CIA_1&2_O&M_Manual_&_Drawings.pdf

Massachusetts Military Reservation Camp Edwards, Cape Cod, MA Contract No.: W912WJ-11-D-0009 / 0005 - SB MARC Charter No.: 2-1009

Charter Environmental, Inc.

560 Harrison Avenue Boston, Massachusetts 02118 (857)246-6800

Operation & Maintenance Manual Central Impact Area Groundwater Treatment System

Camp Edwards, Cape Cod, MA Massachusetts Military Reservation, Camp Edwards, Cape Cod, MA Contract No.: W912WJ-11-D-0009 / 0005 - SB MARC Charter No.: 2-1009

Charter Environmental, Inc.

560 Harrison Avenue Boston, Massachusetts 02118 (857)246-6800

Operation & Maintenance Manual Central Impact Area Groundwater Treatment System

DATE TRANSMITTAL NO.

SECTION I - REQUEST FOR APPROVAL OF THE FOLLOWING ITEMS (This section will be initiated by the contractor)

TO: FROM: CONTRACT NO: CHECK ONE:

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THIS IS A RESUBMITTAL OF TRANSMITTAL

517 West Outer Road 560 Harrison Ave

SPECIFICATION SECTION NO. PROJECT TITLE AND LOCATION:

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(Type size, model number/etc.) CAT., CURVE OF CE

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3 3 N

REMARKS I certify that the above submitted items have been reviewed

Copies to: See page 2 in detail and are correct and in strict conformance with the contract drawings and specifications except as otherwise stated.

NAME AND SIGNATURE OF CONTRACTOR

SECTION II - APPROVAL ACTION

ENCLOSURES RETURNED (List by Item No.) NAME, TITLE AND SIGNATURE OF APPROVING AUTHORITY DATE

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USACE New England District Timothy Cady W912WJ-11-D-0009 /0005 MMR Field Office Charter Environmental, Inc.

00036-1Camp Edwards, MA 02542 Boston, MA 02118

MMR - Central Impact Area Groundwater Treatment System Construction

CONTRACT REFERENCE VARIATION

DOCUMENT

g

Operation & Maintenance Manual - Revisions to 25 FEB 2014 Version Manual

1 Section I will be initiated by the Contractor in the required number of copies.

THE FOLLOWING ACTION CODES ARE GIVEN TO ITEMS SUBMITTED

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Distribution:

Electronic to: Mr Jay Ehert - MMR USACOE

John.F.Ehret@usace.army.mil Ms. Gina Kaso - USACE New England District, MMR Field Office gina.kaso@usace.army.mil

Charter:

Project File 2-1009

INSTRUCTIONS

Each transmittal shall be numbered consecutively in the space provided for "Transmittal Number". This number, in addition to the contract number, will form a serial number for identifying each submittal.

For new submittals or resubmittals mark the appropriate box; on resubmittals, insert transmittal number of last submission as well as the new submittal number.

The "item no." will be the same "item no." as indicated on ENG Form 4288 for each entry on this form.

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Separate transmittal form will be used for submittals under separate sections of the specifications.

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Central Impact Area GWTS Construction Project – Operation & Maintenance Manual

Contract No. W912WJ‐11‐D‐0009 / TO 0005

Groundwater Treatment System Construction Project April 16, 2014 Massachusetts Military Reservation, Cape Cod, MA Charter Environmental, Inc.

TABLE OF CONTENTS

Section 1 ‐ Project Description

Section 2 ‐ General Construction Warranty

Section 3 ‐ Material & Equipment Information

Section 3.1 – Monitoring Wells

3.1.1 ‐ Monitoring Well Construction Diagrams

3.1.2 ‐ Bladder Pump Build Sheets

3.1.3 ‐ Bladder Pumps O&M Manual

Section 3.2 ‐ Extraction Wells

3.2.1 ‐ Extraction Well Construction Diagrams

‐ MW‐614, MW615, MW623, MW624

3.2.2 ‐ Extraction Well Pumps – O&M Manual

‐ Extraction Well Pump Installation Diagrams

‐ Extraction Well Pump Data Sheets

‐ Extraction Well Grundfos Pump O&M Manual

3.2.3 ‐ Extraction Well ‐ Electric Pump Motors – O&M Manual

Section 3.3 ‐ Mobile Water Treatment System

3.3.1 – Mobile Treatment Unit (MTU) #1

‐ Water Treatment System ‐ O&M Manual

‐ Mobile Treatment Unit Components

‐ Mobile Treatment Unit Control Panels

3.3.2 ‐ Mobile Treatment Unit (MTU) #2

‐ Water Treatment System ‐ O&M Manual

‐ Mobile Treatment Unit Components

‐ Mobile Treatment Unit Control Panels

3.3.3 ‐ Mobile Treatment Unit Material Safety Data Sheets

Section 3.4 ‐ Fire Alarm Equipment

3.4.1 ‐ Fire Alarm Control Panel Instruction Manual

3.4.2 ‐ Fire‐Lite Alarms Device Compatibility Document

3.4.3 ‐ AES 7788F RF Subscriber Unit Installation and Operation Manual

Groundwater Treatment System Construction Project April 16, 2014 Massachusetts Military Reservation, Cape Cod, MA Charter Environmental, Inc.

