T-25 Area (OU-1) Ground Water Treatment System Operation and Maintenance Manual Volume 1 of 2.pdf

U.S. Army Soldier Systems Center

Final

T-25 Area (OU-1) Ground Water Treatment System Operations and Maintenance Manual U.S. Army Soldier Systems Center (SSC) Natick, Massachusetts

Volume 1 of 2

Prepared for:

U.S. ARMY SOLDIER SYSTEMS CENTER

NATICK, MASSACHUSETTS

Prepared by:

ICF CONSULTING, INC.

33 Hayden Avenue Lexington, Massachusetts 02421

May 2004

Program Manager: Kathleen Thrun Date

Task Manager: Erin Healy Date

This document is printed on recycled paper and is recyclable.

Final

T-25 Area (OU-1) Ground Water Treatment System Operations and Maintenance Manual

Prepared for

U.S. Army Soldier Systems Center

May 2004

Prepared by

ICF Consulting, Inc.

33 Hayden Avenue Lexington, Massachusetts 02421

ICF Reference 095220.0.050

Natick: Operations and

Section No.: Table of Contents Date: May 2004

Table of Contents Page

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Acronyms and Abbreviations......................................................................................v

1.0 Introduction and Background ...........................................................1-1

1.1 Background Documents ........................................................................ 1-1

1.2 Manual Objectives................................................................................. 1-2

1.3 Manual Contents.................................................................................... 1-2

1.4 Treatment System Design...................................................................... 1-3

1.4.1 Building Containment Features............................................................. 1-4

1.4.2 Extraction Well Pumps and Flow Rate Monitoring System ................. 1-4

1.4.3 Influent Equalization Tank .................................................................... 1-4

1.4.4 Particulate Filter System........................................................................ 1-4

1.4.5 Air Stripper............................................................................................ 1-4

1.4.6 Vapor-Phase Granular-Activated Carbon (VGAC)............................... 1-5

1.4.7 Liquid-Phase Granular-Activated Carbon (LGAC) .............................. 1-5

1.4.8 Programmable Logic Control ................................................................ 1-6

1.5 Procedure for Making Treatment System Modifications ...................... 1-6

2.0 System Start-Up, Operation, and Shut-Down Procedures .............2-1

2.1 System Start-Up..................................................................................... 2-1

2.2 System Operational Procedures............................................................. 2-2

2.3 System Shut-Down................................................................................ 2-3

3.0 Monthly Operation and Maintenance ...............................................3-1

3.1 Waste Generation, Collection, and Disposal......................................... 3-1

3.2 System Inspection Procedures............................................................... 3-2

3.3 Equipment Maintenance........................................................................ 3-2

3.3.1 Extraction Wells and Pumps ................................................................. 3-2

3.3.2 Flow Rate Control and Data Recording Procedures.............................. 3-2

3.3.3 Programmable Logic Control ................................................................ 3-3

3.3.4 Equalization Tank.................................................................................. 3-3

3.3.5 Particulate Filters................................................................................... 3-3

3.3.6 Air Stripper............................................................................................ 3-3

3.3.7 Process Blower and Heater.................................................................... 3-4

3.3.8 Vapor-Phase Granular-Activated Carbon (VGAC) Canisters............... 3-4

3.3.9 Liquid-Phase Granular-Activated Carbon (LGAC) Canisters .............. 3-4

3.3.10 Plumbing................................................................................................ 3-4

3.4 Treatment System Sampling Procedures............................................... 3-4

4.0 Quarterly Operation and Maintenance .............................................4-1

4.1 Building (General)................................................................................. 4-1

4.2 Plumbing Components .......................................................................... 4-1

4.3 Extraction Wells and Pumps ................................................................. 4-1

4.3.1 Extraction Well Redevelopment............................................................ 4-1

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4.4 Equalization Tank.................................................................................. 4-2

4.5 Influent and Effluent Pumps.................................................................. 4-2

4.6 Air Stripper............................................................................................ 4-2

4.7 Liquid-Phase Granular Activated Carbon (LGAC) Canisters............... 4-3

4.8 Process Blower and Heater.................................................................... 4-3

4.9 Vapor-Phase Granular-Activated Carbon (VGAC) Canisters............... 4-3

4.10 Programmable Logic Control Panel (PLC) ........................................... 4-3

4.11 Flow Control and Monitoring Systems ................................................. 4-3

5.0 Annual Operation and Maintenance .................................................5-1

5.1 Building ................................................................................................. 5-1

5.2 Plumbing................................................................................................ 5-1

5.3 Pressure Gauge and Pressure Switch..................................................... 5-1

5.4 Extraction Wells and Pumps ................................................................. 5-1

5.5 Equalization Tank.................................................................................. 5-1

5.6 Particulate Filters................................................................................... 5-2

5.7 Air Stripper............................................................................................ 5-2

5.8 Liquid-Phase Granular-Activated Carbon (LGAC) Canisters .............. 5-2

5.9 Process Blower and Heater.................................................................... 5-2

5.10 Vapor-Phase Granular-Activated Carbon (VGAC) Canisters............... 5-3

5.11 Programmable Logic Control (PLC) ..................................................... 5-3

5.12 Flow Control and Monitoring Systems ................................................. 5-3

6.0 Alarm Conditions/Emergency Response.........................................6-1

6.1 Auto-dialer............................................................................................. 6-3

6.2 Alert Conditions .................................................................................... 6-3

6.2.1 Alert Condition 1 (Corresponds to one or more of the following conditions) ............................................................................................. 6-4

