NCD980840409_19941001_Charles Macon Lagoon & Drum_FRBCERCLA RA_Operations and Maintenance Plan-OCR

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u OPERATION AND MAINTENANCE
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MACON/DOCKERY SITE
RICHMOND COUNTY, NORTH CAROLINA
RECF.n111:o
NOV O 41994
SUPERFUND Sf;CTION
OPERATIONS AND MAINTENANCE PLAN
INC.
REMEDIAL DESIGN AND REMEDIAL ACTION
October 1994
Project Manager
RMT, INC. -GREENVILLE, SC
100 VERDAE BOULEVARD -29607-3825
p_o_ Box 16778 -29606-6778
803/281-0030 -803/281-0288 FAX
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE TABLE OF CONTENTS
TABLE OF CONTENTS
Section Page
ACRONYMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
DOCUMENT CONTROL SHEET ............................................ iii
1. INTRODUCTION ...................................................... 1-1
1 .1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1 .2 Purpose of Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Scope of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Regulatory Requirements -RD/RA Consent Decree . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 Treatment System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.1 Ground Water Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.2 Ground Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.5.3 Soil Vapor Extraction System ................................ 1-15
1.5.4 Remediation of Lagoon 1 O Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.5.5 Vessel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.6 Design Conditions and Prescribed Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.6.1 Macon Ground Water Extraction Wells and
Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.6.2 Upper Dockery Ground Water Extraction Wells and
Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.6.3 Lower Dockery Ground Water Extraction Wells and
Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1.6.4 Macon Soil Vapor Extraction Wells and
Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1. 7 Process Instrumentation and Control Approach . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.8 Organization of Operations Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.9 Training of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
2. OPERATION OF SYSTEMS ............................................. 2-1
2.1 Macon Ground Water Remediation System Description . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 System Description and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 System Start-Up for Ground Water Recovery and Treatment System . . . 2-1 O
2.1.3 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.1.4 Normal Shutdown ........................................ 2-14
2.1.5 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.1.6 Troubleshooting and Alternate Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.2 Lower Dockery Ground Water Remediation System Description . . . . . . . . . . . . . 2-16
2.2.1 System Description and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.2.2 System Start-Up for Ground Water Recovery and Treatment System . . . 2-25
2.1.3 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.2.4 Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.2.5 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.2.6 Troubleshooting and Alternate Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-30
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE TABLE OF CONTENTS
Section
TABLE OF CONTENTS (Continued)
2.3 Lower Dockery Ground Water Remediation System Description . . . . . . . . . . . . . 2-31
2.3.1 System Description and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.3.2 System Start-Up for Ground Water Recovery and Treatment System . . . 2-39
2.3.3 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.3.4 Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.3.5 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.3.6 Troubleshooting and Alternate Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.4 Macon Soil Remediation System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.4.1 System Description and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.4.2 System Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.4.3 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.4.4 Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.4.5 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.4.6 Troubleshooting and Alternate Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-49
2.5 Miscellaneous System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
3. MAINTENANCE OF SYSTEMS ........................................... 3-1
3.1 Ground Water Remediation System Maintenance Tasks . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Mechanical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Instrumentation and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Soil Vapor Extraction System ...................................... ·. 3-3
3.2.1 Mechanical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2 Instrumentation and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
4. HEAL TH AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5.
4.1 Health and Safety Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Standard Operating Procedures and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 System Failure Activtties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Medical Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.2 General Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.3 Personal Injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 Chemical Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.5 Fire or Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.6 Emergency Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
ROUTINE MONITORING, RECORDKEEPING, AND LABORATORY TESTING ........ 5-1
5.1 Monitoring Activities and Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Ground Water Remediation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 Macon Soil Vapor Extraction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Laboratory Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE TABLE OF CONTENTS
Section
TABLE OF CONTENTS (Continued)
Page
5.3 Personnel and Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 Medical Surveillance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.2 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.3 Work Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.4 Accident Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.5 Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4 Systems Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
List of Figures
Figure 1-1 Ground Water Recovery Well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-2 Jet Pump System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1-3 Electrical Submersible Pump Collection System Flow Diagram . . . . . . . . . . . . . . . . . 1-10
Figure 1-4 Diagram of Low Profile Air Stripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Figure 1-5 Upper Dockery and Lower Dockery Metals Removal Systems Flow Diagram . . . . . . . 1-13
Figure 1-6 Macon Metals Removal Systems Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Figure 1-7 Soil Vapor Extraction Flow Diagram ................................... , 1-17
Figure 1-8 Organization of Operations Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Figure 4-1 Hospttal Emergency Route Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
List of Tables
1-1 Summary of SVE Well Construction Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1-2 Macon Site Air Stripping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-3 Upper Dockery Air Stripping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1-4 Lower Dockery Air Stripping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
2-2 Macon Ground Water System Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-3 Troubleshooting and Alternate O&M GW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-4 Lower Dockery Ion Exchange Column Instrumentation ............................ · 2-24
2-5 Lower Dockery Groundwater system Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2-6 Troubleshooting & Attemate O&M GW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2-7 Lower Dockery Ion Exchange Column Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2-8 Lower Dockery Groundwater System Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2-9 Troubleshooting & Attemate O&M-GW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2-10 SVE System Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
2-11 Troubleshooting and Atternate O&M-SVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
5-1 Ground Water Treatment System Maintenance .................................. 5-1
5-2 SVE Maintenance ...................................................... · . 5-2
5-3 Air Sample Test Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE TABLE OF CONTENTS
List of Appendices
Appendix A Process Instrumentation and Control Approach
Appendix B Registration of Emission Sources
Appendix C Records and Reporting Data Sheets
Appendix D Tank Data Sheet
Appendix E Pump Data Sheet -Ground Water
Appendix F Pump Data Sheet -SVE
Appendix G Pump Maintenance -GW & SVE
Appendix H Low Profile Air Stripper Data Sheets
Appendix I Low Profile Air Stripper Trouble Shooting and Maintenance Guide
Appendix J Troubleshooting Centrifugal Pump
Appendix K Underground Injection Control Permtt
List of Drawings
7001714-C04 SVE Process Flow Diagram and Miscellaneous Plans and Sections
7001721-C06 Infiltration Gallery Section and Jet Pump and Manhole Details
7001721-C0B Submersible Pump Details
7001721-K01 Macon Site Process and Instrument Diagram
7001721-K02 Lower Dockery Site Process and Instrument Diagram
7001721-K03 Upper Dockery Site Process and Instrument Diagram
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OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE PREFACE
PREFACE
This Operations and Maintenance Plan is a project deliverable under the approved RD project schedule
that was included in the Remedial Design Workplan. This document provides the Untted States
Environmental Protection Agency (US EPA) and North Carolina Department of Environment, Health, and
Natural Resources (NC DEHNR) wtth the technical basis for site O&M activities as they relate to s,tart up,
shut down, and maintenance of the soil and ground water treatment systems. The components of the O&M
Manual are contained in this O&M Plan. The O&M Manual will be prepared during the O&M Training
Phase of the Remedial Action, and will include vendor manuals and as-built drawings.
Other documents referenced by this Operation and Maintenance Plan include:
Macon/Dockery Site Prefinal/Final Remedial Design Report for Ground Water
Macon/Dockery Site Final Remedial Design Report for Soil Vapor Extraction
Macon/Dockery Site Performance Standards Verttication Plan
A set of drawings has been developed to accompany this submittal. These drawings are referenced by
tttle and number in the Table of Contents following this page, and are provided in the Macon/Dockery Site
Prefinal/Final Remedial Design Report for Ground Water and the Macon/Dockery Stte Final Remedial
~ Design Report for Soil Vapor Extraction.
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OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE ACRONYMS AND ABBREVIATIONS
ACRONYMS AND ABBREVIATIONS
BAQC Bureau of Air Quality Control
BOD, 5 Day Biochemical Oxygen Demand
COD Chemical Oxygen Demand
DO Dissolved Oxygen
FWE Furnished wtth Equipment
g gram
gal gallons(s)
gpd gallons per day
gpd/sq. ft. gallons per day, per square foot
gpm gallons per minute
GWS Graphic Wor1< Station
hp horsepower
IWC lnstream Waste Concentration
kWh kilowatt hour(s)
L liters
lb/day pound(s) per day
mg/L milligrams per liter
mgd million gallons per day
mil.gal million gallons
PLC Programmable Logic Controller
psi pounds per square inch
RD/RA Remedial Design/Remedial Action
ROD Record of Decision
rpm revolutions per minute
NC DEHNR North Carolina Department of Environmental Health and Natural
Resources
sow Statement of Work
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OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE ACRONYMS AND ABBREVIATIONS
ACRONYMS AND ABBREVIATIONS (Continued)
sp gr specttic gravtty
sq ft square foot (feet)
SVE soil vapor extraction
svoc Semi-Volatile Organic Compound
TDS Total Dissolved Solids
TKN Total Kjeldahl Nttrogen
TOC Total Organic Carbon
TSS Total Suspended Solids
UIC Underground Injection Control (Permit)
US EPA United States Environmental Protection Agency
voe Volatile Organic Compound
VMW Vapor Monitoring Well
vss Volatile Suspended Solids
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE DOCUMENT CONTROL SHEET
DOCUMENT CONTROL SHEET
GROUND WATER AND SOIL TREATMENT SYSTEMS
OPERATIONS, MAINTENANCE, AND TRAINING PLAN
MACON/DOCKERY SITE
RICHMOND COUNTY, NORTH CAROLINA
Revision
I Issue Description II Issue Date I No.
0 Working Copy -Issued for Client Review October 25, 1994
1 Working Copy -Issued For EPA Review October 31, 1994
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RMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
1.1 Background
Section 1
INTRODUCTION
OCTOBER 1994
SECTION 1
On September 30, 1991, the Untted States Environmental Protection Agency (US EPA) issued the
Record of Decision for the Macon/Dockery Stte. The Record of Decision was subsequently reissued on
April 21, 1992. This document set forth the remedy selected to address remaining vessels, vessel
contents, and affected soils and ground water iden@ed at the stte. US EPA issued a Unilateral
Administrative Order and Statement of Work for Remedial Design and Remedial Action (the "Order").
The effective date of the Order was June 30, 1992. The Order for the Macon/Dockery Site is one of
the primary reference documents that will be used during both Remedial Design (RD) and Remedial
Action (RA). The Statement of Work lists the requirements for implementing the remedy as described ·
in the Record of Decision and for achieving the Performance Standards set forth in the Record of
Decision and the Statement of Work. The following remedial actions and work elements were specified
for the Macon/Dockery Stte by US EPA:
Ground Water Control. Ground water wtth concentrations of contaminants of concern greater
than the Performance Standards specified in the Statement of Work must be extracted from the
ground, treated on-site via air-stripping, and discharged etther to Solomons Creek or to an
infiltration gallery.
Source Control. Two areas of contaminated soils and related materials must be addressed.
Vadose zone soils underlying Lagoon 7 must be treated via soil vapor extraction to remove
tetrachloroethene to levels below the performance standard of 3 ppm. Materials from Lagoon 1 O
were excavated and disposed of off-site. No additional maintenance or operations involving
Lagoon 10 is anticipated for the remainder of this project.
Vessel Removal. Hazardous materials remaining in tanks and vats at the site were properly
disposed of at a RCRA-approved facility. Non-hazardous vessel contents were recycled or
properly disposed of off-site. The vessels were recycled or decommissioned. Also, H evidence of
leakage was noted after the vessels were removed, the remedial action included clean up of the
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
affected soil. No additional operations or maintenance involving vessels is anticipated for the
remainder of this project.
This Operation and Maintenance Plan is a project deliverable called for under the approved RD project
schedule that was included in the Remedial Design Workplan. The Statement of Work (SOW) outlines
specific US EPA technical requirements concerning the content of this document. This Operation and
Maintenance Plan has been prepared in accordance wtth the requirements of the Macon/Dockery Site
Record of Decision, Unilateral Administrative Order, Statement of Work, and RD Workplan.
1.2 Purpose of Plan
The purpose of this document is to summarize and document the operations and maintenance (O&M)
tasks required to effectively operate the soil and the three ground water treatment systems to be
constructed and operated at the Macon/Dockery Site. It is also the intent of this document to provide
information concerning health and safety, routine monitoring, and troubleshooting activities.
The O&M Plan is a major project deliverable and milestone called tor in the Remedial Design Schedule,
Consent Decree, and Statement of Work (SOW). This plan provides the Untted States Environmental
Protection Agency (US EPA) and North Carolina Department of Environment, Health and Natural
Resources (NC DEHNR) with the operations and maintenance responsibiltties, details about site design
considerations, vendor supplied O&M Manuals, and specifications tor the Macon/Dockery Site. This
document contains the technical basis for site O&M activtties as they relate to start up, shut down, and
maintenance of the soil and ground water treatment systems. Following approval of this document by
the US EPA, the Remedial design contractor will finalize work upon the next significant project
milestone tor the Remedial Design/Remedial Action (RD/RA), the Final Design Report.
1.3 Scope of Work
Items delineated by the US EPA's Statement of Work document requires that the O&M Plan include the
following:
Equipment start-up and operator training;
Description of normal operations and maintenance;
Description of potential operating problems;
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RMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
Description of routine monttoring and laboratory testing;
Description of alternate O&M;
Description of equipment;
Description of adequate safety precautions to be followed; and
ldentttication of records and reporting mechanisms required.
OCTOBER 1994
SECTION 1
This O&M plan has been prepared to address these requirements. For reference, see Task IV, pages
24 through 27 of the SOW. The components of the Operations and Maintenance Manual are contained
in this plan. The Operations and Maintenance Manual will be prepared during the Operations and
Maintenance Training Phase of the Remedial Action.
1.4 Regulatory Requirements • RD/RA Consent Decree
The Macon/Dockery Consent Decree requires that the Prefinal/Final Design Report include, at a
minimum, the following: (1) final plans and specttications; (2) a final construction schedule; (3) operation
and maintenance plan; (4) Performance Standards Verttication Plan (directed at measuring progress
towards meeting Performance Standards); and (5) contingency plan. This O&M Plan is submitted in
compliance wtth this requirement.
The Operations and Maintenance Manual and the Performance Standards Verttication Plan will be
maintained by the Operations and Maintenance Contractor.
1.5 Treatment System Description
The process design for the Macon/Dockery Site remedy consists of:
A system of jet-pump ground water extraction wells for removal of VOC-contaminated ground
water, a low profile air stripping untt for the treatment of the affected ground water and an
infiltration gallery to reinfiltrate ground water at the Macon Stte.
A ground water treatment system similar to the one at the Macon Stte will be used to treat
ground water at the Lower Dockery Stte.
A system of electrical submersible pump ground water extraction wells for removal of VOC-
affected ground water at the Upper Dockery location. A low profile air stripping untt is used for
the treatment of the affected ground water and an infiltration gallery is used to reinfiltrate
ground water.
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MACON/DOCKERY SITE SECTION 1
• A soil vapor extraction system for treatment of the \/QC-affected soils in the former Lagoon 7.
A more detailed process narrative for each of the ground water treatment and soil vapor extraction
systems is provided in Sections 1.5.1 through 1.5.3. At this time, the design crtteria for each of these
systems is based upon the assumption that air emissions from both the ground water and soil removal
systems will not require treatment to achieve minimum NC DEHNR air qualtty requirements.
1.5.1 Ground Water Recovery
The ground water recovery system will consist of a series of ground water recovery wells located
to provide hydraulic containment and to capture ground water that exceeds the performance
standards established in the Statement of Work. Previous field investigations were conducted at
the Macon and Dockery sites to delineate the contaminant plume boundaries. Ground water
capture zone analysis, using conservative assumptions, was conducted during the Preliminary
Design to estimate well locations necessary to provide efficient interception of the plume. More
precise numerical modeling has been conducted during the Intermediate Design to refine the
number and proposed locations of extraction wells.
An evaluation was done to compare the cost-effectiveness of two types of recovery systems:
1) submersible pump systems, and 2) jet pump systems. The intent of etther type of system is to
lower the water table along the line of wells in order to promote flow into the wells and capture
ground water before tt can leave the delineated plume areas. A jet pump system is well sutted for
this purpose because a constant wtthdrawal and therefore a constant water level can be
maintained in the recovery wells. The low anticipated flow rates also favor the jet pump system.
Installation costs for this system are slightly higher than for submersibles and overall usage of
electrictty is typically greater. However, long-term maintenance costs for a jet pump system are
much less than those for a submersible pump system due to their reliability and lack of
mechanical components that are subject to failure.
Recovery Wells
The Macon Stte has four ground water recovery wells in the Lower Macon Area and seven ground
water recovery wells in the Upper Macon Area. Ground water recovered from the Upper and
Lower Macon Areas is piped to a centrally located treatment system referred to as the Macon
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
Ground Water Treatment System. Six ground water recovery wells in the Upper Dockery Area
provide ground water to the Upper Dockery Ground Water Treatment System and four ground
water recovery wells located in the Lower Dockery Area recover ground water for the Lower
Dockery Ground Water Treatment System.
Air rotary was the primary method for installing the 10-inch diameter boreholes used in the ground
water recovery well construction. Well casing and screens are 6-inch diameter Schedule 40 PVC
with threaded, flush joints. Figure 1-1 is a diagram of the type of ground water recovery wells
installed at the Macon/Dockery Stte.
Jet Pump Collect/on System
Based upon evaluations performed during the Intermediate Design, jet pump systems will be used
for extracting ground water at the Macon and Lower Dockery Sites. Based upon numerical
modeling projections, it is anticipated that the recovery systems at the Macon Stte will remain in
operation for over 10 years. Because of the high maintenance costs of submersible pump
systems over this extended period of time, a jet pump system will provide the most economical
long-term operation. Each area (Upper and Lower Macon) will have independently functioning jet
pump systems. Each system will direct recovered ground water to a centrally located treatment
facility. A flow diagram of the jet pump collection systems used at the Macon Stte and the Lower
Dockery stte are presented in Figure 1-2.
A jet pump recovery system consists of a centrttugal pump (prime mover), jet pump eductors, feed
tank, bag filter, and the associated piping. A jet pump eductor is installed in the bottom of each
recovery well. The prime mover supplies a flow of water to the eductor at a specified pressure.
The eductor's venturi assembly imparts a vacuum of sufficient strength to induce flow into the
eductor, out of the well, through the collection piping, and bag fitter, and into the feed tank. The
feed tank serves as the point of suction for the prime mover and provides the water supply
necessary to maintain the minimum water flow throughout the ground water recovery system. The
accumulated discharge from all of the jet pump extraction wells recirculates out
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THREADED CAP
DEPTH (FT.) . 4 ___ O~•ci:O ____ ...lS',.. •·
WATER TABLE ELEVATION
TOP OF BEDROCK
FIGURE 1-1
WELL CASING
CONCRETE PAD
(3'x3'x6")
BOREHOLE
GROUT
BENTONITE SEAL
WELL SCREEN
GROUND WATER EXTRACTION WELL CONSTRUCTION DIAGRAM
Not To Scale
MACON/DOCKERY
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COLLECTION PIPING
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
through the collection piping and returns to the bag filter and feed tank wtth additional water
collected from each extraction well. As the water level increases, the recirculation tank is provided
with an overtlow through which discharges the excess return water by gravity to the low-profile air
stripping system. The following drawings have been provided for a detailed view of the ground
water extraction systems and process and instrumentation diagrams. They are contained in the
"Macon Dockery Stte Prefinal/Final Remedial Design Report for Ground Water."
Drawing Number Description
7001721-C0S Infiltration Gallery Section and Jet Pump and Manhole Details
7001721-C0B Submersible Pump Details
7001721-K01
7001721-K02
7001721-K03
Macon Stte Process and Instrument Diagram
Lower Dockery Site Process and Instrument Diagram
Upper Dockery Site Process and Instrument Diagram
Since the jet pump can operate under "dry" conditions, tt allows the maximum level of drawdown
to be obtained from the extraction well. Each well is equipped wtth flow meters and valves to
facilitate system flexibility and allow monttoring of operation. The Macon system has two
independent jet pump systems with each system consisting of a recirculation/feed tank, prime
mover, recovery wells, and dedicated supply and collection piping. All water returning to the feed
tank from the well field passes through a bag filter. The purpose of the bag filter is to remove
solids such as entrained silts and clay particles from the water stream. The Lower Dockery
system has one jet pump system with the same system components as previously described.
Each system's feed tank overtlow is gravity fed to a low-profile air stripping system.
Electrical Submersible Pump Collection System
An electrical submersible pump system will be used at the Upper Dockery Stte. It is anticipated
that the recovery system at the Upper Dockery stte will accomplish the required remedial goals in
a relatively short period of time (<3 years). Because of this short term of operation, submersible
pump systems were utilized at this location. Submersible pumps minimize power and capttal costs
and their use should be completed before excessive maintenance costs are incurred due to the
need to replace equipment at the end of tts operational lite cycle. The Upper Dockery Stte has a
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recovery and treatment system that is independent of the Macon and Lower Dockery systems. A
flow diagram of the Electrical Submersible Pump Collection System is shown in Figure 1-3.
The ground water extraction system at the Upper Dockery Site consists of a series of extraction
wells equipped with submersible turbine pumps and collection piping. A submersible pump will be
installed at the bottom of each recovery well. The submersible pumps pump the ground water out
of the recovery wells, and through the collection piping and bag filter. Entrained solids such as
silts and clays are removed by the bag filter. The bag filter discharge is piped to a feed tank that
supplies a low profile air stripper with water by a gravity overtlow.
The pump and motor assemblies for each well has been designed using pertormance curves
based on the total estimated static and dynamic head and the desired flow rate from the well.
Drawing 7001714-C0B provides a detailed view of the extraction and treatment systems and piping
proposed for the Upper Dockery Site.
Because of their inherent flow delivery rates, submersible pumps typically must be operated in on
and off cycles. Since each pump will be operated independently, each pump is equipped with
level sensors to prevent the pump from operating under dry conditions.
1.5.2 Ground Water Treatment
Ground water treatment at the Macon, Lower Dockery, and Upper Dockery Sites consists of voe
removal by air stripping and, if necessary, manganese removal by a metals removal unit. A
metals removal demonstration will be conducted for each treatment system. The demonstration
will begin at system start-up and continue for one month. It is anticipated that the metals removal
will not be necessary beyond the one month demonstration. Each of the three sites has a ground
water treatment system that operates independently of the other two.
Air Stripping
The low profile air strippers utilize forced draft, countercurrent air stripping through baffled aeration
trays to remove volatile organic compounds from the extracted ground water. A diagram of a low
profile air stripper is provided as Figure 1-4. Ground water is directed into the inlet chamber and
flows over a distribution weir and along a baffled aeration tray. A blower
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FIGURE 1-3
FLOW DIAGRAM OF AN ELECTRICAL
SUBMERSIBLE PUMP COLLECTION
SYSTEM
NOT TO SCALE
OVERFLOW >
TO AIR STRIPPER·
MACON/DOCKERY
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Turbulent frothing
maximizes volatilization
and scours the aeration tray.
Contaminated
water inlet.
Treated water falls
into holding tank.
Air is vented to the
atmosphere or to vapor
phase treatment of choice.
Water travels around
the full length of the
baffled tray, becoming
· progressively cleaner.
'I"" holes resist
fouling.
Fan blows air up
through hundreds o
holes into the water ..
PHOTOGRAPH TAKEN FROM SHALLOW TRAY AERATION SYSTEM (NORTH EAST ENVIRONMENTAL PRODUCTS, INC.)
1'--------------------------------------1
FIGURE 1-4
DIAGRAM OF LOW-PROFILE AIR STRIPPER
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
discharges an air stream upward through holes in the aeration tray. This action forms a froth of
air bubbles that generates a large mass transfer surface area and induces transfer of VOCs from
the ground water into the air stream. Treated ground water from each air stripper will be pumped
through a bag filter to the inlet of the metals treatment unn, distributed across the media, and
discharged through the bottom outlet to the infiltration gallery. The airstrippers will be registered
as Air Pollution Sources wnh the State of North Carolina. The Registration Procedure is described
in Appendix B of this O&M Plan.
Metals Removal System
The Upper Dockery and Lower Dockery metals removal systems each consist of a centrifugal
pump, bag filter, and two ion exchange columns. Figure 1-5 is a flow diagram of these systems.
The air stripper sump will supply the centrttugal pump wnh ground water. The pump will transfer
the water through a bag filter and two ion exchange columns. The bag filter removes solid metal
oxides that may have formed in the highly oxygenated environment of the air stripper. The ion
exchange columns remove dissolved calcium and manganese from the ground water. The
columns operate in series in a fixed bed downflow configuration.
The metals removal systems have initially been installed as a process demonstration, and n is
anticipated that the systems will not be needed after the 30-day system start-up/process
demonstration. Quick connect hoses with dripless fittings are used for column influent and effluent
lines, and are identical to those in the Upper and Lower Dockery systems. The hoses allow for
quick column replacement during the demonstration period. The spent ion exchange columns will
be sent off-site for regeneration.
The Macon System has a metals treatment system consisting of a centrifugal pump, bag filter, and
four ion exchange columns. Figure 1-6 is a flow diagram of the Macon metals treatment system.
The air stripper sump will supply the centrttugal pump wnh ground water. The pump will transfer
the water through a bag filter. The stream spins and flows through two sets of ion exchange
columns. Each set is comprised of two ion exchange columns in series. The streams recombine
after the ion exchange columns to form one discharge stream that flows to an infiltration gallery.
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70017.23
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UPPER AND LOWER DOCKERY
METALS TREATMENT UNIT
NOT TO SCALE
FLEXIBLE HOSE
(1YPICAL)
REINFILTRATE -
MACON/DOCKERY
DRIPLESS HOSE--------<=
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FIGURE 1-6
MACON METALS
TREATMENT SYSTEM
NOT TO SCALE
FLEXIBLE
HOSE (TYP.)
REINFILTRATE .
MACON/DOCKERY
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1.5.3 Macon Soll Vapor Extraction System
Soil vapor recovery will be used to remediate vadose zone soils beneath former Lagoon 7. The
SVE system will consist of a series of soil vapor extraction and vent wells. A vacuum untt will
induce a vacuum on the extraction wells to recover soil vapors. These vapors will be discharged
to the atmosphere through a vertical discharge stack. Ambient air will enter the vadose zone
through the ground surface and the vent wells, and will replace the extracted soil vapor.
Four existing soil vapor wells, VE-01, OW-1, OW-3, and OW-5, located in or near Lagoon 7, will
be used for vapor extraction. Based on the pilot-scale evaluation, these wells will each produce
18 to 42 SCFM of soil vapor under an induced vacuum of 120 inches of water column (9 inches of
mercury). The average individual well yield is expected to be about 33 SCFM. These wells will
be piped to a central vacuum pump by way of a common header.
Each vapor ex1raction well may be alternately used for passive soil venting or for vacuum
monitoring by adjusting the valves located in each extraction well vault.
The two remaining wells, OW-2 and OW-4, will be used for passive soil venting and vacuum .
monitoring. Passive venting gives ambient air direct access to affected soils at depth. The a_ir
then flows through the soils to the vacuum ex1raction wells. This method enhances the movement
of volatile organic compounds to the vacuum extraction wells by providing posttive directional
control of vapor flow and by increasing the amount of vapor flow to the extraction well. Vacuum
monitoring is accomplished by cutting off the air flow and reading static vacuum.
Recovered vapors will pass through a vacuum untt consisting of an in-line filter and inlet silencer
to the vacuum pump. The in-line filter will trap particulate matter and condensate that may form in
the vacuum lines, while the inlet silencer will muffle noise at the pump inlet. The vacuum pump
will be a rotary lobe posttive displacement pump that will discharge the vapors through the
discharge silencer and the 15-foot discharge stack. Ambient air will enter the system through a
filtered air intake and enter the vapor stream prior to the vacuum pump. This air is necessary_ in
order to operate the vacuum untt under various vacuums and flow rates. Figure 1-7 is a flow.
diagram of the vacuum untt.
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Soll Vapor Extraction (SVE) Wells
The six vapor extraction wells are installed wtthin each area described by the ROD and piped to a
central vacuum pump by way of a common header. The arrangement for this system is shown on
Drawing 7001714-C03. Soil vapor extraction wells were installed approximately eight feet above
the mean high ground water elevation. A well schematic for a soil vapor extraction well is shown
on Figure 1-7. Six SVE wells were constructed during the SVE pilot scale evaluation. The well
materials consisted of Schedule 40 PVC wtth flush joints and "O"-ring seals at the joints. A
summary of well construction details is presented on Table 1-1. The SVE wells were installed
through the augers as the augers were withdrawn from the 10-inch borehole. VE-1 was
constructed wtth 4-inch I.D. material and the vacuum observation wells were constructed with 2-
inch I.D. materials. Wells were installed wtth 10-foot machine-slotted screens wtth a slot size of
0.02 inch. The gravel pack (Morie #2 Well gravel) for all of the wells extended from the total
depth to approximately 17 feet BLS except for well OW-4, in which tt ex1ended to approximately
13 feet BLS. The upper suriace of the gravel pack was sealed with a bentontte pellet seal with a
minimum thickness of two feet. Following hydration of the bentonite pellets, the remaining annular
space was grouted wtth a cement-bentontte grout slurry. The wells were finished below land
surtace inside lockable vault assemblies.
TABLE 1-1
SUMMARY OF SVE WELL CONSTRUCTION DETAILS
Date Installed 4/7/93 4/8/93 4/12/93 4/8/93 4/12/93 4/9/93
Well Diameter (inches) 4 2 2 2 2 2
Screen Slot Size (inches) 0.02 0.02 0.02 0.02 0.02 0.02
Top of Bentontte Seal' 14.9 14.7 14.2 14.8 11.2 15.1
Gravel Pack Interval' 17.1- 16.8-16.3-16.9- 13.2-17.1-
34.4 34.5 34.5 33.9 30.5 33.7
Screened Interval' 24.4- 24.0- 23.7-23.9-19.5-22.6-
34.4 34.0 33.7 33.9 29.5 32.6
Total Depth' 34.4 34.5 34.5 33.9 30.5 33.7
Ground Surtace Elevation 245.45 244.50 249.89 244.92 236.92 243.67
Top of Casing Elevation 244.53 243.55 249.20 243.96 236.32 242.69
a Measurements are feet below land surface
b Measurements are in feet above mean sea level (MSL)
l:\WP\70\70017ZlO&Mlcdf94 1-16
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OBSERVATION
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DISCHARGE TO
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DISCHARGE SILENCER
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LEGEND
txJ BALL VALVE
® PRESSURE INDICATOR
8 HAND $WITCH
J_, CAP
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FIGURE 1-7
FLOW DIAGRAM OF
SVE SYSTEM
MACON/DOCKERY SITE
RICHMOND CO. NORTH CAROLINA
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Treatability test results indicate that the system of six soil vapor wells installed during the pilot test
are sufficient for vapor extraction operations designated by the ROD. The piping and
instrumentation for this system is shown and system details are provided on Drawing 7001714-
C04.
Vacuum Piping
The vapor extraction wells are piped into a central header which leads to the centrally-located
vacuum unit. The vacuum piping is placed in a shallow trench and is encased in concrete. As a
vacuum is applied to the stte soils, recovered vapors will flow through the four-inch pipe header,
into the vacuum untt and then discharged to the atmosphere. The vacuum header is installed at a
continuous grade to prevent condensate from accumulating in the pipeline. In this manner,
condensate not collected by the condensate trap should flow back to the nearest SVE well.
The vacuum unit utilized for the former Lagoon 7 remediation is prefabricated, skid-mounted,
piped, and wired by the vendor. Figure 1-7 is a flow diagram of the vacuum untt, and the major
components of this untt are described below. The technical specifications for this system have
been provided in Section 3.6.2 of the Soil Vapor Extraction Pre-Final/Final Design report.
Condensate Trap
Prior to enlering the vacuum untt, extracted soil vapors first pass through a condensate trap. The
purpose of this unit is to remove entrained water vapor from the air stream before tt passes
through the vacuum pump. Water will collect in the bottom of this trap as time progresses. A high
level shut-down will occur when the condensate level reaches a preset point. A drain will be
manually opened to periodically remove this water from the SVE system. This water will be
periodically discharged to the recirculation tank of the Macon air stripping untt for treatment.
Air FIiter
The soil vapor will then pass through a high efficiency particulate filter to remove fine solids prior
to tts enlry into the vacuum untt. Pressure gages located upstream and downstream of the unit
will be used to monttor the pressure drop across the filter. A high differential pressure switch will
address situations when excess differential pressure exists across the filter.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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Air Intake
Make-up air is provided through a filtered air intake. A valve is positioned on this line to regulate
the amount of make-up air that is fed into the system. A flow meter and pressure gage are
situated upstream of this globe valve to monitor intake conditions. Make-up air is necessary for
starting the vacuum system under no-load conditions and to operate the system at variable levels
of vacuum and vapor flow.
Inlet/Discharge SIiencers
In-line silencers are installed on both the inlet and discharge sides of the vacuum pump. Vacuum
pumps of the size used for SVE operations can be noisy, so silencers are used to reduce the
noise level during site operations.
Vacuum Pump
The vacuum pump will be a rotary lobe, positive displacement pump capable of providing at least
260 SCFM under no load conditions, and capable of operating up to a vacuum of 150 inches of
water column (14 inches mercury). The pump data sheet for the vacuum pump is provided in
Appendix F.
A vacuum relief valve will be located immediately upstream of the vacuum pump. A temperature
~ensor will be located immediately downstream of the vacuum pump. If discharge temperature
exceeds the normal operating temperature, the temperature sensor will transmit a signal to the
control panel and the pump will shut down. A high liquid level signal liquid in the condensate trap
will also cause the vacuum pump to shut down. A temperature indicator and a pressure gauge on
the discharge piping will allow the operator to monitor the physical conditions of the air discharge
stream.
Discharge Stack
Recovered soil vapors and make up air will be discharged to the atmosphere through a 15-foot
high discharge stack. This stack will be fabricated using six-inch schedule 40 PVC pipe. A
sampling port will be located at the appropriate location on the stack for sampling the discharge
stream. Sampling requirements are further discussed in Section 5.2. Air Pollution source
Registration is required for the SVE unit and is described in Appendix B.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
Air Emissions
Because the Macon/Dockery stte is in an attainment area for ozone and because of the relatively
low emission rates for the SVE system, treatment of the soil vapor is not required. Further
discussion of emission control requirements for the SVE system is provided in Section 3.2.2. The
SVE system will be registered as an air pollution source as detailed in Appendix B.
1.5.4 Remediation of Lagoon 10 Waste
Material from Lagoon 1 O was excavated and disposed of off-stte at a TSD facility. No further
remedial operations or maintenance tasks are planned for Lagoon 10.
1.5.5 Vessel Removal
Hazardous material remaining in tanks and vats at the stte were disposed off-site at a RCRA TSD
facility. The vessels have been recycled or decommissioned. No additional and maintenance or
operation involving vessels is anticipated throughout the remainder of this project.
1.6 Design Conditions and Prescribed Treatment
The design condttions and prescribed treatments have been developed to address the technical and
regulatory issues and objectives defined by the US EPA's Record of Decision (ROD) and Statement of
Work (SOW) developed for the Macon/Dockery stte. The stte·s characteristics have been assessed
and, along with the issues and objectives set forth by the ROD and SOW, they provide the design basis
for stte remediation.
The design condttions taken into account include the following items:
Efficiency of VOC removal from ground water and soil vapor to meet North Carolina water and
air quality standards;
Horizontal and vertical control points for the remediation zones of work;
Earthwork;
Roads;
Storm drainage;
Erosion control;
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AMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
Noise control:
Automatic and manual control flexibility;
Centralized systems monttoring and alarms;
Outdoor operations;
Security;
Maintenance.
OCTOBER 1994
SECTION 1
Specific and detailed descriptions of the design condttions are fully described in the Pre-Final/Final
Remedial Design Report. Some of the major design conditions related specttically with the operation
and maintenance of the remediation systems are summarized as follows:
1.6.1 Macon Ground Water Extraction Wells and Process Equipment
Ground water extraction wells are installed to competent bedrock. Eleven ground water
extraction wells are scheduled for operation (four for Lower Macon and seven for Upper
Macon).
Ground water extraction wells are constructed of 6-inch Schedule 80 PVC to facilttate
installation of jet pump assemblies.
Supply and collection lines to extraction wells are constructed below grade for freeze
protection and to minimize concerns for vandalism.
Exposed piping, pumps and valves will be heat traced and insulated to minimize
freezing during winter operations.
Jet pumps will be installed at the theoretical depth of maximum drawdown such that the
net suction head is zero.
Measurements of flow from each well will be provided by a flow indicator for each
recovery well.
Prime movers (centrttugal pumps) are sized to pump the total flow required to. achieve
the desired ground water extraction rates and a minimum circulating flow of 505 gpm
(total) for the Upper and Lower Macon sttes.
The recirculation/accumulation tanks are sized to hold 100 percent of the total volume
of piping anticipated to be in service.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
The equipment and pump pad location is secured by a 6-foot security fence topped
with three strands of barbed wire.
The air stripper is capable of treating affected ground water at flow rates up to 160 gpm
for ground water temperatures of 16 to 18°G. The equipment, power, controls, and
instrumentation are designed for outdoor condttions.
voe effluent concentrations from the air stripping unit are designed to meet stte-
specttic water qualtty crtteria limttations as summarized in Table 1-2.
