TE_6.pdf

Final Submittal

Operation and Maintenance Guide for Tactical Vehicle Wash Facility

Kahuku, Oahu, Hawaii

Prepared For:

U.S. Army Corps of Engineers Honolulu District

Prepared by:

Nagamine Okawa Engineers, Inc.

and HDR Engineering, Inc.

November 2013

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O&M Guide for Tactical Vehicle Wash Facility, Kahuku Training Area

November 2013 i

OPERATION AND MAINTENANCE GUIDE FOR

TACTICAL VEHICLE WASH FACILITY, KAHUKU TRAINING AREA

TABLE OF CONTENTS

A. Overview of this Manual

B. General Description of Facility

C. Individual Process Components

1. Wash Area and Trench Drain

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

2. Sedimentation Basin, Aboveground Oil/Water Separator and Sump Pumps

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

3. Pressure Filters, Filter Backwash Pumps and Screen Filters

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

4. Disinfection System

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

5. Finished Water Storage Tank

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

6. Hose Stream Booster Pumps

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

7. Pressure Washer Units

a. Description

b. Typical Operating Sequence and Procedures

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TABLE OF CONTENTS (CONTINUED)

c. Typical Maintenance

8. Water Well and Pump

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

9. Water Transfer Tank

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

10. Water Supply System

a. Description

b. Typical Operating Sequence and Procedures

11. Process Piping

a. Description

b. Typical Operating Sequence and Procedures

c. Typical Maintenance

12. Process Equipment Alarms

D. Standard Operating Instructions for Military Personnel

November 2013 iii

LIST OF TABLES

Table 1 Wash Area Fixtures

Table 2 Sources of Sump Inflow

Table 3 Sump Pump Characteristics

Table 4 Sump Pump Activation Levels

Table 5 Pressure Filter Characteristics

Table 6 Filter Backwash Pump Characteristics

Table 7 Screen Filter Characteristics

Table 8 Finished Water Storage Tank Piping Connections

Table 9 Hose Stream Booster Pump Characteristics

Table 10 Pressure Washer Characteristics

Table 11 Well Pump Characteristics

Table 12 Well Pump Activation Levels

Table 13 Water Transfer Tank Piping Connections

Table 14 Water Supply System Characteristics

Table 15 Process Piping Characteristics

Table 16 Civil Sitework Piping

Table 17 Process Equipment Alarm Events

Table 18 Wash Procedures for Military Personnel

Table 19 Maintenance Tasks for Military Personnel

Table 20 General Rules for Military Personnel

November 2013 iv

LIST OF FIGURES

Figure 1 Simplified Process Flow Diagram

Figure 2 Process Flow Diagram

Figure 3 Process Piping Plan

Figure 4 Wash Area Plot Plan

Figure 5 Sedimentation Basin Plan and Sections

Figure 6 Aboveground Oil/Water Separator

Figure 7 Sump Plan and Sections

Figure 8 Sump Pumps Schematic Control Diagram

Figure 9 Mechanical Building Plan

Figure 10 Mechanical Building Pressure Filtration and Backwash System

Figure 11 Pressure Filters and Backwash Pumps Schematic Control Diagram –

Filtration

Figure 12 Pressure Filters and Backwash Pumps Schematic Control Diagram –

Backwash

Figure 13 Mechanical Building - Disinfection System

Figure 14 Disinfection System Schematic Control Diagram

Figure 15 Mechanical Building/Storage Tank Plot Plan

Figure 16 Finished Water Storage Tank Plan and Sections

Figure 17 Mechanical Building - Booster Pumps and Pressure Washers

Figure 18 Hose Stream Booster Pumps Schematic Control Diagram

Figure 19 Well Pump Details

Figure 20 Water Transfer Tank and Water Supply System

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APPENDIX

Inspection and Maintenance Forms

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November 2013 1

OPERATION AND MAINTENANCE GUIDE FOR

TACTICAL VEHICLE WASH FACILITY, KAHUKU TRAINING AREA (KTA)

A. OVERVIEW OF THIS MANUAL

This Operations and Maintenance (O&M) Guide is provided to give the O&M Contractor a generalized overview of typical operational procedures and maintenance work required to keep the Tactical Vehicle Wash Facility in proper operating condition. The manual is written assuming that the processes and equipment selected for the project are consistent with the originally specified processes and equipment. This O&M Guide is not intended to replace equipment manufacturers’ O&M manuals that are provided with the purchased equipment. In the event of conflict between this O&M Guide and the equipment manufacturer supplied O&M Manual, the equipment manufacturer supplied O&M Manual shall govern. All activities must be conducted in accordance with the O&M Contractor’s Safety Plan. In the event of a conflict between this O&M Guide and the O&M Contractor’s Safety Plan, the O&M Contractor’s Safety Plan shall govern.

This O&M Guide is structured as follows:

1) Overview of This Manual

2) General Description of the Facility

3) Individual Process Components

i. Description

ii. Typical Operating Sequence/Procedures

iii. Typical Maintenance

4) Standard Operating Instructions for Military Personnel

B. GENERAL DESCRIPTION OF THE FACILITY

The Tactical Vehicle Wash Facility, Kahuku Training Area (KTA), is used as a field wash for vehicles utilizing the Kahuku Training Area. The primary purpose of the facility is to reduce the potential migration of mud and plant seeds to areas outside the Kahuku Training Area.

The Tactical Vehicle Wash Facility recycles spent vehicle washwater for reuse to minimize consumption of water. The recycled washwater is non-potable and is not appropriate for human consumption. A simplified process flow diagram showing the main process components for the facility is shown on Figure 1. The facility utilizes sedimentation (settling), oil/water separation, pressure filtration, screen filtration, disinfection (chlorination), finished water storage, and recycling of the finished water.

