Volume I-A Operations and Maintenance Plan PRIMARY ... · Operations and Maintenance Plan, Volume...

Volume I-A

Operations and Maintenance Plan

PRIMARY TREATMENT SYSTEM (PTS)

OPERATING INFORMATION

Illinois Central Spring Treatment Facility

1550 W. Third Street

Bloomington, IN 47403

Prepared for:

CBS

20 Stanwix Street, 10th

Floor

Pittsburgh, PA 15222

Prepared by:

PSARA Technologies, Inc.

10925 Reed Hartman Highway, Suite 220

Cincinnati, OH 45242

May 2013

PSARA Project # 30500.69

Operations and Maintenance Plan, Volume 1-A: Primary Treatment System ii

Illinois Central Spring Treatment Facility May 2013

Volume I-A

OPERATIONS AND MAINTENANCE PLAN

Primary Treatment System (PTS) Operating Information

Illinois Central Spring Treatment Facility

1550 W. Third Street

Bloomington, Indiana 47403

Prepared for:

CBS

20 Stanwix Street, 10th Floor

Pittsburgh, PA

15222

Prepared by:

PSARA Technologies, Inc.

10925 Reed Hartman Highway

Cincinnati, OH

45242

May 2013

PN 30500.69

Operations and Maintenance Plan, Volume 1-A: Primary Treatment System iii


T A B L E O F C O N T E N T S

Section 1: Introduction ................................................................................................................ 1

1.1 Operations and Maintenance Plan Organization............................................... 1

1.2 Indiana NPDES Substantive Requirements ...................................................... 2

Section 2: General Basis of Design............................................................................................. 4

Section 3: Site Work ................................................................................................................... 5

Section 4: General System Overview ......................................................................................... 6

4.1 Spring Receiving Sump .................................................................................... 6

4.2 Primary Treatment System (PTS) ..................................................................... 7

4.3 Excess Flow Treatment System (EFTS) ........................................................... 8

4.4 PTS Monitoring and Control ............................................................................ 8

4.5 PLC GUI Function Keys ................................................................................... 9

Section 5: Process Operation and Control Description ............................................................. 10

5.1 Spring Receiving Sump .................................................................................. 10

5.1.1 Auto Mode .......................................................................................... 10

5.1.1.1 Water Level .......................................................................... 10

5.1.1.2 Flow Meters ......................................................................... 11

5.1.1.3 Pressure-Indicating Transmitters ......................................... 11

5.1.1.4 Analyzers ............................................................................. 12

5.1.2 Manual Mode ...................................................................................... 12

5.2 SRS Storage Tanks ......................................................................................... 12

5.2.1 Auto Mode .......................................................................................... 12

5.2.1.1 Water Level .......................................................................... 12

5.2.1.2 Tank Drain Valves ............................................................... 13

5.2.1.3 Flow Meter ........................................................................... 14

5.2.2 Manual Mode ...................................................................................... 14

5.3 Inclined Plate Clarifier .................................................................................... 14

5.3.1 Auto Mode .......................................................................................... 14

5.3.1.1 Water Level .......................................................................... 14

5.3.1.2 Flow Meter ........................................................................... 14

5.3.2 Manual Mode ...................................................................................... 15

5.4 Process Water Floor Sump.............................................................................. 15

5.4.1 Auto Mode .......................................................................................... 15

5.4.1.1 Water Level .......................................................................... 15

5.4.1.2 Flow Meter ........................................................................... 15

5.4.2 Manual Mode ...................................................................................... 15

5.5 Wastewater Floor Sump .................................................................................. 16

5.6 Effluent/Backwash Supply Tank .................................................................... 16

5.6.1 Auto Mode .......................................................................................... 17

5.6.1.1 Water Level .......................................................................... 17

5.6.1.2 Pumps ................................................................................... 17

5.6.1.3 Flow Meter ........................................................................... 18

5.6.2 Manual Mode ...................................................................................... 18

continued

Operations and Maintenance Plan, Volume 1-A: Primary Treatment System iv


T A B L E O F C O N T E N T S ( C O N T I N U E D )

5.7 Filter Feed Tank .............................................................................................. 18

5.7.1 Auto Mode .......................................................................................... 18

5.7.1.1 Water Level .......................................................................... 19

5.7.1.2 Flow Meter ........................................................................... 19

5.7.2 Manual Mode ...................................................................................... 20

5.8 Multimedia Filters ........................................................................................... 20

5.8.1 Auto Mode .......................................................................................... 20

5.8.1.1 Normal Mode ....................................................................... 20

5.8.1.2 Backwash Mode ................................................................... 22

5.8.1.3 Recycle Mode (Not Installed) .............................................. 24

5.8.1.4 Analyzers (Not Installed) ..................................................... 24

5.8.2 Manual Mode ...................................................................................... 24

5.9 Bag Filters ....................................................................................................... 25

5.10 GAC Filters ..................................................................................................... 25

5.10.1 Auto Mode (Normal Mode) ................................................................ 26

5.10.2 Backwash Mode (Manual Mode) ........................................................ 26

5.10.3 GAC Vessel Change-out ..................................................................... 27

5.11 Clarifier Sludge Thickener .............................................................................. 27

5.11.1 Auto Mode .......................................................................................... 27

5.11.1.1 Water Level .......................................................................... 27

5.11.2 Manual Mode ...................................................................................... 28

5.12 GAC and Multimedia Filter Sludge Thickener ............................................... 29

5.12.1 Auto Mode .......................................................................................... 29

5.12.1.1 Water Level .......................................................................... 29

5.12.2 Manual Mode ...................................................................................... 29

5.13 Filter Press ...................................................................................................... 30

5.14 Air Compressor ............................................................................................... 30

Section 6: Process Start/Stop Conditions .................................................................................. 32

6.1 Process Feed Pumps ........................................................................................ 32

6.2 SRS Storage Tank Pumps ............................................................................... 32

6.3 Filter Feed Pumps ........................................................................................... 33

6.3.1 During Normal Operation ................................................................... 33

6.3.2 During Backwashing ........................................................................... 34

6.4 Backwash Feed Pumps ................................................................................... 34

6.5 Process Water Sump Pump ............................................................................. 35

Section 7: Process Alarm Response .......................................................................................... 36

Section 8: Standard Operating Procedures................................................................................ 37

Section 9: Sampling and Analysis ............................................................................................ 38

9.1 Sampling ......................................................................................................... 38

9.1.1 Governmental Parameters ................................................................... 38

9.1.2 Operational Parameters ....................................................................... 38

9.1.3 Methods............................................................................................... 38

continued

Operations and Maintenance Plan, Volume 1-A: Primary Treatment System v


T A B L E O F C O N T E N T S ( C O N T I N U E D )

9.1.3.1 Sample Collection, Preservation, and Decontamination

Procedures ............................................................................ 38

9.1.3.2 Sample Labeling Procedures................................................ 39

9.1.3.3 Sample Storage and Shipment ............................................. 39

9.1.3.4 Field Chain-of-Custody Procedures ..................................... 39

9.2 Analysis........................................................................................................... 39

9.3 Sample Parameters and Potential Locations ................................................... 40

9.3.1 PCBs and TSS ..................................................................................... 40

9.3.2 TSS Only ............................................................................................. 41

9.3.3 DO ....................................................................................................... 42

9.3.4 pH ........................................................................................................ 42

9.3.5 Turbidity and Conductivity ................................................................. 42

9.3.6 Temperature ........................................................................................ 42

9.3.7 Percent Moisture Content ................................................................... 42

9.3.8 Particle Size Distribution .................................................................... 43

Section 10: Equipment Maintenance .......................................................................................... 44

10.1 System Component Contacts .......................................................................... 44

10.2 Spare Parts ...................................................................................................... 44

10.3 Preventative Maintenance ............................................................................... 44

Section 11: Reporting Requirements .......................................................................................... 45

11.1 Routine Reporting ........................................................................................... 45

11.2 Nonroutine Reporting ..................................................................................... 45

Section 12: Contingency Plans ................................................................................................... 46

12.1 Fire and Security ............................................................................................. 46

12.2 Emergency Response ...................................................................................... 46

12.3 System Upset/Bypass ...................................................................................... 46

Section 13: As-built Record Drawings ....................................................................................... 47

List of Tables

Table 1. Storage Tank Draining Time

Table 2. Instrumentation Summary

Table 3. System Alarms

Table 4. System Component Contacts

Table 5. Equipment Maintenance – Spare Parts List

Table 6. Preventive Maintenance Schedule

Appendices

Appendix A. Standard Operating Procedures

Appendix B. As-Built Sump and Tank Sketches

Appendix C. Process & Instrumentation Drawings

Operations and Maintenance Plan, Volume 1-A: Primary Treatment System 1


S E C T I O N 1 : I N T R O D U C T I O N

1.1 OPERATIONS AND MAINTENANCE PLAN ORGANIZATION

This Operations and Maintenance (O&M) Plan is separated into 10 volumes, each contained

within a separate binder. The volumes are summarized as follows:

Volume I-A – Primary Treatment System Operating Information: This volume

describes in detail the operation, maintenance, and associated best management practices

(BMPs) for the original Primary Treatment System (PTS) completed in 2000.

Volume I-B – Excess Flow Treatment System Operating Information: This volume

describes in detail the operation, maintenance, and associated BMPs for the Excess Flow

Treatment System (EFTS) completed in 2011.

Volume II – Equipment Literature A through E: This volume contains the first binder of

equipment manufacturer operations and maintenance manuals.

Volume III – Equipment Literature F: This volume contains the second binder of

equipment manufacturer operations and maintenance manuals.

Volume IV – Equipment Literature G through N: This volume contains the third binder

of equipment manufacturer operations and maintenance manuals.

Volume V – Equipment Literature O through X: This volume contains the fourth binder

of equipment manufacturer operations and maintenance manuals.

Volume VI – Equipment Literature Y: This volume contains the fifth binder of equipment

manufacturer operations and maintenance manuals. This volume also includes PLC ladder

logic diagrams for the PTS.

Volume VII – Contractor/Vendor Submittals – Process Piping: This volume contains

process piping layout shop drawings as submitted by the mechanical contractor.

Volume VIII – Contractor/Vendor Submittals – Process Equipment: This volume

contains process equipment vendor shop drawings.

Volume IX – Contractor/Vendor Submittals – Electrical, Plumbing, HVAC: This

volume contains submittals by the electrical and mechanical contractors.

Volumes X-XI – Excess Flow Treatment System (EFTS) Equipment Literature: These

volumes contain equipment manufacturer operations and maintenance manuals for the EFTS,

including PLC ladder logic diagrams.

This O&M Plan is a dynamic document that will be updated as necessary to reflect significant

changes in operating conditions, equipment, and/or procedures.



1.2 INDIANA NPDES SUBSTANTIVE REQUIREMENTS

In accordance with the Consent Decree Amendment (CDA), this O&M plan has been expanded

to include the State of Indiana National Pollution Discharge Elimination System (NPDES)

substantive requirements. The treatment facility does not need to obtain an NPDES permit

because onsite remedial actions are specifically exempt from such administrative requirements

under Section 121(e) of CERCLA, 42 U.S.C. 96219(e). Nevertheless, certain regulations

enacted by the State of Indiana under its federally approved NPDES program are relevant and

appropriate to discharges from the facility.

The following is a summary of applicable or relevant and appropriate requirements (ARARs)

and how they are incorporated into this O&M plan:

Surface Water Quality Criteria for Specific Substances – 327 IAC 2-1-6, Table 1:

The State of Indiana has stated in correspondence that it sets an effluent limit of 0.3 ppb for

polychlorinated biphenyls (PCBs) discharged by treatment plants into waters other than the

Great Lakes system. Notwithstanding the designation of 327 IAC 2-1-6, Table 1, as an

ARAR, only the discharge limit of 0.3 ppb for PCBs is designated as a performance standard.

Conditions Applicable to All Permits – 327 IAC 5-2-8 (3), (5) - (14):

327 IAC 5-2-8 (3) regarding adverse environmental impacts – The procedures and practices

outlined in this plan are intended to minimize or address any adverse environmental impacts

resulting from noncompliance.

327 IAC 5-2-8 (5) regarding effluent standard changes – The discharge limit of 0.3 ppb for

PCBs is the only applicable effluent standard at this time.