A
B
C
D
E
F
G
H
J
K
L
M
TABLE 1-2
MACON SITE
AIR STRIPPING SYSTEM
Benzene 0.005
Acetone
Chloroform
1, 1 Dichloroethane 0.002
1, 1 Dichloroethene 0.010
1,2 Dichloroethane (Total) 0.0060
Methylene Chloride
Tetrachloroethene (PCE) 0.0022
Toluene 0.00279
1, 1, 1 Trichloroethane 0.0030
Trichloroethene 0.085
Vinyl Chloride
Xylenes (Total)
Air Stripper Flow Rate: 160 gpm, continuous
Minimum Air Temperature: 30"F
Minimum Water Temperature: SO"F
Influent pH: 6
0.00075
2.625
0.00075
2.625
0.00525
0.0525
0.00375
0.00075
0.00075
0.1500
0.0021
0.00075
0.300
The bag filter after the air stripper will remove solids down to 1 0 microns in size. · The
bag filter is equipped wtth a differential pressure indicator so that the pressure drop
across the bag filter may be observed.
The bag filter is equipped wtth a normally closed ball valve in a filter bypass line to
facilitate bag filter replacement wtthout shutting down the treatment system.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
1.6.2
The ion exchange columns will have flexible quick connect hoses for inlet and ,
discharge lines. These hoses will facilttate column replacement during the process
demonstration period.
Each ion exchange column is equipped with a differential pressure indicating swttch
installed across the resin bed so that the pressure drop across the column may be
observed.
Upper Dockery Ground Water Extraction Wells and Process Equipment
Ground water extraction wells are installed to competent bedrock. Six ground water
extraction wells are scheduled for operation.
Ground water extraction wells are constructed of 6-inch Schedule 80 PVC to facilttate
installation of jet pump assemblies.
Collection lines to extraction wells are constructed below grade for freeze protection
and to minimize concerns for vandalism.
Exposed piping, pumps and valves will be heat traced and insulated to minimize
freezing during winter operations.
Electric submersible pumps will be installed at the theoretical depth of maximum·
drawdown such that the net suction head is zero.
Measurements of flow from each well will be provided by a flow indicator for each
recovery well.
The electrical submersible pumps are sized to pump the total flow required to achieve
the desired ground water extraction rates and to deliver the water to the feed tank.
The feed tank has a volume of 3800 .
The equipment and pump pad location is secured by a 6-foot security fence topped
with three strands of barbed wire.
The air stripper is capable of treating water at flow rates of up to 270 gpm for ground
water temperatures of 16 to 18°C. The equipment, power. controls, and
instrumentation are designed for outdoor condttions.
VOC effluent concentrations from the air stripping unit are designed to meet stte-
specttic water qualtty crtteria limttations as summarized in Table 1-3.
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AMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
TABLE 1-3
UPPER DOCKERY
AIR STRIPPING SYSTEM
A Benzene
B Acetone
C Chloroform
D 1, 1 Dichloroethane
E 1, 1 Dichloroethene
F 1,2 Dichloroethane (Total)
G Methylene Chloride
H Tetrachloroethene (PCE)
Toluene
J 1, 1, 1 Trichloroethane
K Trichloroethene
L Vinyl Chloride
M Xylenes (Total)
Air Stripper Flow Rate: 30 gpm, continuous
Minimum Air Temperature: 30°F
Minimum Water Temperature: 50°F
Influent pH: 6
0.0167
0.0017
0.002
0.217
0.0250
0.250
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0.00075
2.625
0.00075
2.625
0.00525
0.0525
0.00375
0.00075
0.00075
0.1500
0.0021
0.00075
0.300
OCTOBER 1994
SECTION 1
The bag filter after the air stripper will remove solids down to 1 0 microns in size., The
bag filter is equipped wtth a differential pressure indicator so that the pressure drop
across the bag filter may be observed.
The bag filter is equipped wtth a normally closed ball valve in a filter bypass line so that
the bag filter may be replaced without shutting down the treatment system.
The ion exchange columns will have flexible quick connect hoses for inlet and
discharge lines. The hoses will facilttate column replacement during the process
demonstration period.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
1.6.3
The ion exchange columns have a dttferential pressure indicter installed across the
resin bed so that the pressure drop across the column may be observed.
Lower Dockery Ground Water Extraction Wells and Process Equipment
Ground water extraction wells are installed to competent bedrock. Four ground water
extraction wells are scheduled for operation.
Ground water extraction wells are constructed of 6-inch Schedule 80 PVC to facilttate
installation of jet pump assemblies.
Supply and collection lines to extraction wells are constructed below grade for freeze
protection and to minimize concerns for vandalism.
Exposed piping, pumps and valves will be heat traced and insulated to minimize
freezing during winter operations.
Jet pumps will be installed at the theoretical depth of maximum drawdown such that the
net suction head is zero.
Measurements of flow from each well will be provided by a flow transmitter and flow
recorder device for each recovery well.
The prime mover (centrifugal pump) is sized to pump the total flow required to achieve
the desired ground water extraction rates and a minimum circulating flow of 190 gpm.
The recirculation/accumulation tank is sized to hold greater than 100 percent of the
total volume of piping anticipated to be in service.
The equipment and pump pad location is secured by a 6-foot security fence topped
with three strands of barbed wire.
The air stripper is capable of treating water at flow rates of up to 60 gpm for ground
water temperatures of 16 to 18°C. The equipment, power, controls, and
instrumentation are designed for outdoor conditions.
VOC effluent concentrations from the air stripping unit are designed to meet stte-
specttic water qualtty crtteria limttations as summarized in Table 1-4.
The bag filter after the air stripper will filter out solids down to 10 microns in size. The
bag filter is equipped wtth a differential pressure indicator so that the pressure drop
across the bag filter may be observed.
The bag filter is equipped wtth a normally closed ball valve in a filter bypass line so that
the bag filter may be replaced without shutting down the treatment system.
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AMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
TABLE 1-4
LOWER DOCKERY
AIR STRIPPING SYSTEM
A Benzene
B Acetone
C Chloroform
D 1 , 1 Dichloroethane
E 1 , 1 Dichloroethene
F 1,2 Dichloroethane (Total)
G Methylene Chloride
H Tetrachloroethene (PCE)
Toluene
J 1, 1, 1 Trichloroethane
K Trichloroethene
L Vinyl Chloride
M Xylenes (Total)
Air Stripper Flow Rate: 60 gpm, continuous
Minimum Air Temperature: 30°F
Minimum Water Temperature: 50°F
Influent pH: 6
0.005
0.0175
0.210
0.00125
0.030
0.033
OCTOBER 1994
SECTION 1
J.iryiJ;
.)OISCHARGE••LIMIT?•••• •1fua@•t
0.00075
2.625
0.00075
2.625
0.00525
0.0525
0.00375
0.00075
0.00075
0.1500
0.0021
0.00075
0.300
The ion exchange columns will have flexible quick connect hoses for inlet and
discharge lines. The hoses will facilttate column replacement during the process
demonstration period.
The ion exchange columns have a differential pressure indicter installed across the
resin bed so that the pressure drop across the column may be observed.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
1.7
1.6.4 Macon Soll Vapor Extraction Wells and Vacuum Unit
Four existing SVE wells, VE-1, OW-1, OW-3, and OW-5, located in or near Lagoon 7
will be used for soil vapor extraction. VE-1 is constructed of 4-inch diameter schedule
40 PVC and Ow-1, OW-3, and OW-5 are constructed of 2-inch diameter schedule 40
PVC. These wells are piped to a central vacuum pump by way of a common header.
The two remaining SVE wells, OW-2 and OW-4 will be used for passive soil venting
and vacuum rnonttoring.
Vacuum lines are buried to minimize the potential for vandalism. The SVE manttold
piping is sized to accommodate up to 50 percent more SVE wells than the number
called for in the Pre-Final/Final Design Report.
The SVE vacuum pump will deliver approximately 260 elm and the design vacuum will
be operated at a vacuum pressure of approximately 150 inches of water column.
Silencers are provided on the air inlets and outlets to minimize noise.
Monitoring systems are provided for sampling on the inlet and outlet of the vacuum
pumps.
The equipment, power connections, instrumentation, and controls are designed for use
outdoors.
No air permtts are required for this system as set forth in the NC DEHNR's Bureau of
Air Qualtty Control (BAQC) permitting waiver.
Process Instrumentation and Control Approach
The ground water treatment system for the Macon/Dockery site is divided into three independent
recovery/treatment systems: one for Upper Dockery, one at Lower Dockery, and a combined system for
Upper and Lower Macon. Each system consists of a series of recovery wells, pumps, storage tanks,
an air stripper, and metals removal columns (ion exchange).
1.8 Organization of Operations Management
Figure 1-8 shows the personnel and contact numbers for operations management at the
Macon/Dockery Site.
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LABORATORY
COORDINATOR
Nome
Telephone #
MACON/DOCKERY
SITE TECHNICAL
COMMITTEE
David L. Jones
CHAIRPERSON
PROJECT MANAGER
Nome
Telephone #
WASTE WATER
TREATMENT OPERATOR
Nome
Telephone #
Field Sampling
Coordinator
ENGINEERING AND
MAINTENANCE
SUPPORT
lfl!ll_, 7DD17.23
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Nome
Telephone # Nome
Telephone #
FIGURE 1-8
ORGANIZATION OF
OPERATIONS MANAGEMENT
US EPA
NC DHEC
I
HEALTH AND
SAFETY
COORDINATOR
Nome
Telephone #
MACON\DOCKERY
ROCKINGHAM, NC
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 1
1.9 Training of Personnel
System Operator(s) will be trained in system operations and maintenance by the remedial design
engineers. Training will include:
The material in this O&M Plan, and
On-stte demonstrations of
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start-up
system operations
system shutdowns
maintenance of system components
1-29
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
2.1
Section 2
OPERATION OF SYSTEMS
Macon Ground Water Remediation System Description
2.1.1 System Description and Equipment
Upper and Lower Macon Ground Water Extraction
Purpose -To remove ground water from above the bedrock and convey ij to a
centralized treatment system.
Equipment Description -Six-inch Schedule 80 PVC extraction wells have been installed
to competent bedrock. Each well is screened from the bottom of the borehole to five
feet above the observed water table. All screens are 0.01-inch machine-slotted. All in-
ground materials are threaded, flush-joint PVC. Feed lines to the recovery wells are
Schedule 80 PVC pipe and are installed underground. Construction connections are
pitless adapters .
Piping wijhin the pumping wells is Schedule 80 PVC and PVC industrial hose material.
The hose material is high tensile cord reinforced to a maximum pressure rating of 250
psi and has a minimum bending diameter of nine (9) inches. All exposed piping,
pumps, and valves are heat traced and insulated.
The jet pump assembly for each well is a one (1 )-inch brass unit located at the depth of
maximum draw-down of each well. The location of each jet pump unij is designed to
induce flow from out of the surrounding aquifer.
All valves and meters wijhin the piping system and in the wells are rated at 200 psi.
The flow into and out of each well is measured locally.
A pressure indicator is located on the inlet valve to each well. Ball valves are located
on the inlet and outlet sides of each well. Two check valves are located beneath the jet
pump to prevent extracted ground water from flowing out of the extraction system back
into the aqutter. Additional check valves are located immediately before the ball valve
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
on the discharge side of each well to prevent extracted ground water from flowing back
into the well head once tt extts the recovery well.
The central collection (return) header of each well system (Upper and Lower Macon) is
also equipped wtth a turnaround system consisting of a pressure gauge, ball valve
followed by a check valve. The check valve serves to prevent the back flow of water
from the recirculation/accumulation tank and the ball valve tends to force the flow of
water out through each of the secondary pipe lines. A high pressure air release valve
is located at wells and at the highest elevation of the return line of each system {Upper
and Lower Macon), air released is vented to the atmosphere.
Operational Description -A centrifugal pump (prime mover) pumps water from the
bottom of the recirculation tank through the piping system to the ground water well.
The water flows down the well and across the jet pump venturi. The affected ground
water is extracted from the aquifer by the momentum transfer and negative suction
created by the jet pump. The extracted ground water then flows out of the well into the
piping system and through a bag filter. The filtered water then flows into the feed tank.
The feed tank serves as the suction head for the prime mover. Any accumulated water
in excess of the design capactty flows by gravtty to the low-profile air stripper treatment
system.
Theory of Operation -Alter the water from the centrifugal pump enters the jet pump tt
passes through a venturi located on the ejection port of the jet pump. The momentum
transfer that occurs wtthin the venturi imparts a vacuum of sufficient strength to induce
flow out of the well and into the collection piping. The flow of newly extracted ground
water joins the flow from the centrttugal pump in the outlet piping of the well. This
combined flow is pumped by the force of the centrifugal pump out of the well and back
to the feed tank.
Bag Filter
Purpose -To remove particulate matter from the water by filtration.
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MACON/DOCKERY SITE SECTION 2
Equipment Description -The bag filter includes a filter housing filter bag, restrainer
basket, and by pass.
The filter housing is equipped wtth inlet and outlet ports and a gasketed top mounted
access plate which tor tilter bag replacement. Gasket material ia BUNA N, and the
tilter housing is constructed of carbon steel.
The filter bag is the active filtering device that removes particulate matter from the
water. Contaminants are collected inside the bag. Filter bags rated tor retention of
particles down to 1 O microns in size are used in the bag filter.
The restrainer basket is a wire mesh basket that holds the filter bag in place. Filtered
water flows through the bag filter and restrainer basket and is discharged through the
outlet port.
The tilter by-pass is a pipe line that allows the water to flow around the bag filter. The
by-pass has an in-line ball valve that is normally closed during ground water recovery
operations so that the incoming water passes through the bag filter. To replace the
bag filter, the by pass valve is opened and the bag filter inlet and outlet valves are
closed. The bag filter can then be replaced while the rest of the treatment system
remains in operation.
The differential pressure (inlet pressure-outlet pressure) is monttored by a differential
pressure indicator and swttch, high (dPISH -1202 for Lower Macon, and dPISH -1205
tor Upper Macon). The dPISH allows differential pressure across the bag filter to be
read at the bag tilter. In case of an unacceptably high differential pressure across the
bag filter, the swttch will operate a visual alarm on the control panel and shut down the
treatment system.
Operational Description -Ground water extracted from the Upper Macon areas will be
transported to a bag filter through dedicated collection (return) piping. Ground water
received from the Lower Macon area will also be transported to a dedicated bag filter
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
through the Lower Macon collection (return) piping. Ground water flows through the
bag filter inlet and through the filter bag, restrainer basket and bag filter outlet.
Particulate matter remains within the filter bag.
Feed Tanks
Purpose -To accumulate water, serve as the suction head for the centrttugal pumps,
and provide the source of affected ground water for the air stripper untt.
Equipment Description -The two feed tanks are constructed of epoxy coated carbon
steel. Feed tank T-1001 has a volume of 7000 gallons and receives ground water from
the Lower Macon jet pump system. Feed tank T-1002 has a volume of 8000 gallons
and receives ground water from the Upper Macon jet pump system. These tanks will
be positively vented to the atmosphere. The tank data sheets, are found in
Appendix C.
The ports on each tank are shown on the tank data sheets. An inlet port from the
extraction wells is located on the upper half of each tank. An overflow exit port is
located near the top of each tank to direct affected ground water to the air stripper.
The recirculation pump suction ports located near the bottom of each tank.
The water level in feed tank T-1001 is monttored by a level indicating transmitter (LIT-
1201). Level swttches (LSL-1201, LSH-1201, LSHH-1201) are located within the PLC.
These level swttches operate two alarms tt the tank volume reaches the preset level.
The preset level alarms occur at LSL-1201 and LSHH-1201 corresponding to level
alarm low (LAL) and level alann high high (LAHH). The alarms are visually indicated at
both the control panel and the observation stte. Simultaneously, LSL and LSHH will
shut down the centrttugal pumps. This action triggers a sequential shut-down of the air
stripper .
The water level in Feed Tank T-1002 is monitored by a level indicating transmttter (LIT
-1204). Level swttches (LSL -1204, LSH -1204, LSHH -1204) are located wtthin the
PLC. These level swttches operate two alarms tt the tank water level reaches the
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
control setpoints. The preset level alarms occur at LSL -1204 and LSHH -1204
corresponding to level alarm low (LAL) and level alarm high high (LAHH). The alarms
are visually indicated at both the control panel and the observation stte.
Simultaneously, LSL and LSHH will shut down the centrttugal pumps. This action
triggers a sequential shut down of the air stripper.
Operational Description -Water extracted from Upper and Lower Macon Recovery wells
is directed through the collection return piping to tanks T-1001 and T-1002 from ports
located on the upper hatt of each tank. The water is accumulated in the tank and
either overflows out to the air stripper to be treated or is drawn out by the centrttugal
pumps to be used in further ground water extraction.
Recirculation Pump (Prime Mover)
Purpose -Provide a supply of water to the corresponding system's extraction wells
necessary to create the momentum transfer required by each well's jet pump assembly.
The recirculation pump provides the force for conveyance of the extracted water out of
the well, through the bag filter, and into the feed tank. Recirculation pump P-1001
supplies the Lower Macon jet pump system and Recirculation pump P-1002 supplies
the Upper Macon jet pump system.
Equipment Description -The pump specttied for the treatment system is a horizontal
centrttugal pump rated for continuous service (Appendix D). Each pump is connected
' to a motor alarm (designated as MA-1109 for Lower Macon and MA-1119 for Upper
Macon) which is activated during normal operating condttions. Alarms from both
systems are located on the control panel. Each pump is operated by a H-O-A
handswttch located on the. control panel. Prior to each system's (Upper and Lower)
recirculation pump is a ball valve. Following each pump are a check valve, ball valve,
and a pressure indicator (Pl).
Operational Description -Each pump draws water from its respective feed tank. The
pump provides the flow needed for the jet pumps to function and the force necessary to
convey extracted water to the feed tank.
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MACON/DOCKERY SITE
Conveyance From Tank to the Air Stripper
Purpose -To provide a flow of affected ground water from the recirculation/
accumulation tank to the low-profile air stripper.
Equipment Description -The piping is Schedule 80 PVC.
SECTION 2
Operational Description -The pipe conveys affected ground water from the feed tank to
the low-profile air stripper by gravity.
Air Stripper
Purpose -To aerate the ground water and promote the volatilization and subsequent
removal of volatile organic compounds (VOCs). Air Stripper AS-1001 treats ground
water from the Upper and Lower Macon areas.
Equipment Description -The air stripper is a Shallow Tray Model 31221 two tray air
stripper (Appendix G). The air stripper is a 7-foot high rectangular tower with an overall
width of 5.8 feet and an overall length of 12.5 feet. This system can accommodate
flows in the range of 1 to 180 gpm. The tower is constructed of 304L stainless steel.
Other equipment accompanying the air stripper includes a centrifugal blower, effluent
holding sump, an inlet screen and damper. steel demister, air pressure gauge, sight
tube, and Schedule 80 PVC piping. The blower is a 1 O Hp blower capable of delivering
up to 1800 elm of atmospheric air to the tower.
The centrttugal blower is located outside on the lower hatt of the stripper. The
atmospheric air flow is controlled by an inlet plate on the side of the pump. The
blower should never be operated with this plate more than half way open,
The level in the effluent holding tank is monitored by a level switches (LSL-1303,
LSH-1303, LSHH-1303) which are connected by a data link to the PLC. When the
effluent level in the tank rises to the preset high high level, alarm (LAHH-1303) will
activate. The alarm is located on the main control panel.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
The air flow from the blower is also monttored to dete6t low flow. If a low flow condition
! occurs, the flow switch low (FSL-1304) is activated. Tris signal is fed to the PLC,
which in turn, activates alarms FAL-1304 at the main control panel. The system shuts
. '
down automatically upon a deviation from normal operating conditions.
I
i
I Operational Description -The feed tanks receive affected ground water. When the
I
tanks fill to the preset outlet level, the affected ground Water overflows from the tanks,
I
combines into one stream and flows to the air stripper ,by gravtty. The affected ground
water then flows across the upper distribution tray of the air stripper, where tt is
uniformly distributed over a pattern of 3/16-inch diamefer holes through which a
continuous stream of air is passed. The extracted gro~nd water then drains by gravity
through one addttional tray to a sump located at the bottom of the air stripper. As the
I
extracted ground water passes downward through thes'e trays, an air stream is
continuously forced upward through the ground water Jy the air blower.
I
Upon extting the second and final tray, the treated gro~nd water enters an effluent
holding tank. The level of the water in the holding tank is maintained by an inverted
"U" trap, which prevents air from extting the air stripperlwith the treated water.
i
After passing through the tower, the exiting gas stream flows through a de-mister to
I
remove any entrained moisture present in the gas. This stream flows by gravtty back
through the baffles of the air stripper. The gas extts thJ air stripper at the top through a
6" PVC stack. The 6" PVC stack will exhaust directly tJ the atmosphere.
'
Theory of Operation -Air stripping is a physical process in which voes are forced into
I
equilibrium between water and air phases. The two tray, low-profile air stripping system .
I
uses forced air in combination with the chemical properties of the VOCs to efficiently
I remove the VOCs from the ground water. A VOC's abiltty to be air stripped is
I
measured by its tendencies to volatilize from water. The baffles wtthin the tower
enhance the air stripping process by providing a surfac~ for highly effective air -water
contact .
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
This counter-current flow of extracted ground water and air induces mass transfer of
I
voes from the ground water and into the air stream. The voes are stripped from the
I
water phase and introduced to the air phase. At start-up treated ground water will be
I
pumped from the low-profile air stripper to the metals removal unit. After completion of
I
the metals removal demonstration {about 30 days after start up), it is anticipated that I
the water will be pumped from the air stripper to;an infiltration gallery.
Metals Removal System
I
Purpose -To remove metals in the ground water during the metals removal
demonstration. Bag filter BF-1003 and ion exch1ange columns MR-1001, MR-1002,
I MR-1003, MR-1004 comprise the metals removal system. It is anticipated that the
metals removal system will be removed from the 1ground water treatment system after
the demonstration is complete.
' i
Equipment Description -The bag filter unit is a larger version of the filtering unit
described previously on page 2-2. dPISH-1307 allows differential pressure across the
'
bag filter to be read at the bag filter. In case of an unacceptably high differential
i
pressure, the switch will operate a visual alarm oh the control panel and shut down the
I
water treatment system.
I
Each ion exchange column is a vertical tank that holds approximately 30 cubic feet of
Resin material and is constructed from fiberglass 1reinforced plastic {frp). Each column
' will be able to treat ground water for approximately three days, at which time, the
column will be replaced. Regeneration of the ion 1exchange resin will occur off-site.
The tanks come equipped with a 2" male kamlock bottom outlet connection 1/2 inch
diameter threaded ports are provided for a differe~tial pressure indicator switch high
{dPISH). The dPISH is used to read the differenti~I pressure at each ion exchange
column. If the column has an unacceptably high differential pressure, the switch will
operate a visual alarm on {dPAH) on the control panel. 1/2 inch threaded ports are
I
also provided for pressure indicators {Pl) on the in.let piping. The following table
summarizes the contents associated with each ta~k.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
TABLE 2-1
MACON SYSTEM ION EXCHANGE COLUMN I_NSTRUMENTATION
MR -1001 dPISH -1403 dPAH -1403 Pl -1401
I MR -1002 dPISH -1503 dPAH -1503 Pl -1401
I
MR -1003 dPISH -1603 dPAH -1603 Pl -1601
MR -1004 dPISH -1703 dPAH -1793 Pl -1701
I
The ion exchange columns are arranged in two p!rallel sets with each set consisting of
'
two ion exchange columns placed in senes. Flexible hoses with dripless quick connect
ftttings are used to connect the columns to the ground water treatment system and to
!
each other..
Operational Descnption -Effluent pump P-1002 pumps the ground water through bag
' filter BF-1003. The water stream then splits into tiNo equal streams. One stream flows
I
through ion exchange columns MR-1003 and MR-;1004 while the other stream flows
through MR-1001 and MR-1002. After passing thlough the ion exchange columns, the
I ' streams recombine and discharge into an infiltrati~n gallery.
I
Theory of Operation -The bag filter removes particulates, specttically insoluble metal
! hydroxides that may have formed in the aerated environment of the air stripper. The
I
ion exchange columns remove dissolved metal ions such as calcium, manganese and
' ' magnesium from the water. I
Ion exchange resin is a polymer bead material tha) exchanges one ion for another,
holds i1 temporarily, and then releases it to a regenerant solution. Ion exchange occurs
when raw water ions diffuse into the bead structur~ and the displaced ions from the
' bead structure dtt1use back into the water solution! For the Macon metals removal
demonstration, an ion exchange resin is used to remove dissolved manganese from the
I
water. Due to the nature of the resin material, dissolved calcium and magnesium will
I also be removed during the process. 1
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
During the demonstration, the ion exchange colurhns will be replaced as the ion
exchange capactty of the resin is exhausted. De!ign calculations estimate a single ion
exchange column life to be 3,5 days. The used ciolumns will shipped off-stte for
I
regeneration and reuse.
2,1,2 System Start-Up for Ground Water Recovery and Treatment System
Feed tanks T-1001 and T-1002 and the jet pump system 'piping must be filled with water prior
to initial start-up. Fill water is from the municipal water sJpply that can be obtained from
spigots located near the entrance to the Macon Site. ThJ water will be etther pumped or
I
trucked to the treatment systems and transferred to the feed tanks using the spare pore located
' on the top of the each tank. The following start-up guide 'assumes that the initial filling of the
feed tank and jet pump system piping has been completed.
1.
2.
The water level of the tank must be at the invert of the discharge pipe.
Using HS-1304 on the control panel turn the bloJer (B-1001) on by placing the switch ' in the HAND posttion,
I
a. Each time start up is performed check and m~ke sure the blower is turning in the
direction indicated on the blower casing. '
b. Upon inttial start up, follow the sequence of steps below:
I
1)
2)
3)
Turn off electrical components and clos1e drain and sample valves. Check
that all electrical components associated wtth the untt are turned off, and all
drain and sample valves are closed. (~ate: Be sure that the sight tube valve
is open,) I
On inttial start-up, the air stripper sump:tank must be filled wtth clean water to
a height of one toot, Make sure the valve to the sight tube is open. The air
stripper sump tank can be filled via clean-out ports, located on the left side of
the unit, or through the inlet piping. :
Fill the air stripper inlet chambers wtth clean water. To fill the inlet chambers
(this is not necessary tor a one-tray system), start the air blower and the
water flow to the untt. Let both run tor ~bout two minutes, then shut them off.
When the wheel to the blower stops spinning, restart both the blower and the
water flow. This procedure allows the water to drip into the seal pots, It the
seal pots won't fill by this method, they :can be filled manually. First try
spraying a stream of water through the 'clean-out ports, on the left side of the
untt. The stream of water must be sprayed straight across the system and hit
the oppostte side. The splashing action should till the seal pots. It the ,
preceding methods don't work, remove the trays, fill the seal pots, and re-
assemble, New untts provide inlet charl-iber tilling ports,
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
3,
4,
5,
6,
7,
8,
9,
10,
11,
12,
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
I Turn 'ON' the master power disconnect. switch on the power disconnect
panel. I
Check the blower rotation. Check the blower rotation by momentarily
switching on the blower switch and observing whether the blades turn in the
direction of the arrow on the blower casing.
If blower rotation is correct, fully open the air inlet damper and turn the
blower switch to 'ON." Otherwise check wiring per manufacturer's
instructions and correct tt necessary. This step should be performed by, a
qualttied electrician. i ·
Start the clean water flow to the unit. Let the clean water and blower run for
two minutes then shut both off. Once the blower wheel stops rotating, restart
both the blower and the feed water flow. This procedure should fill the inlet
chambers as described below. I
Fill the inlet chambers with clean water.
Connect contaminated feed water line. i Replace clean water feed line with
contaminated feed line. '
Check the air pressure readings. Afte~ the unit has been operating five to ten
minutes, the air pressure readings should be approximately 11 inches
(pressure readings may vary slightly) of water column.
The system is now ready for operation! It is not necessary to perform initial
start-up procedures each time the system is shut down. The system will
already be primed from the last run.
I
Vertty that the bag filter by-pass valves for bag filters BF-1001, BF-1002, and BF-1003
are closed. If the valves are open, close them now.
I
I
Vertty that the in-line valves for bag filters BF-1001, BF-1002, and BF-1003 are open.
If the valves are closed, open them now,
' Vertty that the in-line valves for the ion exchange columns MR-1001, MR-1002,
I MR-1003, and MR-1004 are open. If the valves are closed, open them now.
I
I Start the Air Stripper Effluent Pump (P-1002) by switch HS-1305 to AUTO,
Start up each jet pump system (Upper and Lowe1r Macon) separately.
Manually close the ball valves in each recovery lell's valve vault (the Upper Macon
System has seven wells and the Lower Macon ~ystem has four wells). ·
'
Manually open the ball valve between the feed tank and the recirculation pump,
I I
Manually open the ball valve immediately followi~g the recirculation pump.
I
Open the ball valve on the collection (return) pipe at the feed tank,
I
Using the hand switch on the control panel (HS-1109 for Lower Macon System and HS-
1119 for Upper Macon System), turn the recirculation pump on. Follow the steps below
for turning the pump on. i
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
13.
14.
15.
16.
17.
18.
19.
20.
a. Lock out power to motor.
b, Make sure coupling hubs are securely fastened to shafts.
c. Check impeller clearance (factory set at ,015 in.); this could change based upon
the piping attachment. I
d. Unlock motor power.
e. Jog motor long enough to determine direction1 of rotation, It must correspond to the
direction indicated by the arrow on the bearing housing.
f. Lock out power to motor. I
g. Make sure suction valve and any recirculation or cooling lines are open.
h. Fully close or partially open discharge valve as indicated by system condttions.
i. Unlock motor power.
j. Start driver.
Check flow meters on each well.
Proceed to manually open the ball valves within e'ach wells valve vault.
I
Close the valve at the turnaround valve ptt. ' I
Check the pressure gauges for each well. I
a, The pressure of the jet pump should be 160 psi,
b. The pressure gauge in the vault should indicate less than 160 psi.
I
' Check the water level in each well with a probe, !
' ' Modulate the valve at the turnaround valve pit to adjust flow rates for the overall
ey~m. ,
I
I
Adjust ball valve on the return line for each individual well to maintain the specttied
water level in that well. i
I
Repeat steps four (4) through fourteen (14) for the second system (Upper Macon or
Lower Macon),
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER '1994
MACON/DOCKERY SITE SECTION 2
TABLE 2-2
I
MACON GROUND WATER SYSTEM START-UP
I
' The level of the air stripper sump must be at the invert of the discharge pipe.
2 Using HS-1304 on the control panel turn the blower (blower B-1001) on.
a. Check blower rotation. I
b. For inttial system start up, refer to page 2-1 O (!f O&M manual.
3 Start up each jet pump System A and B separately, !
4 Manually close the ball valves in each well's valve vault (Upper Macon has
seven wells and Lower Macon has four wells). !
5 Manually open the ball valve between the feed tank and the recirculation
' ·pump.
6 Manually open the ball valve immediately following th~ recirculation pump.
7 Open the ball valve on the collection (return) pipe at t~e feed tank.
' 8 Using the hand swttch on the control panel (HS-1119 for Upper Macon system
and HS-1109 for Lower Macon system) turn the recirc'ulation pump on. Follow
. '
9
10
11
12
13
14
15
the steps below for turning the pump on, I
Check flow meters on each well.
Proceed to manually open the ball valves within each :well's valve vault.
Close the valve at the turnaround valve pit.
Check the pressure gauges for each well. 1
a. The pressure of the jet pump should be 160 psi.
b. The pressure gauge in the vault should indicate less than 160 psi.
Check the water level in each well with a probe. I
' Modulate the valve at the turnaround valve pit to adjust flow rates for the
' overall system, '
Adjust ball valve on the return line for each individual[well to maintain the
specttied water level in that well.
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MACON/DOCKERY SITE SECTION 2
2.1.3 Nonnal Operation
I The ground water remediation system is virtually sett auto.mated once the system is running. In
I
case of an automatic system shutdown, the autodialer will_ notify the operator that the system
has shutdown. It is necessary to run periodic checks on 1:he jet pump extraction and treatment
system to monitor integrity of the systems,
I Pump operating motor alarm lights at the main control pa~el indicate that the recirculation
pumps are running.
A series of tables located in Section 5.4 provide a list of n1ecessary periodic monitoring.
'
Monitoring includes flow, pressure at pressure gauges, an:d physical conditions of the piping
and equipment to maintain the flawless working condition of the system.
2.1.4 Normal Shutdown
Normal shutdown of the Macon ground water remediation :system is performed by the following
sequence of steps.
1)
2)
3)
2.1.5
Turn off both centrifugal pumps with the hand swltthes on the control panel. HS-1109
operates Lower Macon recirculation pump and HS0-1119 operates Upper Macon
recirculation pump and HS-1305 operates the efflJent pump.
' Check the pressure indicators for each well. When all wells have no pressure proceed
to step #3.
Check the flow quantity indicator for the outlet piping from the air stripper located on
the control panel as FQl-1308. When this indicates zero (0) flow, turn the blower to the
air stripper off. The blower may be turned off by ~S-1304 at the control panel.
Emergency Shutdown
Emergency shutdown can occur under several different conditions. When the level alarm high
I high (LAHH) in one of the feed tanks is activated both recirculation pumps are automatically
I shutdown. The blower to the air stripper is shutdown after, a delay period in order to clear out
any water already in the air stripper.
I
' In the case of a low level in one of the feed tanks, only foieseeable through vandalism or a'
I leak in the tank, the level alarm low (LAL) would be activated. Both the recirculation pump and
' the blower for the air stripper would be sequentially shutdo_wn automatically. A malfunction of
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
the blower includes any incidence that prohibits the necessary volumetric flow of atmospheric
I
a•r to the air stripper trays. Sttuations that may cause this would be a power outage, a short in I
the system, or the sliding door that controls the atmospheric air flow to the blower has been
' closed too far. If this occurs, both recirculation pumps are automatically shutdown. The
autodialer will nottty the designated treatment system opelator of emergency shutdown.
'
2.1.6 Troubleshooting and Alternate Operation I The system will shut down and cease discharge to the infiltration trench in the event of a
I
system mattunction. The risk associated wtth inadvertent discharge of untreated ground water
with this sttuation is minimal. The system will automatically shut down, and the autodialer will
contact the treatment system operator in the event of any bf the potential problems listed
below. I
The level in the feed tanks reaches etther the high high or low level,
I
' A motor malfunction to either recirculation pump, I
A high level in the sump of the air stripper,
Flow out of the blower to the stripper is low,
A motor failure at the blower,
High flow level out of the air stripper, or
Power failure.
I
For troubleshooting tips associated wtth the pump see Appendix I (Table 7, Troubleshooting
I Pump). For other troubleshooting tips see the table below!
'
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MACON/DOCKERY SITE SECTION 2
2.2
TABLE 2-3
I TROUBLESHOOTING & ALTERNATE O & M • GW
efil?iiii;i PAV$i l
Low Level in tank Leak in the tank.
High High level in tank System clogging down stream.
Inadequate pumping Refer to Appendix G and J.
Flow in or out of well is Ball valves on inlet or outlet
out of spec. area not correctly set.
Pressure is out of
specification on inlet
piping of a well
Pressure after the
centrttugal pump is too
high or low
High level in air
stripper sump tank
Problem with the air
stripper
System won't start
Ball valves on inlet or outlet
area not open or closed
appropriately.
Ball valve on inlet to the pump
is not correctly set.
Outlet valve is closed.
Refer to air stripper material in
Appendix H.
Power failure.
I
bontact Project Manager.
I
~) Check the control valves; tt
ihey are open check air stripper,
2) Check air· stripper and
downstream piping for clogging &
clean tt necessary.
I
flefer to Appendix G and J.
I
Adjust the ball valves to obtain
correct readings.
I Adjust the ball valves to obtain
correct readings.
I
Adjust the ball valves to obtain
correct readings.
I
I
Open outlet valve.
!
I
Refer to air stripper material in
~ppendix H.
I
Check main power feed panel
a
1
nd/or power feed.
I
I Lower Dockery Ground Water Remediation system Description
2.2.1 System Description and Equipment !
Lower Dockery Ground Water Extraction I
I
Purpose -To remove ground water from above the bedrock and convey tt to the Lower
I
Dockery Ground Water Treatment System. i
I
Equipment Description -Six-inch Schedule 80 PVC
1
extraction wells have been installed
above competent bedrock. Each well is screened from the bottom of the borehole to
I
I
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
five feet above the observed water table. All screeils are 0.01-inch machine-slotted.
I All in-ground materials are threaded, flush-joint PVC. Feed lines to the recovery wells
I
are Schedule 80 PVC pipe and are installed underground. Construction connections
I
are pltless adapters.
Piping within the pumping wells is Schedule 80 PVC and PVC industrial hose material.
!
The hose material is high tensile cord reinforced to a maximum pressure rating of 250
I
psi and has a minimum bending diameter of nine (9) inches. All exposed piping,
' pumps, and valves are heat traced and insulated.
