental
Protection Agency, Cincinnati, Ohio, July 1982.
13. MSA Research Corporation, Summary Engineering Report on Foam Development
for Hypergolic Propellant Spill Control. USAF Contract F42600-83-C-0615.
Available from: U.S. Air Force, Chief, Chemical Systems Branch, SV/CFPE,
HQ Space Division (AFSC), Los Angeles Air Force Station, P.O. Box 92960,
Los Angeles, CA 90009.
14. Evans, M., and H. Carroll. Handbook for Using Foams to Control Vapors
from Hazardous Spills. EPA-600/8-86/019, U.S. Environmental Protection
Agency, Cincinnati, Ohio, July 1986.
IS. Marshall, M.D. Capture-and-Contalnment Systems for Hazardous Materials
Spills on Land. EPA-600/2-84-084, U.S. Environmental Protection Agency,
Cincinnati, Ohio, April 1984.
16. Hiltz, R.H., and F. Roehlich, Jr. Emergency Collection System for
Spilled Hazardous Materials. EPA-600//2-77-162, U.S. Environmental
Protection Agency, Cincinnati, Ohio, August 1977.
17. Shaw, S.H., R.P. Bishop, and R.J. Powers. Development of a Sorbent Dis-
tribution and Recovery System. EPA-600/7-78-217, U.S. Environmental
Protection Agency, Cincinnati, Ohio, November 1978.
22
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APPENDIX A
ONE-PAGE DESCRIPTIONS OF SPILL RESPONSE PROTOTYPES, CONCEPTS, OR DEVICES
Pesticide Detection
Devices
Descripdon: Aqueous organophosphates
and carbamate pesticides can be detected
in the parts-per-million range using either
of two devices called cholinesterase anta-
gonist monitors (CAM's). One of these
devices is designed for the laboratory
(CAM I) and the other is designed with
more rugged construction for use in the
field (CAM IV). Both work on the same
principal: water is pumped through a
special 3/4-inch pad impregnated with a
cholinesterase enzyme such that the
enzyme cannot be swept from the pad;
electrodes on each side of the pad measure
increases in voltage which occur only
when organophosphate and/or carbamate
pesticides are in the water. Any increasesin
the measured voltage across the pad are
directly proportional to the concentrations
of the pesticides in the water. In addition,
the laboratory model (CAM I) is coupled
to an alarm system which can be set
manually at the desired monitoring level.
The field model is equipped with a strip
chart recorder. The enzyme pads are
reusable over numerous samples provided
there are no organophosphate or carba-
mate pesticides present in the samples.
Practical Applications: CAM I is ideally suited for use at pre-outfall stations throughout a pesti-
cide manufacturing facility. In the event of a spill or a malfunctioning treatment unit, CAM I
can sound an alarm and even actuate automatic flow control systems. Water treatment and
distribution plants can use CAM I as an early warning system at intake pipes to detect
organophosphate and carbamate pesticides. CAM IV can be used by pollution control officials
to track pesticide spills and to assess the danger of such spills to downstream sources of drink-
ing water. CAM IV can also be used to quickly determine levels of pesticides in industry
discharge pipes.
Availability: Free information on CAM I and CAM IV is available by contacting Mark Evans at
JRB Associates, (703) 734-4381. Call collect for full reports on each of these devices, including
field and laboratory test results, drawings, and complete parts lists needed to build these
devices.
23
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Hazardous Materials
Identification Kit
During the response to hazardous chemical spills
and uncontrolled hazardous waste sites, the identity of
contaminants is often unknown. Compact, portable
analytical equipment for rapid pollutant identification
is critical to effect efficient emergency response
activities. However, nearly 300 materials are classified
as hazardous substances by EPA (Federal Register. 16
February 1979). and a field kit capable of rapidly and
accurately identifying each of these substances would
be too unwieldly to be practical. Thus, thirty-six
representative hazardous materials (toxic metals,
anions, organic compounds) were selected and a field
kit was designed to identify these and related
substances (IAG-D6-0096).
The identification (ID) kit consists of two major
components: (1) an inverter/shortwave UVIamp unit for
photochemical and thermal reactions and (2) a package
with reagents and auxiliary equipment, including test
papers, detector tubes, spray reagents, spot test
supplies, and thin-layer chromatography apparatus.
Equipment to facilitate the recovery of contaminants
from water and soil is also included. The field
identification kit contains detailed operating
instructions ajid ' data cards for each of the 36
representative hazardous substances.
Identification of groups of contaminants, rather
than quantification of specific substances, is the
intended use of the identification kit. The ID kit can be
used^iti conjunction with the Hazardous Materials
Detection Kit, which contains a pH meter.
spectrophotometer, conductivity meter, and other
analytical equipment. Utilization of both kits can
improve identification capability, particularly for
inorganic materials. For example, cyanide and fluoride
cannot be distinguished by the ID kit alone; however,
when the kits are used concurrently, identification
becomes possible.
24
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Oxidation Reduction
Field Test Kit
Description: It's a very
simple device; simple to
use and simple to assem-
ble. Just obtain a portable
pH meter capable of meas-
uring electromotive force
in millivolts and prepare
test solutions of O.OOlN
ferrous ammonium sulfate
and O.OOlN potassium
dichromate. Test material
is measured into plastic
beakers containing the test
solutions; the readings
taken on these solutions
determine whether the test
material is an oxidizer, a
reducer, or neither.
Practical Application: Particularly useful for state agencies, this simple device has been used
at several uncontrolled hazardous waste sites for separating potentially reactive drummed
wastes. By segregating oxidizing wastes from reducing wastes, clean-up personnel can be pro-
tected from the violent explosions and reactions that can result from mixing incompatible
chemicals. The technicians that have used this device often had minimal previous training
with analytical equipment or with the handling of hazardous wastes. In every case, however,
the drums were segregated quickly (2-5 minutes/drum), efficiently, and with no injury or
dangerous incidents.
Availability: You can make it yourself. All we want are your comments. For more free infor-
mation and instructions, please contact Mark Evans at JRB Associates. (703) 734-4381. Call
collect.
25
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Particle Size
Analyzer
Description: Developed for use on
off-shore oil platforms, this portable
(32 pounds) automated apparatus
applies time-lapse photomicroscopy
to determine the number, size, and
density of spherical entities in semi-
transparent fluid matrices. The device
can analyze the oil drop size distribu-
tion in oil-brine and other oil-water
mixtures £o provide valuable informa-
tion in selecting or improving the per-
formance of oil separation equipment
or in developing new oil separation
systems. Oil-brine can be diverted
directly from a flow stream with a
common 5/8" garden hose and fed
into the system through a pressure-
reducing standpipe. The fluid then
passes into a flow-through cell where
it is photographed through a micro-
scope at designated intervals.
A solenoid valve interrupts the flow for a brief moment during photographing as a strobe and
reflecting assembly provide electronic flash illumination to facilitate "stop-action" photography.
By comparing photographs taken at known time intervals, the diameter, distribution, and rise
rate of oil drops in the fluid can be ascertained and their densities determined by applying
Stokes Law.
Practical Application: Because of the system's unique flow-through cell and horizontal viewing
axis, it can measure the diameter of particles in the 2 to 100 micrometer range under flowing
conditions, and without introducing significant shear forces which can adversely affect the oil-
drop population. Unlike conventional methods for characterizing particle size distribution, this
system is capable of measuring the density of the photographed objects as well as their size.
Thus the system can differentiate between oil drops, -gat- bubbles, and sand grains or other
foreign materials such as shell fragments. Although developed-for off-shore oil production, the
system is also applicable to on-shore production. In fact, it can be used to characterize the size
and distribution of any immiscible substance in a semi-transparent fluid matrix. It is designed to
be safely operated in explosive atmospheres, meeting all N.E.C. Class 1, Division 1, Group D
Requirements for operation where explosive concentrations of hydrocarbons are known to exist.
Availability: For additional information on this device, please contact Mark Evans at JRB
Associates, (703) 734-4381. Call collect. Comments or ideas on the practical utility of this device
are encouraged.
26
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Foamed Concrete
F-JdUnU
Description: Hazardous
chemical spills can be con-
trolled rapidly through the
installation of free-form dikes
and flow diversion structures
composed of quick-setting
foamed concrete. Foamed
concrete has a density of
about 40 pounds per cubic
foot and sets up extremely
fast (2-3 seconds). The result
is a gelled structure with suffi-
cient strength to build self-
supporting dikes over 2 feet in
height. The initial gel set is
capable of impounding liquids
immediately after being
placed. Once set, it forms a
rigid, non-porous, chemically
resistant barrier. The equipment and raw materials required for applying foamed concrete are
simple and are commercially available. Needed are cement, water, sodium-silicate solution, con-
centrated foam, a mixer for blending a cement-water slurry, a slurry pump, a preformed foam
generator, a storage tank, and a nozzle. These materials can be trailer-mounted and are suitable
for a pick-up truck operation. The types of substrate present at a site are not a critical factor-
tests on clay, shale, chipped limestone, grass, and weed-covered ground have been successful.
In addition, such chemicals as methanol, 1,1.1-trichloroethane, phenol, acetone cyanhydrin and
acrylonitrile do not affect the gel set action.
Practical Application: Foamed concrete is particularly useful to Federal and state chemical spill
response teams, spill clean-up contractors, truck lines, railroads, and fire companies. Costly
clean-ups can be avoided, and environmental damage caused by spilled chemicals can be kept
to a minimum.
Availability: For additional information, please contact Mark Evans at JRB Associates, (703)
734-4381. Call collect. Comments or ideas on the practical utility of this device are encouraged.
27
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Capture and
Containment Bag
Description: Here is a simple and
practical method for capturing and
containing hazardous and non-
hazardous spills from ruptured tank
trucks and railroad can. It is a
double-walled containment bag made
of two types of polyethylene, one in-
side of the other. The inner material
is dear with a heat-sealed seam and
the other material is fiber-reinforced
with a sewn seam. The dimensions of
the bag are approximately 20 feet
long by 8 feet wide with a 10-foot
wide apron at one end and a transfer
tube approximately 30 feet long by 4
inches in diameter at the other end.
The bag weighs approximately 16
pounds and can be stored in less than
2 cubic feet of space. Long tie lines attached to the apron of the bag allow it to be positioned
for a large variety of leak configurations. The transfer tube at the bottom of the bag enables the
captured liquid to be transferred to secondary containment. During field tests, the bag was used
to collect over 1.000 gallons of liquid from a leaking tank car without any leakage. The
polyethylene material was also demonstrated as a suitable barrier for fabricating emergency
holding ponds.
Practical Applications: The capture and containment bag is a simple and practical first-response
device for controlling spills resulting from bulk transport accidents. It is an excellent on-board
tool for emergency spill containment in tank trucks and rail tankers and is also ideally suited
for use by State and local emergency response teams. The unit is lightweight, easy to store, and
inexpensive ($50 to $200/bag) depending on production rates (1981 estimates).
Availability: Prototype bags may soon be available on a free-loan basis to selected interested
parties. All we want are your comments. For more free information and instructions, please
contact Mark Evans at JRB Associates, (703) 734-4381.
28
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Emergency
Collection System
""*•— —r.S~t- "^-. ^r- ^TTr=-.
Description: A prepackaged pumping and storage system has been proven effective for the col-
lection and temporary containment of hazardous and non-hazardous land spills. The-system
features a series of urethane-coated bags into which spilled materials are pumped for temporary
storage. In addition to the collection bags, the system consists of a gasoline-powered pumping
unit and 30m (100 ft) of suction hose mounted on a reinforced aluminum pallet for easy
transport on a pick-up truck. The bag unit has a total capacity of 26,500 1 (7,000 gal) and con-
sists of three cylindrical bags fed by a header bag which stabilizes the system on sloping
ground. At a spill site, quick release of the bag unit is accomplished through a special bag hous-
ing made of corrugated aluminum. Once the bag is deployed and unfolded, the quick-
disconnect fittings are used to attach the hoses and pump. The pump fills the header bag which
serves as a manifold to evenly fill the other three bags. If applied to a tank truck leak, it is
possible to modify the system so that hoses can be connected simultaneously to the tank itself
and to liquid on the ground.
Practical Applications: The pump and bag system can be used to collect accidental spills which
occur during transport of hazardous materials or at industrial sites. The speed of the pump and
bag collection system can significantly lower the high clean-up costs that often result from acci-
dental chemical spills that pollute soils, groundwater, and surface waters. Because it fits readily
on a pick-up truck, a van, or dual-wheeled railroad vehicles, this system can be easily
transported to a spill site making it ideal for use by professional spill response teams in both the
private and public sectors. The entire packed system is only 4 feet by 4 feet and a single tankful
of fuel will provide up to two hours of pumping time.
Availability: For more information, including a full report on this device, please contact Mark
Evans at JRB Associates (703) 734-4381.
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Sorbent Oil
Recovery System
Description: Avoid wasted time and
increase efficiency during oil spill
clean-ups with a sorbent distribution
and recovery system. The device uses
a pneumatic broadcaster to distribute
open-celled polyurethane cubes over
floating oil spills. The saturated sor-
bent is then harvested from the water
through an inclined, open-wire mesh
conveyor, and oily water is squeezed
from the sorbent in a converging belt
press or regenerator. Once
regenerated, the uniformly-designed
cubes (2/3" per side) can be reapplied
to the spilled oil. Tests of this system
have been conducted using spilled
diesel fuel and lubricating oils at boat
speeds ranging up to 5 knots in both
calm and rough water. Oil has been
collected at rates of up to 10.5 cubic
meters per hour, and the oil content
of the recovered liquids has varied
from 38 to 79 percent.
