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Automated
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Materials
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List
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The
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goal
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of
...
the
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Automated
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Materials
...
List
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is
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to
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calculate
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the
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volume
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of
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concrete
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needed,
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areas
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of
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components
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that
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will
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be
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made
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out
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of
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bricks
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(these
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areas
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can
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be
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divided
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by
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the
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area
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of
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one
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brick
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to
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see
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how
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many
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bricks
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are
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needed),
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lengths
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and
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sizes
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of
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pipes,
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amount
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of
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plastic
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sheets
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for
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the
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lamella,
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etc.
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The
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final
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Materials
...
List
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should
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act
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as
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a
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rough
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outline
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for
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on-site
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construction
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and
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facilitate
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the
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job
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of
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the
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engineers
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and
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planners.
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This
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program
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requires
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inputs
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from
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the
...
...
and
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from
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the
...
...
...
to
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compute
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the
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necessary
...
calculations.
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Currently,
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the
...
List
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calculates
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the
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total
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materials
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needed
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for
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construction
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and
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various
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dimensions
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for
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different
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components
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of
...
the
...
plant.
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The
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output
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of
...
the
...
...
...
now
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includes
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a
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list
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of
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several
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variables
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comprising
...
the
...
Materials
...
List.
...
Engineers
...
designing
...
plants
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will
...
now
...
be
...
able
...
see
...
how
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much
...
material
...
is
...
needed
...
to
...
construct
...
the
...
components
...
of
...
the
...
plant,
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including
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the
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walls
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of
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the
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various
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tanks
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and
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channels,
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lengths
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of
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PVC
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pipe,
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corrugated
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plastic
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sheets
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for
...
the
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lamella,
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and
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ferrous
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cement
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for
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the
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floc
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baffles.
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The
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Materials
...
List
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is
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conveniently
...
located
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at
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the
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bottom
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of
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the
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Design
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Values
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excel
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spreadsheet
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that
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is
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returned
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to
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the
...
user
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with
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all
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the
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outputs
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for
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the
...
plant.
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This
...
will
...
allow
...
them
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to
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have
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a
...
better
...
of
...
idea
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of
...
what
...
is
...
needed
...
to
...
construct
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an
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AguaClara
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plant.
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The
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Materials
...
List
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will
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continue
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to
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be
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updated
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based
...
on
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feedback
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from
...
the
...
engineers
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in
...
Honduras
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so
...
that
...
it
...
provides
...
information
...
that
...
is
...
most
...
useful
...
to
...
them
...
in
...
the
...
construction
...
process.
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Materials
...
List
...
Program
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Algorithm
...
...
...
...
...
Automated Materials List Program Outputs
Algorithm
The first step in calculating the materials was to determine the geometry of the different components of the plant and which parts of the plant were constructed out of which types of materials (e.g.
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concrete,
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ferrous
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cement,
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corrugated
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plastic,
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PVC
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pipe).
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Then
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the
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volumes
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and
...
quantities
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were
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calculated
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from
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the
...
dimensions
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used
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in
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each
...
components
...
design
...
algorithm.
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Entrance Tank
The Entrance tank volume was found using the design specifications from the automated entrance tank design program and the user inputs. The tank's volume is calculated by considering the four walls lengths, widths and thicknesses.
Flocculation Tank
The total volume for the flocculation tank depends on the width and total number of floc channels and the length of the sedimentation tank. This information, along with the user inputs and design assumptions, provides all the necessary information to calculation the tank's volume.
The total volume of concrete of the walls of the flocculation tank depends on the length of the flocculation tank, the thickness of the plant wall, the height of the flocculation tank, the number of flocculation channels, and the width of the flocculation channels. Since all of the walls in the flocculation tank are the same thickness, the volume can be easily calculated by multiplying the area of the floc walls by the thickness of the plant wall (T.PlantWall).
The area of the floor of the flocculation tank depends on the length of the flocculation tank, the thickness of the plant wall, the number of flocculation channels, and the width of the flocculation channels. The volume of the floor of the flocculation tank is simply the product of the area and thickness of the floor:
The volume of the floc baffles is dependent on the width of the channels, the thickness of the baffle, the length of the baffle, and the number of baffles per channel. The number of baffles per channel is a calculated variable based on the length of the flocculation tank and the perpendicular spacing between baffles, which differs per channel. The baffles are also split between upper and lower baffles. Since the floc channel begins with a lower baffle, the equation is set-up so an odd number of baffles results in an extra lower baffle. If there are an X number of floc channels in a floc tank, the N.FlocChannelBaffles, L.FlocBaffleUpper, and L.FlocBaffleLower are X value arrays, which allow us to use a simple dot product to find the total length of the tank's baffles, rather than calculating each channel individually.