327 IAC 5-2-8 (6) regarding rights and privileges – No property rights or exclusive

privileges are assumed in conjunction with system operation.

327 IAC 5-2-8 (7) regarding government access – The U.S. Environmental Protection

Agency (USEPA), the Indiana Department of Environmental Management (IDEM), and

authorized representatives will be provided access to the treatment facility for records

review, inspections, or testing as required.

327 IAC 5-2-8 (8) regarding system operation and maintenance – This plan establishes the

procedures and practices for maintaining the treatment facility in good working order and

operating it efficiently.

327 IAC 5-2-8 (9) regarding general monitoring, recordkeeping, and reporting require-

ments – Routine monitoring and recordkeeping practices are summarized in Section 9.0 of

this plan. Routine reporting practices are summarized in Section 11.1.

327 IAC 5-2-8 (10) regarding nonroutine reporting requirements – Nonroutine reporting

practices are summarized in Section 11.2 of this plan.



327 IAC 5-2-8 (11) regarding bypass provisions – This plan outlines system design features

that minimize the potential for bypass. Section 11.2 of this plan summarizes notification

practices for bypass conditions, whereas Section 12.3 summarizes response practices and

other requirements.

327 IAC 5-2-8 (12) regarding upset provisions – This plan outlines system design features

that minimize the potential for upset conditions. Section 12.3 summarizes response practices

and other requirements for system upset conditions.

327 IAC 5-2-8 (13) regarding enforcement action defense – It is understood that halting

operation of the treatment system will not be considered an appropriate defense for

maintaining compliance in the event of an enforcement action.

327 IAC 5-2-8 (14) regarding signatures and certifications – Appropriate signatures and

certifications will continue to be provided with all submittals to USEPA and/or IDEM.

Considerations in the Calculation and Specification of Effluent Limitations – 327 IAC

5-2-11 (a) (1), (2), (3), (4), (5)(C); (c)(2); (d), (e), (f), (g), (h)

The discharge limit of 0.3 ppb for PCBs is the only applicable effluent standard at this time.

Establishment of Water Quality-based Effluent Limitations for Dischargers Not

Discharging Water to Within the Great Lakes System – 327 IAC 5-2-11.1 (a), (b), (d),

(f), (g), (h)

The discharge limit of 0.3 ppb for PCBs is the only applicable effluent standard at this time.

Applicability of Best Management Practices (BMPs) – 327 IAC 5-9-2 (a) – (j)

The only pollutants currently handled and/or potentially discharged from this system are

PCBs and suspended solids. This plan outlines system design features that minimize the

potential for discharge of PCBs into waters of the State. BMPs for system operation and

maintenance are established throughout this O&M plan via standard operating procedures

(SOPs), maintenance schedules, etc. Subsequently, this plan is intended to meet the

requirement for a BMP program in 327 IAC 5-9-2. Additional BMPs will be developed as

needed to address the use of any future maintenance chemicals that could result in other

pollutants being discharged.

Monitoring – 327 IAC 5-2-13 (a), (c), (d), (e), (f)

System monitoring practices are summarized in Section 9.0 of this plan.

Permit Modification, Revocation, Reissuance, and Termination – 327 IAC 5-2-16 (c)(2),

(d)(2)

This O&M plan will be revised as necessary if the conditions specified in 327 IAC 5-2-16

(c)(2) or (d)(2) regarding more stringent effluent limitations and/or requirements become

applicable in the future.



S E C T I O N 2 : G E N E R A L B A S I S O F D E S I G N

Earth Tech (now AECOM) designed the original treatment system. The most important

elements that formed the basis of design were the following assumptions: the plant would be

designed to address a simulated 25yr-6hr (hereinafter 25-year) storm event; the solids loading to

the plant during the first flush of the storm event would be reasonably managed by the plant; and

4 acre-feet of storage would be provided with at least two independent structures (tanks).

Earth Tech modeled a 25-year storm event based on a SCS unit hydrograph that was modified to

mirror data collected at the location during lesser storm events. The change in the hydrograph’s

configuration to mirror actual storm events was believed to be necessary due to the potential of

storage, pressure conduits, and other such features that may be unique to the karst features.

Earth Tech’s review of the data indicated that the majority of the total suspended solids (TSS) is

generated during hours 6 through 18 within a 36-hour elevated flow period as a result of the

6-hour storm event. Earth Tech therefore selected this 12-hour design period for managing

solids and the total 4 acre-feet storage volume to maximize capture of TSS and capture peak TSS

concentrations. The modeled 25-year storm event was used to develop a system TSS mass

balance.

During a storm event, the primary treatment system is capable of processing at a maximum flow

of 1,000 gpm. The storage tanks will fill at a nominal rate of 2,500 or 5,000 gpm depending on

the developed head and number of pumps online. Once the capacity of the Spring Receiving

Sump (SRS) tanks has been exceeded, they will overflow to the Excess Flow Treatment System

(EFTS, completed in March of 2011). Should an event exceed the peak discharge of the SRS

pumps (6,000 gpm combined), the overflow will bypass through the SRS directly to the original

streambed. This potential bypass condition is addressed in Section 12.3 of this plan.

After the elevated spring flows subside to below 900 gpm, the SRS tanks can be drained back to

the SRS. A spreadsheet detailing a singular event of the storage tanks draining back to the spring

receiving sump is provided as Table 1. The design event is based on the premise that the

pumping/sump capacity is sufficient to handle the peak flow of the storm event and that the SRS

storage tanks can be drained within 7 days for the given design event (25yr-6hr).



S E C T I O N 3 : S I T E W O R K

Substantial site work was undertaken to provide two access roads, one to the north side of the

site where the spring surfaces, and one that serves to access the process treatment building and

SRS located at the south side of the site. Substantial grading occurred on the south side to

accommodate the treatment building and tanks.

Additional site work was completed in 2010 to address the Swallow Hole and Quarry Springs

area immediately south of the treatment building. Aside from contaminated soils/sediment

removal and disposal, the Illinois Central Spring Treatment Facility (ICSTF) effluent line was

extended to downstream of both areas to prevent potential recontamination of clean effluent

water.

Additional site work was also completed in 2010 at the Illinois Central Emergence (ICE) area to

improve the efficiency of the existing collection system and to facilitate better separation of

noncontaminated surface runoff.

The plant is supplied with electricity to power the process components, as well as to provide

lighting, air conditioning in the office, heating in the SRS building, and automated ventilation in

both buildings. Natural gas is supplied to heat the process building and to supply hot water.

Potable water and sewer are supplied for the facility and for limited process needs.

Communications lines are provided for personal computer (PC) connections, phones including

an auto-dialer (MMI), faxes, fire alarms, and data transfer.



S E C T I O N 4 : G E N E R A L S Y S T E M O V E R V I E W

Earth Tech designed the PTS to treat TSS and PCBs. The process may remove other

constituents within the waste steam, but this function is not a design component. During design,

a single sample was collected and tested for typical landfill pollutants and discharges that could

originate from such facilities. The test results from this sample were reviewed for possible

interferences with the various processes. No specific or general concerns were identified.

On the north side of the site, north of the railroad track currently owned by the Indiana Railroad

Company, a berm was installed to separate uncontaminated surface runoff from contaminated

spring water. A culvert was installed under this railroad track in two locations. One culvert was

placed at the mouth of the spring to direct contaminated water to the SRS, and a second culvert

was located just east of the berm to allow uncontaminated surface runoff to bypass the treatment

system.

4.1 SPRING RECEIVING SUMP

Contaminated spring water enters the spring receiving sump (SRS) from a 24-in.-diameter

culvert that was placed near the mouth of the spring. From the SRS, water can be pumped to the

treatment process at the preset rates of 200 gpm, 800 gpm, or 1,000 gpm. As a practical matter

and within each pump’s capacity, the flow rate can be changed to any combination of flows

using the variable frequency drives. Water can be simultaneously pumped to the SRS storage

tanks from a separate bank of three pumps at a rate of 2,500 gpm for a single pump or 5,000 gpm

using two pumps. The two storage tanks are nominally sized to hold 644,740 gallons

(approximately 2 acre-feet) of water each. Water stored in the storage tanks can be drained back

to the SRS when a storm event has diminished to the point where the total flow into the sump is

below an operator-defined rate (typically 900 gpm or less). The SRS tanks also act as passive

clarifiers for settleable solids. Design parameters for the SRS tanks are based only on the

holding capacity without the benefit of any trapping efficiency. Initial results indicated that the

tanks are capable of retaining some PCB-laden sediments (settleable solids). In the event the

flow rates into the SRS exceed 6,000 gpm, spring water will overflow the SRS and pass

downstream as untreated flow. All process pumps in the treatment system, including the SRS

pumps, have redundant control systems (i.e., ultrasonic level transmitters and level switches) that

are digitally controlled.

In order to purge the SRS or the SRS tanks of settled sediments, a direct bypass was installed

from the SRS to Thickener #1 (T-301A). The bypass would take heavily laden sediment (high

solids > 2%) directly to the thickener. There is no need to process this waste stream through the

plant since it is already a concentrated load. The bypass operation would typically be scheduled

during low flow events when the system is capable of transporting up to 200 gpm.



4.2 PRIMARY TREATMENT SYSTEM (PTS)

The process flow for the entire treatment system is diagrammed in the as-built piping and

instrumentation drawings included in Appendix C. In order to treat spring water for TSS and

PCBs, the primary treatment system (PTS) includes clarification followed by various stages of

filtration. After passing through a clarifier, water overflows to a filter feed tank and is then

pumped through multimedia, bag, and granular activated carbon (GAC) filter vessels. The

process is driven by 300-gpm and 900-gpm pumps that are controlled based on level in the filter

feed tank. The final effluent, after GAC filtration, flows through an effluent/backwash storage

tank before discharging by gravity to an area downstream of the Quarry Springs monitoring

locations. A 1,000-gpm pump (with backups) transfers effluent from the effluent/backwash tank

to the filter feed tank for backwashing the multimedia filters (automated) and directly to the

GAC filters for GAC filter backwash (manual only operation).

Sludge from the clarifier, the multimedia filters, and the carbon vessels (during backwash) is

directed to two sludge thickeners (intended to operate in parallel) and from there to a filter press

for final dewatering. Two diaphragm pumps transfer sludge from the clarifier to the smaller of

the two thickeners (Thickener #1, T-301A). Multimedia filters are automatically backwashed

based on a differential pressure set point, with backwash water directed to the larger of the two

thickeners (Thickener #2, T-301B). All GAC filters are manually backwashed, with the

backwash water also directed to Thickener #2.

The thickeners are fitted to drain the supernatant (clarified water) from the tanks at four different

levels. With each backwash, the solids are allowed to settle and the water is decanted from the

tank when the clarity is visually observed to be acceptable. Sight glasses are fitted to the drain

manifold for this purpose. After decanting is complete, solids left in the thickeners are pumped

via diaphragm pump (with backup) to the filter press for dewatering. A lime slurry is introduced

to each thickener in order to improve the dewatering process. After each dewatering cycle, dry

filter cakes are removed from filter press and stored within a rolloff box located directly beneath

the filter press. Once the rolloff box is full (by weight), the container is removed for disposal

and then returned for reuse. The weight of dewatered sludge has been estimated to be 105 lb/ft3.

Filtrate from the filter press flows to the process floor sump where it is pumped to the filter feed

tank for processing through the treatment system. The supernatant from the thickeners is drained

to the same process sump. The entire process is designed to operate automatically except for the

following tasks:

• Bag filters must be manually changed;

• GAC filter backwash process is entirely manual;

• Filter press operation is initiated manually with the thickened backwash solids delivered

by semiautomated features. The addition of lime slurry is manually introduced to the

thickener prior to pressing. Air is used to provide a consistent batch mix.



4.3 EXCESS FLOW TREATMENT SYSTEM (EFTS)

In order to treat spring flows resulting from larger storm events, an Excess Flow Treatment

System (EFTS) was constructed in late 2010 and early 2011. This system was designed to treat

all overflows from the SRS tanks at a rate of up to 5,000 gpm. This increases the total system

capacity to 6,000 gpm. All pertinent operation and maintenance information for the EFTS is

included in Volume I-B of the O&M plan.