Sorbent Oil Recovery System
Deployed at a Stream
Practical Application: This system is useful for the recovery of spilled oil from the surface of
river, estuarine, and harbor waters, particularly because it is less sensitive to wave and current
action than conventional oil spill clean-up equipment. In addition, the use of this device
significantly reduces supply and disposal problems associated with other sorbent clean-up
techniques because the sorbent cubes can be reused both at the spill site and at more than one
spill. The system is highly mobile and can be transported in two pick-up trucks. It is also
operable from vessels or from a combination of one or more small boats, a dock, or the shore.
Availability: You can build it yourself with off-the-shelf components. All we want are your
comments. For more free information and instructions, please contact Mark Evans at JRB
Associates, (703) 734-4381.
30
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APPENDIX B
CONTRIBUTORS TO ASSESSMENT ACTIVITIES ON SPILL RESPONSE SYSTEMS
On the following pages are tabulated the names, affiliations, and
locations of the persons who assisted SAIC in this study by providing
information or comments on specific technologies. The technologies are
identified for each contributor in the Table by the code numbers indicated.
Code Mo. Technology
1 CAM-1 and CAM-4
2 HMIDK
3 Insoluble Sinkers Detectors
4 LDH
5 Redox Monitor
6 Particle Size Analyzer
7 Foamed Concrete Dike
8 Leak Plugger
9 Vapor Control Coolants
10 Vapor Control Foams
11 Capture & Containment Bag
12 Emergency Collection Bag
13 Soxbent Oil Recovery System
31.
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APPENDIX B. CONTRIBUTORS TO ASSESSMENT ACTIVITIES ON SPILL RESPONSE SYSTEMS
CJ-
ro
CONTRIBUTOR
J. Bazber
J. Barlan
D. Bervick
J. Betschart
J. Brown
W. Burgess
B. Cage
F. Cole
R. Collins
L. Cording
J. Coving ton
L. Daroico
R. Dashiell
G. Dennison
L. Doemeny
Dr. Eastwood
D. Eitel
H. Enger
A. Ennis
J. Fetter
M. Fingas
A. Fischer
D. Fray ley
J. Gall away
C. Geraci
J. Gibeault
E. Haines
C. Harrison
AFFILIATION
Society of American Foresters
Compressed Gas Assoc.
Dow Chemical Corp.
Mill Air Force Base
Monsanto, Corp.
MD Water Resources Admin.
Midwest Research Institute
Facet Enterprises, Inc.
B.F. Goodrich Co.
LaMotte Chemicals Co.
Natl Emergency Training Cntr
Aero Tech Laboratories
McTighe Industries
Princeton Testing Laboratories
NIOS11 Div. of Phys. Sciences
US Army Corps of Engineers,
Superfund Design Center
Shell Chemical Co.
Craw'ley Environmental Srvcs Corp.
Assbc. of Consulting Foresters
Spill Recovery of Indiana
Environment Canada
Lancy International
Clean Rivers Corp.
Exxon Corp.
NIOSH Div. of Phys Sciences
Analtrad Int'l, Inc.
Goodyear Tire & Rubber Co.
Natl Tank Truck Carriers, Inc.
LOCATION
Bethesda, Md
Arlington, VA
Midland, MI
UT
Ann is ton, AL
Annapolis, MD
Kansas City, KS
Tulsa, OK
Bethesda, MD
Chester town, MD
Emnitsburg, MD
Ramsey, NJ
Bohemia. NY
Princeton, NJ
Cincinnati, OH
Omaha, NB
Axis, AL
Seattle, VA
Bethesda, MD
Indianapolis, IN
Ottaxta, Ont, CA
Zelienople, PA
Portland, OR
Houston, TX
Cincinnati, 01!
Quebec, CA
Akron, OH
Washington, DC
PROTOTYPE"
'!'.
-9
9
12
1
7
1
6
11
5
8,10,11
11
6
4,5
1
2
1
13
2
2,5,7
13
6
6
6
2
5
11
11
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APPENDIX B. (cont'd)
c*>
CO-
CONTRIBUTOR
S. Harrison
C. Harvey
G. Hersh
R. Hlltz
V. Hollls
R. Holm
T. Hoover
V. Huget
L. Karr
B. Kate
R. Kibler
J. Marquis
A. Mason
J. Mason
R. Mayeaux
C. HcDaniel
K. McLaughlin
R. Mel void
R. Meyer
J. Nakao
J. Neisess
E. Norman
D. Norton
M. Norton
B. Offenhartz
S. Palmier!
V. Polett
D. Rhodes
P. Roeser
T. Roller
AFFILIATION
Union Carbide Agricultural Pdts Co.
Carbonic Industries
Rochester Fire Dept.
MSA Research Corp.
Natl Agricultural Chemicals Assn
Rhone-Poulenc, Inc.
USEPA, Southeast Envir. Res. Lab
Cryogenic Soc. of America
Naval Civil Eng. Laboratory
Illinois Chemical Corp.
US Air Force Enviro Policy Croup
Vacpar, Inc.
Assn of American Railroads
Fram Industrial Filter Corp.
Louisiana State Police
USDA Natl Monitoring
& Residue Analysis Lab
Alert Laboratories t Inc.
Rockwell International Corp.
Rockwell International Corp.
CA Dept. of Health Services
USDA, Forest Service
National Foam Co.
Monsanto Corp.
Instafoam Products
B&M Technological Services, Inc.
NJ Taxation Dept
Valpole, Inc.
Centriflcal Systems, Inc.
Cecos International
Libbey-Owens Ford Co.
LOCATION
RTF, NC
Richmond, VA
Rochester, NY
Evans City* PA
Washington, DC
Monmouth .Tnctn, NJ
Athens, CA
Oak Park, IL
Port Huenetne, CA
Highland Park, IL
Washington, DC
Vicksburg, HI
Washington, DC
Tulsa, OK
New Orleans, LA
Gufort, LA
Canton, OH
Canoga Park, CA
Canoga Park, CA
Sacramento, CA
Washington, DC
Lionsville, PA
Ann! s ton, AL
Jolliet, IL
Boston, MA
Trenton, NJ
Mt. Holly, NJ
Houston, TX
Buffalo, NY
Rossf6rd, OH
PROTOTYPE
1,4
9
10
10,12
1
1
4
9
6
13
9
13
6,11
2
1
4
8
3
2
1.8
9,10
8
8
1
5
11
13
5
1
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APPENDIX'.B. (cbnt'd)
CONTRIBUTOR
AFFILIATION
LOCATION
PROTOTYPE
V. .Russer
D. Ryan
R. Sarriera
R. Schaffer
R. Schaller
R. Schmitt
R. Scholten
D. Seely
J. Seymour
S. Shaw
J. Sheffy
J. Silk
A. Sllvestrl
J. Sinclair
A. Sladek
A. Stevens
F. Stevens
J. Stewart
J. Tew
K. Thorn
H. Totten
J. Townsend
S. Tsoukalas
R* Urban
S. Vales
D. Walker
J. White
M. Young
P. Zaine
Canvas Fabricators
Ohio State Fire Marshall
R.E. Sarriera Associates
Centec Corp.
Donaldson Co., Inc.
USEPA, Office of Pesticide Pgms
Milwaukee Railroad
GCA Consultants
Envirotech Services, Inc.
Seaward International Corp.
SOHIO
OSHA, DOL
Chemical Systems Laboratory
US Coast Guard
Philadelphia Fire Dept.
USEPA, MERL, DWRD
Lancy International
Katz Bag Co.
Amer. Assoc. of Textile
Chemists & Colorists
Welding Institute of Canada
Chemical Manufacturers Assn
Texas A&M
Oil & Hazardous Material Training Dlv.
Applied Biology, Inc.
Tennessee Valley Authority
Research Plastics
Fluor Engineering
Fram Industrial Filter Corp.
Giffolyn Co.
Sigma Treatment Systems
Gaithersburg, MD 11
Reynoldsburg, OH 10
Santuce, PR 1
Reston, VA 2
Minneapolis, MN 6
Washington, DC 1
Chicago, IL 11
Bedford, i:A 5,11
Praire du Sac, WI 2,4
Falls Church, VA 13
Houston, TX . 6
Washington, DC 1
Aberdeen, MD 1,2,4
Washington, DC 8
Philadelphia, PA 10
Cincinnati, OH 1,3
Zelienople, PA 6
Indianapolis, IN 11
RTP, NC 9
Oakvllle, Out, CA 9
Washington, DC 1
College Station, TX 10
Atlanta, GA 4
Chattanooga, TN 1
Salem, MA 11
Irvine, CA 10
Tulsa, OK 6
Houston, TX 11
Chester Springs, PA 6
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APPENDIX C
EVALUATION OF CAM-4 AND THE EMERGENCY COLLECTION SYSTEM
by
Barbara H. Offenhartz
David Schwartz
B & M TECHNOLOGICAL SERVICES, INC,
520 Commonwealth Avenue
Boston, Massachusetts 02215
Subcontract No. 2-817-33-956-52-11
to
Contract No. 68-03-3113
HAZARDOUS WASTE ENGINEERING RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
35
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ACKNOWLEDGMENTS
The authors wish to thank Mr. Ralph H. Hiltz of MSA Research Corpor-
ation, Evans City, PA, and Mr. William 6. Jacobs of Midwest Research
Institute, Kansas City, MO, for their technical assistance. We also
wish to thank Mr. Mark Evans of JRB Associates and Mr. Michael Royer of
EPA's Hazardous Waste Engineering Research Laboratory, Edison, NJ, for
their technical assistance and encouragement.
36
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ABSTRACT
Two prototype devices, the CAM-4 pesticide monitor and the emergency
collection system, designed under previous contracts to the U.S. Environmental
Protection Agency, Office of Research and Development (EPA/ORD), have been
examined to Identify potential design cost savings, Identify areas for design
Improvement, and assess their potential for commercial production.
The CAM-4 device, designed by Midwest Research Institute (MRI), 1s
described In the EPA report. "CAM-4. A Portable Warning Device for
Organophosphate Hazardous Material Spills" (1). The CAM-4 (Chollnesterase
Antagonist^Monitor) Is a semi-automated field unit for toxlcity-level detec-
tion of dissolved Organophosphate and carbamate pesticides. Two tasks relat-
ing to this device were performed. First, two Inoperative CAM-4 units and an
Inoperative CAM-1 were examined. The two CAM-4 units were refurbished and
returned to working order, and a demonstration kit containing appropriate
reagents was prepared. Second, the CAM-4 was subjected to a value engineering
analysis. This analysis indicates that the CAM-4 can be manufactured for
$1,746. Additional cost reductions of 30X or more can be achieved if the
systems are manufactured In lots of 25 to 100 units. Estimates of reagent
manufacturing costs, including the cost of enzyme pads, are less than $1 per
unit. The projected cost per test to the CAM-4 user is only one-fortieth of
the current cost of a chromatographic pesticide analysis carried out by a
commercial testing laboratory.
The commercial potential of the CAM-4 design was assessed by comparing the
CAM-4 with analogous commercial field Instruments for monitoring residual
chlorine In natural waters (2, 3). The chlorine monitors and the CAM-4 are
comparable In cost, manufacturability and serviceability. Significant short-
comings of the CAM-4 design are an unreliable fluid-handling system and a data
output system that is both costly and difficult to Interpret correctly.
Possible redesign approaches have been described. The redesigned system 1s
expected to be significantly easier to operate. Improving marketability.
Manufacturing costs of the redesigned system are estimated to be significantly
less ($500) than the present CAM-4 design. The projected redesign effort is
straightforward. On the basis of Its outstanding potential, further applica-
tions research on the CAM technology 1s recomnended.
The emergency collection system, designed by MSA Research Corporation, is
a prepackaged pumping and storage system for the collection and containment of
hazardous land spills and is described 1n the EPA report, "Emergency
Collection System for Spilled Hazardous Materials" (4). The device consists
of two major components: a skid-mounted gasoline-powered pumping unit, and a
37
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disposable collection bag. The value engineering analysis of this device
Indicates that the pumping unit can be manufactured for $5,381 when built In
quantities of 100 units. A cost-reduced pumping unit can be manufactured for
SI.045 in the same quantity.
The cost of manufacturing the disposable collection bag remains uncertain.
At the recommendation of MSA Research Corporation, Helios Industries, MSA's
bag manufacturer, was contacted for cost quotations. Quotes received were
$15,000 for the original segmented bag and $8,038 for a pillow redesign (5).
Ralph H. Hiltz of MSA, has suggested alternate cost estimates of $7,000 and
$5,000, respectively, for corrmercial bag designs incorporating additional
design modifications (see Appendix B). Using even the lowest cost estimate,
the value engineering analysis Indicates that the cost of manufacturing the
disposable collection bag strongly influences system costs. Further design
development 1s recommended to achieve acceptable trade-offs among cost, manu-
facturability and field performance characteristics.
Thlsf'report Is submitted in fulfillment of Subcontract No. 2-817-33-956-52-11
between B & H Technological Services, Inc. (B & M) and JRB Associates under
the sponsorship of the U.S. Environmental Protection Agency, Contract
No. 68-03-3113, Task 21-2. This report covers the period April 26, 1983 to
August 10, 1983. Work was completed on August 31, 1983.