To see how the number of baffles per channel is determined and why there are upper and lower baffles, please consult the flocculator algorithm. The volume needed (of plastic or concrete, depending on the size of the plant) for the the baffles is under the diagram below.
The total surface area of the flocculation baffles can be found be dividing the total volume of all the flocculation baffles by the thickness of one flocculation baffle.
Inlet and Exit Channels
The volumes of the exit and inlet channels are derived from the user-input dimensions for each component. Using the widths, lengths, and thicknesses of each wall, the volume is computed by direct multiplication. The inlet channel also considers the dimensions of the sedimentation manifold entrance and the number of sedimentation inlet pipes. The quantity that is removed from the inlet channel due to the sedimentation inlet pipes is the volume of a single inlet pipe multiplied by the number of pipes.
The wall and floor volumes of the inlet and exit channels similarly depends on their respective length, width, height, and thickness:
The surface area of the walls and the floor of the inlet and exit channels also depend on the respective width, length, height, and thickness:
The inlet and exit channels are attached to tanks containing the weirs that connect to the sedimentation tank. Since the plant weirs are being recoded, these equations will change in the future, but for now, these dimensions were calculated to be built around the nominal diameter of the plant weir and the spacing required between the elbows.
The total length of weir pipes in the inlet and exit channel tanks is derived from the user-input values that are found upon calculating the necessary height of the pipe for the determined water velocity. This height multiplied by the number of weir pipes yields the total length of pipe necessary.
The volumes of the inlet and exit channel tanks are determined by finding the area of the floor of each tank and the area of the walls of each tank. These are then multiplied by the thickness of the channel wall, or T.ChannelWall. The total volume of each tank is equal to the volume of the walls plus the volume of the floor. 
Sedimentation Tank
The volume of the sedimentation tank depends on user-input values. The dimensions of the sludge drain must then be subtracted from the overall volume to account for the design of the drainage system.
The area of the floor of the sedimentation tank depends on the length and width of the sedimentation tanks as well as the number of sedimentation tanks. The volume of the floor of the sedimentation tank is simply the product of the area and thickness of the floor. There has been some question as to whether the thickness of the inner walls of the sedimentation tank (T.PltWall) and that of the outer walls (T.PlantWall) is the same. Assuming they are not the same, the equations for the area and volume of the floor of the sedimentation tank are as follows:
The area and volume of the sedimentation slopes is determined as follows:
The total number of launders is determined by the number of launders per sed bay and the total number of sed bays.
The total length of launder pipe needed is dependent on the individual length of one launder and the total number of launders.
The size of the PVC pipe will depend on the user-input ND.SedLaunder.
The launder also requires a coupling to go through the concrete wall of the sedimentation tank. The number of couplings needed is equal to the number of launders in the plant.
The number of valves and valve couplings needed to drain the tank are found from the sedimentation design specifications with one valve per sedimentation bay.
The necessary output to construct the plate settlers is the number of corrugated sheets used. This is determined by calculating the total number of plate settlers, how many plate settlers would fit on a given sheet of plastic, and and dividing to find the total number of required sheets.
The plate settlers are supported by a sedimentation plate frame constructed of PVC pipes running across the width and length of the sedimentation tank. The length of PVC pipe required to construct this module was determining using the dimensions of the sedimentation tank and the center-to-center distance between each parallel pipe.
Stock Tank
The function of the stock tank to add the alum coagulant to the raw water during rapid mix. The volume of the stock tank is constrained by flow rate and retention time. More specifically, the volume of the stock tank is the maximum flow rate through the aluminum stock tank multiplied by the duration of alum stock tank at maximum alum dose and plant flow rate.
The only other variable that needs be specified by the user to determine the other dimensions of the stock tank is diameter of the stock tank. Once the diameter has been set, the radius is simply half the diameter, and the corresponding required height can subsequently be calculated.
Finally, the total area and the floor area of the stock tank are determined by the previously calculated height and radius:
