Part_1_-_Toe_Seep_Modifications_Plans_and_Specs_4-7-2015.pdf

PROJECT NO. SV-103, SUMMITVILLE MINE TOE SEEP MODIFICATIONS

GENERAL WORK TASKS

1. Mobilization and Demobilization

2. Dewater existing manhole and maintain dewatering effort during construction.

3. Remove existing flow meter and replace with new flow meter.

4. Remove existing pressure transducer and replace with new pressure transducer.

5. Remove existing float controls and replace with new pressure transducers.

6. Reprogram Programmable Logic Controller (PLC).

7. Provide instrument data management capabilities.

8. Install two Grindex pumps provided by Owner.

9. Perform commissioning, operational testing, and pump station startup.

10. Prepare Standard Operating Procedures, Operation and Maintenance Manuals, and provide 1 day of instruction to onsite staff.

SUBMITTALS

Shop Drawings o Product data of proposed products.

Administrative o Work Plan: The plan shall include installation procedures for the equipment and other materials necessary for installation; testing procedures; and other work incidental to installation of the pressure transducers, flow meter, and PLC reprogramming.

o Manufacturer certifications that the provided equipment meets Project requirements and is suitable for the Site conditions.

o Manufacturer shop calibration reports and testing reports for the provided equipment.

o Standard Operating Procedures and Operation and Maintenance Manual.

TASK 1 – MOBILIZATION AND DEMOBILIZATION

Site is located at the Summitville Mine Superfund Site (N 37.4291o, W 106.5875o).

Site is located approximately 18 miles from US Hwy 160 and is accessed via Forest Service Road 380.

TASK 2 – MANHOLE DEWATERING

Existing manhole is full of water and water is currently flowing out of the top of the manhole. Ground conditions around the manhole could be soft.

Expect up to 70 gallons per minute of inflow through collection pipes throughout construction.

Dewater the manhole, and maintain the manhole and surrounding work area dewatered as needed to allow for satisfactory completion of the work.

The water has a pH as low as 2 and high concentrations of heavy metals.

Water removed from the manhole shall be discharged to either the SDI reservoir or Wightman Fork and shall not be allowed to accumulate on the ground surface near the work area.

TASK 3 – FLOW METER REPLACEMENT

Remove existing flow meter from the pumpback pipeline and replace with a new magnetic flow meter.

Make appropriate connections between the new flow meter, power supply, and

PLC.

Provide readout of instantaneous and totalized flow at electrical panel with PLC.

The new flow meter shall have the following characteristics:

o 3-inch diameter o Minimum operating range of 0 to 200 gpm o 4-20 mA Output o +/- 0.5 percent accuracy o Flow tube material PFA, FEP, or ETFE. All additional internal and external materials exposed to Site water shall be stainless steel.

o Sealed and watertight cable connections o ANSI Class 150 flange connections, stainless steel o Remote readout with stainless steel connection box o 50 feet of cable. Cable material FEP or ETFE.

o Compatible with the Site water. Site water has a pH as low as 2 and high concentrations of heavy metals.

Flow meter and cabling shall be rated for measuring of flows within fluids similar to the Site water.

Flow meter and cabling shall be rated for submergence up to 6 months in the Site water.

The acceptable flow meter manufacturer and model is Krohne Optiflux 4000 with appropriate modifications as needed to meet the Project requirements, or approved equivalent.

TASK 4 – PRESSURE TRANSDUCER REPLACEMENT

Remove existing pressure transducer from the pumpback pipeline and replace with a new pressure transducer.

Make appropriate connections between the new pressure transducer, power supply, and PLC.

The new pressure transducer shall have the following characteristics:

o Minimum operating range of 0 to 250 psig o 4-20 mA Output o +/- 0.5 percent accuracy o ¼”-NPT Male Connection Fitting o 50 feet of attached cable. Cable materials FEP or ETFE.

o Water tight cable connections o All internal and external components exposed to Site water shall be stainless steel or titanium o Compatible with the Site water. Site water has a pH as low as 2 and high concentrations of heavy metals.

Transducer and cabling shall be rated for measuring of pressures within fluids similar to the Site water.

Transducer and cabling shall be rated for submergence up to 6 months in the Site water.

The acceptable pressure transducer manufacturer and model is NOSHOK 612 series with appropriate modifications as needed to meet the Project requirements, or approved equivalent.

TASK 5 – CONTROLS REPLACEMENT

Remove existing float controls from within the manhole.

Install two pressure transducers near the bottom of the manhole for measuring water levels. Pressure transducers shall have the following characteristics:

o Nonvented o Minimum operating range of 0 to 25 psia o 4-20 mA Output o +/- 0.5 percent accuracy o 60 feet of attached cable. Cable materials FEP or ETFE.

o All internal and external components exposed to Site water shall be stainless steel or titanium o Compatible with the Site water. Site water has a pH as low as 2 and high concentrations of heavy metals.

Transducer and cabling shall be rated for measuring of pressures within fluids similar to the Site water.