38
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CONTENTS
Acknowledgment 36
Abstract 37
Figures 40
Tables 41
1. Introduction 42
2. Conclusions 44
CAM-4 44
Emergency Collection System 45
3. Recommendations 47
CAM-4 -.-»-. 47
Emergency Collection System 47
4. Refurbishment of the CAM-4 48
5. Evaluation: CAM-4 50
Introduction 50
System Description 51
Component Description 54
Component and System Costs 57
Critique of the CAM-4 Design 59
Redesign of CAM-4 60
6. Evaluation: Emergency Collection System 62
Introduction 62
System Description 62
Component Description 65
Component and System Costs 67
Possible Cost Reductions 69
Reduced Cost System 72
Initial Manufacturing Costs 75
References 76
Appendices
A. CAM-4: Cost Analysis 81
B. Emergency Collection System: Communication MSA 86
39
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FIGURES
Number Page
1 Schematic, CAM-4 52
2 Block Diagram, CAM-4 53
3 Emergency Collection System 63
4 Segmented Collection Bag 64
5 /> 11 low Collection Bag ' '. 73
40
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FIGURES
Number Page
1 CAM-4 Unit and Demonstration Kit 49
2 Specifications 55
3 Parts Cost, CAM-4 57
4 Cost of Components, Emergency Collection System 68
5 Possible Cost Reductions, Emergency Collection System ...... 70
6 Costs Compared, Emergency Collection System 74
7 Selling Price, Emergency Collection System 74
41
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SECTION 1
INTRODUCTION
Two prototype devices, developed under previous contracts to the U.S. EPA,
ORD, for detecting, containing and/or cleaning up chemicals 1n the environ-
ment, have been examined to Identify potential design cost savings. Identify
areas for design Improvement, and assess their potential for commercial pro-
duction. The devices are the CAM-4 water monitor designed by Midwest Research
Institute and the emergency collection system designed by MSA Research
Corporation.
The CAM-4 (Chollnesterase Antagonist Monitor) Is a semi-automated field
unit for toxldty-level detection of dissolved organophosphate and carbamate
pesticides. Two tasks relating to this device were performed: First, two
Inoperative CAM-4 units were restored to working order, and a demonstration
kit containing appropriate reagents was prepared. Second, the CAM-4 design
was subjected to a value engineering analysis. The emergency collection
system, a prepackaged pumping and storage system for the collection and con-
tainment of hazardous land spills, was subjected to a value engineering analy-
sis.
Work carried out on the CAM-4 pesticide detection system 1s described 1n
Sections 4 (Instrument Refurbishment) and 5 (Evaluation). The two CAM-4 units
obtained for refurbishment were both Inoperative upon receipt, and several
parts were missing. Problems Identified Included broken electrical connec-
tions, broken water pumps and deteriorated plumbing. The engineering documen-
tation was Inadequate, and vendor part numbers did not always conform to
components actually found In the units. Nevertheless, both units were
restored to good working order.
The evaluation of the CAM-4 system was based on specifications published
1n EPA Report No. 600/2-80-033, January 1980 (1). Additional Information was
gained as a result of repairing the two units. Prior reports on the
CAM-1 (6), and excerpts from a manual on an updated CAM-1 device, MRI's
CAM-3 (7). were also used In the analysis. The total costs of manufacturing
the CAM-4 prototype and the CAM-4 reagents 1n various lot quantities were
determined based on the current costs of the system components specified.
Labor costs were estimated according to standard manufacturing practices.
Commercially available chlorine water monitors were used as a basis for devel-
oping commercial standards for cost, manufacturability, serviceability, and
ease of use (2, 3, 8, 9). This comparison helped Identify a number of Umlta
42
-------
tlons In the CAM-4 design. Possible design changes to overcome these limita-
tions and Improve the marketability of the CAH-4 prototype design were
explored.
The value engineering analysis on the emergency collection system 1s pre-
sented in Section 6. The evaluation was based on Information contained in EPA
Report No. 600/2-77-162, August 1977 (4), along with additional Information
obtained directly from MSA, including drawings and design updates (10).
Current costs for the pumping component of the emergency collection system
were obtained for the specified subassemblles. Alternate sources of subassem-
blies were identified, labor costs were estimated, and the total costs for
building the unit in various lot quantities were determined. Possible design
changes to reduce costs were explored, and a minimum cost system was speci-
fied. Initial costs to be faced in Initiating production were estimated. For
the disposable collection bag, the second major component of the emergency
collection system, cost quotations obtained from a vendor (5) recommended by
MSA Corporation and MSA's own cost estimates (10) were used in the cost analy-
sis (see-'also Appendix B). These quotations Indicate that the cost of the
collection bag is likely to dominate the overall system cost.
43
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SECTION 2
CONCLUSIONS
CAM-4
The analyses performed In the course of evaluating the CAM-4 system,
together with the experience gained In repairing and operating two CAM-4
units, support the following conclusions:
1. The CAM-4 design specified by Midwest Research Institute can be manu-
factured for SI,746 1n single-unit quantities. When built In 25- to I00-un1t
quantities, & SOX or higher discount on standard parts 1s expected to decrease
manufacturing costs to $1,200 or less. Discounts of this magnitude are
expected when original equipment manufacturers are approached, rather than
equipment distributors.
2. Estimated costs of bottled reagents manufactured 1n 200-un1t quanti-
ties are under $1 per unit. Enzyme pads manufactured according to published
procedures In quantities of 3,500 are expected to cost about $0.10 'per pad.
When manufactured using MRI's proprietary batch processing procedures, enzyme
pads cost less than $0.01 per pad according to William B. Jacobs of Midwest
Research Institute (4).
3. Sales prices for the CAM-4 unit based on the above manufacturing costs
are $3,000 to $4,365. Suggested reagent prices of $10 for buffer (500 ml), $5
for substrate, and $1 per enzyme pad provide customary profit margins.
4. The cost per test calculated for a typical day's use 1n the field 1s
one-fortieth the current cost of a chromatograpMc pesticide analysis per-
formed by a commercial testing laboratory ($40-$50 per test).
5. Low-cost chlorine water monitors manufactured by EPCO and IBM
Instruments (2, 3, 8, 9) were used to establish standards of cost and perfor-
mance applicable to a critique of the CAM-4 prototype design. The CAM-4 was
comparable to the commercial chlorine monitors 1n cost, manufacturability and
serviceability. CAM-4 design shortcomings Identified are as follows:
* The digital printer ($575) Is an unnecessarily costly means
of data output.
* The fluid-handling design can contribute to undetected errors
In data output and Incorporates a water pump that requires
replacement after less than 1000 hours of operation.
44
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* The data outputs are recorded as cell voltages, which require
user Interpretation, and hence a high level of user familiarity
with the technology.
6. Approaches to prototype redesign that would serve to eliminate these
shortcomings are:
* Substitute a liquid crystal display for the digital printer
at a cost savings of approximately $500.
* Redesign the fluid-handling system around peristaltic pumps
of acceptable reliability.
* A complete update of the CAM-4 electronics design, Incorporating
a microprocessor, would permit the convenience of pad change
alerts and alarm warnings, as well as direct data output of
pesticide concentration.
The manufacturing cost of the suggested redesigned CAM-4 Is estimated to be
about $500 less than the present design.
7. Any potential manufacturer'of CAM-type Instrumentation can expect to
Invest some product design effort to assess design variables, set Instrument
specifications, develop prototypes, develop and document commercial protocols,
and develop secondary applications of the technology. While the CAM-4 design
of 1976 requires updating to become commercially acceptable, the level of
redesign effort could be quite modest. The redesign analysis Indicates that a
three- to six-month product development effort at a cost of $25,000 to $50,000
could lead to a successful Initial product.
EMERGENCY COLLECTION SYSTEM
The analyses performed 1n the course of evaluating the emergency collec-
tion system support the following conclusions:
1. The system, as specified. Is designed to meet high standards of per-
formance and durability. Exceptionally durable components were chosen.
2. As specified, the pumping unit can be assembled easily from readily
available standard components at a manufacturing cost of $5,381 In quantities
of 100 units.
3. A less durable and less easily deployed pumping unit can be built for
as Uttle as $1,045. However, this design may not be as safe as the design
originally specified.
4. Product acceptability will depend on appropriate marketing Information
as well as thorough field testing of any proposed alternatives to the original
design approach.
45
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5. The price quotations received for the original segmented bag and a
pillow bag design, $15,000 and $8,038, respectively, are high for a disposable
item. However, these prices are appropriate for small-quantity (1 to 100)
custom orders and are not indicative of commercial manufacturing practices.
6. The commercialization potential of the collection bag, and thus the
emergency collection system, is uncertain at present.
46
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SECTION 3
RECOMMENDATIONS
The engineering analyses reported here are Intended to contribute to an
assessment of the commercialization potential of two technologies, the CAM-4
pesticide monitor and the emergency collection system.
CAM-4
The convenience and low cost per test of the CAM-4 instrumentation suggest
that this technology may become an effective tool in a variety of pesticide
monitoring applications. Some examples of applications arre the analysis>of
run-off from agricultural pesticide spraying, the analysis of pesticide resid-
uals in vegetation and/or soil, and process control measurements in pesticide
manufacturing. Further work Is recommended to Implement the design improve-
ments described in this report.
EMERGENCY COLLECTION SYSTEM
The cost of this system 1s Influenced greatly by the cost of the
7,000-gallon collection bag. a disposable Item. Current cost quotations by
Helios Industries are very high (S8.000 to $15.000), Indicating that this
aspect of the system design requires further investigation (5). MSA's own
estimate (10) Is only $5,000 to $7,000 for bag designs incorporating further
modifications (see also Appendix B). Additional design research Is
recommended In order to meet commercially acceptable criteria of cost,
manufacturability and desired field performance.
47
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SECTION 4
REFURBISHMENT OF THE CAM-4
* This chapter describes the work and events Involved 1n refurbishing a
CAM-4 prototype for demonstration at the Hazardous Materials Management
Conference in Philadelphia, July 12-14, 1983.
Initially, one CAM-4 unit and one CAM-1 unit were received with instruc-
tions to repair the device 1n least need of repair. The CAM-1 device was
badly deteriorated and was received with Improperly secured circuit boards
that were damaged 1n transit. An examination of the CAM-1 unit, built in
1972, revealed that most mechanical parts would probably need replacement due
to extensive corrosion. A printed circuit board contained a burned-out
resistor indicating that circuits had been damaged by overvoltage. Therefore,
this device was not refurbished.
After 1t was decided to repair the CAM-4 device, a second CAM-4 was
received to provide spare parts so that time delays caused by ordering new
parts would be minimized. The problems that were diagnosed and repaired con-
sisted of broken electrical connections, broken water pumps and deteriorated
plumbing.
The lack of adequate engineering documentation available for these units
considerably prolonged the repair process. No working drawings are available,
and vendor part numbers from 1976 had to serve for part specifications. In
performing diagnostics, 1t was necessary to reconcile differences in construc-
tion between the two CAM-4 units, as well as differences between observed per-
formance characteristics and those documented 1n the CAM-4 report. As an
example of the latter, the sampling rate of the refurbished CAM-4 units is
650 ml/min. The CAM-4 specified sampling rate is 200 ml/min (1). The CAM-4
user 1s advised that the observed rate and the specified rate are both con-
sistent with good Instrument performance (1, 6, 12). Units received a final
check-out with active enzyme pads.
One refurbished CAM-4 unit (Control No. L/A 9629) was turned over to the
ORB Project Manager on July 1 together with a demonstration kit containing
appropriate reagents. The 11st of items delivered are shown In Table 1. The
JRB Project Manager was trained 1n the operation of the CAM-4 in preparation
for demonstrating the Instrument at the Hazardous Materials Management
Conference.
As a small addendum to the refurbishment task, the second CAM-4 unit
(Control No. L/A 9630) was also refurbished and returned to the EPA Project
48
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Officer along with the remainder of the unused disposable items that were
purchased. The broken CAM-1 was also returned to EPA.
TABLE 1. CAH-4 UNIT AND DEMONSTRATION KIT
1 CAM-4, control number L/A 9629, refurbished, with accessories:
2 enzyme pad holders
1 vacuum/pressure bulb
1 power cord
2 silastic pump tube
5 paper rolls, thermographlc printer
1 bottle for substrate
1, demonstration kit, containing:
25 enzyme pads, active
2 enzyme pads, inactivated
Ingredients for 4 x 200 ml batches of substrate
1 bottle trisbuffer (1 + lit)
4 vials, 16 mg substrate
4 pasteur pipettes
1 beaker (50 ml)
2 vial inhibitor concentrate
1 bottle tris (solid)
1 bottle substrate (solid)
1 vial inhibitor (solid)
49
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SECTION 5
EVALUATION: CAM-4
INTRODUCTION
The CAM-4 chollnesterase antagonist water monitors are semi-automated
field units for tox1city-level detection of dissolved organophosphate and
carbamate pesticides. The performance characteristics of CAM monitors have
been documented In EPA-sponsored Instrument evaluations (1, 6, 12). More
recently. Midwest Research Institute (MRI) scientists have used CAM Instrumen-
tation effectively In commercially-sponsored Industrial and agricultural
research (11).
The CAM-4 system, designed by Midwest Research Institute, was evaluated on
the basis of specifications published In EPA Report No. 600/2-80-033, January
1980 (1). Additional Information was gained from the repair of two CAM-4
units, as reported In Section 4. Prior reports on the Model CAM-1 (6, 12) and
excerpts from the model CAM-3 manual (7) were also used In the analysis.
