Part_2b_-_Toe_Seep_Modifications_Plans_and_Specs_4-7-2015 (SL).pdf
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- Solicitation number
- DQ1 FAAA FEEA2015000000000001 4
- Issued by
- Rio Grande County, Denver City, Colorado
About this file
This document is a Standard Operating Procedures manual for the Summitville Dam Impoundment pump station in Rio Grande County, Colorado, under the jurisdiction of the State of Colorado Department of Water Resources. The manual provides comprehensive operational guidance for the pump station serving the Summitville Mine toe seep modifications project, classified as a Significant Hazard dam (DAMID: 210103). The document outlines five primary operational chapters: system checkout procedures for equipment restart after extended downtime, system startup procedures including power activation and motor jogging protocols, automatic and manual pump operation procedures, winterization procedures for cold weather protection, and emergency response protocols. The pump station equipment includes pressurized components, high-voltage electrical systems, pressure transducers, flow meters, and automated control systems with a display unit, all housed in an eight-foot-diameter manhole. Work required for the toe seep modifications project, shown as redline revisions on pages 10, 11, and 18, includes removal and replacement of existing pressure transducers, flow meters, and float controls with new pressure transducers, PLC reprogramming, installation of barometric pressure monitoring, and data management system enhancements. The manual references the Summitville Dam Impoundment Emergency Action Plan dated April 1, 2012, and incorporates appendices containing detailed equipment manuals for Panasonic and Sigma PLCs, Grindex pumps, electrical components, and instrumentation.
The document does not contain pricing terms, contract award information, bidding procedures, funding sources, or procurement details. The manual was prepared in March 2013 as Revision 0 and serves as an operational reference for ongoing management of the pump station, which is designed for year-round operation but includes provisions for seasonal winterization when environmental temperatures fall below 40 degrees Fahrenheit. Construction conditions note that the existing manhole is full of water with expected inflow up to 70 gallons per minute throughout the project duration. The document emphasizes safety protocols, including requirements for personnel entering confined spaces, electrical lockout procedures, and monitoring for alarm conditions that trigger automatic system shutdown.
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Text version
PUMP STATION
STANDARD OPERATING PROCEDURES
(SOP)
Summitville Dam Impoundment
Rio Grande County, Colorado HAZARD CLASSIFICATION: Significant
State of Colorado DAMID: 210103 NATID (National Inventory of Dams): CO00785
Water Division: 3 Water District: 20
March 2013 efriend Text Box WORK REQUIRED AS PART OF THE TOE SEEP MODIFICATIONS PRORJECT IS SHOWN AS REDLINE REVISIONS ON PAGES 10, 11, AND 18 efriend Text Box THIS DOCUMENT INCLUDES INFORMATION PERTINENT TO THE SUMMITVILLE MINE TOE SEE MODIFICATIONS
SUMMITVILLE DAM IMPOUNDMENT PUMP STATION STANDARD OPERATING PROCEDURES
DAMID: 210103
Revision 0 March 2013 i
TABLE OF CONTENTS
Chapter 1 – Introduction
Emergency Responses
Chapter 2 – System Check Out Procedure
Chapter 3 – System Startup Procedure
Chapter 4 – Pump Operation
Chapter 5 – Pump Station Winterization
Figures
APPENDICES
Appendix A Pump Station Owner’s Manual Appendix B Electrical Equipment Operation and Maintenance Manual efriend Text Box Pages in the PDF of pertinent items
Panasonic PLC - 49 Grindex pump manual - 55 Sigma PLC - 101 Magelis XBT GT4000 Panel - 178 SSI Technology pressure transducer - 341 Watertronics pressure transducer - 343 Photo of control panel -0 344 Proline flow meter - 346
Page 1 of 9 March 2013
Chapter 1 – Introduction
The purpose of this manual is to outline the standard operating procedures for the pump station at the Summitville Dam Impoundment (SDI) Toe Seep. Additional information about the pump station is presented in the Owner’s Manual in Appendix A and the Electrical Equipment Operation and Maintenance Manual in Appendix B.
The pump station contains pressurized components and high voltages. Use caution while working with pump station components and refer to the Owner’s Manual for additional safety precautions.
The electrical control panel is shown on Figure 1. The controls labeled on Figure 1 will be referred to throughout this manual. Representative images from the DISPLAY UNIT are shown on Figures 2 through 4. The configuration of pump station components within the 8-foot-diameter manhole are shown on Figure 5 and Figure 6.
Emergency Responses
If the SDI embankment is failing or appears to be rapidly approaching failure, the reader of this document shall immediately activate the Summitville Dam Impoundment Emergency Action Plan (EAP).