The facility also utilizes an on-site well and water transfer tank to make up water lost due to vehicle carry-off and evaporation.

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The facility was not designed to provide a final vehicle wash for inspection. Therefore, the recycled washwater contains a small amount of silt and clay, which will remain on the vehicles after the washwater evaporates.

The facility was designed to wash 180 vehicles per day, with each vehicle being washed for approximately 35 minutes.

1) Vehicle Loading = 180 vehicles/day

2) Wash bays provided = 6

3) Design wash time/vehicle = 35 minutes/vehicle

4) Design time to wash 180 vehicles using 6 wash bays = 17.5 hours

5) Design wash event is over a three-day period = 540 vehicles

A process drawing with design data for individual processes is shown on Figure 2. The physical layout of the facility is shown on Figure 3. Specific processes are described in detail in the following sections.

C. INDIVIDUAL PROCESS COMPONENTS

1. Wash Area and Trench Drain

a. Description

The wash area consists of a reinforced concrete pad to accommodate vehicles during a wash event. A plot plan of the concrete wash area is shown on Figure 4. There are a total of six wash area bays (WA). There is one tandem stall to accommodate trucks with trailers and four individual stalls. The wash bays have low-pressure hose connections and high-pressure washer connections. Each of the six wash bays is equipped with the fixtures listed in Table 1:

Table 1

Wash Area Fixtures

Fixture Number per bay Design Flow, lpm (gpm) Pressure, kPa (psi) at delivery point Low-pressure hose connection 2 95 (25) 517 (75) High-pressure connection 2 13 (3.5) 10,350 (1,500)

Spent washwater captured on the concrete wash area enters a concrete trench drain and flows into the Sedimentation Basin. Each wash bay is sloped to a center trench drain, Trench Drain A, which is perpendicular to the wash pads. The trench drain has a U-shaped invert sloped at two percent to optimize hydraulic efficiency and to minimize accumulation of settled solids. The trench drain has a removable traffic-rated, heavy-duty metal grating. Trench Drain A makes a 90-degree bend to the Sedimentation Basin as shown on Figure 3. To facilitate hydraulic efficiency and prevent deposition of solids in the trench drain, the bend consists of a 90-degree curve with a 3.048 m (10 ft) radius. Thus, if the trench drain becomes clogged, the low-pressure hoses can be used

November 2013 3 to flush the trench drain. In addition, the metal grating can be removed by hand to facilitate flushing.

The wash area was designed to wash WHEELED VEHICLES ONLY. If tracked vehicles need to be washed at the facility, the tracked vehicle must be loaded onto a low-boy trailer first. The wash area concrete slab was not designed to accommodate tracked vehicles. DO NOT RUN TRACKED VEHICLES over the wash area.

Do not wash any vehicle that is NOT PARKED ENTIRELY on the concrete wash area as shown on Figure 3 because spent washwater will not be captured and directed to the Sedimentation Basin.

A trench flush nozzle is connected at the upstream end of the trench drain to flush the trench drain as shown on Figure 4. The trench flush nozzle provides a continuous flow of water into the trench drain. The trench flush nozzle is connected to Process Line “D” and is actuated by a pressure-sustaining flow control valve. The pressure-sustaining flow control valve is adjacent to a trench flush gate valve used to isolate the trench flush nozzle. The trench flush gate valve must be opened manually prior to a wash event.

The trench flush gate valve must be manually closed after a wash event. The trench flush nozzle supplies a minimum flow of 189 lpm (50 gpm) throughout the duration of the wash event.

The hose stream booster pumps at the Mechanical Building supply the low-pressure hose connections and the trench flush nozzle. Refer to Section C6 for Hose Stream Booster Pump operation. Individual pressure washer units at the Mechanical Building supply water to the high-pressure washer connections. The maximum design flow rate anticipated from the wash process is 216 lpm (57 gpm) per wash bay, or a total flow rate of 1,294 lpm (342 gpm) when all six wash bays are in use. A maximum flow rate of 1,484 lpm (392 gpm) is anticipated when all six wash bays are in use with the trench flush gate valve open.

b. Typical Operating Sequence and Procedures

Before Wash Event

1) Open the trench flush gate valve at the wash area as shown on Figure 2 and Figure 4. Water may be observed flowing out of the trench flush nozzle from the Water Storage Tank. The water would be recycled through the facility.

2) There are 12 high-pressure hoses at the wash area, E-01 through E-12, shown on Figure 2 and Figure 4. Select nozzle with desired spray pattern from the pressure washer units in the Mechanical Building. Connect pressure washer wands and spray nozzles to individual quick connect couplers at the wash area. Pressure washer wands are stored in the Mechanical Building. Open ball valves at the wash area hose connections after pressure washer wands and spray nozzles have been connected.

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Do not lay pressure washer wands on wash area pavement where vehicles can run over wands.

3) There are 12 low-pressure hoses at the wash area, HC-01 through HC-12, shown on Figure 2 and Figure 4. Open ball valves at the low-pressure hose connections after verifying the low-pressure hose nozzles are attached. Do not lay hose nozzles on the wash area pavement where vehicles can run over nozzles.

4) Activate hose stream booster pumps inside Mechanical Building. Refer to

Section C6 for Hose Stream Booster Pump operation.

5) Activate pressure washer units inside Mechanical Building within 10 minutes of wash event. An automatic time-delay shutdown feature shuts the pressure washer unit off if not used by the user-adjustable time delay selected. Refer to Section C7 for Pressure Washer operation.