The CAM-4 evaluation had the following objectives:
* Develop manufacturing costs for the CAM-4 and for the CAM-4
reagents, as specified;
* Develop design criteria for a commercial prototype, and apply
these criteria to a critique of the CAM-4 design;
* Suggest effective redesign approaches;
* Estimate development and manufacturing costs of the redesigned
CAM-4.
The total costs of manufacturing the CAM-4 prototype and the CAM-4
reagents In various lot quantities were determined. The cost analysis was
based on current vendor Information obtained for the system components speci-
fied. Suppliers contacted and prices obtained are detailed 1n Appendix A and
are cited In the Reference section. Labor costs were estimated assuming stan-
dard manufacturing practices and a burdened rate of $30 per hour.
Commercial water monitors of similar design and analogous function were
used to develop commercially acceptable standards of cost, manufacturability,
serviceability, and ease of use (2, 3, 8, 9). When these standards were
50
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applied to an analysis of the CAM-4, design strengths and limitations were
identified. Possible design changes were explored to improve the marketabil-
ity of the CAM-4 prototype design.
In addition, an estimate was made of the start-up costs Involved in manu-
facturing the CAM-4.
SYSTEM DESCRIPTION
Over the past twelve years. Midwest Research Institute has designed and
constructed a series of CAM instruments for continuously monitoring natural
waters for the presence of subtoxic to toxic levels of organophosphate and
carbamate pesticides. The model CAM-1 (6, 12), designed in 1972, and its
recent update, CAM-3 (7), are fully automated research instruments for bench-
top use. The portable CAM-4, designed in 1976, is an equally sensitive in-
strument designed for field use (1). It can operate on a 12V DC battery as
well/as on 110V AC. The simpler, less costly CAM-4 design is well suited for
the design evaluation, since the objectives of the evaluation are to minimize
manufacturing costs and optimize conntercial performance.
The operation of CAM instruments depends on the inactivation of the enzyme
cholinesterase by organophosphate and carbamate pesticides. The extent of
inactivation depends on pesticide concentration and the nature of the pesti-
cide. Enzyme activity Is gauged by assessing the rate of conversion of an
enzyme-hydrolyzable substrate to detectable products. Common features of CAM
instruments are the electrochemical detection of reaction products, an Immobi-
lized enzyme preparation reusable for several analyses, and a sampling cycle
that permits discrete analyses as well as continuous monitoring.
CAM instrument design, as represented In the CAM-4 schematic shown In
Figure 1 and the block diagram in Figure 2, promotes pesticide detection and
monitoring in the following way. A porous pad coated with entrapped enzyme Is
clamped firmly inside an electrochemical cell assembly. Two detector elec-
trodes contact the enzyme pad on opposite sides. During a sampling cycle, the
enzyme 1s exposed to the water sample and to substrate in a precisely timed
sequence. First water 1s pumped through the pad, permitting dissolved pesti-
cide to reduce the activity of the enzyme. Next, residual water is displaced
by a stream of air. Finally, a stream of substrate is pumped through the
enzyme pad and a constant 2uA current is applied to the electrodes. The cell
voltage is printed out on the digital printer. The next sampling cycle begins
automatically unless manually interrupted.
the cell voltage printed out at the end of the sampling cycle may be
Interpreted as follows. Characteristically low voltages are observed in the
presence of hydrolysis product concentrations produced by an active enzyme
preparation. When the sample contains pesticide concentrations equal to or
greater than the detection threshold of the instrument, a rise in cell voltage
of 10 mv or greater from one sampling cycle to the, next signals the presence
of dissolved pesticide. The voltage rises in direct response to the concen-
tration of hydrolysis product produced by enzyme partially or completely
51
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WATER PUMP
SUBSTRATE PUMP
o-
I PRINTER
DETECTOR
1ECTRONICS
DE
fECTl
I i
CELL WITH
ENZYME PAD
DISCHARGE
FIGURE 1. SCHEMATIC CAM-4
52
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in
CJ
ELECTROCHEMICAL
CELL
Electrodes
Enzyme Pad
SEQUENTIAL TIMER
Timer
Switching
DETECTOR
ELECTRONICS
Current Generator
Voltage Amplifier
A/D Converter
DIGITAL
RECORDER
PUMPS
Water Pump
Air Pump
Substrate Pump
POWER SUPPLY
AC/DC ADAPTOR
FIGURE 2. BLOCK DIAGRAM, CAM-4
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Inactivated by pesticide. As noted 1n the CAM-4 specifications summarized in
Table 2, instrument response Includes a detection threshold of 0.1 parts-per-
milllon (ppm) for the most toxic pesticides, a linear response range for ppm
levels of pesticides» and an overrange response. The latter occurs whenever a
fresh or partially inactivated enzyme pad 1s completely Inactivated.
The CAM-1 and CAM-3 automated monitors have convenience features that are
eliminated in the CAM-4 design. An audible alarm voltage threshold can be set
to signal the presence of pesticides. The degree of Inactivation of enzyme
pads Is monitored by computer logic circuits. An exhausted enzyme pad is
removed automatically and a fresh pad Inserted in the electrochemical cell
assembly. A strip chart recorder Is provided for continuous recording of cell
voltages.
The CAM-4 operator must Interpret the digital recorder printout to deter-
mine the presence and concentration of pesticides and to determine when enzyme
pads require changing. Enzyme pads are changed manually. A cell voltage out-
put jack 1s'provided for the optional use of a chart recorder.
COMPONENT DESCRIPTION
Although the CAM-4 design described In EPA-600/2-80-033 (1) did not
Include a complete unified bill of materials, most components could be iden-
tified from the parts 11st and from examination of the CAM-4 units refurbished
(see Section 4). A complete parts 11st with prices and vendors 1s Included 1n
Appendix A. Major components are discussed below. A more complete descrip-
tion. Including circuit diagrams. Is Included 1n the EPA report (1).
Case Assembly
A sturdy fiberglass carrying case, roughly in the shape of a rounded cube,
opens In the middle to provide two, six-Inch deep compartments that house the
Instrument components. Each compartment Is covered by a panel containing the
operator controls. The right half of the case contains most of the electrical
components, while the left half contains the mechanical components (pumps,
motors, pad holder, water Inlet and outlet, etc.). When set up on a bench
(or, less conveniently, on the ground), all controls and Indicators are easily
accessible. A recessed socket for a 110V AC power cord 1s provided in the
right-hand compartment, together with a pair of DC input terminals for 12V
operation.
Electronics
The electronics of the CAM-4 are contained on three printed circuit
boards: (a) a "DVM" board, which performs analog to digital conversion for
the signal transmitted by the cell voltage amplifier, and which provides the
constant current source for the electrochemical cell; (b) a power supply
board, which provides the required voltages (+15V. -15V, +5V and +5V
54
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TABLE 2. SPECIFICATIONS, CAM-4
The CAM water monitor detects organophosphate and carbamate pesticides In the
ppm range. Detection limits are 0.1 ppm for the most toxic pesticides. The
measurement principle uses pesticide inhibition of the enzyme cholinesterase.
Semi-automated operation permits continuous monitoring with rapid response.
Rugged construction and portability make the CAM-4 well-suited for field use.
PERFORMANCE SPECIFICATIONS
Printer Output; Peak voltage, electrochemical cell. Operator determines
correspondence to pesticide concentration.
Detection Limit; 10 mV shift
Linear Response Range: 10 mV - 200 mV; proportional to pesticide
concentration.
Reproduce Pi lity; + 2W
Over-range Response; 250 mV shift
Detection Cycle; 3 minutes
Substrate Flowrate; 1 ml/rain
Sample Flowrate; 200 ml/m1n
REAGENTS
Substrate; 2.5 x 10-* H butyrylthlocholine Iodide in 0.08 M TRIS buffer,
pH 7.4
Enzyme Pad; 0.4 • 0.8 units of horse serum cholinesterase
Calibrator; 0.2 ppm OOVP
ELECTRICAL REQUIREMENTS
110 V AC, 60 Hz or 12 V DC
PHYSICAL CHARACTERISTICS'
Dimensions; 12" x 11- j( 14"
Weight; 30 Ibs.
Cell Voltage Output; Provided for recorder
55
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unregulated) to the rest of the system, using 40V AC and 4V AC Inputs from the
Inverter; and (c) a timer and switching board, used to power and control the
pumps and time current generation and print-out. In addition, an inverter
unit, mounted on the right-hand front panel to minimize heating problems, pro-
vides 110V AC, 40V AC and 5V AC to the power supply board, using either 110V
AC or 12V DC for input. The inverter is required because the pumps and the
digital printer do not operate off standard +12V or +5V supplies; this com-
ponent could be eliminated if different motors were specified or if 12V DC
field operation was not required.
Pump Assembly
This assembly, mounted behind the left-hand panel of the case, consists of
three pumps plus associated tubing and wiring. The water pump draws in a
400 ml sample over the course of a two-minute cycle; the sample is pumped
through the immobilized enzyme pad. At the end of this period, the water pump
is turned off and the air and substrate pumps are turned on. Approximately
two liters of air is pumped through the cell for one minute to remove excess
liquid from the enzyme pad. Simultaneously, the substrate pump sends 1 ml of
substrate solution to the enzyme pad. During the final forty seconds of
substrate pumping, a 2 uA constant current is applied to the cell, and the
cell voltage is recorded.
All three pumps are constant speed devices; this is particularly critical
for the substrate pump, since a constant speed Is necessary to provide a
constant baseline voltage. All pumps are readily accessible for servicing or
replacement and are available from standard sources (13 - IS).
Cell Assembly
The cell assembly is the only item in the CAM-4 that is not available from
standard sources. It 1s currently manufactured for Midwest Research Institute
for In-house use (11). It consists of two perforated platinum electrode
holders held against the enzyme pad by springs. Two separate inlets are pro-
vided, one for substrate and one for water-samples or air. Waste 1s dis-
charged through a single outlet on the opposite side of the enzyme pad. The
electrodes are contained 1n Injection-molded holders made of Cyclolac plastic
and are fitted to the enzyme pad holder using 0-r1ng seals to provide a leak
tight unit. The two electrode leads are imbedded In the plastic electrode
holders and are connected to the constant current power supply.
Printer
The printer Is a DATEL Systems DPP7-D1, which provides digital output
(four digits plus decimal point) on thermal paper. According to the manufac-
turer, this model has been discontinued and replaced with a model operating on
AC voltage only (16). The circuitry provides for one digital output during
each three-minute cycle; this .output corresponds to the peak voltage of the
cell during the cycle. During continuous monitoring of water samples that do
not contain pesticide, the cell voltage will drift slowly higher, but the
56
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change 1s only about 1 mv (0.001 V as printed) per three-minute cycle. When
the inlet sample contains pesticide, the voltage will increase at a faster
rate. Monitoring may be continued for several cycles to improve the accuracy
of the results. Monitoring of high concentrations of pesticides will cause
the enzyme pad to deteriorate rapidly and will require frequent pad changes.
An increase of 10 mV or more per three-minute cycle should be interpreted as
indicating a significant level of pesticide. However, the CAM-4, unlike its
predecessors, does not provide a separate "alarm" indicator, and the operator
must make the interpretation of hazardous pesticide levels from the printed
data. The operator must also Interpret the data to determine when the enzyme
pad needs to be replaced.
COMPONENT AND SYSTEM COSTS
The parts list for the CAM-4, together with updated prices and vendors, is
provided in Appendix A. This list has been used to prepare Table 3, which
presents a summary of the costs organized according to the major subassemblies
of the CAM-4. The total cost of components for the manufacture of a single
unit is $1,440. Component costs for the manufacture of 25 or 100 units may be
estimated by assuming original equipment manufacturer discounts of 30% and 50%
respectively, which would reduce the costs per unit to SI,008 and S720.
TABLE 3. PARTS COST. CAM-4
PART NO. COMPONENTS COST ($)
63, 64, 75-80, 82 Case Assembly 267.90
PC Board Assembly
1.20 DVM Board 149.96
22-32 Power Supply Board 19.52
33-62 Timer and Triac Switch Board 39.32
70.74 Mounting Hardware 10.72
Pump Assembly
81 Water Pump 34.00
86 Air Pump B.75
83-85 Substrate Pump 158.00
89 Tubing and Sumps 4.15
87, 88, 90 Cell Assembly 131.00
65 Printer 575.00
66-69 AC/DC Adapter Assembly 42.14
TOTAL PARTS 1,440.46
57
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The burdened cost of components 1s typically 115* of the discounted cost
to provide for overhead. Labor in assembly is minimal due to the modular
design of the CAM-4. The bulk of the labor is required for populating the
printed circuit boards, final checkout, and quality control. We estimate
that, in quantity production, two hours of labor would be required per unit.
Labor costs for assembly of a single prototype unit are not particularly
meaningful; we have estimated three hours. The burdened cost of labor in
electronics manufacturing is taken as $30 per hour. Thus, the manufacturer's
cost for 1, 25 or 100 units is estimated as $1,746, $1,219 and $888 respec-
tively.
Selling prices may be estimated by multiplying the burdened manufacturer's
cost by 2.5; this accounts for the costs of advertising, distribution, sales,
and profit. On this basis, we estimate the selling price of the CAM-4 as
$4,365, $3,048 and $2,220 for quantities of 1, 25 and 100. The estimate for a
quantity of one 1s not particularly meaningful given that development costs
and start-up costs are Ignored.