' I
The jet pump assembly tor each well is a one (1 )-in6h brass unit located at the depth of
I .
maximum draw-down of each well. The location of each jet pump unit is designed to
I
induce flow from out of the surrounding_ aquifer. I
All valves and meters within the piping system and iri the wells are rated at 200 psi.
I The flow into and out of each well is measured locally.
i A pressure indicator is located on the inlet valve to each well. Ball valves are located
I
on the inlet and outlet sides of each well. Two check valves are located beneath the jet
pump to prevent extracted ground water from flowing! out of the extraction system back
' ' into the aqutter. Additional check valves are located ,immediately before the ball valve
on the discharge side of each well to prevent extract~d ground water from flowing back
' into the well head once It exits the recovery well. '
The central collection (return) header of the well systJm is also equipped with a
turnaround system consisting of a pressure gauge an~ ball valve followed by a globe
I valve. A high pressure air release valve is located at'
1
wells and at the highest elevation
of the return line to vent entrained air to the atmosphere. :
' I
Operational Description· -A centrifugal pump (prime rriover) pumps water from the
I
bottom of the feed tank through the piping system to the ground water well. The water
' flows down the well and across the jet pump venturi. ~he affected ground water is
I :\WP\ 70\7001723. O&M/cd/94 2-17
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
extracted from the aquifer by the momentum transfer and negative suction created by
the jet pump. The extracted ground water then flows out of the well into the piping,
system and through a bag filter. The filtered water then flows into the feed tank. The
feed tank serves as the suction head for the prime mover. Any accumulated water in
excess of the design capacity flows by gravtty to the low-profile air stripper treatment
system.
Theory of Operation -After the water from the centrttugal pump enters the jet pump it
passes through a venturi located on the ejection port of the jet pump. The momentum
transfer that occurs wtthin the venturi imparts a vacuum of sufficient strength to induce
flow out of the well and into the collection piping. The flow of newly extracted ground
water joins the flow from the centrttugal pump in the outlet piping of the well. This
combined flow is pumped by the force of the centrifugal pump out of the well through
the bag filter and back to the feed tank.
Bag FIiter
Purpose -To remove particulate matter from the water by filtration.
Equipment Description -The bag filter includes a filter housing, filter bag, restrainer
basket, by-pass, line and valving.
The filter housing is equipped wtth inlet and outlet ports and a gasketed top mounted
access plate for filter bag replacement Gasket material is a BUNA N, and the filter
housing is constructed of carbon steel.
The filter bag is the active filtering device that removes particulate matter from the
water. Contaminants are collected inside the bag. Filter bags rated for retention of
particles down to 10 microns in size are used in the bag filter.
The restrainer basket is a wire mesh basket that holds the filter bag in place. Filtered
water flows through the bag filter and restrainer basket and is discharged through the .
outlet port.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
The filter by-pass is a pipe line that allows the water to flow around the bag filter. The
by-pass has an in-line ball valve that is normally closed during ground water recovery
operations so that the incoming water passes through the bag filter. To replace the
bag filter, the by-pass valve is opened and the bag filter inlet and outlet valves are .
closed. The bag filter can then be replaced while the rest of the treatment system
remains in operation.
The differential pressure (inlet pressure-outlet pressure) across the bag filter is
monitored by a differential pressure indicator and swttch, high (dPISH -2202). The
dPISH allows differential pressure across the bag filter to be read at the bag filter.
When high dttferential pressure is reached, the swttch will activate an alarm on the
control panel and shut down the treatment system.
Operational Description -Ground water extracted from the Lower Dockery area will be
conveyed to a bag filter through dedicated collection (return) piping. The ground water
flows through the bag filter inlet and through the filter bag, restrainer basket and bag
filter outlet. Particulate matter remains wtthin the filter bag.
Feed Tank
Purpose -To accumulate water, serve as the suction head for the centrttugal pumps,
and provide the source of affected ground water for the air stripper untt.
Equipment Description -The feed tank (T-2001) is constructed of epoxy coated carbon
steel and has a volume of 3800 gallons. The feed tank receives ground water from the
Lower Dockery jet pump system. The tank will be posttively vented to the atmosphere.
The tank data sheet for this untt is found in Appendix C.
Four ports exist on each tank. A spare port is located on top of the tank. An inlet port
from the extraction wells is located on the upper half of each tank. An overflow extt ·
port is located near the top of each tank to direct affected ground water to the air
...;;--.-. -· stripper. The remaining outlet port is located near the bottom of each tank, and
supplies the centrttugal pump (prime mover) wtth ground water.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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The water level in feed tank T-2001 is monttored by a level indicating transmitter (LIT-
2201 ). Level swttches (LSL-2201, LSH-2201, LSHH-2201) are located within the PLC.
These level switches operate two alarms tt the tank volume reaches the preset level.
The preset level alarms occur at LSL-2201 and LSHH-2201 corresponding to level
alarm low (LAL) and level alarm high high (LAHH). The alarms are visually indicated at
both the control panel and the observation stte. Simultaneously, LSL and LSHH will
shut down the centrttugal pumps. This action triggers a sequential shut-down of the air
stripper.
Operational Description -Water extracted from Lower Dockery Recovery wells is
directed through the collection return piping to tank from a port located on the upper
hatt of the tank. The water is accumulated in the tank and etther overflows out to the
air stripper to be treated or is drawn out by the centrifugal pumps to be used in furt~er
ground water extraction.
Recirculation Pump (Prime Mover)
Purpose -Provide a supply of water to the corresponding system's ex1raction wells
necessary to create the momentum transfer required by each well's jet pump assembly.
The recirculation pump provides the force for conveyance of the ex1racted water out of
the well, through the bag fitter, and into the feed tank. Recirculation pump P-1001
provides water to the Lower Dockery jet pump system.
Equipment Description -The pump specified for the treatment system is a horizontal
centrifugal pump rated for continuous service (Appendix D). Each pump is connected
to a motor alarm; (designated as MA-2109) which is activated during normal operating
condttions. Alarms from the system are located on the control panel. Also linked to
each pump is a hand swttch located on the control panel for manually turning each
pump on or off. Prior to the system's recirculation pump is a ball valve. Following each
pump is a pressure indicator (Pl) and a ball valve.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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Operational Description -The centrifugal pump draws water from the feed tank. The
pump provides the force needed for the jet pumps to function and the force necessary
to convey extracted water through the bag tilter to the feed tank.
Conveyance From Tank to the Air Stripper
Purpose -To provide a flow of affected ground water from the feed tank to the low-
profile air stripper.
Equipment Description -The piping is Schedule 80 six (6) inch PVC.
Operational Description -The pipe provides a gravttational flow of affected ground
water from the teed tank to the low-profile air stripper.
Air Stripper
Purpose -To aerate the ground water to promote the volatilization of volatile organic
compounds (VOCs) and the subsequent removal. Air Stripper AS -2001 aerates
ground water from the Lower Dockery area.
Equipment Description -The air stripper is a Shallow Tray Model 2621 two tray air
stripper (Appendix G). The air stripper is a 5.8 toot high rectangular tower with an
overall width of 4 feet and an overall length of 6.2 feet. This system can accommodate
flows in the range of 1 to 60 gpm. The tower is constructed of 304L stainless steel.
Other equipment accompanying the air stripper include a centrttugal blower, effluent
holding sump, an inlet screen and damper, steel de-mister, air pressure gauge, sight
tube, and Schedule 80 PVC piping. The blower is a 3 Hp blower capable of delivering
up to 600 elm of atmospheric air to the tower.
The centrttugal blower is located outside on the lower haH of the stripper. The
atmospheric air flow is controlled by an inlet plate on the side of the pump. The
blower should never be operated with this plate more than half way open.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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The level in the effluent holding tank is monttored by a level swttches (LSL-2302,
LSH-2303, LSHH-2303) which is connected by a data link to the PLC. When the
effluent level in the tank rises to the preset high mark, alarms (LAHH-2303) will
activate. The alarm is located on the main control panel.
The air flow from the blower is also monttored to detect low flow. If such a sttuation
occurs the flow swttch low (FSL-2304) is activated. This is then fed to the PLC, which
in turn, activates alarms FAL-2304 at the main control panel. The system shuts down
automatically upon a deviation from normal operating condttions.
Operational Description -The feed tank receive affected ground water. When the tank
fill to the preset outlet level, the affected ground water overflows from the tank, and
flows to the air stripper by gravttational flow. The affected ground water then flows
across the upper distribution tray of the air stripper, where it is unttormly distributed
over a pattern of 3/16-inch diameter holes through which a continuous stream of air is
passed. The extracted ground water then drains by gravtty through one additional tray
to a sump located at the bottom of the air stripper. As the extracted ground water
passes downward through these trays, an air stream is continuously forced upward
through the ground water by the air blower.
Upon exiting the second and final tray, the treated ground water enters an effluent
holding tank. The level of the water in the holding tank is maintained by an inverted
"U" trap, which prevents air from extting the air stripper wtth the treated water.
After passing through the tower, the exiting gas stream flows through a de-mister to
remove any entrained moisture present in the gas, which flows by gravity back through
the baffles of the air stripper. The gas exits the air stripper at the top through a 6" PVC
stack. The 6" PVC stack will exhaust directly to the atmosphere.
Theory of Operation -Air stripping is a physical process in which voes are forced into
equilibrium between water and air phases. The two tray, low-profile air stripping system
uses forced air in combination with the chemical properties of the voes to efficiently
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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remove the voes from the ground water. The ability of a voe to be air stripped is
measured by its tendencies to volatilize from water. The baffles within the tower
enhance the air stripping process by providing a surface for highly effective air -water
contact.
This counter-current flow of extracted ground water and air induces mass transfer of
voes from the ground water and into the air stream. The voes are stripped from the
water phase and introduced to the air phase. At start-up treated ground water will be
pumped from the low-profile air stripper to the metals removal unit. After completion of
the metals removal demonstration (about 30 days after start-up), It is anticipated that
the water will be pumped from the air stripper to an infiltration gallery without further
treatment.
Metals Removal System
Purpose -To remove metals from the ground water during the metals removal
demonstration. Bag filter BF-2002 and ion exchange columns MR-2001, MR-2002,
comprise the metals removal system. It is anticipated that the metals removal system
will be removed from the ground water treatment system after the demonstration is
complete .
Equipment Description -The bag filter unit is similar to the filtering unit described
previously on page 2-18. A differential pressure indicating switch (dPISH-1307 allows
differential pressure across the bag filter to be read at the bag filter. If a high
differential pressure is reached, the switch will operate a visual alarm on the control
panel and shut down the treatment system.
Each ion exchange column is a vertical tank constructed of fiberglass reinforced plastic
(FRP) that holds approximately 30 cubic feet of resin material. Each column will be
able to treat ground water for approximately two days, at which time, the column will be
replaced. Regeneration of the ion exchange resin will occur off-site. The tanks are
equipped with a 2-inch male kamlock top inlet and bottom outlet connections flanged
ports are provided for the installation of a differential pressure indicator switch (dPISH).
1.\WP\70\7001723 O&Mlcdf94 2-23
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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The dPISH is used to read the dttferential pressure at each ion exchange column. If a
high differential pressure is reached, the switch will operate a visual alarm on (dPAH)
on the control panel. Threaded ports are also provided for pressure indicators (Pl) on
the inlet piping. The following table summarizes the contents associated wtth each
tank.
TABLE 2-4
LOWER DOCKERY ION EXCHANGE COLUMN INSTRUMENTATION
MR -2001 dPISH -2403 dPAH -2403 Pl -2401
MR -2002 dPISH -2503 dPAH -2503 Pl -2501
The ion exchange columns are arranged in series. Flexible hoses with dripless quick
connect fittings are used to connect the columns to the ground water treatment system
and to each other.
Operational Description -Effluent pump P-2002 pumps the ground water through bag
filter BF-2002. The water stream then spltts into two equl streams. One stream flows
through ion exchange columns MR-1003 and MR-1004 while the other stream flows
through MR-1001 and MR-1002. After passing through the ion exchange columns, the
streams recombine and discharge into an infiltration gallery. Tumn MR-2001 and MR-
2002.
Theory of Operation -The bag filter removes particulates, specttically insoluble metal
hydroxides that may have formed in the aerated environment of the air stripper. The
ion exchange columns remove dissolved metal ions such as calcium, manganese and
magnesium from the water.
Ion exchange resin is a polymer bead material that exchanges one ion for another,
holds tt temporarily, and then releases it to a regenerant solution. Ion exchange occurs
when raw water ions diffuse into the bead structure and the displaced ions from the
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
bead structure dttfuses back into the water solution. For the Lower Dockery metals
removal demonstration, an ion exchange resin is used to remove dissolved manganese
from the water. Due to the nature of the resin material, dissolved calcium and
magnesium will also be removed during the process.
During the demonstration the ion exchange columns will be replaced as the ion
exchange capactty of the resin is exhausted. Designs calculations estimates a single
ion exchange column ltte to be five days. The used columns will shipped off-stte for
regeneration and re-use. Regenerative equipment or regeneration processes will not
occur at the Lower Dockery stte.
2.2.2 System Start-Up for Ground Water Recovery and Treatment System
The feed tank T-2001 and the jet pump collection piping must be filled wtth water prior to inttial
start-up. Fill water is obtained from the municipal water supply that can be obtained from
spigots located near the entrance to the Macon Site. The water may be trucked or pumped to
the treatment system, and transferred to the feed tank using the spare tank bulkhead fitting
located on top of the tanks. The following startup guide assumes that the initial filling of the
feed tank and jet pump collection piping has occurred.
1. The level of the tank must be at the invert of the discharge pipe.
2. Using HS-2304 on the control panel turn the blower {B-2001) on.
a. Each time start up is pertormed check and make sure the blower is turning in the
direction indicated on the blower casing.
b. Upon inttial start up, follow the sequence of steps below:
1) Turn off electrical components and close drain and sample valves. Check
that all electrical components associated wtth the untt are turned off, and all
drain and sample valves are closed. {Note: Be sure that the sight tube valve
is open).
2) On initial start-up, the air stripper sump tank must be filled wtth clean water to
a height of one foot. Make sure the valve to the sight tube is open. The air
stripper sump tank can be filled via clean-out ports, located on the left side of
the unit, or through the inlet piping.
3) Fill the air stripper inlet chambers wtth clean water. To fill the inlet chambers
{this is not necessary for a one-tray system), start the air blower and the
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3.
4.
5.
water flow to the unit. Let both run for about two minutes, then shut them off.
When the wheel to the blower stops spinning, restart both the blower and the
water flow. This procedure allows the water to drip into the seal pots. If the
seal pots won't fill by this method, they can be filled manually. First try
spraying a stream of water through the clean-out ports, on the left side of the
untt. The stream of water must be sprayed straight across the system and hit
the oppostte side. The splashing action should fill the seal pots. If the
preceding methods don't work, remove the trays, fill the seal pots, and re-
assemble. New untts provide inlet chamber filling ports.
(4) Turn 'ON' the master power disconnect swttch on the power disconnect
panel.
(5) Check the blower rotation. Check the blower rotation by momentarily
swttching on the blower switch and observing whether the blades turn in the
direction of the arrow on the blower casing.
(6) If blower rotation is correct, fully open the air inlet damper and turn the
blower switch to 'ON." Otherwise check wiring per manufacturer's
instructions and correct tt necessary. This step should be performed by a
qualified electrician.
(7) Start the clean water flow to the unit. Let the clean water and blower run for
two minutes then shut both off. Once the blower wheel stops rotating, restart
both the blower and the feed water flow. This procedure should fill the inlet
chambers as described below.
(8) Fill the inlet chambers with clean water.
(9) Connect contaminated feed water line. Replace clean water feed line with
contaminated feed line.
(1 O) Check the air pressure readings. After the untt has been operating five to ten
minutes, the air pressure readings should be approximately 11 inches
(pressure readings may vary slightly) of water column.
(11) The system is now ready for operation. It is not necessary to perform initial
start-up procedures each time the system is shut down. The system will
already be primed from the last run.
Vertty that the bag filter by pass valves for bag filters BF-2001, BF-2002, and are
closed. If the valves are open, close them now.
Vertty that the in-line valves for bag filters BF-2001, BF-2002 are open. If the valves
are closed, open them now.
Vertty that the in-line valves for the ion exchange columns MR-2001, MR-2002,
are open. If the valves are closed, open them now.
6. Start the Airstripper Effluent Pump (P-2002) by swttch HS-2303 to Auto
7. Start up the jet pump system.
8. Manually close the ball valves in each recovery well's valve vault.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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9. Manually open the ball valve between the feed tank and the recirculation pump.
10. Manually open the ball valve immediately following the recirculation pump.
11 .
12.
13.
14.
15.
16.
17.
18.
19.
Open the ball valve on the collection (return) pipe at the feed tank.
Using the hand swttch HS-2109 on the control panel turn the recirculation pump on.
Follow the steps below for turning the pump on.
a. Lock out power to motor.
b. Make sure coupling hubs are securely fastened to shafts.
c. Check impeller clearance (factory set at .015 in.); this could change based upon
the piping attachment.
d. Unlock motor power.
e. Jog motor long enough to determine direction of rotation. It must correspond to the
direction indicated by the arrow on the bearing housing.
f. Lock out power to motor.
g. Make sure suction valve and any recirculation or cooling lines are open.
h. Fully close or partially open discharge valve as indicated by system condttions.
i. Unlock motor power.
j. Start driver.
Check flow meters on each well.
Proceed to manually open the ball valves within each wells valve vault.
Close the valve at the turnaround valve pit.
Check the pressure gauges for each well.
a. The pressure of the jet pump should be 140 psi.
b. The pressure gauge in the vault should indicate less than 140 psi.
Check the water level in each well with a probe.
Modulate the valve at the turnaround valve pit to adjust flow rates for the overall
system.
Adjust ball valve on the return line for each individual well to maintain the specttied
water level in that well.
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TABLE 2-5
LOWER DOCKERY GROUND WATER SYSTEM START-UP
I }::/:/::::::::(:::: II 1 :,:,::·:•:•:· -:-.-:,:,·-:-:-.•=·=•-:;::<=·=·=·= ·.-.-.. -.-.... -.. -.-,•,.-.-.. -... -.-.-.-.-.. -.-.. -.... -,.·.-... -.-.. ,,;..-.-:•:·,·.·-·.·:·:·.•.-:•:·.-:;;,•:•:•:······ t:tn:m:mt:t?ItttJ ):fjjj ••. 11·•··
:::::::;:::;:::::::::::::::::::::: I STER<I • !'ROCEss. n lffiT!AL!i }
1 The level of the air stripper sump must be at the invert of the discharge pipe.
2 Using HS-1304 on the control panel turn the blower (blower B-2001) on.
a. Check blower rotation.
b. For initial system start up, refer to page 2-25 of O&M manual.
3 Close the Bag Filters' (BF-2001 and BF-2002) by pass valves
4 Open the Bag Filters' (BF-2001 and BF-2002)
5 Open the ion exchange column's (MR-3001 and MR-3002) in
6 Start the Airstripper Effluent Pump (P-3002) by switching HS-2303 to Auto.
7 Start up each jet pump System A and B separately.
8 Manually close the ball valves in each well's valve vault.
I Manually open the ball valve between the feed tank and the recirculation
pump.
10 Manually open the ball valve immediately following the recirculation pump.
11 Open the ball valve on the collection (return) pipe at the feed tank.
12 Using the hand switch Hs-2104 on the control panel tum the recirculation
pump on. Follow the steps below for turning the pump on.
13 Check flow meters on each well.
14 Proceed to manually open the ball valves within each well's valve vault.
15 Close the valve at the turnaround valve pit.
16 Check the pressure gauges for each well.
a. The pressure of the jet pump should be 140 psi.
b. The pressure gauge in the vault should indicate less than 140 psi.
17 Check the water level in each well with a probe.
18 Modulate the valve at the turnaround valve pit to adjust flow rates for the
overall system.
19 Adjust ball valve on the return line for each individual well to maintain the
specified water level in that well.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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2.2.3 Nonnal Operation
The gro_und water remediation system is virtually sett automated once the system is running.
However, tt is necessary to run and periodic checks on the jet pump extraction and treatment
system to monttor integrtty of the systems.
Pump operating motor alarm lights at the main control panel indicate that the recirculation
pumps are running.
A series of tables located in Section 5.4 provide a list of necessary daily and weekly monitoring.
Monitoring includes flow, pressure at pressure gauges, and physical condttions of the piping
and equipment to maintain the flawless working condition of the system.
2.2.4 Nonnal Shutdown
Normal shutdown of the Lower Dockery ground water remediation system is performed by the
following sequence of steps.
1) Turn off the recirculation pump wtth the hand swttch HS-2109 andthe effluent pump with
HS-2305 on the control panel.
2) Check the pressure indicators for each well. When all wells have no pressure proceed
to step #3.
3) Check the flow quanttty indicator for the outlet piping from the air stripper located on
the control panel as FQl-2308. When this indicates zero (0) flow, turn the blower to the
air stripper off. The blower may be turned off by HS-2304 at the control panel.
2.2.5 Emergency Shutdown
Emergency shutdown can occur under several different condttions. When the level alarm high
high (LAHH) in the feed tank is activated the recirculation pump is automatically shutdown. The
blower to the air stripper is shutdown after a delay period, in order to clear out any water
already in the air stripper.
In the case of a low level in the feed tank, only foreseeable through vandalism or a leak in the
tank, the level alarm low (LAL) would be activated. Both the recirculation pump and the blower
for the air stripper would be sequentially shutdown automatically. A mattunction of the blower
includes any incidence that prohibtts the necessary volumetric flow of atmospheric air to the air
stripper trays. Sttuations that may cause this would be a power outage, a short in the system,
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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or the sliding door that controls the atmospheric air flow to the blower has been closed too, far.
If this occurs, the recirculation pump is automatically shutdown. The autodialer will notify the
operator of system shutdown.
2.2.6 Troubleshooting and Alternate Operation
The system is capable of shutdown and ceasing discharge to the infiltration trench in the event
of a system mattunction. The risk associated wtth inadvertent discharge of untreated ground
water wtth this sttuation is minimal. The system will automatically shut down, and the autodialer
will nottty the operator of shutdown in the event of any of the potential problems listed below.
The level in the feed tanks reaches etther the high high or low level,
A, motor malfunction to either recirculation pump,
A high level in the sump of the air stripper,
Flow out of the blower to the stripper is low,
A motor failure at the blower,
High flow level out of the air stripper, or
Power failure.
For troubleshooting tips associated wtth the pump see Appendix I (Table 7, Troubleshooting;
Pump). For other troubleshooting tips see the table below.
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2.3
TABLE 2-6
TROUBLESHOOTING & ALTERNATE O & M -GW
Low Level in tank Leak in the tank. Contact Project Manager.
High High level in tank System clogging down stream. 1) Check the control valves; tt
they are open check air stripper,
2) Check air stripper and
downstream piping for clogging &
clean tt necessary.
Inadequate pumping Refer to Appendix G and J. Refer to Appendix G and J.
Flow in or out of well is
out of spec.
Pressure is out of
specification on inlet
piping of a well
Pressure after the
centrttugal pump is too
high or low
High level in air
stripper sump tank
Problem with the air
stripper
System won·t start
Ball valves on inlet or outlet
area not correctly set.
Ball valves on inlet or outlet
area not open or closed
appropriately.
Ball valve on inlet to the pump
is not correctly set.
Outlet valve is closed.
Refer to air stripper material in
Appendix H.
Power failure.
Adjust the ball valves to obtain
correct readings.
Adjust the ball valves to obtain
correct readings.
Adjust the ball valves to obtain
correct readings.
Open outlet valve.
Refer to air stripper material in
Appendix H.
Check main power feed panel
and/or power feed.
Upper Dockery Ground Water Remediation system Description
2.3.1 System Description and Equipment
Extraction Wells for Upper Dockery Ground Water Recovery
Purpose -To remove ground water from above the bedrock and convey tt to the Upper
Dockery Ground Water Remediation System.
Equipment Description -Six-inch Schedule 80 PVC extraction wells have been installed
to competent bedrock. Each well is screened from the bottom of the borehole to five
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feet above the observed water table. All screens are 0.01-inch machine-slotted. All in-
ground materials are threaded, flush-joint PVC. Feed lines to the recovery wells are
Schedule 80 PVC pipe and are installed underground. Construction connections aie
pitless adapters.
Piping within the recovery wells is Schedule 80 PVC and PVC industrial hose material.
The hose material is high tensile cord reinforced to a maximum pressure rating of 250
psi and has a minimum bending diameter of nine (9) inches. All exposed piping,
pumps, and valves are heat traced and insulated.
An electric submersible pump has been installed in each well. The pump has been
positioned at the depth to provide a maximum draw-down of each well. The pumps
have been sized to pump the total flow required to achieve the desired ground water
extraction rates and to deliver the water to the feed tank. The Upper Dockery ground
water recovery flow rate is approximately 3 gallons per minute per well. Level switches
have been installed with each submersible pump to sense water level and prevent the
pump from operating under dry conditions.
Valves and meters are rated for a maximum pressure of 150 psi. The flow out of each
well is measure locally by a flow indicator (Fl), and local pressure is measured by a
pressure indicator (Pl). A check valve and a globe valve have been installed on each
wells' discharge piping in order to prevent the back flow of water into the recovery well
and to control the flow of water leaving each well. Recovered ground water is pumped
through a bag filter and into a feed tank.
Operational Description
A level switch senses a high water level in the recovery well and starts the electric
submersible pump. The pump forces the ground water out of the recovery well through
bag filter BF-3001 and into feed tank T-3001. When a low water level switch in the
recovery well senses a low water level, the submersible pump will stop.
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Theory of Operation
The submersible pumps use a hermetically sealed electric motor to drive a multi stage
centrltugal pump. The pump forces the ground water out of the well through a bag filter
an into the feed tank. The submersible pumps operation is controlled by level swttches
that sense the water level in the well and operate the pump. The submersible pumps
will cease pumping It:
The low level swttch senses a low water level.
Blower B-3001 ceases operation
A high water level is detected in Airstripper AS-3001 's sump
A high-high water level is detected in Feed Tank T-3001
Bag Filter
Purpose -To remove particulate matter from the water by filtration.
Equipment Description -The bag filter includes a filter housing filter bag, restrainer
basket, and by pass.
Two parts for inlet and outlet exist on the filter housing, and a gasketed top mounted
access plate allows for filler bag replacement. Gasket material is a BUNA N, and the
filter housing is constructed of carbon steel.
The filter bag is the active filtering device that removes particulate matter from the
water. Contaminants are collected inside the bag. Filter bags rated for retention of
particles down to 20 microns in size are used in the bag filter.
The restrainer basket is a wire mesh basket that holds the filter bag in place. Filtered
water flows through the bag filter and restrainer basket and is discharged through the
filter housing's outlet.
The filter by-pass is a pipe line that allows the water to flow around the bag filter. The
by-pass has an in-line ball valve that is normally closed during ground water recovery
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
operations so that the incoming water passes through the bag filter. To replace the
bag filter the by pass valve is opened and the bag filter inlet and outlet valves are
closed. The bag filter can then be replaced while the rest of the treatment system
remains in operation.
The differential pressure (inlet pressure -outlet pressure} is monttored by a differential
pressure indicator and swttch, high (dPISH -2202). The dPISH allows differential
pressure across the bag filter to be read at the bag filter. In case of an unacceptably
high differential pressure across the bag filter the swttch will operate a visual alarm on
the control panel and shut down the water treatment system.
Operational Description -Ground water extracted from the Upper Dockery area will be
transported to a bag filter through the collection piping. Ground water flows through the
bag fitter inlet an through the filter bag, restrainer basket and bag filter outlet.
Particulate matter remains within the filter bag.
Feed Tank
Purpose -To accumulate ground water, and provide the source of affected ground
water for the air stripper untt.
Equipment Description -The recirculation/accumulation tank is constructed of epoxy
coated carbon steel wtth an operating volume of 2,800 gallons. This tank will be
positively vented to the atmosphere and have an 18-inch man-way. The tank data
sheet for this untt is found in Appendix D.
Four ports exist in the tank. A spare port is located on top of the tank. An inlet port
from the extraction wells is located on the upper half of the tank. An overtlow extt port
is located near the top of the tank to direct affected ground water to the air stripper.
The remaining outlet port is located near the bottom of the tank and is spare.
The water level in the tank is monttored by a level indicating transmitter (LIT-3201 }.
Level swttches (LSL-3201, LSH-3201, LSHH-3201} are located wtthin the PLC. These
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
level swttches operate two alarms tt the tank volume reaches the preset level. The
preset level alarms occur at LSL-3201 and LSHH-3201 corresponding to level alarm
low (LAL) and level alarm high high (LAHH). The alarms are visually indicated at both
the control panel and the observation stte. Simultaneously, LSL and LSHH will shut
down the electrical submersible pumps. This action triggers a sequential shut-down of
the air stripper.
Operational Description -Water extracted from the recovery wells is directed through
the central header and bag filter BF-3001 to the tank from ports located on the upper
half of the tank. The water is accumulated in the tank until tt overflows out to the air
stripper.
Conveyance From Feed Tank to the Air Stripper
Purpose -To provide a flow of affected ground water from the recirculation/
accumulation tank to the low-profile air stripper.
Equipment Description -The piping is Schedule 80 six (6) inch PVC. Three control
valves are located immediately upstream of the air stripper. These valves are spring-
loaded to close and halt water flow from the recirculation tank in the event of a total
power failure.
Operational Description -The pipe provides a gravttational flow of affected ground
water from the recirculation/accumulation tank to the low-profile air stripper.
Air Stripper
Purpose -To aerate the ground water to promote the volatilization of volatile organic
compounds (VOCs) and the subsequent removal.
Equipment Description -The air stripper is a Shallow Tray 2331 three tray air stripper
(Appendix G). The air stripper is a 6.5 foot high rectangular tower wtth an overall width
'
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
of four feet and an overall length of 3.2 feet. This system can accommodate flows in
the range of 1 to 30 gpm. The tower is constructed of 304L stainless steel.
Other equipment accompanying the air stripper include a centrttugal blower, effluent
holding tank, three separate trays, an inlet screen and damper, steel de-mister, air ·
pressure gauge, sight tube, and Schedule 80 PVC piping. The blower is a 3 Hp blower
capable of delivering up to 300 elm of atmospheric air to the tower.
The centrttugal blower is located outside on the lower halt of the stripper. The
atmospheric air flow is controlled by an inlet plate on the side of the pump. The
blower should never be operated with this plate more than half way open.
The level in the effluent holding tank is monttored by a level swttch (LSH-3201) which is
connected by a data link to the PLC. When the effluent level in the tank rises to the
preset high mark, alam,s (LAHH-3201) will activate. Alam,s are located on the main
control panel.
The air flow from the blower is also monttored to detect low flow. If such a sttuation ,
occurs the flow swttch low (FSL-3304) is activated. This is then fed to the PLC, which
in turn, activates alarms FAL-3304 at the main control panel. The system shuts down
automatically upon a deviation from normal operating condttions, and nottties the
operator through the autodialer.
Operational Description -The teed tank receives affected ground water. When the tank
fills to the preset outlet level, the affected ground water overflows from the tank to the
air stripper by gravitational flow. The affected ground water then flows across the
upper distribution tray of the air stripper, where tt is unttormly distributed over a pattern
of 3/16-inch diameter holes through which a continuous stream of air is passed. The
extracted ground water then drains by gravtty through two additional trays to a sump
located at the bottom of the air stripper. As the extracted ground water passes
downward through these trays, an air stream is continuously forced upward through the
ground water by the air blower.
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Upon extting the third and final tray, the treated ground water enters an effluent holding
tank. The level of the water in the holding tank is maintained by an inverted "U" trap,
which prevents air from extting the air stripper wtth the treated water.
After passing through the tower, the exiting gas stream flows through a demister to
remove any entrained moisture present in the gas, which flows by gravity back through
the baffles of the air stripper. The gas exits the air stripper at the top through a 6" PVC
stack. The 6" PVC stack will exhaust directly to the atmosphere through the roof of the
treatment system shelter.
Theory of Operation -Air stripping is a physical process in which VOCs are forced into
equilibrium between water and air phases. The three tray, low-profile air stripping
system uses forced air in combination with the chemical properties of the VOCs to
efficiently remove the VOCs from the ground water. The abiltty of a voe to be air
stripped is measured by tts tendencies to volatilize from water. The baffles wtthin the
tower enhance the air stripping process by providing a sur1ace tor highly effective air -
water contact.
This counter-current flow of extracted ground water and air induces mass transfer of
VOCs from the ground water and into the air stream. The voes are stripped from the
water phase and introduced to the air phase. Treated ground water will flow by gravtty
from the low-profile air stripper through a metals removal system and into an infiltration
gallery.
Metals Removal System
Purpose -To remove metals in the ground water during the metals removal
demonstration. Bag filter BF-3002 and ion exchange columns MR-3001 and MR-3002
comprise the metals removal system. It is anticipated that the metals removal system
will be removed from the ground water treatment system after the demonstration is
complete.
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Equipment Description -The bag filter unit is similar to the filtering unit described
previously on page 2-33. dPISH-3307 allows differential pressure across the bag filter
to be read at the bag filter. In case of an unacceptably high differential pressure, the
switch will operate a visual alarm on the control panel and shut down the water
treatment system.
Each ion exchange column is a vertical tank that holds approximately 30 cubic feet of
Resin material and is constructed from fiberglass reinforced plastic (frp). Each column
will be able to treat ground water for approximately two days, at which time, the column
will be replaced. Regeneration of the ion exchange resin will occur off-site. The tanks
come equipped with a 2" male kamlock bottom outlet connection 1/2 inch diameter,
threaded ports are provided for a differential pressure indicator switch high (dPISH),
The dPISH is used to read the differential pressure at each ion exchange column. In
;has of an unacceptably high differential pressure, the switch will operate a visual alarm
on (dPAH) on the control panel. 1/2 inch threaded ports are also provided for pressure
indicators (Pl) on the inlet piping. The following table summarizes the contents
associated with each tank.
TABLE 2-7
LOWER DOCKERY ION EXCHANGE COLUMN INSTRUMENTATION
I ~;~~ ii ·~~ 1• ! ~~-I l~~i I
MR -3001 dPISH -3403 dPAH -3403 Pl -3403
MR -3002 dPISH -3503 dPAH -3503 Pl -3503
The ion exchange columns are arranged in series. Flexible hoses with dripless quick
connect fittings are used to connect the columns to the ground water treatment system
and to each other.
Operational Description -Effluent pump P-3002 pumps the ground water through bag
filter BF-3002. The filtered water stream then sequentially flows through ion exchange
column MR-3001 and MR-3002.
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Theory of Operation -The bag tilter removes particulates, specttically insoluble metal
hydroxides that may have formed in the aerated environment of the air stripper. The
ion exchange columns remove dissolved metal ions such as calcium, manganese and
magnesium from the water.
Ion exchange resin is a polymer bead material that exchanges one ion for another,
holds tt temporarily, and then releases it to a regenerant solution. Ion exchange occurs
when raw water ions diffuse into the bead structure and the displaced ions from th~
bead structure diffuses back into the water solution. For the Lower Dockery metals
removal demonstration, an ion exchange resin is used to remove dissolved manganese
from the water. Due to the nature of the resin material, dissolved calcium and
magnesium will also be removed during the process.
During the demonstration the ion exchange columns will be replaced as the ion
exchange capactty of the resin is exhausted. Designs calculations estimates a single
ion exchange column lite to be tour days. The used columns will shipped off-stte tor
regeneration and re-use. Regenerative equipment or regeneration processes will not
occur at the Lower Dockery stte.
2.3.2 System Start-Up for Ground Water Recovery and Treatment System
1. Using HS-3304 on the control panel turn the blower (B-3001) on.
a. Each time startup is performed check and make sure the blower is turning in the
direction indicated on the blower casing.
b. Upon inttial startup, follow the sequence of steps below:
1)
2)
3)
Turn off electrical components and close drain and sample valves. Check
that all electrical components associated wtth the untt are turned off, and all
drain and sample valves are closed. (Note: Be sure that the sight tube valve
is open). ,
On inttial start-up, the air stripper's sump tank must be filled wtth clean water
to a height of one toot. Make sure the valve to the sight tube is open. The
sump tank can be filled via clean-out ports, located on the left side of the
untt, or through the inlet piping.
Fill the inlet chambers wtth clean water. To fill the inlet chambers (this is not
necessary tor a one-tray system), start the air blower and the water flow to
the unit. Let both run tor about two minutes, then shut them off. When the
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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2.
3.
4.
5.
6.
7.
8.
wheel to the blower stops spinning, restart both the blower and the water.
flow. This procedure allows the water to drip into the seal pots. If the seal
pots won't fill by this method, they can be filled manually. First try spraying a
stream of water through the clean-out ports, on the left side of the untt. The
stream of water must be sprayed straight across the system and htt the
oppostte side. The splashing action should fill the seal pots. If the preceding
methods don't work, remove the trays, fill the seal pots, and re-assemble.
New untts provide inlet chamber filling ports.
(4) Turn 'ON' the master power disconnect swttch on the power disconnect
panel.
(5) Check the blower rotation. Check the blower rotation by momentarily
swttching on the blower switch and observing whether the blades turn in the
direction of the arrow on the blower casing.