4.4 PTS MONITORING AND CONTROL

Operators control the PTS via a control panel and programmable logic controller (PLC) located

in the office area. A graphical user interface (GUI) monitor (and backup) is provided to enable

the operator to monitor system operation and to control system functions as necessary.

An MMI system (automated voice system) is also provided to place call-outs to operators under

alarm conditions. The transmitting units continuously transfer operating data to the PLC, which

in turn transfers data to a dedicated data PC and to the MMI. A second office PC is used to

generate necessary reports from the operating data. Hard copies of reports are maintained on

file, and both PCs are backed up weekly to an external hard drive. The external hard drive is

stored off-site at the PSARA Bloomington office.

Many of the instruments, including flow meters, level elements, pressure sensors and differential

pressure sensors, are provided with local indicators and/or transmitters. These features enable

system monitoring from the field, the control panel in the office, and remote locations. Solenoid-

operated valves, which can be opened or closed from the control panel, have local indicators to

visually observe the status of each valve. Local control of some valves is not possible without

pulling the circuit or fuse that powers the control circuitry.

A compressor is installed to provide air for carbon transfers, operation of diaphragm pumps,

mixing within the thickeners, and operation of the filter press. The operating pressure is

maintained at 100 psi.

A diesel generator was originally installed to provide backup power for the PTS, but was sized

with excess capacity for future system expansion. Based upon system operating loads, the

generator has sufficient capacity to also provide backup power for the EFTS. The generator has

user-defined limits for starting and powering the generator down. Under current settings, an

automatic throw switch will transfer power to the generator if main line power is lost for more

than 20 seconds. Once main line power has been reestablished and remains on for 15 minutes,

the automatic throw switch will transfer power back to the main line and the generator will begin

a shutdown routine. Changes to the time intervals described above may be made at the generator

panel located inside the treatment building.

Data from all process instrument transmitters are logged to the PLC and then stored on the MMI

and dedicated data PC. This data includes the date and time stamp for all records that are

maintained. This data may be transferred by various means including any electronic format that

is currently available.



The variable frequency drives (VFDs) on the pump motors are provided to ramp flows to the

prescribed rates for the purpose of improving the efficiency of the clarifier and filters. The

VFDs also prolong the life of the pumps, provide automated variable and constant flow rates,

and allow various processes to run at predefined rates for a given time. The VFDs eliminate the

need for throttling valves and also increase the pump efficiency.

4.5 PLC GUI FUNCTION KEYS

The PLC GUI has several different menu screens that show critical information about various

parts of the system. The GUI also has 21 different function keys that control access to the menu

screens and certain system functions. The following is a list of all GUI function keys and their

purpose:

Menu Keys

F9: Menu screen for SRS, SRS pumps, clarifier, and sludge pumps

F10: Menu screen for SRS storage tanks/pumps

F11: Menu screen for filter feed tank/pumps, multimedia and bag filters

F12: Menu screen for GAC filters

F13: Menu screen for sludge thickeners

F14: Menu screen for effluent/backwash tank/pumps and floor sumps/pumps

F15: Menu screen for alarms

F16: Main menu screen

Command Keys

F1-F8: Select or highlight components in each menu screen

F17: Pump/valve automatic mode

F18: Valve off

F19: Pump/valve manual mode

F20: Start pump or open valve

F21: Stop pump or close valve



S E C T I O N 5 : P R O C E S S O P E R A T I O N A N D C O N T R O L

D E S C R I P T I O N

The following subsections describe the sequence of operation for each system component. All

PLC analog and digital input information, including input address, scaling and set points, are

detailed in Table 2: Instrumentation Summary. PLC ladder logic is included in Volume VI.

5.1 SPRING RECEIVING SUMP

Contaminated flows to be treated are directed from the Illinois Central Spring directly into the

SRS. The sump is a below-grade concrete structure that is equipped with two different sets of

pumps: process feed pumps (200 gpm and 800 gpm) and SRS storage tank feed pumps

(2,500 gpm). Pump motors are located above-grade and are protected by a concrete block

building that also houses pump electrical components.

5.1.1 Auto Mode

When the flow into the SRS is less than 200 gpm, the 200-gpm process feed pump cycles based

on the water level in the sump and on the set points of the level element that controls the pumps.

When a rain event occurs and the flow rate exceeds 200 gpm, the 800-gpm process feed pump

also cycles. Under normal operating conditions, the total pumping rate to the treatment process

is 0, 200, or 1,000 gpm. If the pumps are manually manipulated, a flow rate of 800 gpm can be

set without adjusting the VFDs.

When flow into the SRS exceeds 1,000 gpm, a third pump cycles at a nominal rate of 2,500 gpm

and transfers water to the SRS storage tanks. Should the flow into the SRS exceed 2,500 gpm,

the second 2,500-gpm pump comes online to pump more water to the SRS storage tanks. When

the flow into the SRS exceeds 6,000 gpm, all pumps run continuously at 6,000 gpm until such

time that the spring flow rate drops below 6,000 gpm. In the unlikely event that the influent rate

exceeds 6,000 gpm, the SRS will eventually overflow. However, this condition has never been

observed during the more than ten years of operation of the plant.

Activation of the 800-gpm or 2,500-gpm pumps is indicative of a rainfall event or a malfunction

of the pumps. Normal flows are dependent on the ambient conditions, including the antecedent

moisture conditions and the time interval between rainfall events. Typical non-storm flows from

the spring vary between a low of 30 gpm to median range of 60 gpm.

5.1.1.1 Water Level

All SRS pumps and their backups are controlled by the PLC via control set points measured by a

level element and indicating transmitter (LE/LIT-200). LE/LIT-200 has “high-level” and “low-

level” alarm set points as well as “on” and “off” set points for the SRS pumps.

LE/LIT-200 has two other set points. The low set point overrides any other PLC commands and

turns off all seven pumps. The PLC then generates an alarm message on the GUI that reads



“Low level in SRS.” At the high set point, the PLC verifies that all four primary SRS pumps are

on. If any are not, then they are turned on. The PLC then generates an alarm message on the

GUI that reads “High level in SRS.”

Two separate float switches are also installed in the SRS. The high-high float switch (LSH-200)

generates an alarm at the PLC to indicate that the SRS is overflowing. The LSH-200 set point

corresponds with the same elevation as the invert of the SRS overflow. The low-low float switch

(LSL-200) provides redundant protection to prevent the pumps from running dry. LSL-200 does

not operate when the non-VFD SRS pumps (i.e., the 2,500-gpm pumps) are placed in manual

mode. LSL-200 does operate when the VFD SRS pumps (i.e., 200- and 800-gpm pumps) are

placed in manual mode. The operator must be careful not to run the 2,500-gpm pumps dry

when operating in manual mode.

The level element LE/LIT-200 indicates locally, and in the control room, both the level of water

in the SRS (to the nearest hundredth of a foot) and the number of gallons in the main part of the

sump.

The LE/LIT-200 continuously transmits water level data to the PLC . Trending charts can be

generated by the PC, with records of this data stored for the entire operating history of the plant.

5.1.1.2 Flow Meters

There is a flow meter on the combined discharge from process feed pump P-101 and its backup

P-102 (FE/FIT-100). Similarly, there is a flow meter on the combined discharge from process

feed pump P-103 and its backup P-104 (FE/FIT-101). There is also a flow meter on the

combined discharge from SRS storage tank feed pumps P-201 and P-202 and their backup P-203

(FE/FIT-200). These flow meters are programmed to display instantaneous flow rate in gpm and

totalized flow in gallons. They indicate this data locally and remotely to the GUI via the PLC,

with the data used for both monitoring and control. During initial system startup, the VFD-

controlled motor speed required to produce the necessary discharge flow rates from the pumps

were programmed into the PLC. Manual adjustments may be necessary to increase or decrease

the drive speeds to adjust corresponding flow rates as needed.

These flow meters are also involved in a second control sequence. Their input regarding

discharge flow rate is used by the PLC, along with input from LE/LIT-200 regarding the sump

fill/empty rate, to calculate the volumetric flow rate of water into the SRS.

The PLC continuously transmits flow rate and totalized flow data to the data PC and MMI.

Charts of flow rate and totalized flow versus time can be generated by the office PC for trending

purposes. Daily flow reports are also generated by the office PC, and these records are stored for

the entire operating history of the plant (hard copy and electronic versions).

5.1.1.3 Pressure-Indicating Transmitters

There are three pressure-indicating transmitters (PIT) that serve each manifold for the respective

pump discharges (PIT-100 through PIT-200). These transducers are programmed to display

instantaneous pressure in psi. They indicate this data locally and remotely to the PLC and GUI.

This data is for monitoring only, and there is no control by the PLC based on the data. The PLC



continuously transmits pressure data to the data PC and MMI. Trending charts can be generated

by the office PC, with records of this data stored for the entire operating history of the plant.

5.1.1.4 Analyzers

AE/AIT-200 is an in-line turbidity meter that collects a slipstream from the combined discharge

of the 200-gpm pumps to the treatment building. It indicates this data locally and remotely to the

PLC and GUI. This data is for monitoring only, and there is no control by the PLC based on the

data. The PLC continuously transmits turbidity data to the data PC and the MMI. [Note: The

transmission of data from the turbidity meter is problematic. Apparently, the transmitter for the

unit is not of sufficient quality or design to transmit the data from the SRS to the PLC. There is a

possibility that line interference due to placement may contribute to the problem. As a result, the

turbidity meter is not currently used.]

5.1.2 Manual Mode

All SRS pumps can be run manually for troubleshooting or maintenance activities. Each pump

can be isolated, and the backup pumps can be put into service by adjusting manual valves located

on the discharge of each pump and on combined discharge piping [refer to process and

instrumentation drawings (P&IDs) in Appendix C]. A 2,500-gpm pump can be used to

manually backflush another 2,500 gpm pump through discharge valve manipulation. Note: The

operator must be careful to throttle discharge flow when backflushing a 2,500-gpm pump

to avoid damaging the impeller. This should only be done to remove debris if needed after

a heavy storm event.

The SRS is inspected annually for sediment buildup and is typically cleaned every two years.

Refer to Appendix A for SOPs related to SRS maintenance activities.

5.2 SRS STORAGE TANKS

The SRS storage tanks have a capacity of 632,000 gallons each and are designed to store water

when spring flows exceed the PTS flow capacity of 1,000 gpm. The tanks are of welded-steel

panel construction with a cone-shaped bottom set inside a concrete foundation. The tanks have

protective coatings on both the interior and exterior.

5.2.1 Auto Mode

5.2.1.1 Water Level

The three SRS pumps (P-201, P-202, and P-203) discharge to the SRS storage tanks (T-201 and

T-202). The bulk storage pump system is programmed to begin transferring water to the tanks

once the influent flow rate exceeds the process pumping rate of 1,000 gpm. A maximum of two

of three pumps can operate simultaneously at any given time. The SRS tanks are configured for

parallel operation only. Either tank may be taken offline to allow for repair or inspection while

the other remains in operation or in standby. In parallel operation, the water levels are

maintained at the same elevation in both tanks including any overflow to the EFTS.



The SRS storage tank feed pumps are vertical turbine pumps that are programmed to begin

pumping once predefined water levels are exceeded in the SRS. The pumping rates are fixed and

are nominally designed to pump at 2,500 gpm for a single pump and 5,000 gpm for two pumps.

In order to exercise the pumps and maintain a uniform degree of wear, the pumps automatically

alternate between the three. When the SRS influent flow exceeds 1,000 gpm and the sump level

rises to the first set point, a single 2,500-gpm pump is automatically brought online. This pump

will be able to maintain the sump level until the SRS inflow exceeds 3,500 gpm, at which point

the level will rise to the second set point. At this level, a second pump is automatically brought

online to provide a total pumping capacity of 6,000 gpm (1,000 gpm to the plant and 5,000 gpm

to the SRS tanks). The SRS tanks will continue to receive water from one or two of these pumps

until the SRS level drops and influent flow decreases to below 1,000 gpm.

In automatic mode and once the SRS tanks are full (31.0 ft or 644,744 gallons each @ overflow),

the tanks begin to overflow to the EFTS at either 2,500 gpm or 5,000 gpm depending on pump

status. The SRS storage tank feed pumps are not fitted with VFDs and may only be adjusted by

manipulating manual valves. The operator may exercise some control over the system by

placing the pumps in manual operation, changing the valve settings, and taking a tank on- or

offline.