6) Verify the stop gate as shown on Detail 1 on Figure 5 in the Sedimentation

Basin Junction Box from Trench Drain A is open to allow washwater to enter the on-line Sedimentation Basin compartment.

During Wash Event

1) Check for leaking fixtures, hoses, nozzles, and wands at wash area.

2) Check the trench flush nozzle – a stream of water should be flowing from the trench flush nozzle into the trench drain. If only one hose is being used, the flow from the trench flush nozzle should be high. Likewise, as more low-pressure hose connections are opened, the flow from the trench flush nozzle should decrease correspondingly.

3) Check that military personnel leave hose nozzles on the concrete islands whenever vehicles enter and exit wash area bay to prevent vehicles from running over nozzles.

4) Check that military personnel leave pressure washer wands on the concrete islands whenever vehicles enter and exit wash area bay to prevent vehicles from running over pressure washer wands.

After Wash Event

1) Deactivate the individual pressure washer units in the Mechanical Building. Refer to Section C7 for Pressure Washer operation.

2) Keep hose stream booster pumps activated for post-wash cleaning of facility asphalt and concrete pavement by military personnel.

November 2013 5

3) After post-wash pavement cleaning is completed, verify that Trench Drain A is clear of debris or obstructions and concrete wash area and AC paved approach are clear of debris and mud. Military personnel using the facility are responsible for the cleanup of these areas. Refer to Section D for Standard Operating Instructions for Military Personnel.

4) Verify that trench flush nozzle is clear of debris.

5) Shut down hose stream booster pumps. Refer to Section C6 for Hose

Stream Booster Pump operation.

6) Close all low-pressure hose connection valves; manually roll up hoses on hose reels until the hose reel locks into place.

7) Close all high-pressure connection valves; disconnect all pressure washer wands and return to Mechanical Building storage. Manually roll up hoses on hose reels until the hose reel locks into place. Remove pressure washer wand spray nozzles and return to pressure washer units in the Mechanical Building.

8) Close trench flush gate valve at the wash area.

9) Verify water is not discharging from any of the low-pressure hose connections, pressure washer connections, or trench flush nozzle in Trench Drain A.

c. Typical Maintenance

Typical maintenance procedures are recommended below. Refer to Wash Area and Trench Drain Inspection and Maintenance Data Sheet in Appendix A. Note that some typical maintenance procedures are included as part of the typical operating sequence and procedures. Tasks listed with daily maintenance refer to maintenance done on the day of the wash event.

Wash Area

1) Daily: Verify concrete wash area and asphalt approach areas are clear of mud and silt, pebbles, rocks, and other debris. Military personnel are responsible for cleanup of wash area and pavement.

2) Daily: Check condition of low-pressure hose connection ball valves and threaded connections.

3) Daily: Check condition of high-pressure hose connection ball valves and quick connect couplings.

November 2013 6

4) Daily: Check for debris in the hose connection nozzle entrance.

5) Daily: Verify low-pressure hoses and high-pressure hoses are rolled up on hose reels and locking mechanisms are activated.

6) Daily: Conduct general housekeeping around area.

7) Daily: Check the four working level lighting fixtures per wash bay and overhead pole mounted lights for burnt out bulbs.

Trench Drain A

1) Daily: Verify trench drain is clear of mud and silt, pebbles, rocks, and other debris. Military personnel are responsible for cleanup of Trench Drain A.

2) Daily: Check for debris at the Spent Filter Backwash Line connection to Trench Drain A at the 90-degree bend in Trench Drain A. Flush the trench drain as needed.

3) Daily: Ensure that all metal grates are in place over trench drain.

4) Daily: Check condition of metal trench drain grates. Replace or repair as needed.

Trench Flush Control Valve

1) Daily: Check for leakage around piping and valve joints.

2) Daily: Conduct general housekeeping around area.

3) Annually: Check and lubricate flow control valve in accordance with manufacturer’s requirements.

4) Annually: Clean and re-lubricate isolation valve stems on Trench Flush

Control Valve assembly.

5) Annually: Clean and wire brush corroded areas. Spot paint as needed.

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2. Sedimentation Basin, Aboveground Oil/Water Separator, and Sump Pumps

Sedimentation Basin

The Sedimentation Basin is a large concrete tank used to settle out larger clumps of mud, small rocks and pebbles, and other heavy particles washed from the vehicles.

These particles settle to the bottom of the tank as the washwater flows from the inlet side to the outlet side of the tank. The Sedimentation Basin has two compartments, each with a length of approximately 45.720 m (150.0 ft) and width of approximately

7.620 m (25.0 ft). The total depth of the Sedimentation Basin is approximately 1.646m (5.4 ft). The bottom 0.152 m (0.5 ft) depth of the Sedimentation Basin is used for sediment storage, while the upper 0.610 m (2 ft) of the Sedimentation Basin is used for freeboard.

Design characteristics of the Sedimentation Basin are as follows:

1) Maximum flow rate into basin:

12 low-pressure hoses at 95 lpm (25 gpm) = 1,140 lpm (300 gpm) 12 high-pressure wands at 13 lpm (3.5 gpm) = 156 lpm (42 gpm) 1 low-pressure trench flush at 189 lpm (50 gpm) Total maximum inflow = 1,484 lpm (392 gpm)

2) Detention time at maximum inflow = 4.1 hours

3) Basin water storage required = 356,131 liters (94,080 gallons)

4) Basin water volume provided = 365,202 liters (96,476 gallons)

5) Sediment storage required = 71.359 m3 (2,519 ft3)

6) Sediment storage provided = 78.155 m3 (2,760 ft3)

Most of the Sedimentation Basin is below grade and is rectangular-shaped in plan view.