TABLE OF CONTENTS

(Continued)

Section 4 – Final As‐Built Drawings

Drawing C‐101 Overview Map Central Impact Area – 25 FEB 2014

Drawing CIA‐1 Groundwater Extraction & Treatment Components – 25 FEB 2014

Drawing CIA‐2 Groundwater Extraction and Treatment Components – 25 FEB 2014

Drawing CIA‐3 Groundwater Extraction and Treatment Components – 25 FEB 2014

Drawing CIA‐4 North Infiltration Trench Cross Section Detail – 25 FEB 2014

Drawing CIA‐5 South Infiltration Trench Cross Section Detail – 25 FEB 2014

‐ Electronic As‐Built Files are provided in AutoCAD and PDF on CD enclosed

Groundwater Treatment System Construction Project April 16, 2014

SECTION 1

PROJECT DESCRIPTION

This page left blank intentionally for double‐sided printing.

Groundwater Treatment System Construction Project April 16, 2014 Massachusetts Military Reservation, Cape Cod, MA Charter Environmental, Inc.

1.0 INTRODUCTION

1.1 Project Authorization

The work of this Project was performed by Charter Environmental, Inc. (Contractor) of Boston, MA in accordance with MARC Contract No.: W912WJ‐11‐D‐0009, Task Order 0005, Central Impact Area Groundwater Treatment System Construction at the Massachusetts Military Reservation, (MMR), Camp Edwards, Cape Cod, MA.

1.2 Site Location and Description

MMR is located in the western area of Cape Cod in Barnstable County, Massachusetts, approximately 60 miles south of Boston and immediately southeast of the Cape Cod Canal. It occupies approximately 22,000 acres within the towns of Bourne, Falmouth, Mashpee, and Sandwich.

Approximately 16,000 acres occupy the northern 70% of MMR and is used for training and maneuvers.

The work contemplated by the Central Impact Area Groundwater Treatment System Construction Project is located along the East side of Burgoyne Road extending from Monument Beach Road to Avery Road within the 16,000 acre portion of Camp Edwards that is used for training.

The Central Impact Area is a former military training and defense contractor test area where munitions testing and munitions disposal occurred that operated from the 1930s until the 1990s. The primary contaminants within this area are located within the ground water and include perchlorate and Hexahydro‐1,3,5‐Trinitro‐1,3,5‐ Triazine (RDX).

The remedy selected in the Decision Document (USEPA 2012) for groundwater at the Central Impact Area Plume is a combination of Focused Groundwater Extraction with Two Wells, Monitored Natural Attenuation and Land‐Use Controls. The major components of this remedy included: Two 250 GPM groundwater pump and treat systems that include a dedicated 250 GPM groundwater extraction well for each respective treatment unit; mobile treatment units (MTU’s) with GAC and ion exchange resin; and return of the treated water to the aquifer via dedicated infiltration areas.

1.3 Work in Training Ranges and Unexploded Ordnance Risk

The Project was located near an active training range and within a known area of sensitivity to the potential for discovering unexploded ordnance (UXO) while the project was under construction.

Charter’s Site Manager served as the primary Base escort in control of both Charter and Subcontractor personnel at all times.

Each worker employed on the site was required to undergo UXO training and follow a strict procedure relative to the potential for encountering UXO. In the event of encountering UXO, Charter’s Site Manager was to implement the procedure of:

• Recognize the UXO hazard on the project

• Take immediate action (mark and evacuate)

• Report the UXO hazard to the appropriate Camp Edwards authorities

• Use protective measures against the UXO hazard, if required

Groundwater Treatment System Construction Project April 16, 2014 Massachusetts Military Reservation, Cape Cod, MA Charter Environmental, Inc.

As required and instructed by the UXO training, if found, each instance discovered on‐site while excavating during the project was treated as “Live” ordnance and was handled via separate Government UXO technicians until the authorized Government authorities provided clearance for Charter to continue work.

2.0 GROUNDWATER TREATMENT SYSTEM CONSTRUCTION

2.1 Project Scope and Components

The primary Scope and Work Components performed by Charter as part of the Project are as follows:

2.1.1 Work Plan Development and Submission

In accordance with Section 3.1 of the Contract Task Order, a Work Plan was prepared prior to the commencement of work on the project work site. The Work Plan included details for the work elements that were performed onsite and was developed in conjunction with the conceptual schedule created by Charter at the onset of the Project.

2.1.2 Mobilization

Mobilization activities included delivery of both equipment and materials required to complete the project.

2.1.3 Site Access Improvements

Site access improvements mainly consisted of the necessary site preparation to allow for execution of the project scope. Activities associated with this task included tree cutting, brush cutting wood chipping, leveling of work areas, and temporary access roads.

2.1.4 New Electrical Pole and Overhead Primary Power Distribution Installation

Installation of a new electrical pole, secondary transformers and electrical conductors were required to support the new electrical services at the Mobile Treatment Unit Systems (MTU). This work was completed by a Charter subcontractor, TDL Electrical Contractors (TDL).

The new electrical pole was installed approximately 100 feet from the primary electrical pole and approximately 50 feet from the Eastern end of MTU #2.

2.1.5 Construct MTU Pads

The MTU pads were constructed of two different types of foundations; 1.) a gravel pad for the general surrounding area of each MTU; and 2.) the mobile treatment system foundation to structurally support each MTU. The surrounding gravel pad was constructed with a geotextile fabric overlaid with a 6‐inch layer of compacted dense grade, and final 3‐inch thick layer of crushed stone. The MTU foundations were constructed with an initial 12‐inch layer of compacted dense grade, a geogrid layer sandwiched between another 12‐inch dense grade layer, and finally topped with a 3‐inch layer of crushed stone to bring the foundation to grade.

Groundwater Treatment System Construction Project April 16, 2014 Massachusetts Military Reservation, Cape Cod, MA Charter Environmental, Inc.