Reagent Costs
r
The CAM-4 reagents specified consist of the enzyme pad, substrate solution
and a calibration solution. An estimate of enzyme manufacturing costs will be
discussed first. Cholinesterase, the major Initial cost. Is sold by Sigma
Chemical Company for $135 per gram In single-gram quantities (17). If enzyme
pads are prepared according to the procedures detailed In EPA-600/2-80-033
(1), this quantity Is sufficient to prepare 2800 pads, I.e. a cost of $0.048
per pad for enzyme. Based on the same procedures, the time estimated to pre-
pare and test a standard lot of 350 pads 1s three hours at a burdened rate of
$30. Thus the cost of labor, $0.26 per pad, is considerably greater than the
cost of enzyme. The cost of the remaining materials — foam pads, starch,
aluminum hydroxide and buffer — 1s negligible by comparison. Thus the over-
all burdened cost per pad Is about $0.31. However, the manufacturing process
could be streamlined considerably if forty sheets (3500 pads) were processed
at once rather than four sheets (350 pads) as specified. Such a procedure
should reduce the manufacturing cost to about $0.10 per pad. Mr. William
Jacobs of MRI has Indicated that the current cost for manufacture 1s $0.01 or
less, when MRI proprietary batch processing procedures are employed (11).
It should be noted that the shelf life of enzyme pads is excellent; five-
year old pads, used in refurbishing the CAM-4, had acceptable enzyme activity.
• The substrate solution consists of butyrylthiocholine Iodide (2.5 x 10-4 M)
in 0.08 M TRIS buffer (pH 7.4). At this pH, butyrylthiocholine Is unstable,
requiring that fresh solutions be prepared dally. The cost of materials Is
approximately $0.21 per 500 ml if materials are bought In small quantities; a
half-liter is sufficient to conduct 450 tests, or roughly continuous operation
for a 24-hour period.
It 1s typical for instrument manfuacturers to make substantial profits on
the sale and distribution of reagents. For example, the butyrylthiocholine
58
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Iodide could be separately packaged 1n preweighed form; the TRIS buffer could
be packaged the same way or sold in 500 ml polyethylene bottles. Typical
prices, based on the practices of other manufacturers, would be $1 per enzyme
pad, $5 per package of butyrylth1ocho11ne Iodide, and $10 per bottle of TRIS
buffer. The cost to the consumer, under $35 per day for continuous monitor-
Ing, Is less than the cost of a single test done by a commercial testing lab-
oratory ($40 to $50).
CRITIQUE OF THE CAM-4 DESIGN
The objective of the original CAM-4 design effort, to construct a substan-
tially cost-reduced CAM instrument without loss of pesticide sensitivity, has
been met successfully. The cost analysis presented in the previous section
attests to the success of the cost reduction, while the results of the CAM-1/
CAM-4 comparison, published in the CAM-4 report (1), show comparable instru-
ment performance.
Manufacturability, reliability, serviceability, and ease of use must also
be'considered to assess the potential of the CAM-4 as a commercial prototype.
Reasonable criteria for these factors"c*an be developed by comparing the CAM-4
to residual chlorine water monitors manufactured by EPCO and IBM Instruments.
Instruments used in this comparison are the EPCO Chlortect, Models 2000, 3500
and 4000, and the IBM Instruments EC/250 (2, 3, 8. 9).
The chlorine monitors are priced between $2,000 and $4,000 and offer fea-
tures suitable for bench-top operation in secondary applications as well as
continuous monitoring in environmental field applications. As in the CAM-4,
fluid handling 1s automated, and electrochemical detection Is used. The
Instruments are designed in modular fashion so that features suited to spe-
cific applications — 12V DC adaptability, ruggedized case construction and
pumping units, choice of data output technique, etc. — can be incorporated in
or added onto the basic core design. The total market for chlorine monitors
is in the range of 100 to 200 units per year.
A schematic published for the EPCO Chlortect (2), may be compared to the
CAM-4 schematic in Figure 1. Requirements for fluid handling are roughly
similar. The EPCO electrochemical cell is appreciably more complex than the
CAM-4 cell. The EPCO instrument uses a liquid crystal display, while the
CAM-4 produces data output on a thermographlc printer. These differences
aside, the Instruments share a fundamentally similar design approach.
In so far as manufacturabllity 1s concerned, the CAM-4 1s entirely com-
parable to the IBM and EPCO instruments. All three Instrument designs are
based on a modular design approach. Components are readily accessible for
routine servicing and replacement. For the same reason, they are all roughly
equally easy to manufacture. Similarly, the selling price estimated for the
CAM-4, approximately $3,000, is comparable to the EPCO and IBM chlorine moni-
tors.
However, in the context of a low-cost field monitor, the use of a digital
printer in the CAM-4 adds unnecessary cost without commensurate benefits.
59
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(The cost of the printer 1s about one-third of the cost of the total system.)
Use of a liquid crystal display, together with a low-cost microprocessor and
some random access memory (possibly built into the microprocessor chip), could
permit data storage and review. Reviewed data could be recorded manually.
More to the point, this change in the electronics and display would permit the
instrument to calculate automatically baseline slopes and pesticide concen-
trations. In addition, pad change and "alarm" condition alerts could be in-
corporated at little extra cost. These changes would contribute to the ease
of use (and marketability) of the CAM-4 and would greatly reduce the training
time and operator skill level.
Several reliability problems are inherent in the design of the fluid
handling system of the current CAM-4. In both of the CAM-4 units refurbished,
the water pumps were inoperative, although it was clear that neither unit had
been in service for anywhere near the nominal 1000-hour lifetime. In both
cases, the problem was traced to a perforated pump diaphragm, which was punc-
tured by the actuating spring.
Another problem, observed in field tests (1) and confirmed 1n our labora-
tory, occurs when the CAM-4 Is operated at an elevation below that of the
water sample being analyzed — for example, when operated below deck In a
boat, or when the water sample is placed on a shelf above the CAM-4 in the
laboratory. The small head of water pressure present under these conditions
Is sufficient to prevent the' air pump from flushing out the exit tube, leading
to Incorrect results In the measurement cycle. As discussed In the next sec-
tion, both problems could be cured by the use'Of standard peristaltic pumps.
REDESIGN OF THE CAM-4
The CAM-4 design critique tn the previous section suggests that component
costs, overall Instrument manufacturability, and serviceability meet commer-
cial standards. However, design changes are desirable to Improve ease of use,
marketability and reliability of fluid handling.
To Improve reliability, the CAM-4 water and substrate pumps should be
replaced by peristaltic pumps designed for field monitoring. The specifica-
tions of Masterflex peristaltic pumps are suitable (13). Use of a peristaltic
pump for sampling should eliminate the problem of limited diaphragm lifetime
discussed In the previous section. Use of silicone tubing with a Masterflex-
type pump will greatly Improve tubing lifetime, which In the current CAM-4
design is the limiting factor 1n the substrate pumping system. In addition,
use of a peristaltic pump In the sample line should eliminate the problem of
negative fluid pressure when the CAM-4 1s located below the level of the
inlet.
Replacement of the digital thermographlc printer by a liquid crystal
display would save about $550, greatly reducing the overall cost of compo-
nents. Additional savings may be achievable In the power supply. However, to
improve ease of use, several additional components would be required, specifi-
cally, a microprocessor, read only memory, clock and (if not provided on the
60
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microprocessor) a small random access memory. The total cost of these com-
ponents 1s under $20. Given that the original CAM-4 was designed in 1976, It
Is not surprising that microprocessor-based technology was not used. In any
instrument designed in the 1980's, however, mircoprocessors are essential for
"user friendly" instrumentation and to reduce overall cost while increasing
ease of use and marketability.
A microprocessor-based display could provide a variety of outputs includ-
ing direct voltage display and review as 1s provided in the current CAM-4
print-out; correction for baseline drift, which presently must be estimated by
the operator; direct calculation of pesticide concentrations; and light
emitting diode (LED) alerts for alarm conditions and pad replacement. Similar
alerts could also be provided for Internal diagnostics. Such changes in the
design, which are suggestive but hardly comprehensive, could be provided at a
net savings of approximately J550 compared to the current (1976) CAM-4 design.
The cost of such a redesign effort 1s not excessive. We estimate that an
experienced engineering team could complete the work required in three to four
man-months. However, given the relative novelty of the technology required
and the relative scarcity of personnel skilled in the fieTd, even relatively1
established Instrumentation manufacturers might find It necessary to sub-
contract much of the work, which could cause a delay in project completion.
Furthermore, there will be a temptation to redesign all of the CAM-4 electro-
nics around a microprocessor-based control system. This could reduce overall
parts costs even further but would Increase the time and cost required for the
redesign. Depending on the level of effort, an updated CAM-4 redesign could
be accomplished for $25,000 to $50,000.
61
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SECTION 6
EVALUATION: EMERGENCY COLLECTION SYSTEM
INTRODUCTION
The emergency collection system designed by MSA was evaluated based on
information contained in EPA Report 600/2-77-162. August 1977 (4). Additional
information, including drawings and design updates received from MSA, was
included in the analysis reported. The vendor information used in the value
engineering analysis is cited 1n the Reference section of this report.
Current''costs, availability and catalogue Information on the components
specified were obtained for the analysis of the pumping unit. Alternate
sources of components were identified. Labor costs were estimated and the
total costs of building the unit 1n various lot quantities were determined.
Possible design-changes to reduce costs were explored, and a minimum cost
system was specified. The Initial cost to a potential manufacturer was esti-
mated.
Vendor quotes obtained through MSA for the manufacture of the disposable
collection bag, Including two different design approaches, were Incorporated
into the analysis (5). Ralph H. Hiltz of MSA Research Corporation has com-
mented on the vendor quotations in his letter of August 23, 1983 Included in
Appendix B. He has suggested alternate, lower cost estimates for collection
bags manufactured to commercial practice. His cost estimates Include addi-
tional design modifications to reduce manufacturing costs. The vendor quota-
tions and the Hiltz estimates are used 1n the cost analyses presented. Even
when the lowest cost estimate 1s used 1n the value engineering analysis, the
manufacturing cost of the disposable collection bag dominates the cost of the
emergency collection system.
SYSTEM DESCRIPTION
The emergency collection system for spilled hazardous materials was
designed as a complete skid-mounted system that could be put on the bed of a
p1ck-up truck and quickly transported to a spill site. Figure 3 shows the
emergency collection system In operation.
The system consists of a gasoline engine-driven pump that removes spilled
materials through a hose and delivers 1t to a 7000-gallon holding bag
(Figure 4). The suction hoses are coiled on reels. Piping and valving are
provided to minimize the number of field connections.
62
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CO
FIGURE 3. EMERGENCY COLLECTION SYSTEM
-------
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raid ti
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ittp 1 . Mia. k»« t« eallipn i*d tuck U tha ildu it ifce«» b*1e« o« ttch ut«
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n \
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iaad frp« foot i»d
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itt9 «
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(«1 U.)
«* Faldtd
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Fold «p it rtqvlrtd ta « IIIill.lillI CB (4ai40itl !•.)
FIGURE 4. SEGt'£NTED COLLECTION BAG
64
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The objective of providing a system that can be deployed quickly and
easily on sloping ground has significantly influenced the final design. The
two fifty-foot lengths of suction hose are stored on reels so that they can be
easily unrolled. One suction hose is permanently connected to the pump, and
the other has hose connections with quick disconnect fittings. Valving is
provided so that spilled materials can be removed simultaneously from two
collection points. A second storage bag can also be connected in tandem with
the first without stopping the pump. Automatic valves in the quick disconnect
couplings prevent leakage when a bag 1s"connected or removed. In addition,
the bag is packaged so that 1t can be deployed rapidly and is specifically
designed to be stable on sloping ground.
Another design objective is that all components be of a high-quality
material to withstand the effects of a wide and unknown range of spilled
materials. All metal parts that are exposed to the flowage are constructed of
304 or 316 stainless steel. Hose linings are either teflon or cross-linked
polyethelene and are graded for chemical/acid transfer. The bag is made of a
material that will not be seriously weakened after exposure to many chemicals
for 24 hours.
In short, little expense has been spared in the design of the system. It
1s meant to be a top-quality system that will have low maintenance and rela-
tively long life. It can be deployed rapidly and operated easily by semi-
trained personnel.
COMPONENT DESCRIPTION
The major components of the emergency collection system, as specified 1n
the EPA report (4), are described below. A more detailed description of each
component can be obtained by contacting the suppliers referenced in this
report and by obtaining the MSA drawings cited in the EPA report (4).
Pump: ITT Marlow Pump
Self-Priming Centrifugal - Model 1 1/2 HE-19 (18, 19)
This 1s a stainless steel pump, close coupled to a 3 HP Briggs ft Stratton
gasoline engine. It 1s equipped with Internally cooled, mechanical face
seals. It Is self-priming, once a priming chamber 1s manually filled, with a
maximum lift of 25 feet. It will pump 50 gallons/minute at about 55 feet of
head.
Suction Hose; Gates Rubber Co.
Acid/Chemical Hose - 45 HU (20. 21)
Two 50-foot lengths of this two-inch ID hose are supplied. The end fit-
tings on each hose are stainless steel male pipe threads. One hose is wound
up on a "live storage" reel that 1s permanently connected to the pump suction
through one leg of a'three-way valve. The other hose 1s stored on a plain
reel and can be attached to the end of the first to reach spills farther away.
