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OPERATIONS AND MAINTENANCE MANUAL GROUNDWATER TREATMENT FACILITIES #1 AND #2 SITE-WIDE GROUNDWATER AND CURRICULUM CENTER SVE REMEDIAL ACTIONS TUTU WELLFIELD SUPERFUND SITE ST THOMAS, U.S. VIRGIN ISLANDS Submitted to: CDM Federal Programs Corporation 14 Wall Street, Suite 1702 New York, NY 10005 Submitted by: Arrowhead Contracting, Inc. 10981 Eicher Dr. Lenexa, Kansas 66219 February 2013 Revision 1 OPERATIONS AND MAINTENANCE MANUAL GROUNDWATER TREATMENT FACILITIES #1 AND #2 SITEWIDE GROUNDWATER AND CURRICULUM CENTER SVE REMEDIAL ACTIONS TUTU WELLFIELD SUPERFUND SITE ST THOMAS, U.S. VIRGIN ISLANDS Submitted to: CDM Federal Programs Corporation 14 Wall Street, Suite 1702 New York, NY 10005 Submitted by: Arrowhead Contracting, Inc. 10981 Eicher Dr. Lenexa, Kansas 66219 February 2013 Revision 1 Reviewed/ Concurred by: Date: February 7, 2013 Greg Wallace, R.G. Project Manager O and M Manual - Rev 1.doc i Table of Contents List of Tables ................................................................................................................................. iv List of Drawings ............................................................................................................................. v List of Appendices ......................................................................................................................... vi List of Acronyms .......................................................................................................................... vii List of Acronyms (continued) ...................................................................................................... viii 1.0 Introduction ...................................................................................................................... 1-1 1.1 Document Organization ....................................................................................... 1-1 1.2 Supporting Documents......................................................................................... 1-2 1.3 O&M Staffing Plan .............................................................................................. 1-2 1.4 Project Directory .................................................................................................. 1-3 2.0 Background Information and Overview .......................................................................... 2-1 2.1 Site Description .................................................................................................... 2-1 2.2 Remedial Action Objectives ................................................................................ 2-1 2.3 GWTF Design Summary ..................................................................................... 2-2 2.4 O&M Requirements ............................................................................................. 2-6 2.4.1 Operations ................................................................................................ 2-6 2.4.2 Maintenance ............................................................................................. 2-7 2.4.3 Sampling and Monitoring ........................................................................ 2-8 2.4.3.1 Performance and Compliance Monitoring............................... 2-9 2.4.3.2 Sitewide Groundwater Monitoring .......................................... 2-9 3.0 Control Systems Description ........................................................................................... 3-1 3.1 Control Panels ...................................................................................................... 3-1 3.2 Control Logic Overview ...................................................................................... 3-1 3.3 Control System Functionality Overview ............................................................. 3-3 3.4 Human-Machine Interface (HMI) ........................................................................ 3-4 3.4.1 MAIN Screen ........................................................................................... 3-4 3.4.2 MOTORS Screen ..................................................................................... 3-8 3.4.3 PID Screen ............................................................................................. 3-10 3.4.4 ALARMS Screen ................................................................................... 3-13 3.4.5 TREND Screens ..................................................................................... 3-14 3.4.6 Data Logs ............................................................................................... 3-16 3.4.7 Alarm Logs ............................................................................................ 3-17 3.5 Autodialer .......................................................................................................... 3-18 3.6 Remote Access ................................................................................................... 3-18 O and M Manual - Rev 1.doc ii 4.0 Initial Set-Up Procedures ................................................................................................. 4-1 4.1 Control Panels ...................................................................................................... 4-1 4.2 Bag Filters ............................................................................................................ 4-2 4.3 Transfer Pumps .................................................................................................... 4-2 4.4 Air Strippers ......................................................................................................... 4-3 4.5 Submersible Well Pumps ..................................................................................... 4-3 4.6 SVE System (Facility #1) .................................................................................... 4-4 4.7 Chemical Feed Systems ....................................................................................... 4-4 4.8 Off-Gas Treatment System (Facility #1) ............................................................. 4-5 4.9 Heat Exchanger (Facility #1) ............................................................................... 4-5 4.10 Miscellaneous Equipment .................................................................................... 4-5 5.0 Systems Operating Procedures ........................................................................................ 5-1 5.1 Preliminary Checks Prior to System Start-Up ..................................................... 5-1 5.2 Full Automatic Start-Up and Operation ............................................................... 5-1 5.3 Automatic Startup and Operation of Select Equipment ....................................... 5-4 5.4 Manual Speed Control for Submersible Well Pumps .......................................... 5-5 5.5 Operation with Equalization Tank Bypass .......................................................... 5-5 5.6 Routine Operations .............................................................................................. 5-6 5.7 Operator Shutdown .............................................................................................. 5-7 5.8 Automatic Shutdown on Alarm Condition .......................................................... 5-7 5.9 Emergency Shutdown .......................................................................................... 5-8 6.0 Maintenance Procedures .................................................................................................. 6-1 6.1 Preventative Maintenance and Lubrication Schedules ........................................ 6-1 6.2 Replacement of Consumable Items ..................................................................... 6-1 6.2.1 Bag Filters ................................................................................................ 6-1 6.2.2 Chemical Additives .................................................................................. 6-2 6.2.3 Off-Gas Treatment Media ........................................................................ 6-2 6.3 Extraction Well Maintenance .............................................................................. 6-2 6.4 Shutdown for Maintenance, Repair, or Replacement .......................................... 6-3 6.4.1 Bag Filters ................................................................................................ 6-3 6.4.2 Transfer Pumps ........................................................................................ 6-3 6.4.3 Air Strippers ............................................................................................. 6-3 6.4.4 Submersible Well Pumps ......................................................................... 6-3 6.4.5 SVE System ............................................................................................. 6-3 6.4.6 Chemical Feed Systems ........................................................................... 6-3 6.4.7 Off-Gas Treatment System ...................................................................... 6-3 O and M Manual - Rev 1.doc iii 6.4.8 Heat Exchanger ........................................................................................ 6-4 6.5 Spare Parts List .................................................................................................... 6-5 7.0 Inspection and Monitoring Procedures ............................................................................ 7-1 7.1 Extraction Wells and Pumps ................................................................................ 7-1 7.2 Conveyance Piping .............................................................................................. 7-1 7.3 Treatment Plants .................................................................................................. 7-2 8.0 Troubleshooting Guidelines ............................................................................................. 8-1 9.0 Sampling and Monitoring Activities ................................................................................ 9-1 10.0 Health and Safety Guidelines ......................................................................................... 10-1 10.1 Physical and Chemical Hazards ......................................................................... 10-1 10.2 Control Measures and Precautions ..................................................................... 10-2 11.0 Recordkeeping and Reporting........................................................................................ 11-1 11.1 Operations Records ............................................................................................ 11-1 11.2 Maintenance Records ......................................................................................... 11-1 11.3 Monthly Operations Summary Report ............................................................... 11-2 12.0 References ...................................................................................................................... 12-1 O and M Manual - Rev 1.doc iv List of Tables Table Title 1-1 Project O&M Directory 1-2 Vendor O&M Directory 2-1 TPDES Storm Sewer / Surface Water Discharge Criteria 2-2 DPNR Air Discharge Criteria 2-3 Equipment List, Groundwater Extraction and Treatment – GWTF #1 2-4 Equipment List, Soil Vapor Extraction System – GWTF #1 2-5 Equipment List, Off-Gas Treatment System – GWTF #1 2-6 Equipment List, Groundwater Extraction and Treatment – GWTF #2 2-7 Piping and Valve Nomenclature – GWTF #1 2-8 Piping and Valve Nomenclature – GWTF #2 2-9 Sampling and Monitoring Schedule for Long-Term O&M 2-10 Sampling and Monitoring Schedule for Sitewide Groundwater 3-1 Control System Interlocks – GWTF #1 3-2 Control System Interlocks – GWTF #2 3-3 Control Tag Database – GWTF #1 3-4 Control Tag Database – GWTF #2 5-1 Routine Operating Parameters – GWTF #1 5-2 Routine Operating Parameters – GWTF #2 6-1 Routine and Preventative Maintenance Schedule – GWTF #1 6-2 Routine and Preventative Maintenance Schedule – GWTF #2 6-3 Spare Parts List 7-1 Routine Inspection, Monitoring, and Maintenance Schedule 8-1 General Troubleshooting Guidelines – GWTF #1 8-2 General Troubleshooting Guidelines – GWTF #2 O and M Manual - Rev 1.doc v List of Drawings Drawing Title 2-1 Site Layout and Yard Piping – GWTF #1 2-2 Site Layout and Yard Piping – GWTF #2 2-3 Equipment Arrangement and Yard Piping – GWTF #1 2-4 Equipment Arrangement and Yard Piping – GWTF #2 2-5 Recovery Well and Vault Details – RW-6, RW-9, RW-1, and RW-1S 2-6 Recovery Well and Vault Details – RW-7 2-7 SVE Well and Vault Details – SVE-1 2-8 Pull Box Details – GWTF #1 and GWTF #2 2-9 Piping, Instrumentation, and Control Logic Diagram – GWTF #1 2-10 Piping, Instrumentation, and Control Logic Diagram – GWTF #1 2-11 Piping, Instrumentation, and Control Logic Diagram – GWTF #1 2-12 Piping, Instrumentation, and Control Logic Diagram – GWTF #2 2-13 Piping, Instrumentation, and Control Logic Diagram – GWTF #2 2-14 Piping and Valve Nomenclature – GWTF #1 2-15 Piping and Valve Nomenclature – GWTF #1 2-16 Piping and Valve Nomenclature – GWTF #1 2-17 Piping and Valve Nomenclature – GWTF #2 2-18 Piping and Valve Nomenclature – GWTF #2 O and M Manual - Rev 1.doc vi List of Appendices Appendix Title A Equalization Tanks and Vapor Phase Carbon Units (GWTF #1 and #2) B Transfer Pumps (GWTF #1 and #2) C Chemical Feed Systems (GWTF #1 and #2) D Bag Filters (GWTF #1 and #2) E Air Strippers and Blowers (GWTF #1 and #2) F Soil Vapor Extraction System (GWTF#1) G Off-Gas Treatment System (GWTF #1) H Heat Exchanger (GWTF #1) I Supervisory Controls and Data Acquisition (GWTF #1 and #2) J Process Instrumentation and Controls (GWTF #1 and #2) K Miscellaneous Electrical Equipment (GWTF #1 and #2) L Submersible Groundwater Pumps and Transducers (GWTF #1 and #2) M Facility Equipment and Appurtenances (GWTF #1 and #2) N Field Sampling and Monitoring Equipment (GWTF #1 and #2) O Chemical Additives (GWTF #1 and #2) P Air Stripper and Off-Gas Treatment Modeling Data (GWTF #1 and #2) Q Silencer (GWTF #2) R O&M Forms and Logs (GWTF #1 and #2) S Operating Permits (GWTF #1 and #2) T Recovery Well Construction Logs (GWTF #1 and #2) O and M Manual - Rev 1.doc vii List of Acronyms amsl Above mean sea level COC chain-of-custody CQCP Contractor Quality Control Plan CV controlled variable CVOC chlorinated volatile organic compound DCE 1,2-dichloroethene DPNR Department of Planning and Natural Resources EPA U.S. Environmental Protection Agency EQ Equalization GAC granular activated carbon gpm gallons per minute GWTF Groundwater Treatment Facility HMI Human-Machine Interface I/O inputs & outputs (PLC I/O) KVA kilovolt-ampere MCL maximum concentration limits O&M operations and maintenance QA Quality Assurance QAPP Quality Assurance Project Plan QC Quality Control OIT Operator Interface Terminal P&ID Process and instrumentation diagram PCE tetrachloroethene PID Proportional-Integral-Derivative PLC Programmable logic controller ppm parts per million ppmv parts per million by volume RA Remedial Action scfm cubic feet per minute at standard conditions SOP Standard Operating Procedure SSHP Site Safety and Health Plan SVE soil vapor extraction TCE trichloroethene TDH total discharge head O and M Manual - Rev 1.doc viii List of Acronyms (continued) ug/L micrograms per liter UPS Uninterruptible power supply USEPA U.S. Environmental Protection Agency USVI U.S. Virgin Islands VAC volts AC VDC volts DC WAPA Water and Power Authority wc water column O and M Manual - Rev 1.doc 1-1 1.0 Introduction This document presents Revision 1 of the Operations and Maintenance (O&M) Manual for facility operations at the Tutu Wellfield Superfund Site, located in St. Thomas, U.S. Virgin Islands (USVI). This is Revision 1 to the Final O&M Manual prepared during the Remedial Action (RA) (Arrowhead 2004). This revision was prepared by the United States Environmental Protection Agency (EPA) pursuant to Appendix B of the Site Transfer Agreement between the EPA and USVI. Currently, there are two groundwater facilities are operating at the site. The SVE and off-gas systems at Facility #1 have been shut down and were taken off-line in April 2006. 1.1 Document Organization This manual is subdivided into the following sections:  Section 1.0 – Introduction – In addition to presenting the outline for this O&M Manual, this section presents a list relevant supporting documents, a description of O&M subcontractor responsibilities, and a project directory.  Section 2.0 – Background Information and Overview – This section presents general background information about the site and project, including the RA objectives, a summary of the design of each GWTF, and the requirements for O&M.  Section 3.0 – Control Systems Description – This section provides a discussion of the control logic and functionality for each system, including the capabilities of each system’s motor control center.  Section 4.0 – Initial Set-Up Procedures – This section provides procedures for the initial set-up/start-up of each piece of equipment following installation.  Section 5.0 – Systems Operating Procedures – This section presents the procedures for operating each GWTF once the equipment is installed and initial set-up is completed. The primary scenarios for startup, operation, and shutdown are covered.  Section 6.0 – Maintenance Procedures – This section presents the general procedures for preventative maintenance and inspections to optimize the operation of each system. For more detailed maintenance information, readers are referred to the manufacturer- specific O&M literature contained in the appendices.  Section 7.0 – Inspection and Monitoring Procedures – This section presents general procedures for inspection and monitoring of each system, as part of the routine O&M program. O and M Manual - Rev 1.doc 1-2  Section 8.0 – Troubleshooting Guidelines – This section presents general troubleshooting guidelines in the event of system failure or shutdown. For more detailed troubleshooting information, readers are referred to the manufacturer-specific O&M literature contained in the appendices.  Section 9.0 – Sampling and Monitoring Methods – This section provides a general discussion of the sampling and monitoring activities that will be conducted during the O&M of each GWTF.  Section 10.0 – Health and Safety Guidelines – This section provides a general discussion of the health and safety issues associated with the O&M of each GWTF.  Section 11.0 – Recordkeeping and Reporting – This section presents the recordkeeping and reporting requirements applicable to long-term O&M.  Section 12.0 – References – This section presents a list of references associated with this O&M Manual. In addition to the text (described above), this manual contains relevant tables, drawings, and appendices. Appendices include:  Appendices A – M, Q: manufacturer O&M literature and information for equipment associated with each GWTF, including preventative maintenance schedules, troubleshooting guidelines, and spare parts lists.  Appendix N: manufacturer O&M literature for field sampling and monitoring equipment  Appendix O: material safety data sheets (MSDSs) for the chemical additives  Appendix P: predictive modeling data for the air stripper and off-gas treatment system  Appendix R: relevant forms and logs to be used during O&M  Appendix S: copies of the air and water discharge permits  Appendix T: copies of the well construction diagrams for each groundwater extraction well 1.2 Supporting Documents Sampling and monitoring activities are currently being performed in accordance with the site- specific Final Quality Assurance Project Plan (QAPP), April 2009 (CDM Smith, 2009). 1.3 O&M Staffing Plan The staffing requirements for O&M include a project manager and operator. The following paragraphs summarize the responsibilities associated with each position. Upon transition of O and M Manual - Rev 1.doc 1-3 ownership to the USVI, the USVI Department of Planning and Natural Resources (DPNR) or their subcontractor shall be fully responsible for preparing the staffing plan. Project Superisor/Manager  A supervisory position directing the overall operation, maintenance, monitoring, and management of groundwater treatment systems.  In charge of developing plans and making sure that the plans are carried out. Supervise and direct on-site operation of treatment systems. Ensure competency and safety of operations. Ensure compliance with all permit requirements. In charge of approving all changes in treatment system operation. Perform other related administrative and management work, as required. Primary contact to the Contractor. Operator  A supervisory position directing and performing the day-to-day operations, maintenance, monitoring, and management of groundwater treatment systems.  In charge of the day-to-day operation, maintenance, monitoring, sampling, and management of treatment systems, extraction well systems and associated facilities, attainment of effluent and air discharge requirements, record maintenance, reporting, waste disposal, and associated on-site operations. Intimately familiar with all permit regulations and enforcement requirements. Maintains accurate and orderly managed O&M records. Performs other related work including, administration, budgeting, and routine office duties, as required. 1.4 Project Directory Table 1-1 presents a directory (addresses, telephone numbers, and contacts) of the key organizations, regulators, and property owners associated with the Tutu Wellfield O&M. Additionally, Table 1-2 is provided as a directory of the primary vendors, suppliers, and manufacturers of the process equipment and instrumentation. O and M Manual - Rev 1.doc 2-1 2.0 Background Information and Overview This section presents general background information about the site and project, including the RA objectives, a summary of the design of each GWTF, and the requirements for O&M. 2.1 Site Description The Tutu Wellfield Superfund Site is located in the Anna’s Retreat area, east of the city Charlotte Amalie on the island of St. Thomas, USVI. The site is situated within the upper Turpentine Run surface drainage basin. The basin, which covers approximately 2.3 square miles, trends roughly north-south and is bounded by steep slopes of the surrounding hills. The site contains a variety of commercial establishments, schools, churches, and residential units. The project covers of two areas of concern that are being implemented to remediate groundwater contaminated with chlorinated volatile organic compounds (CVOCs). The Northern Plume is upgradient, and is located below and adjacent to the Curriculum Center. The Southern Plume is downgradient and extends to the south of the Esso Tutu Service Station below O’Henry Dry Cleaners. 2.2 Remedial Action Objectives The CVOCs found in groundwater at the site include trichloroethene (TCE), tetrachloroethene (PCE), 1,2-dichloroethene (DCE), and vinyl chloride. Total CVOC concentrations have exceeded 10 parts per million (ppm) in select groundwater samples. The objectives of the program are summarized as follows:  Contaminated groundwater in the Northern Plume is extracted, treated, and discharged to surface water for the purpose of achieving: - Hydraulic control of and CVOC mass removal from the contamination source at the Curriculum Center property (GWTF #1) - Hydraulic control of and CVOC mass removal from the dissolved-phase plume that extends downgradient of the Curriculum Center, just to the south of the Esso Tutu Service Station and exceeds 100 ug/L total CVOCs (GWTF #2). Groundwater quality will improve in the Northern Plume area over time as a result of active CVOC mass removal within the capture zone areas of the GWTF extraction O and M Manual - Rev 1.doc 2-2 systems, and in downgradient areas as a result of hydraulic CVOC source/plume control and natural attenuation processes.  