2.1.6 Design and Construction of MTU’s

Design and construction of the MTU’s was performed by a Charter subcontractor, Lockwood Remediation Technologies LLC (LRT). The MTU’s were designed and fabricated to achieve treatment levels of 0.6 ppb for RDX and 2.0 ppb for perchlorate. The treatment system provides for treatment of the contaminants of concern using Granular Activated Carbon (GAC) Units and Ion‐Exchange (IX) Resin. The MTU’s were pre‐fabricated offsite by LRT, shipped to the project site, and hoisted into place onsite with a crane. Final connections of power and underground piping systems were made on‐site.

2.1.7 Install Extraction Wells

Extraction wells were installed to allow groundwater extraction from the contaminated aquifer. Installation of the extraction wells was performed by a Charter subcontractor, Maher Services. Both extraction wells were installed using air rotary drilling techniques and both wells underwent development procedures with the intent of achieving the desired capacity of 250

GPM.

2.1.8 Construct Infiltration Trench

The infiltration trench was first excavated down to the appropriate subgrade of approximately 3‐feet below the existing ground surface with an excavator. The infiltration trench was initially backfilled with a 1‐foot thick layer of ¾‐inch crushed stone. Next the 6‐inch manifold pipe and the 3‐inch perforated HDPE lateral pipes were installed at a spacing of 6‐feet from one another and have a slight slope of ‐0.5% away from the dispersion manifold that feeds the effluent water to the infiltration trench system. The eight perforated lateral pipes are approximate 100‐feet in length, and a 6‐inch layer of pea stone covers the HDPE. On top of the pea stone, is a layer of nonwoven geotextile placed before the trench was backfilled to grade.

The geotextile serves as a separation layer between the native soil and stone layer to keep the stone clean from infiltrating water.

2.1.9 Underground Effluent Piping from MTU to Infiltration Trench

Effluent piping was installed from the MTU’s to the infiltration trenches. The piping consists of a 6‐inch HDPE fused joint force main located parallel and along the eastern edge of Burgoyne Road. The pipe is approximately 5‐feet deep and enveloped with 3/8‐inch pea stone.

A layer of geogrid 1100 and magnetic blue warning tape reading, “CAUTION – WATER LINE BURIED BELOW,” is installed directly over the pipe approximately 1‐foot below finished grade.

The effluent piping is electrically heat traced and insulated when above the ground surface and down into the ground approximately 4‐feet to the frost line.

2.1.10 Underground Influent Piping and Power lines from Extraction Wells to MTU

Influent piping was installed from each of the Extraction Wells to the MTU’s. The Influent piping from each Extraction Well to the MTU consists of a dedicated 6‐inch HDPE force main approximately 5‐feet deep and enveloped with 3/8‐inch pea stone. Running in parallel and slightly offset to the force main piping is the power and communication conduit with wire for each Extraction Well Pump. The power and communication lines are located approximately 30‐

Groundwater Treatment System Construction Project April 16, 2014 Massachusetts Military Reservation, Cape Cod, MA Charter Environmental, Inc.

inch below finished grade. A layer of geogrid 1100 and magnetic blue warning tape reading, “CAUTION – WATER LINE BURIED BELOW,” and magnetic red tape reading “CAUTION – ELECTRIC LINE” is installed directly over each respective pipe approximately 1 foot below finished grade.

The influent piping is electrically heat traced and insulated when above the ground surface and down into the ground approximately 4 feet to the frost line.

2.1.11 Install Monitoring Wells

Four monitoring well clusters were installed to allow for the monitoring and sampling of groundwater from the contaminated aquifer. Installation of the monitoring well clusters occurred at four different locations as follows: two separate locations off of Avery Road (MW 623 and MW‐624 respectively); one located next to Extraction Well #2 (MW‐614); and the last is located next to Extraction Well #1 (MW‐615).

All extraction wells were performed by a Charter subcontractor, Cascade Drilling. All monitoring well clusters were installed using air rotary drilling techniques. Each of the 4 monitoring well clusters has two, 2‐1/2‐inch PVC wells within them. Each PVC well has a bladder pump installed for sampling at their respective screen interval.

3.0 PROJECT MANAGEMENT AND FIELD SUPERVISION

3.1 The project was performed with the following Charter Management Personnel and Subcontractors

• Project Manager – Stan Carter

• Project On‐Site Supervisor – Tim Bullock

• Project On‐Site Supervisor Alternate – Larry Sullivan

• Electrical Subcontractor – TDL Electric

• Groundwater Treatment System Subcontractor ‐ Lockwood Remediation Technologies (LRT)

• Extraction Well Drilling and Pump Subcontractor – Maher Services

• Monitoring Well Subcontractor – Cascade Drilling LP

4.0 PROJECT SCHEDULE

4.1 The project schedule showing the start and completion dates and the duration of work is provided below:

• Contract Award and Submittals: 7/17/2013 – 9/5/2013

• Mobilization: 8/20/2013

• System Construction: 8/20/2013 – 1/9/2014

• Initial Start Up and Operation: 1/8/2014 – 2/12/2014

• Final Project Acceptance – Upon Acceptance of O&M Manual

SECTION 2

GENERAL CONSTRUCTION WARRANTY

SECTION 3

MATERIAL & EQUIPMENT INFORMATION

SECTION 3.1

MONITORING WELLS

Four monitoring well clusters were installed to allow for the monitoring and sampling of groundwater from the contaminated aquifer. Installation of the monitoring well clusters occurred at four different locations as follows: two separate locations off of Avery Road (MW 623 and MW‐624 respectively); one located next to Extraction Well #2 (MW‐614); and the last is located next to Extraction Well #1 (MW‐615).

Extraction wells were performed by a Charter subcontractor, Cascade Drilling. Monitoring well clusters were installed using air rotary drilling techniques. Each of the 4 monitoring well clusters has two, 2‐1/2‐inch PVC wells within them. Each PVC well has a bladder pump installed for sampling at their respective screen intervals.