(6) If blower rotation is correct, fully open the air inlet damper and turn the
blower swttch to 'ON." Otherwise check wiring per manufacturer's
instructions and correct if necessary. This step should be performed by a
qualified electrician.
(7) Start the clean water flow to the untt. Let the clean water and blower run for
two minutes then shut both off. Once the blower wheel stops rotating, restart
both the blower and the feed water flow. This procedure should fill the inlet
chambers as described below.
(8) Fill the inlet chambers with clean water.
(9) Connect contaminated feed water line. Replace clean water feed line wtth
contaminated feed line.
(10) Check the air pressure readings. After the untt has been operating five to ten
minutes, the air pressure readings should be approximately 11 inches
(pressure readings may vary slightly) of water column.
(11) The system is now ready for operation. It is not necessary to perform initial
start-up procedures each time the system is shut down. The system will
already be primed from the last run.
Verify that the bag filter bypass valves for bag filters BF-3001 and BF-3002 are closed.
If the valves are open, close them now.
Verify that the in-line valves for bag filters BF-3001 and BF-3002 are open. If the
valves are closed, open them now.
Verify that the in-line valves for the ion exchange columns MR-3001 and MR-3002 are
open. If the valves are closed, open them now.
Start up each electric submersible pump separately.
Manually adjust the ball valves in each well's valve vautt to achieve desired flow rate
(approximately 3 gpm).
Check flow meters and pressure gauges on each well.
Check the water level in each well with a probe.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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1
2
3
4
5
6
7
8
9
9. Turn on the effluent pump P-3002 by selecting the Auto position of HS-3305.
TABLE 2-8
LOWER DOCKERY GROUND WATER SYSTEM START-UP
Using HS-3304 on the control panel turn the blower (blower B3001) on.
a. Check blower rotation.
b. For initial system startup, refer to page 2-40 of O&M manual.
Close the bag filters (BF-3001 and BF-3002) bypass valves.
Open the bag filters' (BF-3001 and BF-3002) in-line valves.
Open the ion exchange column's (MR-3001 and MR-3002) in-line valves.
Start up each submersible pump separately.
Manually adjust the ball valves in each well's valve vault.
Check flow meters and pressure gauges on each well.
Check the water level in each well with a probe.
Start the effluent pump (P-3002) using HS-3305.
2.3.3 Nonna! Operation
The ground water remediation system is virtually sett automated once the system is running.
However, It is necessary to run periodic checks on the ground water extraction and treatment
system to monitor integrity of the systems. Pump operating motor alarm lights at the main
control panel indicate that all pumps are running.
A series of tables located in Section 5.4 provide a list of the periodic monitoring. Monitoring
includes flow, pressure at pressure gauges, and physical conditions of the piping and
equipment to maintain the flawless working condition of the system.
2.3.4 Nonnal Shutdown
Normal shutdown of the ground water remediation system is pertormed by the following
sequence of steps.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
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1)
2)
3)
Turn ott the electric submersible pump centrttugal pumps wtth the hand swttches on the
pump control panels.
Check the pressure indicators for each well. When all wells have no pressure proceed
to step #3.
Check the flow quanttty indicator for the outlet piping from the air stripper located on
the control panel as FQl-3308. When this indicates zero (0) flow, turn the blower to the
air stripper ott. The blower may be turned ott by HS-3304 at the control panel. '
2.3.5 Emergency Shutdown
Emergency shutdown can occur under several different conditions. When the level alarm high
high (LAHH) in the feed tank is activated the electric submersible pumps are automatically
shutdown. The blower to the air stripper is shutdown after a delay period, in order to clear out
any water already in the air stripper.
In the case of a low level in the tank, only foreseeable through vandalism or a leak in the tank,
the level alarm low (LAL) would be activated. Both the centrttugal pump and the blower for the
air stripper would be sequentially shutdown automatically. A malfunction of the blower includes
any incidence that prohibtts the necessary volumetric flow of atmospheric air to the air stripper
trays. Sttuations that may cause this would be a power outage, a short in the system, or the
sliding door that controls the atmospheric air flow to the blower has been closed too far. If this
occurs, the electric submersible pumps are automatically shutdown.
2.3.6 Troubleshooting and Alternate Operation
The system is capable of shutdown and ceasing of discharge to the infiltration gallery in the
event of a system mattunction. The risk associated with inadvertent discharge of untreated
ground water wtth this sttuation is minimal. The system will automatically shut down in the
event of any of the potential problems listed below.
The level in the feed tank reaches either the high high or low level,
A high level in the sump tank of the air stripper,
Flow out of the blower to the stripper is low,
A motor failure at the blower,
High flow level out of the air stripper, or
Power failure.
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2.4
Each of these sttuations causes the treatment system to shut down and ceases discharge to
Infiltration Gallery. For troubleshooting tips associated w~h the pump see Appendix I (Table 7,
Troubleshooting Pump). For other troubleshooting tips see the table below.
TABLE 2-9
TROUBLESHOOTING & ALTERNATE O & M -GW
Low Level in tank
High High level in tank
Inadequate pumping
Flow out of well is out
of spec.
Pressure in discharge
piping is too high or
low
High level in air
stripper sump tank
Problem with the air
stripper
System won't start
Leak in the tank.
System clogging down stream.
Refer to Appendix G and J.
Ball valves on outlet area not
correctly set.
Ball valve on outlet is not
correctly set.
Outlet valve is closed.
Refer to air stripper material in
Appendix H.
Power failure.
Soll Remediation System Description
2.4.1 System Description and Equipment
Vapor Extraction Wells
Contact Project Manager
[[phone]]
1) Check the control valves; tt
they are open check air stripper,
2) Check air stripper and
downstream piping for clogging &
clean tt necessary.
Refer to Appendix G and J.
Adjust the ball valve to obtain
correct readings.
Adjust the ball valve to obtain
correct readings.
Open outlet valve.
Refer to air stripper material in
Appendix H.
Check main power feed panel
and/or power feed.
Purpose. To extract tetrachloroethene (PCE) from vadose zone soils (soils located above the
saturated water table).
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Description. VE-01, OW-1, OW-3, and OW-5 are screened approximately eight feet above the
mean high water elevation to the surtace. Each well is approximately 34 feet in depth and has
0.020-inch continuous slotting. Prior to the vapor from each well entering the pump, the vapor
passes through a ball valve and condensate trap, after the central header. The vacuum piping
will be embedded in concrete and run below the surtace.
Filter/Condensate Trap
Purpose. Remove particulate matter and entrained water vapor from the air stream before tt
passes through the vacuum pump.
Operational Description. Upon passing through the central header, vapors enter the
condensate trap. Vapors pass through the length of the condensate trap where entrained water
is removed. The vapor enters on the upper hatt along the side of the trap and is discharged at
the other side. The inlet and outlet openings are four-inch diameter connections. The level of
the water wtthin the sight glass is monttored. In the event that the level rises to the preset
maximum high, a level swttch high (LSH-1100) shuts the vacuum pump off. The water in the
condensate trap may be removed manually, by opening the ball valve and draining the water.
All condensate water removed from the system will be discharged manually to one of the feed
tanks of the ground water treatment system via the 18" man-way.
The filter/condensate trap selected for this application is a Stoddard Silencer Model F65-4 with
a pleated paper filter media.
Air Intake
Purpose. To provide make-up air to the system when necessary to start the vacuum pump.
The air intake will also be used to control the air flow on the intake and thereby regulate the
vacuum pressure applied to each well.
Description. The air intake is equipped wtth a pleated skirt intake filter. This filter is a Stoddard
Silencer Model F64-3 intake filter. Air flow through the system is controlled by a ball valve and
has a maximum flow rating of 285 cfm.
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Operational Description. The air intake brings air from the atmosphere, passes it through a
fitter and ball valve, and flows into the central piping for the SVE system. T~e ball valve serves
to regulate the air flow and pressure. By manipulating the ball valve the vacuum exerted on the
extraction wells is controlled.
Inlet/Discharge Silencers
Purpose. To reduce the noise levels created by the vacuum pump.
In-line silencers are installed on both the inlet and discharge side of the vacuum pump. These
silencers are used to reduce the noise level during site operations. The silencers will be
chambered-type silencers as manufactured by Universal Silencers. A URB series silencer with
a 4-inch diameter inlet will be used for the inlet silencer. A URBY series silencer with a 4-inch
diameter inlet will be used for the discharge silencer.
Operational Description. The extracted air flow enters from.one end of the cylinder and exists
from the other side. The attenuation curve is found in the specttication data sheet for the
silencers. The inlet silencer is directly upstream from the vacuum pump. The discharge
sile"ncer is directly downstream from the vacuum pump.
Vacuum Relief Valve
Purpose. To provide an air inflow to the vacuum pump preventing the collapse of piping
between vacuum pump and the air intake .
Description. The vacuum relief valve is a Kunkle model 215V size 3 spring type valve with cast
iron and bronze trim.
Operational Description. If the vacuum unit was plugged to the extent the vacuum pump was
not receiving sufficient air, the spring valve would open allowing atmospheric air to flow directly
into the vacuum pump.
Vacuum Pump
Purpose. To provide the suction required to extract vapors from the soil.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
Description. A Roots Model 56 RAI rotary lobe posttive displacement blower serves as the
vacuum pump for the SVE system (Appendix E). The pump is capable of producing 260 SCFM
under no load and capable of operating up to a vacuum of 150 inches of water (14 inches Hg).
The inner components and housing dimension and description may be found in Appendix E in
the equipment cut sheet.
Operational Description. The rotation of the lobes provide adequate air transfer to induce a
vacuum on the wells. This vacuum is of sufficient strength to extract soil vapor from the vadose.
zone.
Theory of Operation. Two figure-eight lobe impellers mounted on parallel shafts rotate in
opposite directions. As each impeller passes the blower inlet, tt traps a defintte volume of air
and carries tt around the case to the blower outlet, where the air is discharged. Wtth constant
speed operation, the displaced volume of air is essentially the same regardless of pressure,
temperature and barometric pressure.
A temperature indicator (Tl-1300) and a pressure indicator (Pl-1300) are located directly
downstream of the vacuum pump and allow for visual monttoring of discharge temperature and
pressure.
Other controls on the vacuum pump include a Motor Alarm (MA-1300) which is activated if the
motor stops. A three posttion hand swttch (HS-1500) will be used to turn the pump on or off
manually. Both the motor alarm and the hand swttch are located on the SVE control panel. A
high level signal from the liquid level sensor in the condensate trap will also cause the vacuum
pump to shut down.
Stack
Purpose. To emtt extracted vapors to the atmosphere.
Description. The stack is a 15-foot high Schedule 40 four-inch PVC pipe.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
Operational Description. The extracted vapors extt the discharge silencer and enter the base of
the stack. A sampling port is located near the base for monttoring of the discharge.
2.4.2 System Stan-Up
To activate the soil vapor extraction system, follow these steps.
1)
2)
3)
4)
5)
For inttial start up, check to make sure the rust inhibttor has been removed from ,the
vacuum pump.
Open the globe valve on the air intake.
Start the vacuum pump by the hand swttch (HS-1300) on the SVE control panel.
Open the ball valve to each well that is intended for use.
Modulate the opening of the globe valve on the air intake to achieve the desired .
pressures for the system.
2.4.3 Nonnal Operation
The SVE remediation system is virtually self automated. However, tt is necessary to run
periodic checks on the system. A series of tables in Section 5.4 provide a list of necessary
periodic checks for the SVE system. The checks include temperature and pressure readings at
the gauges, condttions of the piping and equipment, and integrtty of the vacuum wells and site
security.
2.4.4 Nonna! Shutdown
Normal shutdown of the SVE system is performed by the following steps.
·1) Turn the hand switch (HS-1300) located on the control panel for the vacuum pump to
the ott posttion.
2) Open the ball valve on the air intake.
2.4.5 Emergency Shutdown
Emergency shutdown can occur if the water level in the filter/condensate trap is too high. The
vacuum pump is the only piece of equipment turned off during an emergency shut down.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
1
2
3
4
5
TABLE 2-10
SVE SYSTEM START-UP
For inttial start up, check to make sure the rust inhibttor has been removed
from the vacuum pump.
Open the ball valve on the air intake.
Start the vacuum pump by the hand swttch (HS-1300) on the control panel.
Open the ball valve to each well that is intended for use.
Modulate the opening of the ball valve on the air intake to achieve the
pressures for the system (never to exceed 150 in. H,0).
The pump is automatically shut down in the event of one of the following sttuations:
The level of the water in the condensate trap exceeds the preset height and actuates
level switch high (LSH-1300), and
A motor failure of the vacuum pump.
2.4.6 Troubleshooting and Alternate Operation
The automation of the system is designed to handle any problem that may arise. A list of
events that could potentially cause a system shutdown are listed below.
High water level in the condensate trap,
Motor failure to the vacuum pump, or
Power failure.
Each of these situations alone will cause a system shutdown. To assist in troubleshooting of
the vacuum pump refer to the table in Appendix E. For general system troubleshooting refer to
the following table. The risk associated wtth any or all of the mechanical or electrical failure is
minimal, due to the nature of the system.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 2
TABLE 2-11
TROUBLESHOOTING AND ALTERNATE OPERATION· SVE
Level High in condensate trap
High differential pressure
across in-line filter
Low pressure to extraction
wells
High pressure to extraction
wells
Motor failure to vacuum pump
High temperature down
stream from vacuum pump
System Shutdown
l:\WP\70\7001723 O&Mlecff94
Too much water wtthin trap
Damaged or clogged filter
screen
Ball valve to air intake open
too much
Ball valve to air intake
closed too much
Defect or mattunction in
motor
Obstruction in discharge
piping
High water level in
condensate trap
Motor failure for pump
2-49
Open ball valve and remove water
Locate faulty screen and replace
Close ball valve on air intake to
obtain correct pressure on system.
Open ball valve on air intake to
obtain correct pressure on system.
Replace motor.
Inspect discharge piping
Open ball valve: remove the water
Replace motor.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 3
3.1
Section 3
MAINTENANCE OF SYSTEMS
Ground Water Remediation System Maintenance Tasks
3.1.1 Mechanical Equipment
Centrlfugal Pumps
The centrifugal pumps for the jet pump and ion exchange systems are subject to the following
maintenance requirements.
/nit/al Start-up
1. Add oil to bearings up to the center of the sight glass.
2. Pack the stuffing box.
3. Check impeller clearances and reset tt necessary.
First 200 hours
1. Change oil.
Every 3 Months or 3000 hours
1. Check foundation and hold down bolts for tightness
2. If pump has been left idle, check packing. Replace if necessary.
3. Change oil.
4. Regrease bearings.
Annually
1. Check pump capactty, pressure, and power feed. If pump pertormances have
changed dramatically, pump should be disassembled, inspected, and worn parts
should be replaced, otherwise a system inspection should then be pertormed.
For in-depth descriptions of each centrifugal pump, refer to the Pump Equipment Manual at the
treatment pad and see Appendix E, Pump Data Sheet --Ground Water, and Appendix G, Pump
Maintenance Ground Water and SVE, and Appendix C for recordkeeping. A maintenance bar
chart summarizing the required system maintenance will be developed for the Operation and
Maintenance Manual.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 3
Air Strippers
Air strippers are potentially subject to fouling from high dissolved minerals concentrations. This
fouling can potentially clog aeration levels and the demister pad. To remove these mineral
depostts, spray both sides of all three trays wtth a pressure washer. Starting from the lower
most tray, clean from bottom to top; repeat on tray two and then tray one. Remove the
sedimentation and water wtth a wet dry vacuum. These procedures are expanded upon in the
maintenance section of the air stripper handbook found in Appendix I.
Well Screen and Jet Pump
The constttuents present in the ground water do not pose a threat of fouling to the well screen
or jet pump. However, tt fouling does occur the jet pumps and well screens will be cleaned on
an annual basis.
Electric Submersible Pumps
No required maintenance of the electric submersible pumps is anticipated during the lttetime of
groundwater remediation activtty at the Upper Dockery Stte. Individual pumps may require
replacement due to lightning strike or excessive pumping of sitts and sands.
Feed Tank
A visual inspection of the recirculation/accumulation tank will be pertormed monthly. Any
damage or deterioration will be logged. Tank Data Sheets are provided in Appendix D.
Metals Removal System
The metals removal systems have initially been installed as a process demonstration. It is
anticipated that these systems will not be needed after the 30-day system start up/process
demonstration. No maintenance is required for the metals removal system. However,
individual ion exchange columns will be replaced as the metal removal capacity of the resin is
exhausted. A tentative ion exchange column replacement schedule is:
Every 3.5 days for Macon System
Every 4 days for Upper Dockery System
Every 5 days for Lower Dockery System
The actual schedule may vary due to field conditions.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 3
3.2
3.1.2 Instrumentation and Controls
Annual calibration of transmttters. The motor control center, for the system (A and B)
centrttugal pump and to the blower for the air stripper, will be inspected annually and replaced
as indicated by significant wear.
Soll Vapor Extraction System
3.2.1 Mechanical Equipment
Condensate Trap -Check the water level in the trap by the sight glass weekly. When the
water is at the high level glass, open the vent and remove water into a bucket. Manually carry
this water to a feed tank treatment in a ground water remediation system. Pour the water'into
the 18" manway provided for access to the feed tank. (You will need to use the ladder
provided).
In-line Filter/Condensate Trap -The filter element will have to be replaced at an interval to be
established once startup has begun, and is based on operating conditions. A tentaive schedule
is once every six months.
Vacuum Pump -The vacuum pump for the SVE system is subjected to the following
maintenance requirements (refer to Appendix F for the Pump Data Sheet and Appendix G for
maintenance. Maintenance Record Sheets are provided in Appendix C.).
Initial Startup
1) Add oil to reservoir of the gear house to the full mark.
First 100 hours
1) Change oil.
Weekly
1) Check oil level in gearhouse and add lubricant, tt necessary.
Every 1000 Hours
1) Change oil.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 4
Section 4
HEAL TH AND SAFETY
4.1 Health and Safety Plan
A Construction Health and Safety/Contingency Plan for the Macon/Dockery Site was submitted io the
US EPA and NC DEHNR in December 1993. By reference, this Operations and Maintenance manual
' incorporates the Health and Safety Plan in its entirety. A copy of the Health and Safety Plan is readily
accessible on site and is located at each ground water treatment facillty.
The following sections summarize the most important standard operating safety procedures and
controls, the emergency safety procedures and equipment, training requirements, medical surveillance,
and recordkeeping.
4.2 Standard Operating Safety Procedures and Controls
Some of the major standard operating safety procedures and controls are listed below. The reader
should refer to Sections 4 through 13 of the latest revision of the Health and Safety Plan.
Environmental Monitoring
For surtace/intrusive work associated with various wells, borings, and other activities
such as earthwork and grading, trenching, and underground pipe laying, organic vapor
readings will be made using either a Foxboro OVA (Model 128), an HNu
Photoionization Analyzer (Model PF101 ), or a Photovac Microtip.
A periodic (monthly) monitoring of equipment seals, fitting, and well heads should be
made to determine if system leaks are occurring. The monitoring should be pertormed
visually and with either a Foxboro OVA (Model 128), an HNu Photoionization Analyzer
(Model PF101 ), or a Photovac Microtip .
Personal Protective Equipment
Personal protective equipment (PPE) to be worn on site during operation include hard
hat, safety glasses, work boots, and work gloves.
During sampling activities of soils or ground and surtace waters, additional PPE may
include neoprene, nltrile or heavy du1y PVC boots, Tyvek suits, nitrile or neoprene
gloves, and as necessary (if monitoring indicates a need) a full face respirator with
organic vapor cartridges and hearing protection.
Respiratory protection requirements during normal operations should not be required.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 4
Stte securtty shall be maintained to prevent potential vandalism and accidents by
others. The equipment that is not in operation shall be locked out to help prevent
operation by unfamiliar operators or others. The fencing and gates should be visually
inspected for damage or vandalism that may affect the integrity of the remediation
system.
Personal Precautions
Be familiar wtth standard operating safety procedures and adhere to all instructions and
requirements in the stte Health and Safety Plan.
Eating, drinking, chewing gum or tobacco, smoking, or any practice that increases the
probability of hand-to-mouth transfer and ingestion of material is prohibtted in any
contaminated or potentially contaminated area.
Contact lenses shall not be worn in any contaminated area or in any area where safety
glasses or respiratory protection are required.
Hands and face must be thoroughly washed upon leaving the work area. Whenever
decontamination procedures for outer garments are in effect, the entire body should be
thoroughly washed as soon as possible after the protective garment is removed.
No facial hair which interteres with a satisfactory respirator ftt of the mask-to-face-seal
is allowed on personnel required to wear respirators.
Avoid contact wtth contaminated or suspected contaminated surtaces. Whenever
possible, avoid wading through puddles, pools, mud, etc. Avoid kneeling or sitting on
the ground, equipment or drums.
Personal articles shall be prohibited in any contaminated area.
Medicine and alcohol can exacerbate the effects from exposure to toxic chemicals.
Alcoholic beverage intake should be minimized or avoided on off work hours during
field operations. Prescribed drugs should not be taken by personnel on stte operations
where the potential for absorption, inhalation, or ingestion of toxic substances exists
unless specttically approved by a qualttied physician. Do not work when ill.
ldenttty potential health and safety hazards and contact the appropriate person to
inttiate corrective action.
Operational Requirements
Personnel going on-stte shall be adequately trained and thoroughly briefed on
anticipated hazards, equipment to be worn, safety practices to be followed, emergency
procedures, and communications. For stte workers who are reasonably expected to
encounter exposure hazards, this training entails 40 hour health and safety training
along wtth up-to-date refresher training. This training is not required for workers not
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 4
4.3
expected to encounter potential exposure hazards, such as electricians who will not
perform subsurface work.
Respiratory protective devices and/or protective clothing appropriate to the designated
levels of protection shall be worn by all personnel going into areas designated for
wearing protective equipment. A protection level of D is expected around the pump
pads during normal operation. More stringent levels of protection may be required tt
condttions so warrant (i.e. high VOC air concentrations).
During continual operations, on-stte workers shall act as safety backup to each other.
Off-stte personnel shall provide emergency assistance.
Personnel should practice unfamiliar operations prior to doing the actual procedure.
Entrance and exit locations shall be designated and emergency escape routes
delineated. The following warning signals shall be used when necessary:
Hand gripping throat ......................... Can't breathe
Grip partner's wrist or both hands at waist .......... Leave area immediately
Hands on top of head . . . . . . . . . . . . . . . . . . . . . . . . Need assistance
Thumbs up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ok, I am all right, I understand
Thumbs down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No, negative
Communications shall be maintained between field team members at all times. A
permanent telephone will be located at the ground water treatment facility to facilttate
emergency response communications.
Decontamination procedures for leaving a contaminated area shall be followed. Hands
and face shall be washed prior to work breaks and eating. Work areas and
decontamination procedures have been established based on expected stte condttioned
(see Section 11 of the Health and Safety Plan).
System Failure Activities
Preventing accidents is the responsibiltty of each individual on stte. Unsafe or dangerous working
condttions shall be reported immediately to the stte Health and Safety Representative and the Project
Manager. The project Health and Safety Representative and Project Manager will be responsible for
seeing that the Health and Safety Program is properly implemented.
All Contractors and Subcontractors shall be responsible for instructing their workers in safe work
practices and emergency procedures. This is an important duty and respo_nsibiltty for each of the,
contractor(s) and subcontractor(s). The Health and Safety Plan will be made available to all
l:\WP\70\7001723.0&Mlcitl94 4-3
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 4
contractor(s) and subcontractor(s) for their review and information. Each contractor and subcontractor
is responsible for developing and implementing their own stte Health and Safety Plan.
The system operator(s) shall be familiar wtth the Health and Safety Plan and tts contents. Section 4 of
the Health and Safety Plan desclibes the hazard assessment of the chemical constttuents that could
potentially be encountered. Section 13 of the Health and Safety Plan describes Emergency Procedures
and lists phone numbers.
4.3.1 Medical Emergencies
For physical injuries, first aid treatment shall be given at the stte, depending upon the
seriousness of the injury. The victim should undergo decontamination, H necessary, unless
such procedures interfere wtth necessary treatment. In !He-threatening sttuations care shall be
instttuted immediately. Always remove respirators. Protective clothing shall be removed or cut
away if this will not cause delays, interfere wtth treatment, or aggravate the problem. If
;
contaminated protective clothing cannot be removed, wrap the victim in clean materials to help
prevent contamination of medical personnel and ambulances.
For chemical exposure emergencies, decontamination procedures shall be followed unless
severe medical problems requiring !He sustaining measures are evident. Chemical exposures
are unlikely during normal system operations, and are more associated with intrusive
investigations at this stte.
Emergency equipment available on-stte shall include:
•
First Aid Ktts, (as specified by National Safety Council Data Sheet No. 202 or
equivalent),
Portable Eyewash Station (15 minute duration)
Full Face Respirators -HEPNOrganic Vapor Combination Cartridges (GMA-H or·
GMC-H), .
Field Telephone,
Fire Extinguisher.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 4
In the event of injury, the emergency shall be handled according to the procedures described in
the Emergency Procedures (Section 13 of the Health and Safety Manual). The first aid kits
shall be maintained at the control access point to the operation and in support vehicles.
If the victim cannot be safely moved from the contamination area, first aid necessary to stabilize
the victim for safe transport shall be administered at the accident location. Appropriate:
decontamination of all clothing and equipment shall be followed ff necessary.
4.3.2 General Emergency Procedures
In the event that any member of the field crew experiences any adverse effects or
symptoms of exposure while on the scene, the entire field crew shall immediately halt
work and act according to the instructions provided by the HSR.
The discovery of any condition that would suggest the existence of a situation more
hazardous than anticipated, shall result in the evacuation of the field team and re-
evaluation of the hazard and the level of protection required.
In the event that any member of the field crew experiences any adverse effects ;Or
symptoms of exposure while on the site, the entire field crew shall immediately halt
work and act according to the instructions provided by the site HSR. Follow-up action
shall be taken to correct the situation that caused the accident. The HSR then shall
complete an Accident Report.
Solid materials that are spilled will be scooped up, placed in appropriate containers and
held for disposal. Spilled liquids will be neutralized or containerized and held for
disposal. Prior to spill clean up, the Health and Safety Coordinator will be consulted to
confirm that employees are protected during that work.
4.3.3 Personal Injury
Site personnel will be trained in American Red Cross first aid procedures and shall administer
appropriate first aid treatment, including CPR, in emergency situations. The following general
emergency procedures shall be carried in the event of injury:
(1)
(2)
(3)
Notffy the HSR of the incident.
If the victim can be moved safely, remove him/her from the contaminated zone to the
decontamination zone using established control points.
Administer first aid.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 4
(4) Transport victim to nearest hospltal or emergency medical center .Q!: call for ambulance
transport, as appropriate.
NOTE: The HSR shall direct the removal of injured personnel from the contaminated
zone and shall approve any necessary deviation from established
decontamination procedures. Such deviation shall be based upon the severfy
or ltte threatening nature of the injury.
(5) Nottty the HSC of the incident and describe the emergency response actions taken. A
follow-up written report will be provided to the HSC and the Project Manager.
4.3.4 Chemical Exposure
Before entering a contaminated zone, all site personnel shall be thoroughly acquainted with the
types of toxic/hazardous chemicals present on site and their potential concentrations. The
following general procedures shall be followed for chemical exposure emergencies:
(1) Move the victim from the immediate area of exposure/contamination, taking precautions
to prevent additional exposure of other individuals.
(2) Nottty the HSR of the exposure incident.
(3)
(4)
(5)
If the victim can be moved safely, proceed to the decontamination zone through
established control points.
Decontaminate clothing or remove clothing tt safe to do so.
For skin or eye contact, thoroughly wash affected areas with water (eyes should be
flushed for at least 15 minutes).
For inhalation exposure, ensure that victim has adequate fresh air.
Administer additional first aid treatment as appropriate.
(6) Transport victim to nearest hospltal or emergency medical center .Q!: call for ambulance
transport as appropriate.
NOTE: The site HSR shall direct the removal of injured personnel from the
contaminated zone and shall approve any necessary deviation from established
decontamination procedures. Such deviation shall be based upon the securify
or ltte threatening nature of the injury.
(7) Nottty the HSD of the incident and describe the emergency response actions taken.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 4
4.3.5 Fire or Explosion
In the event of a fire or explosion:
(1)
(2)
(3)
(4)
Immediately evacuate injured personnel and leave the area,
Administer first aid as appropriate,
Notffy emergency services,
Notffy the HSC.
4.3.6 Emergency Contacts
The appropriate contact(s) from the following list shall be made for all emergency situations.
Emergency Service Telephone
Fire
EMS
Sheriff
Highway Patrol
911 / [phone]
911 / [phone]
911 / [phone]
911 / [phone]
911 / [phone]
[phone]
Richmond Memorial Hospital
NC Poison Control Center
NOTE: For ambulance, fire or police contacts, give the name of the road and
the nearest intersection. The street address for the Macon/Dockery
Stte is 5 Old Cheraw Road. The portable telephone on site will be
used for emergency notffications. For ambulance, fire or police
· contacts, give the name of the road and the nearest intersection.
The parable telphone on stte iwll be used for emergency notffications.
Richmond Memorial Hospital is located on Long Drive in
Rockingham, NC. From the stte take a left on Highway (Hwy) 1103.
Follow tt to Highway 1108 in Cordova. A Burlington plant is on the
left. Take a right on 1108 Follow tt to the intersection os US Hsy 1.
Take a left. Follow US 1 into Rockingham to the intersection wtth US
Hwy 74. Take a right on US 764. Follow tt for approximately 1.5
miles to Long Drive. Take a left on Long Drive. The hospttal should
be in sight. See map in Figure 4-1.
After contacting emergency services, project contacts designated at the beginning of this Health
and Safety Plan will be notified.
l:\WP\70\70017Z3.0&Micdf94 4-7
-- - ----11111'11 l!!!E l!i!i!I liiiiiiim ·. == == liiil liiiill ----
.m , ·10017.08 I • 0992
FIGURE 4-1
EMERGENCY HOSPITAL ROUTE
NOT TO SCALE
MACON/DOCKERY
CORDOVA, NC.
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE 'SECTION 5
Section 5
ROUTINE MONITORING, RECORDKEEPING, AND LABORATORY TESTING
The following section describes the routine rnonttoring, recordkeeping, and laboratory testing activtties
necessary to meet the requirements of US EPA's SOW under ttems 4 and 8 on pages 27 and 28. The
activtties will help to document and indicate whether the objectives of the ground water and soil
remediation systems described in the RD are being met for the Macon/Dockery Stte. The operator will
normally be on-stte once per week during the work week and will be remotely notttied by the autodialer
in case of emergency system shutdown.
5.1 Monitoring Activities and Schedule
5.1.1 Ground Water Remediation System
The routine monitoring activtties to be performed on the ground water remediation system are
summarized below.
I
TABLE 5-1
GROUND WATER TREATMENT SYSTEM MAINTENANCE
Activity I Schedule I Who
Check liquid level in accumulation tank Once per week and Operator
before each inttial
start up
Check direction of blower rotation Before each start up Operator
Check air pressure or air flow readings at 5-1 O minutes after Operator
blower for air stripper and inlet valve to start up and once per
centrttugal pump week
Check water flow rate through air stripper at Once per week Operator
flow recorder
Perform grab sampling of treated discharge Once per week Operator or Sampling
water (1,2-Dicholoroethane, 1, 1-Dichloroethene, Technician
Tetrachloroethene, Trichloroethane)
In addition, the daily and weekly schedule forms for the ground water system, {Appendix B), should
be completed as noted on those forms.
l:\WP\7017001723 O&Mlectt94 5-1
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 5
5.2
I
5.1.2 Soll Vapor Extraction System
Routine monttoring activtties pertormed on the SVE system are summarized in the
following table.
TABLE 5-2
SVE MAINTENANCE
Activity I Schedule I Who
Check air filter for the SVE at air intake and Once per month Operator
prior to vacuum untt
Damper opening on blower inlet air make-up Once per week Operator
Check flow in manhole between air stripper and Once per week Operator
infiltration gallery
Check manhole for no visible sheen or foam Once per week Operator cir Sampling
Technician
Check erosion, washout piping integrtty Once per week Operator or Sampling
Technician
In addition, the schedule forms for the SVE system (Appendix B) should be completed daily, at
start up and monthly thereafter.
Laboratory Testing
Sampling activtties will be pertormed on the treated ground water, the airstripper's, and SVE air
discharge. Samples of the treated ground water are obtained from the sample cocks located on the
treatment system discharge lines before the lines enter the manhole. The treated ground water sample
' will be analyzed by a certttied laboratory in conformance wtth the protocols contained in the March _1990
US EPA Contract Laboratory Program (CLP) Statements of Work for Organics (DOO Level Ill will
apply). The samples will be analyzed for the constituents listed in the Underground Injection Control
(UIC) permtt application. A copy of the UIC permit application is provided in Appendix K.
Results of the sampling analysis will be provided on a monthly routine to NC DEHNR using Discharge
Monitoring Report Forms (EPA Form 3320-1). Records will show the following information wtth regard
to the sampling:
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AMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
the date, time, and place of sampling.
the date and times of analyses performed,
the laboratory certification number and person(s) performing the analyses
the analytical techniques or methods used, and
the results of the required analyses.
OCTOBER 1994
SECTION 5
Records will be retained for a minimum of three (3) years, or longer if requesied by NC DEHNR.
Records will be maintained by the O&M contractor for inspection by NC DEHNR during normal
business hours.
Air samples are obtained at the:
property line
3 air strippers discharge stacks
SVE system's discharge stack
inlet line to the vacuum unit, and
individual SVE wells.
The sampling method includes directing a 5-liter air sample through a glass tube containing activated
carbon. The glass tube is then sent to a certified laboratory for analysis. Seciotn 3.1.4 of the
Performance Standards Verification Field Sampling and Anlysis Plan for Soil Vapor Extraction describes
this sampling tecdhnique in further detail.
Air sampling will be conducted weekly for the firsyt month, monthly for the first six months, and
quarterly thereafter. The laboratory will use the OSHA 07 mehtod of anlysis, which is equal to the
MiOSH 1501 Method, for the analY,sis of each carbon-filled tube.
I.\WP\70\7001723.0&M/cctl94 5-3
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 5
The following table summarizes the test parameters for each sample location
TABLE 5-3
AIR SAMPLE TEST PARAMETERS
Macon Airstripper X X X X X
Lower Dockery Airstripper X X X X X
Upper Dockery Airstripper X X X X X
SVE Discharge X X X
SVE Inlet X X X
SVE Wells X
The operator or Project Manager will report any non-compliance with the conditions or limitations '.of the
UIC permit which may endanger public health or the environment. The operator or Project Manager
will nottty NC DEHNR within 24 hours of becoming aware of such conditions. A written follow-up will be
submitted within five (5) days of becoming aware of such conditions. Part 11.B.2 of the draft NPDES
permit addresses specttic non-compliance reporting tasks.
5.3 Personnel and Maintenance Records
Logs and reports sufficient to document the implementation and execution of the personnel protection
programs shall be maintained. This documentation shall consist of medical surveillance files, training
files, daily logs and accident reports.
5.3.1 Medical Surveillance
Confidential medical surveillance files will be maintained by the O&M Contractor of the site
operator. These files will document employee participation in a medical surveillance program
and fitness to work on hazardous sites. Access to these files and records will be strictly
controlled by the O&M Contractor.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 5
5.3.2 Training
Documentation of employee training will be maintained in the Health and Safety files under the
direction of the O&M Contractor. These files will be used to document employee participation,
level of training achieved, and any follow-up or refresher instruction received by the employee.
5.3.3. Work Logs
Weekly work logs shall be maintained by the O&M Contractor. Copies of weekly logs shall be
forwarded to the Project Manager or the HSC on request. The weekly_ log shall contain:
Date,
Area(s) or stte(s) worked,
List of employees by area and hours exposed,
Personal protective equipment utilized by employees,
Results of monttoring tests,
Any waste materials removed from work area(s},
List of equipment decontaminated, and
Description of special or unusual events or incidents, including all first aid treatments
not otherwise reportable.
Work logs shall be checked and approved by the O&M Contractor. Any incident resulting in a
work stoppage shall be fully documented in a report prepared by the O&M Contractor and•
submitted to the Project Manager.
5.3.4 Accident Reporting
In addition to descriptions in the work log and work stoppage reports, any accident and/or
chemical exposure incident shall be investigated, analyzed and documented in an accident
investigation report submitted to the Project Manager. These reports, prepared by the O&M
Contractor shall contain a full description and analysis of the incident, including exposure work-
hours and a log of occupational injuries and illnesses (OSHA Form 200 or equivalent as
prescribed by 29 CFR 19904).
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 5
5.4
Formal accident reports shall be prepared for any diagnosed illness or injuries that result in a
lost work day or fataltty. The accident report shall identtty all contributing causes and
recommend future hazard control measures to reduce the risk of recurrence.
Persons on stte are responsible for reporting all injuries as soon as possible to the O&M
Contractor or the Project Manager.