6.2.2 Alert Condition 2................................................................................... 6-5

6.2.3 Alert Condition 3 (Corresponds to one or more of the following conditions) ............................................................................................. 6-5

6.3 Recommended List of Spare Parts ........................................................ 6-7

7.0 Troubleshooting – Manufacturers Instructions...............................7-1

7.1 Influent and Effluent Pumps.................................................................. 7-1

7.1.1 Motor Not Running ............................................................................... 7-1

7.1.2 Little or No Liquid Delivered................................................................ 7-1

7.1.3 Power Consumption Too High.............................................................. 7-1

7.1.4 Excessive Noise and Vibration.............................................................. 7-2

7.2 Shallow Tray Aeration System.............................................................. 7-2

7.2.1 Blower Will Not Start or Run................................................................ 7-2

7.2.2 Effluent Pump Will Not Shut Off.......................................................... 7-3

7.2.3 Pump Will Not Run Or Pump Water..................................................... 7-3

7.2.4 Low Air Pressure/Vacuum in Stripper Tank ......................................... 7-4

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7.2.5 High Pressure/Vacuum in Stripper........................................................ 7-4

7.2.6 Water Will Not Flow into the Unit........................................................ 7-5

7.2.7 Iron Fouling is a Problem ...................................................................... 7-5

7.2.8 Volatile Organic Compound Removal is Less Than Expected ............. 7-6

7.3 Process Blower ...................................................................................... 7-7

7.3.1 Capacity or Pressure Rating .................................................................. 7-7

7.3.2 Vibration and Noise............................................................................... 7-8

7.3.3 Overheated Bearings ............................................................................. 7-8

7.4 Flow Controller ..................................................................................... 7-8

7.4.1 CAL Menu Error Codes ........................................................................ 7-8

7.4.2 RELAY Menu Error Codes ................................................................... 7-9

7.4.3 OUTPUT Menu Error Codes................................................................. 7-9

8.0 Treatment System Sampling and Monitoring Guidelines...............8-1

8.1 Treatment System Sampling Program................................................... 8-1

8.2 Treatment System Sampling Locations................................................. 8-2

8.3 Aqueous Effluent Limits ....................................................................... 8-2

8.4 Effluent Air Monitoring Guidelines ...................................................... 8-3

8.5 Procedure for Notification of Air/Water Discharge Limit Exceedance 8-4

9.0 Procedure for Adding New Extraction Wells ...................................9-1

9.1 Flow Meters........................................................................................... 9-1

9.2 System Pumps ....................................................................................... 9-1

9.3 Air Stripper............................................................................................ 9-2

9.4 Liquid Granular Activated Carbon (LGAC) ......................................... 9-2

9.5 Vapor Phase Granular Activated Carbon (VGAC) ............................... 9-3

9.6 Sampling Protocol for New Extraction Well......................................... 9-3

9.7 Troubleshooting for Air/Water Discharge Exceedance ........................ 9-3

10.0 Treatment System Inspection, Monitoring, and Reporting

Schedules .........................................................................................10-1

11.0 Procedure for Revising this Operations and Maintenance Manual ...........................................................................................................11-1

12.0 References ........................................................................................12-1

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List of Appendices

Appendix A: Standard Operating Procedures (SOPs).............................................A-1 Appendix B: Emissions Standard Calculations ......................................................B-1 Appendix C: Proview Software User’s Guide ........................................................C-1 Appendix D: Electrical Wiring, Logic, and Panel Layout Drawings......................D-1 Appendix E: Equipment Specification Sheets and User’s Manual for System

Components ...................................................................................... E-1 List of Tables

Table 6-1: Treatment System Contact List ..............................................................6-9 Table 8-1: Treatment System Sampling and Analysis Schedule .............................8-6 Table 8-2: Current Analytical Detection Levels ......................................................8-7 Table 8-3: Ambient Water Quality Criteria (AWQC) for COCs.............................8-8

List of Figures

Figure 2-1: Process and Instrumentation Diagram....................................................2-5 Figure 2-2: Programmable Logic Control Start-up Configuration............................2-6 Figure 6-1: Pressure Switch Settings for Particulate Filters....................................6-10 Figure 8-1: Treatment System Aqueous Discharge to Lake Cochituate Flow

Layout.....................................................................................................8-9 Figure 8-2: Decision Matrix for Notification Process.............................................8-10