The soil remedy for the site, consisting of SVE at the Curriculum Center, was implemented concurrently with the groundwater remedial action. The two remedies were integrated to combine common components, such as the building enclosures and process controls. The soil remedy was completed in April 2006, at which point the SVE and off- gas system components were shut down.  Contaminated groundwater in the Southern Plume will be allowed to naturally attenuate under closely monitored conditions.  Changes in groundwater quality resulting from groundwater extraction and from natural attenuation will be closely monitored as part of the site-wide groundwater monitoring program to: - Confirm that Northern CVOC source and plume are being hydraulically controlled and that CVOC concentrations are decreasing in the aquifer over time - Confirm that the current Southern Plume area exceeding federal maximum concentration limits (MCLs) for drinking water is not expanding or moving beyond its current location and that CVOC concentrations are decreasing in the aquifer over time.  The cleanup goals for aquifer groundwater quality at the site are the federal MCLs. Remedial system operation and/or site-wide groundwater monitoring will continue until these cleanup goals are achieved. Surface water and air discharges from GWTFs shall comply with locally permitted discharge criteria, as presented in Tables 2-1 and 2-2, respectively. Copies of the surface water discharge and air emissions permit equivalencies are provided in Appendix S. 2.3 GWTF Design Summary Operations at GWTF #1 include groundwater extraction and treatment consistent with the RA objectives discussed in Section 2.2. The site layout for GWTF #1 is depicted in Drawing 2-1. GWTF #1 is designed to treat up to 60 gpm of groundwater from a network of three extraction wells (RW-6, RW-7, and RW-9; refer to Drawings 2-5 and 2-6). The SVE system at GWTF #1 is capable of extracting 130 scfm at –30 in. wc. SVE wells include SVE-1 and RW-7 (refer to Drawings 2-6 and 2-7). Extraction well RW-7 is a dual-phase well; it is designed and O and M Manual - Rev 1.doc 2-3 constructed for both groundwater and soil vapor extraction. Extraction well construction logs are provided in Appendix T. The SVE and off-gas systems were shut down in April 2006. The overall system design for GWTF #1 incorporates the following pieces of equipment:  Three Grundfos Redi-Flo3 electric submersible well pumps (RW-6, RW-7, and RW-9)  1,000-gallon, cone-bottom equalization (EQ) tank, including a 55-gallon container with 200 lbs vapor phase granular activated carbon (GAC) (only in use when RW-6 is in operation and influent is passed through EQ tank)  Two centrifugal transfer pumps (maximum flow rate 30 gpm @ 56 ft TDH)  Two chemical feed systems [pH adjustment using muriatic acid and anti-scalant (sequesterant) addition], including metering pumps and chemical storage drums  Two bag filters  6-tray, low-profile air stripper (rated for 5 – 80 gpm) and regenerative blower (rated at 350 scfm @ –75 in. wc), piped in an induced-draft configuration (refer to Appendix P for predictive modeling simulations and results)  Air-to-air heat exchanger (aftercooler) - currently in-line but not turned on as part of operations  Off-gas treatment system, consisting of one vapor phase GAC vessel (5,000 lbs capacity) and one potassium permanganate-impregnated vessel (7,000 lbs capacity)– currently offline  Soil vapor extraction system, consisting of a regenerative blower (rated at 140 scfm @ – 70 in. wc) and a 40-gallon moisture separator tank – currently offline and moisture separator tank removed due to severe rusting  Appurtenances, including air inlet filters, discharge silencers, Y-strainers, vacuum breaker (anti-siphon), and sample ports  Instrumentation, including temperature gauges, temperature switches, pressure gauges, pressure switches, flow meters, flow transmitters, and level switches  Motor control centers (see below) Drawing 2-3 depicts the equipment arrangement, building floor plan, and yard piping for GWTF #1. The air stripper, transfer pumps, and SVE system are located within the process building. This building is subdivided into process room and office. The office also houses the control panels and transformers. The EQ tank, off-gas treatment vessels, and heat exchanger are O and M Manual - Rev 1.doc 2-4 mounted on concrete pads located outside and adjacent to the process building. Secondary containment for the EQ tank is provided via a concrete berm along the perimeter of the pad. Secondary containment for equipment located inside the building is provided by a concrete berm along the perimeter of the process room. The “treatment plant” is comprised of the process building, interior equipment, and pad-mounted equipment located outside the building. Currently extraction well RW-7 is used as the primary extraction well, with RW-9 serving as a secondary well for use during periods of high groundwater elevations. Extraction well RW-6 is pumped once per week for about one hour until the well is pumped dry. Contaminated groundwater is pumped to the treatment plant via a network of underground aboveground yard piping (refer to Drawings 2-1 and 2-3). Underground piping and electrical conduit pass through pull boxes (Drawing 2-8) located between the process building and extraction well vaults (Drawings 2-5 through 2-7). The EQ tank and transfer pumps are currently bypassed under normal operating conditions, except during operation of RW-6. When the EQ tank is used, the influent is temporarily stored there prior to being transferred (by the centrifugal transfer pumps) to the air stripper. Scale inhibitor is injected upstream of the EQ tank. Muriatic acid is added in the air stripper sump for pH adjustment prior to discharge. The treated water from the air stripper is then discharged to a local storm sewer inlet (located approximately 300 ft west of the treatment plant; refer to Drawing 2-1). Contaminated vapors from the air stripper are no longer routed through the off-gas treatment system, but rather bypass the units which remain on site without media present in the vessels. The system was taken off-line in April 2006 because it was determined to no longer be necessary to meet the air permit requirements. The off-gas passes through the upstream heat exchanger (after-cooler) which no longer requires operation to maintain air temperatures. The treated air stream is discharged to the atmosphere through a stack mounted on the side of the process building. The SVE system which consisted of a moisture separator, particulate filter, regenerative blower and discharge silencer has been offline since 2006. GWTF #2 (refer to Drawing 2-2) operations consist of groundwater extraction and air stripping. The influent CVOC concentrations have historically been below permitted air emissions limits, so off-gas treatment was not required for GWTF #2. GWTF #2 is designed to treat up to 30 gpm of groundwater from two extraction wells (RW-1 and RW-1S; refer to Drawing 2-5). Extraction well RW-1 has not been used as part of the remedy. The overall system design for GWTF #2 incorporates the following pieces of equipment: O and M Manual - Rev 1.doc 2-5  Two Grudfos Redi-Flo3 electric submersible well pumps  500-gallon cone-bottom equalization tank, including a 55-gallon container with 200 lbs vapor phase GAC – currently offline and in storage  One centrifugal transfer pump (maximum flow rate 30 gpm @ 56 ft TDH)  Two chemical feed systems (pH adjustment using muriatic acid and anti- scalant/sequesterant addition), including metering pumps and chemical storage drums  Two bag filters  6-tray, low-profile air stripper (rated for 1 – 35 gpm) and regenerative blower (rated at 150 scfm @ –65 in. wc), piped in an induced draft configuration  Appurtenances, including air inlet filters, discharge silencers, Y-strainers, vacuum breaker (anti-siphon), and sample ports  Instrumentation, including temperature gauges, pressure gauges, pressure switches, flow meters, flow transmitters, and level switches  Motor control centers (see below) Drawing 2-4 depicts the equipment arrangement, building floor plan, and yard piping for GWTF #2. The treatment equipment, including the EQ tank, is located within the process building. Similar to GWTF #1, the building is subdivided into a process room and office/control room. Contaminated groundwater from each extraction well passes through a pull box as shown on Drawing 2-8. Only RW-1S has been operated as part of the remedy. The EQ tank and transfer pumps are currently bypassed. Influent groundwater is routed though the air stripper followed by direct discharge of the off-gas to the atmosphere through a stack mounted to the side of the building. Treated water from the air stripper is discharged to a local storm sewer inlet (located approximately 150 ft southwest of the treatment plant; refer to Drawing 2-2). A comprehensive equipment list for GWTF #2 is provided in Table 2-6. The control systems for GWTF #1 and GWTF #2 are based on a 480-VAC control panel containing an Operator Interface Terminal (OIT), programmable logic controller (PLC), Grundfos® CU-300 pump controllers, autodialer, and associated 24VDC power supplies for DC input/output (I/O) circuits. The facility receives incoming power @ 208VAC, 3Ø from Water and Power Authority (WAPA) pole-mounted transformers. The electrical drop connects to a power meter mounted on the poles. Power is brought from the meter underground into each building where it is split in a wireway to feed a 100A 208VAC lighting distribution panel, P1, O and M Manual - Rev 1.doc 2-6 and a 75KVA, 3Ø transformer that provides the 480VAC power necessary for the control panel. The control panel is equipped with its own 7.5KVA transformer to provide 240VAC single- phase power to the Grundfos® pump controllers and 120VAC power for the OIT, PLC and other equipment provided in the control panel. Details are provided in the electrical schematics (E- series drawings) from the set of as-built drawings. Section 3.1 provides further information regarding the control panel hardware and software. The overall control logic scheme is depicted graphically in P&ID diagrams, Drawings 2-9 through 2-13. A standard nomenclature system was developed for the piping, valves, and sample ports at each GWTF. Drawings 2-14 through 2-18 identifies each pipe run, valve, and sample port according to this system. Tables 2-7 and 2-8 provide a comprehensive listing of each identifier, including a nomenclature abbreviation key. 2.4 O&M Requirements This subsection summarizes the specified requirements for operations, maintenance, sampling and monitoring to be implemented by the O&M subcontractor. 2.4.1 Operations The following are the operational requirements applicable to each GWTF:  Operate all equipment, systems, processes, and appurtenances in accordance with the subcontract agreement, equipment manufacturer’s specifications and O&M instructions, and the approved O&M Manual.  Extract groundwater on a continuous basis to achieve hydraulic control of the groundwater CVOC plume at each treatment plant location, and treat groundwater in accordance with the permitted requirements for surface water and air discharges.  Containerize, characterize, transport, and dispose of all process and sampling waste residuals at an approved waste disposal facility.  Procure all equipment, spare parts, supplies, and services required for operation, maintenance, monitoring, and management of the treatment systems.  Manage and maintain an inventory of equipment, spare parts, supplies, and tools required for continuous operation with minimal downtime.  Monitor treatment system performance, permit compliance, and remedial progress by collecting specified samples and field measurements (refer to Section 9.0). O and M Manual - Rev 1.doc 2-7  Prepare operational records and maintain project files (refer to Section 11.0). Prepare and submit progress reports.  Abide by all permits required to operate and report any non-compliant conditions to DPNR immediately.  Optimize the use of process equipment and chemicals to minimize operational costs.  Maintain treatment plant uptime in excess of 95% per quarter.  Notify DPNR immediately of any system downtime greater than 24 hours or any non- compliance with discharge requirements. 2.4.2 Maintenance The following are the maintenance requirements applicable to each GWTF:  Provide routine, preventative, and corrective maintenance of the GWTFs, including all processes, equipment, controls, facilities, and appurtenances.  Perform routine, preventative, and corrective maintenance of the GWTFs in accordance with the equipment manufacturer’s specifications and this O&M Manual.  Store all tools, spare parts, equipment, and supplies in an appropriate storage area at each GWTF. Manage the inventory and maintenance of such items to minimize downtime for maintenance.  Maintain good housekeeping practices. Facilities shall be kept neat, organized, and litter-free. Clean and remove accidental spills.  Containerize, characterize, and promptly dispose all wastes generated at the site, such as bag filters and tank sediment.  Routinely inspect and maintain the physical condition of exterior facilities, equipment, and grounds as follows. - Fencing and locks shall be maintained, and repaired or replaced when necessary. - Vegetation shall be maintained in a manner that is consistent with the surrounding and cut when necessary. - Touch-up painting shall be performed as necessary to prevent corrosion or other damage associated with environmental exposure. - Well vaults shall be inspected for surface leaks; access hatch seals and grading shall be replaced/corrected when needed. O and M Manual - Rev 1.doc 2-8 - Structural support systems, such as concrete footers, structural anchoring, and guy wires, shall be periodically checked for structural integrity and adjusted/repaired if necessary. - Building openings and access ways, including doors, louvers, fans, air conditioners shall be periodically checked for leakage and structural integrity; adjust/tighten hardware, apply caulk, and replace weather stripping when needed. 2.4.3 Sampling and Monitoring As part of the overall O&M of each system, sampling and monitoring activities will be conducted to evaluate the following:  Treatment system compliance to confirm that permitted discharge requirements are being met for surface water and air discharges.  Treatment system performance to confirm that hydraulic control is being maintained and that treatment systems are operating properly. Subcontractor shall monitor influent flow and water quality from extraction wells, drawdown and hydraulic control of groundwater, and unit process performance. Information shall be used to support decisions regarding adjustments to pumping rates, unit process operations, chemical dosage rates for the purpose of maximizing remedial performance and minimizing associated operational costs.  Remedial progress by monitoring changes in source-area and site-wide groundwater quality, levels, and flow over time. This shall include the areas subjected to groundwater extraction and treatment and the area subjected to monitored natural attenuation. Information shall be compared against design assumptions and predictions regarding remedy performance, and it shall be used to refine such assumptions and predictions and the environmental monitoring program as more information is gathered. The long-term O&M phase includes two primary sampling and monitoring programs:  Performance and compliance monitoring  Site wide groundwater monitoring The following subsections present the general sampling and field measurement requirements for each program. The data quality objectives for performance and compliance monitoring and sitewide groundwater monitoring are presented in the site-specific QAPP (CDM Smith, 2009). O and M Manual - Rev 1.doc 2-9 2.4.3.1 Performance and Compliance Monitoring Performance and compliance monitoring will entail routine sample collection and field measurements to (1) verify that the treatment systems are performing as designed and (2) verify compliance with air emissions and surface water discharge permits (refer to Tables 2-1 and 2-2 and Appendix S). The minimum requirements for performance and compliance monitoring are specified in Table 2-9. All sampling and field measurements shall be performed in accordance with the site-specific QAPP (CDM Smith, 2009). Water and air/vapor samples that will be collected and/or monitored as part of long-term O&M performance and compliance monitoring include:  Groundwater influent samples from each extraction well (VOCs)  Treated water effluent samples (VOCs, TOC, and TSS)  Air emissions samples from the stack at GWTF #1 (VOCs via Method TO-15) In addition to water and air samples, operational parameters shall be recorded on a routine basis from process instruments, meters, and gauges, including the following:  Extraction well water level  Extraction well pump flow rate, pressure, and totalized flow  Influent flow rate and totalized flow  Air stripper influent flow rate and totalized flow  Transfer pump(s) discharge pressure and flow rate  Bag filter differential pressure  Air stripper blower flow rate  Air stripper blower vacuum, discharge pressure, and temperature  Chemical injection rates  Treated water effluent pH  Other routine operating parameters (refer to Tables 5-1 and 5-2) A comprehensive schedule for performance and compliance monitoring (during the first year of long-term O&M) is presented in Table 2-9. 2.4.3.2 Sitewide Groundwater Monitoring During long-term O&M, groundwater samples and synoptic water level measurements will be collected from the sitewide network of groundwater monitoring wells. Groundwater samples will be collected on an annual basis. Synoptic water levels will be measured on a monthly basis. O and M Manual - Rev 1.doc 2-10 Additionally, continuous water levels will be recorded from six groundwater monitoring wells using dedicated pressure transducers with datalogging capabilities. The requirements for sitewide groundwater monitoring are specified in Table 2-10. All sampling and water level measurements shall be performed in accordance with the site-specific QAPP (CDM Smith, 2009). O and M Manual - Rev 1.doc 3-1 3.0 Control Systems Description This section provides a discussion of the control system logic, programming, and functionality, including the capabilities of each system’s control panel. The control logic scheme is depicted graphically on the P&ID diagrams, Drawings 2-9 through 2-13. Control ladder diagrams are included in Appendix I. It should be noted that the SVE and off-gas systems are currently offline. 3.1 Control Panels The control panel is equipped with an Allen-Bradley VersaView 1500P 15-inch touch-screen OIT from which the on-site operator and remote users control and monitor all automated processes in the system (refer to Appendix I). The VersaView OIT is an industrial computer with a Windows XP® operating system, a CD-RW drive, 3-1/2 floppy drive, internal modem, keyboard, mouse, uninterruptible power supply (UPS) and several serial and USB ports for peripheral devices. The OIT is connected to an Allen-Bradley MicroLogix 1500® PLC located on a panel behind the OIT. Two 24VDC power supplies are provided in the control panel – one for analog I/O and the other for the discrete 24VDC circuits shown in the electrical schematics. The control panel also includes Grundfos® CU300 pump controllers used to control the speed (pumping rate) of each recovery well pump. 3.2 Control Logic Overview The control systems for each GWTF are programmed with ladder logic to implement interlocks, control system processes, cycle process equipment, initiate local and remote alarms, and safely start up and shut down each system. The control interlocks are depicted graphically in the P&ID drawings (Drawings 2-9 through 2-13) and listed in Tables 3-1 (GWTF #1) and 3-2 (GWTF #2). It is important to understand that AUTO mode must be selected in order for the interlocks to function as designed. Any piece of equipment placed in MAN(ual) mode will have its control interlocks bypassed. The control interlocks begin to function automatically upon start up. Clicking the System START button on the MAIN screen first removes any previously existing stop commands, places all process equipment in AUTO mode, and then sequentially starts the following in order: O and M Manual - Rev 1.doc 3-2 GWTF #1  Air stripper blower, B-1  Transfer pump, P-1 – currently bypassed  Transfer pump, P-2 – currently bypassed  Well pump, P-6  Well pump, P-7  Well pump, P-9  Sequestering agent metering pump, M-2  Muriatic acid metering pump, M-3 GWTF #2  Air stripper blower, B-1  Transfer pump, P-2 – currently bypassed  Well pump, P-1– currently unused  Well pump, P-1S  Sequestering agent metering pump, M-2  Muriatic acid metering pump, M-3 The systems can also be started by the START pushbutton on the front of the control panel. The START sequence tests for sufficient water levels in the influent EQ tank and recovery wells. If these levels are above the low level shut-offs for each location, then the pumps will run. Well pump RW-6 is run manual mode. The pump runs until a low level condition (dry run alarm condition) is achieved. Upon reaching a low level condition, the CU300 recognizes high amp draws, and alarms out for a dry run condition. The pump is then turned off. The other well pumps (P-7, P-9, and P-1S) will automatically go into dynamic level control whereby a preset water table elevation is maintained using proportional-integral-derivative (PID) level controllers (refer to Section 3.4.3). In the event any of these levels gets out of control for any reason, high and low level interlocks are in place to cycle the pumps as necessary and prevent them from running dry. The sequestering agent metering pump is interlocked with the recovery well pumps. At least one recovery well pump must be running for either of these pumps to run in AUTO mode. After starting, the speed of these pumps is controlled manually at the metering pump based on influent flow rates and the rate of fouling of the bag filters and the air stripper trays. O and M Manual - Rev 1.doc 3-3 The muriatic acid metering pump is interlocked with the air stripper influent flow rate . A minimum flow rate of 5 gpm must be maintained in order for the muriatic acid metering pump to run in AUTO mode. After starting, the speed of this pump is controlled automatically by its PID controller to maintain the desired pH setpoint entered by the operator in the PID screen. All upstream groundwater equipment is interlocked with the air stripper blower, B-1. The air stripper blower must be running in order for any pumps to run in AUTO mode. In the event of a normal shutdown in which the operator clicks the System STOP button, all upstream equipment will shut off immediately while the air stripper blower continues to run for 5 minutes in order to treat all water remaining on its trays. In GWTF #1 the heat exchanger (no longer in use), HX-1, is interlocked (no longer interlocked) with both the air stripper blower (B-1) and the SVE blower (B-2) (no longer in use). The heat exchanger will not run in AUTO mode unless one of these blowers is running. The air stripper blower and SVE blower in GWTF #1 have separate shutdown interlocks (no longer in use) listed in Table 3-1. One interlock in particular is shared between these two blowers – the heat exchanger high temperature switch, TSH-1625. In the event the heat exchanger fails or for whatever reason the air temperature leading to the off-gas treatment system exceeds 120 °F, each blower and the entire facility shuts down (no longer applicable). 3.3 Control System Functionality Overview The control system is designed for automatic, unattended operation after completing manual set- up tasks described in Section 4.0. The Human-Machine Interface (HMI) software running on the OIT provides graphical images of the processes and equipment associated with the facility. Graphical control panels are provided for each motor which include Windows® push buttons for START, STOP, AUTO and MAN(ual). System-wide START, STOP & RESET pushbuttons are also provided on the front of the control panel. All analog inputs used by the system are displayed in real-time, including groundwater influent flow rate and totalized gallons, recovery well water levels, chemical metering pump dosage rates, etc. All alarm conditions are displayed in their appropriate positions in the P&ID formatted MAIN screen and in an ALARM summary screen from which alarms are acknowledged by the operator. All I/O, including alarm conditions, is logged in database formatted (*.dbf) files, which can be downloaded to remote PCs and directly accessed with Microsoft Excel®. All alarm conditions cause autodialer callouts to a O and M Manual - Rev 1.doc 3-4 select list of respondents via voice, fax or pager (refer to Section 3.5). Remote access is provided via PC-to-PC direct wireless modem communications using pcAnywhere® remote access software (refer to Section 3.6). This remote connection gives authorized remote callers full access to the OIT for control, monitoring and downloading data files. 3.4 Human-Machine Interface (HMI) The HMI software running on the OIT provides the operator with a process control and monitoring workstation. It consists of a touch screen industrial computer mounted in the front of the control panel enclosure (located in the field office portion of each building) running Rockwell Automation’s RSView32 Works software. The components of the configured software used by the operator include:  Process control screens depicting all controlled processes in P&ID format  Master System Start, System Stop and Reset buttons  Pop-up motor control panels for starting, stopping and selecting modes of operation for individual motors  PID controllers for controlling recovery well water levels and effluent pH  Alarm display listing any current alarm condition  Data logs for all integrated process and status variables  Alarm logs listing all previous alarm conditions  Trend screens depicting real-time and historical process data in “line graph” format The HMI software starts automatically whenever power is applied to the OIT. The MAIN screen, described in Section 3.4.1, is the first to be displayed after power up. All other screens are accessed through an intuitive menu system of Windows® buttons using a touch screen pointer, mouse or finger. A detailed discussion of the features and functions of each of the HMI screens is provided in the ensuing subsections. 3.4.1 MAIN Screen The MAIN screens shown in Figures 1 and 2 include all of the process equipment controlled by the PLC, analog and discrete I/O, and alarm conditions for the system. The functionality of this screen includes images of pumps and blowers that when clicked bring up the pop-up control panels depicted in Figures 3 and 4, plus each image is animated to indicate whether the motor is running. Each pop-up panel contains buttons for AUTO or MAN(ual) modes, START and STOP, and status indicators for the motors and buttons. Additional functionality is provided by real-time numerical displays of water table elevations in recovery wells, influent groundwater O and M Manual - Rev 1.doc 3-5 flow rate, totalized influent gallons and effluent pH. To access the other HMI screens, the operator must click the SCREENS button at the top of the MAIN screen. Figure 1 – MAIN Screen, GWTF #1 O and M Manual - Rev 1.doc 3-6 Figure 2 – MAIN Screen, GWTF #2 O and M Manual - Rev 1.doc 3-7 Figure 3 – MAIN Screen with Pop-Up Motor Control Panels, GWTF #1 O and M Manual - Rev 1.doc 3-8 Figure 4 – MAIN Screen with Pop-Up Motor Control Panels, GWTF #2 3.4.2 MOTORS Screen The pop-up motor control panels accessed from the MAIN screen are all available on the MOTORS screen shown in Figures 5 and 6. The motor controls are configured to select AUTO or MAN(ual) modes of operation for each motor. In AUTO mode all control and safety interlocks are applied to the motor control circuits. Conversely, in MAN mode no interlocks are applied. The motor control panels also include status indicators for AUTO / MAN modes, START and STOP switch status, and the current ON / OFF status of the motor. When the operator initiates system start up by pressing the System START button available at the top of all HMI screens the PLC control program automatically places all motors in AUTO mode and then sequentially starts each piece of equipment beginning with the air stripper blower. When the operator stops the system with the System STOP button all motors except the air stripper blower are stopped immediately as though the operator had stopped each individual motor through its O and M Manual - Rev 1.doc 3-9 motor control panel. The air stripper blower is programmed to keep running for five minutes during a normal system shutdown using the System STOP button. All motors remain in AUTO mode at all times during startup and shutdown unless MAN modes are selected by the operator. Figure 5 – MOTORS Screen, GWTF #1 The Motors screen includes a “BYPASS” button that allows the operator to bypass the equalization tank. In BYPASS mode, the recovery well pumps convey groundwater from the wells directly to the air stripper pre-filters – the transfer pumps are not used and are prevented from running. Pressing the BYPASS button causes the entire system to be shut down and placed in bypass mode. The system is then restarted as described in Section 5.0. O and M Manual - Rev 1.doc 3-10 Figure 6 – MOTORS Screen, GWTF #2 3.4.3 PID Screen The PID screen includes PID process controllers for recovery well water table elevation control and effluent pH control. (The term “PID” comes from the proportional-integral-derivative actions that a controller can make in response to an analog input, e.g., water table elevation.) Using water table elevation control as an example, the operator selects a setpoint for the water table elevation in feet amsl by touching or mouse-clicking repeatedly on the increment (+1) or decrement (-1) push buttons provided on either side of the setpoint numerical display on the level (PID) controller until the desired setpoint is displayed. If the PID controller is in AUTO mode the controller will automatically manipulate the speed of the recovery well pump through its analog output to the Grundfos® CU300 controller to achieve the setpoint water table elevation. Manual control of pump speed is provided by the controller by selecting MAN mode and O and M Manual - Rev 1.doc 3-11 incrementing or decrementing the pushbuttons on either side of the controlled variable (CV) numeric display. The CV display is ranged from 0 – 100% which corresponds to a 4 – 20mA analog output signal to the controlled device, i.e., CU300 or effluent muriatic acid metering pump. The PID controllers allow the operator to enable or disable automatic cycling of the controller between AUTO and MAN modes of operation. During normal operations PID controllers are cycled automatically (cycling enabled) between AUTO and MAN modes to maintain a constant controller output when the associated process equipment cycles off. For example, when water flow to the air stripper cycles off the muriatic acid metering pump must cycle off otherwise the PID controller would be making drastically different adjustments than before to accommodate the very different (and meaningless) process dynamics of trying to control pH in small volume of stationary water in a pipe. Whenever the water would begin to flow again the metering pump and pH controller would likely be too slow to react and effluent pH would go out of control. By automatically cycling to MAN mode when water flow stops the PID controller output will be exactly where it was just before the water flow stopped and therefore much closer to where it needs to be and pH control is maintained. The recovery well pumps equipped with PID level control are not expected to cycle off so in actual practice this feature will probably seldom be used on these controllers. But it might be desirable to disable this auto-cycling feature for the effluent pH controller during maintenance or calibration activities since it will otherwise be forced into MAN mode whenever it cycles off. The PID screen is shown below in Figures 7 and 8. The PID action of the recovery well level controllers may be enhanced by enabling “Extra PID logic” by toggling the associated button below each controller. When enabled, this logic will reduce the degree of setpoint “overshoot” sometimes exhibited when the system is first started and the recovery well is drawn down, gradually at first, then rapidly as it nears the water table elevation setpoint. O and M Manual - Rev 1.doc 3-12 Figure 7 – PID Screen, GWTF #1 O and M Manual - Rev 1.doc 3-13 Figure 8 – PID Screen, GWTF #2 3.4.4 ALARMS Screen The presence of an alarm condition is indicated on all HMI screens in the system when the ALARM button at the top of each screen is either flashing red or steady yellow. Flashing red ALARM buttons indicate new alarm conditions not yet acknowledged by the operator. Steady yellow ALARM buttons indicate existing alarm conditions not cleared or reset, but that have already been acknowledged by the operator. The normal state, i.e., no alarms, is indicated by green ALARM buttons, as shown in Figure 9 (representative of both GWTFs). Alarm conditions are identified and acknowledged by clicking the ALARM button on any screen that brings up the Alarm screen shown below. Alarms are acknowledged using one of the three acknowledge buttons provided at the bottom of the screen. Alarm conditions and other control interlocks are listed in Tables 3-1 and 3-2. O and M Manual - Rev 1.doc 3-14 Figure 9 – ALARM Screen, GWTF #1 3.4.5 TREND Screens A real-time trend screen, Figure 10, is configured for the combined influent and air stripper flow rates. Real-time flow rates from the most recent 2-hour period scroll across this screen from right to left. Real-time trend data is not cached when the HMI software (RSView32) is not running and therefore this trend will initially be empty of data when the program is started. Historical trend screens have been configured for combined well influent and air stripper influent flow rates and recovery well water table elevations. These trend screens obtain data from the “pv” data log files and display 28 days of data over any given time period selected by the O and M Manual - Rev 1.doc 3-15 Operator using the scroll backward and scroll forward buttons provided a the bottom of the screens. Figure 11 depicts the historical trend screen for GWTF #1. Figure 10 – Real-Time TREND Screen, GWTF #1 O and M Manual - Rev 1.doc 3-16 Figure 11 – Historical TREND Screen, GWTF #1 3.4.6 Data Logs The HMI is configured to have two types of datalogs, i.e., one that contains analog process variables, or pv’s, expressed in engineering units such as, psig, scfm, etc, and another that contains discrete status variables, or sv’s, which indicate the on-off status of discrete inputs such as motors or switches. Process variables and status variables are created in the HMI by defining a “tag” and assigning a “tagname” to each source of data. Although defining tags and variables is not within the Operator’s realm of responsibility, nor within the scope of this O&M Manual, the terms should be understood when examining data displayed or logged within the HMI. A complete listing of all tags defined in the HMI system is provided in Tables 3-3 and 3-4 for GWTF #1 and GWTF #2, respectively. These tables identify the type of tag (analog or discrete), tagname, tag description, whether it is included in the alarm log (discussed in the next section), O and M Manual - Rev 1.doc 3-17 and whether it is included in the datalog. All analog tags are included in the “pv” datalog and all discrete tags (not included in the alarm log) are included in the “sv” datalog. The pv datalog is an all-inclusive log that polls every process variable defined in the HMI once every 10 minutes. The sv datalog polls every status variable defined in the HMI whenever there is a change of status for any sv tag and at least once every 8 hours at a minimum regardless of status changes. All datalogs are generated in database format files, or *.DBF files. Datalogs may be opened using Microsoft Excel® from the following folders on the C: drive of each OIT:  c:\program files\rockwell software\rsview\tutu1\dlglog\pv1\  c:\program files\rockwell software\rsview\tutu1\dlglog\sv1\  c:\program files\rockwell software\rsview\tutu2\dlglog\pv2\  c:\program files\rockwell software\rsview\tutu2\dlglog\sv2\ Operators and remote callers should first copy the target *.dbf datalog file to another folder or computer before opening the file in order to maintain the integrity of the original files located in the folders listed above. Each datalog file is based on a day of data beginning and ending at midnight. Datalog file names follow a date convention where, for example, “2003 12 01 0000 pv (Wide).DBF” would correspond to the pv file for December 1, 2003. There are actually two files created each day: One labeled “Wide” and the other labeled “Tagname.” The data of interest to the Operator is always found in the files labeled “Wide.” The other file is an index of tagnames of little or no use to the Operator or other users. 3.4.7 Alarm Logs All system alarms in the HMI are displayed in the Alarm screen and copied to an alarm log that resembles the status variable log discussed previously. These log files are generated on a daily basis beginning at midnight using filenames corresponding to the file date exactly like the “sv” datalogs except having the filename suffix “al” instead of “sv”, for example, 20031201AL.DBF corresponding to the alarm file generated on December 1, 2003. The database listing provided above indicates each of the tags that are configured as alarms under the column heading “Alarmed”, where a “Y” next to a tag indicates that tag is so configured. The alarm log files may be found in the following folder: O and M Manual - Rev 1.doc 3-18  c:\program files\rockwell software\rsview\tutu1\almlog\  c:\program files\rockwell software\rsview\tutu2\almlog\ 3.5 Autodialer A Phonetics Sensaphone 2000 alarm autodialer is installed in each control panel to notify remote personnel of conditions requiring attention prior to the next regularly scheduled site visit. Tables 3-1 and 3-2 provide a complete listing of alarm call-out conditions and associated autodialer channel numbers for GWTF #1 and GWTF #2, respectively. The autodialer is capable of calling voice lines, pagers and faxes. Email is an option but not currently configured. Voice calls include a pre-recorded message for the site location and each currently active alarm condition. Alarm call recipients are prompted to enter an acknowledgement code. 3.6 Remote Access Remote access to each facility is accomplished via the internet using Symantec® pcAnywhere® software. Remote access procedures are discussed in pcAnywhere® help files. Setup depends on each remote caller’s individual PC configuration but it can generally be described very simple. New callers must obtain a username and password from project management in order to gain access to the system, download data files and perform remote printing tasks. On-site access numbers are as follows: GWTF #1  Wireless modem static IP address – 166.136.143.26  Autodialer – (340) 774-7297 GWTF #2  Wireless modem static IP address –166.136.143.137  Autodialer – (340) 774-7277 O and M Manual - Rev 1.doc 4-1 4.0 Initial Set-Up Procedures This section provides procedures for the initial set-up and start-up of each piece of equipment following installation or a prolonged shutdown. 4.1 Control Panels The control panel is powered from a 75 KVA 480VAC, 3-phase, 4-wire transformer. This transformer is powered from the 208VAC, 3-phase electrical service (WAPA) to each facility building. WARNING – Do not power the panel until this procedure is complete. Damage to the panel may result. 1. Switch the disconnect to the “OFF” position and open the inner door. Verify that the inner door disconnect is in the off position. 2. Switch on the main incoming power to the panel. (CAUTION - The disconnect now has power.) 3. Confirm that incoming power is 480 V on all three phases. If the incoming power has a “high leg” (a four wire delta system), measure the voltage from each leg to ground. It is critical that L1and L3 to ground be 120 volts. Power for the control panel is taken from either L1 or L3. If the high leg (usually L2, 208V) is wired in the L1 or L3 position, the panel may be damaged upon powering the system. 4. Record the following operating conditions on the initial set-up form provided in Appendix R:  L1 to ground  L2 to ground  L3 to ground  L1 to L2  L1 to L3  L2 to L3 5. Be sure that all circuit breakers are reset. 6. Close the inner door. 7. Turn the inner disconnect to the “ON” position. The panel should have power and the OIT should startup. Alarm lights may be lit on the OIT. If so, press the “RESET” button. If the alarms will not reset, refer to Section 5.2 for details. 8. Rotation needs to be verified on all 3-phase motors. To do so, place each motor in MAN mode from the OIT and bump by quickly clicking START then STOP. Rotation arrows are located most pieces of equipment. If rotation is backwards, swap two incoming power leads. O and M Manual - Rev 1.doc 4-2 (CAUTION - Be sure to lock out and tag the main incoming power. Verify that the power is isolated using a multimeter/voltmeter.) 4.2 Bag Filters 1. Shut down the transfer pumps and remove any pressure that may be in the influent piping by opening the nearest sample port valve (refer to Drawings 2-14 through 2-18 for piping and valve nomenclature) to drain the piping. Then, close the sample port valve. 2. Select and install the correct size filter bag (50 micron to begin the project). 3. To install, open the lid and insert the filter bag into the metal filter basket. Make sure the filter bag is “seated” to the top of the basket and tightly close the lid. 4. Make sure all water connections are made and valves are open or closed as necessary. 5. Open the vent plug on lid to allow air to escape from housing. 6. When the housing body is full of water, close the vent. 7. Open the outlet connection and fully open the inlet connection. Housing is now operating properly. 4.3 Transfer Pumps – Currently Bypassed Unless RW-6 is Running 1. Ensure that the equalization tank has sufficient water and that all valves up stream on the pump are open. (Note: Valves up stream should never be used to throttle the pump. All valves located up stream of a pump are strictly isolation valves for servicing the pump.) Close all sample taps. 2. Turn on the air stripper. 3. Bump the pump to verify rotation as described in Section 4.1, Step #8. Rotation arrows are located on the pump to signify proper rotation. If rotation is backwards, have an electrician exchange two of the power leads as discussed in Section 4.1, Step #8. 4. Prime the pump by running with the discharge throttling valve (HV-INF-TP and HV2-INF- TP) mostly closed then adjust the valve for normal operation. (Note: Never exceed the design hydraulic capacity of the air strippers – 60 gpm at GWTF #1 and 30 gpm at GWTF #2.) 5. Test the prime. Run the pump for a few seconds to verify that water is flowing through the pump at a constant rate and pressure. If not, turn the pump off, loosen the pump housing plug, examine for air, and, if necessary, fill housing with water. Then, repeat Step #3. O and M Manual - Rev 1.doc 4-3 6. Put the pump OIT control panel in the “MAN” position with sufficient water in the equalization tank and click START. Throttle the pump to the desired flow. Record the following operating conditions on the initial set-up form provided in Appendix R:  PUMP motor amp draw  PUMP pressure  PUMP flow rate  Deadhead pressure [pressure with pump isolation valve (HV-INF-TP and HV2-INF-TP) closed] 4.4 Air Strippers 1. Verify that all influent and effluent connections have been made, and open the air inlet valve (HV-VAP-AS) to ensure that there are no restrictions on the blower. Close all sample taps. 2. Verify that the panel is operational and installed is correctly (refer to Section 4.1). 3. For GWTF #1, turn on the heat exchanger after completing the initial setup procedure presented in Section 4.9 (Heat Exchanger is no longer in use). 4. Bump the blower to verify rotation as described in Section 4.1, Step 8. Rotation arrows are located on the blower to signify proper rotation. If rotation is backwards, have an electrician exchange two of the power leads as discussed in Section 4.1, Step #8. 5. Once rotation has been confirmed to be correct, and the blower has completely stopped from Step #4, put the STAT blower OIT control panel in the “AUTO” position and click START to start the blower. Let the blower run with no load for a few minutes. 6. Introduce water into the system. 7. Adjust the air inlet valve (HV-VAP-AS) until the desired air flow rate is achieved. 8. Once the system has reached operating conditions, record the following applicable operating conditions on the initial set-up form provided in Appendix R:  STAT sump pressure  STAT motor amp draw  STAT back pressure, if there is off-gas treatment  Air flow rate  Water flow rate 4.5 Submersible Well Pumps 1. Verify that all pump effluent connections have been made, and open all valves downstream of the pump. Close all sample taps. 2. Review the Grundfos® CU300 Installation and Operation Instructions (refer to Appendix L) and set up each well pump for remote on-off control using the R100 hand-held remote O and M Manual - Rev 1.doc 4-4 control unit. Set up RW-6 pump P-6 for dry run protection. Set up RW-7 pump P-7, RW-9 pump P-9, RW-1 pump P-1, and RW-1S pump P-1S for 4 – 20 mA external speed control. 3. From the OIT PID screen, set RW-7, RW-9, RW-1 and RW-1S level controllers to DISABLE AUTO cycling, and MAN control mode. Manually set the output from each level controller to 100%. 4. Ensure that there is sufficient excess capacity in the EQ tank for temporary storage of recovered groundwater during this initial setup procedure. 5. Close the EQ tank bypass valve (HV-INF-EQB). 6. From the OIT MOTORS screen, place each pump in MAN mode and bump the pump to verify proper operation by clicking START, allowing sufficient time for air to be driven from the empty discharge lines, then clicking STOP. 7. If no there is no flow, then the pump is either not submerged or not wired correctly. If necessary, re-examine the wiring connections versus manufacturer’s installation instructions. Verify water level in each well. Do not run the pump for an extended length of time without water. The pump height should be reevaluated. 