Trench Drain A discharges to the Sedimentation Basin Junction Box as shown on the Sedimentation Basin plan view on Figure 5. Two openings in the Sedimentation Basin Junction Box direct flow to Sedimentation Basin Compartments A and B. During normal operations, both compartments are operational and flow enters Compartment A and B.

Fiberglass reinforced plastic (FRP) stop gates mounted within the Sedimentation Basin Junction Box allows either compartment to be isolated for maintenance.

Washwater enters the Sedimentation Basin through the Sedimentation Basin Junction Box, flows through the Sedimentation Basin to the opposite end, over the outlet weir, and into the outlet trench. The Sedimentation Basin compartments are covered by a geomembrane cover to prevent excessive evaporation due to high winds and low humidity and to reduce the growth rate of algae in the Sedimentation Basin.

The outlet trench is a rectangular shaped concrete trench as shown on Detail 2 on Figure 5. The outlet trench is connected to the Aboveground Oil/Water Separator through a 250-mm (10-in) DI pipe connection. The two Sedimentation Basin

November 2013 8 compartments share the same outlet trench and connection to the Aboveground Oil/Water Separator.

The bottom of the Sedimentation Basin was sized to provide sediment storage for approximately six months. If wash activity exceeds the design criteria, sediment is expected to accumulate more rapidly and will require cleaning more frequently. To facilitate Sedimentation Basin draining during sediment removal, a telescoping valve system allows water levels to be drawn down. A telescoping valve in each compartment, Telescoping Valves A and B, allows water to be decanted from a normal operating depth of approximately 1.036 m (3.4 ft) down to a depth of approximately

0.152 m (0.5 ft), which is the estimated six-month sediment accumulation depth. The telescoping valve allows the operator to manually draw down the water in the Sedimentation Basin and maintain control over the amount of silt-laden water discharging to the sump.

In addition, a diaphragm pump is located between the two compartments of the Sedimentation Basin as shown on Figure 5 to allow washwater to be transferred from one compartment to the other. Piping and valves are configured to provide flexibility in pumping from either compartment. The diaphragm pump, piping, and valves are located below the grating on the Sedimentation Basin walkway.

After the water level reaches a depth of approximately 0.152 m (0.5 ft), the accumulated sediment should be left for several days in the Sedimentation Basin, if possible, to facilitate additional dewatering via evaporation.

Aboveground Oil/Water Separator

The Aboveground Oil/Water Separator is a prefabricated steel rectangular “in-line” device used to remove oil and grease as shown on Figure 6. The Aboveground Oil/Water Separator receives water from the Sedimentation Basin outlet trench via a 250-mm (10-inch) DI pipe, and the outlet is connected to the sump through a short 250-mm (10-inch) DI pipe. The Aboveground Oil/Water Separator is equipped with internal baffles and coalescers to facilitate the oil/water separation process. Oil and grease accumulate on the water surface within the Aboveground Oil/Water Separator while effluent is discharged by gravity to the sump.

Prior to a severe weather event, the Aboveground Oil/Water Separator could be isolated by removing the flexible coupling upstream of the Aboveground Oil/Water Separator adjacent to the flanged coupling adapter as shown on Figure 6 and installing a blind flange. The blind flange would reduce the potential for a washout during a severe weather event. The Sedimentation Basin outlet piping must be supported prior to and during the period when the flexible coupling is disconnected.

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Sump and Sump Pumps

The sump is a rectangular concrete structure and functions similarly to a pump station wet well. The sump and sump pumps are shown on Figure 7. Effluent from the Aboveground Oil/Water Separator discharges into the sump and is pumped through the pressure filters, screen filters and into the Finished Water Storage Tank. The sump receives water from several sources indicated in Table 2 and shown on Figure 7.

Table 2 Sources of Sump Inflow

Source Pipe size, mm

(in) Frequency of discharge Aboveground Oil/Water Separator 250 (10) During wash operations or rainfall event Telescoping Valves A and B 150 (6) During drawdown of water level for sediment removal Recirculation Line 75 (3) During recirculation of storage tank water Chlorine Residual Discharge Line 13 (0.5) Constant

The sump is equipped with two submersible non-clog pumps, normally operated with one pump in operation and the other in standby. The pumps are equipped with an auto-alternator to automatically alternate operating and standby modes between the two pumps. Sump pump characteristics are listed in Table 3.

Table 3 Sump Pump Characteristics

Number 2 – 1 operating/1 standby Type Submersible, centrifugal, non-clog Design Operating Points 2,233 lpm @18.651m (590 gpm @ 61.2 ft)

1,484 lpm @ 24.079 m (392 gpm @ 79 ft) Electrical Characteristics 14.9 kW, 460 VAC, 3 phase, 60 Hz

The pumps are normally always activated and will operate during a storm event if water levels in the sump rise. Pump operation is activated by a level transducer at water levels in the sump listed in Table 4.

November 2013 10

Table 4 Sump Pump Activation Levels

Water elevation (m) Water depth above sump bottom (m) Action Notes

133.185 1.670 High water level alarm

(LAH)

Pump control panel red light and horn activated

133.035 1.520 Lag pump on

132.885 1.370 Lead pump on

132.275 0.760 Pump off

132.125 0.610 Low water level alarm

(LAL)

Pump control panel red light and horn activated

131.515 --- Bottom of sump

A schematic control diagram for the sump pumps is shown on Figure 8. The pumps are wired for five alarm conditions: Level alarm high, Level alarm low, motor overload, Emergency Shutdown, and high temperature. Each of the alarm conditions activate a red light and audible horn on the sump pump control panel mounted in the Mechanical Building Electrical Room. The control panel alarm signals are also transmitted to the Emergency Shutdown/Alarm Cabinet mounted on the outside face of the Mechanical Building. A plan view of the Mechanical Building is shown on Figure 9. The sump pumps are connected to the Emergency Shutdown/Alarm Cabinet. The disconnect switch at the Emergency Shutdown/Alarm Cabinet can be used to shut down all processes automatically in the event of an emergency.