List of Plates

Plate 1: Treatment System Components

Section No.: Acronyms

Acronyms and Abbreviations

AWQC Ambient Water Quality Criteria CCC Criterion Continuous Concentration CMC Criterion Maximum Concentration COC Contaminant of Concern DNAPL Dense Nonaqueous Phase Liquid EPA U.S. Environmental Protection Agency EPH Extractable Petroleum Hydrocarbons FFS/TS Focused Feasibility Study/Treatability Study GFAA Graphite Furnace Atomic Absorption Spectrophotometer gpm Gallons Per Minute hp Horse Power ICP Inductively Coupled Plasma kW Kilowatt LGAC Liquid-Phase Granular-Activated Carbon MCL Maximum Contaminant Level NPDES National Pollutant Discharge Elimination System O&M Operation and Maintenance PC Personal Computer PCE Tetrachloroethene P&ID Process and Instrumentation Design (P&ID) PID Photoionization Detector PLC Programmable Logic Control Panel ppb Parts Per Billion ppbv Parts Per Billion by Volume psi Pounds Per Square Inch PVC Polyvinyl Chloride RCRA Resource Conservation and Recovery Act SOP Standard Operating Procedures SSC Soldier Systems Center TAL Target Analyte List TCE Trichloroethene TCL Target Compound List TCLP Toxicity Characteristic Leaching Procedure TOSS Task Order Support Service TPH Total Petroleum Hydrocarbons TS Treatment System VGAC Vapor-Phase Granular-Activated Carbon VOA Volatile Organic Analysis VOC Volatile Organic Compound VPH Volatile Petroleum Hydrocarbons

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Section No.: 1.0

1.0 Introduction and Background

This Operations and Maintenance (O&M) Manual for the ground water treatment system (TS) located at the T-25 Area of the Soldier Systems Center (SSC) in Natick, Massachusetts was prepared by ICF Consulting Inc. This manual describes and illustrates the procedures for:

• Operating and maintaining the TS, including methods for troubleshooting problems

• Efficient criteria along with TS monitoring and notification procedures in the event of a contaminant discharge exceedance

• Making modifications to the TS.

The TS was constructed for a treatability study of the T-25 Area ground water which contains elevated concentrations of trichloroethene (TCE) and tetrachloroethene (PCE).

The Army commenced operation of the TS during November 1997, in accordance with the approved Treatability Study Work Plan (Arthur D. Little, 1997). After an extensive treatability study, the pump and treat system was approved through the Record of Decision (ROD) as of September 2001.

1.1 Background Documents

The Final Phase I Remedial Investigation Report of the T-25 Area (Arthur D. Little, 1996) and the Final Phase II Remedial Investigation Report of the T-25 Area (Arthur D.

Little, 1998) describe contamination at the T-25 Area. The ground water associated with the T-25 Area contains concentrations of TCE and PCE above the federal and state drinking water maximum contaminant level (MCL) of 5 ug/L for each contaminant. A Treatability Study was performed to evaluate whether the contamination could be contained using the proposed extraction well system and to assess the effectiveness of the proposed system. The results of the Treatability Study are presented in the Final Focused Feasibility Study /Treatability Study Report for the T-25 Area (Arthur D.

Little, 1999).

The procedures described in this manual for operating and maintaining the TS are based on information gathered since system start up in 1997 (including the Treatability Study). As more information is gathered, procedures may be changed according to the modification process described in Section 1.5.

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1.2 Manual Objectives

The SSC Treatment System O&M Manual serves as a management and procedure tool to assist personnel with operation of the treatment system. Competent management combined with correct operating and maintenance procedures for the TS are essential to ensure continued compliance with applicable federal, state, and local regulations.

This manual establishes the baseline for the operation and maintenance of the TS. It provides users with both detailed standard operating procedures (SOPs), and general guideline and policy information needed to access information not contained within this manual.

1.3 Manual Contents

This manual contains sections on all procedures required to operate and maintain the TS. SOPs that detail specific, step-by-step instructions on how to complete activities are included in Appendix A and are referenced throughout the manual. Appendix B includes the MADEP Policy #WSC-94-150 which describes the air emission standard calculation for determining the need for air emission controls. The Proview software user’s guide for remote monitoring of the TS is provided in Appendix C. The electrical wiring diagrams, logic diagrams, and panel layout drawings are included in Appendix D. The equipment specification sheets and user’s manuals for specific components of the system are provided in Appendix E

The sections of the manual are detailed below.

• Section 1.0 – Introduction and Background contains general information about the SSC Treatment System O&M Manual. This section provides a brief description of the TS and procedures for gaining approval for TS modifications.

• Section 2.0 - System Start, Operation, and Shutdown Procedures contains the start-up and shutdown procedures for the TS.

• Section 3.0 – Monthly Operation and Maintenance provides detailed information and procedures on the monthly operations and maintenance of the TS, including inspection checklists, sampling procedures, and the bi-weekly change out of the bag filters.

• Section 4.0 – Quarterly Operation and Maintenance provides detailed information and procedures on the quarterly maintenance of the TS, including the inorganic/organic scale removal from the equalization tank, particulate filters, and extraction wells and pumps, cleaning the air stripper, and backwashing the liquid-phase carbon canisters.