8. After verifying flow in MAN mode, put the pump control panel in the “AUTO” position. Throttle the P-6 to the desired flow. Set the level controller setpoint for the other pumps per the Routine Operating Parameters, Tables 5-1 and 5-2. Place each PID controller in ENABLE cycle control and AUTO level control mode. Record the following operating conditions on the initial set-up form provided in Appendix R:  PUMP motor amp draw  PUMP pressure  PUMP flow rate  Deadhead pressure [pressure with wellhead shutoff valve (HV-INF-RW6V, -RW7V, etc) closed] 4.6 SVE System (Facility #1)- Currently Offline The SVE system was taken offline in April 2006. 4.7 Chemical Feed Systems 1. Verify that all influent and effluent connection have been made, and open all outlet, valves to ensure that there are no restrictions on the pump. 2. Prime the pump as discussed in the LMI Operations Manual (Appendix C) with the recycle tubing open to the storage tank. To prime the pump without enabling the entire system, place the chemical feed pump OIT control panel in MAN. O and M Manual - Rev 1.doc 4-5 3. Once the pump has been primed, adjust the stroke speed and length to the recommended settings, and adjust the tubing valves from recycle to discharge. For the muriatic acid pumps, this should be done by first putting the pH controller in the PID screen in DISABLE AUTO cycle and MAN controller mode. Manually adjust the controller output to 100%, then adjust stroke speed and length. 4. With all other systems running, put the pump control panel in the AUTO position. Record the following operating conditions on the initial set-up form provided in Appendix R:  Speed setting  Stroke setting  Maximum rate flow (from tag on the pump body) 4.8 Off-Gas Treatment System (Facility #1) - Currently Offline The off-gas treatment system was taken offline in April 2006. 4.9 Heat Exchanger (Facility #1) - Currently Offline The heat exchanger is not currently operated. 4.10 Miscellaneous Equipment 1. Check the magnetic flow meters for the combined well influent and air stripper influent for proper operation after starting the well pumps and transfer pumps. Verify flow rates based on change in water level in the EQ tanks. 2. Calibrate the effluent pH transmitters per manufacturer’s instructions. 3. Calibrate the water table elevation calculations for RW-7, RW-9, and RW-1S using the PID screens for each facility. With the recovery well pumps turned off and the water column readings fairly stable, obtain a depth to water reading from each well. Using the current water column reading obtained from the PID screens, perform the following calculation: TOC-DTW-WC = LTEL (where each of these acronyms are defined in the PID screen) and enter the resulting new value for LTEL for each well. The re-calibrated water table elevation calculations will begin instantly in the PLC, as displayed on the PID screens. 4. Verify proper operation and make adjustments as necessary for the air stripper influent bag filters by throttling the filter discharge valves (HV2-INF-BF1 and HV2-INF-BF2) and reading the upstream and downstream pressure gauges. O and M Manual - Rev 1.doc 4-6 O and M Manual - Rev 1.doc 5-1 5.0 Systems Operating Procedures This section presents the procedures for operating each GWTF once the equipment is installed and initial set-up (refer to Section 4.0) is completed. In the event the system is shutdown for a period of months or years, the procedures presented in Section 4.0 should be repeated. Both systems currently operate with bypass of the EQ tank and transfer pumps. 5.1 Preliminary Checks Prior to System Start-Up A series of checks must be performed prior to starting up the system following a prolonged shutdown, a maintenance/repair event, a valve adjustment, or other change in system conditions. Preliminary, visual checks shall include the following items:  Check to be sure that each extraction well shutoff valve (HV-INF-RW6V, -RW7V, etc) inside the wellhead vault is in the normal, open position.  Check the groundwater line Y-strainers, and clean as necessary.  Check to be sure that the groundwater influent line isolation valves (HV-INF-RW6, HV2-INF-RW6, HV-INF-RW7, HV2-INF-RW7, etc) are open.  Check to be sure that the treated water discharge valve is open.  Check the bag filters and replace as necessary.  Check to be sure that the EQ tank bypass valve (HV-INF-EQB) is closed, unless bypass mode is desired (refer to Section 5.5)  Check to be sure that the transfer pumps isolation valves (HV-INF-TP and HV2-INF-TP) are closed, unless no bypass mode is desired (refer to Section 5.5).  Check the chemical levels in each drum. Batch and refill as necessary.  Check the chemical feed pumps for prime. If necessary, prime the pump(s) in accordance with LMI instructions (Appendix C). 5.2 Full Automatic Start-Up and Operation The start-up procedure described here begins only after all mechanical and electrical start-up procedures are completed in accordance with Section 4.0. Assuming that electrical power has been successfully applied to the building, control panel and all process motors, including checking for correct rotation on all 3-phase motors, the on-site operator should examine any alarm conditions indicated on any OIT screen by a flashing red or steady yellow condition of the ALARM button in the top right hand corner. If this button is not steady green, the operator O and M Manual - Rev 1.doc 5-2 should click on the ALARM button to access a description of the alarm condition, acknowledge the alarm with the ACKNOWLEDGE button at the bottom of the ALARM screen, and investigate. As indicated in Tables 3-1 and 3-2, some alarm conditions will prevent the system from running and must therefore be corrected prior to start-up. Take all appropriate corrective measures to resolve any alarm condition before proceeding with start-up. Refer to the troubleshooting section (Section 8.0) for more information on resolving alarm conditions. Once the condition causing an alarm is resolved, the operator must click RESET to clear any latched conditions that may prevent start-up. Prior to startup, the operator must examine the setpoints and outputs for all PID controllers and decide whether to make changes or leave them as is. Setpoints only change as a result of operator intervention to adjust a setpoint in the manner described earlier by clicking on the increment or decrement buttons on each controller. Unless a change in operational parameters is warranted, these values would remain set regardless of whether the system has recently been down or running. The PID outputs change automatically and therefore should be examined to make sure that system startup proceeds smoothly and as expected. The PID controllers are programmed to maintain their last output prior to the point at which the corresponding process equipment was turned off or shutdown automatically. But system conditions may have changed significantly since the last time a piece of equipment ran under PID control and therefore a significant change in controller output may be required prior to startup, or the PID controller may need to be operated in MAN(ual) mode for a short period of time during and after startup to assure a smooth transition to steady-state operation. The system is configured for two modes of start-up, i.e., automatic and manual start-up. Automatic start-up is initiated by clicking the System START button on any OIT screen, or by pressing the START pushbutton on the front of the control panel. The control system automatically starts all motors and controllers in AUTO modes in sequential order, as described in Section 3.2. Manual startup involves sequentially starting each motor by selecting it from either the MAIN scr\een or MOTORS screen in the OIT. In a manual startup the Operator must be careful to select AUTO mode for each motor and PID controller. Each motor in the system can be placed in service or out of service with a button provided in its control panel. When a motor is taken out of service it will not be started automatically with the O and M Manual - Rev 1.doc 5-3 rest of the system by clicking the System START button. Any motor taken out of service is so indicated on its control panel, the MAIN screen, and the MOTORS screen. Full automatic startup starts all motors and processes in the system, as follows: 1. Power up the control panel and OIT from the 60 amp circuit breaker in Panel P-1. The RSView32® HMI software will start automatically and display the MAIN screen. 2. Switch to the MOTORS screen and select all motors for service using the service button in each motor control panel. 3. Switch to the PID screen and examine the setpoints and outputs for all PID controllers. In particular, make sure the effluent pH controller output is not at 100%. A good place to start for the pH controller output and the dosage rates would be the last values of each controller prior to the previous system shutdown, as displayed on the historical Trend screens. To change any controller output, first, disable the AUTO cycling feature of the controller, then place the controller in MAN mode and manually adjust the controller output using the increment and decrement buttons. Place all controllers back into AUTO mode and enable AUTO cycling. Examine the dosage rate (ppmv) for sequestering agent. Adjust chemical feed rate manually at metering pump. 4. Check the Grundfos® CU300 controller for each recovery well submersible pump to make sure it is set for remote speed and on-off control. (Follow manufacturer’s instructions provided in Appendix L.) 5. Click the System START button at the top of any screen. Startup will take a few seconds during which time the message box at the top of the screen will indicate that the system is starting. All motors and processes will be started. 6. Confirm that all motors and processes have started and observe operations for at least 30 minutes to see if any alarms occur. Any alarm condition will require acknowledgement and RESET through the OIT (or the RESET pushbutton on the control panel). If necessary, see the Troubleshooting Guidelines in Section 8.0 for further discussion on resolving alarm conditions. 7. When EQ tank is used such as when operating RW-6, adjust the transfer pump discharge valves (HV2-INF-TP1 and HV2-INF-TP2) to ensure that the well pumps do not cycle, yet maximize the time it takes to drain the EQ tanks. In other words, the transfer pumping rate should be set slightly higher than the combined well influent rate when all pumps are running. O and M Manual - Rev 1.doc 5-4 5.3 Automatic Startup and Operation of Select Equipment Some motors or processes may not be functioning or may not be part of the desired operational plan. In these instances, follow the procedure below. 1. Power up the control panel and OIT from the 60 amp circuit breaker in Panel P-1. The RSView32® HMI software will start automatically and display the MAIN screen. 2. Switch to the MOTORS screen and select only the motors required for service using the service button in each motor control panel. 3. Switch to the PID screen and examine the setpoints and outputs for all PID controllers. In particular, make sure the effluent pH controller output is not at 100%. A good place to start for the pH controller output and the dosage rates would be the last values of each controller prior to the previous system shutdown, as displayed on the historical Trend screens. To change any controller output, first, disable the AUTO cycling feature of the controller, then place the controller in MAN mode and manually adjust the controller output using the increment and decrement buttons. Place all controllers back into AUTO mode and enable AUTO cycling. Examine the dosage rate (ppmv) for sequestering agent. Enter the desired dosage rates at each numeric input using the OIT keyboard. 4. Check the Grundfos® CU300 controller for each recovery well submersible pump to make sure it is set for remote speed and on-off control. (Follow manufacturer’s instructions provided in Appendix L.) 5. Click the System START button at the top of any screen. Startup will take a few seconds during which time the message box at the top of the screen will indicate that the system is starting. Only the selected motors and processes will be started. PID controllers associated with motors taken out of service will remain in MAN mode but the outputs will have no effect on any processes. 6. Confirm that selected motors and processes have started and observe operations for at least 30 minutes to see if any alarms occur. Any alarm condition will require acknowledgement and RESET through the OIT (or the RESET pushbutton on the control panel). If necessary, see the Troubleshooting Guidelines in Section 8.0 for further discussion on resolving alarm conditions. 7. When EQ tank is used such as when operating RW-6, adjust the transfer pump discharge throttling valves (HV2-INF-TP1 and HV2-INF-TP2) to ensure that the well pumps do not cycle, yet maximize the time it takes to drain the EQ tanks. In other words, the transfer O and M Manual - Rev 1.doc 5-5 pumping rate should be set slightly higher than the combined well influent rate when all pumps are running. 5.4 Manual Speed Control for Submersible Well Pumps The recovery well PID level controllers may be placed in MAN(ual) mode to control the submersible well pump motor speed and flow rate directly, as follows: 1. From the PID screen or PID controller pop-up window on the MAIN screen, disable AUTO cycling and place the controller in MAN(ual) mode. 2. Adjust the controller output using the increment and decrement buttons on either side of the CV numeric display. The speed of the pump motor may be adjusted from 0 to 100% of range which corresponds to the full range of the Grundfos® CU300 controller for each pump. 3. Check the flow rates manually by reading the totalizing flow meter for each recovery well installed in the influent piping header system. These are located at GWTF #1 on the wall of the equalization tank secondary containment structure and at GWTF #2 on an exterior wall of the building. 4. With the PID controllers in MAN(ual) mode, the recovery well water table elevation control is no longer tied to the setpoint for water table elevation. Instead, the water level in the wells will be controlled between discrete high and low elevations programmed from the level transmitter signal for each well. Note that in order for these high and low level elevations to control (cycle) the recovery well pumps, the motors must be in AUTO mode as set through each motor control panel or the MOTORS screen. The high and low level elevation settings are indicated in the Routine Operating Parameters (Tables 5-1 and 5-2) for each facility. 5.5 Operation with Equalization Tank Bypass Both facilities currently operate with bypass of the EQ tank. If desired, this may be implemented as follows: 1. From the MOTORS screen, turn off all recovery well pumps and allow the rest of the groundwater treatment system to run until the EQ tank is drained to the low level shut off for the transfer pumps. 2. Manually drain any water or sludge remaining in the bottom of the equalization tank and drum for off-site disposal. O and M Manual - Rev 1.doc 5-6 3. Open the EQ tank manual bypass valves (HV-INF-EQB) and close the transfer pump isolation valves (HV-INF-TP and HV2-INF-TP). 4. From the MOTORS screen, take the transfer pumps out of service by toggling the SERVICE button in each motor control panel. 5. Disconnect power to each transfer pump at the disconnect switches provided inside the equipment room at each facility. 6. From the MOTORS screen, select BYPASS mode and turn on all recovery well pumps desired for operation. The control system will now function as before except the transfer pumps and EQ tank will not be utilized. 5.6 Routine Operations The groundwater recovery and treatment systems are designed for unattended operation in AUTO mode. All automated process control interlocks (refer to Tables 3-1 and 3-2) will be applied in AUTO mode and safety interlocks will cause system shutdown in the event such alarm conditions occur. During routine operations, on-site and off-site operators can adjust recovery well water table elevations, sequestering agent dosage rates, and effluent pH setpoint without shutting the system down. The expected (normal) values and upper and lower limits for the routine operating parameters associated with each system are provided in Tables 5-1 and 5-2. Various modes of operation are possible with the groundwater recovery and treatment system, but the initial control strategy is to maintain water table elevations in recovery wells RW-1S, RW-7 the desired setpoints in terms of feet above mean sea level (amsl). RW-9 is only operated as required to enhance drawdown at RW-7 during period of high groundwater levels. If well yields are sufficient, these pumps will run continuously in the absence of any other process upsets downstream. Water table elevation calculations should be checked periodically as a part of routine operations to ensure accurate water level sensing and the correct calculation of water table elevations. PID control and low well water shutdown interlocks depend on the accuracy of these process values. The procedure for checking and perhaps making adjustments to this calculation is herein referred to as a “calibration”. Calibration involves taking a manual depth- to-water reading in the recovery well, observing the water column value displayed in the PID screen, and calculating a new level transmitter elevation according to the formula provided on the screen. The new level transmitter elevation thus calculated is entered into the PLC data table through the numeric input provided in the PID screen. The recovery well pumps may need to be shut down temporarily in order to obtain steady depth-to-water or water column readings. O and M Manual - Rev 1.doc 5-7 The sequestering agent dosage rates are selected by the operator based on experience with the treatment system and rate of accumulation of scale and bio-fouling in the air stripper pre-filters and air stripper trays. The initial settings anticipated prior to system installation were 125 ppmv for sequestering agent. Adjustments to the dosage rates are made manually at the metering pump. 5.7 Operator Shutdown The systems can be shut down by the operator either automatically or manually. Automatic shutdown occurs when the operator clicks System STOP from any of the OIT screens or by pressing the STOP pushbutton on the front of the control panel. Alternatively, the Operator may choose to shut down any or all system components by selecting each from either the MAIN or MOTORS screens. Refer to the control logic section (Section 3.2) for further information on interlocks and the effect of shutting down individual motors. All motors and processes stop according to a pre-programmed sequence wherein everything stops immediately except the air stripper and heat exchanger continue to run for 5 minutes to treat any water remaining on the air stripper trays. In automatic shutdown the air stripper blower remains running for 5 minutes following the shutdown of all other liquid pumps in the system in order to treat any water remaining on the air stripper trays. 5.8 Automatic Shutdown on Alarm Condition Automatic shutdown will occur in accordance with the interlocks listed in Table 3-1 and Table 3-2 for GWTF #1 and GWTF #2, respectively. Select recipients will be called according to the alarm callout list. Automatic shutdown conditions will cause an alarm interlock which must be investigated and reset prior to re-starting the system using the RESET button on any OIT screen or the RESET pushbutton on the front of the control panel. Tables 3-1 and 3-2 list the alarm conditions that cause system shutdowns. The process is automatic and no intervention is required by the operator to initiate this type of shutdown. Alarm conditions must be acknowledged and RESET using the RESET button on any screen or the RESET pushbutton on the front of the control panel. Refer to the Troubleshooting Guidelines for specific details on resolving alarm conditions. O and M Manual - Rev 1.doc 5-8 5.9 Emergency Shutdown An emergency shutdown is initiated by pressing the E-STOP button on the front of the control panel. This de-energizes all I/O circuits and power supplies instantly and independently of the PLC and OIT. This would rarely be used except in emergency situations involving, e.g., fire, spills, motor bearing failures or any situation where the operator determines it is necessary to prevent a potential problem. The E-STOP is reset by twisting and pulling out on the E-STOP pushbutton. O and M Manual - Rev 1.doc 6-1 6.0 Maintenance Procedures Each GWTF is comprised of a number of commercially available equipment, instrumentation, and appurtenances. This section presents general procedures for preventative maintenance, repair, and replacement. The information in this section supplements the manufacturer O&M literature contained in Appendices A through M. 6.1 Preventative Maintenance and Lubrication Schedules The components of the treatment plant require regular maintenance. Each major component has a preventative maintenance program established by the component manufacturer. Tables 6-1 and 6-2 are provided as a general guide for preventative maintenance. The recommended maintenance intervals are based upon past experience with the equipment and equipment manufacturer recommendations. Records of maintenance for each component should be maintained as discussed in Section 11.2. A maintenance log sheet is provided in Appendix R. For additional preventative maintenance and lubrication details, refer to the manufacturer specific O&M manuals in Appendices A through M. 6.2 Replacement of Consumable Items Consumable items should be replaced at regular intervals and/or when field measurements suggest that replacement is necessary. 6.2.1 Bag Filters When used, the Bag Filter should be changed whenever the pressure drop across the filter increases 12 psi higher than the pressure drop for new/clean filters. The following general procedure should be followed: 1. When the differential pressure across the housing reaches approximately 12 psi, the filter bag(s), need to be replaced. (Note: It may take days or weeks for the differential pressure to reach 12 psi, but the differential pressure will rise very quickly when it approaches 12 psi.) 2. Relieve pressure through the sample tap on lid and drain using the valve (HV-D-BF1 and HV-D-BF2) near the bottom of housing. 3. Loosen eye nuts on housing, and swing the lid to gain full access to the inside of the housing. 4. Pull the filter out of the basket and discard the filter in accordance with the EPP. 5. Remove filter baskets and clean thoroughly. O and M Manual - Rev 1.doc 6-2 6. Debris and sludge should be removed from the housing, to prolong filter efficiency. 7. Install filter basket and new filter bag in housing and follow the start up procedure (refer to Section 4.2). 6.2.2 Chemical Additives The scale inhibitor (sequesterant) and muriatic (hydrochloric) acid solutions are batched in respective 50-gallon HPDE tanks (drums). On a weekly basis, the tanks must be checked and refilled or replaced as necessary. Currently, sequesterant is being batched at 9 gallons of Caltrol 100 to 41 gallons of water (equivalent to a 20% solution). Muriatic acid is being batched at 16 gallons of muriatic acid (31.45% HCl) to 34 gallons of water. This ratio, based on experience, is optimal for achieving pH control at both sites. Refer to Appendix O for MSDSs for each product. Since muriatic acid is a solution of hydrochloric acid gas, beware of toxic or irritating gaseous emissions. 6.2.3 Off-Gas Treatment Media – Currently Offline The off-gas system was taken offline in April 2006. 