5.3.5 Maintenance Records
Records and logs will be maintained and based on actual system maintenance activtties
performed. Information to be recorded should include costs, downtime (if any), equipment type,
date. personnel utilized for maintenance activities, cause for non-preventive maintenance and
whether preventive measures or improvements could be made to resolve the cause, and
system condttion data prior to and following the maintenance work.
Systems Reporting
The following data sheets are to be used for systems monttoring and reporting for the ground water and
soil vapor treatment systems. These sheets are also provided in Appendix C of this plan.
t\WP\ 70\ 7001723. O&.Mlcdl94 5-6
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 5
VACUUM UNIT
OPERATIONAL READINESS CHECKLIST
POWER SUPPLY
Trace power lines and check that all connections have been made
Locate and vertty that all circutt breakers are in off posttion
Locate grounding rod and vertty that equipment is adequately grounded
Locate and tag the three wire leads to motor for motor rotation check
UNIT COMPONENTS
Vertty that maintenance check has been pertormed and any outstanding
ttems have been completed
Drain condensate trap of any liquids and close drain valve
Examine betts and sheaves for tightness and alignment
Check betts and sheaves for easiness of rotation
Check bett guard is in place and provides total enclosure
PIPING
Check all flange botts for tightness
Check all gaskets for alignment and signs of fatigue (cracking, splitting,
discoloration)
Vemy that all suction and vent valves are fully open
Remove any loose objects from intakes
Check discharge piping and stack for obstructions
Temperature gauge reading
SAFETY
Ear protection available
Vapor monitoring equipment available
l:\WP\70\7001723 O&Mlcdl94 5.7
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MACON/DOCKERY SITE
Operator:
VAPOR FLOW RATES
Vacuum Manttold:
Air Intake:
VACUUM READINGS
Vacuum Manttold:
Air Intake:
Across lnline Filtration
H2O
COMMENTS:
1:\Wf'\70\7001723. O&.Mlcdt94
VACUUM UNIT PERFORMANCE
Table No.----
Date:
Time:
TEMPERATURES
CFM Vacuum Manttold:
CFM Air Intake:
VAPOR SAMPLES
inches H2O Vacuum Manttold Sample No.
•F
•F
inches H,O Discharge Stack Vapor Sample No.
inches
5-8
OCTOBER 1994
SECTION 5
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AMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
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SVE WELL
PRODUCTION LOG
WELL NO.
OPERATOR: DATE:
Time Vacuum Flow
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OCTOBER 1994
SECTION 5
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE SECTION 5
SVE WELL SAMPLING LOG
Operator: Date:
SVE WELL SAMPLE TIME SAMPLE NUMBER SAMPLE VOLUME SAMPLE TYPE •
VE-01
OW-1
OW-2
OW-3
OW-4
OW-5
COMMENTS
• Sample Type = charcoal tube, tedlar bag, glass cylinder, other (explain)
l:IWP\70\7001723. OA.Mlcdt94 5-10
Operator: _____________ _
VACUUM MONITORING
WELL LOG
-·· ··········-·"'"· ..
:_ruil _-. :-:-.-.--::.:~. -,., .
TIME VE-01 OW-1 OW-2
SheM ~---
Date: ______ _
.• /A1 .. _
OW-3 OW-4 OW-5
Vacuum Flow Rate Vacuum Flow Rate Vacuum Flow Rate Vacuum Flow Rate Vacuum Flow Rate Vacuum Flow Rate
--
-
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RMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
APPENDIX A
PROCESS INSTRUMENTATION AND CONTROL APPROACH
l:\WP\ 70\7001723. O&Mledt94
OCTOBER 1994
APPENDIX A
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MACON/DOCKERY SITE
A.1 Macon Ground Water Remediation System
LOWER MACON (P&ID 7001721-K01)
Recovery Wells (LM-1 thru LM-4)
OCTOBER 1994
APPENDIX A
Lower Macon consists of a series of four six-inch recovery wells. Water is removed from the wells via
' a jet pump system. Recirculation Pump P-1001 pumps water through a jet pump at the bottom of the
wells which suctions water out of the wells and into the return piping. At each well is a valve/meter_ pit.
Within the pit on the inlet line there is local pressure indication, local flow indication, and a ball valve.
Within the pit on the discharge line there is local pressure indication, a check valve, and a globe valve.
Turn Around Manhole
Circulating water from Tank T-1001 that does not enter the Recovery Wells' inlet line and exit by the
discharge line, enters the return piping to Tank T-1001 through the turn around piping in the Turn
Around Manhole. There is a globe valve and local pressure indicator Pl-1203 located in the Manh9le.
Recirculation Pump P-1001
Pump P-1001 supplies a circulating flow from Tank T-1001. P-1001 has H-O-A switch HS-1109 and
motor alarm MA-1109 located on the Macon Control Panel (MCP). A check valve, ball valve and local
pressure indicator Pl-1110 are located at the pump discharge. In AUTO Pump P-1001 will STOP and
issue alarms if the level in Tank T-1001 reaches Low Level LSL-1201 or High-High Level LSHH-1201, tt
Blower B-1001 STOPS, or tt one of the Metal Removal Columns has High Differential Pressure. In
AUTO the Pump will START at High Level LSH-1201 in Tank T-1001. In HAND P-1001 will run without
any interlocks .
Filter BF-1001
If the filter becomes too full, Differential Pressure Switch dPISH-1202 will issue alarm dPAH-1202 which
is located on the Macon Control Panel.
Feed Tank T-1001
The ground water recovery system for Lower Macon discharges into Tank T-1001 and overflows by
gravity to Air Stripper AS-1001. Level transmitter LIT-1201 is located at Tank T-1001. Level indicator
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX A
Ll-1201 is located on the Macon Control Panel. LSL-1201, LSH-1201 and LSHH-1201 are within the
Macon Control Panel and are not located in the programmable logic controller (PLC).
UPPER MACON (P&ID 7001721•K01)
Recovery Wells (UM-1 thru UM-7)
Upper Macon consists of a series of seven six-inch recovery wells. Water is removed from the wells
via a jet pump system. Pump P-1003 pumps water through a jet pump at the bottom of the wells which
suctions water out of the wells and into the return piping. At each well is a valve/meter pit. Within the
pit on the inlet line there is local _pressure indication, local flow indication, and a ball valve.
Turn Around Manhole
Circulating water from Tank T-1002 that does not enter the Recovery Wells' inlet line and exit by the
discharge line, enters the return piping to Tank T-1002 through the turn around piping in the Turn
Around Manhole. There is a globe valve and local pressure indication P-1206 located in the Manhole.
Recirculation Pump P-1003
Pump P-1003 supplies a circulating flow from Tank T-1002. P-1003 has H-O-A switch HS-1119 and
motor alarm MA-1119 located on the Macon Control Panel (MCP). A check valve, ball valve and local
pressure indicator Pl-1120 are located at the pump discharge. In AUTO pump P-1003 will STOP and
issue alarms if the level in Tank T-1002 reaches Low Level LSL-1204 or High-High Level LSHH-1204, tt
Blower B-1001 STOPS, or tt one of the Metal Removal Columns have High Differential Pressure. In
AUTO the Pump will START at High Level LSH-1204 in Tank T-1002. In HAND P-1003 will run without
any interlocks.
Fiber BF-1002
If the fiber becomes too full, Differential Pressure Switch dPISH-1205 will issue alarm dPAH-1205 which
is located on the Macon Control Panel.
Feed Tank T-1002
The ground water recovery system for Upper Macon discharges into Tank T-1002 and overtlows by
gravity to Air Stripper AS-1001. Level transmitter LIT-1204 is located at Tank T-1002. Level indicator
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX A
Ll-1204 is located on the Macon Control Panel. LSL-1204, LSH-1204 and LSHH-1204 are within the
Macon Control Panel and are not located in the programmable logic controller (PLC).
UPPER AND LOWER MACON
Air Strtpper AS-1001
Tanks T-1001 and T-1002 overflow by gravity to Air Stripper AS-1001. The reservoir in the bottom of
AS-1001 supplies water for Pump P-1002 to Bag Fitter BF-1003 and Metals Removal Columns
MR-1001, MR-1002, MR-1003 and MR-1004. In AUTO the reservoir low level switch LSL-1303 will
STOP Pump P-1002 and high level switch LSH-1303 will START Pump P-1002. High-high level switch
LSHH-1303 in the Stripper will STOP Pumps P-1001 and P-1003. Level alarm LAHH-1303 is located
on the Macon Control Panel.
Blower B-1001
Blower B-1001 provides the air for AS-1001. H-O-A switch HS-1304 is located at the blower. Motor
run alarm MA-1304 is on the Macon Control Panel. Local flow switch FSL-1304 (FWE -Furnished With
Equipment) located at the blower discharge monitors the presence of air flow to the AS-1001. In AUTO
FSL-1304 will STOP Pumps P-1001 and P-1003. In HAND B-1001 will run without any interlocks.
With H-O-A in AUTO high dttferential pressures in the Metal Removal Columns sends an alarm to the
Macon Control Panel and shuts down P-1001, P-1002, P-1003 and Blower B-1001.
Effluent Pump P-1002
Pump P-1002 supplies flow to the Metals Removal Columns. The suction source for P-1002 is the
reservoir in AS-1001. P-1002 has H-O-A switch HS-1305 and motor alarm MA-1305 located on the
Macon Control Panel. Local pressure indicator Pl-1306 is located at the pump discharge. Low level
switch LSL-1303 in AS-1001 will shut OFF Pump P-1002. Pump P-1002 will START when the reservoir
level reaches a High Level LSH-1303. Pump P-1002 will STOP tt either of the Metal Removal Columns
are unable to operate due to High Differential Pressure. In HAND P-1002 will run without any
interlocks.
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RMT OPERATIONS AND MAINTENANCE Pl.AN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX A
Fitter BF-1003
If the filter becomes too full, Differential Pressure Swttch dPISH-1307 will issue alarm dPAH-1307 which
is located on the Macon Control Panel.
Discharge Flow Measurement
Flow leaving Bag Filter BF-1003 to the Metal Removal Columns will be totalized and indicated by
FQl-1308. Both indications will be displayed on the Macon Control Panel.
Metals Removal MR-1001, MR-1002, MR-1003 and MR-1004
Water from P-1002 is pumped through the ion exchange columns. Series connected MR-1001 and
MR-1002 operate in parallel wtth series connected MR-1003 and MR-1004.
Wtth H-O-A in AUTO high differential pressures in the Metal Removal Columns sends an alarm to the
Macon Control Panel and shuts down P-1001, P-1002, P-1003 and Blower B-1001.
A.2 Lower Dockery Ground Water Remediation System (P&ID 7001721-K02)
Recovery Wells (LD-1 thru LD-4)
Lower Dockery consists of a series of four six-inch recovery wells. Water is removed from the wells via
a jet pump system. Pump P-2001 pumps water through a jet pump at the bottom of the wells which
suctions water out of the wells and into the return piping. At each well is a valve/meter ptt. Within the
ptt on the inlet line there is local pressure indication, local flow indication, and a ball valve. Wtthin the
pit on the discharge line there is local flow indication, a check valve, and a globe valve.
Tum Around Manhole
Circulating water from Tank T-2001 that does not enter the Recovery Wells' inlet line and extt by the
discharge line, enters the return piping to Tank T-1002 through the turn around piping in the Turn
Around Manhole. There is a globe valve and local pressure indication P-2203 located in the Manhole.
Recirculation Pump P-2001
Pump P-2001 supplies a circulating flow from Tank T-2001. P-2001 has H-O-A swttch HS-2109 and
motor alarm MA-2109 located on the Lower Dockery Control Panel (LDCP). Local pressure indicator
Pl-2110 is located at the pump discharge. In AUTO Pump P-2001 will STOP and issue alarms if the
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX A
level in Tank T-2001 reaches Low Level LSL-2201 or High-High Level LSHH-2201, ff Blower B-2oq1
' STOPS, or ff one of the Metal Removal Columns have High Differential Pressure. In AUTO the Pump
will START at High Level LSH-2201 in Feed Tank T-2001. In HAND P-2001 will run without any
interlocks.
Fitter BF-2001
If the filter becomes too full, Differential Pressure Switch dPISH-2002 will issue alarm dPAH-2002 which
is located on the Lower Dockery Control Panel.
Feed Tank T-2001
The ground water recovery system for Lower Dockery discharges into Tank T-2001 and overflows by
gravity to Air Stripper AS-2001. Level transmitter LIT-2201 is located at Tank T-2001. Level indicator
Ll-2201 is located on the Lower Dockery Control Panel. LSL-2201, LSH-2201 and LSHH-2201 are
located in the programmable logic controller (PLC).
Air Stripper AS-2001
Tanks T-2001 overflows by gravity to Air Stripper AS-2001. The reservoir in the bottom of AS-2001
supplies water for Pump P-2002 to pump through Bag Filter BF-2002 and Metals Removal Columns
MR-2001 and MR-2002. In AUTO the reservoir low level switch LSL-2303 will STOP Pump P-2002 and
high level switch LSH-2303 will START Pump P-2002. High-high level switch LSHH-2303 in the
Stripper will STOP Pump P-2001. Level alarm LAHH-2303 is located on the Lower Dockery Contro_l
Panel.
Blower B-2001
Blower B-2001 provides the air for AS-2001. H-0-A switch HS-2304 is located at the blower. Motor
run alarm MA-2304 is on the Lower Dockery Control Panel. Local Low Flow Switch FSL-2304 (F"'.'E)
located at the blower discharge monitors the presence of air flow to the AS-2001. Low Flow Switch
FSL-2304 will STOP Pumps P-2001 and P-2002. In HAND B-2001 will run without interlocks.
With H-O-A in AUTO high dffferential pressures in the Metal Removal Columns sends an alarm to the
Lower Dockery Control Panel and shuts down P-2001, P-2002, and Blower B-2001.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX A
Effluent Pump P-2002
Pump P-2002 supplies flow tor the Metals Removal Columns MR-2001 and MR-2002. The suction
source for P-2002 is the reservoir in AS-2001. P-2002 has H-O-A switch HS-2305 and motor alarm
MA-2305 located on the Lower Dockery Control Panel. Local Pressure Indicator Pl-2306 is located at
the pump discharge. In AUTO Low Level Switch LSL-2303 in AS-2001 will shut OFF Pump P-2002.
Pump P-2002 will Start when the reservoir reaches a High Level LSH-2303. Pump P-2003 will STOP tt
MR-2001 and MR-2002 are unable to operate due to a High Differential Pressures across the columns.
The outlet valve of Pump P-2002 will be adjusted to sufficiently reduce flow to prevent fast cycling of
P-2002.
Filter BF-2002
' It the tilter becomes too full, Differential Pressure Switch dPISH-2307 will issue alarm dPAH-2307 which
is located on the Lower Dockery Control Panel.
Discharge Flow Measurement
Pump P-2002 discharge flow rate to the Columns will be measured. Totalized flow and instantaneous
flow from FQl-2308 will be displayed on the panel.
Metals Removal Columns MR-2001 and MR-2002
Water from P-2002 is pumped through the Metals Removal Columns. The Columns operate in series.
With H-O-A in AUTO high dttlerential pressures in the Metal Removal Columns sends an alarm to the·
Lower Dockery Control Panel and shuts down P-2001, P-2002, and Blower B-2001.
A.3 Upper Dockery Ground Water Remediation System (P&ID 7001721-K03)
Recovery Wells (UD-1 thru UD-6)
Upper Dockery consists of a series of six six-inch recovery wells. Water is removed from the wells via.
submersible pumps located in each well. Each submersible pump has a local control panel with a
manual start switch and level probes to maintain the proper water table elevation in each well, as
indicated on the drawings. A motor alarm is present which alarms at the local panel and on the Upper
Dockery Control Panel (UDCP) at the Treatment System Pad. If High Level Switch LSH-3201 in Tank
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX A
T-3001 is activated, the Recovery Well pumps will STOP and alarm LAH-3201 will be issued. High-
high Level Switch LSHH-3303 and Low Flow Switch FSL-3304 in Air Stripper AS-3001 will STOP the
Well Pumps.
At each well is a vendor supplied local control panel and level sensor. The local control panel has an
isolated contact which signals the PLC when the pump is running. The Panel will receive an isolated
contact from the PLC giving permission to operate.
Filter BF,3001
It the filter becomes too full, Differential Pressure Switch dPISH-3202 will issue alarm dPAH-3202 which
is located on the Upper Dockery Control Panel.
Feed Tank T-3001
The ground water recovery system tor Upper Dockery discharges into Tank T-3001. The Tank
overflows by gravity to Air Stripper AS-3001. Level transmlt1er LIT-3201 is located at Tank T-3001.
Level indicator Ll-3201 is located on the Upper Dockery Control Panel. LSL-3201, LSH-3201 and
LSHH-3201 are within the Upper Dockery Control Panel and are not located in the programmable logic
controller (PLC).
Air Stripper AS-3001
Tank T-3001 overflows by gravity to Air Stripper AS-3001. The reservoir in the bottom of AS-3001
supplies water tor Pump P-3002 to pump through Bag Filter BF-3002 and Metals Removal Columns
MR-3001 and MR-3002. In AUTO, the reservoir low level switch LSL-3303 will STOP Pump P-3002
and high level switch LSH-3303 will START Pump P-3002. High-high level switch LSHH-3303 in the ,
Stripper will STOP all Well Pumps. Level alarm LAHH-3303 is located on the Upper Dockery Control
Panel.
Blower B-3001
Blower B-3001 provides the air for AS-3001. H-O-A switch HS-3304 is located on the Upper Dockery
Control Panel. Motor run alarm MA-3304 is on the Upper Dockery Control Panel. Local Low Flow
Switch FSL-3304 (FWE) located at the blower discharge monitors the presence of air flow to AS-3001.
In AUTO FSL-3304 will STOP Pumps P-3001 and P-3002. In HAND B-3001 will run without interlocks.
I :\WP\ 7017001723. O&Mlccff94
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX A
With H'O-A in AUTO high differential pressures in the Metal Removal Columns sends an alarm to the
Upper Dockery Control Panel and shuts down the Well Pumps, P-3002 and Blower B-3001.
Effluent Pump P-3002
Pump P-3002 supplies flow for the Metals Removal Columns MR-3001 and MR-3002. The suction
source for P-3002 is the reservoir in AS-3001 . P-3002 has H-O-A switch HS-3305 and motor alarm
MA-3305 located on the Upper Dockery Control Panel. Local Pressure Indicator Pl-3306 is located at
the pump discharge. In AUTO Low Level Switch LSL-3303 in AS-3001 will shut OFF Pump P-3002.
Pump P-3002 will START when the reservoir level reaches High Level LSH-3303. P-3002 will STOP if
MR-3001 and MR-3002 are unable to operate due to High Differential Pressure across the columns:
In HAND P-3002 will run without any interlocks.
The outlet valve of Pump P-3002 will be adjusted to sufficiently reduce flow to prevent fast cycling of
P-3002.
Filter BF-3002
If the filter becomes too full, Dijferential Pressure Switch dPISH-3307 will issue alarm dPAH-3307 which
is located on the Lower Dockery Control Panel.
Discharge Flow Measurement
Pump P-3002 discharge flow rate to the Columns will be measured. Totalized flow and instantaneous
flow from FQl-3308 will be displayed on the panel.
Metals Removal Columns MR-3001 and MR-3002
Water from P-3002 is pumped through the Metals Removal Columns. The Columns operate in series.
With H-O-A in AUTO high differential pressures in the Metal Removal Columns sends an alarm to the ..
Upper Dockery Control Panel and shuts down P-3001, P-3002 and Blower B-3001.
I.\WP\717,70017Z3 O&.M1cdf94
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX A
A.4 Macon Soll Remediation System (Refer to Drawing )
The soil remediation system is automated through relays provided by the vendor. The system relays
shut the system down in the event of a system malfunction. Monitored values include the water level in
the condensate trap and temperature of the gases downstream from the pump and the motor function
of the vacuum pump. If any of these values deviate outside of their specified operating range limits the
system will shut down.
l:IWP\70\7001 723. O&.Mleclt94
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RMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
APPENDIX B
NC DEHNR BAQC AIR POLLUTION SOURCE REGISTRATION
l.\WP\ 70\ 7001723. O&Micctl94
OCTOBER 1994
APPENDIX B
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX B
The Macon/Dockery site is located in Richmond County, North Carolina. This county is, as of March
1994, in compliance or attainment with ozone (O,) Air Quality Standards. Since this facility is in
attainment for ozone, no pollution control equipment will be required for the Soil Vacuum Extraction unit
or the Air Stnpper/Shallow Tray units.
Based on telephone conversations with personnel from the North Carolina DEHNR Air Quality Division,
North Carolina Administrative Code, Chapter 2 -Environmental Management, Subchapter 2D -Air
Pollution Control Requirements, Section 0.0202 -Registration of Air Pollution Sources, Subsection (b),
which requires registration of emission sources, applies to this site. This section lists ten requirements
that must be fuffilled for registration of an emission source. These requirements include the following:
1. the name of the person, company, or corporation operating sources;
2. the address, location, and county;
3. principal officer of the company;
4. quantities and kinds of raw materials used;
5. process flow sheets;
6. operating schedules;
7. total weights and kinds of air pollution released;
8. types and quantities of fuels used;
9. stack heights; and
10. other information considered essential in evaluating the potential of the source to cause air
pollution.
Registration of emission sources to be constructed during the Macon/Dockery Site Remedial ·
Action will be the responsibility of the Remedial Action contractor.
North Carolina also enforces Subchapter 2D -Air Pollution Control Requirements, Section
0.0518 -Miscellaneous Volatile Organic Compound Emissions, Subsection (d), which allows up
to 40 pounds of VOC emissions per day (24 hours) from each site without requiring air pollution
control equipment. Emissions were calculated for each of the units involved. The sum of
emissions from the three ground water treatment units and the SVE unit is not expected to
approach 40 pounds per day. The SVE unit emissions are calculated to be 1.6 pounds of VOC
per day, and the air stripper emissions are calculated, using the Airstrip® model output, to be
0.6 pounds of VOC per day. Therefore, the total calculated emission rate is approximately 2.2
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX B
pounds of voe per day, and no air pollution control equipment will be required for the
proposed remediation systems.
North Carolina Air pollution rules {15A NCAC 2D.1104) require permitting for the emission of
toxic VOCs for any faciltty whose actual emissions from all sources are greater than any one of
the emission rates listed in 15A NCAC 2H.0600 {h). For faciltties emitting toxic VOCs in
quantities less than the 2H.0600 regulation, the faciltty must register wtth the State.
The compounds listed in 2H.0600 were compared wtth estimated ground water composttions at
the Macon/Dockery Site, and projected worst case air emission rates for each of the three air
strippers were calculated. Tables 3-2, 3-3, and 3-4 summarize air stripper air emission rates
for the Macon, Upper Dockery and Lower Dockery air strippers, respectively. Table 3-5 shows
the combined projected worst case air stripper air emission rates, and Table 3-6 presents
projected worst case air emission rates from the Soil Vacuum Ex1raction Untt.
Table 3-7 shows the projected worst case air emission rates from all emission sources at the
Macon/Dockery Site. All of these are below the thresholds for individual air toxics regulated by
l;\WF'.70'17'001723.0&M/cctf94
--- ---- ------11!!1!!1
TABLE ~2 WORST CASE AIR EMISSION RATES MACON AIR sm1PPER INFLUENT
POUNDS PER 15 MINUTE POUNDS PER DAY POUNDS PER YEAR CornDound Flow (Cfpm) Cone, (ug/1) Actual Threahotd Actual ThrHhOld Actual ThtHhold Benzene 48 0.52 3.26e-06 NV 3.13e-04 NV 1.14e-01 8.1 Tetrachloroethene 48 1.90 1.19e-05 NV 1.14e-03 NV 4.17e-01 13000 T richloroethene 48 6.30 3.95e-05 NV 3.79e-03 NV 1.38e+OO 4000 Toluene 48 2.70 1.69e-05 3.60 1.62e-03 98 5.93e-01 NV Vinvl chloride 48 0.00 0.00 NV 0.00 NV 0.00 26 Xylenes 48 5.90 3.70e-05 4.10 3.55e-03 57 1.29e+OO NV
TABLE 3--3 WORST CASE AIR EMISSfON RATES UPPER DOCKERY AIR STRIPPER INA.UENT
POUNDS PER 15 MtN\ITE POUNDS PER DAY POUNDS PER YEAR Compound Flow(gpm) Cone. (ug/1) Actual Threshold Actual ,.....,, ... Actual -•Id Benzene 6 0.00 0.00 NV 0.00 NV 0.00 8.1 T etrachloroothene 6 1.70 1.33e-06 NV 1.28e-04 NV 4.66e-02 13000 Trichloroethane 6 2.50 1.96e-06 NV 1.88e-04 NV 6.86e-02 4000 Toluene 6 2.00 1.57e-06 3.60 1.SOe-04 98 5.49e-02 NV Vinyl chloride 6 0.00 0.00 NV 0.00 NV 0.00 26 Xy)enes 6 25.00 1.96e-05 4.10 1.88e-03 57 6.86e-01 NV
TABLE3-4 WORST CASE AIR EMISStoN RATES LOWER DOCKERY AtR smrPPER rNFLUENT
POUNDS PER 15 MINUTE POUNDS PER DAY POUNDS PER YEAR Compound Flow (gpm) Cone. (ug/1) Actual ThrHhokl Actual -•Id Actual ,.....,, ... Benzene 28 0.25 9.14e-07 NV 8.77e-05 NV 3.20e-02 8.1 Tetrachloroethene 28 0.00 0.00 NV 0.00 NV 0.00 13000 Trichloroethene 28 1.25 4.57e-06 NV 4.38e-04 NV 1.60e-01 4000 Toluene 28 0.00 0.00 3.60 0.00 98 0.00 NV Vinyl Chloride 28 0.00 0.00 NV 0.00 NV 0.00 26 Xylenes 28 0.25 9.14e-07 4. 10 8.77e-05 57 3.20e-02 NV NV = No Value Given
l:IWP\70\.7001723. O&Mlcdf94
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER'1994
MACON/DOCKERY SITE APPENDIX 8
TABLE 3-5 COMBINED AIR STRIPPER WORST CASE AIR EMISSION RATES
Pounds per 15 minutes Pounds per day Pounds per year
Compound Actual Threshold Actual Threshold Actual Threshold
Benzene 4.17E-6 NV 4.01 e-04 NV 1.46e-01 8.1
Tetrachloroethene 1 .32E-5 NV 1 .27e-03 NV 4.64e-01 13000
Trichloroethane 4.60E-5 NV 4.42e-03 NV 1.61 4000
Toluene 1.85E-5 3.60 1.77e-03 98 6.46e-01 NV
Vinyl chloride 0.00 NV 0.00 NV 0.00 26
Xylenes 5.75E-5 4.10 5.52e-03 57 2.01 NV
TABLE 3-6 SVE UNIT WORST CASE AIR EMISSION RATES
.
Pounds per 15 minutes Pounds per day Pounds per yaar
Comcound Actual Threshold Actual Threshold Actual Threshold
Benzene 2.8E-7 NV 2.7E-5 NV 9.9E-3 8.1
Tetrachloroethene 4.3E-3 NV 0.42 NV 153 13000
Trichloroethene 6.9E-6 NV 6.63E-4 NV 2.4E-1 4000
Toluene 2.4E-5 3.60 2.3E-3 98 8.4E-1 NV
Vinyl chloride 0.00 NV 0.00 NV 0.00 26
Xylenes 2.1 E-3 4.10 0.20 57 73 NV
TABLE 3-7 MACON/DOCKERY SITE WORST CASE AIR EMISSION RATES
Pounds per 15 minutes Pounds per day Pounds per year
Compound Actual Threshold Actual Threshold Actual Threshold
Benzene 4.3E-6 NV 4.1 E-4 NV 1.6E-1 8.1 :
T etrachloroethene 4.4E-3 NV 4.21 E-1 NV 153.4 13000
Trichloroethane 5.3E-5 NV 5.1 E-1 NV 1.85 4000
Toluene 4.2E-5 3.60 4.2E-3 98 1.50 NV
Vinvl chloride 0.00 NV 0.00 NV 0.00 26
Xylenes 2.1 E-3 4.10 2.1 E-1 57 75 NV
NV a No Value Given
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX C
APPENDIX C
RECORDS AND REPORTING DATA SHEETS
l:\WP\70\7001723. O&Mlcdf94
- - - - - - - --.. -l!!i!!il == liiiii, -- --..
WEEKLY CHECK OF GROUND WATER REMEDIATION SYSTEM
1 Is there any erosion at Infiltration Gallery?
2 Is the diffuser and all related equipment functioning properly? (Check for
turbulence or visible sheen or loam that may indicate problems.)
3 Flow reading on the discharge pipe
4 Pressure in the sump tank of the air stripper
5 Is there any erosion on the grade between the air stripper and the creek?
6 Pressure reading on System A's centrifugal pump and check for any visible
irregularities.
7 Pressure reading on System B's centrifugal pump and check for any visible
irregularities.
8
9
10
11
a) Pressure into Well 101 (found in well vautt)
b) Flow into Well 101 (101A)
C) Flow out Well 101 (101B)
a) Pressure into Well 102 (found in well vautt)
b) Flow into Well 102 (102A)
c) Flow out Well 102 (102B)
a) Pressure into Well 103 (found in well vautt)
b) Flow into Well 103 (103A)
c) Flow out Well 103 (103B)
a) Pressure into Well 104 (found in well vautt)
b) Flow into Well 104 (104A)
c) Flow out Well 104 (104B)
Check an readings with the previous day's and note any differences and reason for that difference.
For any eq~ipment needing repair, indicate action taken to initiate these repairs.
l:\WP\ 70\7001 723. O&M!c:df94
Date __ / __ / __
--,_ --l!!l!l!I --li!!iil -= == . ·. iiiii liiiii -- - --liill
DAILY CHECK OF GROUND WATER REMEDIATION SYSTEM -···· ?
12
13
14
15
16
17
18
a) Pressure into Well 105 (found in well vauh)
b) Flow into Well 105 (105A)
c) Flow out Well 105 (105B)
a) Pressure into Well 106 (found in well vauh)
b) Flow into Well 106 (106A)
c) Flow oU1 Well 106 (106B)
a) Pressure into Well 107 (found in well vauh)
b) Flow into Well 107 (107A)
C) Flow oU1 Well 107 (107B)
a) Pressure into Well 201 (found in well vauh)
b) Flow into Well 201 (201 A)
C) Flow oU1 Well 201 (201 B)
a) Pressure into Well 202 (found in well vauh)
b) Flow into Well 202 (202A)
c) Flow oU1 Well 202 (202B)
a) Pressure into Well 203 (fourid in well vauh)
b) Flow into Well 203 (203A)
C) Flow oU1 Well 203 (203B)
a) Pressure into Well 204 (found in well vauh)
b) Flow into Well 204 (204A)
C) Flow oU1 Well 204 (204B)
Check an readings with the previous day's and riote any ctitt9rences and reason for that difference.
For any equipment needing repair, indicate action taken to initiate these repairs.
l:\WP\70\7001723.0&Mlodf94
Page 2 of 2
olaE~eio,~a\ i,-Ill ij\ijiH;t\l,f
-111111a l!!!i!!!! -= == .liiiiil tiiii -- -,_ .. -
WEEKLY CHECK OF SVE SYSTEM
1 Stack: Is there any apparent damage?
2 Is the discharge silencer functioning normally (are there any unusual noises)?
3 Pressure between discharge silencer and vacuum pump (Pl 1300)
4 Temperature between discharge silencer and vacuum pump Tl 1300
5 Is the vacuum pump functioning normally?
6 Is the inlet silencer functioning normally?
7 What is the pressure reading on the air intake (Pl 1202)?
8 What is the flow reading on the air intake (Fl 1202)?
9 Is the air intake operating normally (how there been any vandalism)?
1 0 What is the differential pressure across the in-line filter?
11 Does the filter function normally? II not, filter may need to be replaced.
12 Where is the water level in the condensate trap? (II it is at the high port, it
must be emptied into air stripper. See maintenance section of O&M.)
13 Is the condensate trap functioning normally?
14 Is there any erosion across the system? (Around the wells, piping, or unit.)
Check aR readings with the previous day's and note any major differences and reason for that difference.
For any equipment needing repair, indicate action taken to. initiate these repairs.
l:\WP\70\ 7001723. O&Mlodl94
Date __ ! __ ! __
--l!ii!B !11111 == ;;;a . liiiiiil --- -·-..
WEEKLY CHECK FOR GROUND WATER SYSTEM
Is there any vandalism on the system or on the site? (List location and extent
of damage.)
2 Check each tray of the air stripper for any mineral deposits, or bacterial
growth: or corrosion.
3 Is there any erosion across the system? (List location and extent around
wells, manholes, piping, concrete equipment pad, near the discharge at the
creek.)
4 Are there any visual indications of fluid leaks near the equipment, piping, or
discharge of the system? (treated or untreated ground water, lubricating oils)
Check an information with the previous week's recordings and note any major differences.
For any necessary corrective action, indicate action taken to initiate maintenance.
l:\WP\7(1..7001723.0& Mlodl94
Week of __ / __ / __ to __ / __ / __ -
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GROUND WATER PUMP MAINTENANCE TABLE
Chan e oil
has been idle
Re rease bearin s
has been idle
has been idle
has been idle
Re rease bearin s
Check foundation & hold down bolts for ti htness
Check pump capactty, pressure & power against
specttications
Repeat this schedule for every [3 month or 3000 hrs]
NOTE: Initial each task following tts completion.
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PROCEDURE
Add oil to fill mark at start-up
Change oil first 100 hours
Change oil every 1000 hours
of operation
PROCEDURE
Check oil level in gear
and add lubricant tt
necessary
l:\WP\70\7001723. O&.M/cdt94
SVE PUMP MAINTENANCE TABLE
INITIALS DATE
INITIALS DATE
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PUMP MAINTENANCE TABLE
Chan e oil
has been idle
has been idle
has been idle
has been idle
Check foundation & hold down bolts for ti htness
Check pump capacity, pressure & power against
specttications
Repeat this schedule for every (3 months or 3000 hrs)
NOTE: Initial each task following Its completion.
l:\WP\70\7001723 O&M/cd!94
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I AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994 MACON/DOCKERY SITE APPENDIX D
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TANK DATA SHEET
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® (0
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-'-."::.I
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270" H';---ll:=f-----~\ -/ ;~: ---90"
1/~ I X
~
225"
~
®-t
®-t
~ -f( l
'Y
C
B
1 so·
10•-4•
~35·
~--LADDER ANO CAGE
(BY ';,[NOOR) _
I
-~'!mlrln!u.f'I 1'2-1.)
/
~ ,-,AURJ,l.> KAILS SHALL BE IN
-"'CUKOANCE 111TH OSHA REQUIREMENTS.
t----© ;.-
I ::
}-®
. NOZZLE SCHEDULE I
MK QTY SIZE SERVICE PROJ. ELEV. IMl<lciTYTsirr,-ci~~;::.._:::_:::.;.;~s'=,,-=--."'"'"""-...R"'E-:--;MA'"'R"'KJS DESIGN CONDITIONS 1 ATM 125 "F I
A 1 6" RECIRC. PUMP sue. 8" o· 6" t~~~+~=~~1~~~~f~~~~~J~~~~jt~±~~~~:=f==~=J voe 1 -OPERATING CONDITIONS l__~TM ____ psig
~ i ____ , I
....:i..O ___ , I B 1 6'" TO STRIPPER 7" 9· o·
C 1 1 o· VENT 8"
D 1 3" DRAIN 6" MIN.
lc1,hii-1l---_'._~S~:..=.c~+~;--l-2~':!_--J...~::___j CORROSION ALLOWANCE _l.LB"
~"T,rf.;-t---;~~---j-~;;-J-.,..;-:-~Wf"-/GOOSEN~~[(l(~ TANK CONTENTS_W"'A-'-TE~R'----,,,=~-=----I _ CODE STAMP & t~=~+~~~:+~~~~~~~~~~~~~~~j~=±==~=:=t==-~=j CODE APl-650 NA T'L BO.REG._-=:_ __ E 1 3" LEVEL TRANSMITTER 7"'
F 1 6" RECIRC. PUMP RET. 8" 8' o· 1 REFERENCED SPEC._UJ.Qf\~--------ir.l,r;;--r=~~~'.:___'.:..':..'.+~,--1---"S....::.':!_-+.,...;-:__J RADIOGRAPHY -
~--t,h~l-----;:;-;;~~~::;;-;:;--+~;--;~~::-;;-~w~ /IB!::!Li!:I_N~D SHELL SPEC. -A:--;s'""'T''"'M'-:-A--""3-::-5---------·-G 1 3· SPARE 7"
H 1 1" SAMPLE POINT 6" 3' o·
N 1 20" ACCESS PORT 4" 3• o·
r--;;;,7"h;:;-il---~==~~:'--+~,---j~'-='~+__.:_-:__j HEAD SPEC. ASTM A-36 API 650 DISHED
r1-'--r71---~~2ie...!:'.'~!..__+~____jp!:.=!Q::..~W'!....(/_s81_!F:_jALL WETTED PARTS TO BE CARBON STEEL
1--,-t-----jl---------+-____jf------J----J GASKET SPEC. (PROCESS) AR AMID NBR 1 /16' THK I GASKET SPEC.(STEAM)-='------'------t--t--t--f-------+--=-1---=---1-__.:_:__ PIPE SPEC.(INTERNAL):----------
'----L___JL._____j_ ______ __J____::.__L_:::..___l___::__j PIPE SPEC.(EXTERN AL)
10° CS SCH 10S
12·
---=rr= =r=
DETAIL: NOZZLE C
FLANGE SPEC. ASTM A:-:1-:a0-;:5:-.------------
RA TING_l 50.ff_ TYPE RF
SOL TS/NUTS SPEC.ASTM -;A719"'3~G-r."" 87~'.J,-,.,A~S=TM-A-1~9-4_G_R __ 2H
PAINT SPEC. 09900 (S'=E'=E="'-'N=O-'-TE~3'-'). _____ _
INSULATION NOT RE=O=U,~IR_,.,E""D'----------
COUPUNGS -CAP ACI TY~7;;;0"'0"0 ___ u __ s=-_--=c:-A-L-. _S_P ___ G_R ___ ,...,_~. o_-_-_-_
TEST PROCEDURE_-_____________ _
IR]VENDOR TO ESTABLISH ALL MAT"L THICKNESSES
[ZJVENDOR TO FURNISH DRAWINGS FOR APPROVAL
IRJPURCHASER WILL FURNISH FINAL NOZZLE ORIENT.