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• Section 5.0 – Annual Operation and Maintenance provides detailed information and procedures on the annual maintenance of the TS, including all the procedures that are in the quarterly maintenance, plus the regeneration of the liquid-phase and carbon-phase canisters, as well as the testing of the well sensors.

• Section 6.0 – Alarm Conditions / Emergency Response describes the emergency response system, including the actions to follow for each alert condition.

• Section 7.0 – Trouble Shooting – Manufacturers Instructions includes troubleshooting procedures for the influent/effluent pumps, air stripper, process blower, and the flow controller.

• Section 8.0 –Treatment System Sampling and Monitoring Guidelines describes the TS sampling schedule and the effluent monitoring guidelines.

• Section 9.0 –Procedure for Adding New Extraction Wells describes the procedures for adding additional extraction wells to the TS.

• Section 10.0 – Future Treatment System Inspection, Monitoring, and

Reporting provides guidance for ongoing evaluation of TS effectiveness and efficiency.

• Section 11.0 – Procedure for Revising this Operations and Maintenance

Manual provides requirements for altering this manual.

• Section 12.0 – References provides a list of references used to create this document.

1.4 Treatment System Design

The TS is based on ground water pump-and-treat technology and is illustrated in Plate 1. Ground water is removed from the subsurface via extraction wells. The primary aboveground treatment is an air stripper. The ground water is pumped through a particulate filter prior to the air stripper and through granulated activated carbon after the air stripper. Vapors from the air stripper are treated using granular activated carbon.

In addition to treating contaminated ground water, pumping through the extraction wells induces a hydraulic gradient that results in the contaminated groundwater within the T-25 Area being contained.

The major components of the system are: building containment features, extraction well pumps and flow rate monitoring system, influent equalization tank, particulate filters, air stripper, carbon adsorption canisters, process blower and heater, and the programmable logic controller. A brief description of each of the TS major components is presented below.

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1.4.1 Building Containment Features

The TS building was constructed to provide secondary containment in the event of a plumbing or component leakage. The building is equipped with a 1-foot wide berm around the perimeter of the interior of the building, which has a volume of 11,100 gallons. The floor slopes towards a floor sump equipped with a water level indicator. If this water level indicator is activated, the system is shut down and the system’s telemetry module telephones the on-call TS operator for notification. This and other TS alarm conditions are described in detail in Section 6.

1.4.2 Extraction Well Pumps and Flow Rate Monitoring System

There are four extraction wells online with one extraction well offline. In April of 2003, three new extraction wells (MW-94B-4, MW-95B-4, MW-96B-4) were brought online in addition to the already functioning MW-90B, and one existing extraction well was taken offline (MW-15B). Each extraction well contains a submersible pump capable of producing approximately 60 gallons-per-minute (gpm) flow rate with approximately 76 feet of total dynamic head. . The pump intakes are placed immediately above the top of each well screen. Each pump is equipped with a 2 horsepower (hp) motor capable of handling a range of chemical resistivity and pH.

Flow rates are monitored by paddle-wheel flow sensors, with an accuracy of plus or minus 0.1 percent. The extraction well pump rates are controlled by throttling the flow with butterfly valves or gate valves. Flow readings are recorded and saved by a monitoring panel through which the operator can download flow data. The extraction well pump, flow meter, and monitoring panel are shown on Plate 1.

1.4.3 Influent Equalization Tank

Ground water is pumped into a 3,000-gallon holding tank for equalization prior to treatment. This holding tank serves to equalize any variations in contaminant concentration or extraction flow prior to pumping into the system (see Plate 1). This ensures a consistent flow rate and water quality to the TS. A 20-minute retention time is provided by this tank so that larger suspended solids settle out prior to treatment.

1.4.4 Particulate Filter System

A particulate filter system is installed prior to the air stripper to reduce the risks of iron fouling or plugging of the stripper and the liquid phase granular activated carbon (LGAC) canisters (see Plate 1). The filter system consists of two cast iron dual-bag filters each of which contain two poly-mesh 100-micron bag filters.

1.4.5 Air Stripper

Ground water is pumped from the equalization tank through a particulate filter, then into the air stripper. Air stripping is based on the principle that volatile contaminants can be removed from aqueous waste streams by blowing air through a liquid-phase interface. The volatile components are transferred from the aqueous phase to the

095220.0.050.04.GSA_2004_O&M_Manual.doc.05/10/04 1-4 gaseous phase, at a rate dependent on the process variables and contaminant characteristics. The air stripper currently operating in the SSC TS is a shallow tray air stripper equipped with four trays that provide the appropriate surface area, air/water interface, and removal efficiency (see Plate 1). The air stripper is equipped with a 10-hp blower that supplies approximately 700 cubic feet per minute of airflow. A maximum aqueous flow rate through the air stripper is rated at 160-gpm.

1.4.6 Vapor-Phase Granular-Activated Carbon (VGAC)

The TS includes two 1,000-pound carbon adsorption canisters for removal of volatile organics from the air-stripper off-gas (see Plate 1). Activated carbon treatment efficiently removes organics from the stripper's off-gas, and allows for compliance with applicable air pollution control regulations.