The sump pumps are interlocked with the pressure filter backwash pumps to prevent both units from operating at the same time. Refer to Section C3 for Filter Backwash Pump operations.

1) Verify Trench Drain A leading into the Sedimentation Basin is clear of debris. Remove or flush any observed debris. Do not allow water to flow into Sedimentation Basin with debris in its inlet or outlet.

2) Verify Sedimentation Basin Junction Box is clear of debris. Remove or flush any observed debris.

3) If one of the Sedimentation Basin compartments is out of service, verify that the stop gate at the Sedimentation Basin Junction Box is closed for that compartment.

4) Verify Sedimentation Basin outlet trench is clear of debris. Remove or

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5) Verify the sump pumps are activated at the sump pump control panel at the Mechanical Building Electrical Room.

6) Check for oil or grease on the water surface in the sump. If oil or grease is visible, remove the oil or grease from the sump and check the oil level in the Aboveground Oil/Water Separator. Check the oil level in the Aboveground Oil/Water Separator by placing a dipstick with water detection paste into the port on the top of the separator cover. If the oil level is approximately 14 inches thick, or 26 inches below the top of the separator, there is approximately 800 gallons of accumulated oil and oil must be removed from the separator. To remove and collect oil, open the two-inch drawoff port with ball valve on the side of the separator. Call for oil pumping service when necessary. Test the oil for chlorinated solvents to determine whether the oil must be handled and disposed of as a hazardous waste.

1) If sump pump is running, open manual air release valve at top of piping header assembly to vent discharge line as shown on Section B on Figure 7.

2) If there is an alarm condition, the red light and annunciator at the Emergency Shutdown/Alarm Cabinet at the Mechanical Building will activate. If there is an alarm condition, go to Emergency Shutdown/Alarm Cabinet and shut down process. Check source of alarm condition and resolve before re-setting alarm.

1) With hose stream booster pumps still active, water will continue to flow into the Sedimentation Basin from cleaning operations conducted by military personnel along the wash area.

2) Upon completion of cleaning operations, verify that Trench Drain A leading to the Sedimentation Basin is clear of debris. Remove or flush any observed debris.

3) Verify the Sedimentation Basin Junction Box is clear of debris. Remove or

4) Verify the Sedimentation Basin outlet trench is clear of debris. Remove or

5) Shut down hose stream booster pumps after cleaning operations are completed.

November 2013 12

Typical maintenance procedures are recommended as follows. Refer to Sedimentation Basin, Aboveground Oil/Water Separator and Sump Pumps Inspection and Maintenance Data Sheet in Appendix A. Note that some typical maintenance procedures are included as part of the typical operating sequence and procedures.

Tasks listed with daily maintenance refer to maintenance done on day of wash event.

Sedimentation Basin

1) Daily: Check that Trench Drain A and Sedimentation Basin Junction Box are clear of debris. Military personnel are responsible for cleaning of Sedimentation Basin Junction Box and Trench Drain A.

2) Daily: Check outlet trench for debris on water surface. Remove any floating debris.

3) Daily: Check outlet trench for debris. Remove any debris.

4) Daily: Check condition of geomembrane cover fabric. Repair or patch any rips, tears, or holes.

5) Daily: General housekeeping around Sedimentation Basin area.

6) Monthly: Clean Sedimentation Basin walkway with the wash hose located on the walkway. Activate the hose stream booster pumps to use wash hoses on walkway. Roll up hose on hose reel after cleaning is completed.

Refer to Section C6 for Hose Stream Booster Pump operation.

7) Monthly: Check condition of removable fiberglass reinforced plastic stop gates A and B in Sedimentation Basin Junction Box. Stop gates are normally stored inside the Mechanical Building when not in use.

8) Monthly: Check condition of stop gate guides in Sedimentation Basin

Junction Box. Stop gates are normally stored inside the Mechanical Building when not in use.

9) Monthly: Check Sedimentation Basin curbing and exposed concrete surfaces for cracks or other signs of concrete distress. Repair as needed.

10) Semi-Annually: Clean and re-lubricate telescoping valve stems in accordance with manufacturer’s recommendations.

11) Semi-Annually: Drain Sedimentation Basin and remove accumulated silt.

Refer to Procedures for Removal of Accumulated Sediment below.

November 2013 13

12) Semi-Annually: Lubricate moving components of the diaphragm pump in accordance with manufacturer’s recommendations.

Procedures for Removal of Accumulated Sediment

Note: Removal of accumulated sediment is expected to be more effective during the summer months due to higher evaporation rates and drier weather. Based on the facility design parameters, it is estimated that accumulated sediment would require removal twice per year. Procedures for draining and cleaning Compartment A are described below. Procedures for draining and cleaning Compartment B are similar.

1) Insert stop gate A into the stop gate guide at the Sedimentation Basin Junction Box. This will divert all water from a wash or rainfall event into Compartment B.

2) Leave the Sedimentation Basin compartment unused for at least 24 hours, if possible, to allow particles to settle prior to sediment removal. This will aid in decanting of liquid from the Sedimentation Basin compartment.