SECTION 3.1.1

MONITORING WELL CONSTRUCTION DIAGRAMS

MW‐614 & MW‐615

Project Name/Number: CIA MTU Pilot Borings KEY

Loc. I.D.: MW-614M1/M2

Location: CIAMW2 (EW2) Schedule 80 PVC Natural Cave-In

Drilling Contractor/Driller: Cascade Drilling (2.5' bgs OD)

Field Technician: Derek Koenig

Drilling Method: Roto Sonic Bentonite Seal 00N; Sand

Sampling Method: Profile samples collected

Start Date: 8/30/2013 "0" Filter Pack 10 slot screen

Complete Date: 8/30/2013

Total Drilled Depth: 325' bgs

M1 Screen Interval: 275' bgs - 285' bgs

M2 Screen Interval: 215' bgs - 225' bgs

Top Casing - Road Box at ground surface Ground Surface Elevation 195' bgs estimated

MP Elevation M1 194.49' bgs surveyed M2 194.47' bgs surveyed

Natural Cave-in

Top of Bentonite - 205' bgs

Top of Fine Sand - 212' bgs Fine Sand = 00 Sand Top of Sand Filter Pack - 212.5' bgs

Top of M2 Screen - 215' bgs

Sand Filter Pack = "0" Sand Bottom of M2 Screen - 225' bgs

Bottom of Sand Filter Pack - 226' bgs Bottom of 8" OD Borehole - 226' bgs

Natural Cave-in

Top of Bentonite - 266' bgs

Top of Fine Sand - 272' bgs Fine Sand = 00 Sand Top of Sand Filter Pack - 272.5' bgs

Top of M1 Screen - 275' bgs

Sand Filter Pack = "0" Sand Bottom of M1 Screen - 285' bgs

Bottom of Sand Filter Pack - 286' bgs Bottom of 6" OD Borehole - 325' bgs

Charter Environmental Monitoring Well Construction Diagram

Project Name/Number: CIA MTU Pilot Borings KEY

Loc. I.D.: MW-615M1/M2

Location: CIAMW1 (EW1) Schedule 80 PVC Natural Cave-In

Drilling Contractor/Driller: Cascade Drilling (2.5' bgs OD)

Field Technician: Derek Koenig

Drilling Method: Roto Sonic Bentonite Seal 00N; Sand

Sampling Method: Profile samples collected

Start Date: 9/6/2013 "0" Filter Pack 10 slot screen

Complete Date: 9/6/2013

Total Drilled Depth: 305' bgs

M1 Screen Interval: 260' bgs - 270' bgs

M2 Screen Interval: 200' bgs - 210' bgs

Top Casing - Road Box at ground surface Ground Surface Elevation 181' bgs estimated

MP Elevation M1 180.72' bgs surveyed M2 180.65' bgs surveyed

Natural Cave-in

Top of Bentonite - 190' bgs

Top of Fine Sand - 197' bgs Fine Sand = 00 Sand Top of Sand Filter Pack - 198' bgs

Top of M2 Screen - 200' bgs

Sand Filter Pack = "0" Sand Bottom of M2 Screen - 210' bgs

Bottom of Sand Filter Pack - 211' bgs Bottom of 8" OD Borehole - 211' bgs

Natural Cave-in

Top of Bentonite - 250' bgs

Top of Fine Sand - 257' bgs Fine Sand = 00 Sand Top of Sand Filter Pack - 258' bgs

Top of M1 Screen - 260' bgs

Sand Filter Pack = "0" Sand Bottom of M1 Screen - 270' bgs

Bottom of Sand Filter Pack - 271' bgs Bottom of 6" OD Borehole - 305' bgs

MW‐623 & MW‐624

Project Name/Number: CIA KEY

Loc. I.D.: MW-623M1/MW-623M3

Location: CIA6 Schedule 80 PVC Natural Cave-In

Drilling Contractor/Driller: Cascade Drilling (2.5' bgs OD)

Field Technician: Derek Koenig

Drilling Method: Roto Sonic Bentonite Seal 00N; Sand

Sampling Method: Profile samples collected

Start Date: 11/13/2013 "0" Filter Pack 10 slot screen

Complete Date: 11/13/2013

Total Drilled Depth: 365'

M1 Screen Interval: 340' bgs - 350' bgs

M3 Screen Interval: 275' bgs - 285' bgs

NOTE: M2 screen installed by Watermark

Top Casing - Road Box at ground surface Ground Surface Elevation 245' bgs estimated

MP Elevation M1 245.09' bgs surveyed M3 245.07' bgs surveyed

Natural Cave-in

Top of Bentonite - 262' bgs

Top of Fine Sand - 271' bgs Fine Sand = 00 Sand Top of Sand Filter Pack - 272' bgs

Top of M3 Screen - 275' bgs

Sand Filter Pack = "0" Sand Bottom of M3 Screen - 285' bgs

Bottom of Sand Filter Pack - 287' bgs Bottom of 8" OD Borehole - 287' bgs

Natural Cave-in

Top of Bentonite - 327' bgs

Top of Fine Sand - 336.5' bgs Fine Sand = 00 Sand Top of Sand Filter Pack - 337.5' bgs

Top of M1 Screen - 340' bgs

Sand Filter Pack = "0" Sand Bottom of M1 Screen - 350' bgs

Bottom of Sand Filter Pack - 352' bgs Bottom of 6" OD Borehole - 365' bgs

Project Name/Number: CIA KEY

Loc. I.D.: MW-624M1/MW-624M2

Location: CIA7 Schedule 80 PVC Natural Cave-In

Drilling Contractor/Driller: Cascade Drilling (2.5' bgs OD)