The air-stripper's off-gas, which contains water vapor and volatiles stripped from the ground water, first passes through a heater followed by a dual-bed carbon adsorption system that is operated similarly to the liquid carbon adsorption equipment. The heater is a 8 kilowatt (kW) convective space heater that increases the temperature of the off-gas in order to lower the relative humidity (see Plate 1). The heater is controlled by a thermoswitch located downstream of the heater. The thermoswitch is factory set to maintain the off-gas air stream entering the primary VGAC at a temperature of approximately 90°F. The thermoswitch maintains the air stream at this temperature by turning the heater on and off. When the temperature of the air stream falls below a temperature of approximately 85°F, the thermoswitch turns the heater on. When the temperature reaches approximately 95°F, the thermoswitch turns the heater off. The off-gas temperature discharging from the air stripper is maintained year round between 50°F and 60°F due to the fairly constant temperature of the ground water. The decrease in the relative humidity of the air stream entering the primary VGAC increases the lifetime of the vapor-phase carbon units and, thus, improves the cost-effectiveness of this portion of the TS. Carbon regeneration is discussed in Section 5.10 of this Operations and Maintenance Manual and SOP 20.0 (Appendix A)

1.4.7 Liquid-Phase Granular-Activated Carbon (LGAC)

The liquid effluent from the stripper is polished using carbon to adsorb any organic contaminants remaining in the stripped ground water stream. Although the air stripper is capable of reducing the PCE and TCE concentrations to non-detectable concentrations, the liquid-phase activated carbon has been included as a contingency, in case the air stripper malfunctions or compounds other than those previously detected are extracted from the aquifer. The carbon-polishing equipment minimizes the potential for discharge of effluent that does not meet the discharge criteria. The carbon equipment consists of two steel canisters containing 2,000 pounds each of granular-activated carbon (see Plate 1). The carbon canisters are operated in series with a primary carbon unit and a secondary carbon unit. This configuration, coupled with the air stripping system, is triply redundant, providing three unit operations capable of removing the contaminants from ground water.

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1.4.8 Programmable Logic Control

The Programmable Logic Control panel (PLC) (see Plate 1) controls the operation of the following TS components by a computer program built into the unit:

• Five extraction well pumps (3 extraction wells wired through separate panel)

• Two transfer pumps

• Two process blower fan motors

• One in-line duct heater for the air stripper effluent air

• Two motorized ball valves located on Skid 1

The PLC also controls the system alarms triggered by conditions including:

• High and low equalization tank levels

• High filter pressure for the particulate filter canisters

• High air-stripper sump level

• Low air pressure in the air stripper

• High pressure in the liquid-phase carbon canisters

• High floor sump water level

• High air temperature out of the duct heater and into the vapor phase

Responses to these alarm conditions are also controlled by the PLC. The alarm conditions and PLC response are presented in Section 6 of this report.

The PLC also includes a monitoring panel which is connected to the SSC network. This monitoring panel allows for remote access to the system and allows the operator to view real time aqueous flow rates for each extraction well, the system aqueous flow rate, level of ground water in the equalization tank, the air flow rate from the air stripper, and any alarm conditions that may have been activated. Extraction well flow rates can be downloaded and the alarm checked and re-set.

1.5 Procedure for Making Treatment System Modifications

Prior to modifying the TS, the following procedure must be followed to obtain approvals from the Army and regulators:

• The proposed system modifications will be designed, documented and submitted to the SSC restoration officer

• Following approval from the restoration officer, the proposed changes will be communicated to the EPA and MADEP project managers

• Following concurrence from EPA and the MADEP, the modification will be implemented during the subsequent treatment-system maintenance event

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Section No.: 2.0

2.0 System Start-Up, Operation, and Shut-Down Procedures

This section presents procedures for correct start-up, operation, and shut down of the TS. These procedures must be followed to ensure safe and appropriate system operation. The start-up instructions are simple to follow with emphasis on correct valve settings throughout the system. Incorrect valve settings can result in an emergency shutdown and bursting pipes. The system operation is mostly automated with minor manual adjustments. Shut-down procedures are simple to follow and can be completed in minutes.

2.1 System Start-Up

The following steps document the correct procedures to follow for system start-up. See Figure 2-1, the system Process and Instrumentation Design (P&ID), and Figure 2-2 for valve and equipment locations.

1. Check that appropriate valves are open on the LGAC phase valve rack. These valves should be locked in the correct position and are only adjusted for carbon backwashing as described in SOP 17.0 (Appendix A).

2. Check that appropriate valves are open on the VGAC phase valve rack. These valves should be locked in the correct position and are only adjusted for carbon regeneration as described in SOP 20.0 (Appendix A).

3. Check that extraction well throttling valves are open.

4. Check that the ball valves above the influent and effluent pumps are open.

5. Check motorized ball valves on Skid 1; one valve should show red on the valve stem indicator and one should show green on the valve stem indicator. If both are red (or partially red), open one motorized valve BY HAND at the PLC panel by switching the appropriate valve to HAND for 5 seconds and then switching back to AUTO.