65
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Alternatively, it can be attached to the other leg of the three-way valve for
dual suction.
Alternate Supplier: MGT, Inc., Canada, "Coronado" product line (22).
Suction Selector Valve: Quality Control
Three-way FuTport Rotor Valve 123. 24)
This two-inch stainless steel valve is a'Wee-port design that allows the
suction of the pump to be connected to either or both of the suction hoses.
Suction Line Fittings; Ever-TUe Coupling Co.
Cam Type. Quick Couplings (25. 26)
Two male parts (Part A adapters) and two female parts (Part 0 couplers)
are provided. They are of stainless steel and have two-inch female pipe
threads on one end. They allow the two lengths of suction hose to be con-
nected together or used in tandem, a coarse strainer to be attached, and con-
nection to be made through a tank car adapter to the tank car opening. These
connections are made by screwing the coupler or adapter to the pipe nipple on
the hose. The connection is completed by pushing the two pieces of the quick
coupling together and locking it In place by pulling down the handles.
Alternate Supplier: Parker-Andrews (27, 28)
Coarse Suction Strainer (29)
This screen can be made of a relatively open mesh or perforated metal. It
Is attached at the end of the suction hose as it enters the spill and prevents
gravel from entering the hose.
Discharge Hose: Industrial Products Group
Titeflex R276 Conductive Hose (307111
Ten feet of this one and one-half inch diameter hose is provided. It has
a teflon Inner liner which Is impregnated with carbon to make it electrically
conductive. The hose is reinforced with fiberglass and stainless steel wire
braid. It 1s connected to the storage bag.
Discharge Fittings; Hansen Manufacturing Company
LL20-H51 and LL20-K51 132. 33)
These are two-inch quick connect fittings with integral shut-off valves 1n
both the male and female parts. These valves act automatically so that when
the connection is broken, there Is no leakage from either end. One female
part (the socket) Is attached to the discharge hose. Two male parts (the
plugs) are manifolded to the pump discharge. This allows a second bag to be
connected while the first full one is removed without stopping the pump.
Alternate Supplier: Dover Corp. - Kamvalok (34, 28)
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Hose Reels; G.B. Hannay & Son
One each of C-8226-33-34 and 8226-33-34 (35, 36)
These reels are used to store the suction hose. One has stainless steel
internals and a small joint. This allows the hose to be permanently connected
to the pump suction before it 1s unrolled. The other reel does not have this
feature. Both reels have a hard crane for hose retrieval.
Alternate Supplier: Philadelphia Valve Co.
Piping Assembly (29)
The piping assembly permanently connects the pump to the two discharge and
suction connections. It Incorporates a basket-type strainer iMcMaster-Carr
9874K15) In the suction line to prevent particles from entering the pump. We
assumed that it was made up from:
2-fnch stainless fittings 1 1/2 stainless fittings
1 90- bend 2
45- bend 2
lateral 1
2 close nipple 6
3" nipple 4
12" nipple 1
1 24" nipple 1
Storage Bag; Helios Industries (5)
A 7000-gallon fabric bag 1s used to "hold the spill. It 1s manufactured
from urethane-coated two-ply nylon. It consists of three bags connected by a
header bag, MSA Part Number C-3077 (4). This design Is stable on sloping
ground. It serves only as a temporary holding tank for the hazardous
material. The contents must be pumped out into another tank to be transported
for final disposal. The bag 1s Intended to be thrown away after use.
Bag Holder (37)
The fabric storage bag 1s itself stored within an aluminum housing. This
housing Is fabricated from corrugated sheet. It has a quick opening dam to
provide access to the bag.
Skid (37)
The skid 1s constructed of aluminum. The pump, hose reels, bag holder and
piping assembly are attached to 1t. Lifting lugs are provided so that the
entire assembly can be lifted on/off the truck.
COMPONENT AND SYSTEM COSTS
• The system as specified by MSA was broken down into Us individual com-
ponents. Manufacturers or distributors of the components were contacted to
67
-------
get current prices. Vendor communications are cited in the Reference section.
Prices were requested on quantities sufficient to build one, fifty and one
hundred collection systems at a time. For the pumping unit that would be
assembled by the system manufacturer, labor was estimated based on typical
shop practices. Labor costs were calculated based on a fully burdened rate of
$30 per hour.
The results of this cost breakdown study are shown in Table 4. "For
building the pumping units, the total cost to the manufacturer for labor and
materials is: $6,925 for one; $5,622 for 50; and $5,381 for 100. As shown in
Table 4, the totdl cost to a manufacturer is $20,381 when the cost of the
disposable collection bag is added. If we mark-up the cost of materials by
15X to reflect overhead and wish to sell the equipment for a typical mark-up
of two and one-half times its cost, the unit selling price for 100 units
becomes $58,078.
TABLE 4. COST OF COMPONENTS
COMPONENT
COST ($) PER SYSTEM WHEN BUILT
IN QUANTITES OF:
1 50 100
VENDOR REF.
Engine Driven Pump
Hose Reel With S.S.
Hose Reel For Storage Only
Suction Hoses (2)
Discharge Hose (with ends)
Basket Suction Strainer
Suction Selector Valve
Discharge Fittings- Sockets (2)
Discharge Fittings - Plugs (1)
Gas/Priming Can (1 Gal)
Suction Line Fittings (2 pair)
Coarse Strainer
NPT Hose Ends (4)
Miscellaneous Hardware
Material for Piping Assembly
Skid Material
Burdened Labor ($30/hour)
Bag Holder Material
Burdened Labor ($3Q/hour)
Bag*
SYSTEM COST
952
770
280
1.320
420
428
475
718
280
18
167
5
88
10
207
178
255
234
120
15.000
21.925
857
732
266
950
420
364
356
647
252
14
142
4
79
10
187
71
120
91
60
15.000
20.622
814
693
252
865
360
364
356
647
252
14
142
4
79
10
187
71
120
91
60
15,000
20,381
18,
35.
35,
20,
30,
29
23.
32.
32.
29
25,
29
29
29
29
37
37
5
19
36
36
21
31
24
33
33
26
* An alternate estimate of $7.000 has been suggested by MSA Research
Corporation for a modified
bag design
(10). See
Appendix B.
68
-------
It should be noted that the value of the labor added by the system
assembler is small. The major thing that he 1s providing is the design for an
Integrated, prepackaged system. The end user could put together a similar
system, which would not be as nicely packaged, for almost half the cost of the
specified system.
POSSIBLE COST REDUCTIONS
There are a number of areas where design or material changes could be made
to reduce the cost of the system. In many instances, these changes have a
negative impact on the life, ease of use, and possibly the safety of the
system. It is beyond the scope of this project to study the implications of
every possible design change. However, in discussing the options, we have
tried to point out the questions that must be answered before the changes are
made.
Table 5 summarizes design modifications that will result in reductions in
cost from the MSA-specified design. Table 5 also presents the potential cost
savings.when one, fifty and one hundred modified units are built at a time.
Vendor 'references for.component specifications and costs are also provided.
Details of the potential modifications are described below.
Hose
Use of a Gates 45 HW one and one-half inch diameter hose (20, 21) Instead
of a Titeflex metal braid hose (30, 31) would reduce the cost by $320.
However, build-up of static electricity could become a problem. Use of a
rubber hose (Gates 39 HW) for both suction and discharge would save S1026
(20, 21). Use of a spiral reinforced PVC hose (Tlgerflex General Purpose or
Pacific Echo SpiralUe 120) for suction and discharge would increase the
savings to $1515 (22, 38, 39). However, with rubber or PVC, static build-up
could be a hazard, and rapid degradation could occur with some spilled
materials.
By carrying the pump to the spill, a short length of PVC spiral reinforced
suction hose could be used together with approximately 100 feet of flat PVC
hose (Kuriyama Flat PVC or Pacific Echo Splralite 210) for discharge
(22, 38, 39). This would result in a savings of $1558 and would eliminate
some of the connectors. The weight of the pump, 65 pounds, makes this a
feasible option. In these cases, the hose would be treated virtually as a
disposable item, although It must be capable of retaining Its strength long
enough to pick up a single spill. Howevecf-*noving the pump close to the spill
could present an explosion hazard.
Using one size smaller diameter hoses would reduce the price of hose by
about 10X and is thus probably not worthwhile.
69
-------
TABLE 5. POSSIBLE COST REDUCTIONS
SAVINGS PER UNIT WHEN
1 50
COMPONENT UNITS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
-
*
Hose
a. Replace Titeflex with
1 1/2 Gates
b. Use rubber water hose
for suction and discharge
c. Use spiral PVC
d. Use flat PVC for
discharge
Hose Reels
a. Eliminate both reels
b. Use two dry storage type
Pump
a. Use a cast Iron pump
b. U£e a plastic pump
Piping Assembly
a. Use galvanized steel
b. Use PVC
Suction Valve
a. Two S.S. Butterfly
b. Two PVC ball
c. Single suction port
Suction quick connects
a. Steel
b. Plastic
Discharge Quick Connects
a. Single Hansen coupling
b. Single connection with
PVC valves
c. Two connectors with steel
Hansen couplings
d. Two connectors with brass
Hansen couplings
Suction Strainer of Plastic
or Steel
Fabric Cover for Storage Bag
Storage Bag*
a. Pillow bag (7000 gal.)
b. Pillow bag (5000 gal.)
320
1.026
1.515
1,558
1,050
490
705
677
165
181
278
362
475
112
140
389
909
526
637
358
304
5,354
6,962
R.H. H1ltz of MSA Research Corporation
of $8,000 to $10,000 may be realized If
340
835
1,201
1,243
9913
465
634
623
149
164
206
270
356
121
131
353
830
473
574
303
--*• 116
5,354
6.962
BUILDING:
100
290
690
1,056
1.098
945
441
603
588
149
164
206
270
356
121
131
353
830
473
574
303
116
5.354
6,962
has suggested that a
additional
VENDOR REFS.
20,
20,
22,
22,
35,
35.
40,
41,
29
29
46.
48.
23,
28
28
32.
32.
32.
32.
29
21
21
38,
38,
36
36
19
42
47
49
24
33
33
33
33
39
39
estimate
5
5
cost reduction
design modifications
are Implemented (10). Appendix B.
70
-------
Hose Reels
. The hose reels can be eliminated at a savings of $1050. If dry storage
reels (Hannay C-8226-33-34} are used in place of the specified reels, the
savings would be S490 (35, 36). In either case, ft would take longer to
deploy the system at the spill site.
Pump Material
A pump made of cast Iron (ITT Marlow 2AM32) (40, 19) could be substituted
for the stainless unit at a savings of $705. This substitution would require
periodic rebuilding of the pump to replace corroded components at a cost of
about $180. A plastic pump (Marland 864326-974-853) could also be used at a
savings of $677 (41. 42). However, plastic is susceptible to chemical attack,
as well as to rapid wear from abrasive materials in the pumpage. A study
would be required to determine relative material lifetimes under field con-
ditions. Gorman-Rupp pumps promise similar cost benefit trade-offs (46, 47).
Piping Assembly
The assembly could be constructed from galvanized steel (saving $165) or
PVC (saving $181) (29). As with the hose and pump material, the lifetime of
the assembly might be reduced.
Suction Valve
This valve can be replaced by two stainless ball valves, Milwaukee
BB-SS300, (46, 47) saving $278, by two Hayward PVC ball valves (48, 49),
saving $362, or eliminated entirely (saving $475). Use of two ball valves 1s
equivalent to the single three-way valve 1n versatility. Eliminating the
valve completely means that spilled material cannot be removed from two areas
simultaneously.
Suction Quick Connects
A savings of $112 could be achieved by using steel couplings. Use of
plastic would save $140 (28). Material lifetime might be shortened.
Discharge Quick Connects
If only one connection were provided at the pump discharge. It would be
necessary to shut down the pump while changing bags. The savings would be
$389. If this single connection used PVC valves at the bag and pump end for
shut off, the savings would be $909. There would be no leakage as long as the
operator closed the valves before disconnecting the line.
If two connectors are provided, as in the current design, the material
used for the Hansen couplers (32, 33) could be changed to brass (saving $637)
or steel ($526). Material lifetime might be reduced.
71
-------
Suction Strainer
The basket-type strainer on the pump inlet could be made of plastic or
steel instead of stainless (29). For either substitution, the savings would
be $358.
Storage Bag Holder
This aluminum box could be eliminated. The storage bag could instead be
encased in a quick-opening valve cover at estimated savings of $304.
Storage Bag
Any system manufacturer would have to look closely at finding ways to
reduce the cost of the storage bag. In our opinion, cost reduction by a fac-
tor of 5 to 10 1s desirable to Increase the commercial viability of the
system. It 1s by far the most expensive item. In addition, the bag is
Intended to be thrown away after use.
A less'expensive pillow-type bag has been designed more recently by MSA
under an Air Force Contract. The general design for this bag is shown In
Figure 5. The price quote from Helios Industries for the pillow bag design Is
$9,646 (quantity 1 to 100) for a 7000-gallon capacity bag and $8,038 (quantity
1 to 100) for a 5000-gallon capacity bag (5). The cost savings with respect
to the original MSA design are $6,962 and $5,354, respectively. It should be
noted, however, that a pillow bag, when filled, will only be stable on level
ground. On sloping or uneven ground, a pillow bag would require a stabilizing
support structure. MSA Research Corporation has suggested additional design
modifications In the Interest of cost reduction. The modifications and their
estimated impact on cost are discussed in Appendix B. A modified segmented
bag 1s expected to cost $7,000, a modified pillow bag, $5,000.