3) Activate the diaphragm pump at the Sedimentation Basin to transfer water from Compartment A to Compartment B. If Compartment B is in use or out of service for maintenance, use the telescoping valve to drain Compartment A.

a. Lower Telescoping Valve A slowly to decant the water in

Compartment A. The telescoping valve is capable of drawing down approximately 0.884 m (2.9 ft) of water, leaving a water depth of approximately 0.152 m (0.5 ft) in the Sedimentation Basin.

b. Do not allow sediment to enter the telescoping valve.

4) Leave the remaining sediment slurry in place for several days, longer if possible, to dry after draining the Sedimentation Basin with the geomembrane cover open. At the end of each day, close the geomembrane cover to prevent a rain event from re-wetting the sediment.

5) The remaining sediment shall be tested for hazardous waste classification.

A Toxicity Characteristic Leaching Procedure (TCLP) test shall be conducted to verify that the sediment is not classified as hazardous and is suitable for disposal at the site designated by DPW within the installation.

6) Use a compact front-end loader or manual removal methods to remove sediment. If the accumulated material is still in slurry form, a combination jet/vac truck or vacuum truck can be used to pump out the slurry. If using a compact front-end loader, do not drag bucket on the bottom of the Sedimentation Basin as this may damage the concrete slab.

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7) Place the sediment on the surface of the Sediment Drying Bed located on the south side of the Sedimentation Basin to remove excess water. After sediment has dried, it can be removed from the Sediment Drying Bed and disposed at the designated site within the installation.

8) Inspect the interior surfaces of the Sedimentation Basin after the accumulated sediment is removed from the Sedimentation Basin. Note any cracks in the concrete or other signs of distress. Repair any cracks noted in the Sedimentation Basin prior to placing the compartment back into service.

Aboveground Oil/Water Separator

1) Daily: General housekeeping around Aboveground Oil/Water Separator area.

2) Daily: Check for leakage around flanges and joints.

3) Monthly: Check oil level in the separator by placing a dipstick with water detection paste into the port on the top of the separator cover. If the oil level is approximately 14 inches thick, or 26 inches below the top of the separator, there is approximately 800 gallons of accumulated oil and oil must be removed from the separator. To remove and collect oil, open the two-inch drawoff port with ball valve on the side of the separator. Call for oil pumping service when necessary. Test the oil for chlorinated solvents to determine whether the oil must be handled and disposed of as a hazardous waste.

4) Semi-Annually: Check exposed concrete pad for cracks or other signs of concrete distress. Repair as needed.

5) Semi-Annually: Inspect sludge buildup in the separator’s inlet chamber by lowering a stick to the bottom of the separator. Any resistance observed in pushing the stick to the bottom of the separator indicates sludge buildup. Call a combination jet/vac truck or vacuum truck to pump out sludge and clean the separator when the buildup reaches six inches deep.

The bulk liquid should be sent to a licensed facility where the oils and solids are treated before disposal. Refill the separator with water after oil and solids are removed.

6) Semi-Annually: Remove the coalescing plates from the separator and clean the plates before they become “blinded” or coated with silt and solids.

7) Annually: If it becomes necessary to drain and enter the Aboveground

Oil/Water Separator for cleaning or inspection, follow all Permit Required deanna.m.yamada Highlight deanna.m.yamada Highlight deanna.m.yamada Highlight

November 2013 15

Confined Space (PRCS) conditions to enter the empty Aboveground Oil/Water Separator.

8) Annually: Inspect exterior of the separator tank and spot paint if needed.

Sump and Sump Pumps

1) Daily: Check for unusual sounds from sump pumps.

2) Daily: Check and record sump pump current and ammeter fluctuations in accordance with manufacturer’s recommendations.

3) Daily: Check for oil or grease accumulation in sump. If oil or grease is visible, remove the oil or grease and check the oil level in the Aboveground Oil/Water Separator.

4) Daily: Vent manual air release valve at top of sump pump piping discharge header. Pump must be operating to properly vent air from piping header.

5) Daily: Check sump pump control panel and indicator lights inside the

Mechanical Building Electrical Room.

6) Daily: Check for level transducer entanglement in sump.

7) Daily: Check for excessive movement of check valve on sump pump discharge header piping.

8) Daily: General housekeeping around area.

9) Monthly: Check and record motor temperature using a thermal gun.

10) Monthly: Measure the sump pump’s insulation resistance in accordance with manufacturer’s recommendations.

11) Monthly: Check inside sump and look for leakage around pipe connection flanges or joints and valves.

12) Monthly: Check and lubricate check valve grease fittings in accordance with manufacturer’s recommendations.

13) Semi-Annually: Remove sump pumps from sump, check the motor’s mechanical seals, and replace as necessary in accordance with manufacturer’s recommendations.

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14) Annually: Check and lubricate pump and motor in accordance with manufacturer requirements.

15) Annually: Replace sump pump parts as needed in accordance with

16) Annually: Clean, wire brush corroded areas and spot paint as needed.

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3. Pressure Filters, Filter Backwash Pumps and Screen Filters

Pressure Filters

There are three skid-mounted sand media pressure filters in the Mechanical Building.