AFTER RECEIPT OF VENDOR ORA WING.
NOTES:
1. NOZZLE PROJECTIONS ARE REFERENCED FROM OUTSIDE OF
TANK WALL TO FACE OF FLANGE.
2. NOZZLE ELEVATIONS ARE REFERENCED FROM TANK BOTTOM
TO CENTERUNE OF FLANGE.
3. EXTERIOR SURF ACES-SYSTEM 1.
INTERIOR SURFACES-SYSTEM 2.
4. GUARD RAIL ANO LADDER SHALL BE PAINTED OSHA SAFETY
YELLOW.
MACON/DOCKERY SITE REMEDIATION
GROUND WATER RECOVERY
ltemNo.F[[Q TANK T-1001
100 Ver doe Boulevard
P.O. Box 16778
Greenville, SC 29606
[phone]
I I
I
SPEC. 11300 -STEEL STORAGE TANK VESSEL DATA SHEET SPEC. 09900 -SURFACE PREPARATION ANO PAINTING
8 ISSUED FOR REVIEW 10-11-~ JSH OPS _ DR. HC I CK. DB SCALE: NONE
tt~A~=t~IS~S~U~E~D=F~O~R~~R~E~Vl~E~Wfu~i=========i9-~~29-~~94~~H~C~~±~:~:+~-~;;h~~;;p-~~;;;;;~;=4====================;;~~~~;~~==========================~D~A~T~E=: ~~9 /~2~9~1 /~9~4======j DWG. /SPEC. NO. NO. REVISION DA TE DRWN CHK"D APPVO APPVO REF.OWG.NO. PROJ.: 70 □l 7•21 7001721-T -1001 ~===~====-------.:.::..c.:.::..c.::.:.: _________ _i.=.:..:.:.:::....1..::..:.:.:.:.:...r.::::..::..:..::'..1::::_:_'..::.i...'.:'.~~......'.:.~::.:~~_l_ _________ ~R~E~FE~R:!E~N~C~E~SC=----=======--'-A_R_E_A_:_M_A_C:..cO::.:.N.:.._:S.:..:IT~E~ _ _j_ __ --::-______ j
FILE NAME: T-1001 BY:. HS.
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45'
N
/ -,v;.,; -· j_
0 "" ,/
270"--+---i-,;i~,-i-~ ~ \ -/-~ -I -~go·
~><~~x
NOZZLE SCHEDULE
MK QT'!' SIZE SERVICE PROJ. ELEV.
A 1 6" RECIRC. PUMP sue. 8" o· 6'
'-.-t--;-r,;:i,=-J==-==-=-.;,;;--=-=-+-~:'.:..l---';=:::.:'.;..._L'.R'.::E::MAR:_:l~K::JS DESIGN CONDITIONS 1 A TM voe 125 r
I -=-=---r rc+-;--1~.-f=~~~~~➔~=-1-"'..=:~...J._-=-'....' _J OPERA TING CONDITIONS ~1M_----5.Q. ___ r 8 1 5• TO STRIPPER 7" 10·-o·
C 1 10· VENT 8"
1-;<-+-;--1~;.f--...!.:::'.~~..!:....=!.:.....-+-..!.=-~~~...J._--=-...._J CORROSION ALLOWANCE _u_,. .. _____ _
'n-+-;--,h;.+---::C:~-:----+~;;-1----=,-~•!efCMJ(~~(l(~ TANK CON TEN TS_Wc_:A.c;T:.Ecc.R __ -;,;-;:=--;ac.:-;--=--~--
0 1 3" DRAIN 6" MIN. 1 CODE STAMP &
E 1 3" LEVEL TRANSMITTER 7" t-'f'-t--;-i~.-t,~;=;-~T.;;~=,;,;-J-~ .... ~~.:..._...J.___:_-...._JcoDE APl-650 NA T'L SD.REG._:;. __
F 1 5• RECIRC. PUMP RET. 8" g' o·
t-;::---t--;--i~.-+:~;,:;,,,.:.:.;~;:;;::..;,.;;:;:..+_:_c-----'l--=.-.l----1 REFERENCED SPEC. _U.J.Q.n,.,_ _______ _
G 1 3" SPARE 7"
H 1 1. SAMPLE POINT 6" 3' o·
t-;::-t--;-t--;;,;---i-'-'=-=-'-==:-:c-:-=~_..:..:::..:..:+-~-J.-=-.~~.!-_::__j RADIOGRAPHY_-c=c-c--~-=----·-----·-
~+-;--r.:.--J-:cc-~c..;-'~-::--:-:,---+--..!,.,,-1---=---~WY_J_' /~IB~Ui!:!N~D SHELL SPEC. ~A"'S'-=TM~A~-__,3='6:--c-=,--,c=-~----HEAD SPEC. ASTM A-36 APl-650 DISHED
N 1 20" ACCESS PORT 4• 3' o· ttt=t==t~~~==1~t§;~tii~i==:t=:;::=:t~~~~==tw;L /~'B~Fj ALL WETTED PARTS TO BE CARBON STEEL_,. ___ _ 1 GASKET SPEC.(PROCESS)ARAMID N8R_Q16 THK
t-+-t--+-------J--~1---.l---1 GASKET SPEC.(STEAM) __ -_______________ _ -t-+-t---t-------+--=---1---=---+---=--1 p;pE SPEC.(INTERNAL) __________ _
1_....1.....--1_....1... ______ _L-=_J--=-_L_:__j PIPE SPEC.(EXTERNAL)_=~--------------
FLANGE SPEC. __,A""S"-'TM""-"-'A-"1 0"'5,__ ________ _
RA TING....!.?iJjl_TYPE RF
SOL TS/NU TS SPEC. ~S..TM 7A-:'c1 9ac3~G,-r ."8'"7c-c/,;7"A"S' T"M7 A::-:1"'9:-:4-::Gc:R--::. 2H
PAINT SPEC. 0990Q..:':-( S~E~E=-"N-"OccT!:.E...:3,.,),__ ____ _
INSULATION NOT REQUIRED
COUPLINGS -CAPACITY _-,;8"00"'os--_-_-_-u---=.s-. G-A-L-.S--:P,--_-Gc::-R-. _-=-1_-=.o_,-_-_-_
TEST PROCEDURE_-________________ _ ,,lr -~"
LADDER AND CAGE __ _,, B ,, , , ._ ~
(BY VENDOR) ~
IX] VENDOR TO ESTABLISH ALL MA T'L THICKNESSES
IZ]VENDOR TO FURNISH DRAWINGS FOR APPROVAL
IZJPURCHASER WILL FURNISH FINAL NOZZLE ORIENT.
0
I
N
®---{
~~
___,)-'-
180"
~ =rF'
@fJN.S.
10· 4•
-----------
a:;UR" 0 ),LS SHALL BE IN
/ ACCUHDANCE 111TH OSHA REQUIREMENTS.
=-0--®
SPEC. 11300 -STEEL STORAGE TANK
DETAIL: NOZZLE C
SPEC. 09900 -SURFACE PREPARATION AND PAINTING
10• CS SCH 10S AFTER RECEIPT OF VENDOR DRAWING.
NOTES:
1. NOZZLE PROJECTIONS ARE REFERENCED FROM OUTSIDE OF
TANK WAU TO FACE OF FLANGE.
2. NOZZLE ELEVATIONS ARE REFERENCED FROM TANK BOTTOM
TO CENTERUNE OF FLANGE.
3. EXTERIOR SURFACES-SYSTEM I.
INTERIOR SURFACES-SYSTEM 2
4. GUARD RAIL AND LAODER SHALL BE PAINTED OSHA SAFETY
YELLOW.
MACON/DOCKERY SITE REMEDIATION
GROUND WATER RECOVERY
Item No. FEED TANK T-1002
100 Verdae Boulevard
P.O. Box 16778
Greenville, SC 29606
[phone]
VESSEL DATA SHEET
FILE NAME: T-1002 BY: HC
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-~ ~ ~ -\.~
-''
1Mvr.:;,;;=,-----;c;.,;:.=;;,,,=--..:..:__:;:~:;_::,.-,--=-~~=-=d OESIGN . CONOITIONS REMARKS
1 ATM NOZZLE SCHEDULE
MK QTY SIZE SERVICE PROJ. ELEV. ____ voe
125 __ 'F
____ 'F
A 1 s· RECIRC. PUMP sue. a· o· 6
B 1 4• TO STRIPPER 7" 8'-0'"
-t--:-+...=:,;--i:,,:.:e::::::~..:...:::.::::,..,,.::=+~c-l__.::'.,2'...,--1------J OPERA TING CONOITIONS l...A_T_M ___ psig
+-;-f-:-;:,;4--~~~..!....!::~-+___!.-c--1-,oc..=~+,..-----J CORROSION ALLOWANCE --'-'1 {Jc.;8,._" ______ _
_¼l_'F
C 1 1 Q" VENT 8" -
D 1 2· DRAIN s· MIN.
-r"7"h:::.--l--....::::.:,.1---+~c-l-..,::..-.,!;W'Y/1~=~CI( TANK CONTENTS WA lJcc..R. __________ _ CODE STAMP &
NAT'L BO.REG._=. __ E 1 3• LEVEL TRANSMITTER 7" -
F 1 s· RECIRC. PUMP RET. 8" 7'-o·
G 1 .3" SPARE 7" -
H 1 1. SAMPLE POINT 6"
-i.=+77ra'n=c=--'i;;~;;;-;-;=d~;,._+--:.::::.::.....+---J CODE APl-650 -1-::-+-,--,i--::-c-+=.;::.;.,~~:::,::..:,.:;::.:+_.:...-+-----l-----J REFERENCED SPEC. _U..:l.Q.Q. ________ _
l-::--+-:-+--,:.-if--C..:.:..:.:.:....:....:_.:..._..:.:.::.:.c:..i-~--1....:.._.::~+--·---J R AOIOGR APH y_-__ -:c-:--,-=:-----------
W /BLINO SHELL SPEC.-"-A"=S-.;,TM:-"--'A'--.-3~_,6,,__ ___ ~~----t-:':-+-:-t--::.-ll--c,---=c.:,.::=----l--~--1---..PC.:::_:"..'..':'.J HEAD SPEC. ASTM A-36 APl-650 DISHED 3' o·
N 1 20· ACCESS PORT 4" 3' o·
I
W/8F ALL WETTED PARTS TO BE CARBON STEEL_,..____ ,
r-t--'-t--""'-11-~"'=-""'-..'::..',!!.:..!_+.:!...,-J_.,/_.=!cL._.µ.':L-..!~ GASKET SPEC. (PROCESS) AR AMID -NBR _iZlL,lHK 1
a I ffi. E
270· H>--ffu--~\x-~ ~ X ---90"
,,,? -~~5
B ',nncD AND CAGE
180"
@f>N.S.
®-t
®--+
8'-o·
==H1 c~~~1w._HALL BE IN
~'--4~J@A)±E~ 111TH OSHA i = REQUIREMENTS.
"----
}--®
/-+-1'--t-------+--+----+---J GASKET SPEC.(STEAM)_::: _______________ _ --t--t--f---j--------+----1--=--+--·---J PIPE SPEC.(INTERNAL) ____________ _
L-...L_L_.....J _______ _i_...=__i_-=.._.L_..----J PIPE SPEC.(EXTERNAL)~~~---·--·-______ _
FLANGE SPEC,...,A'-'.S."-'T"'M'--"A,.:.,1 o"'s,_ ________ _
10• CS SCH 10S
I
12· -=rr==r=
DETAIL: NOZZLE C
RATING 150_.i_TYPE..:.R.:.:.F __ ~=------BOLTS/NUTS SPEC.ASTM A193 Gr.B7_jASTMA194 GR.2H
PAINT SPEC. 09900 _(.SEE NOTE 3) _____ I
INSULATION NOT RE~O=U.~IR_"'E • ..,,D'------·-----
COUPUNGS_---=-=------------~-----CAPACITY _ _,1§.QQ ____ U.S.GAL. SP.GR . ..}.c.9 ___ _
TEST PROCEDURE_-__________________ _
IRJ VENDOR TO ESTABLISH ALL MA T'L THICKNESSES
[XJVENOOR TO FURNISH DRAWINGS FOR APPROVAL
IK]PURCHASER WILL FURNISH FINAL NOZZLE ORIENT.
AFTER RECEIPT OF VENDOR DRAWING.
NOTES:
1. NOZZLE PROJECTIONS ARE REFERENCED FROM OUTSIDE OF
TANK WALL TO FACE OF FLANGE.
2. NOZZLE ELEVATIONS ARE REFERENCED FROM TANK BOTTOM
TO CENTERUNE OF FLANGE.
3. EXTERIOR SURFACES-SYSTEM 1.
INTERIOR SURFACES-SYSTEM 2.
4. GUARD RAIL AND LADDER SHALL BE PAINTED OSHA SAFETY
YELLOW. -
MACON/DOCKERY SITE REMEDIATION
GROUND WATER RECOVERY
Item No.FEED TANK T-2001
100 Verdoe Boulevard
P.O. Box 16778
Greenville, SC 29606
[phone]
SPEC. 11300 STEEL STORAGE TANK VESSEL DATA SHEET
SPEC. 09900 SURFACE PREPARATION ANO PAINTING
OR. HC I CK. DB SCALE: NONE
rB~r,;IS~S~U7iE'i'D;o=F;:;O.,R1Rt,E~Vl~EW',;-_____ --J;;l~0-;;;11-;-9;;4r,J';;S;:"H-+-"cD!:..PB~-=..-f--=:_-f:.__----+---------------------------~D~A;,TE~: __,;91:,/:c,2~9 /~'9c;;4::_ __ ___jDWG./SPEC. NO.
'rJAO:---f-l_S_SU_E_D_FO_R_Rr;E-F'VlviEisWiON:-------f,9-,j2~9-i94TnH'i'iC~frc:;;:;r,<l-;;-om1tl..,-m?i,f-~Cc'i"'="7.'.,_--t-----------,,.=;=;=;;-;=-;=-acc;c-------------+P'.,..;R;O~J::.:_.:._;7;0;0;,;17;;.2::.'.1=~---J 7001 7 21 _ T _ 2001 1 NO. REVISION DATE ORWN CHK D APPVD APPVD REF.OWG.NO. REFERENCES AREA: MACON SITE
FILE NAME: T-2001 BY: HC
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315·
(0
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225·
-----
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===lll ,,--GAURD RAILS SHALL BE IN I/ ACCORDANCE 'MTH OSHA i = REQUIREMENTS.
"--'--...
]-® IL-.-_8_ o· ____JI___,___
1 ATM ~-' ____ voe ___ F
NOZZLE SCHEDULE
MK QTY SIZE SERVICE PROJ. ELEV.
--.:is~r-..::'.::.~~~.----,:;-;:,.,...--,;R""E"'"""'",J DESIGN CONDITIONS MARKS hi---t,n-t-~7'~~~-+~;;-~~~+--=-_j OPERA TING CONDITIONS 1-..AJM psig --5Q_F h=:-t,t--;=;;-1!-___.:..:~~;:'--'-~-+~---+~~!._+---=--CORROSION ALLOWANCE _ __,1_,_,, Ille..• ______ _
A , 2· FROM WELLS 5• ,o· a·
B 1 3· TO STRIPPER 7" -s· o· '7'i-j--,---'f--';;'ry---;;';:~;-----+~;;-!-~--1'W'!.f./CUG)(~~(l( TANK CON TENTS_W"-'A-'-TE='R---==-=~= ,-,=---1 _ CODE STAMP & t7-j-1 ~.-t,7,,;=,~';;-;;;i=.;,""d-~.-!-=.:..._-i--_,:_~ CODE AP/ -650 NA iL SD.REG. -

·

C , ,a· VENT s· -D 1 2· DRAIN 5• MIN.
t,:;---t-,t~f=----=~-:;:;--;;::;;='::.:_:_:..:::.,:+-::..--+--+-.._:.-_J REFER EN CED SPEC. _U.J.Qi" ----t.:;-t',1~;-f----;::-;:;-;~:"-;::~~-+--:-;;-1---::o-=-::-=---+W'.'.,r fc,:18~U~N!!!.jD RADIOGRAPH y_-c-::-::=-c----:--=-----------
E 1 3· LEVEL TRANSMITTER 7" -
G , 3• SPARE r -
-SHELL SPEC. ~A"cS,-=T,:,cM,__,A,,__-__ -::3c'-6 _____ """"c=----t";';-"i"-;-t-;;';;,;i-";':::=:=--'=':=-+-.::'..:-+--=c=:__+-W--=:. /8_F__J HEAD SPEC. ASTM A -36 APl-650 DI SHED ALL WETTED PARTS TO BE CARBON STEEL 1"1--t----jf-------+----+---+---_-GASKET SPEC.(PROCESS) ARAMID NBR 1 /is"-fHK
H 1 ,· SAMPLE POINT 5• 3· o·
N , 20· ACCESS PORT 4• 3· o·
1-t---"'r-t-------+---=:__f---=.--i--___::_~ GASKET SPEC.(STEAM)_-_____________ _ 1-t---,r-+-------+---=:__1-~-:_---+_=.-_j PIPE SPEC.(INTERNAL) ___________ _ '----'----J'---'-------_L __ L_ __ _L_~PIPE SPEC.(EXTERNAL)'.=-=------------FLANGE SPEC .. ~A=S'-'TM"-'-A'-'1-"0::.5 ________ _
10• CS SCH lOS
12·
DET All: NOZZLE C
RA TING 150# TYPE-'-R"'-F=-=--=---=-=~=-,-,----BOL TS/NUTS SPEC.~~TM A 193 Gr.87 /ASTM A 194 GR.2H PAINT __fil'J~~ 0990Q_l,,,,SE,.,E._.::N,_,0'-"TE.,.__,e.3L.) _____ _ INSULATION NOT REO"'U"'IR,.,E,.eDc__ _______ _
COUPLINGS_-...,...,=-------------
CAPACITY _d~QQ___u.S.GAL. SP.GR._1,~-,e,O __ _ TEST PROCEDURE_-___________ -_
!&]VENDOR TO ESTABLISH ALL MAiL THICKNESSES [&]VENDOR TO FURNISH DRAWINGS FOR APPROVAL [ZJPURCHASER WILL FURNISH FINAL NOZZLE ORIENT. AFTER RECEIPT OF VENDOR DRAWING.
NOTES:
1. NOZZLE PROJECTIONS ARE REFERENCED FROM OUTSIDE OF TANK WALL TO FACE OF FLANGE.
2-NOZZLE ELEVA TlONS ARE REFERENCED FROM T ~NK BOTTOM TO CENTERLINE OF FLANGE. 3. EXTERIOR SURF ACES-SYSTEM 1. INTERIOR SURF ACES-SYSTEM 2. 4. GUARD RAIL AND LADDER SHALL BE PAINTED JSHA SAFETY YELLOW.
MACON/DOCKERY SITE REMEDIATION GROUND WATER RECOVERY
Item No.FEED TANK T-30C1
100 Verde~ Boulevard
P.O. Box : :3778 Greenville. SC 29606 [phone]
STEEL STORAGE TANK VESSEL DATA SHFET SURFACE PREPARATION AND PAINTING r-BA~,s~sfiufE~D -'iF:'Fo;iR-jR~E~Vli.E=iwi,-------f'~0-;n;-~94~J~S~H-J-_!!D!::Pi:!.B-l-=---l---=--t:,_:__ ____ L __ -_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_~ __ ,l;gD§Rt•j~H:::c~~(~bl}C~K~ _---~D~B~~~j.;s'.;c~A!:!LE;;==.,_~"~o::_N!:_E __ ..j tl~Ad~,s~s~U~E~D='=FO~R~RjE~Vl~E~W~~=====fl9~-2~9-~9=4~H~C~r
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DWG./SPEC. f\ J.
NO. REVISION DATE DRWN CHK D APPVD APPVD REF.DWG.NO.
PROJ.:
7
00l
7
•
21 7001721 T 3001 REFERENCES AREA: MACON SITE
FILE NAME: T-3:J1 BY: HC
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RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX E
APPENDIX E
PUMP DATA SHEET· GW
t:\WP\7017001723 O&Mlcdf94
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t-G,.Ll\:'.,.(..\.AI-H-f t<IN_ , 4 F~ r ~
DimeRsions Model 319&
All dimensions in inches and {m m ) Not to be used tor construction.
~c , s• , • ""'· , I I ,
I
i
___ ,
" -. -: z .::i ---
IMENSIONS DEnR
I ANSI I Dn~Mtw,n I I • I I • '
111 l½~ AA I '½ •• I '½ ' 1½•3-6 13½ • sy. 7Y, ,,,, I'.,.. I 2 8½ (185) ST (3'3) (102} (1331 (HM) 11 I 1 ½--8 AA ''• l,½13·11 •• 1'/1 ' 2.,.. .,, 2 3 8\', [2101
3 • ,.7 '" 3 " 12110l ,.u ''° 2 3 91h 12•2!
J • ... a A70 • I ll !280)
z
'½
(11'1
~•-·'
P-I 00 I
P-iw~
f -2,fJO \
I
HO
KA:____;__,j
Shaft • .. ·-~ • Cs,tv,
lleJ-w-,
3 3½', '• .,.,¥,,
(76.2) (95.3) (22.2) 1,.a _. 2.•1
I .. m, WMQhl
lltt,. (kg.)
I "(38]
92 1•21
95 (•JI
100 !•S! ' ! 108 ('91 ' 180 {112)
220 11001
ZOO (91)
220 {100) 3 I ,-aG A70 " (280) ; 19''1 I , 8¼ 220 {100) \ l 1 • 2-10 AOS fl½ 1216) : , .• ., I '"" ! 1 '.7 • 3·10 ASO 1'h 8'h (216) ,,,, 12 I 3•10 "° 2 3 9'/2 (2,21 IIT''
3 • ,.,o .,, 3 ' " (2110)
3•••t0H i "" 3 I 12½ (3181
••6-10 "" • ' 13'!, (3'31 I '½ :I 3.,3 A20 1y, 3 10•;, (267) I
111½ • 2 ,i; 3-13 A30 3 11 'f, (292)
3 • .... ,3 "" 3 12'!, (3111) (495) , (102)
I 4 • 6-13 '"' ' 13½ (3'3) ' ! 6 • 8--13 '" ' • ,, (406) I I e • 10-13 ""° • " ,, (457) I "" ) 6 1-&-15 A\\0 • " (457) 2111t i 8 IJ.T ' 110111 i (1!2) I fl I 10-15 "20 " " !483) ' ! 1 8 ._ 10·15G A120 " ,, (483) ' ••on LTC trame. snar, d1am11e1 ••coupling•• l'Jt. 1,1.&1 key••Y ,s 'liM • •;.-. (12.7) • (641 l)S.
-DIMENSIONS OEnRMINEO BY MOTOR a_ a•
I I MOTOR I IIEDPL..ATE
Modal ... 1 ~= I C I .. I HI I HG'""fl.5) 1=· I•• I SIZn Mn. -,. (3,2) Weight t Ape»lte11tMt Lbl. lilt-)
,,.
11T
I' I
¥192
I "½ I " I " (3,13) (25"} , 11891 3 {78.2)
j l~~I i {~) I ~1) I ,il&i l
I I~) i ,;:,, I ,,:a, I 1~6!1 I
.. ,,., ,,. , .. , , .. , .. ,
"' {70) ...
(13)
, ..
(1091
25
(210)
10
(254)
14'1,
"'"
12•,; •½ ••• n,
(3111) ,,,,, 112,, f9$.3J
10. 8½ • sv.
1478) (165) (203) (133)
""'POU
L..an1 ... n Rif!Q Cormection or Seel Fhnfl
Cuing Drain
{wilh ason10I guletl
Allemale Cuing Ofa,n
Buring Frame Coo1,r19
Suction Ga9S Connechon
By0'U1 Connecuon
D 2 Tapa on Moo.I :S1N XlT.
200 !91)
220 (1001
'% Y. • ~ .tJO P0'1
(211.8) (&., • 3.2) l 265 1120)
j275{12S)
305 (138)
2,5p11)
275 (125)
330 (150)
405 Pi'l
560 (25")
670 /30,I,) , ..
% • "'·· 610 ,2111 (80.31 115.9 • 7.91 740 {3361
710 !l22)
I .,.
"'
I '
2 ,..
■ Ad-10 anC11 Ad-1:S ri.... no tap. 314-1 and 31 .... 13 f\&1119 Y.0 (fl.Al tap
Model 3196 MT lllustrafed. Dimensions apply fo
3196 ST,3196 MT and 3196 XLT. Dimensions apply to both 150 and 300 pound flanges. Flanges are
drilled to ANSI dimensions.
'Applies lo pumps wftef9 D • 1y.-
'Aoplin 10 putn;11 ~ D • 10"'
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Parformancs Curves Model 3196 s10
• • ! •
,,
I -
~ -00 · 'loo· 1100 ':"00 ,, ..
•,-~ .. --.. ..,..--.,--.,~--,.,~--,,,",--,-.",--,-.. " ...
1750 RPM
I "6011 l 1111.;-;.T j ro" AU.oY COHST"IUC'TION 'll ' ... -eG
I_,"°' l00•1•'i
'11!1n "iUl"i
'Tl Ult II.Cl
.. --
....
hoo
,.,_
so--,--:-----··-------· ' -. --
,---------:---• >-...._16NI'. l\~lO'!_I'
"'"' ___ o
o~ic:o--,c_,~-,cio _.:... ;oo (.-u;:i• .. 1 ll>CO 700 ... lcio ~,-,"
0 ..
3560 RPM
I s',.--
i•~--
... ..
~ ""·
...
oai---
i1"i()· ..
i100r
Z"iD·r -·
... ,. __ -------
,,,--~.,-~-,.,~--,,.
I a z 1b
3560 RPM
100 1"i0 zoo •• J. --
... -------~ ____ ...
--
MT
3x 4-8
A70
MT
3 I 4-86
A70
Alli
IT
l'lt x 3-10
A50
;~;-~ CO►isntUCTIOH 1-~L,1!._';.,•.------
1"1--····
IO------· ----··---
'!'! a-;,Lllllti ,-111,.
...
" 1150 RPM
.~o ~lOOaPIO~~~I.. --;oo-,,io --oo ~o
io ..0 ,;,o .0 70 ID 'IO a\.• --
·.' ·-------·--'-u,JiliL.J._ p 100 Zl.ll tOO ..00 "101) · loCIO GI' ..
0 lO <oO 1110 IQ 100 IZO •""
1750 RPM
0o zo .. IO IOO llO G '"
o I ,, iii 1<
§ 1750 RPM
..---. ,. • i W-7•··-
Section 196
0 Motor Data
_.,_...... . • ~ . . -· ...... -..... ---~ .·.1 -. ' .• ·-.••. -.---··· ... ~
Motor Enclosuras
The selection of a motor enclosure depends upon the ambient
1--and surrounding conditions. The two general classifications of
motor enclosures are open and totally enclosed. An open motor
~-· has ventilating openings which permit passage of external air
over and around the motor windings. A totally enclosed motor is
I.~ constructed to prevent the free exchange of air between the
inside and outside of the frame, but not sufficiently enclosed to
be termed air-tight.
These two categories are further broken down by enclosure
I design, type of insulation, and/or cooling method. The most
common of these types are listed below.
Open Dripproof -An open motor in which all ventilating open-
ings are so constructed that drops of liquid er solid particles
I falling en the meter at any angle from O to 15 degrees from
ve:rtical cannot enter the machine. This is the most common
type and is designed tor use in nonhazardous, relatively clean,
I ind us trial areas.
EnCapaulated -A dripproof motor with the stator windings com-
pletely surrounded by a protective coating. An encapsulated
motor offers mere resistance to moisture and/or corrosive en-
vironments than an COP motor.
Totally Encloaed, Fan-Cooled -A enclosed motor equipped tor
externaJ cooling by means cf a tan integral with the motor, but
extemaJ to the enclosed pans. TEFC motors are designed for use
In extremely wet, dirty, or dusty areas.
Explolion ... Proof, Duat-lgnltlon•Proof -An enclosed motor
whose enclosure is designed to withstand an explosion of a
specified dust. gas, or vapor which may occur within the motor
and to prevent the ignition of this dust, gas, or vapor surrounding
the motor. A motor manufacturer should be consulted regarding
the various classes and groups of explosion-proof motors avail-
able and the application of each.
Motor insulation is classified according to the totaJ allowable
temperature. This is made up of a maximum ambient temperature
plus a maximwn temperature riSe plus allowances for hot spots
and service factors. Class B insulation is the standard and allows
for a total temperature of 13CTC. The maximum ambient is 40•c,
and the temperature rise is nrc, lor ODP motors and 75"C tor
TEFC motors.
1· I 196-2 NEMA Frame Assignments
SINGLE-PHASE MOTORS HORIZONTAL AND VERTICAL
DeaiCJf' ~ fJll cyclea, clau B Insulation
system, open type, 1.15 MMe• factor.
hp IP•ed.-
3600 1800 1200
¾ --145T t 1'3T t82T
I
I
I
I
r
-1 ½ 1'3T 145T 184T open __________________________________ _ 2 145T t82T -
3 182T t84T -5 184T 213T -7½ 213T 21ST -
POLYPHASE SQUIRREL-CAGE MOTORS HORIZONTAL AND VERTICAL
open type __________________ _
OlaJgna A and B-clau B lnaul1tlon system, open
type 1 15 service factor, 60 cycles
hp apeed. rpm
3600 1800 1200 !IOO
½ ---t'3T
¾ --14:JT 145T 1 -1'3T 145T 182T
1 ½ 1'3T 145T 182T 184T
2 145T 145T 184T 213T
3 145T 182T 213T 21ST
5 182T 184T 21ST 254T
71/, 184T 213T 254T 256T
10 213T 21ST 256T 284T
15 215T 254T 284T 286T
20 254T 256T 286T 324T
25 256T 284T 324T 326T
30 284TS 286T 326T 364T
40 286TS 324T 364T 365T so 324TS 326T 365T 404T so 326TS 364TS 404T 405T 75 364TS 365TS 405T 444T
100 365TS 404TS 444T <145T
125 404TS 405TS <145T -150 405TS .... TS --200 444TS 445TS --250 445TSt ---
r;::., 1ftf!
fan-cooled_ ________________ _
0Higna A and B-cl1a 8 lnaufatlon syatem totally-
enclosed fan-cooled type, 1.00 service factor, SO-cycJea.
hp -lld,-3tlOO 1800 I
½ --¾ --1 -1'3T
1½ 1'3T 145T
2 145T 145T
3 182T 182T
5 184T 184T 7½ 213T 213T
10 21ST 21ST
15 254T 254T
20 256T 256T
25 284TS 284T
30 286TS 286T
40 324TS 324T so 326TS 325T so 364TS 364TS
75 365TS 365TS 100 405TS 405TS
125 444TS 444TS I 150 <145TS 445TS
tThe 250 hp rating at the 3600 rpm speed has a 1.0 service !actor.
1200 -1'3T
145T
182T
t84T
213T
215T
254T
256T
284T
286T
324T
326T
364T
365T
404T
405T .... T
<145T -
tlOO
14:JT
145T
182T
184T
213T
215T
254T
256T
284T
286T
324T
326T
364T
365T
404T
405T
444T
,1.451" --
T l
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TO 17067375962
~ Goulds Pumps, Inc.
RMT
Inquiry No:
Proposal No: A'I9479SLICB
Item No: P-1002
MODEL: 3196 Size: txl.S-8 STX
Ooerating Conditions
SE1\VICE PROCESS P'UJU
UOUID WA?D
QTY: l
CAPACITY 1f1J.OOP¥ (100 DqP, 1.000 /IP.GR)
HEAD U0.0/1
Performance at 3600 RPM
PUBUSHED EFFY S1.01' (CZ).!')
RA TEC EfFY .S7. o•
'RATiO HP U.9 ,JIIJi<lll"'11Hl11,2
NPSHR lftl 14.0 (,r,oil,,l,u N1'SH ii JJ.0)
DISCH PRESSURE tlfJ.91S/ (&Mi aa a.O S«.pn.u)
PERF.CURVE JJ00-2 (CW .IIMIU/on)
SHL/T OFF HEAC• 2/JD.Ojl
MIN FLOW "10 OPAi
D'CJC11U lltON
DL'C7'1U IltON
P002/008 P.3
e 0c:to11er 111114
Ann DAN J101JtLUND
PRICE BREAKDOWN
P\unp Unit • :a,:an
T .. tlng
Driver • HI Box .• Prt
TotalUnlt f 2,IH
Shipment: 4 WEEKS,
·Materials
CASING
ST.BOX covm
IMPEU.ER
SHAFT
DUC11U! IRON ( 7. 675 rasllll din. {INW•) • .,,,.,., , a. (X}(}() """K .5. 0000)
&Ul ,uo
JJISSS
FLOOD OIL
SHAFT SLEEVE
LUBRICATION
BEARINGS
COUPLING
COUPLING OFID
BASE PLAT£
SD 6J0'1 (Radial) W S106 ,C/CJ (Coupli1w ,nd)
RDNORD O.IIBGtt 1IEX BUSTOMER· &~4 nut. .
C(S7' IRON COlBER n:>I' E0002SA
Sealing Method
PACK IN cf NOIMSll1U10S
Driver MOTOR
FURNISHED BY OQUUJ$
RATING "10HP
PHASE/HZ/VOL TS JK,DIJJ0/'8J
INSUL.A TIONISF P II.JS
Wei£hts and Measurements
TOTAr GROSS /JNIT WEIGHT
$HIPPING GROSS VOL/JM/!
. ~!<Ll,t,oJC!
Manufacturer: GOULDS cn010.
127 u..
1',10 n:I
MOUNTEO BY OOULDS
ENCLOSURE CREII l>Vlf mun J.11 • a.u,, llllf
SPEED ~~ RPM
FRAME 2561'
D I 0·06o¢t ~ !~" 04:M~,(~·tr-l':'KPS INC,
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TO 17067375962 P006/008 P.4
.___
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IU~UOOCT 28 '94 04:02f'M RMT 11-1:.ara ma.
~ Goulds Pumps, Inc.
RMT
Inquiry No:
Proposal No: AT9479.5LJCB
Item No: P.2002
MODEL: 3196 Size: lxl.5-8 STX
Onerating Conditions asiv1cs P11ocus PUMP
LIQUID WAID
QTY: I
CAPACITY fD.0 0/'II (Joa 0., '• J.aaa SP. OR)
HEAD 16'.0 /I
Performance at 3600 RPM
PUBLISHED EFFY 47.H (c:t)8)
IIIATED EFFY 47.01!
RA TED HP S.J ,Ila,, di,.... 0111 1.8
NPSHR lftl 4.0 (1Jwtl/Abll NPSH It J:t.0)
DISCH PRESSURE 71.0PI/ (B,,,M1 • 0.0 k,pnu)
PEl'.F.CURVE Zll»-2 fC!t'R"'41rioA)
SHUT OFF HEAD ldS,O~
MIN FLOW 20.0 GIJI
DVC11LB 'QI.ON
DUcm.BIRON
• WWtlf W1"\I
e Ociober 1894
Attn DAN lUOUJ..tJND
PRICE IIREAKCOWN
Pump Unit • :a, 117
TuUna
Drfvar • J:12
Box.l Fn
Total Unit • a,,,,
Shipment: 4 WEEKS
Materials
CASlNG
ST.BOX COVER
IMPELLER
SHAFT
DUCffU IRON ( S,17S Nld du,. (lndw), ,, • .,. .. a. 0000 mi4 • S.0000)
8,Ul4UO
JJ6SS
1'1,,0()l) Oil.
SHAFT SLEEVE
WBRICATION
BEARINGS
COUPLING
COUPLING GRC
BASE PLAT£
/!/KJI' Ql)1 ~ SD l.J06 A/CJ (Coyli"I/ •Iii)
REXNORD a.llEa.t REX ELASTOMER-l!S-.1
8'11!El.