6. Ensure that all electrical disconnects are in the ON position.

7. Put all PLC switches on AUTO except for the extraction wells, influent pump, and effluent pump. (refer to Figure 2-2). If the system is started with all switches on AUTO, there is the risk of an electrical power surge.

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8. Turn Power switch to the ON position in the Monitoring panel and extraction well Expansion panel.

9. Turn the power switch to ON in the Main PLC panel to turn the system on.

10. Once the system is turned on, the High Heat Discharge Alarm from the heater may be activated due to the air stream, produced from the air stripper blower, not having sufficient time to reach the heater to cool it off. When this occurs, hit the RESET button and the alarm will shut off.

11. Check the motorized ball valves on Skid 1 again as described in Step 4 of this section.

12. Turn the effluent pump to the AUTO position.

13. Turn the influent pump to the AUTO position.

14. Turn each of the extraction wells to the AUTO position and check that proper flow rates are achieved.

15. Adjust influent pump throttling valve (marked on skid 1) if needed. The valve should be in the FULL open position for a flow rate of 140 to 150-gpm.

16. Adjust extraction well throttling valves to desired flow rates. The total flow rate from the extraction wells should total at least 10 gpm less than the flow rate of the influent pump.

17. Adjust the effluent pump throttling valve so that the flow rate is approximately

10 gpm greater than the influent pump flow rate.

14. Perform system inspection.

2.2 System Operational Procedures

The TS is completely automated during operation. The system will run if all PLC switches are either in the AUTO or HAND (manual mode) positions and no alarm conditions exist. Alarm conditions are described fully in Section 6.0, Alarm Conditions/Emergency Response. The following activities should be completed while the system is operating. The procedures for these activities are presented in Section 3.0, Monthly Operation and Maintenance:

1. System inspection

2. Flow rate recording

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3. Floor sump inspection and, if necessary, removal of fluids

4. Particulate bag filter change outs

Flow rates, pressures, temperatures, etc. are obtained during the system inspection per SOP 1.0 (Appendix A). The inspection sheet presented in SOP 1.0 should guide the TS operator in determining abnormal readings after a series of readings have been recorded.

2.3 System Shut-Down

The following steps document the correct procedures for system shutdown.

1. Turn extraction well pump switches to the OFF position at the Expansion panel and Main panel.

2. Allow the influent pump to reduce the amount of water in the equalization tank to the low water level float switch. This will automatically shut down the influent pump.

3. Turn influent pump switch to the OFF position at the Main panel.

4. Allow effluent pump to reduce Air Stripper Sump water level to the low water level float switch which will automatically shut the effluent pump off.

5. Allow the air stripper blower, process blower, and effluent pump to operate for an additional 10 minutes. This will allow the air stripping process to complete for ground water still remaining within the air stripper trays (approximately 200 gallons). Leave the effluent pump switch in the AUTO position. During the 10 minute period, remaining ground water will flow down the air stripper trays, filling the stripper tank, activating the high water level float switch, which will activate the effluent pump. The effluent pump will shut off automatically after the water level in the stripper tank has reached the low water level switch. This process may occur two times during the 10 minute waiting period. After the 10 minute waiting period, the system can be shut down. If the blowers and effluent pump are shut down immediately, the ground water within the air stripper trays will fill the air stripper tank with ground water that may still be contaminated.

6. After the 10 minute waiting period, turn the effluent pump to the OFF position at the Main panel.

7. Turn power switch to the OFF position at the Main panel and Expansion panel.

8. Turn the electrical disconnects to the off position.

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9. Check that all switches are in the AUTO position except for the extraction well pumps, influent pump, and effluent pump. The extraction well pumps, influent and effluent pumps should be in the OFF position.

NEVER USE THE PANIC BUTTON TO SHUT OFF THE SYSTEM

(USE ONLY IN CASE OF EMERGENCY).

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Figure 2-2: Programmable Logic Control Start-up Configuration

Main Panel

PLC Monitoring Panel - Extraction Well Expansion Panel

Start-up Procedure:

• Check that appropriate valves are OPEN on liquid and vapor phase valve racks and the extraction well pumps.

• Check that ball valve above the influent and effluent pumps are OPEN and motorized ball valves ok Skid 1 are OPEN (green).

• Put all disconnects in ON position.

• Put all switches on AUTO except the extraction well pumps, influent pump, and effluent pump.

• Turn Power to On in Monitoring Panel and then turn the Power switch to ON in the Main Panel.

• Turn on Effluent Pump, and then Influent Pump, and then turn the extraction wells on.

• Adjust Influent Ball Valve (Marked on Skid 1) so that the desired flow rate on the PLC is obtained.

• Adjust extraction well throttling valves to desired flow rates.

• Check motorized ball valve on Skid 1; one valve should show red and one should show green.

• Perform system inspection.

Section No.: 3.0

3.0 Monthly Operation and Maintenance

This section outlines general operations and maintenance procedures that should be performed monthly, to assure the TS runs efficiently. These instructions, along with the figures, will guide the technician through each maintenance task.