The SRS tanks are fitted with level elements and transmitters (LE/LIT-201 and LE/LIT-202) that

display locally and on the GUI via the PLC. They display water level in feet (to the nearest tenth

of a foot) and in gallons. The reference point for the tank level is at the top of the cone where it

meets the vertical sidewall. This corresponds to an elevation of “0 feet” relative to the SRS tank

levels.

As in the SRS, the PLC uses the data from LE/LIT-201 and LE/LIT-202 to display tank levels

and storage volumes. This data may be compared to data from flow meters to verify the

accuracy of instruments. All water entering and leaving the SRS tanks is metered. SRS tank

overflow volume is measured by the EFTS effluent flow meter.

The PLC continuously transmits water level elevation and volume data to the data PC and MMI.

Charts of volume versus time can be generated from the PC for trending purposes.

5.2.1.2 Tank Drain Valves

In the event that the SRS tanks receive water, they will continue to hold water (or overflow to the

EFTS) until the SRS influent flow rate drops below 1,000 gpm. When the flow rate drops below

900 gpm, the tanks can be drained back to the SRS through manual valve manipulation. The

SRS drain valve (ZSC 206) was originally intended to provide automatic control of SRS tank

draining; however, it is now only operated in manual mode because of functionality issues. A

butterfly valve located upstream of the ZSC 206 is left normally closed and is only opened

during the tank draining process. The SRS drain valve is then manually adjusted to achieve the

desired draining rate, as indicated by a flow meter installed in the drain line. Note: The

operator must be careful to balance the SRS tank draining rate with the calculated SRS

influent flow rate so that the combined flow does not exceed the 1,000 gpm capacity of the

PTS.



5.2.1.3 Flow Meter

There is a flow element and indicating transmitter (FE/FIT-201) installed on the drain line from

the SRS storage tanks. As described above, this flow data is used by the Operator to control the

SRS tank draining process through manual valve manipulation. The flow meter is programmed

to display instantaneous flow rate in gpm and totalized flow in gallons. The meter indicates this

data locally and transmits the data to the PLC and GUI. The PLC continuously transmits water

flow rate and totalized flow data to the data PC and MMI. Trending charts can be generated by

the office PC, with records of this data stored for the entire operating history of the plant.

5.2.2 Manual Mode

It is possible to use Hand-Off-Auto (HOA) switches to manually control the 2,500-gpm SRS

pumps that discharge to the storage tanks. The SRS tanks themselves can be managed through

manual valve changes so that the tanks can be operated together in parallel or individually. As

previously mentioned, manual draining of the SRS tanks is now standard practice.

5.3 INCLINED PLATE CLARIFIER

The inclined plate clarifier (T-101) is the first treatment component in the PTS that removes

solids and sediment. SRS process feed pumps discharge directly to the clarifier at flow rates of

200, 800, or 1,000 gpm. When the water level in the clarifier reaches the invert elevation of its

overflow pipe, clarified water overflows by gravity to the filter feed tank. Solids collect in the

bottom of the clarifier unit and are periodically transferred to sludge thickener T-301A.

5.3.1 Auto Mode

The clarifier sludge pumps (P-301, P-302) are automatically controlled by a timer within the

system PLC. The timer cycles a sludge pump on for a specific timeframe and then off for a

specific timeframe, both of which are configurable through the GUI. Refer to the Clarifier

Sludge Pump Settings SOP in Appendix A for specific guidelines on timer settings.

5.3.1.1 Water Level

The level element and level indicating transmitter (LE/LIT-100) was originally installed to

monitor clarifier water level; however, this unit was removed from service. It is not necessary

for effective operation of the clarifier, so it has never been replaced.

LSH-100 is a high-level switch that is set above the top of the pipe that overflows from the

clarifier to the filter feed tank. When the PLC notes this alarm condition, it shuts down all SRS

process feed pumps.

5.3.1.2 Flow Meter

A flow element and indicating transmitter (FE/FIT-300) is located on the discharge pipe of the

sludge pumps. It is programmed to display instantaneous flow rate in gpm and totalized flow in

gallons. It will indicate this data locally and remotely to the PLC and GUI. The PLC

continuously transmits water flow rate and totalized flow data to the data PC and MMI.



Trending charts can be generated by the office PC, with records of this data stored for the entire

operating history of the plant.

5.3.2 Manual Mode

The clarifier can be bypassed, if needed, by adjusting manual valves on the inlet side of the

clarifier. Also, each clarifier sludge pump can be isolated for maintenance or put into service as

needed by manually adjusting valves located on the inlet and discharge sides of each pump.

5.4 PROCESS WATER FLOOR SUMP

The process floor sump (S-301) has three inputs including the following: manual-only

discharges of supernatant from the thickener tanks to a floor drain; manual-only discharges of

filtrate from the filter press to a floor drain; and gravity overflows of process water from the

filter feed tank (T-102). Note that all these inputs are of process water that contains PCBs. The

sump has two outputs including an overflow back to the SRS and a pumped discharge to the

filter feed tank. A backup pump was placed in inventory at the site. The base, wiring, and

plumbing (with modification) are available for the unit or it may replace the existing installation.

5.4.1 Auto Mode

5.4.1.1 Water Level

Four level switches provide input to the PLC for automatic control of the sump discharge pump

P-309 and its backup P-310. Level switch LSL-300 turns the pump off, and LSH-300 turns the

pump on. LSLL-300 provides redundant protection against running the pump dry and turns the

pump off; it also represents an alarm condition. LSHH-300 provides redundant protection

against overflowing the sump to the SRS and also represents an alarm condition. The set point

for LSHH-300 should correspond with the invert elevation of the sump overflow to the SRS.

These four level switches are all hardwired to sump pumps P-309 and P-310.

5.4.1.2 Flow Meter

There is a flow element and flow indicating transmitter (FE/FIT-301) on the combined discharge

of the sump pumps to the filter feed tank. It is programmed to display instantaneous flow rate in

gpm and totalized flow in gallons. It indicates this data locally and remotely to the PLC and

GUI. The PLC continuously transmits water flow rate and totalized flow data to the data PC and

MMI. Trending charts can be generated by the office PC, with records of this data stored for the

entire operating history of the plant.

5.4.2 Manual Mode

The sump pumps do not have VFDs, and their throttling valves are not automated. Therefore,

the operator must use data from flow meter FE/FIT-301 to determine the pump discharge rate

and manually adjust the throttling valve as needed. Note: The maximum flow rate from the

sump to the filter feed tank should not exceed 200 gpm.



Using H-O-A switches, the operator can override the automatic, PLC-controlled operation of the

sump pump (P-309 or P-310) and can run it manually. The pump can be manually controlled by

adjusting the throttling valve located on the discharge side of the pump.

5.5 WASTEWATER FLOOR SUMP

The wastewater floor sump (S-501) has one input. It is the open drain that runs the full length of

the building combined with the floor drains at all building entrances. The sump has three outlets:

the sanitary sewer (valved off and not used), the process water floor sump, and the overflow to

the SRS. It has two level switches that provide data to the PLC. LSH-500 has a set point

corresponding to the invert elevation of the sanitary sewer discharge line. LSHH-500 has a set

point corresponding to the invert elevation of the sump overflow pipe to the SRS.

Both LSH-500 and LSHH-500 provide input to the PLC that controls visual alarms on the GUI.

The LSH-500 alarm will indicate “Potential sanitary sewer discharge from wastewater sump.”

The LSHH-500 alarm will indicate “Wastewater sump overflow to SRS.” When the PLC

receives a signal from LSHH-500, it shuts down the SRS process feed pumps. This is necessary

since the cause of the high water level in the sump may be a leak or break in the process pipe or

treatment vessels.

The discharge from the wastewater floor sump to the sanitary sewer was specifically designed to

be completely manual to guard against inadvertent discharges of PCBs to the sanitary sewer.

The sanitary sewer discharge valve is kept closed at all times and is not used. The inflatable plug

between the two sumps has been removed to increase the working volume of the process water

floor sump.

If the sanitary sewer discharge valve is ever needed in the future, the inflatable plug would have

to be re-installed to separate the two sumps. Wastewater floor sump contents would then have to

be transferred to the process water floor sump for treatment, and the sump would have to be

thoroughly decontaminated. Prior to discharge of any water to the sanitary sewer, sampling and

analyses would be required to ensure that there are no PCBs in the water. Note: PCBs must not

be discharged to the sanitary sewer under any circumstances.

5.6 EFFLUENT/BACKWASH SUPPLY TANK

The effluent/backwash supply (EBS) tank (T-401) has a working capacity of 30,000 gallons. It

has two inputs. It receives fully treated effluent from the GAC filters as well as potable water.

The EBS tank has two outputs (plus a drain valve). Fully treated water from the GAC filters

overflows the EBS tank and drains by gravity to the new outfall downstream of the Swallow

Hole and Quarry Springs areas. The EBS tank also supplies treated water for backwashing the

GAC and multimedia filters (if required) using pumps P-401, P-402, and P-403 (added with the

EFTS). The backwash feed pumps each supply up to 1,000 gpm of flow during a GAC

backwash or a multimedia filter backwash, but the pumps cannot backwash these systems

simultaneously. These pumps can also supply water to the thickeners to break up solidified

sludge if needed, though this is an entirely manual process. The normal operating mode for this

tank is to be full so that water is always available for backwashing.



5.6.1 Auto Mode

Effluent from the GAC filters is generated when the system is in automatic mode. Influent from

the potable water supply occurs only manually. The discharge from the backwash feed pumps to

the filter feed tank is an automated function, whereas the discharge for GAC backwashing and

the discharge to the thickeners are completely manual operations.

5.6.1.1 Water Level

The level element and level-indicating transmitter (LE/LIT-400) displays output locally and on

the GUI via the PLC. In both locations, LE/LIT-400 displays the tank contents in feet (to the

nearest tenth of a foot) and gallons. As with the SRS and other tanks, the PLC uses the data from

LE/LIT-400 to compute and display tank fill and drain rates. This data can be compared to the

flow meter data to verify instrument accuracy.

LE/LIT-400 has two set points. When the PLC receives input from the low set point, it overrides

any other commands and turns off P-401, P-402, and P-403. This alarm condition displays

locally and on the GUI and reads “Low level in effluent/backwash supply tank.” When the PLC

receives input from the high set point, it overrides any other commands and shuts down the filter

feed pumps P-105, P-106, P-107, and P-108 that discharge to the EBS tank via the three filtration

systems (multimedia, bag, and GAC). This alarm condition is displayed locally and on the GUI

and reads “High level in effluent/backwash supply tank.”

Separate level switches (LSH-401 and LSL-401) are installed in the EBS tank to provide

redundancy for pump and spill protection. Each has one set point. When the PLC receives input

from LSH-401, the low-level set point, it overrides any other commands and turns off P-401,

P-402, and P-403. This alarm condition is displayed on the GUI and reads “Low level in

effluent/backwash supply tank.” When the PLC receives input from LSH-401, the high set

point, it overrides any other commands and shuts down the filter feeds pumps P-105, P-106,

P-107, and P-108 that discharge to the EBS tank via the three filter systems. This alarm

condition is displayed on the GUI and reads “High level in effluent/backwash supply tank.”

LSH-401 and LSL-401 elevations correspond to the elevations of the high-level and low-level

alarm points of LE/LIT-400. LSH-401 and LSL-401 are hardwired to the pumps that they

control.

The PLC continuously transmits data from these water level instruments to the storage device

and the MMI. Trending charts can be generated by the office PC, with records of this data stored

for the entire operating history of the plant.

5.6.1.2 Pumps

As described above, the backwash feed pumps (P-401, P-402, and P-403) are shut down by the

PLC when it receives low-level alarm signals from LE/LIT-400 or LSL-401. Normally, these

pumps are controlled manually to backwash the GAC filters or automatically by level switches in

the filter feed tank to ensure sufficient backwash volume for the multimedia filters. The system

is not designed to provide water to the GAC and multimedia filters simultaneously from the



backwash feed pumps. These pumps are supplied with VFDs in case the actual required

backwash flow rates differ from the design backwash flow rates.