Field Technician: Derek Koenig

Drilling Method: Roto Sonic Bentonite Seal 00N; Sand

Sampling Method: Profile samples collected

Start Date: 11/15/2013 "0" Filter Pack 10 slot screen

Complete Date: 11/15/2013

Total Drilled Depth: 365'

M1 Screen Interval: 284' bgs - 294' bgs

M2 Screen Interval: 254' bgs - 264' bgs

Top Casing - Road Box at ground surface Ground Surface Elevation 224' bgs estimated

MP Elevation M1 224.3' bgs surveyed M2 224.29' bgs surveyed

Natural Cave-in

Top of Bentonite - 240' bgs

Top of Fine Sand - 250' bgs Fine Sand = 00 Sand Top of Sand Filter Pack - 251' bgs

Top of M2 Screen - 254' bgs

Sand Filter Pack = "0" Sand Bottom of M2 Screen - 264' bgs

Bottom of Sand Filter Pack - 266' bgs Bottom of 8" OD Borehole - 266' bgs

Natural Cave-in

Top of Bentonite - 272' bgs

Top of Fine Sand - 281.5' bgs Fine Sand = 00 Sand Top of Sand Filter Pack - 282.5' bgs

Top of M1 Screen - 284' bgs

Sand Filter Pack = "0" Sand Bottom of M1 Screen - 294' bgs

Bottom of Sand Filter Pack - 296' bgs Bottom of 6" OD Borehole - 365' bgs

SECTION 3.1.2

BLADDER PUMP BUILD SHEETS

scarter Text Box Central Impact Area GWTS Construction Project Bladder Pump Build Sheets

SECTION 3.1.3

BLADDER PUMP O&M MANUAL

I N S TA L L AT IONIN S TA L L AT ION

GU IDEG U IDE

P/N 34999 6-16-11

P.O. B ox 3726 Ann Arbor, MI 48106-3726 US A

1-800-624-2026 FAX (734) 995-1170

info@ qedenv.com www.qedenv.com

RWELL WIZARD

Dedicated Monitoring Systems

Patent No. RE34754

Table of Contents

Topic Page

Introducing Well Wizard

Sampling Pump

How Bladder Pump Works

Pump Tubing/Inlet Screen/Well Cap

Well Cap

Installing the Sample Pump

Installing the Sample Pump With Bulk Tubing

Portable Components

Installing the Components

Bladder Pump Operation In Low Submergence

Installing the Inlet Screen

Install Or Replace Pump Connectors

Sample Pump Troubleshooting Guide

Contacting QED/

QED Well Wizard Warranty

2-3

4-5

15-17

12-13

Well Wizard System Type A (Basic System)

Well Wizard System Type L (Inlet Extension)

21-22

TOC

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Introducing Well Wizard

Introduction

To monitor the quality of ground water, you need an efficient way to collect unbiased samples. Well Wizard is a total system for meeting all your ground water monitoring needs - with the flexibility to meet your special requirements. This section describes the components of the Well Wizard System.

The Well Wizard system includes both dedicated and portable components. The water contacting components are dedicated;

you permanently install them in each well. The control elements are portable; you transport them from well to well.

BASIC DEDICATED COMPONENTS

A sampling pump Pump Tubing An optional inlet screen A well cap Discharge Adapter Freeze Protection

The following sections describe these components.

Contacting QED

Please call our Customer Service Department at one of the following numbers for assistance

Monday through Friday, 8:30 a.m. to 5:00 p.m. EST:

(734) 995-2547

After Hours and weekends: 1-800-272-9559 (or 1-734-746-8045 if you are outside the U.S.)

R

Sampling Pump

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Discharge Adapter

Well Cap

Pump Tubing

Pump

Pump inlet Screen

Water Level

Ground Level

Optional

A Well Wizard sampling pump is an air-actuated bladder pump that you permanently position in the well.

Figure 1

Sampling Pump

As figure 1 shows, you normally position the pump inlet midway in the screened section of the well, suspending it by two tubes that supply air to the pump and convey the water sample to the well cap. Whenever possible, pumps are shipped already preassembled to the tubing and the well cap assembly.

Several types of Well Wizard bladder pumps are available.

1100 Series Pumps

The 1100 series pumps include 4 major components:

Upper-end check valve assembly (polyvinyl chloride (PVC or Teflon )

Lower-end check valve assembly (PVC or Teflon)

Bladder Cartridge (Teflon)

Pump Body (PVC or Teflon )

Bladder Cartridge assembly (either Teflon and stainless steel or PVC and stainless steel)

Pump Body (Stainless Steel)

You can totally disassemble the pump without tools by unscrewing each end cap and pushing the bladder cartridge out of the pump body (for more information refer to the instructions included with the field-replaceable bladder kit).

You can partially disassemble the pump (for more information refer to the instructions included with the field-replaceable bladder kit).

1200 Series Pumps

The 1200 series pumps include 2 major components

How Bladder Pump Works

Fill Tube Entrance/ Exit Hole

Fill Tube Entrance/ Exit Hole

Pump Inlet

Central Fill tube

Bladder Squeezes

Lower Check ball Seated

Liquid Discharge Tubing

Air Line

Upper Check Ball Rises

The bladder pump has two alternating cycles (refer to figures 2 & 3).

Discharge Cycle

During the discharge cycle, air forced into the space between the pump body and the pump bladder squeezes the water inside the bladder into the exit/entrance holes of the fill rod. As air pressure increases, liquid-having no place else to go - is forced up the discharge line and to the surface. At the same time, the top check ball rises with the discharging liquid while the bottom check ball is forced down by the air pressure; this seals the pump inlet so that no water can enter the bladder chamber.