Additional cost reductions may be realized if automation can be Introduced
in the bag manufacturing process. The cost of special jigs and fixtures to
support automation must be recoverable through quantity orders. Reducing the
cost per bag to a commercially viable level may be possible if markets can be
Identified that will support sufficiently high-quantity orders.
REDUCED COST SYSTEM
Based on the preceding work, we can define a new system whose major design
premise Is to keep costs down. In this system, the pump would still be
mounted on the skid but would be constructed of cast Iron. Spiral reinforced
PVC hose would be used. The hose would be coiled and placed on the skid
(I.e., no hose reels) when not in use. Connections would be made with PVC
quick connects. Two suction connections with PVC valves would be provided. A
PVC suction strainer within PVC skid piping would be used. A single discharge
connection with PVC ball valves would be provided, and the system would use a
pillow bag stored 1n a fabric cover.
72
-------
t*>
1. Dag
2. Ground Cloth
3. Carrying Case
4. Inlet
5. Outlet
6. Vent Pipe
7. Relief Valve
8. Pipe Cap
FIGURE 5. PILLOW COLLECTION BAG DESIGN
MODIFIED FOR THE U.S. AIR FORCE
0
-------
The revised system costs, which Incorporate most of the cost savings pre-
sented in Table 5, are shown In Table 6. This system would not be as easy to
deploy or operate. Furthermore, components might fall more rapidly than 1n
the system specified by MSA. The pillow bag would require an additional sup-
port structure if used on non-level ground. Typical selling prices are noted
1n Table 7.
TABLE 6. COSTS COMPARED
QUANTITY
1 50
System I, MSA
Pumping Unit
Storage Bag
System 1 1 a, (Cost Reduced)
Pumping Unit
Bag (Pillow Design - 7000 gallon)
System lib, (Cost Reduced)
Pumping Unit
Bag (Pillow Design - 5000 gallon)
21,925
5,925
15,000*
11,258
1,612
9,646**
9,650
1,612
8,038
20,622
5,622
15,000
10,803
1,157
9,646
9,195
1,157
8,038
100
20,381
5,381
15,000
10,691
1,045
9,646
9,083
1,045
8,038
* Alternate estimates of $7,000 and ** $5,000 were obtained from MSA
Research Corporation (see Appendix B).
TABLE 7. SELLING PRICE*
System I, MSA 58,078
Pumping Unit 14,953
Replacement Storage Bag (7000 gal.) 43,125**
System II, Cost Reduced 25,596
Pumping Unit 2,487
Replacement Storage Bag (5000 gal.) 23,109
* Selling Price - Kcost of material)!.15 + burdened Iaborj2.5
** An alternate selling price of $19,125 Is obtained when using the cost
estimate of S7,000/bag provided by MSA Research Corporation (Appendix B),
74
-------
INITIAL MANUFACTURING COSTS
Any potential manufacturer will face start-up costs before production can
begin. These costs will be associated with design review, preparation of
drawings and preparation of manufacturing facilities. The additional costs
associated with advertising and marketing are not considered.
The goal of the design review will be to select each Item In. the system.
Questions such as those raised In the cost reduction discussion will have to
be answered. Firm quotations must be obtained from all vendors. This stage
will require the services of an engineer and a purchasing agent. It will
result in component specifications and system sketches for drafting. It 1s
estimated that 80 hours of engineering time and 40 hours of purchasing time
will be required for the skid-mounted pump unit. The disposable bag will
require an additional design effort focussed on fine-tuning the bag design.
It is estimated that 100 hours of engineering effort will be sufficient to
develop a design with acceptable trade-offs among manufacturability, cost, and
field performance characteristics. This redesign effort should be conducted
in close consultation with potential bag manufacturers and will require an
estimated 20 hours of support from the purchasing agent.
The next step would be for a draftsperson to produce shop drawings from
the engineer's sketches. This would be straight forward and would require 40
hours plus 2 hours for engineering services.
The manufacturing area would also have to be set up. The amount of set-up
required 1s small even when quantities of 100 units are envisioned. This 1s
because the amount of labor Involved per system Is so small. Some time will
be spent on producing templates, jigs and fixtures. Between this and the
establishment of a quality control and testing procedure, we estimate 25 hours
of work by a shop foreman.
75
-------
REFERENCES
1. Goodson, L.H. and B.R., Cage. CAM-4, A Portable Warning Device for
Organophosphate Hazardous Material Spills. EPA-600/2-80-033, U.S.
Environmental Protection Agency, Cincinnati, Ohio, January 1980. 59 pp.
2. EPCO, Danbury, Connecticut. Chlorine Monitoring Systems Catalog, 2.5M
1080.
3. IBM Instruments, Inc., Danbury, Connecticut. Electrochemical Instruments
Accessories Supplies, pp. 12-13.
4. H1ltz, R.H. and F. Roehllch, Jr.. Emergency Collection System for Spilled
Hazardous Materials. EPA-600/2-77-162, U.S. .Environmental Protection
Agency, Cincinnati, Ohio, August 1977. 95_jpp.-"
5. Helios Industries, Hayward, California. Quotation from Eric Erlcson,
Product Manager, July 25, 1983.
6. Goodson, L.H. and VI.B. Jacobs. Evaluation of 'CAM-1', A Warning Device
for Organophosphate Hazardous Material Spills. EPA-600/2-77-219, U.S.
Environmental Protection Agency, Cincinnati, Ohio, November 1977. 54 pp.
7. Midwest Research Institute, CAM-3 Manual.
8. EPCO, Danbury, Connecticut. Price lists and quotation from Sales
Representative, July 1983.-
9. IBM Instruments, Inc., Danbury Connecticut. Price lists and quotation
from Sales Representative, July 1983.
10. MSA Research Corporation, Evans City, Pennsylvania. Personal com-
munications with Ralph H. Hlltz, Staff Engineer, July and August 1983.
11. Midwest Research Institute, Kansas City, Missouri. Personal com-
munications with William B. Jacobs, Staff Scientist, June 1983.
12. Goodson, L. H. and W.B. Jacobs. Rapid Detection System for
Organophosphates and Carbamate Insecticides 1n Water. EPA-R2-72-010, U.S.
Environmental Protection Agency, Cincinnati, Ohio, August 1972.
13. Cole-Partner Instrument Company, Chicago, Illinois. Catalog 1983, pp,
428-429, 441.
76
-------
14. Greylor Company, Elgin, Illinois. Model PQ Plastic Gear Pump.
15. Scientific Industries, Inc., Bohemia, New York. Quotation from Gall
Lawrence, Sales Representative, June 1983.
16. Datel-Irttersll, Mansfield, Massachusetts. Quotation from Sales
Representative, June 1983.
17. Sigma Chemical Company, St. Louis, Missouri. Biochemical and Organic
Compounds for Research and Diagnostic Clinical Reagents, Product Number
C 7512, February 1983.
18. ITT Marlow,, Midland Park, New Jersey. Catalogue Section 380, March 1983,
pp. 17-20, 23, 24.
19. ITT Marlow, Boston, Massachusetts (Distributor). Quotation from William
Bell, Sales Representative, July 1983.
0. The Gates Rubber Company, Denver, Colorado. Catalogue No. 39993, June
1981, pp. 27, 61.
21. The Gates Rubber Company (New Jersey Distributor). Quotation from Pat
Engle, Sales Representative, July 1983.
22. Richardson Corp., Providence, Rhode Island (Distributor for MGT, Inc.,
Canada, and Pacific Echo, Inc.). Quotation from William Mitchell, Sales
Representative, July 1983.
23. Quality Controls, Inc., Tilton, New Hampshire. Catalog No. 102, pp. 2-5.
24. Quality Controls, Inc., Tilton, New Hampshire. Quotation from J. King,
Sales Representative, July 1983.
25. Ever-Tlte Coupling Co., Inc., New York, New York. Catalog No. 1080100M,
The Original Cam-Locking Quick Couplings, 1979, pp. 4.
26. Richardson Corporation. Providence, Rhode*Island (Distributor for
Ever-Tite Coupling Co.). Quotation from William Mitchell, Sales
Representative, July 1983.
27. Parker-Andrews. Inc.. Dayton. New Jersey. Catalog No. 668, Cam & Groove
Couplings for Hose and Pipe.
28. H.H. Watson, Inc., East Providence, Rhode Island (Distributor for
Parker-Andrews, Dover Corporation, and Dynaflow Couplings). Quotation
from Sales Representative, July 1983.
29. McMaster Carr Supplies, Chicago, Illinois. Catalogue No. 85. 1981.
30. Industrial Products Group, Springfield, Massachusetts. Catalog 126-0283,
Part No. R272/R276-24, p. 19.
77
-------
31. Accurate Hydraulics, Inc., Hopklnton. Massachusetts (Distributor for
Industrial Products Group). Quotation from Jesse Eschenheimer, Sales
Representative, July 1983.
32. The Hansen Manufacturing Company, Cleveland, Ohio. A Condensed Guide to
Fluid Line Quick Connective Couplings, Section 70-2, pp. 5-8.
33. Pearse-Pearson Co., Inc., MilUs, Massachusetts. Quotation from Lionel W.
Stewart, Jr., Sales Representative, July 1983.
34. Dover Corporation/OPW Division, Cincinnati, Ohio. Catalog KVL, 1975.
35. Clifford B. Hannay & Son, Inic., Uesterlo, New York. Catalog H-7612-ID,
Hose Reels, pp. 16, Price List 1983.
36. Clifford B. Hannay & Son, Inc., Westerlo, New York. Quotation from Roger
Hannay, July 1983.
37. Edgcomb Steel of New England, Nashua, New Hampshire. Quotation from Sales
Representative, July 1983.
38. H.H. Watson, Inc., East Providence, Rhode Island (Distributor for KuHyama
Hose Company, Japan). Quotation from Sales Representative, July 1983.
39. Pacific Echo, Inc., Torrance, California. Hose Catalogue.
40. ITT Marlow, Midland Park, New Jersey. Pump Catalogue, 1980, pp. 1, 2.
41. Marland Pumps, Leola, Pennsylvania. Bulletin No. Code M979-1-CMR, Model
No. 864326-974-853, p. 3.03.
42. Blake Equipment Company, Inc., Cranston, Rhode Island (Distributor for
Marland Pumps). Quotation from Kevin La Riviera, Sales Representative,
July 1983.
43. The Gorman-Rupp Company, Mansfield, Ohio. Specification Data, Section 55,
October 8, 1982. pp. 100.
44. The Gorman-Rupp Company, Mansfield, Ohio, Specification Data, Section 40,
March 20. 1980, pp. 92. .^-+
45. Haves Pump & Machinery Co., Inc., West Concord, Massachusetts.(Gorman-Rupp
distributor). Quotation Nos. 3/1387/CC and 3/1387/CC-Rev. A, from Phil
Pruchansky, Sales Engineer. July 19 and 29, 1983.
46. Milwaukee Valve Company, Inc., Madison, Wisconsin. Form S100, 6-80.
47. The Serpa Corporation (Manufacturing Representative for Milwaukee Valve).
Quotation from Gary Serpa, July 1983.
78
-------
48. Hayward Manufacturing Company, Inc., Elizabeth, New Jersey. Bulletin
BV-105, September 1977, p. 6.
49. Allen i Reed Co., Providence, Rhode Island (Distributor for Hayward
Manufacturing Company). Quotation from Sales Representative, July 1983.
50. P.M. Associates, North Billerica, Massachusetts. Quotation from Phil
Miller, Sales Representative, June 1983.
51. Analog Devices, Norwood, Massachusetts. Quotation from Marcta Richards,
Sales Representative, June 1983.
52. Schweber, Bedford, Massachusetts. Quotation from Virginia Bruce, Sales
Representative, June 1983.
53. Arrow, Uoburn, Massachusetts. Quotation from Sales Representative, June
1983.
54. Impact Sales, Canton, Massachusetts. Quotation from Donald Terras 1, Sales
Representative, June 1983.
55. Semiconductor Specialists of America, Inc.*, Rutland, Vermont. Quotation
from Virginia Kelley, Sales Representative, June 1983.
56. Greenshaw, Newton, Massachusets. Quotation from Sales Representative,
June 1983.
57. Gerber Electronics, Norwood, Massachusetts. Components Catalog, 1983-84.
58. Harvey Electronics, Lexington, Massachusetts. Quotation from Sales
Representative, June 1983.
59. Sager, Hlngham, Massachusetts. Quotation from John Mahoney, Sales
Representative, June 1983.
60. Sager Electrical Supply Co., Hlngham, Massachusetts. 95th Anniversary
Catalog, 1981.
61. Skydyne, Port Jervls, New York. Quotation from MUce Barnansky. Sales
Representative, June 1983.
62. M C Speciality Co., Inc., Burlington, Massachusetts. Quotation from Manny
Calado, Chief Machinist, June 1983.
63. Rotron Inc./EG&G, Uakefleld. Massachusetts. Quotation from Sales
Representative, June 1983.
64. Camblon, Cambridge, Massachusetts. Quotation from Sales Representative,
June 1983.
79
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65. Cronln Electronics, Cambridge, Massachusetts. Quotation from Sales
Representative, June 1983.
66. Cole-Parmer Instrument Company, Chicago, Illinois. Quotation from Julia
Sturgeon, Sales Representative, June 1983.