5.6.1.3 Flow Meter

There are two flow elements with indicating transmitters related to the EBS tank. One flow

meter (FE/FIT-102) measures effluent discharge through a Parshall flume in the floor at the

northwest interior corner of the plant. FE/FIT-102 is for monitoring purposes only and has no

control function. FE/FIT-400 is located on the discharge of P-401, P-402, and P-403. FE/FIT-

400 is for monitoring backwash flow rates only and has no control function. Over time, VFD

speeds may have to be manually adjusted to maintain the desired flow rates during backwashing.

These flow meters are programmed to display instantaneous flow rate in gpm and totalized flow

in gallons. They indicate this data locally and remotely to the GUI via the PLC. The PLC

continuously transmits the data to the data PC and the MMI. Trending charts can be generated


5.6.2 Manual Mode

The backwash feed pumps (P-401, P-402, and P-403) are controlled manually to backwash the

GAC filters. Manual operation is performed using H-O-A switches. Manual operation of these

pumps incorporates functions applied by the VFD (i.e., in manual mode, these pumps should

ramp up to 1,000 gpm). Each pump can be throttled, isolated for maintenance, or placed into

service as needed by adjusting the manual valves located on the inlet and outlet of each pump.

These pumps can also be manually diverted to add water to the thickeners to break up solidified

sludge. Putting potable water into the EBS tank is an exclusively manual operation. It is

possible to bypass the EBS tank and pump water directly to the ICS outfall by adjusting

exclusively manual valves.

5.7 FILTER FEED TANK

The main purpose of this tank is to provide a way to pump through the three filter systems in the

treatment train (multimedia, bag, and GAC). The volume of the filter feed tank is

11,000 gallons, and the working volume is 8,300 gallons. The filter feed tank has three inputs

and three outputs, plus a drain valve. The inputs include the following: overflow from, or

bypass around, the clarifier; discharge from the process water floor sump; and discharge from the

backwash feed pumps. The outputs include the gravity overflow to the process water floor

sump, one output to the 300-gpm pumps (P-105 and P-106), and one output to the 900-gpm

pumps (P-107 and P-108).

5.7.1 Auto Mode

Auto mode means that the entire system is controlled automatically by the PLC. In auto mode,

the multimedia filters, which receive flow from the filter feed tank, have three operating modes:

normal mode (forward flow through the filter for processing), backwash mode (reverse flow for

cleaning the media), and recycle mode (not currently installed). These operational modes are

discussed in more detail in Section 5.8 Multimedia Filters below.



5.7.1.1 Water Level

The level element and indicating transmitter (LE/LIT-102) displays output locally and on the

GUI via the PLC. In both locations, the tank contents are displayed in feet (to the nearest tenth

of a foot) and gallons. As with the SRS and other tanks, the PLC uses the data from LE/LIT-102

to compute and display tank fill and drain rates. This data may be compared to flow meter data

to verify instrument accuracy.

LE/LIT-102 has several set points: those that control the filter feed pumps and two set points for

pump/overflow protection. When the PLC receives input from the low-level set point, it

overrides any other commands and turns off all filter feed pumps (P-105, P-106, P-107, and

P-108). This alarm condition is displayed locally and on the GUI and reads “Low level in filter

feed tank.”

When the PLC receives input from the high-level set point, it overrides any other commands and

shuts down the SRS process feed pumps (P-101, P-102, P-103, and P-104) that discharge to the

filter feed tank via the clarifier. This alarm condition is displayed locally and on the GUI and

reads “High level in filter feed tank.”

Separate level switches (LSH-103 and LSL-103) are installed in the filter feed tank to provide

redundancy for pump/overflow protection. Each level switch has one set point. When the PLC

receives input from the low-level switch (LSL-103), it overrides any other commands and turns

off the filter feed pumps. This alarm condition is displayed on the GUI and reads “Low level in

filter feed tank.” When the PLC receives input from LSH-103, the high-level switch, it overrides

any other commands and shuts down the SRS process feed pumps. This alarm condition is

displayed on the GUI and reads “High level in the filter feed tank.” LSH-103 and LSL-103

elevations correspond to the elevations of the high-level and low-level alarm points of LE/LIT-

102. LSH-103 and LSL-103 are also hardwired to the pumps that they control.

The PLC continuously transmits data from these water level instruments to the data PC and the

MMI. Trending charts can be generated by the office PC, with records of this data stored for the

entire operating history of the plant.

5.7.1.2 Flow Meter

A flow meter (FE/FIT-103) is located on the combined discharge of the filter feed pumps. It

provides input to the PLC that controls the speed of the filter feed pumps through the VFDs.

When a 300-gpm pump (P-105 or P-106) is operating alone, the flow rate is 250 gpm. When a

900-gpm pump (P-107 or P-108) is operating alone, the flow rate is 850 gpm. In auto mode, the

larger pump only runs when the smaller pump is on, such that the discharge flow rate is either

250 gpm or 1,100 gpm. The PLC controls the filter feed pumps based on input from FE/FIT-103

in the same way whether the multimedia filter is in normal or backwash mode. This could

change, however, if operating experience indicates that the backwash flow rate should be

different than the forward flow rate.

During initial system startup, the VFD-controlled motor speed required to produce the necessary

discharge flow rates from the pumps was programmed into the PLC. Over time, the VFD speeds

may have to be manually adjusted to maintain the desired flow rates. The VFDs on the SRS



process feed pumps and filter feed pumps are useful in balancing the influent and effluent flow

rates from the filter feed tank to minimize the potential for tank level alarms, as well as to avoid

excessive pump starts. They are also useful in addressing small process flow changes that could

occur over time.

The flow meter is programmed to display instantaneous flow rate in gpm and totalized flow in

gallons. It indicates this data locally and remotely to the GUI via the PLC. The PLC



5.7.2 Manual Mode

The filters feed pumps may be controlled manually using H-O-A switches. Manual operation of

these pumps incorporates functions applied by the VFD (i.e., in manual mode, these pumps will

ramp up to their desired discharge rate). Each pump can be throttled, isolated for maintenance,

or placed into service as needed by adjusting the manual valves located on the inlet and outlet of

each pump.

5.8 MULTIMEDIA FILTERS

The multimedia filters are pressurized vessels that can operate in the following two automatic

modes: normal mode (“A” and “B” modes with forward flow when process water is being

treated) and backwash mode (back flow for cleaning the filter media). In normal mode, flow

enters the top of the unit and discharges from the bottom, whereas in backwash mode the flow is

reversed to enter the bottom and discharge from the top. The PLC controls which mode the filter

is in based on input from pressure transmitters. The GUI indicates which mode the filter is in at

any given time based on input from the PLC. Head pressures are automatically monitored and

recorded by the PLC and displayed on the GUI. Note: Filter automated features are based on

differential pressure and not head pressure. A correlation exists between the two, but only

the differential pressure controls system function.

Head pressure data is continuously transmitted from the multimedia filters to the PLC. The PLC



5.8.1 Auto Mode

5.8.1.1 Normal Mode

The filter feed pumps (P-105, P-106, P-107, and P-108) are sized to provide different process

flow rates through the system. P-105 and P-106 are 300-gpm pumps that provide an actual flow

rate of 250 gpm, whereas P-107 and P-108 are 900-gpm pumps that provide an actual flow rate

of 850 gpm. As a result, the flow rates through the multimedia filters are 0, 250, or 1,100 gpm in

normal (forward-flow) mode depending on the influent flow rate to the filter feed tank.

When the flow rate into the filter feed tank is 0 gpm, it does not fill and the filter feed pumps do

not turn on. When the influent flow rate is 200 gpm from the clarifier or process sump, the filter



feed tank fills to the “on” level set point for the 300-gpm filter feed pump. This pump is

activated and the tank level drops until the pump “off” level set point is reached. This pump will

continue to cycle on and off as needed.

The flow rate into the filter feed tank is 400 gpm when both the 200-gpm SRS process feed

pump and the 200-gpm process floor sump pump are on. The flow rate is 1,000 gpm when both

the 200-gpm and 800-gpm SRS process feed pumps are on. At these flows, the filter feed tank

fills past the “on” set point for 300-gpm pump and also activates the 900-gpm pump. The total

flow rate with both filter feed pumps operating is 1,100 gpm, which causes the tank level to drop

until the 900-gpm pump “off” level set point is reached. The 300-gpm pump stays on during this

time and the tank begins to fill until the 900-gpm pump cycles on again.

In the event that both SRS process feed pumps turn off soon after the 300-gpm and 900-gpm

filter feed pumps turn on, the net discharge rate from the filter feed tank will be 1,100 gpm and

the tank level will drop to the pump “off” level set points very quickly (4 to 5 minutes).

The flow rate into the filter feed tank is 1,200 gpm when both the 200-gpm and 800-gpm SRS

process feed pumps are on and the 200-gpm process floor sump pump is on. At this flow rate,

the filter feed tank fills past the set point for 300-gpm pump and also activates the 900-gpm

pump. The total flow rate with both filter feed pumps operating is 1,100 gpm, which causes the

tank level to rise slowly. The tank level continues to rise until either the SRS process feed

pumps or the process floor sump pump turns off (either on their own or due to a filter feed tank

high-level set point).

Under normal conditions, the manual valves on the discharge of the EBS tank need to be

properly set such that flow from these pumps is directed to the filter feed tank. Backwashing the

GAC filters to the thickeners is not a normal operation and can only be performed manually

when the multimedia filters are not in backwash mode.

“A” Operational Mode

In mode “A,” the multimedia filters operate as originally designed. All three filter units are

continuously online, except when a backwash cycle occurs. If the differential pressure between

the inlet and discharge piping of a unit exceeds the system set point, then that unit is

automatically sent into backwash mode. Backwash mode involves an automatic change of

valves such that the flow is reversed through the unit to clean the media. Only one unit at a time

can be backwashed. If a second unit requires backwashing during a backwash cycle already in

progress, the second unit will continue to process water until the first backwash cycle is complete

and that unit is brought back online.

With the automatic change of valves, the backwash water for the unit to be cleaned is taken from

the two units that remain online. In this mode of operation, two units are always online while the

third unit is in backwash mode. The backwash water is directed to Thickener #2 (T-301B).

During backwash, there is no flow to the bag filters. Once the backwash cycle is complete, the

unit is automatically put back into service. Alarms have been dampened with delays to

overcome pressure spikes that develop when the valves change the direction of flow. Based on

operating experience, mode “A” is the normal and preferred configuration.



“B” Operational Mode

In mode “B,” the multimedia filters operate with two units online and a third in reserve. In this

mode of operation, the units alternate with each backwash cycle. The unit held in reserve is

automatically brought online when backwash is required. Alarm conditions due to hydraulic

pressure spikes are avoided due to the sequence in which the valves operate with two units

online.

5.8.1.2 Backwash Mode

During backwash mode, solids accumulating on the filter media create a pressure drop between

the inlet and discharge sides. Differential pressure transducers and indicators (PDI-100 located

on T-103C, PDI-107 located on T-103B, and PDI-108 located on T-103A) monitor this pressure

drop across each unit. The differential pressure is not displayed on the GUI, nor is it recorded

through the PLC. Instead, the units have been fitted to display the head pressure in psi both

locally and remotely to the GUI and PLC.

Each of the three filter vessels also has a differential pressure switch (PDSH-100, PDSH-107,

and PDSH-108), which have been set to trigger at the same predefined set point. When the set

point of the transducer is exceeded, there is an output to the PLC that causes the GUI to indicate

“High differential pressure on multimedia filter X.” The PLC then sends a signal to

automatically backwash that vessel.

When a unit differential pressure transducer or switch calls for backwash mode, the PLC

automatically initiates a backwash cycle. A backwash cycle in automatic mode requires that

manual valves on the discharge of the backwash feed pumps (P-401, P-402, and P-403) are

properly positioned to transfer water to the filter feed tank. Other manual valves must be

positioned to valve off flow to the GAC filters and thickeners. These valves are normally

positioned in this manner because GAC filter backwashing is an entirely manual process. Prior

to manual backwashing of a GAC filter, the operator must disable the multimedia filter

automatic backwash mode.