6.3 Extraction Well Maintenance At least once per year, each extraction well pump should be pulled and inspected for bacterial accumulation (“slime”). Flow rates from each well should be monitored closely. If, for example, the flow rate from a well declines, even though the valve positioning has not changed, then the specific capacity of the well has changed, the pump is not functioning properly, or the in-line Y-strainer is plugged. The Y-strainer should be checked on a regular basis and cleaned as necessary. The groundwater extraction wells may be subject to bacterial activity that causes biofouling. As a preventative measure, shock chlorination should be performed whenever the treatment plant is shutdown for maintenance or during other prolonged shutdown periods. It is recommended that approximately ½ gallon of chlorine bleach be poured into each well and allowed to set for around 12 hours. Shock chlorination may only be performed after all groundwater sampling activities are completed. O and M Manual - Rev 1.doc 6-3 6.4 Shutdown for Maintenance, Repair, or Replacement The following general procedures should be followed in the event a piece of equipment must be shutdown for prolonged maintenance, repair, or replacement. CAUTION – When disabling any motor or piece of equipment, be certain that all source of power and fluid have been locked out and tagged. 6.4.1 Bag Filters 1. Disable all source of water up stream of the bag filters. 2. Drain the filter housing. 6.4.2 Transfer Pumps 1. Disable pump. 2. Drain pump head and all inlet and effluent lines. 6.4.3 Air Strippers 1. Be sure that all sources of water are disabled. 2. Let system blower continue to run for 10 minutes. 3. Disable blower. 4. Remove all remaining water in the sump. 6.4.4 Submersible Well Pumps 1. Disable pump. 2. Drain all water from pump effluent line. 6.4.5 SVE System – Currently Offline The SVE system is offline. 6.4.6 Chemical Feed Systems 1. Disable power to the pump. 2. Drain pump head and all inlet and effluent lines. 6.4.7 Off-Gas Treatment System – Currently Offline The off-gas system is offline. O and M Manual - Rev 1.doc 6-4 6.4.8 Heat Exchanger – Not Used The heat exchanger is currently not operated. 6.5 Spare Parts List Table 6-3 provides a list of spare parts and identification numbers for the primary pieces of equipment in each system. O and M Manual - Rev 1.doc 7-1 7.0 Inspection and Monitoring Procedures This section discusses the general inspection and monitoring procedures required to:  Ensure safe operation of the treatment plant  Identify signs that maintenance is necessary  Promote conformance of operation with relevant regulations and permit requirements  Reduce unplanned shutdowns of the plant  Prevent accidental discharges of untreated groundwater and chemicals  Prolong the service life of plant components  Enhance treatment performance In addition to routine preventative maintenance (refer to Section 6.0), all components of the treatment plant will require regular inspection and monitoring during long-term O&M. A general schedule for routine inspection, monitoring, and maintenance is presented in Table 7-1. (Table 7-1 supplements Table 6-1 with respect to preventative maintenance requirements.) The inspection, monitoring, and maintenance frequencies presented in Table 7-1 are based on operating experience and manufacturer recommendations. 7.1 Extraction Wells and Pumps The groundwater extraction wells and submersible pumps must be regularly monitored to evaluate the performance of groundwater extraction system. The following parameters should be monitored and recorded:  Position of the shutoff valve at each wellhead  Wellhead/pump pressure readings  Pump totalized flow and flow rate A groundwater extraction well monitoring log is included in Appendix R. Operators should regularly inspect all equipment associated with the wells and perform maintenance as needed, as discussed in Section 6.4. 7.2 Conveyance Piping A thorough inspection of visible portions of the conveyance system should be performed at least monthly. The primary issues of concern for the conveyance system are leakage, deterioration of O and M Manual - Rev 1.doc 7-2 the pipelines, and clogging of the pipelines due to scaling, biofouling, or other physical obstructions. The following items should be addressed:  Piping must not be allowed to release fluids. Any evidence of leakage outside a containment features must be reported to DPNR immediately. Leaking pipes must be shutdown, isolated, repaired, and pressure tested as soon as possible.  Low-point sumps should be inspected on a regular basis and emptied as necessary.  All valves and appurtenances should be inspected and maintained as recommended by the manufacturer. 7.3 Treatment Plants The treatment plant operating and process parameters must be monitored on a daily basis (during visits to each GWTF). Routine inspection and monitoring activities shall include:  Checking the OIT for alarm conditions  Recording relevant operating parameters, including: - Extraction well water level - Extraction well pump flow rate, pressure, and totalized flow - Air stripper influent flow rate and totalized flow - Transfer pump(s) discharge pressure and flow rate, when used - Bag filter differential pressure - Air stripper blower flow rate - Air stripper blower vacuum, discharge pressure, and temperature - Chemical injection rates - Treated water effluent pH - Other routine operating parameters (refer to Tables 5-1 and 5-2)  Checking the position of isolation and throttling valves (refer to Drawings 2-14 through 2-18 for piping and valve nomenclature)  Adjusting operations, as necessary  Performing scheduled routine maintenance (refer to Tables 6-1 and 7-1), as necessary The expected (normal) values for the primary operating parameters are presented in Tables 5-1 and 5-2. Operating parameter values shall be recorded manually using the log sheets/forms provided in Appendix R or printed in a hardcopy report format using the datalogging function of the OIT (refer to Section 3.4.6). All other plant information and operating data should be kept in a field logbook. O and M Manual - Rev 1.doc 8-1 8.0 Troubleshooting Guidelines The general troubleshooting guidelines for each primary piece of equipment are presented in Tables 8-1 and 8-2. Further details are provided in the manufacturer-specific O&M literature contained in Appendices A through M. In general, any time the system will not run, and there is not an alarm condition present, verify the following: 1. The control panel and OIT are powered. (The OIT is configured to come on automatically each time its power is restored.) Check voltages on L1, L2 & L3 entering the control panel for 480VAC between each. 2. All circuit breakers are reset. Open the inner door and reset any circuit breakers that may have been tripped. Inspect the system for abnormal conditions. 3. On the control panel terminal strip, verify that positions 121, 121A and 201 all have 120VAC. 4. Verify that all motor temperature switches are wired. Some motors have internal temperature switches that do not require external connection. If a motor has internal temperature switches, the provided space in the panel for external temperature switches must be wired to close the circuit. O and M Manual - Rev 1.doc 9-1 9.0 Sampling and Monitoring Activities This section provides a brief summary of the sampling and field measurements requirements for long-term O&M. For details, the reader is referred to the site-specific QAPP (CDM Smith, 2009). These documents cover, among other things, data quality objectives, field sampling procedures, analytical methods, field and laboratory QA/QC, and sample documentation protocols. Environmental sampling, monitoring, and field measurement data will be collected as part of the following long-term O&M programs:  Performance and compliance monitoring  Sitewide groundwater monitoring Tables 2-9 and 2-10 from this document present the schedule for each of these programs, including the types of environmental samples and field measurements that will be collected, collection frequencies, and the sample and measurement locations. Performance and Compliance Monitoring  Groundwater influent samples from each extraction well  Treated water effluent samples  Air emissions samples from the stack at GWTF #1  Readings from each system’s instrumentation, meters, and gauges Sitewide Groundwater Monitoring  Groundwater monitoring well samples and field measurements  Groundwater level measurements (synoptic and continuous) O and M Manual - Rev 1.doc 10-1 10.0 Health and Safety Guidelines The O&M subcontractor is responsible for preparing and implementing a SSHP in accordance with all applicable reference standards. This section of the O&M Manual is not intended to duplicate information to be contained in the SSHP. Rather, this section highlights the most significant health and safety issues specific to O&M. 10.1 Physical and Chemical Hazards During O&M, operators will be exposed to the following physical and chemicals hazards:  Heavy Equipment – Operators must be aware of the potential physical hazards associated with use of heavy equipment (fork lifts, vacuum trucks, cranes, and other vehicles) and electrical equipment (electrical panels, electric motors, electrical controls, and energized wires) during the operation and maintenance of each treatment plant.  Slip/Trip/Fall – Significant slip/trip/fall hazards exist within the treatment plant, including piping, vaults, equipment skids, and secondary containment berms.  Chemical Vapors – Volatile organic vapors may be released from process equipment and piping due to leaks. These vapors could potentially accumulate within the process building at unsafe levels.  Chemical Additives – The chemical additives used in the process include muriatic acid, and anti-scalant. These chemicals will be stored in drums located inside the process room. The material safety data sheets (MSDS) for each chemical are provided in Appendix O. Since muriatic acid is a solution of hydrochloric acid, operators must beware of toxic or irritating gaseous emissions.  Hazardous Energy – The unexpected startup of equipment is a serious hazard during maintenance and repair events. Lockout/tagout procedures must be implemented (consistent with the specific piece of equipment) to ensure that power and other sources of energy are de-energized or isolated.  Noise – It is likely that noise (decibel) levels inside the process room will exceed OSHA permissible exposure limits. O and M Manual - Rev 1.doc 10-2 10.2 Control Measures and Precautions Appropriate O&M control measures include, but are not limited to, the following:  Wearing hard-hats, safety glasses, and steel-toed boots  Wearing gloves when handling heavy equipment  Using hearing protection when noise levels exceed OSHA limits, particularly when working near running blowers  Properly grounding electrical equipment  Using lock out/tag out practices when electrically powered equipment must be taken out of service for maintenance  Wearing protective equipment when handling acid  Providing adequate ventilation by opening doors, louvers, and operating the exhaust fan, as appropriate  Having first aid kit(s), eye wash stations, and fire extinguishers available at each facility  Marking slip/trip/fall hazards with signs, paint schemes, or physical barriers, as appropriate. Additional, system-specific safety precautions are listed here for reference:  Never enter an equipment vessel without adequate ventilation, proper atmospheric testing and safety equipment. An equipment vessel is considered a confined space and therefore OSHA confined space entry safety procedures must be followed (29 CFR 1910.146).  Safety goggles, chemical-resistant gloves, and a chemical-resistant apron must be worn when filling or replacing chemical tanks.  Concentrated muriatic acid and sodium hypochlorite must NEVER be mixed.  Once locks have been applied to a piece of equipment being serviced, the operator must attempt to start the equipment (i.e. by engaging the disconnect switch). In addition, the operator must test the power feed to the equipment using a multimeter/voltmeter. These steps are intended to ensure that the power has been properly de-energized or isolated. O and M Manual - Rev 1.doc 11-1 11.0 Recordkeeping and Reporting This section discusses the general recordkeeping and reporting requirements for operations and maintenance. Applicable forms and logs are provided in Appendix R, including:  System runtime and shutdown  Groundwater influent monitoring  GWTF systems monitoring  Monthly water levels  Groundwater extraction well monitoring  Chemical usage  Maintenance activities  Equipment initial start-up and testing 11.1 Operations Records Routine operating parameters should be recorded on a monthly basis and recorded on the treatment plant monitoring log provided in Appendix R. Operators shall record the date, time, and value for each parameter obtained from one of the following sources:  Manual readings from instruments, meters, and gauges  OIT MAIN screen  OIT real-time trend screens Off-site record keeping will include at least monthly data file transfers of all “pv”, “sv” and “alarm” logs stored on the hard drive at the locations described in Sections 3.4.6 & 3.4.7. Each groundwater extraction well shall be monitored on a weekly basis to verify the position of the wellhead shutoff valve, wellhead pressure, and water flow rate. Chemical usage information shall be recorded each time the feed tank/drum is filled or replaced. 11.2 Maintenance Records A record of maintenance and lubrication for each component should also be maintained. A file should be maintained for each component requiring or receiving maintenance or repair. The maintenance log sheet contained in Appendix R should be used to record the date, component serviced, nature of service (lubrication, cleaning, filter replacement, condensate removal, etc.), O and M Manual - Rev 1.doc 11-2 and all additional related comments. A log of system shutdowns (refer to Appendix R) should also be maintained, including the date of the shutdown, the type of shutdown (planned or unplanned), root cause, and corrective actions, as applicable. 11.3 Monthly Operations Summary Report The O&M Subcontractor shall prepare a monthly report summarizing the O&M data and systems monitoring information collected during the calendar month, including, but not limited to, the following items:  Percentage of system uptime and hours of operation  Measured values for all standard operating parameters  Description of adjustments performed  Analytical results for groundwater, treated water, and vapor samples  Results of all field measurements (i.e. water levels)  Summary of maintenance performed  Description of any shutdown events  Operational problems and remedies  Utility usage and costs  Chemical consumption  Labor requirements  Health and safety issues  Technical support  General systems observations Applicable forms and logs (Appendix R) shall be submitted as attachments to the monthly operations summary report. O and M Manual - Rev 1.doc 12-1 12.0 References Arrowhead Contracting, Inc. June 2004. Final Operations and Maintenance Manual, Groundwater Treatment Facilities #1 and #2, Site-wide Groundwater and Curriculum Center SVE Remedial Actions, Tutu Wellfield Superfund Site, St. Thomas, U.S. Virgin Islands CDM Smith. April 2009. Final Quality Assurance Project Plan, Tutu Wellfield Site, Long Term Response Action, St. Thomas, U.S. Virgin Islands, Work Assignment No. 003-RALR-021D Table 1-1 Project O&M Directory COMPANY / ORGANIZATION ROLE / TITLE ADDRESS / PHONE CONTACT U.S. EPA, Region 2 Project Manager 290 Broadway – 20th Floor New York, NY 10007-1866 (212) 637-4275 Caroline Kwan Department of Planning and Natural Resources (DPNR) Water Discharge Permitting Div. of Environmental Protection Cyril E. King Airport Terminal Building, 2nd Floor St. Thomas, VI 00802 (340) 774-3320 Rhonda Liburd Air Discharge Permitting Div. of Environmental Protection Cyril E. King Airport Terminal Building, 2nd Floor St. Thomas, VI 00802 (340) 774-3320 Aurea Olive Groundwater, UST, Terminal Facility Program Manager Div. of Environmental Protection 45 Estate Mars Hill Frederiksted, VI 00840 (340)-773-1082 Syed Syedali Director Div. of Environmental Protection Cyril E. King Airport Terminal Building, 2nd Floor St. Thomas, VI 00802 (340) 774-3320 David Alvaro Simon Department of Public Works Chief Engineer 82-44 Subbase St. Thomas, VI 00802 (340) 776-4844 Nicole Turner Property Owners/Representatives: Department of Education DOE Commissioner 1834 Kongens Gade St. Thomas, VI 00802 (340) 774-2810 LaVerne Terry Curriculum Center Curriculum Center Management Curriculum Center #386 Anna’s Retreat St. Thomas, VI 00802 (340) 775-2250 Jeanette Smith-Barry Curriculum Center Territorial Director of Maintenance 1834 Kongens Gade #386 Anna’s Retreat St. Thomas, VI 00802 (340) 774-0100 Luis Hughes Department of Human Services Deputy Commissioner Knud Hasnen Complex Building A 1303 Hospital Ground Charlotte Amalie, VI 00802 (340) 774-0930 Afiah Clendinen Department of Public Works Deputy Commissioner of Operations 82-44 Subbase St. Thomas, VI 00802 (340) 776-4844 Othniel Vanterpool Grace Gospel Church Pastor P.O. Box 9790 St. Thomas, VI 00801 TBD TNT Laundry Tenant/Operator P.O. Box 1841 St. Thomas, VI 00801 TBD Table 1-2 Vendor O&M Directory COMPANY FUNCTION / EQUIP. ADDRESS/PHONE CONTACT Carbonair Environmental Systems, Inc. Process Equipment Fabricator, Warranty Information 2731 Nevada Avenue North New Hope, Minnesota 55427 (800) 526-4999 Chris Riddle Mark Hansen Don Weirens Rockwell Automation Software (RSView32) and Hardware (440) 646-5800 Tech Support Rensenhouse Electric Supply Rockwell Automation 1919 Cherry St. Kansas City, Missouri 64108 (816) 421-7350 Bill Motley Pressure Systems, Inc. Pressure Transducers 34 Research Drive Hampton, Virginia 23666 (800) 328-3665 Marsha Gray Geotechnical Services Submersible Well Pumps 2852 Walnut Ave Tustin, CA 92780 (714) 832-5610 Fred Schramm Instrument Specialties, Inc. Electromagnetic Water Flow Meters 3885 St. Johns Parkway Sanford, Florida 3277 (407) 324-7800 x105 Steven Manning Chemline Plastics LTD Check Valves 55 Guardsman Rd. Thornhill, Ontario LT3 6L2 (905) 889-7890 x104 Michael Nissenthall R.S. Corcoran Co. Transfer Pumps 500 N. Vine Street New Lenox, IL 60451 (800) 637-1067 Mick Kramer Rotron Blowers Air Stripper & SVE Blowers 75 North Street Saugerties, NY 12477 (914) 246-3401 Neil Lintch Hersey Products, Inc. Mechanical Water Flow Meters 150 Venture Blvd Spartanburg, SC 29305 Tech Support LMI / Milton Roy Chemical Feed Pumps 8 Post Office Square Acton, MA 01720 (508) 263-9800 Tech Support Krystil Klear Filtration Bag Filters 9449 South 550 West Winamac, IN 46996 (800) 869-0325 Jay Stonebraker Xchanger, Inc Heat Exchanger 1401 South 7th Street Hopkins, MN 55343 (952) 933-2559 David Wangensteen Barksdale Temperature and Pressure Switches 3211 Fruitland Ave Los Angles, CA 90058 (213) 589-6181 Tech Support Hydrosil International LTD Hydrosil HS-600 Media 1180 St Charles Street Elgin, IL 60120 (847) 741-1600 Bill Waldschmidt Signet Scientific Co. pH Meter/Transmitter 3401Aerojet Ave El Monte, CA 91731 (626) 571-2770 Tech Support Table 2-1 TPDES Storm Sewer / Surface Water Discharge Criteria PARAMETER DISCHARGE CRITERIA VALUE UNITS Storm Sewer / Surface Water (TPDES) Discharge: pH 7.0 to 8.3 Total Organic Carbon 20 mg/L Total Suspended Solids 40 mg/L Vinyl Chloride >99.9% reduction or ND Cis-1,2-DCE >99.9% reduction or ND Trans-1,2-DCE >99.9% reduction or ND TCE >99.9% reduction or ND PCE >99.9% reduction or ND Table 2-2 DPNR Air Discharge Criteria PARAMETER DISCHARGE CRITERIA VALUE UNITS Air (DPNR) Discharge: Vinyl Chloride 0.01 lb/d cis – 1,2-DCE 14.29 lb/d TCE 0.16 lb/d PCE 0.42 lb/d Total VOCs 14.48 lb/d Table 2-3 Equipment List Groundwater Extraction and Treatment – GWTF #1 (1) Grunfos 5 Redi-Flo3-250 submersible pump, ½ hp, 230 VAC, 1 ph, w/communications electronics for CU300 control, PN 5SQE05B-250NE, w/CU300 controller equipped for Remote control, and 130 feet of #12 AWG motor leads w/ground (RW-1) (1) Grunfos 22Redi-Flo3-140 submersible pump, 3/4 hp, 230 VAC, 1 ph, w/communications electronics for CU300 control, PN 22SQE07B-140-NE, w/CU 300 controller equipped for Remote control, and 60 feet of #12 AWG motor leads w/ground (RW-9) (1) Grundfos 30 Redi-Flo3-160 submersible pump, 1-1/2 hp, 230VAC, 1 ph, w/communications electronics for CU300 control, PN 30SQE15C-160NE, w/CU300 controller equipped for Remote control, and 80 feet of #12 AWG motor leads w/ground (RW-7) (2) KPSI #710-140-0030 Submersible level transducers, Tefzel vented cable, and aneroid bellows #815 (RW-7 and RW-9) Well Pump Piping, Fittings & Misc. Equipment: (3) Ashcroft Model 1005 Pressure gauge, 0 – 100 psi (3) Wye Line Strainers 1 ½” PVC (3) Colonial Check valves 1 ½” PVC (3) Apollo 70-300 Series Ball valves 1 ½” Bronze (3) Sample port (shipped loose) (1) Hersey MVR-30 water flow meter for RW-6 - 30 gpm capacity - Local readout with totalizer (1) Hersey MVR-50 water flow meter for RW-7 - 50 gpm capacity - Local readout with totalizer (1) Hersey MVR-30 water flow meter for RW-8 - 30 gpm capacity - Local readout with totalizer (1) Equalization tank - 1,000 gallon capacity - HDPE, cone bottom construction (45 degree cone) - 64” diameter x 116.5” high - Steel stand (Tnemec-coated per Section 11246 2.03.A.3) & containment high level conductivity switch - High and low level alarm and pump operation switches (Flowline Switch-Tek #LU101045 ultrasonic gap style switches, bulkhead mounted); locate switches per Arrowhead instructions - Connections for tank influent, effluent, and vapor bleed-off (per Arrowhead detail); connections shall conform to Section 11246 2.04B - Valved outlet at tank bottom for clean out (per Arrowhead detail); cleanout line and valve shall extend horizontally to edge of tank to facilitate access (1) Carbonair GPC 3 vapor phase carbon adsorber - HDPE construction (55-gallon poly drum or equivalent) - Influent and effluent sample ports - Condensate drain line - 200 lbs. of reactivated vapor phase carbon - Piped to tank vent (2) R.S. Corcoran Series 2000, Model D.G. VE, 1.5” suction x 1” discharge, 4.25” impeller, 316 stainless steel (skid-mounted, see below) - Maximum flow rate 30 gpm @ 56’ TDH - Motor, 1 hp, 3450 rpm, 460VAC, 3 phase, TEFC - Discharge check valve, throttling valve, and pressure gauge (1) Scale Inhibitor feed system - LMI A941-155S chemical feed pump with 4-20mA input (115V, single phase motor), with Digi- Pulse run-feedback option - Injection fittings, 4 way valve, pressure relief, and back pressure valve - Dosage range of 0.006 – 0.66 gallons per hour (actual dosage rate to be determined) - 50 gallon HDPE tank with Flowline Ultrasonic low level alarm switch - 100 ml calibration column - 60 ft. Teflon PTFE tubing (1/4”) (1) Hersey B.E.P. magnetic flow meter/transmitter with Model 1000 local readout/totalizer (NEMA 4X rated) - 4-20 mA output - By-pass piping - Provided with local readout in GPM (2) Krystil Klear model 88 bag filters (skid-mounted, see below) - 30” stainless steel housing each (per Section 13720 2.01C) - (25) 50 micron filter bags (4.4 sq. ft. surface area) - 2” side inlet and outlet connections each - 100 psi maximum design pressure each - Inlet and outlet pressure gauges (0 – 30 psi) - Interconnecting piping and valving for parallel operation (Sch 80 PVC) (1) Barksdale #DPD1T-A80 Differential pressure switch - 0.4 – 60 psig range (1) Temperature gauge - 50-300 oF (2) Pressure gauges - 0-30 psig each (1) Carbonair STAT 80 low profile air stripper, 304 stainless steel, (skid-mounted