67. VWR Scientific, Inc., Boston, Massachusetts. Scientific Apparatus Catalog
82/83, 1982.
80
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APPENDIX A
*—+
CAM-4 PARTS LIST
Parts
(KM BOASD (FICUU Se)
Printed Circuit Board
ADC-UOO
IC1
IC2
IC3
Tl
T2
T3
T4
Zl
01. 02
Cl. C2
C3
ai. R3
R2
R3
R4
R6
PI
P2
Deacrlptiea
Analog to Dlxlral Converter
LMK1CK Operational Aeellfler
7400 Quad Name Cat*
MC&46P
2N3904 NPN
2N3903 PHP
2N356J HPN
HFF102 m
ZB82A Zener
1N914 Diode*
22 uf/25 T Tantalm cape.
0.02 uf Kylar cap.
3.3 Efl 1/4 v ELeslacor
1.3 U) 1/4 v Resistor
1.0 KB 74 v Resistor
2.7 HO ,/4 w Resistor
470 0 1/4 v Resistor
30 Xfl Trlopoe 3006P-1-503
1 tO Trlaoot 3006P-1-10J
Manufacturer or Supplier
Teletren
Analos Device*
National Semiconductor
National Semiconductor
Motorola
Semiconductor Specialise*
Semiconductor Specialists
Semiconductor Specialists
Semiconductor Specialists
Semiconductor Specialists
Semiconductor Specialist*
Newark
Newark
Newark
Newark
Newark
Newark
Newark
Bourne Newark
Bourne Newark
• Resistors sre 1/4 v unless otherwise Identified.
POWER SUPPLY BOAID (FIGURE Sb)
Printed Circuit Board
BR1
BBL2. BU
Regulator 1
Regulator 2
IC1
Cl. C2
C3
Ci
Rl
R2
Bridge Rectifier U110
Bridge Rectifier KBPCBOOJ. DPC1003
7803
4195
LM553CM
220 vf/33 v Electrolytic
3,000 uf/10 v electrolytic
0.1 uf electrolytic
: .3 o. 1/2 v
220 Q 1/4 v
TXKE& AMD TRIAC SWITCH BOAID (nCDU T)
1 'rioted Circuit Board
Cl
IC2. 1C3. 1C4
IC3
ICIi
1C'
ica
IC9. IC10
ICll
.11
T2. 13. 14. TS
T6
T7. TB
03
Timer U1S55CN
11L Decade Counter 7490
Decade Decoder 7442
Triple 3 Input Hand 7410
Dual 4 input Hand 7420
8 input Hand 7430
Optical Isolator* 7N2B
DTL Gate* 660P
2N3903
2N336S
2N3906
RCA Trlac Type 40326
IBJ.7Q Rectifier
Teletron
Semiconductor Specialist*
Semiconductor Specialists
Semiconductor Specialist*
Semiconductor Specialists
National Service
Teletron
National Semiconductor
National Semiconductor
National Semiconductor
National Semiconductor
National Semiconductor
National Semiconductor
Ho to ro la
Motorola
Semiconductor Specialist*
Semiconductor Specialist*
Semiconductor Specialist*
Semiconductor Specialist*
PART #
2
5
8
9
f
19
24
11
38
r
i
81
-------
Pares
TIMER AND TRIAC SWITCH BOARD
Zl
PI
P2
Cl
C2, C3. C6
C4
C5
Rl. R2. R3. W
R5
R6
R7. R8. R9. RIO
Rll. RI2, R13, Rl»
R15, R16
R17. RIB
Dejcriptloo
(FIGURE 7) Contd.
Zeoer (IS v) ZB13A
1 >£ Triipar Sp*eeral Tvpe 43P105
iO '1C Irinpot Spectral Type <.J?50A
1 u£ Mvlar
0.005 uf
A uf/230 v Ucctrolvcic _,
0.022 uf Eltetrolytic
1.2 1C Electrolytic
10 R Electrolytic
1.500 n Electrolytic
1.3 K Electrolytic
180 Q Electrolytic
42 K Electrolytic
8.2 K Electrolytic
3 Kfl 6 w Elaetrolrtie
Hanufacturer or Supplier
Seaiconductor Soecialists
Seuirk
Newark
Newark
Newark
Newark
Newark
Newark
Newark
Newark
Newark
Newark
raVERIER AMD OTHER PARIS (TlGOtSS 2. 3. 6. 8)
Case
ReRulator (S v)
PC Sockets
Card Cuid« (6 r«q.)
Binding Pom
SW1
Sub*tr«t« Pump
Electrochemical Cell Holder
Electrochemical Cell Injec-
tion Molded with PlaCluuB
Aaoda and Cathode
Model 92300
OPP-7
Model 12-113
UP6377
40 v CT Type 18A1487
LH309
22S-22221-4 OlTlTTl
T-309-48
T-101-300
S-200
XTS-802-36
Typ« 29-1
Tvne 7693U 4PDT
KTA106D
Delrln Plaetic No. 7012
Sorite Tubeucla/faa
Rotor
Tubing Support
Outboard Bearlna Plata
Aquarium Type
Datel
Cravhill
Aleo
Scientific Industries
Scientific Industries
Hush
Teletroa
KU
48
59
H
52 .
63
64
Z9
79
81
52
83
84
95
86
87
88
82
-------
CAM-4 PARTS LIST UPDATE. VENDORS AND COSTS
PART NO.
OVM BOARD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
POWER SUPPLY BOARD
22
23
24
25
26
27
28
29
30
31
32
TIMER AND TRIAC
SWITCH BOARD
33
34
35
36
37
38
39
MANUFACTURER OR SUPPLIER COST
P.M. Associates (Set-Up 90.00}
Analog Devices
Schweber
National/Arrow
Motorola/ Impact Sales
Arrow
Arrow
Arrow
Semiconductor Specialists
Semiconductor Specialists
Arrow
Greenshaw
Mill gray/Greens haw
Schweber
Schweber
Schweber ^— *
Schweber
Schweber
Gerber
Gerber
P.M. Associates; (Set-Up 90.00)
Semiconductor Specialists
Semiconductor Specialists
Harvey Electronics
Semiconductor Specialists
Schweber
Gerber
Gerber
Arrow
Gerber
Schweber
P.M. Associates; (Set-Up 90.00)
Schweber
National/Arrow
Gerber
National/Arrow
National/Arrow
National /Arrow
LIST PRICE
7.65
132.00
.75
.25
.93
.08
.46
.24
2.00*
.75*
.02 (2)
.81 (2)
.99
.08
.08
.08
.08
.08
1.20
1.20
7.65
1.10
3.85
.60
1.50
.40
.63
3.24
.14
.33
.08
7.65
.40 (2)
.33
.44
.25
.25
.42
VENDOR
REF.
50
51
52
53
54
53
53
53
55
55
53
56
56
52
52
52
52
52
57
57
50
55
55
58
55
52
57
57
53
57
52
50
52
53
57
53
53
53
83
-------
PART NO.
MANUFACTURER OR SUPPLIER
COST LIST PRICE VENDOR
REF.
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
SB
59
60
61
62
CASE
63
64
82
PRINTER
65
AC/DC ADAPTOR
66
67
68
69
PC BOARD MOUNTING
HARDWARE
70
71
72
73
74
FRONT PANEL,
MISCELLANEOUS
75
76
Motorola/Sager
Motorola/Sager
Arrow
Arrow
Arrow
Semiconductor Specialists
Semiconductor Specialists
Semiconductor Specialists
Semiconductor Specialists
Semiconductor Specialists
Semiconductor Specialists
Impact Sales
Gerber
Arrow
Arrow
Arrow
Arrow
Arrow
Arrow >•—*•
Arrow
Arrow
Arrow
Arrow
Skydyne, Inc.
MC Speciality
Rotron
Datel (AC only)
Nucleonlc Products
Stancor/Gerber
Stancor
Gerber
Schweber
Camblon
Camblon
Camblon
Camblon
Sager
Cutler H aimer/ Impact Sales
.90 (2) 59,
2.25
.46
59,
53
60
60
.24 (2) 53
.12
4.00* {
1.00* !
5.00*
.48
1.75
1.75
.26
53
2} 55
2) 55
55
55
55
55
54
.11 (3) 57
.23'
.21
53
53
.14 (4) 53
.17
.12
.14 (t
.11 I
.18 (I
53
53
0 53
I 53
>) 53
.12 (2) 53
.14
53
107.90 61
55.00 (2) 62
17.60
575.00
15.00*
10.05
15.00*
2.09
3.12
63
16
—
57
~
57
52
.17 (6) 64
2.00*
64
.18 (6) 64
3.50*
64
1.62 (3) 58.
1.50
54
59
84
-------
PART NO.
MANUFACTURER OR SUPPLIER
COST LIST PRICE VENDOR
REF.
77
78
79
80
PUMPS
81
83, 84, 85
86
89 (not listed)
ELECTROCHEMICAL CELL
87
88
90 (not listed)
Sager
Gerber
Cronln Electronics
Beldon/Gerber
Col e-P armer/Greyl or
Scientific Industries
Cole-Panner
VWR (tubing, traps)
MC Specialty (holder assembly)
Engineering Estimate;
(mold charge 300.00)
MC Speciality (holder)
2.25 (3)
.60 (3)
15.15
2.34
34.00 13,
158.00
8.75
4.15
28.00
85.00
18.00
58, 59
57
65
57
14, 66
15
13, 66
67
62
—
62
* Part not Identified, cost estimated by device type.
() Quantity used 1n assembly.
85
-------
MSA Research Corporation • Evans City, Pennsylvania 16033 • Telephone- 412/538-3510
23 August 1983
APPENDIX B
Dr. Barbara Offenhartz
B & M Technological Services, Inc.
520 Commonwealth Avenue
Boston, MA 02215
Dear Dr. Offenhartz:
With reference to our telephone conversatfon of August 22,
1983, the following are the areas where cost cutting modifications could
be made to the emergency collection system.
As we discussed, the costs for bags you have received from
Helios are out of line with what I expect if the bags were made to com-
mercial practice. I am sure Helios Is quoting a price based upon the
current Air Force specification they are meeting. I am sure the pillow
bag could be obtained for a price around $5000 and the segmented bag
for about $7000.
The above assumes the following: plastic flanges with stan-
dard gasketing, a fold and roll type of package rather than the accordlan
pleats required by the Air Force, and standard hardware rather than posi-
tive closure quick disconnects.
It should be noted In selecting a bag design that pillow bags
will roll on a slope as shallow as one-half degree.
The box to house the bag could be eliminated and the bag stowed
1n some other fashion. The Air Force uses a tear away plastic carrier
which protects the bag which Is relatively expensive. Additionally, It
provides easier handling when moving the bag.
Modifications can also be made.In the storage of hoses. In
the current configuration one reel has an integral connection through an
Internal rotating seal. This could be eliminated and replaced with ex-
ternal manual connections for the hoses to the pumping system. It 1s
possible to consider elimination of the hose reels completely. A simple
box could be used to hold colled hoses. Note that the minimum bend radius
for 2" chemical hose fs 5". This bend can be achieved using the reel. If
the hose is hand coiled, even directly Into a box, 2 in" should be added
to the inside bend radius because of the rigidity of the hose.
86
Division of Mine Safety Appliances Company
-------
_ _ . _-, . . o ^i^h^H«MHb« MSA Research Coiporanon
Dr. Barbara Offenhartz -2-
23 August 1983
The pallet is formed aluminum. It was selected because of
weight. A wooden pallet would be significantly cheaper but should be
treated for chemical resistance.
The above are the main areas for cost reduction. Some other
reductions could be made by changes in the plumbing. The three way valve
could be replaced by 2 two way ball valves, and the positive closure pro-
vision of the quick disconnects could be eliminated. I have some problem
with the latter. The cost difference is small but the hazard factor is
large. Without positive closures the hazardous material can leak out when
disconnecting hoses, etc. More importantly, actuation of the system with-
out all connections properly made can result in uncontrolled discharge of
the hazardous material being collected.
I hope the above will be beneficial to your report. Based
upon our cost analysis of one year ago, these modifications taken col-
lectively would reduce the price by about 401.
Sincerely,
Ralph H. Hiltz
/bhh
87
-------
TECHNICAL REPORT DATA
Iflcase read Inunctions on ilie reverie before completing]
1 REPORT NO.
""87-165-619
2.
3. RECIPIENT'S ACCESSION NO.
4. ,*E AND SUBTITLE
EVALUATION OF THIRTEEN SPILL RESPONSE TECHNOLOGIES
5. REPORT DATE
6. PERFORMING ORGANIZATION CODE
7. AUTHOR4S]
Mark L. Evans and Holly A. Carroll
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
TEJY1A
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Science Applications International Corporation
8400 Westpark Drive
McLean, Virginia 22102
11. CONTRACT/GRANT NO.
68-03-3113
12. SPONSORING AGENCY NAME AND ADDRESS
Hazardous Waste Engineering Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
13. TYPE OF REPORT AND PERIOD COVERED
Final Report 3/«3 - 9/85
14. SPONSORING AGENCY CODE
EPA/600/14
15. SUPPLEMENTARY NOTES
Project Offfcer: Mary K. Stinson (201) 321-6683
16. ABSTRACT
Thirteen spill response devices, concepts, or prototypes, developed under previous con-
tracts to the U.S. Environmental Protection Agency for detection, containment, and
cleanup of chemicals, were evaluated by potential users and manufacturers. The main
•nal of this project was to inform potential users and manufacturers of the existence
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