Backwash mode requires a total volume of 7,500 gallons of water for each cycle. Backwash

mode may occur under a variety of conditions. When both SRS process feed pumps are

operating, the normal (forward) flow rate into the filter feed tank is 1,000 gpm. This provides

sufficient water in the filter feed tank to supply backwash needs, assuming that the filter feed

pumps do not shut off during the backwash cycle. If the filter feed pumps do shut down during

the backwash cycle, then supplemental water is required in the filter feed tank. Supplemental

water is required in the filter feed tank at other times as well, such as when a backwash cycle is

initiated and one or both of the 200-gpm pumps (i.e., the SRS process feed pump and/or process

water floor sump pump) are on. Supplemental water is also needed when one of these pumps

shuts down in the middle of a backwash cycle and there is no longer influent flow to the filter

feed tank.

Supplemental water to the filter feed tank, when required by backwash mode, is supplied from

the EBS tank via the backwash feed pumps (P-401, P-402, and P-403). Level set points in the

filter feed tank control these pumps automatically. When the appropriate set point is triggered

during backwash mode, one of the pumps delivers 1,000 gpm of flow to the filter feed tank to



ensure that there is sufficient water to complete a backwash cycle. The EBS tank is always kept

full to provide adequate water for backwashing the multimedia filters.

In the filter feed tank, the “on” level set point for supplemental water is located above the “off”

level set point for the filter feed pumps. This ensures that the backwash supply pumps begin to

fill the filter feed tank with supplemental water before the filter feed pumps are automatically

shut down. This also ensures that the available backwash supply flow is always 1,000 gpm.

In multimedia filter backwash mode, both SRS process feed pumps, the process floor sump

pump, and the backwash feed pump can all be running simultaneously. This is considered the

“worst-case” operating scenario, with the flow rate into the filter feed tank being 2,200 gpm. As

soon as the water level rises above the “off” level set point for the backwash feed pump, which is

set above the “on” set point for the filter feed pump, the backwash feed pump turns off. This

ensures that the backwash feed pump only turns off when the filter feed tank is full and also

ensures that the backwash cycle can run to completion.

In multimedia filter backwash mode, the PLC enables a backwash feed pump to turn on and off

in accordance with level set points in the filter feed tank (monitored by LE/LIT-102). However,

the PLC will shut down the backwash feed pumps, regardless of filter feed tank level, if the EBS

tank level drops to the pump “off” set point (monitored by LE/LIT-400).

The multimedia filter backwash control sequence performed by the PLC is summarized as

follows:

1) The PLC initiates backwash mode for a specific filter unit as long as a GAC filter is not

being backwashed manually. The PLC indicates “Multimedia filter backwash mode” on

the GUI.

2) When the filter feed tank is filled to the “on” level set point for the 900-gpm filter feed

pump (monitored by LE/LIT-102), both the 300-gpm and 900-gpm pumps will run to

provide a backwash flow rate of 800 gpm.

3) The PLC initiates valve changes required for backwash of the specific unit (inlet valve

closed, backwash valves opened, and system outlet valve to bag filters closed).

4) A flow of 800 gpm is processed through two units while the other one is backwashed

with the filtrate from those units.

5) The backwash water is directed to Thickener #2 (T-301B) and there is no flow to the

GAC or bag filters.

6) The timer tells the PLC to terminate the backwash cycle, reverse position on the unit and

system valves, and reestablish normal operating mode.

7) The PLC controls the operation of the backwash feed pump based on level input from the

filter feed tank (LE/LIT-102) and the EBS tank (LE/LIT-400). This ensures that the filter

feed tank stays full of water and that the backwash cycle proceeds with an uninterrupted

flow rate of 800 gpm.



When backwash mode is complete, the PLC returns to the normal operational mode (“A” or

“B”). In normal mode, forward flow is reestablished through the multimedia filters to the bag

and GAC filters.

5.8.1.3 Recycle Mode (Not Installed)

Recycling of filtrate back to the filter feed tank is not anticipated but can be accomplished in this

mode. The multimedia filters are provided with a blind flange for a recycle line, but there is

currently no piping to finish the connection back to the filter feed tank. Should operation in

recycle mode become desirable, this piping can be added. If used in the future, the recycle mode

feature will enable the multimedia filter to receive continuous flow in the normal, forward-flow

direction without interruption during periods when insufficient flow is available. It is possible

that running the multimedia filters with continuous flow rather than intermittent (as it currently

functions) would improve their performance. It is important to note that that the only time this

feature would be useful is when the flow rate into the filter feed tank is 0 to 200 gpm. In these

situations, however, there may be no need for enhancement since TSS concentrations are likely

to be very low. No additional PLC programming to accommodate recycle mode is anticipated.

Since the system has operated well without this feature, it does not appear to be necessary and

there are no current plans to implement it.

5.8.1.4 Analyzers (Not Installed)

AE/AIT-100 is intended to be an in-line turbidity meter that collects a slipstream from the

combined discharge of the filter feed pumps to the multimedia filters. AE/AIT-101 is intended

to be an in-line turbidity meter that collects a slipstream from the piping between the multimedia

and bag filters. Although these analyzers are indicated on the P&IDs, neither has been installed

at this time. Retrofitting the system to include them should be a simple matter, since the wiring

and PLC programming are already in place.

The PLC is programmed to compare the turbidity at these two locations and make an assessment

of the performance of the multimedia filters. If the assessment indicates that there is inefficient

turbidity removal in the multimedia filters, the PLC would cause an alarm condition display on

the GUI indicating “High turbidity in multimedia filter effluent.” If the turbidity in the

multimedia filter influent exceeds a predetermined NTU level, the PLC would cause an alarm

condition display on the GUI indicating “High turbidity in clarifier effluent.” Eventually, it may

be possible for the PLC to use input from the turbidity meters to initiate backwash cycles or to

determine the proper cycle of the clarifier sludge pumps.

5.8.2 Manual Mode

The operator may be able to determine through operating experience that the multimedia filters

can be bypassed during periods of base flow in the ICS or during times that the multimedia

filters are in need of repair. Manual valve adjustments would make this possible. Manually

overriding the automated valves on the multimedia filters makes it possible to take one or more

filter units out of service.

The filter feed pumps (P-105, P-106, P-107, and P-108) can all be controlled manually at the

PLC. Manual operation of these pumps incorporates functions applied by the VFD (i.e., in



manual mode, these pumps will ramp up to their desired discharge rate). Each pump can be

throttled, isolated for maintenance, or placed into service as needed by adjusting the manual

valves located on the inlet and outlet of each pump.

5.9 BAG FILTERS

During normal operation, the filter feed pumps discharge through the multimedia filters to one of

two bag filters piped in parallel. Flow enters the top of the bag filter units and discharges from

the bottom. The bag filters are pressurized vessels without backwash capabilities. Instead, these

units rely on disposable filter bags that must be changed periodically as solids accumulate and

create a pressure drop across the unit. Refer to the Bag Filter Change SOP in Appendix A for

specific procedures.

As with the multimedia filters, differential pressure is monitored by a transducer and indicator

located on each vessel (PDI-101 located on T-104A and PDI-102 located on T-104B). Head

pressure is also monitored and this data is transmitted to the GUI via the PLC. Head pressure

instrumentation is located on piping connected to both the inlet and discharge sides of each

vessel; consequently, either head or tail pressure can be monitored depending on how isolation

valves are arranged. Note: If both isolation valves are open, they will cause a partial bypass

of the bag filters through the ½-inch piping.

Each of the two vessels has a differential pressure switch (PDSH-101 on T-104A and PDSH-102

on T-104B). These switches have differential pressure set points that generate an alarm message

on the GUI via the PLC. When this alarm condition occurs, the GUI indicates “High differential

pressure on bag filter,” which prompts the operator to change out the filter bags in the

appropriate unit. The operator isolates the unit needing filter bag replacement through manual

valve changes, which allows the other unit to continue operating. The operator must be careful

not to isolate both units, as this will dead-head the filter feed pumps. Note: Back pressure

from the GAC units may create an abnormally low differential pressure across the bag

filters, indicating that the high system pressures are related to the GAC units.

Head pressure data is continuously transmitted from the bag filters to the PLC. The PLC



5.10 GAC FILTERS

There are four 20,000-pound GAC vessels in the treatment process, which is the final treatment

step prior to discharge. The four GAC vessels are grouped into two sets operating in parallel,

each with a lead and lag vessel arrangement. The vessels are designated as T-105A1, T-105A2,

T-105B1, and T-105B2, with “A” and “B” representing the two parallel trains and “1” and “2”

representing the lead and lag vessels in each train. During normal operation, flow enters the top

of each vessel and discharges from the bottom; the flow is reversed in backwash mode.



Note: The GAC in carbon vessel “1” of each train was replaced in 2010. As a result,

carbon vessel lead/lag arrangement was changed such that “2” is now the lead vessel in

each train to maximize the treatment capacity of the available GAC.

Since the two GAC filter trains operate in parallel, the flow is split between them. For example,

when the 300-gpm filter feed pump is on (operating at 250 gpm), each train receives 125 gpm of

flow. Only one vessel can be manually backwashed at a time, so the flow must be managed

appropriately through the other vessels. Note: Each train can only handle a maximum of 600

gpm. Beyond this flow, the back pressure across the multimedia filters will activate the

pressure-relief valves and create an alarm condition.

There is one pressure differential transducer and indicator (PDI) and one pressure differential

switch (PDSH) associated with each vessel. PDI-103 and PDSH-103 are located on T-105B1.

PDI-104 and PDSH-104 are located on T-105B2. PDI-105 and PDSH-105 are located on

T-105A1. PDI-106 and PDSH-106 are located on T-105A2. The original PDI analog gauges

have been replaced with digital readouts and sending units. The pressures measured by these

gauges are recorded on the data logger and displayed on the GUI.

5.10.1 Auto Mode (Normal Mode)

In auto mode, the filter feed pumps discharge through the multimedia filters, the bag filters, and

the GAC filters, all of which are pressurized systems. Normal forward-flow operation of the

GAC vessels is completely automated, with no operator involvement required. All other GAC

filter operations, including backwashing and changing out carbon, is completely manual.

5.10.2 Backwash Mode (Manual Mode)

When sediment accumulates on the GAC filters, the pressure drop across each unit increases;

this is measured by a pressure differential transducer (with indicator) located on each vessel.

The pressure differential transducers are programmed to display differential pressure in psi and

to transmit this data remotely to the GUI via the PLC.

Each of the vessels also has a pressure differential switch (PDSH). These switches have

differential pressure set points that create an alarm condition on the GUI indicating “High

differential pressure across GAC vessel X.” At this time, the operator responds by manually

adjusting valves to isolate the vessel with high differential pressure. Only one GAC vessel can

be backwashed at a time. Note: Backpressure across the GAC is reflected as an increase in

pressure in the upstream bag filter gauges, which can provide a false high pressure reading

for the bag filter.

When the operator receives the high GAC differential pressure alarm, the EBS tank is filled with

potable water to make up any difference in level if the tank is not already full. When filled, the

operator initiates a backwash cycle, which is a completely manual operation. No part of the

GAC backwash procedure is automated in any way, since backwashes are typically completed

after each rainfall event. Manual valves are adjusted to divert flow from the EBS tank to the

GAC filters instead of the multimedia filters. Also, manual valves are adjusted to isolate the

GAC vessel that requires backwashing. When the backwash procedure is initiated, the backwash

pump is throttled to yield 600 gpm and the pump remains on in manual mode until the procedure



is completed and the pump is manually turned off. This procedure may then be repeated for a

second, third, and fourth GAC vessel as needed. Refer to the Carbon Backwash SOPs in

Appendix A for procedure details.

Pressure data is continuously transmitted from the GAC filters to the PLC. The PLC



5.10.3 GAC Vessel Change-out

Removing spent carbon from a GAC vessel and replacing it with virgin carbon (i.e., a carbon

change-out) is a totally manual operation. It requires that the operator adjust manual valves to

isolate the vessel receiving the change-out. Carbon change-out is indicated when the vessel

cannot be adequately cleaned by backwashing or if PCB levels in plant effluent consistently rise

above 0.3 ppb.