Detailed discussions of common indicators of a possible approaching dam failure and the necessary emergency action and procedure responses are provided in the Summitville Dam Impoundment EAP dated April 1, 2012. Refer to the EAP for details regarding unusual and emergency events and required responses.
Page 2 of 9 March 2013
Chapter 2 – System Check Out Procedure
The following procedures must be performed when restarting the pump station after it has been out of service for at least one month. The locations of the electrical controls are shown on Figure 1. The locations of pump station components within the 8-foot-diameter manhole are shown on Figure 5.
1. Turn the MAIN DISCONNECT switch OFF.
2. The Control Enclosure may contain a foreign voltage from an external source NOT routed through the MAIN DISCONNECT switch. As of the date of this document, all voltage sources to the Control Enclosure can be disconnected at either the transformer or the exterior of the SDI building as shown on Figure 7.
3. De-energize and lock out the electrical disconnect on the exterior of the SDI building prior to opening the electrical control panel.
4. HAND/OFF/AUTO (HOA) switches must be in the OFF positions.
5. Open the electrical control panel.
a. Check mounting and termination of all electrical equipment. Studs, screws, and nuts should be in place. Wire terminals can vibrate loose during prolonged periods of operation. Re-torque periodically (Spring and Fall).
b. Check that all wiring is free of kinks and torn, charred, or missing insulation. If there is evidence of short circuit, over current, or water damage, the pump station must not be placed into service until the cause is identified and corrected.
6. Check for surge damage, charring, or swelling to the lightning arrestor.
7. Ensure the electrical panel is properly grounded.
8. The following items may require personnel entering the 8-foot-diameter manhole if visual confirmation cannot be made from above:
a. Check for leaks and damage to the pressure transducer and flow meter in the 8-foot-diameter manhole. Keep the connections of these components clean. Water in the pump station piping is under pressure. Close isolation valves or drain water from the pumpback line prior to adjusting or removing fittings.
b. Ensure that terminal box covers and coupling guards are in place on the pump motors.
9. Ensure that the air valve is free from obstruction. The air valve is located in the 4-foot-diameter manhole near the south end of the SDI crest.
10. Ensure that the discharge end of the pumpback line is free from obstruction. The discharge consists of a black rubber check valve near the south end of the SDI crest on the upstream slope.
Page 3 of 9 March 2013
Chapter 3 – System Startup Procedure
The following procedures should be performed to start up the pump station after the checkout procedures in Chapter 2 have been completed. The locations of the electrical controls are shown on Figure 1.
1. Close the electrical control panel and re-energize the electrical disconnect.
2. Turn the MAIN DISCONNECT switch ON.
3. Turn the PANEL POWER selector switch ON.
4. The DISPLAY UNIT should now be powered-up, displaying the SELECT screen (Figure 2). If the DISPLAY UNIT does NOT power-up, it could mean that the PHASE VOLTAGE MONITOR has cut off power to the controls. This occurs if there is an abnormal power supply.
Troubleshooting would be required to identify and resolve the power supply problem. An LED indicator on the Phase Voltage Monitor indicates the power supply status as follows:
LED Status Indicator Green Steady Normal/Relay ON Green Flashing Power Up/Restart Delay Red Steady Unbalance Red Flashing Undervoltage/Overvoltage Amber Steady Reversal Amber Flashing Loss Green/Red Alternating Undervoltage/Overvoltage Trip Pending Red/Amber Alternating Nominal Voltage Set Error
If the green light on the phase monitor is not illuminated, please call Watertronics at 1-800-356- 6686. Also, call Watertronics if the green light on the Phase Monitor is illuminated but the control panel is not powered up.
5. Upon power-up the DISPLAY UNIT will display a PHASE/VOLTAGE alarm. To clear the alarm, press the red RESET button.
6. After pressing the red RESET button the alarm alert will stop scrolling in the banner at the top of the SELECT screen (Figure 2) and alarm line will stop flashing.
7. Each motor needs to be jogged (operated for about 1 second or less) to check for proper rotation.
To jog a motor, turn the HOA switch to the HAND position for less than 1 second and return the switch to the OFF position. Monitor the discharge pressure while running each pump to check for pump rotation. The pressure transducer should measure between 35 and 50 psi when a pump is operating. If pressure is low, TURN OFF the MAIN DISCONNECT and rotate motor power leads. Reapply power to run the pump and pressure should climb to the design point.
Page 4 of 9 March 2013
Chapter 4 – Pump Operation
After the startup procedures in Chapter 3 have been completed, the pump station is ready to be operated.