CUT IJION C,WIIIUI TOP BOOCIS~
Sealin2 Method
PACKINlf NOJI..-WIESlW
Driver MOTOR
l'UI\NISHED BY OOULl»
RATlt.lG 10.0'HP
PHASE/HZNOLTS JM/J/2J0/4e
INSULATION/SF P 11,1'
Weii:,hts and Measurements
TOTA! GROSS UN" WEJGHT
SHl/>PING OROSS VOI.IJME
Rf'1..1 ... i.lCC
Manufacturer: ~ OIOit:a
MOUNTED BY OOUU>I
,01 LI>• ,.ao r.n
ENCLOSLIIE aIEJ/ Drnr 1mJ1:Fn I.IS 1' ~ r IHI
SPEED J61)(J RPM
FRAME atsr
0
oz
....
OL
-
Db-
3 • -iii -
II/~ °ti Oti ~ I I
Wd9 Otiz 002 091 0c
WOHA
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' '
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.................
l ■■I .Ill 1 ■11
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! . ' ' " :I . ~
•• ••••1111 ■llllllllll1 . . -
. _ -~I~~lSN(':>
~-3"1JOIG . ~
,~~ t:lil ... ~
I . . ' '
,.111 ~~-E_ 01110
1609S. -••14
-,. i, "IIUI ... I ~.
11 -c:, I x t msa.u..u..i.U-1-~..+-U+H--H'f'I'
lS 4161E. , ... . ' I I I 1 ■ I
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Z-OOIZ IGG OO!ai IWII 13U111Wffillt0 4■11iil llllWIU.DD ..........
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os.z
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... ...
Pl -t
cu.-to-1 "'iul
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TO 17067315962 fUU4/UU~ P. 7
1011theest lep:,Gel Wm
~~r. lTEJIO ~~ 10(Ji3 ~ Goulds Pumps, Inc. ra /4041 <'4~1"1 -------4 l'AJ( H~I 1061 ~ •. , .•. ~
RMT
Inquiry No:
Proposal No: AT9CfflLICB
Item No: P-3002
MODEL: 3196 Size: txl.5-6 STX
Ooerating Conditions
&Eflv1CE l'ROCIW 1'UJl1'
LIQUID WAJD
QTY: I
CAPACllY !IO.O C1l'II (100 IJ., T, J.000 fll'. GR J
HEAD JQZ,O Jt
Performance at 3600 RPM
PUBLISHED EFFY 87,<Wt (Cm)
RA nil EFFY 11.0'ft
RA TEI) HP :u .Jlo. t11 -OIII I, 4
NPSHR lfll 2.0 (NII~ N1'SR II JJ.OJ
DISCH PRESSURE 41. 11'S1 (.B,t#tl OIi 0.0 ~.pra,J
PERF.CUAVE ;;ior.J-, (CW llollflOII)
SHUT OFF HEAD JOS,0/1
MIN FLOW 20.0 Gnl
DUC'l1U IRON
DUCTlUI IRON
8 October 1994-
Att,1 DAN B10UI..t7ND
PRICE BREAKDOWN,
Pump Unit , 1,IH
Ttlting
Driver • io•
Box.I Fn
Total Unit • J,DH
Shipment: •I WEEKS
Materials
CASING
ST.BOX COVER
IMPELLER
SHAFT
DUCl'ILE IRON ( "-6" r--1 dJ4. (lndt,s), ..,.,.. • f.OISZ5 ,ni,,-J.S(IOO)
SAH4UO
IJtW
l'LOODOlL
SHAFT SLEEVE
LUBRICATION
BEARINGS
COUPLING
COUPLING ORD
BASEPLATE
SD Q//'l (Rlldllll) !SXF :SJ06 A/CJ (C,,,,,,11111: l!>ld)
REXNORD OAIE~ REX ELASTOMER-ES·,'
S'1UL
G4S1' TRON CUIIIER TOI' .IOOMOA
Seelln2: Method
PAOONiY NON-.WJ1!810S
Driver MOTOR
R,lRNlSHED BY OOUW.S
RATING :S,08'
PHASEJHZNOLTS ll60/2J(J/46)
INSULATION/SF TII,1:S
Weiimts and Measuremenu TOTAl-GROSS UNIT WEIGHT
SHIPl'ING GROSS VOL IJMI
R..-1.,A,.X~
Manufacturer: <.OU¼.BS CHOICE
MOUNTED BY GOtltDS
122 U.a ,.:ao ,a
ENCLOSURE aaJJDVTrnDU'1l.llPa.u6,INI
SPEED J6DO RPM
FRAME lU'I'
...
l&I
Ill
LI.
180
I&· ! 1'10
E 12-
10 0~
e 0
6 O'"
.. 0
2 0 ·-
0 0
I n
1-12-10
•GOUlDS PUMPS. INC. l!Yil 9NID.'""15. .,., ...... . '
rr
" ..
20
~
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1-29-91 ISSUE.5 P-3 a;l.
4-23-82 ISSUE *4
llff,DITI 3-17-78 ISSUE""43 8.E.E
RffllfVIAl Pllllf CIWllatEllfflCI RPM 1 '5 00 CDS 207'>-'i
r I 111.l_.a ....I......__. 1111 ■11
FOR DUCTILE IRON
CONSTRUCTION
' ' . -
MODR '319b ST
SIZE l >< I 1/2 -6
,~-.-.111,. DWI. 7 6 777
hlliRI 56088
ftllREA 1, llf la'
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15 20
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l]GOULDS PUMPS, INC. NDUSTRIAL PRODUCTS GROUP PUMP OUTLINE DRAWING
ENGINEERED PRODUCTS DIV. MODEL 3196 STX
··-·-
·-··· .. ... .'Tl -c 1i.10 --+-.t-,-SUCTION : °''°"''-I· ; , I
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"'oToR tJ1,..eNS10!<s 11eF~ 1 PUMI' SIU ,.V,.ILAII~! 0PTIQN~
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t, .. T U.iO , ... II I . , I 111 I •••
16.!T 14,SO .... .. l • I 1/t J I .. , JIii$ CFUIIIIIIU
,an 11.10 .... 100 I c,u, ~AN CNOT ,1 lflHIMD
cnt 11.00 •••• 110 l C IIOf ANll A.AT ,11ica
111, 11.ao .... ''° z "-"'G&I Cl I ,of t:' IAIIIID PACI.
IUT u.,o I·"" ... I C100f .. 11 A.AT ,14 ■
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I "' "" I I WIIOKT
NII. ""' .. i:Jl = •• I HI .. ... I c•n ITEIL ,.,. STIii. ·-111m.-
,H
I 10 )S .... 1.11 1. ID I.II 1.11 J.00 . ... :II. :,0 I. It ,, ., u 1~·a1 I 11 •• l,U 1.J1 I.II 1-0I J. II 1.11 -',ID )I.,., 1.)1 .. , .. ZI
• 11 '4 I.II ,.u , ... ... , ,. • DD 1.ca 0 $0 '·'' , .. 117 u
♦ Ti.,.slfileill ii •,18 -0 ,09 CAST _. 11191L.Aft, CERTFIEO fa! WN:i!R\.CTI0N Pl.lfOSfS OU V4£N $1",1@.
■ ~ mMI! ~. OIICHAICI! PIMX WU 11! SlGNAME DATE . ' a:;. ,.,. , WIii ... IJIC I ,, 1'1 : t : ::t •. :~ ...,:ft caTOIIR
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FOR T APPEO OP'l:NINGS REFER 1151 Ill. .
TO ORAWINCl NO, A04190A. SS!VlCE.
I~ CRAWi~ IS NOi TO SW ~ tj:I.L l.l<AWKi Rf.VI IOK 0 0116Slefi5 N ~ 0'I 'ii"s A04191A 111:IQlTS WI A/If IJ'PROXIMATE r,-1◄➔•
FORII NO. Z31Z
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4-lnch
and Larger Wells
~!TWJD~lf@~
$~nff ®~~ St~®Il
~ruilbm®~fi[bl~ IPrnumps
MODELS:
SS, 7S, 10S, 16S,
25S, 40S, 60S & 75S
WELL SIZE:
4-lnch and Larger
FLOW RANGE: 1.2 to 95 GPM
HP RANGE: 1h to 10 HP
RPM: 3450
For increased capacity and pressure ranges,
see Grundfos 6. 8. 10-lnch and Larger Wells
and Deep Set submersible pump catalogs.
--~4 .-:··
.. '.:-: ·t
GRUNDFOS®
I
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FLOW RANGE
1.2 to 7 GPM
PUMP OUTLET
1" NPT
5GPM
. . ~ .,: ' ; . '
GRUNDFOs· ., ; . ' -.
PERFORMANCE CURVES
900
800
700
600
~ 500 w w ~
C < w
:I: <IOO
300
200
100
0
5S15·2611'hHP
' . ..,,_ .
1ss10-22(1 HPH~
'
15S05-13 ('hHP)-1 --, :-·
...._.
'5S03-9 ('f., HP
--· -
OP'EFI.ATlNGRAHGE: 1..21ci7GN CAPACITIES BELOW 1 2GPM -tr,.. A.FIE NOT AY,t,ILA8LE
'
.
--·
-"
'
,.
'
....
'
0 2 3 •
CAPACITY (GPM)
DIMENSIONS AND WEIGHTS
LENGTH WIDTH
MODELNO. HP (INCHES) (INCHES)
5S03-9 'f., 24¾ 3¾
5S05-13 ½ 28½ 33/,
5S07-18 ¾ 33¼ 3¾
5S10-22 1 37 ',;, 33/,
5S1S.26 1 'h 42 3¾
5S15-31 1½ 47% 33/,
Specsficat1ons are subject to change without notice.
3450c:
RPMI=
'
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' '
' . '
I :-~ . . i
I I
'. • ' • I
5 6 7
APPROX. UNIT
SHIPPING WT. (LBS.)
27
31
34
42
46
58
•
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0
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C:IFIUNDFOS" · ... : . . : ·?. . .
SELECTION CHARTS
(Ratings are in GALLONS PER HOUR -GPH)
PUMP MODEL HP PSI '
2D 40 6D SD 1DD
0 429 401
20 420 393 366 339
5S03-9 'h 30 389 362 335 306
40 400 358 330 303 265
50 369 327 296 265 208
60 337 294 253 211 114
Slun~tt PSI: 102 94 85 76 68
0
20 437 418 399
5S05-13 'h 30 434 415 396 m
40 431 412 393 375 358
50 409 390 372 353 335
60 368 369 350 332 312
SIIUl~tt PSI: 152 143 134 126 117
0
20
5S07-18 3;. 30 421
40 432 419 405
50 430 417 403 390
60 428 415 401 368 374
ShU1-0tt PSI: 213 2()4 195 187 178
0
20
5S10-22 1 30
40
50 429 418
60 427 416 405
SIIUl~tt PSI: 245 237 228
0
20
5515-26 1'h 30
40
50
60
SIIU1-ott PSI:
0
20
5S15-31 11h 30
40
50
60
StlUl-•otl PSI:
120
374
312
276
228
150
59
423
380
359
336
316
293
108
423
407
392
376
361
169
420
407
394
219
419
269
5GPM
FLOW RANGE PUMPOlJTLET
1.2to7GPM 1" NPT
OEl'TH TO PUMPING WATER LEVEL (LIFT) IN FEET
140 160 180 2DD 220 240 260 2BD 3DD 340 4DD 460 520 6DD 7DD BDD 9DD 1DDD 11DD
347 320 288 256 191 127
277 242 169 95
225 174 87
143
75
50 42 33 24 16 7
405 386 367 349 330 311 289 267 233 137
362 343 324 305 282 259 222 185 117
340 322 301 281 251 222 170 117
318 299 275 250 210 170 94
295 273 242 210 153 95
267 241 197 153 76
100 91 82 74 65 56 46 39 30 13
427 413 400 386 373 360 346 333 305 254 163
409 396 382 369 355 342 329 315 300 267 193
394 380 367 353 340 327 313 299 282 242 149
378 365 351 336 325 311 296 291 291 212 92
363 349 336 323 308 294 277 259 235 173
347 334 320 307 291 275 255 234 203 123
161 152 143 135 126 117 109 100 91 74 46 22
429 415 404 393 382 371 349 316 279 228 103
423 '12 401 390 379 368 357 346 324 299 241 167
421 410 399 368 377 366 355 344 334 311 273 216 126
409 398 387 376 365 354 343 332 321 297 255 188 75
396 385 374 363 352 341 330 319 307 282 233 149
38.' ~72 361 350 340 329 317 306 293 265 207 103
211 202 194 185 176 168 159 150 142 124 98 72 46 12
427 418 408 399 381 353 325 296 245 126
424 m 406 396 387 378 359 332 303 269 202
423 414 404 395 386 376 367 349 321 290 253 175
422 412 403 394 384 375 366 357 336 310 277 235 142
420 411 401 392 383 374 364 355 346 327 298 262 214 102
409 400 391 381 372 363 354 345 335 317 296 245 188
260 252 243 234 226 217 208 200 191 174 146 122 96 61 18
425 417 401 378 355 331 299 246 158
423 415 407 399 383 360 337 313 277 212 94
421 413 406 398 390 374 351 328 303 265 191 53
420 413 405 397 389 381 365 342 318 293 252 166
427 419 411 403 395 368 380 372 357 333 309 283 237 138
426 418 '10 402 395 387 379 371 363 348 324 300 271 219 104
320 311 303 294 295 277 268 259 251 233 207 181 155 121 77 34
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AUTOMATED DESIGN AND MANUFACTURING PROCESSES ASSURE
QUALITY CONSTRUCTION, TOP PERFORMANCE, AND LONG OPERA TING
LIFE.
Pump Selection Guide
MIN. FLOW MAX. MAX.
MODEL WELL RANGE HEAD HEAD
SIZE (GPM) (FEET) (PSI)
4 Inch &.. Larger Wells
SS 4" 1.2-7 870 377
7S 4" 3-10 680 294
10S 4" 5-14 950 411
16S 4" 10-20 990 429
25S 4" 18-32 630 273
40S 4"&6" 24-55 755 327
60S 4" 40-75 505 219
75S 4" 45-95 460 199
6, 8, 10-Inch &.. Larger Wells
80S 6" 48-110 845 366
135S 6" 75-200 835 361
225S 6"&8" 150-290 680 294
375S 8" 230-500 310 134
SOOS 10" 350-800 420 182
1000S 1 0" 600-1300 575 249
Deep Set
SS-DS 4" 1.2-7 1330 576
10S-DS 4"&5" 5-14 1550 671
16S-DS 6" 10-20 1980 857
25S-DS 6" 18-32 1255 543
40S-DS 6" 24-55 1655 716
B0S-DS 6"&8" 48-110 1745 755
135S-DS 8" 75-200 1910 827
225S-DS 8" 150-290 1220 528
375S-DS 8" 230-500 1080 467
600S-DS 10" 350-800 590 255
1000S-DS 10" 600-1300 860 372
Exclusive Grundfos Designs
1. FAIL-SAFE CHECK VALVE DESIGN: Grundfos
stainless steel check valves are built into the top pump
chamber to prevent backflow. These positive, non-clogging,
non-slamming valves are sized to meet the maximum
pressures for each model.
2. STAINLESS STEEL FABRICATION YIELDS MAXIMUM
HYDRAULIC PERFORMANCE: Grundfos fabrication tech-
niques for stainless steel permit ideal shaping of impeller
and diffuser vanes for top performance and high efficiency.
3. EXCLUSIVE PRIMING INDUCER PROTECTS
AGAINST DRY RUNNING: The exclusive Grundfos priming
inducer protects against damage due to dry running should
water levels drop unexpectedly in the well. Located inside
the suction interconnector at the pump inlet, this small, axial
flow screw provides enough water to lubricate the pump
until the well has time to recover.
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PENBERTHY
Section 1000
Bulletin 1200
Issued 5187
Replaces 1/82
JET PUMP TECHNICAL DATA
■ pumping
liquids
This technical bulletin includes general information
about Penberthy Jet Pumps plus specific details for
selecting the proper unit. The two basic series of
Penberthy Jet Pumps covered in this bulletin are used
for pumping liquids only.
L m -I ,h/1,1,V 1-tv\ -A-
U D -1 lhfl.,U UD-0
L D -\ -rh /l,(A I-D-4-
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PVC-LL, LM, LH
PVC-LL, LM, LH DIMENSIONS (in inches)
,·.SIZE . -::, .. ; •,-\//;f~ A B C D E F
'hA LL, LM, LH 3¥, , 111,6 1511& "· 'hB LL,LM, LH 3¥, , ,,,,6 15,116 "· 'h LL, LM, LH 4% 111/15 151,&
¥, LL, LM, LH s~. 1'1,
LL 67/, 21/1 151'16
LM,LH 67/a 2'1, 15/ie ,
LL 91/,, 2¥, 1'k 1¼ n.
1¼ LM,LH 91/u 2¥, 1'k 11/, 1 v ..
1 'h LL, LM 1015/,, 3 H. 1'k 1'k
LH 10151',, 3 H. 1¼ 1'h 1'k
2 LL,LM 14~,, 3'k 11¥11 2 2
2 LH 14:1/1, 3'k 1 '51',, 1'k 2 2
2'k LI., LM 181'2 4 2'k 2'k 2'k
2'k LH 181'2 4 2'h 2 2'k 2'k
3 LI., LM, LH. 243111 4'k 3 2 3 3
FABRICATED -LL,LM,LH
' ·,-, .. _:~-~-
'
'
FABRICATED -LL,LM,LH DIMENSIONS (In Inches)
'SIZEJf;> A B C D .. E F
4 LL,LM,LH 38 ,,. 5 .,. 8 3 4 4
6 LL,LM,LH 52 '/, 5 ,,, 9 '/, 4 6 6
8 LL,LM,LH 74 ,,,. 8 ,,,. 13 6 8 8
10 LL,LM,LH 87 ,,, 1Q l/1 14 8 10 10
12 LL,LM,LH 110 ,,. 11 ,,. 18 10 12 12
•·Bolting corresponds to ASA 150 lbs. Bolt hOles in O flange ol all sizes are blind .
tapped.
8
'
E(NPT-.L_-4--_ __.$.c.J......!....J.>--.::: na1 faced flange
D (NPT-on sizes 4 & 6)
flat faced flBllge on size 6)
F(NPT-
llal tacec flange
on sizes, & 6)
CAST -LL, LM, LH DIMENSIONS (in inches)
SIZE
'l,A LL, LM, LH 4'/, 1 '/, , ,,. '/, 'I, '/,
'/, B LL, LM, LH 4'/, , ,,, , ,,. '/, '/, '/,
'I, LL 4'/, , ,,. , .,. '/, '/, 'I,
LM, LH 4'/, , ,,, 1 '/, "' 'I, 'I, .,. LL 5'/, 2 1 '/, "' .,. "' LM, LH 5'/, 2 1 '/, '/, . ,. ., .
1 LL 7'/, 2'/, Pl, 'I, 1 1
LMAH J 7'1, 2'/, Pl, .,. 1 1
1 .,. LL 9 2'/, 2'/. . ,. , ., . 1 '/,
LM, LH 9 2'/, 2'/, 1 , .,. , '/, , ,,, LL, LM 11 2'/,. 2'/, 1 , ,,, 11/1
LH 11 211. 2'/t 1 ,,. 111. 11/1
2 LL, LM 141/1 3'1, 3 1 'I. 2 2
LH 14111 3'11 3 1 'It 2 ' 2
2'/1 LL, LM 18'/, 31/1 4 ,,. 11/J 21/1 21/1
LH 181/1 31/1 411, 2 21/1 . 21/1
3 LL.LM,LH 23'/, 4 5 2 3 3
4 LL, LM, LH 32'1, 5 6 3 4-• 4n.ng,·
6 LL, LM, LH 471/, 5'/■ 5'/a 411anoe• 6-· 6-· /bl<na (tJind
' lapp,a """'" boltholesJ boll holcts)
•Bolting corresponds to ASA 150 lbs. Bolt holes in O and E ftanges of size 6 are blind
tapped.
MOLDED -LL, LM, LH
..... -~ .. "·. ,:: ·: ·,, ··.·
·• • "'··--&; • •
MOLDED-LL, LM, LH DIMENSIONS(in Inches)
:SIZE · .. ;:.:~t-~~ A B C D . .. E-~~·:-Fl
¾ LL, LM, LH 51s,1, 2 1't. 'h ¾ ¾
LL, LM, LH 7't. 211. 1'h ¾
1 ,,. LL, LM, LH 9'\o 211/11 ,,. 1 .,. 1 't.
1'h LL. LM. LH 1111,. 3 211,, 1'J. 1'k 1'h
f
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Penberthy L Series liquid-operated
jets are available for low. medium
and high discharge pressures.
Sizes available
Each model is available in 15 sizes
from 1h to 12 inches suction and
discharge. Units are cast construc-
tion in sizes ½ through 6. Sizes 4
through 12 are available with fabri-
cated c~>nstruction. Certain sizes
of units are also available in PVC
or molded construction as shown
in the charts on page 8.
The following information is
needed for selection:
• Temperatures ol operating and
suction liquids
· • Available operating liquid pres-
sure PSIG (hml
• Available volume of operating
liquid GPM (0ml
• Suction tift in feet of water (h5)
• Discharge head in feet ol water
(h,)
•
• Required pumping capacity
GPM(Q,)
• Specific gravity of operating
liquid
• Specific gravity of suction liquid
• Viscosity of operating liquid
• Viscosity of suction liquid
NOTE; Always specify material,
model and unit size when order•
ing. For available materials,
check Penberthy Material
Specification Sheet.
MODEL
Operating medium
Operating medium pressure range
Nominal operating medium pressure
PSIG/ft.of discharge head
Discharge heap pressure range
Suction lift
Minimum NPSH•
•How to calculate NPSH
In the selection chart above, the
operating liquid is assumed to be
at ambient temperature. When the
operating liquid is at higher tem-
peratures or when the vapor pres-
sure is other than that of water,
the liquid may vaporize wlthin the
jet pump and reduce pumping
capacity.
For jet pumps, both motive and
suction liquids must be considered
for purposes of calculating net
positive suction head (NPSH).
Whichever liquid has the higher
vapor pressure should be used as
the basis of the calculation. Both
liquids will be at the same temper-
ature when they meet at the jet
center line.
NPSH available is the dynamic
~ressure, in feet of liquid absolute,
measured at the center line of the
jet, tess the vapor pressure. It must
equal or exceed the NPSH that
is required to achieve stated
performance.
To calculate NPSH for your appli-
cation, use the following formula:
NPSH • 2.31 (P, -Pvpl + h, -H1
SG
where:
P 1 • Pressure in !'he suction ves-
sel in pounds per square
inch absolute (PSIA).
Pvp • Vapor Pressure ol the
pumped liquid in PSIA. .
So • Specific Gravity ol pump-
ed liquid (lbs) at pumping
temperature.
• Feel !hat the fluid is
below or above the jet
pump center line (nega-
live ii below; positive ii
above).
H1 • Friction Loss in the sue•
lion line (feet of liquid).
LL LM
Low Head Medium Head
Liquid Liquid
15-200 PSIG 15-200 PSIG 15-200 PSIG
2 PSIG 1.5 PSIG 1.0 PSIG
(SP. GR. 1.0) (SP. GR. 1.0) (SP. GR. 1.0)
to 50 ft. 40 to BO ft. 80 ft. or more
to 27 ft. to 27 It. to 27 ft·
3 ft. 3 ft. 3 ft.
NPSH EXAMPLE CALCULATION:
To pump water at 120°F with the surface of the water 12 feet
below the jet pump center line:
Fluid Height(h1) ..........•.......•.•......••••...... -12
Vessel Pressure (P5) .•••••••••••••• 14.7 PSlA
Vapor Pressure (Pvp) ............................ 1.942 PSlA
Friction Loss (H1) ••••••••••••••••••••••••••••••••••••• 1 foot
Specific Gravity (So) ................................. 0.988
Using the formula given above:
NPSH = 2.31 (14.7-1.942) + 1_12) _ 1 .988
NPSH = 16.82 feet of water absolute
The feet of water supported by 14.7 PSIA minus NPSH equals
Suction Lift in feet:
Suciion Utt= (2.31 x 14.7) -16.62 = 17.1 feet of water
•
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I CONSIDERATIONS WHEN INSTALLING OR OPERATING JET PUMPS
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Installation
Penberthy Jet Pumps will
operate in any position. They
should be installed with mini-
mum length of piping and with
as few elbows and valves as
possible to limit friclion losses.
Inlet piping
Piping must be large enough
to supply jet pump at maxi-
mum flow. Inlet pressure should
be as specified in the perfor-mance data for the application.
Suction piping
To insure maximum capacity
and highest possible vacuum,
all suction piping must be air-
tight.
When lifting liquids by suction,
locate the jet as ctose to the
liquid level as practical, with
the remainder of the elevation
on the discharge side. Design
pressure loss should not ex-
ceed two feet, including strain-
er, foot valve and other piping
at desig11 suction flow rate.
Typical jet pump installation
Discharge piping
Piping should be equal in size
to that of the pump . It dis•
charge line is long, piping size
should be increased to mini•
mize the discharge head.
Start•UP of steam jet pumps
When starting steam jet pumps,
the steam valve should be
opened slowly to enable the
unit to stc!rt smoothly. All
valves should then be ad• justed to permit operation ac-cording to design conditions.
Maintenance.
If properly selected, Penberthy
Jet Pumps will operate for ex-
tended periods without main-
tenance or parts replacement.
Faulty operation, or reduced
performance, particularly on
small units, may be caused by
scale or foreign matter in the
lines. Install suitable strainers
in the inlet lines to eliminate
this problem. Scale can be re·
moved mechanically by dis-
assembly or by chemical treat-
ment.
PENBERTHY
P.O. Box 112. Prophetstown, IL 61277 USA
TEL: [phone] FAX: [phone]
TELEX: 257-339 PMCO PAWN
C 1987 Penberthy. All rights reserved.
, .. ···! . .. ..
IN, HG.
VACUUM
" ,.
" " "
PIIUSUIIIENACuu• CC)IIPAIUITNl SCA.LU
IN. HG. A&S. l"IIA ... ,. ,.
"
"
.... 'l. WAT(III
'l.WATEA
IUCTJON
""
-,o-'----'---_...__ ____ _
AaSOLJJTE n•o
---'---'11USURE
1 • Hg = 0.49 PSI = 1.13' Water 2.04" Hg = 1.0 PSI = 2.31' Water 0.88"Hg = 0.43PSI = 1.0' Water
Unit conversions
1 kPa = 0.145 PSIG
= 0.335 ft water (20'C)
= 0.295 in Hg (20'C) 1cm = 0.394 in
1 m = 3.28 ft
1 1/S = 15.85 GPM
1 mPa•s = 1 cP
1 kg/h = 2.205 lb/hr (steam)
Printed in U.S.A.
'-'
~ 1½ LL, LM, LH PERFORMANCE csuc:r10N CAPACITY GPM ~
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··., 14 25 35
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LL, LM, LH CAPACITY FACTOR
Sill llA 1'B 11 1' 1¼ 111 2 2!; 3 46810121
FACT08 .030 .047 .121 208 .344 .613 1.00 1.82 3.17 5.92 11.8 24 49 71 123
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7 5 18 15 2, · II 26 2• 111 28 2S 2, 211 25 30 28 25 31 211 25 31 21 2e 31 21 26 31 28 29 31 28 26 31 211 28
,. • 2, 20 2, 9 211 2s 17 28 25 2, 28 25 31 211 2s 31 n a 31 211 211 J1 28 21 31 2a is J1 n 211
10 3 19 1' 2, 23 25 1 \ 28 25 18 28 2S 25 211 25 31 21 2S 31 21 26 31 28 20 31 28 26 31 211 28
6 15 2, 17 25 25 25 12 28 25 HI 28 25 30 28 211 31 28 26 31 21 28 31 28 26 31 28 211
12 21 12 25 20 25 II 28 25 13 28 25 25 21 21 31 28 26 31 28 26 31 28 26 31 28 28
5 13 1 23 10 25 1lil 25 2 27 25 15 28 29 25 28 26 31 28 21 31 28 26 31 28 211
6 111 25 10 25 17 25 , 28 2t 111 28 26 H 28 26 31 28 26 31 28 28
9 11 25 25 2' H 7 211 26 17 28 29 26 28 26 31 28 28
2 16 19 25 18 2e 28 26 8 23 28 22 28 26 28 28 28
5 12 21 729 2226 28211221126202828
6 15 29 ,. 26 21 26 2 2a 26 11 211 211
2 16 26 12 28 26 26 28 26
5 18 29 1126 2,21
8 21 26 10 28
12 23 20
18 16 19 20 \8 2, 20 28 2, 20 27 2, 2\ 27 2, 22 27 2, 22 27 2, 22 27 2, 22 27 2, 23 27 2, 23 27 24 23 27 2, 23 27 2, 23
3 4 18 15 20 8 23 20 18 2, 21 25 2, 22 27 2, 22 27 2, 12 27 2, 22 27 24 23 27 2, 23 27 24 23 27 2, 23 27 24 23
11, 20 11 20• 8 2, 21 18 2, 22 25 2, 22 27 2, 22 27 2, 22 27 24 23. 27, 2, 23 27 24 23 27 2, 23 27 24 23
5-1 16 12 20 21 21 11 2, 22 19 2, 22 25 2, 22 27 2, 22 27 2, 23 27 2, 23 27 2, 23 27 2, 23 27 2, 23
'111 20 10 22 15 22 2' 22 2, 22 20 2, 23 27 2, 23 27 2, 23 27 2, 23 27 2, 23
s: 12 22 8 22 18 :l2 2, 22 10 24 23 21 24 23 27 24 23 27 2, 23 27 24 23
:I 9 17 22 622 22Z3' 2,23132,:n222,23212,23
,_.-J 2 10 11 22 13 2:1 2• 23 4 24 n 1, 2, 23 25 a. 23
6 1, 23 11 23 24 23 2, 23 I 2, 23
.~ .;•.t 1S 23 123 2323 2423
···1 5 11 23 23 21 23
,4 Ci 7 ·21. 23 723
-., .. ·.12 22 · 23 ,, 11 11 12 18 11 20 11 11: 21 19 11 21 1a 11 2, 20 11 21 20 11 21 20 18 21 20 11 21 20 19 21 20 1a 21 20 19 21 20 111
I 10 I 17 17 11 11 1T: 19 19 17 20 11 11· 21 20 111 21 20 lS 21 20 18 21 20 11 21 20 111 21 20 19 21 20 19 21 20 18
1.S: 10 17 2 11 17':11 19 17 Ill 11 11 21 20 18 21 20 11 21 20 18 21 20 18 21 20 111 21 20 U, 21 20 Ill 21 20 11
• 1, , 11 14 11: 3 111 11 13 19 11 20 20 111 21 20 11 21 20 18 21 20 u, 21 20 19 21 20. ,, 21 20 111 21 20 11
3 15 t 171 18 17 8 1t 11 1' 20 11 20 20 11 21 20 18 21 20 11 21 20 19 21 20 11 21 20 111 21 20 11
·l 11 3 1T 12 17 19 11 7 20 18 1' 20 18 21 20 111 21 20 11 21 20 111 21 20 HII 21 20 19 21 20 18
,.J 17~ 17 17 11 20 18 II 20 18 16 20 18 21 20 19, 21 20 19 21 20 111 21 20 19 21 20 Ht
-· I 4 13. 17 12 11. 20 II ' 20 11" 11 20 111 20 20 1a 21 20 11 21 20 11 21 20 111 21 20 19
• ..,j . ·10: 12 7 11< 15 18 20 18 5 20 18 111 20 11 21 20 Ill 21 20 11 21 20 111 21 20 1~
I r. ta. a 18 ,. 1a 20 18 7 20 19 15 20 19 21 20 ti 21 20 111 21 20 tt
·-.~ 14" 18 4 16 13 18 20 19 I 20 19 17 20 19 21 20 11i1 21 20 , •
If 16 11' 3 11 11 19 20 111 I 20 18 18 20 Ill 21 20 11'
1• 9 11 111 101, 20111 2011102019202019
~ 3 11 18 ,. 17111 20112.112019172011
5 1, 19 t 19 20 HII 20 111 , 20 11
11 111 7 .,, 20 19 20 1'11
te 11 -UI 519 1111 ., S 1 12 19 4 ,.
2 19 11
ATEA.•\9.2 u 2s' ,, 11 29 13 20 38 15 24 41 11 26 46° 18 29 s, 20 31 ss' 21 33 58 23 35 62 2• 31 65 28 41 n, 28 44 n 30 47 83 32 50 as 34 53 s2 · M(Qm) , ,
7
RMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX F
APPENDIX F
PUMP DATA SHEET· SVE
l:\WP\ 7017001723. O&Mledt9d
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TROUBLE
No Air Flow
Low capacity
Excessive Power
Overheating of
Bearings. or Gears
Vibration
ITEM
l
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
TROUBLE SHOOTING CHECKLIST
POSSIBLE CAUSE REMEDY
Speed too low Check by tachometer and compare with speed
shown on Roots Order Acknowledgement.
Wrong rotation Compare actual rotation with Figure 2.
Change driver if wrong.
Obstruction in piping Check piping, screen. valves, silencer, to assure
an open now oath.
Speed too low See item 1. If belt drive, check for slippage and
readjust tensio11. .
Excessive pressure Check inlet vacuum and discharge pressure,
and compare these figures with specified
operating conditions on Order.
Obstruction in piping See item 3.
Excessive slip Check inside of casing for worn or eroded sur•
faces causing excessive clearances.
Speed too high Check speed and compare with Roots Order
Acknowledgement.
Pressure too high See item 5.
Impellers rubbing I11Spect outside of cylinder and headplates for
high temperatures areas, then check for im·
peller contacts at these points. Correct blower
mounting. drive alignment.
Inadequate lubrication Restore correct oil levels in gearbox and
lubricate.
Excessive lubrication Check gear oil level If incorrect, drain end refill
with clean oil of recommended grade.
Excessive pressure rise See item 5.
Coupling misalignment Check carefully. Realign if questionable.
Excessive belt tension Readjust for correct tensio11.
Speed too low Speeds lower than the minimum recommended
will overheat the entire blower.
Misalignment See item 14.
Impellers rubbing See item 10.
W om bearings/gear, Check gear backlash and C011dition of bearings.
Unbalanced or rnbbing Scale or process material may build up on cas·
impellers Ing and impellers, or inside impellers. Remove
build-up to retore original clearances and im-
peller belence
Driver or blower 1oose· Tighten mounting bolts securely.
Piping resolllllces Determine whether standing wave pressure
pulsations are present in the piping. Refer to
Distributors.
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BASIC PACKAGE
DESCRIPTION
Roots offers 5 Roots Pak sizes of com-
pletely assembled, factory engineered and
guaranteed packages inccrporating 16
frame sizes of Universal RAI rotary posi-
tive blowers with flows to 1600 ICFM,
pressures to 15 psig or vacuums to 16"
Hg.
SPECIFICATIONS
~iOOTSP.:1J/Jf~™
P R nns.r ,
The basic package consists of the
blower, V-belt drive, OSHA guard, motor
slide base, inlet filter and inlet silencer all
mounted on top of a heavy-duty, unnized
base/discharge silencer in one compact,
easy to install package. A pressure relief
valve is mounted on the discharge si-
lencer. "Motor and other accessories op-
tional.
Universal RAI®
Packaged units (Patent pending)
The combination base/discharge si-
lencer is a rigid, one-piece weldment, re-
inforced for minimal vibration. The inlet
filter is supplied with a 10 micron pleated
paper element. All standard components
are designed for indoor or outdoor opera-
tion.
The Universal RAI blower consists of
a cast iron casing, carburized and ground
alloy steel timing gears secured to steel
shafts with a taper mounting and locknut,
and cast iron involute impellers. Oversized
anti-friction bearings are used, with a cy-
lindrical roller bearing at the drive shaft on
OUTLINE DRAWING & DIMENSIONAL TABLE
RELIEF VALVE
INLET FILTER
INLET SILENCER
7,,,-.....L',r-,-rti:::::ic::__EXPANSION
JOINT
A
C
all models to provide increased bearing
life and to withstand V-belt pull. The
Universal RAI features thrust control, wnh
splash oil lube on the gear end and grease
lube on the drive end.
RootsPak units are factory painted
and skidded for shipping and handling.
-!-~.fi ~
EVERY GROWING PLANT NEEDS ROOTS
I--B _j
D -MPT DISCHARGE CONNECTION UNITIZED BASE/ DISCHARGE SILENCER
NOTES:
1. All dimensions ant in inches.
2. OimensDns are approximate-do not use for construction. Pacir.ages may no! be exactty u shown.
3. Basic padtage weights do no! indude blower _and motor. For blower weight, see reverse side of sheet.
4. V-belt guard IS furnished, but not ahown in above drawing.
RootsPak Blower A B C D Approx. net
Size Frame Sizes weight (3)
2 22,24,32,33,42 35 22 48 2 190 lbs.
2·1/2 36,45,53 40 24 65 2-1/2 230 lbs.
4 56,59, 76 56 28 75 4 , 460 lbs.
6 68,615,711 70 36 84 6 s.