5.11 CLARIFIER SLUDGE THICKENER

Sludge thickener T-301A receives sludge from the bottom of the clarifier and from the SRS

when the clarifier is bypassed. There are six pressurized inputs and six outputs. The six inputs

include the following: sludge from the bottom of the clarifier, sludge directly from the SRS

(during clarifier bypass), thickening aid (lime) from the thickening aid storage tank, core purge

from the filter press, fully treated water from the EBS tank (for breaking up solidified sludge),

and air (for mixing during filter press operations). The six outputs include the following: an

underflow at the base of the cone bottom from which sludge is pumped to the filter press; an

unvalved overflow outlet at the top of the tank that discharges by gravity to the process water

floor sump; and four mid-level decant lines from different tank levels (2 feet apart). These four

decant lines are controlled by manual valves to send flow to either the filter press suction line or

the process water floor sump. This thickener operates independently or in parallel (not series)

with the other thickener.

5.11.1 Auto Mode

The only automated feature of the thickener involves level controls that prevent potential

overflows from pumps that automatically transfer water and/or solids to this vessel.

5.11.1.1 Water Level

The level element and indicating transmitter (LE/LIT-301) displays output locally and on the

GUI via the PLC. In both locations, the tank level is displayed in feet above the top of the cone

(to the nearest tenth of a foot) and in gallons. As with the SRS and other tanks, the PLC uses the

data from LE/LIT-301 to compute and display tank fill and drain rates. This data is compared to


When the PLC receives input from the high-level set point, it overrides any other commands and

shuts down the backwash feed pumps (P-401, P-402, P-403) and the clarifier sludge pumps



(P-301, P-302) to prevent the thickener from overflowing. This alarm condition is displayed

locally and on the GUI as “High level in thickener tank A.”

A separate level switch (LSH-301) is installed in the thickener tank to provide redundancy for

overflow protection. When the PLC receives input from LSH-301, it overrides any other

commands and shuts down the backwash feed pumps (P-401, P-402, P-403) and the clarifier

sludge pumps (P-301, P-302) to prevent the thickener from overflowing. This alarm condition is

also displayed on the GUI as “High level in thickener tank A.” The LSH-301 elevation

corresponds to the elevation of the high-level set point for LE/LIT-301.

Level data is continuously transmitted from the thickener to the PLC. The PLC continuously

transmits the data to the data PC and the MMI. Trending charts can be generated by the office

PC, with records of this data stored for the entire operating history of the plant.

5.11.2 Manual Mode

There are many manually operated valves associated with the thickener. The inlet from the

clarifier has a manual valve that is normally open during auto mode, since the clarifier sludge

pumps may automatically pump to the thickener. This valve has a chain wheel actuator so that it

can be operated from the floor level. The inlet from the filter press (air core purge) and the inlet

from the EBS tank are also manually controlled through operator valve changes. The four

supernatant overflow lines have manual valves with chain actuators so that the operator can open

and close them from the floor. Refer to the Decanting Thickeners SOP in Appendix A for

specific operational procedures.

As the thickener supernatant is decanted, additional sludge can be transferred to the thickener.

With each transfer operation, the solids concentration within the thickener increases. Once the

solids reach a concentration of approximately 2% by weight, the thickener is ready to transfer

solids to the filter press for dewatering. Previous bench-scale and full-scale filter press tests have

shown that this solids concentration results in acceptable filter press cakes.

After all the solids from the thickener are processed and the thickener is empty, the operator

must flush the underflow lines between the bottom of the thickener and the filter press. This

action ensures that sludge inside these pipes does not accumulate and compact itself into

immovable plugs that inhibit system operation during subsequent storm events. To accomplish

this, the operator must manually open the valve from the EBS tank and partially fill the thickener

with treated effluent via the backwash feed pumps (P-401, P-402, or P-403). This water can then

be run through the filter press to clean out its pipes in the process.

Each of the filter press feed pumps (P-305 and P-306) can be throttled, isolated for maintenance,

or put into service as needed by manually adjusting the valves located on the inlet and outlet of

each pump.



5.12 GAC AND MULTIMEDIA FILTER SLUDGE THICKENER

The GAC and multimedia filter backwash sludge thickener (T-301B) has five pressurized inputs

and six outputs. The five inputs include the following: sludge from backwashing the multimedia

filters, sludge from backwashing the GAC filters (including the EFTS GAC units), thickening

aid (lime) from the thickening aid storage tank, treated water from the EBS tank (for breaking up

solidified sludge), and air for mixing. The six outputs include the following: an underflow at the

base of the cone bottom from which sludge is pumped to the filter press; an unvalved overflow

outlet at the top of the tank that flows by gravity to the process water floor sump; and four mid-

level decant lines at four different tank levels (2 feet apart). These decant lines are controlled by

manual valves that direct flow to either the filter press or the process water floor sump. This

thickener operates independently of the other thickener.

5.12.1 Auto Mode

Two automated features are provided for the thickener. The multimedia filter backwash cycle,

which directs flow to the thickener, is fully automated. In addition, level controls in the

thickener automatically shut down system pumps to prevent overflow.

5.12.1.1 Water Level

The level sensor and indicating transmitter (LE/LIT-302) displays output locally and on the GUI

via the PLC. In both locations, tank contents are displayed in feet above the top of the cone (to

the nearest tenth of a foot) and in gallons. As with the SRS and other tanks, the PLC uses the

data from LE/LIT-302 to compute and display tank fill and drain rates. This data is compared to


When the PLC receives input from the high-level set point of LE/LIT-302, it overrides any other

commands and shuts down the filter feed pumps (P-105, P-106, P-107, P-108) and the backwash

feed pumps (P-401, P-402, P-403) to prevent the thickener from overflowing. This alarm

condition is displayed locally and on the GUI as “High level in thickener tank B.”

A separate level switch (LSH-302) is installed in the thickener tank to provide redundancy for

overflow protection. When the PLC receives input from LSH-302, it overrides any other

commands and shuts down the filter feed pumps (P-105, P-106, P-107, P-108) and the backwash

feed pumps (P-401, P-402, P-403) to prevent the thickener from overflowing. This alarm

condition is displayed on the GUI as “High level in thickener tank B.” The LSH-302 elevation

corresponds to the elevation of the high-level set point for LE/LIT-302.

Level data is continuously transmitted from the thickener to the PLC. The PLC continuously

transmits the data to the data PC and the MMI. Trending charts can be generated by the office

PC, with records of this data stored for the entire operating history of the plant.

5.12.2 Manual Mode

There are many manually operated valves associated with the thickener. The inlet from the

multimedia and GAC filter backwashes has a manual valve that is normally open during auto

mode since the filter feed pumps automatically pump to the thickener during multimedia filter



backwashing. This valve has a chain wheel actuator so that it can be operated from the floor

level. The inlet from the EBS tank is manually valved since transferring effluent from the EBS

tank for breaking up sludge is entirely manual. The four supernatant overflow lines have manual

valves with chain actuators so that the operator can open and close them from the floor. Refer to

the Decanting Thickeners SOP in Appendix A for specific operational procedures.

After all the solids from a storm event are processed and the thickener is empty, the operator

must flush the underflow lines between the bottom of the thickener and the filter press. This

action ensures that sludge inside these pipes does not accumulate and compact itself into

immovable plugs that prevent operation of the system during a subsequent storm event. To

accomplish this, the operator must manually open the valve from the EBS tank and partially fill

the thickener with treated effluent via the backwash feed pumps (P-401, P-402, P-403). This

water can then be run through the filter press, cleaning out those pipes in the process.

Each of the filter press feed pumps (P-305, P-306) can be throttled, isolated for maintenance, or

placed into service as needed by manually adjusting the valves located on the inlet and outlet of

each pump.

5.13 FILTER PRESS

The filter press is the primary dewatering device for sludge stored in the thickening tanks. It

allows the sludge to be dewatered from approximately 2% solids by weight to >50% solids by

weight. The press is a plate-and-frame type with a capacity of 50 cubic feet. It has no

connection to the system PLC; however, it has its own internal PLC to control each dewatering

cycle. The filter press is only operated when sufficient sludge has collected in the thickeners to

warrant a full load.

Sludge is pumped from the thickeners by the filter press feed pumps (P-305, P-306) and is

deposited into void spaces between the press plates. As the feed pumps continue to operate, the

pressure inside the plate void spaces increases and forces water out through the filter cloths and

into the filtrate piping. The press PLC automatically increases the pumping pressure in timed

stages throughout the cycle to maximize dewatering. Filter press filtrate is discharged back to

the process floor sump for retreatment through the system. At the end of the cycle, air is

automatically blown through the press core to remove any remaining solids or liquids. This

material is automatically directed to the clarifier sludge thickener (T-301A). When each

dewatering cycle is complete, the press plates are separated by the operator with the assistance of

a semiautomatic plate shifter, and the dry cakes fall into the rolloff box below. Prior to

transporting full rolloff boxes off-site, an additional dewatering step is taken. A small

submersible pump attached to a screened PVC tube is placed in the north side of the rolloff box

and used to pump out any remaining free water. Refer to the Filter Press SOP in Appendix A for

specific operating procedures.

5.14 AIR COMPRESSOR

The air compressor is fully automated and only communicates with the system PLC for

monitoring and alarm purposes. There is a set of contacts on the compressor control panel that



can transmit any one of 14 different alarm conditions to the main system PLC. When this

occurs, the PLC indicates an alarm condition on the GUI, and the MMI initiates the call-out

sequence. The alarm message on the GUI and MMI is “Compressor alarm condition.” The

alarm condition alerts the operator to the fact that the compressor is malfunctioning but does not

specify the problem. In order to troubleshoot, the operator must physically inspect the

compressor and its local control panel. Compressor pressure data is continuously transmitted to

the main system PLC. The PLC continuously transmits the data to the data PC and the MMI.

Trending charts can be generated by the office PC, with records of this data stored for the entire

operating history of the plant.



S E C T I O N 6 : P R O C E S S S T A R T / S T O P C O N D I T I O N S

Pump start/stop conditions are based on the original system programming by Frakes

Engineering. All system set points are listed in Table 2: Instrumentation Summary.

6.1 PROCESS FEED PUMPS

Start conditions for both 200-gpm (P-101, P-102) and 800-gpm (P-103, P-104) pumps:

1) SRS not low level by LE/LIT-200 or LSL-200F.

2) Clarifier not high level by LSH-100.

3) Filter feed tank not high level by LE/LIT-102 or LSH-103.

Stop conditions for both 200-gpm (P-101, P-102) and 800-gpm (P-103, P-104) pumps:

1) SRS low level by LE/LIT-200 or LSL-200F.

2) Clarifier high level by LSH-100.

3) Filter feed tank high level by LE/LIT-102 or LSH-103.

Start condition for only the 200-gpm (P-101, P-102) pump:

1) SRS level equal to or greater than LE/LIT-200 “on” set point for P-101 and P-102.

Stop condition for only the 200-gpm (P-101, P-102) pump:

1) SRS level equal to or less than LE/LIT-200 “off” set point for P-101 and P-102.

Start condition for only the 800-gpm (P-103, P-104) pump:

1) SRS level greater than or equal to LE/LIT-200 “on” set point for P-103 and P-104.

Stop condition for only the 800-gpm (P-103, P-104) pump:

1) SRS level equal to or less than LE/LIT-200 “off” set point for P-103 and P-104.

6.2 SRS STORAGE TANK PUMPS

Start conditions for lead and lag 2,500-gpm (P-201 – P-203) pumps:

1) SRS not low level by LE/LIT-200 or LSL-200F.

2) Lead pump starts at its LE/LIT-200 “on” set point.

3) Lag pump starts at its LE/LIT-200 “on” set point.



Stop conditions for lead and lag 2,500-gpm (P-201 – P-203) pumps:

1) SRS low level by LE/LIT-200 or LSL-200F.

2) Lag pump stops at its LE/LIT-200 “off” set point.

3) Lead pump stops at its LE/LIT-200 “off” set point.

Start condition for only the lead pump:

1) SRS level greater than or equal to LE/LIT-200 “on” set point.

Start condition for only the lag pump:

1) SRS level greater than or equal to LE/LIT-200 “on” set point.

6.3 FILTER FEED PUMPS

6.3.1 During Normal Operation

Start conditions for 300-gpm (P-105, P-106) and 900-gpm (P-107, P-108) pumps:

1) Filter feed tank not low level by LE/LIT-102 or LSL-103.

2) No GAC or multimedia filter vessels indicating high differential pressure.

3) EBS tank not high level by LE/LIT-400 or LSH-401.

Stop conditions for 300-gpm (P-105, P-106) and 900-gpm (P-107, P-108) pumps:

1) Filter feed tank low level by LE/LIT-102 or LSL-103.