Figure 2

How Bladder Pump Works

Upper Check Ball Seated

Bladder Expands

Lower Check Ball Rises

Caution: A Well Wizard pump bladder can be punctured if you pump sand. So be sure to use an inlet screen in wells with high sand and sediment content, or when the inlet of the pump is placed within 2 feet of the bottom of the well.

Remember, the Well Wizard 10-year warranty is void if you do not use an inlet screen.

Figure 3

Refill Cycle

During the refill cycle, with no air pressure holding it down, the water pressure pushes the bottom check ball up, allowing the water to reenter the bladder chamber. The bladder expands as it refills with water.

Simultaneously, the top check ball is forced down and seals because of the force of the water pressure above it from the water in the discharge tubing, this prevents the water in the discharge tube from reenter-ing the bladder chamber.

Pump Tubing/ Inlet Screen/ Well Cap

Pump Tubing

A ground water sample is only as good as the tubing it runs through.

Your Well Wizard was shipped with one of the following types of superior-quality tubing:

Inlet Screen

An inlet screen can protect the bladder in your Well Wizard pump by preventing sand from contacting the bladder. If you install a screen on your dedicated Well Wizard bladder pump, QED warranties the pump for a full 10 years.

Well Cap

You fit a well cap to the top of the well casing to suspend the pump and tubing. There are two terminal fittings inside the basic well cap (see figure 4).

Polyethylene

Teflon -lined polyethylene

Teflon

A compression through fitting for the discharge line

A short brass quick-connect nipple for the pump air-supply line

Most tubing is supplied as a bonded pair (air supply and discharge), to save time and avoid tube entanglement.

Unless your order specified that you wanted bulk tubing, the tubing for your Well Wizard bladder pump is pre-cut to the correct length for your well.

The protected well cap has a lid with a lock pin. You can record well identification and reference date information on the cap label. The unprotected well cap is meant for wells located within a user-supplied protected standpipe.

Well Cap (Figure 4)

Figure 4

Unprotected Well Cap

Protected Well Cap

Discharge Line

Discharge Line

Air Supply Line

Air Supply Line

Portable Components

Portable Well Wizard components include a cycle controller, water-level meter, disposable sample filters, and a flow-through cell.

Controller

A controller controls operation of the Well Wizard pump by regulating the air flow from a compressed-gas source to the pump.When connect-ed to an appropriate compressed-gas source, the controller alternately pressurizes then vents the air supply line to the pump, allowing the pump to discharge and then fill with water. For more information, please refer to the operation and installationmanuals for the individual controllers.

Water Level Meter

The model MP30 drawdown/water level meter can be connected to the QED cycle controllers to automatically control the drawdown during purging and sampling.

The series 6000 electronic water-level meters use a portable cond-uctivity probe attached to a calibrated tape. There is a light and audio signal when the probe touches the water surface.

Flow Cell

The MP20 is QED's optional flow cell. The MP20 lets you know when it's okay to sample - generally saving you from spending a lot of time and from removing large volumes of purge water. The MP20 signals when stabilization has been achieved for selected water parameters.

QuickFilter

To ensure accurate samples of dissolved metals, you can use an optional QED QuickFilter. It removes solids larger than 0.45 micron.

Because QuickFilters are disposable - you use one for each samp-ling event - there's no need to try to clean or decontaminate the filter from well to well.

Installing the Components

If you've received a set of preassembled dedicated components, you'll find that unpacking them and installing them is easy when you follow the following instructions. Because not everyone needs to read this whole section, the first section helps you decide which of the other sections you need to read.

If, instead of preassembled components you've received unassembled components and bulk tubing, read the section titled "Installing a Pump Using Bulk Tubing."

Unpack the Components

Here's how to unpack the Well Wizard dedicated components.

1. If you need to install a Well Wizard system in more than one well, decide which well you want to do first. Then find the box of components with the correct well-identification number written on the outside of the box.

2. Carry the box to the well site, then open the box, but don't touch anything yet.

3. Open the box, then, before unpacking the rest of the box, put on a pair of latex gloves.

4. Taking care to not kink the tubing, gently remove the plastic-wrapped pump and tubing from the box. A label on the package provides the well cap ID, cap, and tubing length. You may need this information later, so save the label.

5. Open the plastic wrapping, then gently slide the pump out of the bag.

Caution: Touching well components with your bare hands can contaminate the components and degrade the quality of the samples obtained using the Well Wizard system, and at any other time when your hands might touch a water-contacting component.

Note: The plastic bag also contains the lab-clean certificate on which is recorded the pump batch serial number. Keep this tag for each pump you install. It's your proof that the pump is contaminant free - if you need to, you can call QED with the serial number to find out which lab certified the pump.

Installing the Inlet Screen

1. Still wearing the latex gloves, open the plastic wrapping, then remove the screen.

2. Thread the screen onto the male-threaded pump inlet, making sure the screen is firmly tight.

1. Still wearing the latex gloves, open the plastic wrapping, then remove from the bag both the screen and the small plastic bag that contains spare set screws and a small Allen wrench.

2. Find the groove around the inlet end of the stainless steel pump body (the end opposite the air and water connectors), then slide the screen onto the bottom of the pump assembly, aligning the top rim of the screen with the top groove.

3. Using the Allen wrench, lightly tighten each of the set screws, then make sure the screws have engaged the groove.

4. Using the Allen wrench, firmly tighten each of the set screws.

5. Check to make sure the screen is secure.

Install the Inlet Screen

Well Wizard bladder pumps have a 10 year warranty that is valid only if you use the appropriate inlet screen.