Each pressure filter is 1.676 m (5.5 ft) in diameter and has separate layers of sand and support gravel. The pressure filters filter the settled washwater to remove smaller particles that did not settle in the Sedimentation Basin. The pressure filters are shown in the Mechanical Building on Figures 9 and 10. The sump pumps pump water into the pressure filters and through the screen filters prior to disinfection. Pressure filters are periodically backwashed with skid-mounted filter backwash pumps to flush the filter media of any accumulated material. The pressure filters have design characteristics listed in Table 5:

Table 5 Pressure Filter Characteristics

Filter diameter 1.676 m (5.5 ft) Filter loading rate 224 lpm/m2 (5.5 gpm/ft2) Design flowrate 1484 lpm (392 gpm)

The pressure filters are designed to run concurrently during a wash event. If one of the filters is out of service, flow will be routed through the remaining two filters. The three filters have electric motor actuated butterfly control valves, which open or close the butterfly valves depending on the mode of operation. There are two operating modes for the pressure filters: normal filtration mode and backwash mode. The flow routing for the filters during normal filtration mode is shown on Figure 11. The flow routing for the filters during backwashing operations is shown on Figure 12.

The pressure filter control panel has selector switches for the electric motor actuated butterfly control valves for each filter vessel. During normal operation, all selector switches would be set in “Auto Backwash.” With the selector switches in “Auto Backwash,” the butterfly valves activate and change positions when any backwash mode is activated.

The filter backwash sequence can be operated in one of three modes: (1) manual, (2) time delay, or (3) pressure differential. Under normal operation, the filters would be operated in manual activation mode, which allows the operator to manually start the backwash process prior to a wash event or after completion of a wash event. The time delay mode allows the backwash sequence to start after a preset time delay, such as 30 minutes after completion of the wash event. The pressure differential setting allows the operator to preset a differential pressure. An instrument measures the differential pressure between the inlet and outlet of the filters. When the preset differential pressure is reached, the backwash sequence is automatically initiated. The desired

November 2013 18 backwash mode is selected using the backwash controller inside the pressure filter control panel.

The filter control system is configured to remove all three filter vessels from service during backwash and to backwash only one filter vessel at a time due to the capacity of the backwash pump. Thus, during backwash events, all three filters will need to be backwashed, one at a time, before re-starting the filtration process. During the backwash sequence, filter vessel 1 will backwash, then filter vessel 2, until all three vessels have completed the backwash cycle. The estimated time to backwash each vessel is approximately 5 minutes, or a total time of approximately 15 minutes to backwash all three filters. Washing activity must be stopped during filter backwashing.

Backwash water is discharged to the Sedimentation Basin through the Spent Filter Backwash Line via Trench Drain A.

The pressure filter control panel has an alarm condition for a loss of power due to backwash controller fail. The alarm condition is conveyed to the Emergency/Shutdown Alarm Cabinet.

Filter Backwash Pumps

There are two skid-mounted pumps in the Mechanical Building to backwash the pressure filters. The filter backwash pumps flush out material accumulated on the filter media. The filter backwash pumps are configured in an operating/standby mode.

Water from the Finished Water Storage Tank feeds the filter backwash pumps via Process Line “C.” Backwash water from the pressure filters is pumped back to Trench Drain A via the Spent Filter Backwash Line as shown on Figure 3. The filter backwash pumps have design characteristics listed in Table 6:

Table 6 Filter Backwash Pump Characteristics

Type End suction, centrifugal Design Operating Points 1,363 lpm @17.679 m (360 gpm @ 58 ft) Electrical Characteristics 7.5 kW, 460 VAC, 3 phase, 60 Hz

The filter backwash pumps are controlled using the backwash pump control panel.

During normal operation, both pump selector switches are in the “Off” position and would be switched to “Auto” prior to activating a manual backwash sequence. With the selector switch in “Alt,” backwash pumps are automatically alternated. The backwash pumps have the following alarm conditions: low suction pressure and high system pressure. These alarm conditions are indicated at the backwash pump control panel, which activates an alarm condition at the Emergency Shutdown/Alarm Cabinet at the Mechanical Building.

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A manually operated butterfly valve on the filter backwash discharge piping is positioned to prevent sand media from being flushed out during backwashing. The valve position should be left unchanged.

Screen Filters

There are three automatic self-cleaning steel vessel screen filters inside the Mechanical Building. Each screen filter has a fine screen to capture particles that are 25 microns or larger. The screen filters add a second level of filtration for protection against potential particle breakthrough in the pressure filters. The screen filters filter water from the pressure filters prior to disinfection and storage. The screen filters are backwashed to remove fine particles captured on the screens. A 50 mm (2 inch) screen filter drain line is connected to the 75 mm (3 inch) recirculation line, which discharges the screen filter backwash water to the sump. The screen filters have design characteristics as listed in Table 7.

Table 7 Screen Filter Characteristics

Number 3 – 3 operating (1 can be used for standby) Filter screen area 0.650 m2 (7.0 ft2) Filter particle removal size 25 microns or greater Design flowrate, each 946 lpm (250 gpm)

The three screen filters are operated concurrently, however, if maintenance is required, one screen filter can be removed from service by manually closing the valve on the inlet and outlet of the selected screen filter. The flow will be routed through the remaining two screen filters. The screen filter inlet and outlet piping is valved to allow bypassing of any unit or complete bypassing of all screen filters.

The screen filter backwash sequence can be operated in one of three modes: (1) manual, (2) time delay, or (3) pressure differential. During normal operation, the screen filters are operated in pressure differential mode and are monitored by the pressure differential switch (PDS). The PDS can sense the pressure drop between the inlet and outlet of the filter. The PDS is preset to start the flush cycle at 48.263 kPa (7 psi) pressure differential. However, the PDS can be manually adjusted between 0 and 15 psi to allow an operator adjustable differential pressure to be used to activate a backwash sequence. When the pressure drop between the inlet and outlet of the screen filter reaches the preset value, the filter screen cleaning is activated automatically. The cleaning operation occurs for approximately 15 seconds. The filter will remain on-line and the filtration process will remain uninterrupted during the cleaning process.