The locations of the electrical controls are shown on Figure 1.
It is anticipated that the pump station will operate automatically most of the time. The following procedures should be performed to operate the pump station automatically:
1. Turn the HOA switches to the AUTO positions. The pumps will cycle on and off automatically based on the water level in the 8-foot-diameter manhole.
2. The pump station will turn itself off if an ALARM condition is detected, and an ALARM message will be displayed on the DISPLAY UNIT. If this occurs, take the necessary steps to correct the ALARM condition. When the problem is corrected, press the red RESET button.
Occasionally it may be desirable to operate the pump station manually. If so, the following procedures should be performed:
1. Turn the HOA switches to the OFF positions to turn the pumps off and stop automatic operation.
2. Turn an HOA switch to the HAND position to manually operate a pump. Return the HOA switch to the OFF position to turn the pump off.
3. During manual operation, it is important that the water level in the 8-foot-diameter manhole NOT be drawn down to the level of the pump intake to avoid damage to the pump.
Page 5 of 9 March 2013
Chapter 5 – Pump Station Winterization
The pump station was designed and is intended to be operated year-round. However, it is also possible to winterize the pump station. The pump station manufacturer recommends that winterization procedures be performed if the pump station environment (interior of the 8-foot-diameter manhole) will be colder than 40o F to prevent damage to the pump station components.
If the pump station is winterized, seepage from the SDI will fill the manhole, seep onto the ground surface, and enter Wightman Fork downstream of the SDI. Freezing of water in the upper portion of the manhole could damage pump station components and would impede efforts to restart the pump station next spring.
If the pump station is not winterized, there is a chance that the pump station could stop operating during the winter if there is a power failure or if an alarm condition shuts down the pumps. In this situation, water would also fill the manhole, freeze, and enter Wightman Fork. The pump station alarms are not programmed to notify offsite personnel of a power failure during the unstaffed season.
The following procedures should be performed if the pump station is winterized. The locations of the electrical controls are shown on Figure 1. The locations of pump station components within the 8-foot-diameter manhole are shown on Figure 5.
1. Turn off the PANEL POWER and the MAIN DISCONNECT. Shut off the disconnect on the exterior of the SDI building and lock the disconnect so power cannot be applied unintentionally.
2. Remove the pressure transducer wire by removing the keeper screw located below the liquid-filled gauge on the discharge manifold. Remove the pressure transducer unit by unthreading it from the T-fitting and store it in a location where it will not be subjected to freezing. Damage will occur if the pressure transducer is exposed to temperatures below 32o F.
3. Install new corrosion inhibitors in the electrical control panel.
4. Remove the pumps from the manhole.
5. Invert the pumps with the discharge facing down to allow any water to run out.
6. Drain the pump cooling jackets by opening the air vent screws at the top of the cooling jacket.
7. Inspect the pumps with special attention to the seals and the cable entry.
8. Store the pumps in a location where they will not be subjected to freezing. The pump impeller/propeller must be rotated every other month to prevent the seals from sticking together.
9. The pump station manufacturer also recommends that any piping that would remain in standing water over the winter months be removed and drained of water. This would include all of the piping in the 8-foot-diameter manhole.
10. When the pump station is returned to service the following spring, reassemble the removed components and perform the System Check Out procedures from Chapter 2.
Page 6 of 9 March 2013
Figures
Figure 1. Electrical Control Panel
Figure 2. Display Unit “Select Screen”
Banner
Main Disconnect
Panel Power
Display Unit
HOA
Switches
Reset
Page 7 of 9 March 2013
Figure 3. Display Unit “Overview Screen”
Figure 4. Display Unit “Alarms Screen”
Page 8 of 9 March 2013
Figure 5. Pump Station Plan and Profile aprochaska Callout
REMOVE EXISTING PRESSURE TRANSDUCER AND REPLACE WITH NEW INSTRUMENT
aprochaska Callout
REMOVE EXISTING FLOW METER AND REPLACE WITH NEW INSTRUMENT
aprochaska Callout
REMOVE EXISTING FLOAT CONTROLS AND REPLACE WITH PRESSURE TRANSDUCERS
aprochaska Callout EXISTING MANHOLE IS FULL OF WATER. EXPECT UP TO 70 GPM MINUTE INFLOW THROUGH COLLECTION PIPES THROUGHOUT CONSTRUCTION aprochaska Callout REPROGRAM PLC, INSTALL PRESSURE TRANSDUCER TO MONITOR BAROMETRIC PRESSURE, AND PROVIDE INSTRUMENT DATA MANAGEMENT CAPABILITIES
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