3.1 Waste Generation, Collection, and Disposal

Waste generated during any maintenance activity shall be collected and stored appropriately in labeled 55-gallon drums or polyethylene storage tanks. The only wastes that should be generated are:

• Spent LGAC

• Spent VGAC

• Carbon backwashing sludge

• Waste cleaning acids.

The waste LGAC, VGAC, and sludge should be analyzed for TCLP, ignitability, corrosivity, and reactivity when generated. Based on previous analyses, these wastes are not expected to be hazardous.

The spent LGAC and VGAC is removed from the site when generated (changed-out) by the carbon vendor and taken to a disposal facility where it is regenerated. Spent carbon leaving the site is manifested through a bill of laden and non-hazardous waste manifestation form. The spent carbon, both vapor phase and liquid phase, has always been classified as RCRA non-hazardous. The disposal facility also provides the generator ( U.S. Army) with a VOC Destruction and Activated Carbon Reactivation certificate. This certificate states that the disposal facility received the spent carbon and that the spent carbon was reactivated in accordance to state and federal regulations by thermal processing that removes and destroys volatile and semi-volatile organic compounds adsorbed on the spent carbon.

The waste cleaning acids are generated in small quantities from use of a dilute muriatic acid solution used for cleaning system components, and are neutralized when put into a polyethylene storage tank in the treatment system facility. The neutralized decant water is pumped into the equalization tank for treatment, and the sludge is stored in 55-gallon drums in the SSC hazardous storage area and managed by the US Army, consistent with State and Federal requirements.

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LGAC backwash water is handled the same way. Iron sludge generated will be sampled and analyzed for TCLP, including ignitability, corrosivity, and reactivity. The onsite SSC hazardous waste manager will be notified and will supply 55-gallon polyethylene drums. The iron sludge will be pumped to each drum, each drum labeled with a proper hazardous/non-hazardous label, and stored at the SSC hazardous storage area. The SSC will manage the disposal of the waste and will be provided with the results of the TCLP analysis.

3.2 System Inspection Procedures

Weekly inspections were performed for the first three years of TS operation. This schedule has since been updated to a monthly inspection. There are numerous items that must be checked and completed each period to ensure proper operation of the TS.

The inspection program was designed to ensure these items are checked appropriately and recorded for use by the TS operator.

Detailed directions for performing a system inspection are included in SOP 1.0 (Appendix A) including tables describing an inspection form and typical results.

3.3 Equipment Maintenance

The following sections describe maintenance that may have to be performed monthly for each piece of equipment, building, or plumbing component. The maintenance activities will depend on results of the monthly system inspection. If possible, maintenance activities should be performed during the quarterly or annual shutdowns.

However, occasional emergency maintenance may be required prior to these events.

Bag filters require bi-weekly change outs.

3.3.1 Extraction Wells and Pumps

The extraction well pumps are checked by observing their flow rates during the operational inspection (Section 3.2) as well as measuring the ground water level within the well. If large flow rate variations are observed from week to week and the extraction well throttling valves have not been adjusted, or the ground water level has dropped significantly, the extraction well pumps and the well screens should be inspected for inorganic/organic scale. If scaling exists, follow procedures for removing scale presented in SOPs 4.0 and 5.0 (Appendix A).

3.3.2 Flow Rate Control and Data Recording Procedures

The extraction well flow rates are checked and adjustments should be made to the flow control valve to maintain flow at the optimum pump rates for all wells. The extraction well flow meters are wired to the monitoring panel which stores flow rate data for each extraction well electronically. The flow rate data are stored and backed up according to

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SOP 3.0 (Appendix A) so that data can be downloaded remotely or onsite. The TS flow rate and volume of water treated are recorded from the PLC during the inspection.

3.3.3 Programmable Logic Control

The PLC is inspected during the system inspection to determine if any bulbs have burnt out. If this has occurred, follow instructions in SOP 27.0 (Appendix A) to change out the bulbs on the switches.

3.3.4 Equalization Tank

The equalization tank is checked during the operational inspection. The inspection also includes the observation of leaks and excessive suspended solids accumulation. Leaks may occur from the tank outlet, the float switch bushings (tank water level floats), and pressure transducer installed on the tank. Excessive suspended solids accumulation on the bottom of the tank should be visually inspected through the porthole on the top of the tank. If excessive solids are observed at the bottom of the equalization tank, follow instructions in SOP 8.0 (Appendix A) for removal.

3.3.5 Particulate Filters

During normal operation, one motorized ball valve will be open while the other is closed. For example, bag filter 1 is open while bag filter 2 is closed. If bag filter 1 should become “clogged” the pressure switch will detect high pressure and send a signal to the PLC control panel. The motorized ball valve for bag filter 1 will close and at the same time the motorized ball valve for bag filter 2 will open. Bag filter 1 is now closed waiting for change out and bag filter 2 is now open. If bag filter 2 should become “clogged”, the pressure switch will detect high pressure and send a signal to the control panel. The control panel will then close motorized ball valve 2 and open motorized ball valve 1. If bag filter 1 has not been changed out and is still causing a high-pressure signal, the control panel will shut down the system. Once the high-pressure bag filter alarm is signaled, the call-out system will alert the system operator with Alert Condition #2. Alarm conditions are described in detail in Section 6.