The screen filter control panel allows the operator to adjust the time delay period, flush duration, and dwell time. The screen filter backwash controller also contains a backwash counter, elapsed time meter, and manual start pushbutton.

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1) Check sump pump control panel inside Mechanical Building Electrical Room. Verify that there are no alarm conditions. If there are alarm conditions, do not start the wash sequence. Resolve alarm condition before starting wash sequence.

2) Check pressure filter and filter backwash pump control panels. Verify that there are no alarm conditions. If there are alarm conditions, do not start the wash sequence. Resolve alarm condition before starting wash sequence.

3) Activate a manual filter backwash sequence for the pressure filters. Do not start wash sequence until all three filter vessels have completed the backwash cycle.

1) Verify that there are no alarm conditions at the pressure filter backwash pumps. Normally, if there is an alarm condition, the red light and annunciator at the Emergency Shutdown/Alarm Cabinet at the Mechanical Building will activate. If there is an alarm condition, go to Emergency Shutdown/Alarm Cabinet and shut down process by pressing Emergency Shutdown button. Check source of alarm condition and resolve before re-setting alarm.

2) Monitor pressure on the pressure filter influent and effluent header.

Differential pressure between influent and effluent lines should not be greater than 8 psi. If the differential pressure is greater than 8 psi, stop the wash sequence and activate a manual filter backwash sequence.

Washing can be resumed after the backwash sequence is completed.

3) A butterfly valve on the backwash discharge piping is positioned to prevent sand media from being flushed out during backwashing. Do not change the valve position.

4) Monitor pressure on the screen filters’ influent and effluent header.

Differential pressure between influent and effluent lines should not be greater than 7 psi. If the differential pressure is greater than 7 psi, the screen filter should start the cleaning operation automatically. If the cleaning operation does not start, bypass the screen filter and contact maintenance after the wash event.

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1) Verify sump pumps are not pumping prior to activating a manual filter backwash sequence. The interlock on the filter backwash pumps and sump pumps will prevent both systems from operating at the same time.

2) After the pressure filter backwash sequence is completed, which is approximately 15 minutes, verify that there are no alarm conditions at the backwash pump control panel. If there is an alarm condition, resolve problem before securing facility.

Typical maintenance procedures are recommended below. Refer to Pressure Filters, Filter Backwash Pumps and Screen Filters Inspection and Maintenance Data Sheets in Appendix A. Note that some typical maintenance procedures are included as part of the typical operating sequence and procedures. Tasks listed with daily maintenance refer to maintenance done on day of wash event.

Pressure Filters

1) Daily: Check electric actuator system for proper operation.

2) Daily: Check for leakage around flanges and joints.

3) Daily: Check for unusual sounds.

4) Daily: Check valve positions at influent and effluent piping.

5) Daily: General housekeeping around area.

6) Daily: Check differential pressure before backwash.

7) Daily: Check differential pressure after backwash.

8) Monthly: Check control panels and lights.

9) Monthly: Check filter backwashing operations and cycle.

10) Monthly: Check mechanical equipment for lubrication requirements.

11) Semi-Annually: Check differential pressure gage.

12) Semi-Annually: Check and flush differential pressure gage strainer.

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13) Semi-Annually: Shut down one filter at a time and check filter media elevation. Also check media for unevenness, grease and oil, mud balls or slime.

14) Semi-Annually: Check condition of electric actuator valves.

15) Annually: Check control panels for proper operation and deficiencies.

16) Annually: Thoroughly check electric actuator valve system.

17) Annually: Check air relief valve on top of filter.

18) Annually: Check the level of filter media in each filter by opening the fillport. Some minor loss of media is expected, so a small amount of media may need to be added. Insert a probe into the media bed to determine whether it is has remained loose. If the media is crusted on top or is becoming hardened, this indicates a serious problem. Consult the manufacturer’s Troubleshooting Guide and follow manufacturer’s instructions.

19) Annually: Check and service backwash valves in accordance with

20) Annually: Inspect exterior of tanks and spot paint if needed.

Filter Backwash Pumps

1) Daily: Check if pump operational or not.

2) Daily: Read pump running time.

3) Daily: Read pump amperage.

4) Daily: Read pump discharge pressure.

5) Daily: Check for leakage around flanges and joints.

6) Daily: Check for unusual sounds from pump.

7) Daily: General housekeeping around area.

8) Monthly: Exercise spare pump.

9) Semi-Annually: Check pump and motor bearings and seals.

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10) Annually: Check and lubricate pump and motor in accordance with manufacturer’s requirements.

11) Annually: Clean and re-lubricate valve stems.

12) Annually: Clean, wire brush corroded areas and spot paint as needed.

Screen Filters

1) Daily: Check for leakage around flanges and joints.

2) Daily: Check for unusual sounds.

3) Daily: Check the valve position at 150 mm (6-inch) bypassing pipe. The valve is normally closed. The valve would be opened only if all screen filters need to be bypassed.

4) Daily: Check valve positions at influent and effluent piping. The valves are normally open. The valve would be closed only if the screen filter needs to be bypassed.

5) Daily: General housekeeping around area.

6) Daily: Check differential pressure.

7) Monthly: Check control panels and lights.

8) Monthly: Check mechanical equipment for lubrication requirements.

9) Semi-Annually: Check differential pressure gages.

10) Semi-Annually: Check and flush differential pressure gage strainer.

11) Semi-Annually: Inspect internal components in accordance with manufacturer’s instructions.

12) Annually: Inspect exterior of filters and spot paint if needed.

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4. Disinfection System

There is a skid-mounted disinfection…