along with blower, see below) - Piped for induced-draft air flow - SST gravity drain sump with high level alarm switch - 6 trays with demister (polypropylene) and fasteners - Rotron CP909FJ72WLR regenerative blower, 350 cfm @ - 75” wc, 15 HP, 480 V, 3 phase, TEFC with optional corrosion resistant surface treatments and seals (skid-mounted along with air stripper, see below) - Dwyer Series 1950 Blower Low (#1950-5) & High (#1950P-2) pressure alarm switches - Blower pressure gauge (0-100” wc) - Blower inlet filter - Bleed air valve with silencer - Rotron FM40A450Q air flow meter, 90 – 450 scfm - Air temperature gauge (50-300 oF) - Inlet and outlet sample ports - 4” Chemline Series WP Wafer check valve (polypropylene with viton seals); located downstream of blower, prior to combined air stripper/SVE header line (1) pH adjustment feed system - WALCHEM-ClassEWB11Y1-PC chemical feed pump with 4-20 mA input (115V, single phase motor) and with Digi-Pulse run feedback option - Glass fiber reienforced polypropylene pump head and fittings. Polytetrafluorethylene diaphragm and Injection fittings, 4 way valve, pressure relief, and back pressure valve Gaskets. Aluminum ceramic valve balls. Fluoroelastomer valve seat and seals - Dosage range of 0.006 – 0.66 gallons per hour (actual dosage rate to be determined) - 50 gallon HDPE tank with Flowline Ultrasonic low level alarm switch - 100 ml calibration column - 30 ft. polyethylene tubing (3/8”) (1) Signet pH sensor and transmitter - SIGNET 3-2760-11 PRE AMP for pH Sensor - Model 3-2724 bulb electrode sensor - Model 3-8750-1P monitor/transmitter - 4-20 mA output (1) Xchanger, Inc. AA-500 air-to-air heat exchanger - currently not operated - 500 scfm process air - 1,850 scfm ambient air (fan) - 1 HP TEFC motor - Heresite P-413 baked phenolic coating (1) Barksdale Model ML1H-H204S high temperature switch, -50 – 200 F (mounted downstream of heat exchanger) (1) Vacuum breaker (anti-siphon valve) for treated water effluent discharge line (1) High level alarm switch for surface water discharge location (shipped loose), Flowline Switch-Tek Powered Level Switch #LU101405 with 10’ cable, 4-inch long polypropylene sensor, 3/4” MPT. (2) Skids (Tnemec-coated), as follows: - Skid #1 – Dual-level @ 18” high for two transfer pumps and 6” high for bag filters - Skid #2 – STAT 80 air stripper and Rotron blower @ 6” high (1) Series 3000 programmable logic controller (PLC)-based Control System: For operation on 460 volt, 3Ø, 3 wire incoming electrical service. To control the 10 HP extraction blower, three extraction well pumps, 10 HP STAT low-profile air stripper blower, two 1 HP transfer pumps, and three (fractional HP) chemical feed pumps. Furnished loose for mounting by others. To include: QTY DESCRIPTION 1 Enclosure, NEMA 4X, freestanding computer/PLC/motor control enclosure; Hoffman APX (or equal) sized as required 1 Disconnect, non-fusible, 80A with padlockable operating handle and shaft 1 Power distribution terminal block, 3 pole; L1, L2, L3 1 Three phase surge arrestor 1 Lightning arrestor; 600 volt, 4 wire with bracket 2 Motor starter: Contactor 23A FLA with 1 aux. contact/Overload relay 3.7-12A, 3Ø, manual reset; transfer pumps (**revise as necessary for two 1 HP motors) 2 Motor starter: Contactor 23A FLA with 1 aux. contact/Overload relay 12-32A, 3Ø, manual reset; blowers 3 Mount and wire CU300 well pump controllers (provided by Arrowhead) per Grundfos specifications 2 Circuit breaker 460V 3P15A 22k/460,65K/230; transfer pumps 2 Circuit breaker 460V 3P25A 22k/460,65K/230; STAT and SVE blowers 3 Circuit breaker 230V 2P15A 14k; extraction wells 3 Fuseholder/fuse; chemical feed pumps 1 Forced air ventilation (170 cfm) with stainless steel shroud 1 Transformer; 480/240-120, 7.5 kVA with primary and secondary overcurrent protection 1 Allen-Bradley MicroLogix 1500 PLC including #1764-24AWA base unit, #1764-LRP processor & #1764-MM2RTC memory module, with required I/O (programming by Arrowhead) 1 Mount and wire Allen-Bradley VersaView 1500P industrial computer/touch screen (provided by Arrowhead; including any required cables, interface cards and adapters to communicate with MicroLogix 1500) (all programming by Arrowhead) 3 Switch; three position; Hand-Off-Auto with integral Run (green/LED) indication; blowers, transfer pumps 1 Pushbutton, Emergency Stop (red, NO/NC) 3 Pushbuttons, illuminated: System Start; System Stop & System Reset 2 24VDC power supply, 30W, 1.3A, DIN rail mount (analog power & discrete power) 1 Panel heater w/integral thermostat, 100W, 115VAC 1 Powerware 9125 Uninterruptable power supply (UPS) for PLC, OIT, autodialer, and all I/O circuits 1 Sensaphone 2000 alarm dialer - I/O circuit breakers & fuses per Specs Section 13320 - Engraved laminated legends for all door mounted devices - Terminal blocks for external connections and fusing as required - Color-coded wiring with wire markers at all terminations - Serialized UL508 Industrial Control Panel label Table 2-4 Equipment List Soil Vapor Extraction System – GWTF #1 1 (2) Inlet vacuum gauges - 0-100” wc vacuum (2) Rotron model FM30A250Q Venturi flow meter (one before the air bleed one on the blower discharge) - 50-250 cfm capacity - 3” connections - Aluminum construction - Low pressure drop (2-4” wc typical) (1) Sample port (1) Air dilution butterfly valve with inlet filter (1) Carbonair CE 858 SVE system (skid-mounted, see below) - Rotron Model CP707FW72MXLR regenerative blower, 140 scfm @ - 70” wc, 5 HP, 3 phase, 480V, TEFC, with optional corrosion resistant surface treatments and seals - Maximum flow rate 400 cfm / Maximum vacuum 98" wc - 40 gallon capacity moisture separator tank (all steel surfaces Tnemec-coated)(Removed) - Sight glass with high-level alarm switch (Removed) - Vacuum relief valve (Removed) - In-line air filter with differential pressure gauge and small filter silencer (Removed) - Inlet temperature gauge (50-300 oF) (Removed) - Inlet vacuum gauge (0-100” wc vacuum) (Removed) - Inlet sample port - Discharge pressure relief valve - Mounted on a steel frame - 4” Chemline Series WP Wafer check valve (polypropylene with viton seals); located downstream of blower, prior to combined air stripper/SVE header line (1) Inline inlet & discharge silencers (all steel surfaces Tnemec-coated) (1) Pressure gauge (0-30” wc) (1) Temperature gauge (50-300 oF) (1) Low flow switch (mounted on discharge side of blower) (1) Barksdale Model ML1H-H354S high temperature switch, 100 – 350 F (mounted on discharge side of blower) (Removed) (1) Skid for all of the above items @ 6” high (Tnemec-coated) Controls – Refer to Table 2-3. Note: 1. Soil Vapor Extraction system has been offline since 2006 and Moisture Separator Tank has been removed due to severe rusting. Table 2-5 Equipment List Off-Gas Treatment System – GWTF #1 1 (1) Carbonair GPC 50R vapor phase carbon adsorber (Rental) - 8 ft. diameter x 7 ft. high steel vessels - 5,000 lbs. carbon capacity per vessel - 12 ¾” OD inlet/outlet connections - 24” top manway - 1/2“ drain valves - Forkliftable channel iron base (1) Carbonair GPC 28R vapor phase permanganate adsorber (Rental) - 6 ft. diameter x 7 ft. 3 in. high steel vessel - 7,000 lbs. of permanganate impregnated zeolite capacity (per vessel) - 8” OD inlet/outlet connections - 24” top manway - 1/2“ drain valves - Forkliftable channel iron base (1) Vapor phase adsorber piping kit - 125’ uncut 4” diameter DURA-VENT flexible hose with connection fittings (4” x 12” reducers to the GPC 50R’s and 4” x 8” reducers to GPC 20R’s) - (4) Pressure gauges (0 – 60 in. wc) - (4) Sample ports Note: 1. The Offgas System has been offline since 2006. Table 2-6 Equipment List Groundwater Extraction and Treatment – GWTF #2 (1) Grundfos 5 Redi-Flo3-170 submersible pump, ½ hp, 230VAC, 1 ph, w/communications electronics for CU300 control, PN 5SQE05A-170NE, w/ CU300 controller equipped for Remote control, and 120 feet of #12 AWG motor leads w/ground (RW-1) (1) Grundfos 30 Redi-Flo3-160 submersible pump, 1-1/2 hp, 230VAC, 1 ph, w/communications electronics for CU300 control, PN 30SQE15C-160NE, w/CU300 controller equipped for Remote control, and 120 feet of #12 AWG motor leads w/ ground (RW-15) (2) KPSI #710-140-0030 Submersible level transducers, Tefzel vented cable, and aneroid bellows #815 (RW-1 and RW-15) Well Pump Piping, Fittings & Misc. Equipment (2) Ashcroft Model 1005 Pressure gauge, 0 – 100 psi (2) Wye Line Strainers 1 ½” PVC (2) Colonial Check valves 1 ½” PVC (2) Apollo 70-300 Series Ball valves 1 ½” Bronze (2) Sample port (shipped loose) (1) Hersey MVR-30 water flow meter for RW-1 - 30 gpm capacity - Local readout with totalizer (1) Hersey MVR-50 water flow meter for RW-1 - 50 gpm capacity - Local readout with totalizer (1) Scale Inhibitor feed system - LMI A941-155S chemical feed pump with 4-20mA input (115V, single phase motor), with Digi- Pulse run-feedback option - Injection fittings, 4 way valve, pressure relief, and back pressure valve - Dosage range of 0.006 – 0.66 gallons per hour (actual dosage rate to be determined) - 50 gallon HDPE tank with Flowline Ultrasonic low level alarm switch - 100 ml calibration column - 25 ft. Teflon PTFE tubing (1/4”) (1) Equalization tank (skid-mounted, see below) - 500 gallon capacity - HDPE, cone bottom construction (45 degree cone) - 64” diameter x 90.5” high - Steel stand (Tnemec-coated per Section 11246 2.03.A.3) & containment high level conductivity switch - High and low level alarm and pump operation switches (Flowline Switch-Tek #LU101045 ultrasonic gap style switches, bulkhead mounted); locate switches per Arrowhead instructions - Connections for tank influent, effluent, and vapor bleed-off (per Arrowhead detail); connections shall conform to Section 11246 2.04B - Valved outlet at tank bottom for cleanout (per Arrowhead detail); cleanout line and valve shall extend horizontally to edge of tank to facilitate access (1) Carbonair GPC 3 vapor phase carbon adsorber (Presently disconnected for EQ Tank which is not in use) - HDPE construction (55-gallon poly drum or equivalent) - Influent and effluent sample ports - Condensate drain line - 200 lbs. of reactivated vapor phase carbon - Piped to tank vent (1) R.S. Corcoran Series 2000, Model D.G. VE, 1.5” suction x 1” discharge, 4.25” impeller, 316 stainless steel (skid-mounted, see below) - Maximum flow rate 30 gpm @ 56’ TDH - Motor, 1 hp, 3450 rpm, 460VAC, 3 phase, TEFC - Discharge check valve, throttling valve, and pressure gauge (1) Hersey B.E.P. magnetic flow meter/transmitter with Model 1000 local readout/totalizer (NEMA 4X rated) - 4-20 mA output - By-pass piping - Provided with local readout in GPM (2) Krystil Klear model 88 bag filters (skid-mounted, see below) - 30” stainless steel housing each (per Section 13720 2.01C) - (25) 50 micron filter bags (4.4 sq. ft. surface area) - 2” side inlet and bottom outlet connections each - 100 psi maximum design pressure each - Inlet and outlet pressure gauges (0 – 30 psi) - Interconnecting piping and valving for parallel operation (Sch 80 PVC) (1) Barksdale #DPD1T-A80 Differential pressure switch - 0.4 – 60 psig range (1) Temperature gauge - 50-300 oF (2) Pressure gauges - 0 – 30 psig each (1) Carbonair STAT 30 low profile air stripper, 304 stainless steel (skid-mounted, see below) - Piped for induced-draft air flow - SST gravity drain sump with high level alarm switch - 6 trays with demister (polypropylene) and fasteners - Rotron CP707FF72MXLR regenerative blower, 150 cfm @ - 65” wc, 5 HP, 480 V, 3 phase, TEFC with optional corrosion resistant surface treatments and seals (skid-mounted along with air stripper, see below) - Dwyer Series 1950 Blower low (#1950-5) & high (#1950P-2) pressure alarm switches - Blower pressure gauge (0-100” wc) - Blower inlet filter - Bleed air valve with silencer - Rotron FM30A250Q air flow meter, 50 - 250 scfm - Air temperature gauge (50-300 oF) - Inlet and outlet sample ports (1) pH adjustment feed system - LMI A941-155S chemical feed pump with 4-20 mA input (115V, single phase motor) and with Digi-Pulse run feedback option - Injection fittings, 4 way valve, pressure relief, and back pressure valve - Dosage range of 0.006 – 0.66 gallons per hour (actual dosage rate to be determined) - 50 gallon HDPE tank with Flowline Ultrasonic low level alarm switch - 100 ml calibration column - 20 ft. Teflon PTFE tubing (1/4”) (1) Signet pH sensor and transmitter - Model 3-2716 bulb electrode sensor - Model 3-8750-1P monitor/transmitter - 4-20 mA output (1) Vacuum breaker (anti-siphon valve) for treated water effluent discharge line (1) High level alarm switch for surface water discharge location (shipped loose) Switch-Tek Powered Level Switch #LU101405 with 10’ cable, 4-inch long polypropylene sensor, 3/4” MPT., (2) Skids (Tnemec-coated), as follows: - Skid #1 – EQ tank, transfer pump, and bag filters @ 6” high - Skid #2 – STAT 80 air stripper AND Rotron blower @ 6” high (1) Series 3000 programmable logic controller (PLC)-based Control System For operation on 460 volt, 3Ø, 3 wire incoming electrical service. To control the two extraction well pumps, 7-½ HP STAT low-profile air stripper blower, 1 HP transfer pump and three (fractional HP) chemical feed pumps. Furnished loose for mounting by others. To include: QTY DESCRIPTION 1 Enclosure, NEMA 4X, freestanding computer/PLC/motor control enclosure; Hoffman APX (or equal) sized as required 1 Disconnect, non-fusible, 40A with padlockable operating handle and shaft 1 Power distribution terminal block, 3 pole; L1, L2, L3 1 Three phase surge arrestor 1 Lightning arrestor; 600 volt, 4 wire with bracket 1 Motor starter: Contactor 23A FLA with 1 aux. contact/Overload relay 3.7-12A, 3Ø, manual reset; transfer pump 1 Motor starter: Contactor 23A FLA with 1 aux. contact/Overload relay 12-32A, 3Ø, manual reset; blower 2 Mount and wire CU300 well pump controllers (provided by Arrowhead) per Grundfos specifications 1 Circuit breaker 460V 3P15A 22k/460,65K/230; transfer pump 1 Circuit breaker 460V 3P25A 22k/460,65K/230; STAT blower 2 Circuit breaker 230V 2P15A 14k; extraction wells 3 Fuseholder/fuse; chemical feed pumps 1 Forced air ventilation (170 cfm) with stainless steel shroud 1 Transformer; 480/240-120, 5 kVA with primary and secondary overcurrent protection 1 Allen-Bradley MicroLogix 1500 PLC including #1764-24AWA base unit, #1764-LRP processor & #1764-MM2RTC memory module, with required I/O (all programming by Arrowhead) 1 Mount and wire Allen-Bradley VersaView 1500P industrial computer/touch screen (provided by Arrowhead; including any required cables, interface cards and adapters to communicate with MicroLogix 1500) (all programming by Arrowhead) 2 Switch; three position; Hand-Off-Auto with integral Run (green/LED) indication; blowers, transfer pumps 1 Pushbutton, Emergency Stop (red, NO/NC) 3 Pushbuttons, illuminated: System Start; System Stop & System Reset 2 24VDC power supply, 30W, 1.3A, DIN rail mount (analog power & discrete power) 1 Panel heater w/integral thermostat, 100W, 115VAC 1 Powerware 9125 Uninterruptable power supply (UPS) for PLC, OIT, autodialer, and all I/O circuits 1 Sensaphone 2000 alarm dialer - I/O circuit breakers & fuses per Specs Section 13320 - Engraved laminated legends for all door mounted devices - Terminal blocks for external connections and fusing as required - Color-coded wiring with wire markers at all terminations - Serialized UL508 Industrial Control Panel label Table 2-7 Piping and Valve Nomenclature – GWTF #1 Piping CGW-INF-RW6 CGW-INF-RW7 CGW-INF-RW-9 CGW-INF-CMB CGW-INF-EQ CGW-INF-EQB CGW-INF-AS TW-EFF-SS AIR-AS VAP-INF-AS AIR-SVE VAP-INF-SVE VAP-INF-CMB VAP-EFF-ATM Valves HV-INF-RW-6V HV-INF-RW-7V HV-VAP-SVE-7V HV-INF-RW-9V HV-INF-RW-6 CV-INF-RW-6 HV2-INF-RW-6 HV-INF-RW-7 CV-INF-RW-7 HV2-INF-RW-7 HV-INF-RW-9 CV-INF-RW-9 HV2-INF-RW-9 HV-INF-CMB HV2-INF-CMB HV-INF-EQ HV2-INF-EQ HV-D-EQ HV-INF-EQB HV2-INF-EQB HV-INF-TP1 HV-INF-TP2 CV-INF-TP1 CV-INF-TP2 HV2-INF-TP1 HV2-INF-TP2 HV-INF-BF1 HV-INF-BF2 HV2-INF-BF1 HV2-INF-BF2 HV-D-BF1 HV-D-BF2 HV-INF-FM HV2-INF-FM HV-INF-FMB HV-TW-EFF HV-VAP-AS CV-VAP-AS HV-VAP-SVE1V HV-AIR-SVE HV-D-SVE CV-VAP-SVE HV-D-HX1 HV-D-GAC1 HV-D-GAC2 HV-D-PP1 HV-D-PP2 HV-D-STACK Sample Taps SVE-1 SVE-7 SVE-INF (after air dilution) RW-6 RW-7 RW-9 GW1-INF1 (b/f EQ) GW1-INF2 (after TP1) GW1-INF3 (after TP2) GW1-EFF VAP-INF GAC1-EFF GAC2-EFF PP1-EFF VAP-EFF Refer to Drawings 2-14 through 2-16 for piping and valve diagrams with nomenclature. Abbreviations: AS – air stripper HV – hand valve (i.e. ball valve) CV – check valve INF – influent line EFF – effluent line CGW – contaminated groundwater TW – treated water VAP – vapor/air AIR – air (outside/atmospheric) ATM – atmosphere CMB – combined streams TP – Transfer pump EQ – Equalization tan k EQB – Equalization tank bypass line FM – Flow meter FMB – Flow meter bypass line BF – Bag filter MS – Moisture separator V (i.e. RW-6V) – Well vault D – Drain Table 2-8 Piping and Valve Nomenclature – GWTF #2 Piping CGW-INF-RW-1 CGW-INF-RW-1S CGW-INF-CMB CGW-INF-EQB CGW-INF-EQ CGW-INF-AS TW-EFF-SS AIR-AS VAP-EFF-ATM Valves HV-INF-RW-1V HV-INF-RW-1SV HV-INF-RW-1 CV-INF-RW-1 HV2-INF-RW-1 HV-INF-RW-1S CV-INF-RW-1S HV2-INF-RW-1S HV-INF-CMB HV2-INF-CMB HV-INF-EQB HV-INF-EQ HV2-INF-EQ HV3-INF-EQ HV4-INF-EQ HV-INF-TP CV-INF-TP HV-INF-BF1 HV-INF-BF2 HV2-INF-BF1 HV2-INF-BF2 HV-INF-FM HV2-INF-FM HV-INF-FMB HV-VAP-AS HV-D-EQ HV-D-BF1 HV-D-BF2 HV-D-STACK Sample Taps RW-1 RW-1S GW2-INF1 (b/f EQ) GW2-INF2 (after TP) GW2-INF3 (b/f AS) GW2-EFF Refer to Drawings 2-17 and 2-18 for piping and valve diagrams with nomenclature. Abbreviations: AS – air stripper HV – hand valve (i.e. ball valve) CV – check valve INF – influent line EFF – effluent line CGW – contaminated groundwater TW – treated water VAP – vapor/air AIR – air (outside/atmospheric) ATM – atmosphere CMB – combined streams TP – Transfer pump EQ – Equalization tan k EQB – Equalization tank bypass line FM – Flow meter FMB – Flow meter bypass line BF – Bag filter MS – Moisture separator V (i.e. RW-6V) – Well vault D – Drain Table 2-9 Sampling and Monitoring Schedule for Long-Term Operations and Maintenance Daily Weekly Monthly Quarterly Semi-Annual Annual VOCs TOC TSS Nitrate Sulfate Chloride Ethane/ Ethene Chlorine (Hach) pH DO Cond. Temp Turb. ORP TO-14 AM 4.02 VOCs - PID Pressure/ Vacuum Temp. Flow pH Level Extraction well RW-6 sampling and monitoring RW influent sample port   Extraction well RW-7 sampling and monitoring RW influent sample port   Extraction well RW-9 sampling and monitoring RW influent sample port   GW influent (combined) sampling and monitoring EQ tank effluent sample port   GWT system monitoring and field measurements Gauges, meters, instruments       Treated water effluent - TPDES permit sampling and monitoring (monthly) Air stripper effluent sample port   1 Treated water effluent - TPDES permit sampling and monitoring (weekly) Air stripper effluent sample port      1 Off-gas treatment system, air permit sampling Stack sample ports   2 Extraction well RW-1 sampling and monitoring RW influent sample port   GWT system monitoring and field measurements Gauges, meters, instruments       Treated water effluent - TPDES permit sampling and monitoring (monthly) Air stripper effluent sample port         1 Treated water effluent - TPDES permit sampling and monitoring (weekly) Air stripper effluent sample port      1 Site-wide GW, Annual sampling Refer to list of wells, Table 2-10.             3 PRP Site-wide GW, semi-annual sampling by Texaco and annual sampling by Esso Refer to list of wells, Table 2-10.   Site-wide GW, continuous water levels Refer to list of wells, Table 2-10.  Site-wide GW, monthly water levels Refer to list of wells, Table 2-10.  NOTES: 1 2 3 Field Measurements GW Monitoring Parameters Per DPNR Air Pollution Control Permit Conditions, dated July 22, 2003 (refer to Appendix S). Sampling for TOC, nitrate, sulfate, chloride, and ethane/ethene applies to Southern Plume wells only (refer to Table 2-10). GW Samples Frequency System or Wells Location Sampling and/or Monitoring Activity GWTF#1 GWTF#2 Per DPNR TPDES Permit Equivalency No. VID982272569, effective March 1, 2009 (refer to Appendix S). GW Monitoring Wells Water Levels Notes Air Samples Table 2-10 Sampling and Monitoring Schedule for Site-wide Groundwater AREA WELL SAMPLING 3,5 WATER LEVEL MEASUREMENT LOCATION Annual Notes Continuous Monthly Notes Curriculum BP-1 X Center/ BP-2 X GWTF #1 BP-3 X IW-1 X IW-1S X IW-2 X IW-2S X MW-17 X MW-1D X X MW-13 X MW-13D X X MW-14 X X MW-15 X X MW-16 X 7 X RW-8 X RD-9 X X RD-10 X RD-11 X 7 X RD-12 X RD-13 X X Texaco MW-2 X MW-3 X 7 X MW-4 MW-4D MW-5 MW-6R MW-6D X MW-7 X RD-5 X TT-1 TT-3D TT-5 TT-6 X Tillett X Esso CHT-1 CHT-3 CHT-4 CHT-7D DW-1 MW-8 X MW-9 MW-9S MW-10 MW-10D X MW-25 X P-1 SW-1R SW-2R SW-8R SW-9 SW-10 Table 2-10 Sampling and Monitoring Schedule for Site-wide Groundwater AREA WELL SAMPLING 3,5 WATER LEVEL MEASUREMENT LOCATION Annual Notes Continuous Monthly Notes GWTF #2 DW-2 X X 7 X MW-11D X X MW-12D X X MW-19 X RD-4 X RD-7 X X SW-6 X Eglin I X Eglin III X 6 Southern Delegard X 4,6 Plume Laplace X 4,6 MW-21D X X 7 X PZ-4 X RD-1 X X RD-2 X X RD-3 X 4 X RD-6 X X RD-8 X X RD-14 X 7 X Smith X 4,6 Steele X 4,6 Notes: 1. Not used 2. Not used 3. Sampling includes VOCs, unless otherwise noted. 6. Active supply well. 7. Continuous water levels will be collected by transducers. Acronyms: DO - dissolved oxygen GWTF - groundwater treatment facility O&M - operations and maintenance ORP - oxidation reduction potential RA - remedial action TOC - total organic carbon VOC - volatile organic compound 4. Sampling includes VOCs, TOC, nitrate, sulfate, chloride, and ethane/ethene (intrinsic biodegradation parameters). 