Transducer and cabling shall be rated for continual submergence in the Site water.

o The acceptable pressure transducer manufacturer and model is NOSHOK 612 series with appropriate modifications as needed to meet the Project requirements, or approved equivalent.

Install one pressure transducer near the electrical panel for measuring atmospheric pressure. Pressure transducer shall have the following characteristics:

o Nonvented o Minimum operating range of 0 to 16 psia.

o 4-20 mA Output o +/- 0.5 percent accuracy o 3 feet of attached cable. Cable materials FEP or ETFE.

o Stainless steel or titanium construction o The acceptable pressure transducer manufacturer and model is NOSHOK

612 series or Measurement Specialties Model KPSI 320 with appropriate modifications as needed to meet the Project requirements, or approved equivalent.

Make appropriate connections between the new pressure transducers, power supply, and PLC.

TASK 6 – REPROGRAM PLC

The existing PLC is a Panasonic Nais FP , FPG-C32T2. Additional information is provided in the existing Standard Operating Procedures manual.

Reprogram the PLC to control the pump station using the new pressure transducers installed as part of Task 3.

o The PLC shall use the pressure readings to calculate the height of water above the floor of the manhole. Pressure measurements shall be corrected for barometric pressure using the new pressure transducer installed at the control panel.

o The PLC shall interpret the readings from the two pressure transducers inside the manhole at 1-minute intervals as follows:

If both transducers are operating and their readings differ by less than 5 percent, the PLC shall use the average of the two readings as data input.

If both transducers are operating and their readings differ by more than 5 percent, the PLC shall use the average of the two readings as data input and send a “Control Error” alarm to the Display Unit in the electrical panel.

If one transducer is not operating, the PLC shall ignore its reading, use the other transducer as data input, and send a “Control Malfunction” alarm to the Display Unit in the electrical panel.

o Program the PLC to send a “High Pressure” alarm to the Display Unit in the electrical panel and shut down the pumps if the pipeline pressure measured by the pressure transducer installed under Task 4 exceeds 55 psi.

o The PLC shall control the pumps as follows:

Lead and lag pumps shall alternate every pumping cycle. The lead pump is the pump that turns on first, and the lag pump is the pump that turns on if the water level in the manhole continues to rise after the lead pump is running.

The lead pump shall turn on when the water level reaches 5.8 feet above the manhole floor.

If the water level rises to 6.0 above the manhole floor, the lead and lag pumps shall both operate and a “High Water Level” alarm shall be sent to the Display Unit in the electrical panel.

The pumps shall turn off when the water level reaches 1.5 feet above the manhole floor.

If the water level reaches 0.8 feet above the manhole floor, the pumps shall turn off and a “Low Water Level” alarm shall be sent to the Display Unit in the electrical panel.

Aside from reprogramming the water level controls and High Pressure alarm, do not disable or override any existing alarms or pump controls. The existing alarms are included in the provided existing Standard Operating Procedures Manual.

TASK 7 – INSTRUMENT DATA MANAGEMENT

Provide capabilities for recording and storing instrument data.

o Reconfigure the PLC, as necessary, to allow for the data management.

o Provide and install new components at the existing electrical panel, as necessary, to record and store the data.

o Provide the capabilities to store up to 6-months-worth of data.

o Provide the capabilities to download the collected data.

o The collected data shall consist of the following:

The start and stop times of each pump.

Cumulative run times of each pump.

Cumulative flow volume recorded by the flow meter. Collect one data point at the beginning of each pump cycle (when the pump turns on) and one data point at the end of each pump cycle (when the pump turns off).

Provide the capability to compare pump run times and flow rates for each pumping cycle.

TASK 8 – PUMP INSTALLATION

Install and connect two Owner-provided Grindex Major Inox pumps to the existing piping in the manhole.

TASK 9 – COMMISSIONING, TESTING, AND STARTUP

Installation o General Provide all materials, equipment, and labor necessary to install all items associated with the scope of work Install in accordance with manufacturers recommendations.

o Start up Representative or manufacturer shall be on site during initial start up and testing.

Operate pumping system through three cycles of normal start and stop, and fully loaded operating conditions. Demonstrate that the system operates within equipment manufacturer’s accepted tolerances and demonstrate general fitness for service. All defects shall be corrected and adjustments made at CONTRACTOR’s expense. Perform testing in presence of ENGINEER.

Water can be obtained from Wightman Fork to expedite filling of the manhole during start up.

Test the accuracy of the flow meter and correct operation of the data logger.

Test shall be repeated until the pump station operates automatically through three cycles of normal start and stop within equipment manufacturer’s accepted tolerances. Provide start up assistance for one 8-hour day unless otherwise specified.

TASK 10 – MANUALS AND TRAINING

Provide three hard copies and one electronic copy in pdf format of Standard Operating Procedures for instruments installed and PLC reprogramming performed as part of this work.

Provide three hard copies and one electronic copy in pdf format of an Operation and Maintenance Manual for instruments installed and PLC reprogramming performed as part of this work.

Provide training and operation and maintenance instructions to onsite staff.