There are two types of inlet screens: One that you thread onto the inlet for 1100 series pumps, and one that you secure with set screws for 1200 and 1300 series pumps. The correct screen for each pump is usually included with the other components for the well - the box label tells you where to find the screen. The following sections describe how to install the two types of inlet screens.

Screens For 1100 Series Pumps

To install a screen on an 1100 series pump, follow these steps:

pump

Screens For 1200 and 1300 Series Pumps

To install a screen on an 1200 & 1300 series pump, follow these steps:

Note: If you have difficulty installing the screen, use the Allen wrench to loosen the set screws a little.

Installing the Sampling Pump

Caution: Make sure that you don't bring the tubing or other pump components in contact with the ground or any other surface. It's often helpful to spread out a polypropylene tarp next to the well during installation.

1. Still wearing the latex gloves, if you have a protected well cap, mark any necessary information - such as well ID and depth - on the label inside the well cap.

2. Slowly lower the pump into the well while uncoiling the tubing bundle, until the entire length of tubing is in the well.

Attaching Tubing to the Well Cap

To attach tubing to the well cap, follow the instructions included with the shipment for the appropriate well cap.

Installing a Pump with Bulk Tubing

This section is for you if you ordered your Well Wizard components and tubing unassembled, The following sections tell you how to assemble the components and tubing.

Getting Ready

It's important to not contaminate pump components. Doing so can degrade the quality of the samples obtained using your Well Wizard system. Always wear latex gloves when unpacking and installing Well Wizard components, and any other time when your hands might touch a water-contacting component.

Install the Inlet Screen

Well Wizard bladder pumps have a 10 year warranty that is valid only if you use the appropriate inlet screen.

There are two types of inlet screen: One that you thread onto the pump inlet for 1100 series pumps, and one that you secure with set screws for 1200 and 1300 series pumps. The correct screen for each pump is usually included with the other components for the well - the box label tells you where to find the screen. The following sections describe how to install the two types of inlet screens.

1. Still wearing the latex gloves, open the plastic wrapping, then remove the screen.

2. Thread the screen onto the male-threaded pump inlet, making sure the screen is firmly tight.

1. Still wearing the latex gloves, open the plastic wrapping, then remove from the bag both the screen and the small plastic bag that contains spare set screws and a small Allen wrench.

2. Find the groove around the inlet end of the stainless steel pump body (the end opposite the air and water connectors), then slide the screen onto the bottom of the pump assembly, aligning the top rim of the screen with the top groove.

Screens For 1100 Series Pumps

To install a screen on an 1100 series pump, follow these steps:

Screens For 1200 and 1300 Series Pumps

To install a screen on an 1200 & 1300 series pump, follow these steps:

Installing a Pump with Bulk Tubing

3. Using the Allen wrench, lightly tighten each of the set screws, then make sure the screws have engaged the groove.

4. Using the Allen wrench, firmly tighten each of the set screws.

5. Check to make sure the screen is secure.

Note: If you have difficulty installing the screen, use the Allen wrench to loosen the set screws a little.

Note: This is usually 3 to 4 inches. You determine the exact length by checking both fitting nuts for full tube insertion after loose assembly.

1. Separate the discharge (larger) tubing from the air-supply (smaller) tube for 8-12 inches from one end.

2. Loosen the nut-and-ferrule assembly as much as possible without actually removing the nut.

3. Push the air-supply tube into the matching fitting on the top end of the pump.

4. Tighten the nut.

5. Cut off a short length from the end of the discharge tubing to compensate for the offset height of the discharge tube fitting.

1. Lower the pump into the well until the pump touches the bottom of the well.

2. Raise the pump up, as follows:

6. Make sure that the tube-to-pump fit is correct before pro-ceeding.

7. If the discharge tubing is 3/8" O.D. or larger, or if it has a Teflon lining, you must use a tubing insert, just push the insert into the tubing before inserting the tubing into the tubing fitting.

8. Tighten both fitting nuts finger tight.

9. For each fitting nut, hold the fitting base with one wrench and the fitting nut with another wrench, then tighten the fitting nut one additional turn.

Connect the Pump to the Tubing

To connect the pump to the tubing, follow these steps:

Cut Tubing to Length

To cut the tubing to the correct lengths, follow these steps:

1 foot, for low recovery wells To the middle of the screen, for high recovery wells

Attaching Tubing to the Well Cap

To attach tubing to the well cap, follow the instructions included with the shipment for the appropriate well cap.

Bladder Pump Operation in Low-Submergence

Bladder Pump Operation in Low-Submergence Applications

Pump submergence is defined as the height of the static water column above the top of the pump. In wells in which this water column height is 5 feet or less, the pump is considered to be in a low-submergence application.

QED sampling bladder pumps fill by hydrostatic pressure. As the inside of the pump's bladder fills with water, the bladder expands.

This filling and expanding of the bladder is referred to as the "refill" half of the pump cycle. When air pressure is applied to the outside of the bladder, the bladder is squeezed, forcing the water up the discharge tubing. This is referred to as the "discharge" half of the pump cycle. In low-submergence applications, there is less water pressure available to expand the bladder during the refill.

This can result in a smaller volume of water being pumped with each pump cycle because the bladder may not fully expand.

As a result of the lower volume per cycle, more time will be required to bring the water to the surface. An easy way to verify that the pump is working, prior to the water reaching the surface, is to submerge the pump's discharge tubing in a beaker of water. Each time the pump goes into discharge, air in the discharge tubing, which is displaced as the water level in the tubing rises, can be seen as air bubbles coming from the end of the tubing. To optimize the pumping rate, the refill time should be set long enough to achieve the maximum volume of air bubbles on each pump cycle, and the discharge time should be set long enough to ensure that the air has stopped bubbling out of the tube before the pump controller switches back into refill.