5. Field measurements shall be taken for water level, turbidity, DO, temperature, conductivity, pH, and ORP at all wells during sampling. Control System Interlocks - GWTF #1 Alarm Condition Result #1 Result #2 Line no. P&ID Tagname HMI Tagname Description HMI Tagname Description Description 14 OS-1061 P6 CU300 fault status P6_FAIL P6 CU300 fault autodialer ch 6 15 OS-1071 P7 CU300 fault status P7_FAIL P7 CU300 fault autodialer ch 6 16 OS-1081 P9 CU300 fault status P9_FAIL P9 CU300 fault autodialer ch 6 17 OS-1200 NaOCl metering pump flow switch MP1_FAL MP-1 low flow alarm autodialer ch 8 18 OS-1210 anti-scalant metering pump flow sw MP2_FAL MP-2 low flow alarm autodialer ch 8 19 OS-1400 acid metering pump flow switch MP3_FAL MP-3 low flow alarm autodialer ch 8 20 OS-1500 B1_AUX air stripper blower aux contacts P1_OUT P1 run output 21 OS-1500 B1_AUX air stripper blower aux contacts P2_OUT P2 run output 22 OS-1500 & OS-1610 B1_AUX & B2_AUX air stripper blower aux contacts & SVE blower MS auxillary contacts HX_OUT heat exchanger run output 23 LSH-1200 NASC_LAH NaOCl secondary containment GWSYS_SD GW system shutdown autodialer ch 4 24 LSL-1200 NA_LAL NaOCl storage autodialer ch 7 25 LSH-1210 SASC_LAH anti-scalant secondary containment GWSYS_SD GW system shutdown autodialer ch 4 26 LSL-1210 SA_LAL anti-scalant storage autodialer ch 7 27 LSHH-1100 EQ_LAH equalization tank GWSYS_SD GW system shutdown autodialer ch 3 28 LSH-1100 EQ_LSH equalization tank P1_OUT P1 transfer pump run output 29 LSH-1100 EQ_LSH equalization tank P2_OUT P2 transfer pump run output 30 LSL-1100 EQ_LSL equalization tank P1_OUT P1 transfer pump run output 31 LSL-1100 EQ_LSL equalization tank P2_OUT P2 transfer pump run output autodialer ch 3 32 LSLL-1100 EQ_LAL equalization tank GWSYS_SD GW system shutdown 33 LSHH-1400 HCLSC_LAH muriatic acid secondary containment GWSYS_SD GW system shutdown autodialer ch 4 34 LSLL-1400 HCL_LAL muriatic acid storage autodialer ch 7 35 PSH-1300 FLTR_PAH filter differential pressure GWSYS_SD GW system shutdown autodialer ch 5 36 LSHH-1500 AS_LAH air stripper sump GWSYS_SD GW system shutdown autodialer ch 3 37 LSHH-1501 BLDG_LAH building secondary containment GWSYS_SD GW system shutdown autodialer ch 4 38 LSHH-1501 BLDG_LAH building secondary containment SVESYS_SD SVE system shutdown autodialer ch 4 39 PSL-1500 AS_PAL air stripper blower low pressure GWSYS_SD GW system shutdown autodialer ch 5 40 PSH-1500 AS_PAH air stripper blower high pressure GWSYS_SD GW system shutdown autodialer ch 5 41 FSL-1620 B2_FAL SVE blower low flow switch SVESYS_SD SVE system shutdown autodialer ch 5 Table 3-1 Alarm Condition Result #1 Result #2 Line no. P&ID Tagname HMI Tagname Description HMI Tagname Description Description 42 TSH-1620 B2_TAH SVE blower high temperature SVESYS_SD SVE system shutdown autodialer ch 5 43 LSHH-1101 EQSC_LAH EQ tank secondary containment GWSYS_SD GW system shutdown autodialer ch 4 44 LSH-1590 EFF_LSHH effluent discharge GWSYS_SD GW system shutdown autodialer ch 3 45 LSHH-1610 KO_LSHH knockout tank high level SVESYS_SD SVE system shutdown autodialer ch 3 46 TSH-1625 HX_TAH heat exchanger high temperature GWSYS_SD GW system shutdown autodialer ch 5 47 TSH-1625 HX_TAH heat exchanger high temperature SVESYS_SD SVE system shutdown autodialer ch 5 48 LSH-1070 RW7_WTE RW-7 water table elevation P7_OUT P7 run output 49 LSL-1070 RW7_WTE RW-7 water table elevation P7_OUT P7 run output 50 LSLL-1070 RW7_WTE RW-7 water table elevation P7_OUT P7 run output autodialer ch 6 51 LSH-1080 RW9_WTE RW-9 water table elevation P9_OUT P9 run output 52 LSL-1080 RW9_WTE RW-9 water table elevation P9_OUT P9 run output 53 LSLL-1080 RW9_WTE RW-9 water table elevation P9_OUT P9 run output autodialer ch 6 54 FIT-1300 ASIN_FR air stripper influent flow transmitter GWSYS_SD GW system shutdown autodailer ch 5 55 AIT-1500 EFF_AAH effluent pH transmitter GWSYS_SD GW system shutdown autodailer ch 5 56 AIT-1500 EFF_AAL effluent pH transmitter GWSYS_SD GW system shutdown autodailer ch 5 NOTES: Any GW system shutdown causes autodialer ch 1 output. Any SVE system shutdown causes autodialer ch 2 output. P1 & P2 transfer pumps do not operate when in EQ Tank Bypass mode. SVE/Offgas systems have been offline since 2006. Control System Interlocks - GWTF #2 Alarm Condition Result #1 Result #2 Line no. P&ID Tagname HMI Tagname Description HMI Tagname Description Description 14 OS-2011 P1 CU300 fault status P1_FAIL P1 CU300 fault autodialer ch 6 15 OS-2021 P1S CU300 fault status P1S_FAIL P1S CU300 fault autodialer ch 6 16 OS-2200 NaOCl metering pump flow switch MP1_FAL MP-1 low flow alarm autodialer ch 8 17 OS-2210 anti-scalant metering pump flow sw MP2_FAL MP-2 low flow alarm autodialer ch 8 18 OS-2400 acid metering pump flow switch MP3_FAL MP-3 low flow alarm autodialer ch 8 19 OS-2500 B1_AUX air stripper blower aux contacts P2_OUT P2 run output 20 LSH-2200 NASC_LAH NaOCl secondary containment GWSYS_SD GW system shutdown autodialer ch 4 21 LSL-2200 NA_LAL NaOCl storage autodialer ch 7 22 LSH-2210 SASC_LAH anti-scalant secondary containment GWSYS_SD GW system shutdown autodialer ch 4 23 LSL-2210 SA_LAL anti-scalant storage autodialer ch 7 24 LSHH-2100 EQ_LAH equalization tank GWSYS_SD GW system shutdown autodialer ch 3 25 LSH-2100 EQ_LSH equalization tank P2_OUT P2 transfer pump run output 26 LSL-2100 EQ_LSL equalization tank P2_OUT P2 transfer pump run output autodialer ch 3 27 LSLL-2100 EQ_LAL equalization tank GWSYS_SD GW system shutdown 28 LSHH-2400 HCLSC_LAH muriatic acid secondary containment GWSYS_SD GW system shutdown autodialer ch 4 29 LSLL-2400 HCL_LAL muriatic acid storage autodialer ch 7 30 PSH-2300 FLTR_PAH filter differential pressure GWSYS_SD GW system shutdown autodialer ch 5 31 LSHH-2500 AS_LAH air stripper sump GWSYS_SD GW system shutdown autodialer ch 3 32 LSHH-2501 BLDG_LAH building secondary containment GWSYS_SD GW system shutdown autodialer ch 4 33 PSL-2500 AS_PAL air stripper blower low pressure GWSYS_SD GW system shutdown autodialer ch 5 34 PSH-2500 AS_PAH air stripper blower high pressure GWSYS_SD GW system shutdown autodialer ch 5 35 LSH-2590 EFF_LSHH effluent discharge GWSYS_SD GW system shutdown autodialer ch 3 36 LSH-2010 RW1_WTE RW-1 water table elevation P7_OUT P7 run output 37 LSL-2010 RW1_WTE RW-1 water table elevation P7_OUT P7 run output 38 LSLL-2010 RW1_WTE RW-1 water table elevation P7_OUT P7 run output autodialer ch 6 39 LSH-2020 RW1S_WTE RW-1S water table elevation P8_OUT P8 run output 40 LSL-2020 RW1S_WTE RW-1S water table elevation P8_OUT P8 run output 41 LSLL-2020 RW1S_WTE RW-1S water table elevation P8_OUT P8 run output autodialer ch 6 Table 3-2 Alarm Condition Result #1 Result #2 Line no. P&ID Tagname HMI Tagname Description HMI Tagname Description Description 42 FIT-2300 ASIN_FR air stripper influent flow transmitter GWSYS_SD GW system shutdown autodailer ch 5 43 AIT-2500 EFF_AAH effluent pH transmitter GWSYS_SD GW system shutdown autodailer ch 5 44 AIT-2500 EFF_AAL effluent pH transmitter GWSYS_SD GW system shutdown autodailer ch 5 NOTES: Any GW system shutdown causes autodialer ch 1 output. Autodialer ch 2 output is spare. P2 transfer pump does not operate when in EQ Tank Bypass mode. Table 3-3 Control Tag Database - GWTF #1 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address A alarm_status alarm status N N A all_alarms all alarms N N D AS_LAH air stripper sump LAH Y N B3:40/0 D AS_PAH air stripper blower high pressure Y N B3:40/2 D AS_PAL air stripper blower low pressure Y N B3:40/1 A ASIN_100MG air stripper influent totalizer 100,000,000 gals N Y F8:22 A ASIN_10KG air stripper influent 10K gals totalizer, 10K's gals N Y F8:23 D ASIN_FAL air stripper influent low flow alarm Y Y b3:42/8 A ASIN_FR air stripper influent flow rate, gpm N Y gpm F8:2 A ASIN_G air stripperi nfluent totalizer, gals N Y gals F8:24 D B1_0R B-1 stop request N Y B3:30/0 A B1_100HRS air stripper blower runtime, 100 hrs N Y N7:0 D B1_1R air stripper blower start req N Y B3:20/0 D B1_AM air stripper blower auto / man N Y B3:10/0 D B1_AUX air stripper blower aux contacts N Y I:0/11 D B1_OUT B1 run output N Y O:0/8 D B1_SERV B! in service N Y B3:4/8 D B2_0R B-2 stop req N Y B3:31/0 A B2_100HRS SVE blower 100 hours N Y N7:2 D B2_1R B-2 start req N Y B3:20/9 D B2_AM B-2 auto / man N Y B3:10/9 D B2_AUX SVE blower MS auxillary contacts N Y I:1/0 D B2_FAL SVE blower low flow alarm Y N B3:41/0 D B2_OUT SVE blower run output N Y O:0/9 D B2_SERV B2 in service N Y B3:4/9 D B2_TAH SVE blower high temperature alarm Y N B3:41/1 D BLDG_LAH building secondary containment alarm Y N B3:40/10 D EFF_AAH effluent pH high alarm Y N B3:40/14 D EFF_AAL effluent pH low alarm Y N B3:40/15 D EFF_AIC_AM EFF-AIC auto / man N Y PD10:2/AM D EFF_AIC_CE EFF-AIC cycle enable N Y B3:50/2 A EFF_AIC_CV EFF-AIC CV output, 0-16383 N Y PD10:2.CVP A EFF_AIC_OUT EFF-AIC CV output, 0-16383 N Y N9:83 A EFF_AIC_SP EFF-AIC setpoint, 0-14 pH N Y PD10:2.SPS D EFF_LAH effluent high level alarm Y N B3:40/8 Table 3-3 Control Tag Database - GWTF #1 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address A EFF_PH effluent pH N Y F8:4 D EQ_BYPASS EQ tank bypass mode N Y B3:4/13 D EQ_ID MMI initiate EQ drain N Y B3:1/3 D EQ_IF MMI initiate EQ tankfill N Y B3:1/8 D EQ_LAH EQ tank high-high level Y N B3:40/5 D EQ_LAL EQ tank low-low level Y N B3:40/6 D EQ_LSH equalization tank N Y I:1/6 D EQ_LSL equalization tank N Y I:1/7 D EQINF_FAL equalization tank influent low flow alarm Y N B3:42/9 A EQINF_FR EQ tank influent flow rate, gpm N Y F8:3 A EQINF_LIM equalization tank influent flow rate low limit N Y f8:15 D EQSC_LAH EQ tank secondary containment Y N B3:42/4 D FLTR_PAH filter differential pressure high alarm Y N B3:40/9 A GW_RTIME GW system runtime today N Y mins c5:6.acc D GWSTOPPING GW system stopping N Y B3:0/6 D GWSYS_SD GW system shutdown Y N B3:45/0 D HCL_LAL muriatic acid low level alarm Y N b3:42/5 D HCLSC_LAH muriatic acid secondary containment alarm Y N B3:40/7 D HX_0R HX stop req N Y B3:31/1 A HX_100HRS HX runtime, 100 hours N Y N7:20 D HX_1R HX start req N Y B3:20/10 D HX_AM HX auto / man N Y B3:10/10 D HX_AUX heat exchanger aux N Y I:2/8 D HX_OUT heat exchanger run output N Y O:3/6 D HX_TAH HX high temperature Y N B3:40/11 D KO_LAH SVE knockout tank high level alarm Y N B3:41/2 D MMI_RESET system reset N Y B3:0/2 D MMI_START system start N Y B3:0/0 D MMI_STOP system stop N Y B3:0/1 D MP1_0R MP-1 stop req N Y B3:30/6 A MP1_100HRS MP1 runtime, 100 hours N Y N7:14 D MP1_1R MP-1 start req N Y B3:20/6 D MP1_AM MP-1 auto / man N Y B3:10/6 A MP1_DRCONC NaOCl dosage rate from MMI, ppmv N Y F8:9 A MP1_DRFLOW NaOCl dosage rate calculated in PLC, gal/hr N Y gph F8:11 Table 3-3 Control Tag Database - GWTF #1 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address D MP1_FAL MP1 low flow alarm Y N B3:40/12 D MP1_OUT MP1 run output N Y O:0/3 D MP1_SERV MP1 in service N Y B3:4/5 D MP2_0R MP-2 stop req N Y B3:30/7 A MP2_100HRS MP2 runtime, 100 hours N Y N7:16 D MP2_1R MP-2 start req N Y B3:20/7 D MP2_AM MP-2 auto / man N Y B3:10/7 A MP2_DRCONC sequestering agentdosage rate from MMI, ppmv N Y ppmv F8:12 A MP2_DRFLOW sequestering agent dosage rate calculated in PLC, gal/hr N Y gph F8:14 D MP2_FAL MP2 low flow alarm Y N B3:40/13 D MP2_OUT MP2 run output N Y O:0/4 D MP2_SERV MP2 in service N Y B3:4/6 D MP3_0R MP-3 stop req N Y B3:30/8 A MP3_100HRS MP3 runtime, 100 hours N Y N7:18 D MP3_1R MP-3 start req N Y B3:20/8 D MP3_AM MP-3 auto / man N Y B3:10/8 D MP3_OUT MP3 run output N Y O:0/7 D MP3_SERV MP3 in service N Y B3:4/7 D NA_LAL NaOCl low level alarm Y N b3:42/6 D NASC_LAH NaOCl secondary containment alarm Y N B3:40/3 D P1_0R P-1 stop req N Y B3:30/1 A P1_100HRS P1 runtime, 100 hours N Y N7:4 D P1_1R P-1 start req N Y B3:20/1 D P1_AM P-1 auto / man N Y B3:10/1 D P1_AUX P1 MS auxillary contacts N Y I:0/8 D P1_OUT P1 run output N Y O:0/5 D P1_SEL P1 select to run N Y b3:3/3 D P1_SERV P1 in service N Y B3:4/0 D P2_0R P-2 stop req N Y B3:30/2 A P2_100HRS P2 runtime, 100 hours N Y N7:6 D P2_1R P-2 start req N Y B3:20/2 D P2_AM P-2 auto / man N Y B3:10/2 D P2_AUX P2 MS auxillary contacts N Y I:0/9 D P2_OUT P2 run output N Y O:0/6 D P2_SEL P1 select to run N Y b3:3/4 Table 3-3 Control Tag Database - GWTF #1 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address D P2_SERV P2 in service N Y B3:4/13 D P6_0R P-6 stop req N Y B3:30/3 A P6_100HRS P6 runtime, 100 hours N Y N7:8 D P6_1R P-6 start req N Y B3:20/3 D P6_AM P-6 auto / man N Y B3:10/3 D P6_AUX P6 CU300 run status N Y I:0/0 D P6_FAIL P-6 auto shutdown Y N B3:45/4 D P6_OUT P6 run output N Y O:0/0 D P6_SERV P6 in service N Y B3:4/2 D P7_0R P-7 stop req N Y B3:30/4 A P7_100HRS P7 runtime, 100 hours N Y N7:10 D P7_1R P-7 start req N Y B3:20/4 D P7_AM P-7 auto / man N Y B3:10/4 D P7_AUX P7 CU300 run status N Y I:0/2 D P7_FAIL P-7 CU300 fault Y N B3:42/1 D P7_OUT P7 run output N Y O:0/1 D P7_SERV P7 in service N Y B3:4/3 D P9_0R P-9 stop req N Y B3:30/5 A P9_100HRS P9 runtime, 100 hours N Y N7:12 D P9_1R P-9 start req N Y B3:20/5 D P9_AM P-9 auto / man N Y B3:10/5 D P9_AUX P9 CU300 run status N Y I:0/4 D P9_FAIL P-9 CU300 fault Y N B3:42/3 D P9_OUT P9 run output N Y O:0/2 D P9_SERV P9 in service N Y B3:4/4 D RW7_EXT_SP RW7-LIC external setpoint N Y f8:16 D RW7_ID RW-7 pump down control N Y B3:1/15 D RW7_LAL RW7 low level alarm Y N b3:42/0 D RW7_LIC_AM RW7-LIC auto / man N Y PD10:0/AM D RW7_LIC_CE RW7-LIC cycle enable N Y B3:50/0 A RW7_LIC_CV RW7-LIC CV, 0-100% N Y PD10:0.CVP A RW7_LIC_LE RW7-LIC extra logic enable N Y b3:51/0 A RW7_LIC_OUT RW7-LIC CV output, 0-16383 N Y N9:23 A RW7_LIC_SP RW7-LIC setpoint, 150-200 ft amsl N Y ft amsl PD10:0.SPS A RW7_LTEL RW-7 level transmitter elevation, ft amsl N Y F8:5 Table 3-3 Control Tag Database - GWTF #1 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address A RW7_WC RW-7 water column, ft N Y F8:0 A RW7_WTE RW-7 water table elevation, ft amsl N Y F8:6 D RW9_EXT_SP RW9-LIC external setpoint N Y f8:28 D RW9_ID RW-9 pump down control N Y B3:2/5 D RW9_LAL RW9 low level alarm Y N b3:42/2 D RW9_LIC_AM RW9-LIC auto / man N Y PD10:1/AM D RW9_LIC_CE RW9-LIC cycle enable N Y B3:50/1 A RW9_LIC_CV RW9-LIC CV, 0-100% N Y PD10:1.CVP A RW9_LIC_LE RW9-LIC extra logic enable N Y b3:51/1 A RW9_LIC_OUT RW9-LIC CV output, 0-16383 N Y N9:53 A RW9_LIC_SP RW9-LIC setpoint, 150-200 ft amsl N Y ft amsl PD10:1.SPS A RW9_LTEL RW-9 level transmitter elevation, ft amsl N Y F8:7 A RW9_WC RW-9 water column, ft N Y F8:1 A RW9_WTE RW-9 water tableelevation, ft amsl N Y F8:8 D SA_LAL sequestering agent low level alarm Y N b3:42/7 D SASC_LAH sequestering agent secondary containment alarm Y N B3:40/4 D STARTING system starting N Y B3:0/3 D STOPPED system stopped N Y B3:0/7 D SVE_RTIME SVE system runtime today N Y mins c5:7.acc D SVESYS_SD SVE system shutdown Y N B3:46/0 A unacked_alarms unacknowledged alarms N N Tag Type: A= analog (process variable, pv) D= discrete (status variable, sv) SVE/Offgas systems have been offline since 2006. Table 3-4 Control Tag Database - GWTF #2 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address A alarm_status alarm status N N A all_alarms all alarms N N D AS_LAH air stripper sump LAH Y N B3:40/0 D AS_PAH air stripper blower high pressure Y N B3:40/2 D AS_PAL air stripper blower low pressure Y N B3:40/1 A ASIN_100MG air stripper influent totalizer 100,000,000 gals N Y F8:22 A ASIN_10KG air stripper influent 10K gals totalizer, 10K's gals N Y F8:23 D ASIN_FAL air stripper influent low flow alarm Y Y b3:42/8 A ASIN_FR air stripper influent flow rate, gpm N Y gpm F8:2 A ASIN_G air stripper influent totalizer, gals N Y gals F8:24 D B1_0R B-1 stop request N Y B3:30/0 A B1_100HRS air stripper blower runtime, 100 hrs N Y N7:0 D B1_1R air stripper blower start req N Y B3:20/0 D B1_AM air stripper blower auto / man N Y B3:10/0 D B1_AUX air stripper blower aux contacts N Y I:0/11 A B1_HRS air stripper blower runtime, hours N Y N7:1 D B1_OUT B1 run output N Y O:0/8 D BLDG_LAH building secondary containment alarm Y N B3:40/10 D EFF_AAH effluent pH high alarm Y N B3:40/14 D EFF_AAL effluent pH low alarm Y N B3:40/15 D EFF_AIC_AM EFF-AIC auto / man N Y PD10:2/AM D EFF_AIC_CE EFF-AIC cycle enable N Y B3:50/2 A EFF_AIC_CV EFF-AIC CV output, 0-16383 N Y PD10:2.CVP A EFF_AIC_OUT EFF-AIC CV output,0-16383 N Y N9:83 A EFF_AIC_SP EFF-AIC setpoint, 0-14 pH N Y PD10:2.SPS D EFF_LAH effluent high level alarm Y N B3:40/8 A EFF_PH effluent pH N Y F8:4 D EQ_BYPASS EQ tank bypass mode N Y B3:1/10 D EQ_ID MMI initiate EQ drain N Y B3:1/3 D EQ_IF MMI initiate EQ tankfill N Y B3:1/8 D EQ_LAH EQ tank high-high level Y N B3:40/5 D EQ_LAL EQ tank low-low level Y N B3:40/6 D EQ_LSH equalization tank N Y I:1/6 D EQ_LSL equalization tank N Y I:1/7 D EQINF_FAL EQ tank influent low flow alarm Y N B3:42/10 Table 3-4 Control Tag Database - GWTF #2 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address A EQINF_FR EQ tank influent flow rate, gpm N Y F8:3 A EQINF_LIM EQ tank influent low flow limit, gpm N Y F8:15 D FLTR_PAH filter differential pressure high alarm Y N B3:40/9 D GWSTOPPING GW system stopping N Y B3:0/6 D GWSYS_SD GW system shutdown Y N B3:45/0 D HCL_LAL muriatic acid low level alarm Y N b3:42/5 D HCLSC_LAH muriatic acid secondary containment alarm Y N B3:40/7 D MMI_RESET system reset N Y B3:0/2 D MMI_START system start N Y B3:0/0 D MMI_STOP system stop N Y B3:0/1 D MP1_0R MP-1 stop req N Y B3:30/6 A MP1_100HRS MP-1 runtime, 100 hours N Y n7:8 D MP1_AM MP-1 auto / man N Y B3:10/6 A MP1_DRCONC NaOCl dosage rate from MMI, ppmv N Y F8:9 A MP1_DRFLOW NaOCl dosage rate calculated in PLC, gal/hr N Y gph F8:11 D MP1_FAL MP1 low flow alarm Y N B3:40/12 D MP1_OUT MP1 run output N Y O:0/3 D MP1_SERV MP-1 in service N Y b3:3/3 D MP2_0R MP-2 stop req N Y B3:30/7 A MP2_100HRS MP-2 runtime, 100 hours N Y n7:10 D MP2_1R MP-2 start req N Y B3:20/7 D MP2_AM MP-2 auto / man N Y B3:10/7 A MP2_DRCONC sequestering agent dosage rate from MMI, ppmv N Y ppmv F8:12 A MP2_DRFLOW sequestering agent dosage rate calculated in PLC, gal/hr N Y gph F8:14 D MP2_FAL MP2 low flow alarm Y N B3:40/13 D MP2_OUT MP2 run output N Y O:0/4 D MP2_SERV MP2 in service N Y b3:3/4 D MP3_0R MP-3 stop req N Y B3:30/8 A MP3_100HRS MP3 runtime, 100 hours N Y n7:12 D MP3_1R MP-3 start req N Y B3:20/8 D MP3_AM MP-3 auto / man N Y B3:10/8 D MP3_OUT MP3 run output N Y O:0/7 D MP3_SERV MP3 in service N Y b3:3/5 D NA_LAL NaOCl low level alarm Y N b3:42/6 D NASC_LAH NaOCl secondary containment alarm Y N B3:40/3 Table 3-4 Control Tag Database - GWTF #2 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address D P1_0R P-1 stop req N Y B3:30/4 A P1_100HRS P1 runtime, 100 hours N Y N7:2 D P1_1R P-1 start req N Y B3:20/4 D P1_AM P-1 auto / man N Y B3:10/4 D P1_AUX P1 CU300 run status N Y I:0/2 D P1_FAIL P-1 CU300 fault Y N B3:42/1 D P1_OUT P1 run output N Y O:0/1 D P1_SERV P1 in service N Y B3:3/1 D P1S_0R P-1S stop req N Y B3:30/5 A P1S_100HRS P1S runtime, 100 hours N Y N7:4 D P1S_1R P-1S start req N Y B3:20/5 D P1S_AM P-1S auto / man N Y B3:10/5 D P1S_AUX P1S CU300 run status N Y I:0/4 D P1S_FAIL P-1S CU300 fault Y N B3:42/3 D P1S_OUT P1S run output N Y O:0/2 D P1S_SERV P1S in service N Y B3:3/2 D P2_0R P-2 stop req N Y B3:30/1 A P2_100HRS P2 runtime, 100 hours N Y N7:6 D P2_1R P-2 start req N Y B3:20/1 D P2_AM P-2 auto / man N Y B3:10/1 D P2_AUX P2 MS auxillary contacts N Y I:0/6 D P2_FAL P2 low flow alarm Y N B3:42/8 D P2_OUT P2 run output N Y O:0/4 D P2_SEL P2 select to run N Y b3:3/4 D P2_SERV P2 in service N Y B3:3/0 D RW1_ID RW-1 pump down control N Y B3:1/15 D RW1_LAL RW1 low level alarm Y N b3:42/0 D RW1_LIC_AM RW1-LIC auto / man N Y PD10:0/AM D RW1_LIC_CE RW1-LIC cycle enable N Y B3:50/0 A RW1_LIC_CV RW1-LIC CV, 0-100% N Y PD10:0.CVP A RW1_LIC_OUT RW1-LIC CV output, 0-16383 N Y N9:23 A RW1_LIC_SP RW1-LIC setpoint, 150-200 ft amsl N Y ft amsl PD10:0.SPS A RW1_LTEL RW-1 level transmitter elevation, ft amsl N Y F8:5 A RW1_WC RW-1 water column, ft N Y F8:0 A RW1_WTE RW-1 water table elevation, ft amsl N Y F8:6 Table 3-4 Control Tag Database - GWTF #2 Tag Type Tag Name Tag Description Alarmed Data Logged Units Address D RW1S_ID RW-8 pump down control N Y B3:2/5 D RW1S_LAL RW1S low level alarm Y N b3:42/2 D RW1S_LIC_AM RW1S-LIC auto / man N Y PD10:1/AM D RW1S_LIC_CE RW1S-LIC cycle enable N Y B3:50/1 A RW1S_LIC_CV RW1S-LIC CV, 0-100% N Y PD10:1.CVP A RW1S_LIC_OUT RW1S-LIC CV output,0-16383 N Y N9:53 A RW1S_LIC_SP RW1S-LIC setpoint, 150-200 ft amsl N Y ft amsl PD10:1.SPS A RW1S_LTEL RW-1S level transmitter elevation, ft amsl N Y F8:7 A RW1S_WC RW-1S water column, ft N Y F8:1 A RW1S_WTE RW-1S water table elevation, ft amsl N Y F8:8 D SA_LAL sequestering agent low level alarm Y N b3:42/7 D SASC_LAH sequestering agent secondary containment alarm Y N B3:40/4 D STARTING system starting N Y B3:0/3 D STOPPED system stopped N Y B3:0/7 D SYS_RTIME system runtime today N Y mins c5:6.acc A unacked_alarms unacknowledged alarms N N Tag Type: A= analog (process variable, pv) D= discrete (status variable, sv) Table 5-1 Routine Operating Parameters - GWTF #1 Parameter Description Normal Value Upper Limit Lower Limit Units RW-6 water table elevation 150 180 130 ft amsl Recovery well pump P-6 pressure 30 160 0 psig Recovery well pump P-6 flow rate 4 7 0 gpm RW-7 water table elevation 153 180 135 ft amsl Recovery well pump P-7 pressure 15 97 0 psig Recovery well pump P-7 flow rate 20 36 0 gpm RW-9 water table elevation 170 180 135 ft amsl Recovery well pump P-9 pressure 20 82 0 psig Recovery well pump P-9 flow rate 10 27 0 gpm Transfer pump P-1 pumping rate (am) 30 - 35 60 4 gpm Transfer pump P-1 motor current 1.4 - 1.6 FLA = 1.8 --- amps Transfer pump P-2 pumping rate (pm) 30 - 35 60 4 gpm Transfer pump P-1 and P-2 discharge pressure 27 40 20 psig Transfer pump P-2 motor current 1.4 - 1.6 FLA = 1.8 --- amps NaOCl concentration in influent 20 na na ppmv NaOCl dosage rate 0.042 0.66 0 gal/hr MP-1 stroke length 100 100 0 % Sequesterant (20%) conc in influent 17 na na ppmv Sequestering agent dosage rate 0.036 0.66 0 gal/hr MP-2 pump stroke length 100 100 20 % Bag filter differential pressure <12 20 0 psig Air stripper blower B-1 flow rate 300 - 350 400 300 scfm Air stripper blower B-1 motor current 16 - 18 FLA = 22.0 --- amps Air stripper blower suction pressure 45 70 40 inches W.C. vacuum Air stripper blower discharge pressure 48 60 40 inches W.C. pressure Air stripper blower discharge temperature 190 160 220 °F Effluent pH 7.5 8.3 7 pH units SVE-1 wellhead vacuum 30 40 20 inches W.C. vacuum SVE influent flow rate 140 160 120 scfm SVE blower motor current 5.5 - 7.0 FLA = 8.0 --- amps SVE blower suction pressure 30 40 20 inches W.C. vacuum SVE blower discharge pressure 45 60 40 inches W.C. pressure SVE blower discharge temperature 170 180 158 °F Heat exchanger motor current 1 - 1.4 FLA = 1.9 --- amps Heat exchanger discharge temp 110 120 100 °F GAC #1 discharge pressure 30 --- --- inches W.C. pressure GAC #2 discharge pressure 15 --- --- inches W.C. pressure KMnO4 #1 discharge pressure 5 --- --- inches W.C. pressure Note: SVE/Offgas systems have been offline since 2006. Table 5-2 Routine Operating Parameters - GWTF #2 Parameter Description Normal Value Upper Limit Lower Limit Units RW-1 water table elevation 111 150 85 ft amsl Recovery well pump P-1 pressure 30 104 0 psig Recovery well pump P-1 flow rate 4 7 0 gpm RW-1S water table elevation 122 150 85 ft amsl Recovery well pump P-1S pressure 20 97 0 psig Recovery well pump P-1S flow rate 15 36 0 gpm Transfer pump pumping rate 25 60 4 gpm Transfer pump motor current 1.4 - 1.6 FLA = 1.8 0 amps Transfer pump discharge pressure 25 40 20 psig NaOCl concentration in influent 20 na na ppmv NaOCl dosage rate 0.03 0.66 0 gal/hr MP-1 stroke length 100 100 20 % Sequesterant (20%) conc in influent 12 na na ppmv Sequestering agent dosage rate 0.018 0.66 0 gal/hr MP-2 stroke length 100 100 20 % Bag filter differential pressure <12 20 0 psig Air stripper blower B-1 flow rate 150 200 0 scfm Air stripper blower B-1 motor current 6.5 - 7 FLA = 8.0 0 amps Air stripper blower suction pressure 43 70 30 inches W.C. vacuum Air stripper blower discharge pressure <10 --- --- inches W.C. pressure Air stripper blower discharge temperature 200 250 160 °F Effluent pH 7.5 8.3 7 pH units Table 6-1 Routine and Preventative Maintenance Schedule – GWTF #1 System Task Recommend frequency STAT 80 Air Stripper and Blower Clean trays, and demister As needed, depending on the amount of hardness in the water. An initial inspection of the trays is suggested after the two to three weeks. If the differential pressure across the unit exceeds 7” of water pressure per tray, the system should be cleaned. Clean site glass and level assembly As needed, depending on the amount of hardness in the water. If the site glass every becomes rust colored, the site glass should be cleaned. Replace tray gaskets. As needed. Blower filter cleaning or replacement As needed, depending on air quality conditions Grease blower motor bearings with NLGI #2. Grease, if applicable. Yearly Replace bearings After 15,000 – 20,000 hours, on average. Bag Filters Clean/replace bag filters As needed, depending on the amount of sediment. If the differential pressure across the bag exceeds 12 psi, then the bag should be serviced. Transfer Pumps Disassemble, inspect, and clean impeller housing Yearly, but may require service more often if the water hardness level is high. Grease motor with NLGI #2, if applicable. Yearly Chemical Feed Pumps Monitor chemical usage Monitor the chemical usage rate at your convenience. Check pump for proper zero position (stroke knob). Periodically. Replace Liquifram (Diaphragm), cartridge valves or seal rings/valve balls, valve cap assemblies, and injection check valve spring. Yearly. System Task Recommend frequency Exhaust Fans Lubricate motors using SAE 20 non-detergent oil. Every six months. Clean