The bag filters should be changed out bi-weekly from the primary (skid 1) particulate filters as described in SOP 11.0 (Appendix A).

3.3.6 Air Stripper

The air stripper is inspected to observe air and water flow rates and air pressures. The effluent pump pressure should also be checked. Both of these items should be checked as part of the operational inspection. If the pressures or flow rates are too high or too low, adjustments should be made to the air damper regulating the inlet airflow and/or the effluent water pump as described in SOP 14 (Appendix A).

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3.3.7 Process Blower and Heater

Per SOP 1.0, humidity and pressure in the air stream before the heater (at sample port B) and after the heater (before the VGAC), should be measured using a temperature/humidity probe. Prior to using the temperature/humidity probe, calibrate the instrument following the procedures outlined in SOP 31.0 (Appendix A). If the effluent temperature is not between 85°F and 95°F and the humidity is not approximately 50 percent, ensure that the heater is working and evaluate the need for temperature gauge maintenance or replacement.

3.3.8 Vapor-Phase Granular-Activated Carbon (VGAC) Canisters

Pressure readings of the canisters are recorded during the monthly inspection. If the pressure in either canister exceeds 15 ounces per square inch, the carbon may be clogged with moisture. Follow the procedures described in SOP 26.0 (Appendix A).

3.3.9 Liquid-Phase Granular-Activated Carbon (LGAC) Canisters The influent and effluent pressures are read for each canister to determine the pressure drop across the beds. If the pressure drop exceeds 12 psi, the LGAC canister(s) should be backwashed, following the procedures in SOP 17.0 (Appendix A). The effluent from the LGAC canisters is inspected for the presence of carbon in the effluent stream. This can be done by inspecting the clear pipe on the effluent line of the secondary LGAC canister. If carbon is detected in the effluent stream, the canister's distributor has failed and needs maintenance or replacement. Contact the carbon vendor, Tetrasolv at 1-508- 224-1784 to inspect each canister and replace the faulty distributor(s).

3.3.10 Plumbing

The system's plumbing components are examined as part of the operational inspection.

Specific procedures for plumbing inspections are described in SOP 24 (Appendix A).

3.4 Treatment System Sampling Procedures

Plate 1 illustrates the TS sampling locations throughout the treatment process.

Procedures for collecting the samples are described in SOP 2.0 (Appendix A). Sample locations are identified below for reference, although not all locations will be sampled on a regular basis.

• Location MW90B (formerly Location A1) — Extraction well MW-90B-4

• Location MW15B (formerly Location A2) — Extraction well MW-15B

• Location MW94B (formerly Location A4) – Extraction well MW-94B-4

• Location MW95B (formerly Location A5) – Extraction well MW-95B-4

• Location MW96B (formerly Location A6)– Extraction well MW-96B-4

• Location A — At the discharge of the equalization tank

• Location B (vapor) — Between the air-stripper and the vapor-phase carbon

• Location C1 (Vapor) — Discharge from the primary vapor-phase carbon

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• Location C2 (Vapor) — Discharge from the secondary vapor-phase carbon

• Location D — Between the air-stripper and the primary liquid-phase carbon

• Location F — Between the primary and secondary liquid-phase carbon

• Location G — At discharge from the liquid-phase carbon system

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Section No.: 4.0

4.0 Quarterly Operation and Maintenance

Quarterly maintenance activities should be done when the TS is shut down for SSC quarterly ground water sampling events. The following sections summarize the quarterly maintenance items that may have to be performed for the building, plumbing components, or each piece of equipment. The TS operator should determine, based on operating conditions, what activities should be completed and document their completion in the TS log book. This section is divided into building and process components requiring quarterly maintenance.

4.1 Building (General)

The heat and fans in the building are checked quarterly by SSC facility personnel to ensure that proper heating and ventilation occurs. The floors are also swept and mopped during the quarterly events. In the event the floors are extremely dirty or the paint is cracking, arrange for either a professional cleaning or repainting.

4.2 Plumbing Components

Inorganic scale should be removed from the influent flow rate control valves for the extraction wells and the valves on the primary particulate filter skid. The operations of all valves are checked during this time. Any valves not operating properly are disassembled and inorganic scale removed from their surfaces, following instructions in SOP 22.0 (Appendix A).

4.3 Extraction Wells and Pumps

The extraction well pumps and the condition of the well screen is checked quarterly by pumping each well at its maximum sustainable flow rate. If the wells are not capable of sustaining their rates, the well screens and/or pumps may be fouled by inorganic or organic scale. Procedures for removing iron scale from the extraction well screen and pump are provided in SOPs 4.0 and 5.0 (Appendix A).

4.3.1 Extraction Well Redevelopment

When ground water draw down in the extraction well begins to approach the elevation of the extraction well pump inlet, the extraction well should be redeveloped. Well yields will decline over time due to iron scaling within the screen and sand pack.

Many methods exist for redevelopment of the extraction wells. Chemical methods consist of injecting acids and/or bases to dissolve mineral and bacterial scale. Following

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