PERFORMANCE TABLE
,·;•. , , .....
II
I I BLOWER
FRAME 1PSI .... .... 4 PSI ·IPSI IPSI JPSI . '·: ;; 'c'; 10PSI . 11 PSI UPSI ·_:-.. ·,s PSI IIAX. VACUUM
.
I I
I i ,
I -~
I I
I I
II
....
SZE --~
22
1321
24
1431
32
(69\
33
(74\
38
1102\
42
188\
cs
1109\
47
'1281
53 " .. ,
'56
' 1170\
511
(204\
I 65
(245\
68
12851 I 615
1425\
--76
(400)
711
(530) .
SPEED CFII BHP CFM Rlll
1160 10 02 7
3600 49 0,6 46
5275 76 0,8 73
1160 24 0,3 19
3600 102 0,8 97
5275 156 12 150
1160 40 0,4 34
2800 113 1,0 108
3600 149 1 ,3 144
1160 55 0,5 46
2800 156 12 149
3600 205 1,6 199
1160 95 0,7 85
2800 262 1,7 253
3600 344 2.2 334
680 38 0.4 32
1760 92 0,8 87
3600 204 1.7 198
680 79 0.6 68
1760 198 1.3 177
3600 410 2.6 400
860 109 0.8 97
1760 253 u; 241
3600 546 3,2 535
700 72 0.6 63
1760 211 1.5 203
""'" .,, .. '46
700 123 0.9 110
1760 358 22 345
2850 598 3,6 585
•= 10, ,.~' 1 ,v
1760 529 3,0 513
2850 881 4.9 865
700 140 1.0 126
1760 400 2.6 387
2350 546 3.5 532
700 224 1,5 203
1760 643 3,8 621
2350 876 5.0 855
700 420 2,6 380
1760 1205 6.4 1164
2350 1641 8.6 1601
575 195 1.3 179
1400 526 3.2 511
2050 788 •. 7 772
575 362 22 336
1400 970 5,3 944
2050 1450 7.7 1424
BHP CFII BHP CFM BHP CFM BHP
0,3 4 0,3 2 0,4
0,8 43 1, 1 41 1,3 39 1,6
1,2 70 1,6 68 1,9 68 2.3
0.4 15 0,6 11 0,8 8 0,9
1,3 93 1.8 89 2.3 86 2,8
1,9 146 2,7 143 3,4 140 42
0,6 30 0,9 27 1.1 24 1.3
1,8 104 2,1 101 2.7 98 32
2,0 140 2,7 137 3,4 134 4,1
0,8 43 1,1 39 1 ,4 35 1.7
2,0 144 2,7 140 3.5 136 42
2,5 193 3.5 189 4,5 185 5,4
12 78 1,7 72 2.3 66 2.8
3,0 245 42 239 5.4 234 6.7
3,8 327 5,4 321 7.0 315 8.6
0,6 28 0,9 24 1. 1 21 1.3
1.3 82 1.8 78 22 75 2.7
2,6 194 3.6 190 4.5 186 5.5
1.1 60 1.5 53 2.0 48 2.4
22 169 3.1 162 4.1 156 5,0
4,5 392 6,4 385 8,3 379 10.2
1 ,4 89 2,0 81 2,6 74 3.2
2,8 232 4,0 225 5.3 218 6,5
5,7 526 8,2 518 10.7 511 13.2
1,0 56 1.4 51 1.8 46 22
2.6 196 3.6 191 4,6 186 5.6 . . '4n '" ,,,,. 7 ... ·-o,
1,6 100 22 92 2.9 85 3.6
3.9 335 5.6 326 7.3 319 9.0
6.4 575 9.1 S67 11.9 .. ,,, .... ~ ..,
2.2 156 3.2 147 42 138 5.1
5.5 500 6,0 490 10.5 480 12.9
8,9 852 12.9 842 16.9 832 20.9
1.8 116 2,6 107 3.3 100 4.1
4.5 377 6.4 368 8.3 360 10.2
6,0 522 8.5 513 11.1 506 13,6
2.7 187 3,9 172 5.1 160 6.3
6,8 605 9.8 591 12.9 579 15.9
9,1 838 13.1 824 17.2 812 21.2
4,8 351 7.1 323 9.3 301 11.6
12.1 1133 17.8 1-107 23.5 1084 29.1
16.1 1570 23.7 1544 31.3 1521 38.9
2.3 168 3.3 158 4,3 150 S.•
5,7 500 8.1 490 10.6 481 13.0
8,3 761 11.9 751 15.5 742 19.1
4,0 316 5.9 299 7.7 264 9,6
9,8 925 14.3 908 18.8 893 23,3
14.3 1404 20.9 1387 27.5 1373 34.1
CFII BHP CFM BHP CFII BHP CAI BHP CFll BHP CFll BHP .... CFII BHP .. _,,. .. , ·.':
4 6 0,3
38 1,8 36 2,1 32 2.8 31 3,1 29 3,3 14 28 2,0
64 2,7 63 3,1 59 42 57 4.5 56 4,9 14 55 3,0
8 12 0,6
83 3,3 81 3,8 14 69 3,8
137 4,9 135 5,6 14 122 5,5
21 1,6 19 1.8 10 18 1,3
95 3,8 93 4,3 86 6,0 84 6.5 62 7,1 77 6,7 15 78 4.5
131 4,8 129 5,5 122 7,7 120 8,4 118 9,1 113 112 15 114 5,8
31 2.1 28 2.4 10 27 1 ,7
132 5,0 129 5.7 120 8.0 118 8.7 116 9.5 14 113 5,6
181 8.4 178 7.4 170 10.3 167 11.2 165 12.2 14 163 72
61 3,3 57 3,8 1U 55 2.7
229 7.9 224 92 12 213 7.8
310 10.2 306 11.8 14 284 11.6
18 1.5 15 1.8 8 19 1,1
72 3,1 89 3.6 62 5.0 80 5.5 58 5.9 14 56 3.5
183 6,4 181 7.4 173 10.2 171 112 169 12.1 163 1S.O 14 167 7.2
42 2,9 37 3.4 8 46 1,9
151 5.9 146 8,9 133 9.6 12 134 5,8
374 12J 369 14.0 356 19.7 14 345 13.7
68 3,8 63 4.4 8 72 2.5
212 7,7 206 8,9 12 193 7.5
505 15,8 500 18.3 14 473 17.9
42 2.6 38 3,0 10 36 22
181 6.6 177 7.6 167 10.7 163 11.7 160 12.7 14 158 7.5
""' . ., ""1 1•. """ .. " ""7 ,e.c 304 20,5 295 25.4 14 301 12.1
78 4,3 72 4.9 10 70 3.5
312 10.7 306 12.4 290 17.5 ,. 278 12.1 ... ... ...... .. --. '. 517 19.7
130 6.1 8 135 4.1
472 15.4 464 17.9 12 445 15.1
824 25.0 816 29,0 14 779 28,3
93 4,8 86 5.5 70 7.8 12 71 4.7
353 12.1 347 13.9 330 19,6 325 15.3 320 23.4 307 29.1 16 300 15,5
499 16.1 492 18.6 475 26,2 470 28,7 466 31.2 452 38,8 .16 445 20,7
149 7.5 139 8.7 10 135 6.2
567 18.9 557 22.0 530 31,0 522 34.1 515 37,1 15 495 23.0
801 25.3 790 29.3 763 41.5 755 45.5 748 49.6 i16 715 32,6
279 13,8 8 292 9,1
1063 34.8 12 997 34,1
1500 46,5 12 1433 45,5
142 6.4 134 7,4 115 10.4 12 117 62
473 15.5 466 17.9 447 25,3 441 27.8 438 30.2 421 37.6 16 413 20,0
734 22.7 727 26.3 708 37.1 703 40.7 697 44.2 682 55.0 16 674 29,2
271 11.4 258 13.3 226 18.8 12 228 11.2
880 27,8 867 32,3 635 45.8 15 793 33.8
1359 40.7 1347 47.3 1315 67.1 16 1256 52.7 I Notes: !: Pressu,e ratings based on inlet air at standard pressure of 14.7 psia, standard temperature of 68'F, and specific gravity of 1.0.
Vacuum ratings based on inlet air at standard temperature of 68'F, discharge pressure of 30" Hg and specific gravity of 1.0.
Consutt factory for RootsPak optional vacuum packages.
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3. Blower weights shown are approximate net weights in pounds.
DESIGN & CONSTRUCTION FEATURES
1. Factory engineered, factory guaranteed
2. Compact package designed for ease of handling and installation
3. Indoor or ouldoor operation (when ordered with sultable motor enclosure)
4. Blower covered by 18124 month uncontested warranty
5. Refer to bulletin B-5125 for Universal RAI blower details
I I ROOTS
· DRESSER INDUSTRIES. INC.
ROOTS DIVISION
900 WEST MOUNT STREET, CONNERSVILLE. INDIANA 47331
TELEPHONE: [phone] FAX: [phone]
I•" S-5121P
Revised Augus1, 1991
Al spec;!ications suDjed 1D ctlarigo Wllhcut l'IOIICO
C1Q91. OresSo! 1r.dustnes. Irle.
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WASTEWATER TREATMENT MANUAL SECT!Of.l 4.A
PAGE 7 February, 1992
4.A-(Continued) RCCJTS PAK~;,. ROTARY BLOWER PACKAGES
SIZES 2 THROUGH 6
DESCRIPTION
Roots offers 5 RootsPak sizes of completely assembled,
factory engineered and guaranteed packages incorporating
16 frame sizes of Universal RA/ rotary positive blowers.
The basic package consists of the blower, V•balt drive,
weatherproof OSHA guard, motor slide base, In/at filter and inlet silencer all mounted on top of a heavy-duty, unitized
base/discharge silencer in one compac1, easy to install pack-
age. A pressure relief valve is mounted on the discharge
silencer. Motor and other ac:eessories are optional.
The combination base/discharge silencer is a rigid, one-
piece weldment, reinforced for minimal vibration. The inlet
filter is supplied with a 10 micron plaated paper e/emant. All
standard components are designed for indoor or outdoor
operation.
For details on the Universal RA/ blower, rafer to Sec1ion
4.A, page 1.
PERFORMANCE MAP
ROOTSPAK BLOWER PACKAGES 16r----r-r--""""1==i-r---r----,r---r---r----,-------, ,--I 42 I
FIGURE 4.A•S
POOTS
ROOTS DIVISION, DRcSSER INDUSTRIES. INC. 1100 WE ST MOUNT STREET
CONNERSVILLE. INOIANA •733•
17
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1:
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j~ 07 '9J lJ:05 Ett'A: ~ ............. ~,.,.,,.,SC . ~~,i~. ~93325:..=~44~5~$ TO:
ROOTS DIVISION DRESSER INDUSTRIES, INC.
CONNERSVILLE, IN. 47331
PRINTED IN U.S.A.
PERFORMANCE BASED ON se·F
INLET AIR~ DISCHARGE PRESSURE -30" HG ABS
~ I... u
w
~ :J
..J 0 >
~ w i -
a: ~
Q..
LLJ !Q
0 ::c:
LLJ ~ < a: tD
600
500
A.00
300
200
,oo
0
30
25
20
15
10
s
0
1000
JUNE 1990
PERF"ORMANCE
56 UN I VERSAL RA [ ® e!..OWER
MAXIMUM VACUUM: 1,• HG
MAXIMUM SPEEO. zeso RPM
1500 2(00 2500
SPEED -RPM
14• HG
12• HGi-....+-1-1
10• HG
e• HG
s• HG
3000
...._YC :.,! Z • !SS __
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RMT OPERATIONS AND MAINTENANCE PL.AN
MACON/DOCKERY SITE
APPENDIX G
PUMP MAINTENANCE • GW & SVE
l:\WP\70\7001723 O&M/cdf94
OCTOBER 1994
APPENDIX H
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GROUND WATER PUMP MAINTENANCE TABLE
Add oil to bearin s
Chan e oil
}a·•·MoNtttsoii·~ HOURS ' 1 i'.i&ih ! ;; ;•/dittl;h\i ;;~t;•,1i;;;·i·iitL ... ·.·.·.···· .. j ;; ;;
Chan e oil
has been idle
Re rease bearin s
Check foundation & hold down bolts for t Illness
Check foundation & hold down bolts for ti Illness
& Moti@s;o~ ~ fiouiitn)'l:di:i@; iiifaE;;;;;@ii;;tHti I 1!)11 jj(li\ /\)); I:
Chan e oil
hs been Idle
Re rease bearin s
Check foundation & hold down bolts
Chan e oil
has been idle
Re rease bearin s
Check foundation & hold down bolts for ti Illness
Check pump capacity, pressure & power against
specttications
Repeat this schedule for every (3 month or 3000 hrs)
NOTE: Initial each task following its completion.
l:\~130MM.MFSICOF93
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START-UP
Add oil to fill marl<
Change oil every 1000 hours
f:\WP\;\938130MM.MFS.a)F93
SVE PUMP MAINTENANCE TABLE
INITIALS DATE
.
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RMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
APPENDIX H
LOW PROFILE AIR STRIPPER DATA SHEET
l:\WP\70\7001723 OlMicctl94
OCTOBER 1994
APPENDIX H
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Low Profile
The discreet size of a ShallowTray® air stripper
does not advertise a contamination site. It is easily
accessed for maintenance and can be installed
inside a building. The system is also ideal as a
trailer-mounted, portable stripper for pump tests,
pilot studies, short-term cleanup, or emergency
. response. There is no tower.
Treatment
The ShallowTray process
uses forced draft, . . . countercurrent air stnppmg
through baffled aeration
trays to remove volatile
organic compounds
from water.
Contaminated water is
sprayed into the inlet
chamber through a coarse
mist spray nozzle. The
water flows over a flow
distribution weir and along
the baffled aeration tray.
Clean air, blown up
through ½," diameter holes
in the aeration tray, forms a
froth of bubbles generating
a large mass transfer surface
area where the contaminants are volatilized. The
necessarv contact or residence time to reach ;
required volatilization is achieved through model
size, addition of trays, and flow rate selection.
Resistant to Fouling
ShallowTray systems are resistant to fouling
problems. Treatment trays have large 3/,,' diameter
aeration holes. In addition, the turbulent action of
the froth scours the surfaces of the tray reducing
build-up of oxidized iron.
If, under extreme conditions, oxidized iron
accumulates or hardness begins to scale up, trays
can be easily cleaned through ports using a
washing wand and pressure washer. Trays canals,,
be easily removed for a thorough inspection and
deaning.
Full Range Turndown
:-.Jot only are Shallow Tray systems forgiving of
.. surprise" inorganics in the water, they also allow
operation anywhere within the rated flow range.
In fact, as the flow rate is reduced, performance
System Size
increases. Also, as
demands change (stricter
effluent contaminant
levels) so can the
ShallowTray system. Its
modular design allows
for the addition of trays
which increase the
percent removal of
contammants.
No Disposal
ShallowTray systems
have no packing or
diffusers to contend
with and no costs
associated with GAC
breakthrough, fouling
or disposal and
replacement.
To determine the system size required for your
site, first identify the flow rate. This guides you to
the ShallowTray Series needed. As an example,
with a flow rate of 30gpm, select the 2300 Series,
which is rated for flows from 1 to 45gpm.
Next, identify the contaminants present and the
removal requirement. Generally, this determines
the number of trays required. However, the graphs
in this brochure should be used as a guideline only.
For a proposal, send us or your representative the
specifications. Request for Quotation ·sheets are
available.
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SIGHTTUIIE---ll
w""ru1 ounETl--1.l_
··-
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IH---"°"'"
0
Model Pictured: 1331"
Options chosen for system pictured:
if Discharge pump, TEFC
il'NEMA 3R control ranel with level
controls for pump, :ilarm
interlocks, motor starter, relays,
I 00 db alarm horn
ii' Main disconnect switch
ii' Low air pressure alarm switch
:z:I' High level alarm switch
ii' Discharge pump level switch
:z! Water pressure gauges
"if Air flow meter
"if Line sampling ports
L_,. ___ ...... __ ~ _ ___J
FRONT VIEW RIGHT SIDE VIEW
I ·use these drawings as a guideline only. Systems are built to your project's specttications . ..
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1311 1-45gpm 1 4'0" 3'2"
1311 1-45gpm 2 4'0" 3'2"
1331 1-45gpm 3 4'0" 3'2"
1341 1-45gpm 4 4'0" 3'2"
Shal low profile
2300 AERATION TRAY
I I II) Ft INLE1
" I •
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5'0" 300
5'9" 300
6'6' 300
7'3' 300
l nil ovnmo
COMER '--Y~
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TOP VIEW
765
845
925
1005
Ill
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'Per·cent' Removal vs.' Ffow Rate.
,.,_ ••-
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lrCEl , _________ j---~---
Benzene
•-+---i--+---1----'·•e,,;...•-. _M_T_B_E--+--+-'-+--+----'-
•·•·1·•·•,, ·-,,_
j ......... ,04---i--+---1---1-~---+--=+~....l...--+---,-~, ............ -·-·-.,_
.,_ Four Trays ,
•-'--~---''--;._~---+--'--....l...--+---1--1
.. ,-
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'[--..•. , I I I: BenzJ:;•,
,.,4----'l--'-'--'-"'~ .• --'-I--, ----'----'---,-'--'--'-I
'·,: I I ... ... r, .. MTBE I
i .. ; .. _ 1 I .,,4--_ _;__..;__.;....._.;....._...c..,__,_-'---'--....l...-~-1
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.,. Three Trays· 1
• i ,.,. ,.;.
••· .. ,.
.,.
E ,oo~
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a:
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The graphs represent approximate removal ett1ciencies at SO'F. Use the
ShallowTray· Modelerr-1 software to calculate expe,..ted performance.
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PANEL co,m,c><
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SIGHTTVB ,_
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LOW AIR PRESS
SwrTCt-1
AIR PRESS G"GE
WATER FLOW METER
INLET WATER
"-OWER
FRONT VIEW
I •use these drawings as a guideline only. Systems are built to your project's specifications.
~
Model Pictured: 1631
Options chosen for system pictured:
if Discharge pump
ii!' EXP pump and blower motors
if NEMA 3R control panel with level
controls for pump, alarm
interlocks, motor starters, relays,
I 00 db alarm horn
if Control panel intrinsically safe
components for remote mounted
NEMA 3R panel
if Low pressure alarm switch
rif High level alarm switch
;J/f Discharge pump level switch
iif \X,'atcr pressure gauges
;J/f Line sampling ports
l '"' -52 rn.
43 in. ,
34 in,
= 7 in.
RIGHT SIDE VIEW
80'"
7 in,
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. .:,,J. Yflow~ ..... ~,,~· .·-: .. · ;~~'n}i~ ... ~~,-::,,._.. .,_ min. .. approL
-.;; .:•.rate, ·;im,s·::-:';11:ngth height,·. cfm· ·· lbs.
1611 1·90gpm 1 4'0" 6'2" 5'0" 600 935
16!21 1-90gpm 2 4'0" 6'2" 5'9" 600 1050
1631 1-90gpm 3 4'0" 6'2" 6'6" 600 1165
1641 1-90gpm 4 4'0" 6'2" 7'3" 600 1280
L $1!~,
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~600 AERATION TRAY
11 W.I.TfR IN!.l:T
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Ill
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. '. Percent Removal ·vs._ Flow' Rate
I lrCE' I I I ,oo-.,,-
• ,,_
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.,_ I t-··-~!.8E i I
.,,-+--+--'-----'---,-----,-----;------1 .,_ I i I ! ! .•• ··,··-·-!.. •.•.•• -
I I i ' : ,,,_ Three. Trays i :
.,,_
.,_
Benzene
; I 1 i I I i •oo-1 I i · TCE
::~ .. I ==r-T--< .
·• ! I : "",.. : 1•., ! I • .. ! ... ; I I ...... .. -+--+---.,----,------"--....,---,-------1
I ·• , I , --, . [\ i ! i .......... __
I : . ·-... i MTBE ,o-+-----,,----'-..C...i----------~-----,
&O-ij i : ......... ......... I
i ' i ··•, .. ······1:···· 1-' ···-•• " T~o Trays
E ,oo-I I " fl8-; ::~ t ..
u .. +--f-'"c-'C..,...-~------'---~·~·--,-----j
u ' ' TCE 1· .,_ N-I ......
" I I : ...... I I i "".,.; I I A. n-..... I : ! i""..... i
; ... 1 : ! ....... , ~enzene: ,o-+--+-'--.c''----'-----'----="'----.--=-'"-----,
I ·1····•~ .... ,: MTBE i --1-··----.,_ ', ~--............. . !
1 I ,..,, .. ,!,, .. ,.,,., '
,,,_ One Tray ! i i 1 ·-·· :·· -
,p "' "' .. .. .. *
1j Percent: of_• Ra t e d I ! . ; i
, , I , I ; 2600
.. .,
CrPM
i
The graphs represent approximate ~emoval efficiencies at S0"F. Use !he
ShallowTray· Modelerr11 software to calculate excec:ed performance. :-~
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IRONTVIEW
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~ = WATEIIFI.OW~ . . .. I . ~ t_
WATV' "-El --£"
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11
I 'Use these drawings as a guideline onfy. Systems are built to your project's specifications.
Model Pictured: 31221
Options chosen for system pictured:
iifNEMA 4 control panel with alarm
interlocks, motor staner, relays,
100 db alarm horn
if Main disconnect switch
!if Low air pressure alarm switch
if High water level alarm switch
!il'Water pressure gauges
!if Line sampling pons
iC 6 •61 •• • IP 'A 6 .61 Iv • • ·e 6 6' '• • • l 7111n • 67• ...
43m.
0 , •.
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76 lrl
RIGHT SIDE VIEW
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31 !111 1-270gpm 1 5'1 o· 12'6" 6'0" 1800 2565
312!11 1-270gpm 2 · 5'10" 12'6" 7'0" 1800 2910
31231 1-270gpm 3 5'10" 12'6" 8'0" 1800 3255
Sbal
low profile air strippers
31200 AERATION TRAY
If l'I._TER INlET
C'1AMBER I I I
U.....-iL---i ......... -iL.1/
I I I
TOPVJEW
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" a. .,
Perce.nfRemoval vs; flow Rate
I lrce !
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•._) ! I : ......... I r,. I I : ... .., , I " j 1 1 1 .,. • I ·... , ! Be:nze:ne: '1 . ' ' ·. ·. ·,., I i·, MTBE
: ·,. I I .• , ••.
I I
Three Trays
·• I :. ·\ I ·, i
·t•,. MTBE
i I
' II I : I Two Trays
'\•·-....... ..
Benzene
·1···········~······ I .. , .. , ~
I
I TCE.
. I Benzene
~ "' GPM
31200
n t; off R ~ t e ~
! I i : ' i
The graphs represenl approximate removal etficiencies at S0"F. Use the
Shallow Tray· Modelern1 software to calculate expeCt"'fl pertormance.
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AMT OPERATIONS AND MAINTENANCE PLAN OCTOBER 1994
MACON/DOCKERY SITE APPENDIX I
APPENDIX I
LOW PROFILE AIR STRIPPER TROUBLE SHOOTING GUIDE
l:\WP\70\7001723.0&Mlcdf94
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MAINTENANCE
Equipment
Maintenance
Instructions
Cleaning
Instructions
Equipment
Required
Pressure Washer
Washer Wand
Clean Water
Supply
Minerals, dissolved in high concentrations, tend to precipitate out of groundwater
during aeration processes. These minerals form insoluble deposits commonly
referred to as 'fouling.' Although the ShallowTray low profile air stripper system is
designed to be fouling resistant, proper steps must be taken when treating water
with high mineral concentrations. Deposits from iron-rich feed water can be
reduced by pre-treating ii with sequestering agents (Call Bill Comish, at Water
Solutions, 508-758-6120 for information). The recommended cleaning procedure
is pressure washing. Follow the instructions detailed below.
2 gpm minimum flow at 900 psi max. Equipment rental companies can usually
supply such a unit on a daily rental basis.
Washer wand with spray nozzle obtainable from North East Environmental
Products as an option, and an adapter to connect the wand to the pressure
washer hose end. All washer wand connections are 1/4" NPT.
Clean water supply with a capacity of at least 2 gpm at 20 psi, connected to the
pressure washer by means of an ordinary garden hose.
"
ShallowTray Operation and Maintenance Manual 4-1
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MAINTENANCE
Cleaning the Unit
Step 1
Turn off
equipment.
Step 2
Provide for waste
disposal.
Step3
Remove cleanout
port covers.
Step4
Tum on water and
pressure washer.
Step 5
Insert wand and
start water flow.
Tum off and disconnect the feed water supply and all associated electrical
equipment.
Make provisions for disposing of the sludge and waste generated during
cleaning. A weVdry vacuum may be required.
Remove all cleanout port covers.
Tum on the water supply to the pressure washer. Then, tum on the pressure
washer Itself. Wear protective goggles while spraying.
Insert the wand all the way into the s• deanout port on the sump tank. Have the
spray nozzle pointed up toward the bottom of the lowest tray. Holding the wand
tightly, pull the trigger to start the pressurized water flow. Expect the wand to kick
back as flow starts , ,
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Step 6
Move wand side
to side.
Step7
Inspect cleaned
area.
Steps
Clean top side
of tray.
Step 9
Repeat for
all trays.
Move the wand side to side at a rate of about 1 • per second. Be sure to cover the
entire tray bottom area. Recommended cleaning limes for one side of one tray
are given below:
Model 1300
Model 2300
Model 2600
Model 3600
Model 31200
2min
4min
Smin
12 min
24min
Periodically stop the cleaning operation and inspect the cleaned area by shining
a light into the unit. The area is clean when there are no deposits around the aer-
ation holes.
Also check the water level in the sump tank periodically and drain it when neces-
sary.
When the surface appears clean, move the wand to the top side of the tray by
inserting it in the next highest cleanout port. Continue spraying with the nozzle
pointed down onto the top surface of the tray. Remove all visible deposits from
the tray baffles and the walls of the unit
Repeat the procedure for the bottom of the next higher tray, etc., working up to
the top tray.
ShallowTray Operation and Maintenance Manual 4-3
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MAINTENANCE
Step 10
Rinse.
Step 11
Clean the spray
nozzle.
Check the
demister pad.
Replace the
demister pad.
After the cleaning operation is finished, rinse the trays, baffles, and walls with the
pressure sprayer. Work down from the top tray to the sump tank. Make sure the
surfaces are clean and the holes are not blocked by loosened debris.
Remove the top cover, flip it over and wash the bottom side. Inspect the demister
pad for fouling.
If the spray nozzle shows evidence of deposits it should be removed and
scrubbed with a wire brush.
Clean the demister pad.
Use the pressure sprayer to remove debris, deposits and gummy residues some-
times found on the demister pad.
Demister pads that are excessively plugged should be replaced. The old pad is
removed by loosening the retainer screws on the hold-down brackets; and a new
pad is installed in the same fashion.
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TROUBLESHOOTING
Problem Blower Won't Start Or Run
No power to
blower
Blown Fuse
Check that all switches are In "ON" or "AUTO" position.
Position main disconnect switch to "ON" position. Tum control switches to "ON"
or"AUTO.'
Check to see If fuses are ok. Check fuses In main disconnect switch
and In control panel.
Overload relay
trips
Tubinq_ to
pressure switch
plugged with
water or debris.
Blower wheel
. jammed against
side of housing.
If blown, replace with fuse of same size and rating.
Locate reset button on blower overload relay.
Push reset button in. Reasons for tripping: incorrect line voltage, motor wired
incorrectly, inadequate ventilation, bearings are bad.
Remove tubing from pressure switch and blow Into It towards tank.
Clean or replace tubing if plugged or kinked.
TURN OFF ALL power to the system. Try to spin wheel by hand.
Wheel should rotate freely.
Call North East Environmental Products.
"
ShallowTray Operation and Maintenance Manual 5-1
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TROUBLESHOOTING
Problem Outlet Pump Won't Shut Off
Suction or
discharge piping
for pump is
clogged.
Roat switch In
tank Is stuck In
down position.
Normal Operation
-Water level in
sump is OK.
Check water flow from discharge pipe. Piping should be clean Inside.
Look for narrowing caused by scale or Iron accumulation.
Remove piping, inspect and clean or replace as necessary.
Remove s• inspection cap and check that all floats are floating on
the water.
Clean all deposits from float. Replace float If necessary.
Pump will stop when water level reaches pre-determined height in tank.
Allow water level to decrease until pump turns off.
Let water level reach predetermined lower level, which will cause outlet pump to
tum off.
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I Problem Outlet Pump Won't Start Or Run
No power to pump
Blown fuse.
Overload relay
trips.
Normal operation
-Water level in
sump is OK.
Level switch In
tank is wired
Incorrectly In
control panel.
Impeller, seal or
bearing damage.
Check that all switches are in "ON" or "AUTO" position.
Position main disconnect switch to "ON" position. Tum control switches to "ON"
or"AUTO."
Check to see if fuses are ok. Check fuses in main disconnect switch
and in control panel.
If blown, replace with fuse of same size and rating.
Locate reset button on pump overload relay.
Push reset button in. Reasons for tripping: incorrect line voltage, motor wires
incorrectly, inadequate ventilation, bearings are bad.
Pump will start when water level reaches predetermined height in tank.
Allow water level to increase until pump turns on. Be sure pump
switch is in "Auto" position.
Let water level reach predetermined upper level, which will cause outlet pump to
tum on.
Check wiring circuit against diagram. See that all connections are
tight and no short circuits exist because of worn insulation, crossed
wires, etc.
Rewire any incorrect circuits. lighten connections, replace defective wires.
TURN OFF POWER. Try to turn impeller by hand.
If impeller won't tum, remove housing and locate source of binding.
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ShallowTray Oporation and Maintonance Manual 5-3
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TROUBLESHOOTING I I
Problem Low Air Pressure In Stripper Tank I I Blower damper
closed.
I Visually check position of damper on Inlet of blower. I
Open damper to get proper reading on pressure gage. Firmly lighten screw.
I Motor rotation I backwards.
Watch rotation of blower wheel at slow speed. I I Reconnect for proper rotation as per motor diagram.
Gravity discharge
I trap installed I Incorrectly.
Trap should be positioned vertically as an "upside down U."
I Install discharge trap per outlet plumbing drawings provided in appendix A. I
Inlet chamber
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(sea/pot) in each I tray is not full of
water.
I
Slide tray aside and look at water level in chamber. I Remove 4" rubber caps on end of trays. Fill up inlet dlambers with a hose. Or,
follow inlet chambers fill up procedure above In Initial Start Up. I I Rubber clean out
caps not in place.
All cleanout ports must have a rubber cap Installed. I I Tighten clamp on all rubber caps.
Tubing to I I pressure ga!il.e
plugged w,th
water or debris. I I Remove tubing from pressure gage and blow Into it towards tank.
Clean or replace tubing if plugged or kinked.
I Unit has gravity I feed, and inlet
pipe on inside of I g ShallowTray cover
Is not submerged
In inlet chamber
water. " I u Remove cover and measure length of piping hanging from inside of
i cover. Length is to be about 101h" from cover surface. I i Adjust length of inlet pipe on inside of cover until total length is about 10½".
DO NOT INSTALL NOZZLE ON A GRAVITY FEED UNIT.
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Debris blocking
blower intake.
Normal operation
for automatic unit.
Look at blower Intake screen.
Remove debris from screen.
When Inlet pump starts, blower will start, air pressure will rise to
operational level.
No action necessary.
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ShallcwTray Operalicn and Maintanance Manual 5-5
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TROUBLESHOOTING
Problem High Pressure In Stripper
Air exhaust piping
Is restricted.
Air holes In
bottom of trays
are plugged.
Demister pad is
plugged.
Check vent piping for bird nests or other obstructions. Check that
vent pipe diameter does not decrease.
Vent piping diameter must be the same as the outlet vent diameter on the cover.
Remove inspection and cleanout caps and visually Inspect holes.
For iron fouling, clean out unit with a 1000 psi pressure washer. For scaling,
scrape or bang scale from all surfaces, then use a pressure washer to open
holes. Consider using sequestering agent to reduce scaling.
Remove cover from ShallowTray and inspect the bottom of the
demister pad in the cover.
Remove demister pad from cover and clean. Replace if necessary.
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Problem Water Won't Flow Into Unit
Inlet/well pump
functioning
properly.
Tank air pressure
Is low. System is
In alarm condition.
Spray nozzle or
inlet piping is
plugged.
Allow water level to rise In well pump, which will turn on inlet pump
to system.
No action necessary.
Read tank air pressure from pressure gage. System should be in
alarm condition If pressure Is below about 2 Inches w.c.
Check that blower is operating property. Check that all rubber caps are in place
on end of trays.
Remove cover and inspect nozzle and piping for debris and buildup.
Clean or replace clogged parts.
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ShaJlowTray Operation and Maintenance Manual 5.7
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TROUBLESHOOTING
Problem Iron Fouling Is A Problem
Iron precipitates
out of water when
treated with an Bir
stripper causing
Iron build up
In unit.
Remove clean out caps and Inspect Inside of tray for buildup/fouling.
• Clean out unit with 1000 psi pressure washer on routine basis.
• Pretreat incoming water.
• Meter a sequestering agent into the Inlet water.
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RMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
l:\WP\ 7017001723. 0&.Mlcdt94
APPENDIX J
TROUBLESHOOTING CENTRIFUGAL PUMP
OCTOBER 1994
APPENDIX J
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TROUBLE SHOOTING
Table 7
Troubleshootina Pump
PROBLEM PROBABLE CAUSE REMEDY
~ nal primed, Rlprin1 pump, ctlld< lhal puJT4) and IUdXll\
llnl III tun ofmuid.
Sud ion lino ............ AomOYI Dbstl\lC!ions.
l__,ler ....,_,,,_d with lolti-mlllerial. Bad< flush ··•-10 clean .....n.r.
No Uquld dlllv1r.d. Chan;■ rllllllion 1D concur wlh dnc1iDn
Wffing dirldiln of IDllliDn. ilcfic:alld by 1110W on bearing housing or
'"""" casino. '
Foct valw or suction~ opening nal Ccnsul! lactDry tor prcper dllpth. Use baflle
u,mer_.., enou•h. to oliminat1 vonioes.
Sudion ill too hinh. Shon,n 1ue1ion """'·
Ar loak thru ···k,t. D-lact ·••kif.
Ar leak thru stuflino box "'"'!act or r111diust """"""""tehanieal soal.
Pump not produc~n; r■ttd flow or head. 1-11er """I• ct--•ed. Bad< flush numn to clean ifflNIJer.
Worn 1uclion 1idAl"lla11 or wear ri• .. •s. "'"'lace deltctivt 0811 u r-uired. ·
Insufficient lut:lion head. Ensure thal suction line shutofl valve is lully
....,n and in, is unobstructed.
Wom or broken i=ller. lnsoect end reolec, ii necesserv.
lmoro"""" •rimed numo. 11-rime oumo. m
Pump a tarts then 11ll01 pumping. Air or -r -""els in suclion tine. Rterrance oioinc to tlilminatt air ood<tts.
A• leak in sue!ion line. R-eir lclu01 leak.
lmorc-r alicnmtnt. R•alion cumo and driver.
Bnrlnga run hot. 1-ro-r lubrieation. Chick lubrican1 for sunabifrtv and level .
lube ooolin•. I Chick coo lino svstem.
1-... ro-r numnldriver a/innmant. Aicn shlhs.
Pal11v cbaaed irn""lllr causinc imbalan"'. Beci<-flush cu= to clean""""""·
Broken 01 ben1 im-llor or shah. Roni ace as recuired.
Pump 11 noisy or vibrates. Foundalion not rigid. i,ght,n hold down bcb ol pump and mot01
01' adiUS1 stilts .
Wom bearincs. ....... , .. ,.
Suclion or distharvt piping nol anchored or Ancll01 par Hydraulic Institute Standards
-""••-ned. Manual recommendations
Pumo is cavitatin•. Sue1em eroblem.
Packin• •land . tdiUS1ed. i.,ht,n eland nuts.
Sluffino bcx im•-rt• ""cl<ed. Chick ""tkino and r-•k bcx. E.lc111iv1 lukaga lrom 1tufflng bo1. Wom mtehanieal soal ··-. a...i.-warn """'·
Owrhlatinc mochanical 11al. Cheek lul>ricalion and 000i"" rmes.
Shaftslttvt soortd. Rtmechint 01 reolace as ...,,uirld.
Head lower thin rating. PU11111 IDO much Consuft lactory, Install thro!lle Vllve,
lnuid. Qll'-"11er.
Mctor r■qulrtl lll:IHIVI power. I "'Uid heavier than ■-Id. Check mo<ific aravilv and vis001ilv.
Stuffin too titiht, Rtadius! ""ckinn. Ronlace H worn.
Rotating pll1I bind, Chee!<. inttrnal wtaring par1I tor prgper
clearanais.
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AMT OPERATIONS AND MAINTENANCE PLAN
MACON/DOCKERY SITE
l:\Wf'\70\7001723.0&Mledf94
APPENDIX K
UNDERGROUND INJECTION CONTROL PERMIT
The MDSG will submtt a UIC Permtt Application during the
Final Design Phase.
OCTOBER 1994
APPENDIX K