propeller blades and motor of excessive dirt. Periodically. Air Conditioners Lubricate fan motor using 2 – 3 drops of light machine oil. Every three months. Clean intake filter. Periodically. Roll-Up Doors Lubricate roller chains, spur gears, guides, end brackets, bearings, and lock mechanisms. Periodically. Table 6-2 Routine and Preventative Maintenance Schedule – GWTF #2 System Task Recommend frequency STAT 30 Air Stripper and Blower Clean trays, and demister As needed, depending on the amount of hardness in the water. An initial inspection of the trays is suggested after the two to three weeks. If the differential pressure across the unit exceeds 7” of water pressure per tray, the system should be cleaned. Clean site glass and level assembly As needed, depending on the amount of hardness in the water. If the site glass every becomes rust colored, the site glass should be cleaned. Replace tray gaskets As needed. Blower filter cleaning or replacement As needed, depending on air quality conditions Grease blower motor bearings with NLGI #2. Grease, if applicable. Yearly Replace bearings After 15,000 – 20,000 hours, on average. Bag Filters Clean/replace bag filters As needed, depending on the amount of sediment. If the differential pressure across the bag exceeds 12 psi, then the bag should be serviced. Transfer Pumps Disassemble, inspect, and clean impeller housing Yearly, but may require service more often if the water hardness level is high. Grease motor with NLGI #2, if applicable. Yearly Chemical Feed Pumps Monitor chemical usage Monitor the chemical usage rate at your convenience. Check pump for proper zero position (stroke knob). Periodically. Replace Liquifram (Diaphragm), cartridge valves or seal rings/valve balls, valve cap assemblies, and injection check valve spring. Yearly. Exhaust Fans Lubricate motors using SAE 20 non-detergent oil. Every six months. System Task Recommend frequency Clean propeller blades and motor of excessive dirt. Periodically. Air Conditioners Lubricate fan motor using 2 – 3 drops of light machine oil. Every three months. Clean intake filter. Periodically. Roll-Up Doors Lubricate roller chains, spur gears, guides, end brackets, bearings, and lock mechanisms. Periodically. Table 6-3 Spare Parts List System Spare Part(s) Description On-Hand Upon Request STAT 80 Air Stripper Carbonair #211451 STAT 80 tray gasket X Carbonair #127581 STAT 30/80 polypropylene mist eliminator pad X Carbonair #117842 VL GD flapper X Carbonair #117923 Float ball 5 SS X Carbonair #211451 STAT 80 tray gasket X Carbonair #128272 Pressure gauge (0-100" wc) X Carbonair #108357 Sample port X Carbonair #124827 Dwyer model 1950-5 differential pressure switch X STAT 30 Air Stripper Carbonair #117842 VL GD flapper X Carbonair #117923 Float ball 5 SS X Carbonair #211452 STAT30 tray gasket X Carbonair #128272 Pressure gauge (0-100" wc) X Carbonair #127581 STAT 30/80 polypropylene mist eliminator pad X Carbonair #108357 Sample port X Carbonair #124827 Dwyer model 1950-5 differential pressure switch X Bag Filters Carbonair #108357 Sample port X Carbonair #211320 25 Micron bag filter X Carbonair #210027 50 Micron bag filter X Carbonair #166980 Bag filter, oil removing X Carbonair #165924 Pressure gauge (0-60 psi) X Carbonair #108365 Pressure gauge (0-100 psi) X Carbonair #214737 O-ring for bag filter housing lid X Carbonair #214738 O-ring for bag filter basket X Carbonair #163286 Barksdale model DPD1T-GH80SS differential pressure switch (4-80 PSI) X Filter basket X Chemical Feed Pumps No on-hand spare parts recommended. Spare Parts Kit or RPM ProPacs available from LMI. Refer to the information contained in Appendix C. X Well Pumps No on-hand spare parts recommended. Service kits and service tools available from Grundfos. Refer to the information contained in Appendix L. X Pressure Transducers No on-hand spare parts recommended. Service provided by Pressure Systems. Refer to the information contained in Appendix L. X Transfer pumps No on-hand spare parts recommended. Replacement parts available from Corcoran. Refer to spare parts list in Appendix B. X Exhaust Fans No on-hand spare parts recommended. Replacement parts available from Dayton. Refer to spare parts list in Appendix M. X Air conditioners No on-hand spare parts recommended. Replacement parts available from Nordic Air. Refer to spare parts list in Appendix M. X System Spare Part(s) Description On-Hand Upon Request Roll-up doors No on-hand spare parts recommended. Replacement parts available from Cornell KH International. Refer to spare parts list in Appendix M. X Table 7-1 Routine Inspection, Monitoring, and Maintenance Schedule Daily/Weekly Checklist Items  Check/record readings from all instruments, meters, and gauges  Check overall plant operations  Check OIT/PLC for alarm conditions  Check all valve positions  Change bag filters when DP reaches 12 psig  Pull weeds and clean grounds  Check all sumps in the SVE lines and drain if necessary Monthly Checklist Items  Check off-gas treatment vessels and stacks for moisture collection  Check well vaults and pull boxes for leaks  Restart computers Quarterly Checklist Items  Turn all valves Bi-Annual Checklist Items  Change eyewash liquid  Lubricate exhaust fan motors  Lubricate roll-up doors Annual Checklist Items  Grease fittings on blowers  Grease/lubricate all motors  Grease transfer pump and clean impeller housing as needed  Pull and check well pump for biofouling  Shock-chlorinate recovery wells as needed  Clean transformers (certified electrician)  Clean exhaust fan blades Periodic / As-Needed Checklist Items  Drain moisture separator  Clean or replace blower inlet air filters (all blowers)  Clean AC intake filter  Empty condensate collection drums at TU#2 and TU#4 and treat at TU#3 NOTE: Refer to Tables 6-1 and 6-2 for additional details regarding routine maintenance. Table 8-1 General Troubleshooting Guidelines – GWTF #1 System Problem Possible Cause Solution GWTF #1 - Overview One or more components will not run in AUTO System-wide shutdown conditions exist Examine the ALARM screen, acknowledge any existing alarms, click the RESET button at the top of any screen, and investigate any remaining alarm conditions. All alarm conditions capable of preventing AUTO operation are listed in Table 3-1. SVE Blower1 Blower will run in “MAN” but not in “AUTO” Alarm conditions – General Clear any alarm condition and reset the control panel, see “Section 3” for alarm interlocks. Conditions with obvious solutions include high KO tank water level, secondary containment leak detection. See HX troubleshooting for high HX discharge temperature. Low flow alarm Remove and inspect flow switch and flapper. Check continuity across switch terminals with flapper in up and down positions. If switching action is not detected, replace switch. If switching action is detected, examine flapper for scale or corrosion buildup. Clean and replace. SVE blower high discharge temperature Check for low flow situation (may not be low enough for a low flow alarm), high differential pressure across the inlet filter, or high discharge pressure indicating blockage in the off-gas treatment system. Clean or replace filter. Check vacuum at wellhead versus KO tank and determine if pressure losses are excessive. Check for blockage in piping. Check pressure drops across GAC and KMnO4 vessels. Blower will not run in the “MAN” position Tripped circuit protector Open the inner door and reset the circuit protector. Inspect the system thoroughly and check the operating conditions. If it will run at least momentarily, check amps at startup and compare to initial operating conditions. Motor temperature switch is inoperative Check to see that the motor temperature switch has been wired, or that there is a jumper, if a switch is not present. Faulty Blower Refer to Appendix or contact CARBONAIR for help in diagnosing faulty blower. System Problem Possible Cause Solution Blower runs at a reduced performance Incorrect blower rotation Verify and change rotation Inlet filter fouled Clean or replace inlet filter Excessive effluent pressure Verify operating condition. Ensure that there is not excessive backpressure on the unit, (eg, fouled Carbon bed) Moisture separator relief valve set to low Adjust pressure relief valve, be careful not to overload blower motor Abnormal sound Impeller rubbing against housing Adjust impeller Inlet filter fouled Clean or replace inlet filter Bearings defective Change bearings Motor overheats Impeller rubbing against housing Adjust impeller Inlet filter fouled Clean or replace inlet filter Bearings defective Change bearings One phase of stator winding short circuited Rewind or purchase new motor Operating beyond performance range Reduce system pressure/vacuum Well Pumps Pump will run in “MAN” but not in “AUTO” Alarm conditions – General Clear any alarm condition and reset the control panel. See “Section 3” for alarm interlocks. CU300 fault Check the CU300 controller for a fault condition. Follow instructions in Grundfos® manual for troubleshooting Well water level is below the cycle off level. Check the LSL switch setting in the interlocks Table and allow the aquifer sufficient time to re-charge the well. When the water table elevation exceeds the low level switch, click the START button on the pump control panel. Pump will not run in the “MAN” position CU300 controller not properly setup for remote control. Check CU300 controller for proper setup for remote control of on-off and motor speed. PID controller output set to 0% Adjust the PID controller output. Tripped circuit protector Open the inner door and reset the circuit protector. Inspect the system thoroughly and check the operating conditions. Motor temperature switch is inoperative Check to see that the motor temperature switch has been wired, or that there is a jumper, if a switch is not present. System Problem Possible Cause Solution Faulty pump Refer to Appendix or contact CARBONAIR for help in diagnosing faulty pump. Pump operating, but at reduced performance Incorrect pump rotation Verify and change rotation Pumping sediment The pump may be too close to the bottom of the well. Move the pump up. Pump restricted Inspect and clean all effluent lines. Check to ensure that discharge valves are open. STAT Air Stripper Water in air discharge line Water flow rate too high Verify water flow rate conditions and adjust flow rate accordingly Air flow rate too high Verify airflow rate conditions and adjust flow rate accordingly. Foaming Contact CARBONAIR for a foaming test kit. High Pressure Drop Pressure in the unit exceeds the recommended maximum (9” H2O per tray). Water flow rate too high Verify water flow rate conditions and adjust flow rate accordingly Air flow rate too high Verify airflow rate conditions and adjust flow rate accordingly. Excessive effluent pressure Verify operating condition. Ensure that there is not excessive backpressure on the unit, (i.e. reduced pipe sizes, fouled Carbon bed, or fouled CATOX.) Trays fouled Inspect and clean trays Reduction in treatment performance Inadequate air/water ratio Verify that the system flows are within design specifications Aeration trays are fouled Clean STAT trays Leaky Gaskets Pressure drop too high See “STAT-High Pressure Drop” section Damaged gaskets Replace leaky gasket STAT Blower1 Blower will run in “MAN” but not in “AUTO” Alarm conditions – General Clear any alarm condition and reset the control panel. See “Section 3” for alarm interlocks. High pressure alarm Check for high discharge pressure indicating blockage in the off-gas treatment system. Check pressure drops across GAC and KMnO4 vessels. Check for proper operation of the discharge check valve. Check for adequate accumulation of water on air stripper trays. Check pressure switch adjustment. System Problem Possible Cause Solution Low pressure alarm Check the inlet filter and clean or replace as necessary. Check air stripper trays for fouling and clean if necessary. Check pressure switch adjustment. Blower will not run in the “MAN” position Tripped circuit protector Open the inner door and reset the circuit protector. Inspect the system thoroughly and check the operating conditions. . If it will run at least momentarily, check amps at startup and compare to initial operating conditions. Motor temperature switch is inoperative Check to see that the motor temperature switch has been wired, or that there is a jumper, if a switch is not present. Faulty Blower Refer to Appendix or contact CARBONAIR for help in diagnosing faulty blower. Blower runs at a reduced performance Incorrect blower rotation Verify and change rotation Inlet filter fouled Clean or replace inlet filter Excessive effluent pressure See “STAT-High Pressure Drop” section Abnormal sound Impeller rubbing against housing Adjust impeller Inlet filter fouled Clean or replace inlet filter Bearings defective Change bearings Motor overheats Impeller rubbing against housing Adjust impeller Inlet filter fouled Clean or replace inlet filter Bearings defective Change bearings One phase of stator winding short circuited Rewind or purchase new motor Operating beyond performance range Reduce system pressure/vacuum Transfer Pumps Pump will run in “MAN” but not in “AUTO” Alarm conditions – General Clear any alarm condition and reset the control panel. See “Section 3” for alarm interlocks. Equalization tank water level too low Fill the tank to any level above the LSL (cycle off level) and click the START button on the pump control panel. Pump will not run in the “MAN” position Tripped circuit protector Open the inner door and reset the circuit protector. Inspect the system thoroughly and check the operating conditions. . If it will run at least momentarily, check amps at startup and compare to initial operating conditions. System Problem Possible Cause Solution Motor temperature switch is inoperative Check to see that the motor temperature switch has been wired, or that there is a jumper, if a switch is not present. Faulty pump Refer to Appendix or contact CARBONAIR for help in diagnosing faulty pump. Pump operating, but at reduced performance Incorrect pump rotation Verify and change rotation Pump restricted Inspect and clean all influent lines, pump head and effluent lines. Pump leaking at seal Shaft seal worn Replace shaft seal Leak in system Inspect system for leaks Chemical Feed Pumps Pump will run in “MAN” but not in “AUTO” Low flow alarm Check Digi-Pulse unit for proper operation, adjustment and pulse output. Pump will not run in the “MAN” position PID controller output or dosage rate too low. Check PID controller output on PID screen and adjust as necessary. Check dosage rate on PID screen and enter new value as necessary. Pump loses prime Out of Chemical Add more chemical Check valve not working or installed incorrectly See Appendix for installation, make sure check valve functioning. Pump will not prime Output not set properly Set speed and stroke to 100% Suction lift too high Lower pump Pump fails to pump Worn seal ring, or diaphragm. Inspect and replace damaged item Stroke setting too low Adjust setting to a higher value Pump in not getting power Confirm that the pump is getting power and be sure that the pump is enabled. Pump has failed Refer to Appendix or contact CARBONAIR for help in diagnosing faulty pump. GPC Vessels1 Early breakthrough or increased carbon usage Actual concentrations higher than designed Sample and Analyze influent water to determine if design contaminants or concentrations are different than anticipated. Contact Carbonair for revised modeling Additional contaminants present High inlet temperature Add heat exchanger High inlet relative Humidity Add in-line duct heater for humidity control Higher than normal pressure drop High inlet temperature Check heat exchanger discharge temperature switch for proper operation. High inlet relative Humidity Check GPC inlet piping for mist or water droplets and, if found, troubleshoot the air stripper as described earlier. System Problem Possible Cause Solution Accumulation of particles Sample the carbon to determine if solids are clogging the bed. Back track to determine the source and correct Wet carbon Dry out the carbon bed by draining any condensate and blow clean-dry air through the vessel. Exhaust Fan Excessive noise Noisy motor bearings Lubricate or replace bearings Loose fan blade Tighten set screws Crooked or damaged propeller Straighten or replace fan blade Insufficient air flow Damper (shutter) closed/shut Repair shutter Low voltage Determine cause and correct Note: 1. SVE/Offgas systems have been offline since 2006. Table 8-2 General Troubleshooting Guidelines – GWTF #2 System Problem Possible Cause Solution GWTF #2 - Overview One or more components will not run in AUTO System-wide shutdown conditions exist Examine the ALARM screen, acknowledge any existing alarms, click the RESET button at the top of any screen, and investigate any remaining alarm conditions. All alarm conditions capable of preventing AUTO operation are listed in Table 3-2. Well Pumps Pump will run in “MAN” but not in “AUTO” Alarm conditions – General Clear any alarm condition and reset the control panel. See “Section 3” for alarm interlocks. CU300 fault Check the CU300 controller for a fault condition. Follow instructions in Grundfos® manual for troubleshooting Well water level is below the cycle off level. Check the LSL switch setting in the interlocks Table and allow the aquifer sufficient time to re-charge the well. When the water table elevation exceeds the low level switch, click the START button on the pump control panel. Pump will not run in the “MAN” position CU300 controller not properly setup for remote control. Check CU300 controller for proper setup for remote control of on-off and motor speed. PID controller output set to 0% Adjust the PID controller output. Tripped circuit protector Open the inner door and reset the circuit protector. Inspect the system thoroughly and check the operating conditions. Motor temperature switch is inoperative Check to see that the motor temperature switch has been wired, or that there is a jumper, if a switch is not present. Faulty pump Refer to Appendix or contact CARBONAIR for help in diagnosing faulty pump. Pump operating, but at reduced performance Incorrect pump rotation Verify and change rotation Pumping sediment The pump may be too close to the bottom of the well. Move the pump up. Pump restricted Inspect and clean all effluent lines. Check to ensure that discharge valves are open. System Problem Possible Cause Solution STAT Air Stripper Water in air discharge line Water flow rate too high Verify water flow rate conditions and adjust flow rate accordingly Air flow rate too high Verify airflow rate conditions and adjust flow rate accordingly. Foaming Contact CARBONAIR for a foaming test kit. High Pressure Drop Pressure in the unit exceeds the recommended maximum (9” H2O per tray). Water flow rate too high Verify water flow rate conditions and adjust flow rate accordingly Air flow rate too high Verify airflow rate conditions and adjust flow rate accordingly. Excessive effluent pressure Verify operating condition. Ensure that there is not excessive backpressure on the unit. Trays fouled Inspect and clean trays Reduction in treatment performance Inadequate air/water ratio Verify that the system flows are within design specifications Aeration trays are fouled Clean STAT trays Leaky Gaskets Pressure drop too high See “STAT-High Pressure Drop” section Damaged gaskets Replace leaky gasket STAT Blower Blower will run in “MAN” but not in “AUTO” Alarm conditions – General Clear any alarm condition and reset the control panel. See “Section 3” for alarm interlocks. High pressure alarm Check for high discharge pressure indicating blockage in the off-gas discharge piping. Check for adequate accumulation of water on air stripper trays. Check pressure switch adjustment. Low pressure alarm Check the inlet filter and clean or replace as necessary. Check air stripper trays for fouling and clean if necessary. Check pressure switch adjustment. Blower will not run in the “MAN” position Tripped circuit protector Open the inner door and reset the circuit protector. Inspect the system thoroughly and check the operating conditions. . If it will run at least momentarily, check amps at startup and compare to initial operating conditions. Motor temperature switch is inoperative Check to see that the motor temperature switch has been wired, or that there is a jumper, if a switch is not present. Faulty Blower Refer to Appendix or contact CARBONAIR for help in diagnosing faulty blower. Blower runs at a reduced performance Incorrect blower rotation Verify and change rotation Inlet filter fouled Clean or replace inlet filter System Problem Possible Cause Solution Excessive effluent pressure See “STAT-High Pressure Drop” section Abnormal sound Impeller rubbing against housing Adjust impeller Inlet filter fouled Clean or replace inlet filter Bearings defective Change bearings Motor overheats Impeller rubbing against housing Adjust impeller Inlet filter fouled Clean or replace inlet filter Bearings defective Change bearings One phase of stator winding short circuited Rewind or purchase new motor Operating beyond performance range Reduce system pressure/vacuum Transfer Pump Pump will run in “MAN” but not in “AUTO” Alarm conditions – General Clear any alarm condition and reset the control panel. See “Section 3” for alarm interlocks. Equalization tank water level too low Fill the tank to any level above the LSL (cycle off level) and click the START button on the pump control panel. Pump will not run in the “MAN” position Tripped circuit protector Open the inner door and reset the circuit protector. Inspect the system thoroughly and check the operating conditions. . If it will run at least momentarily, check amps at startup and compare to initial operating conditions. Motor temperature switch is inoperative Check to see that the motor temperature switch has been wired, or that there is a jumper, if a switch is not present. Faulty pump Refer to Appendix or contact CARBONAIR for help in diagnosing faulty pump. Pump operating, but at reduced performance Incorrect pump rotation Verify and change rotation Pump restricted Inspect and clean all influent lines, pump head and effluent lines. Pump leaking at seal Shaft seal worn Replace shaft seal Leak in system Inspect system for leaks Chemical Feed Pumps Pump will run in “MAN” but not in “AUTO” Low flow alarm Check Digi-Pulse unit for proper operation, adjustment and pulse output. Pump will not run in the “MAN” position PID controller output or dosage rate too low. Check PID controller output on PID screen and adjust as necessary. Check dosage rate on PID screen and enter new value as necessary. System Problem Possible Cause Solution Pump loses prime Out of Chemical Add more chemical Check valve not working or installed incorrectly See Appendix for installation, make sure check valve functioning. Pump will not prime Output not set properly Set speed and stroke to 100% Suction lift too high Lower pump Pump fails to pump Worn seal ring, or diaphragm. Inspect and replace damaged item Stroke setting too low Adjust setting to a higher value Pump in not getting power Confirm that the pump is getting power and be sure that the pump is enabled. Pump has failed Refer to Appendix or contact CARBONAIR for help in diagnosing faulty pump. Exhaust Fan Excessive noise Noisy motor bearings Lubricate or replace bearings Loose fan blade Tighten set screws Crooked or damaged propeller Straighten or replace fan blade Insufficient air flow Damper (shutter) closed/shut Repair shutter Low voltage Determine cause and correct