In low submergence wells, it is critical that the air pressure driving the pump not be more than 10-15psi higher than the minimum re-quirement of 0.42psi per foot of pump depth. Higher pressures than this can cause the bladder to be squeezed too tightly during discharge, a condition which can prevent the bladder from expanding during refill.

To avoid this condition in deeper wells, it is suggested that the air pressure applied to the pump be gradually increased as the water level in the pump's discharge tubing rises. It is recommended that the air pressure be set at 15psi initially, and slowly increased in increments of 10psi as needed until the water reaches the surface. Submerging the end of the discharge tubing under water as described above will verify whether the air pressure is set high enough.

Install or Replace Pump Connectors

The following sections describe how to install or replace the three types of connectors that may be included in your Well Wizard system.

Stainless Steel Connectors

Swagelok tube fittings, which include four pieces (see figure 5), come to you completely assembled, finger tight.

TM

Figure 5

Parts of the Swagelok Tube Fitting

Body

Front Ferrule

Tubing Insert (If Required)

Back Ferrule Nut

Caution: If you disassemble a connector before you use it, dirt or foreign material can get into the fitting and later cause a leak.

1. If you are working with a 1/2- or 3/4-inch connector, wrap the male threads under the nut with Teflon tape.

2. Insert the tubing into the Swagelok tube fitting as follows:

To install a stainless steel connector, follow these steps:

For 1/4 -inch tubing, insert it approximately 5/8 inch For 3/4 -inch tubing, insert it up to 7/8 inch

Make sure that the tubing firmly contacts the shoulder of the fitting and that the nut is finger tight.

Note: If the discharge tubing is 3/8 inch or larger, you must use a tubing insert, just push the stainless steel insert into the tubing before inserting the tubing into the tube fitting.

Figure 6

Clock Positions

3. Referring to figure 6, scribe or mark the nut at the 6 o'clock position.

4. While holding the fitting body steady with a backup wrench or vise, tighten the nut as follows, depending on the size of the tube fitting:

For fittings larger than 3/16 inch, turn the fitting one and one quarter turns (watch the scribe mark make one complete turn, then continue to the 3 o'clock position).

For fittings sizes 1/6, 1/8, and 3/16 inch, turn the fitting three quarters of a turn (watch the scribe mark turn to the 9 o'clock position).

Note: These are guidelines, you may need to further tighten the nut.

Figure 7

1. Cut the tubing cleanly and squarely to length.

2. If the tubing is larger than 1/2 inch, push an insert into the tube.

3. Push the tubing into the completely assembled connector until it contacts the shoulder inside the fitting (see figure 7).

4. Tighten the nut with a wrench, but be careful to not over tighten it; the nut should not come in contact with the shoulder of the body (see figure 7).

Polypropylene Connector

To install a polypropylene connector, follow these steps.

Body Shoulder

Inside Shoulder

Nut

Nut

Body

Front Ferrule

Back Ferrule

Well Screen

Figure A-1

Sampling System Type A

Figure A-1 shows the Type A sampling system, the basic bladder pump

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Discharge Adapter

Well Cap

Pump Tubing

Pump

Pump inlet Screen

Water Level

Ground Level

Optional

Sampling System Type L

Figure A-2 shows the Type L sampling system, a bladder pump with an inlet extension.

Figure A-2

Well Screen

Well Cap

Pump Tubing

Pump

Water Level

Ground Level

Pump Inlet

Inlet Extension

Weight

Discharge Adapter

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Sampling Pump Troubleshooting Guide

Well Wizard System Warranty

QED ENVIRONMENTAL SYSTEMS, INC. ("Q.E.D.") warrants to the original purchaser of its products that, subject to the limitations and conditions provided below, the products, materials and/or workman-ship shall reasonably conform to descriptions of the products and shall be free of defects in materials and work-manship. Any failure of the products to conform to this warranty will be remedied by Q.E.D. in the manner provided herein.

This warranty shall be limited to the duration and the conditions set forth below.

All warranty durations are calculated from the original date of purchase.

1. Dedicated-Use Systems Products- 10 year warranty on dedicated bladder pumps equipped with Q.E.D. inlet screens, and purge pumps used in periodic, non continuous groundwater sampling (up to 52 sampling events per year.) All other components, equipment and accessories are warranted for one year.

2. Portable-Use Systems- Controllers and water level meters are warranted for one year. Hose reels, Pumps and Caps are warranted for ninety (90) days.

Tubing and Purge Mizers are covered by a ninety (90) day material and work-manship warranty. There will be no warranty for application on tubing and Purge Mizers when used as part of a Portable System.

3. Separately sold parts and Spare Parts Kits- Separately sold parts and spare parts kits are warranted for ninety (90) days. Repairs performed by Q.E.D. are warranted for ninety (90) days from date of repair or for the full term of the original warranty, whichever is longer.

Buyers' exclusive remedy for breach of said warranty shall be as follows: if, and only if, Q.E.D. is notified in writing within applicable warranty period of the existence of any such defect in the said products, and Q.E.D. upon examin-ation of any such defects, shall find the same to be within the term of and covered by the warranty running from Q.E.D. to Buyer, Q.E.D. will, at its option, as soon as reasonably possible, replace or repair any such product, without charge to Buyer. If Q.E.D. for any reason, cannot repair a product covered hereby within four (4) weeks after receipt of the original Purchaser's/Buyer's notification of a warranty claim, then Q.E.D.'s sole responsibility shall be, at its option, either to replace the defective product with a comparable new unit at no charge to the Buyer, or to refund the full purchase price. In no event shall such allegedly defective products be returned to Q.E.D.