2) GAC or multimedia filter vessels indicating high differential pressure.

3) EBS tank high level by LE/LIT-400 or LSH-401.

Start condition for only the 300-gpm (P-105, P-106) pumps:

1) Filter feed tank level greater than or equal to LE/LIT-102 “on” set point.

Stop condition for only the 300-gpm (P-105, P-106) pumps:

1) Filter feed tank level below LE/LIT-102 “off” set point.

Start condition for only the 900-gpm (P-107, P-108) pumps:

1) Filter feed tank level greater than or equal to LE/LIT-102 “on” set point.

Stop condition for only the 900-gpm (P-107, P-108) pumps:

1) Filter feed tank level below LE/LIT-102 “off” set point.



6.3.2 During Backwashing

Start condition for 300-gpm (P-105, P-106) and 900-gpm (P-107, P-108) pumps:

1) Filter feed tank not low level by LE/LIT-102 or LSL-103.

Stop condition for 300-gpm (P-105, P-106) and 900-gpm (P-107, P-108) pumps:

1) Filter feed tank low level by LE/LIT-102 or LSL-103.

Start conditions for multimedia filter backwashing:

1) Multimedia filter (T-103A-C) indicating high differential pressure.

2) 300-gpm filter feed pump (P-105 or P-106) in Auto.

3) 900-gpm filter feed pump (P-107 or P-108) in Auto.

4) Backwash feed pumps (P-401, P-402, P-403) in Auto.

5) EBS tank level greater than or equal to set point by LE/LIT-400.

6) Sludge thickener T-103B level less than or equal to set point by LE/LIT-302.

Stop conditions for multimedia filter backwashing:

1) 300-gpm filter feed pump (P-105 or P-106) not in Auto.

2) 900-gpm filter feed pump (P-107 or P-108) not in Auto.

3) Backwash feed pumps (P-401, P-402, P-403) not in Auto.

4) EBS tank level less than set point by LE/LIT-400.

5) Sludge thickener T-103B level greater than set point by LE/LIT-302.

6) Backwash process done.

“Backwash Process Done” conditions after 3 minutes:

1) Multimedia filter unit inlet valve closed.

2) Multimedia filter unit backwash valve opened.

3) Multimedia filter system discharge valve closed.

4) 300-gpm filter feed pump (P-105 or P-106) running.

5) 900-gpm filter feed pump (P-107 or P-108) running.

6.4 BACKWASH FEED PUMPS

Start conditions for P-401, P-402, P-403:

1) EBS tank not low level by LE/LIT-400 or LSL-401.

2) EBS tank level greater than or equal to set point by LE/LIT-400.


4) Filter feed tank less than or equal to set point by LE/LIT-102.



Stop conditions for P-401, P-402, P-403:

1) EBS tank low level by LE/LIT-400 or LSL-401.

2) EBS tank level less than set point by LE/LIT-400.


4) Filter feed tank level greater than set point by LE/LIT-102.

6.5 PROCESS WATER SUMP PUMP

Start conditions for P-309, P-310:


2) Filter feed tank level less than or equal to set point by LE/LIT-102.

3) Sump high level by LSH-300.

4) Sump high-high level by LSHH-300.

Stop conditions for P-309, P-310:


2) Filter feed tank level greater than set point by LE/LIT-102.

3) Sump low level by LSL-300.

4) Sump low level by LSLL-300.



S E C T I O N 7 : P R O C E S S A L A R M R E S P O N S E

The PLC receives and transmits the date, time, and description of alarm conditions to the data PC

and the MMI. Reports can be generated from the office PC for review and printing. During

alarm conditions, the MMI calls the operator (via the preprogrammed call list) to relay alarm

conditions and initiate response. If the operator is unavailable, the backup operator is called. If

the backup operator is unavailable, the tertiary operator is called and the cycle repeats until the

alarm is acknowledged. All alarm conditions, set points, and resulting actions are presented in

Table 3.



S E C T I O N 8 : S T A N D A R D O P E R A T I N G P R O C E D U R E S

Standard operating procedures have been developed for the system over the past several years.

The SOPs are intended to supplement equipment manufacturer manuals included in Volumes II –

X of this O&M plan. The SOPs address both routine operations (filter press, carbon vessel

backwashing, etc.) as well as nonroutine maintenance activities (SRS cleaning, SRS pump

removal/installation, etc.). All current SOPs are included in Appendix A; additional SOPs are

added as they are developed. These SOPs are also intended to serve as BMPs required by

applicable Indiana NPDES regulations.



S E C T I O N 9 : S A M P L I N G A N D A N A L Y S I S

9.1 SAMPLING

All samples collected from the treatment system fall into one of two categories: government-

required samples that are reported to USEPA on a regular basis, and operational samples that are

used by the operator to evaluate system performance and troubleshoot when necessary.

9.1.1 Governmental Parameters

Effluent samples are collected weekly for PCB analysis by an outside contract laboratory. In

addition, an effluent sample is collected monthly for TSS analysis, which is performed by the

operator in the treatment building lab.

Sludge sampling is conducted at two locations to ensure proper characterization for disposal.

Samples are collected from the thickener tanks and are analyzed by an outside laboratory for

PCB content. This allows for accurate characterization under TSCA regulations, since the

samples are collected prior to the addition of lime (used as a dewatering aid for the filter press).

Composite samples of filter cake are also collected from the roll-off box after dewatering in the

filter press and are analyzed for RCRA parameters prior to transport.

9.1.2 Operational Parameters

Operational parameters that are analyzed for each effluent sample include turbidity, temperature,

pH, dissolved oxygen (DO), and conductivity. These parameters help the operator evaluate

system operation and also provide a basis for system troubleshooting when necessary.

Additional PCB samples may be collected during major storm events to evaluate the

effectiveness of individual system components. Sample ports are located on the inlet and outlet

sides of all major system components. Wipe and solid PCB samples can also be collected at the

operator’s discretion.

Refer to the system P&IDs in Appendix C for the locations of all sample ports.

9.1.3 Methods

For all sampling events, the operator performs the manual flow calculation previously described

to determine the influent flow rate. In addition, effluent flow meters from both the PTS and the

EFTS are used to determine daily totals (gallons) of water treated through the system. When the

operator prepares summary reports of analytical data for submission to USEPA, the influent flow

rate and the daily treated volumes are always included. This allows flows to be taken into

consideration when evaluating effluent results.

9.1.3.1 Sample Collection, Preservation, and Decontamination Procedures

Effluent samples are collected from the Parshall flume prior to discharge from the PTS or from

other sample ports during troubleshooting as necessary. Collected samples are placed into



properly prepared sample bottles. All sample collection procedures are in accordance with Part

1060 of the 22nd edition of “Standard Methods for the Examination of Water and Wastewater”.

For personal protection equipment requirements during sampling, refer to the latest Master

Health and Safety Plan for the facility. Except for the automated sampler, all sampling

equipment comprises dedicated or disposable materials. Where decontamination is required, the

appropriate protocols are followed as specified by the Health & Safety Plan or by common

industry standards.

9.1.3.2 Sample Labeling Procedures

The outside of each container is wiped clean and allowed to dry after sample collection. Legible,

complete, and securely attached labels are placed on each sample container at the time of

collection. The sample label includes the following information:

• Sample identification (sample location)

• Name or initials of sampler

• Date and time of collection

• Site identification

• Preservation technique

Waterproof writing utensils are used to avoid running or smearing of label information. The

operator gives each sample a unique identification (i.e., sample ID) that contains information

about both the location and date of sampling.

9.1.3.3 Sample Storage and Shipment

Upon sample collection and preservation, the filled sample containers are packed into a cooler of

sturdy construction or transferred to the site refrigerator until they are picked up for shipment

and analysis. For shipping purposes, the samples are packed to protect against damage and iced

to maintain samples at or near 4°C. Due to the potential for breakage during transportation,

samples are shipped with a duplicate for analysis if problems occur with the initial sample.

9.1.3.4 Field Chain-of-Custody Procedures

Possession of samples from the time of collection through delivery to the laboratory is

documented by a chain-of-custody (COC) form. The original COC follows the samples with

copies maintained indefinitely at the site or as otherwise directed by USEPA. Information

contained on the COC will include sample name/location, sampling date and time, analysis to be

performed, preservation methods, analytical laboratory, and any other information pertinent to

the sampling event.

9.2 ANALYSIS

All outside lab analyses are performed using the latest edition of “Standard Methods for the

Examination of Water and Wastewater” or as listed in 40 CFR 136.3, Appendix A. The lab is

responsible for the receipt, log-in, and storage of all client samples. Each sample is labeled with



a unique number that is entered into the sample receiving log system. The samples are placed

into appropriate storage within an access-controlled location. All samples are to be maintained

under proper storage conditions for 30 days past generation of the analytical report.

TSS analysis is performed by the operator in the treatment building laboratory using appropriate

standard methods.

In-house laboratory analyses, including pH, DO, turbidity, temperature, and conductivity, are

performed using a single or a multi-parameter probe. Manufacturer’s instructions are followed

explicitly for proper use and calibration of this equipment. Except for continuous reading

monitors, the probes and/or sensors are calibrated prior to use. DO is corrected for temperature

and pressure. Temperature is measured with a non-mercury thermometer. pH measurements are

corrected for temperature and the pH meters are calibrated with two reference buffer solutions.

Instrument calibrations are recorded and maintained on-file.

The analytical data is reviewed for possible errors and inconsistencies, with quality

assurance/quality control (QA/QC) data reviewed as needed. Analytical data (both in-house and

laboratory-generated data) is maintained on site and forwarded to USEPA on a regular basis as

required. The operators use all analytical data to evaluate and optimize the performance of the

treatment system. This data is also used to identify potential system improvements.

9.3 SAMPLE PARAMETERS AND POTENTIAL LOCATIONS

The following sections outline the importance of each parameter analyzed as well as the benefits

of collecting samples at specific locations for troubleshooting purposes.

9.3.1 PCBs and TSS

PCB and TSS data is important for the following reasons:

1) Verify PCB levels meet effluent standards;

2) Evaluate the performance of individual unit processes;

3) Perform mass balance calculations to understand how PCBs and TSS move through the

system;

4) Understand how storm events and ICS influent flow rates affect system performance;

5) Estimate current and future solids handling needs and disposal costs; and

6) Estimate future GAC use rates and replacement costs.

7) Provide characterization of sludge for disposal in accordance with TSCA regulations.

The following is a summary of potential sampling locations and their benefits:



Building Influent

• Compare against final effluent data to evaluate overall system performance.

• Determine the effect of storm events and ICS influent flow on effluent results.

• Determine how concentrations vary during storm events.

• Confirm concentrations present at low-flow conditions and evaluate trends.

Clarifier Effluent

• Compare against building influent data to evaluate the effectiveness of the clarifier.

Multimedia Filter Effluent

• Compare against clarifier effluent data to evaluate the effectiveness of the multimedia

filters.

Bag Filter Effluent (also PTS GAC Influent)

• Compare against multimedia filter effluent data to evaluate the effectiveness of the bag

filters.

EFTS GAC Influent (at EFTS Receiving Tank)

• Allow for evaluation of GAC vessel effectiveness.

GAC Vessel Effluent (PTS or EFTS)

• Compare against GAC influent data to evaluate the effectiveness of the GAC vessel.

• Gauge when backwash of units may be required.

• Gauge when carbon is losing effectiveness and needs to be changed out.

Thickener Tanks (Sludge)

• Provide characterization for proper disposal under TSCA regulations.

9.3.2 TSS Only

Clarifier Influent

• Determine influent solids loading and concentration to the PTS.

Clarifier Sludge Outlet to Thickener (T-301A)

• Compare against clarifier influent data to evaluate the effectiveness of the clarifier.

Thickener Supernatant

• Compare against various thickener inflow data to evaluate settling efficiency.



SRS Storage Tank Influent, Under Drain, and Overflow (EFTS Influent at Receiving Tank)

• Evaluate solids settling effectiveness of the storage tanks.

Carbon Vessel Backwash

• Determine solids loading removed by GAC vessels.

Multimedia Filter Backwash

• Determine solids loading removed by multimedia filters.

9.3.3 DO

PTS Effluent

• DO is a measured parameter of system influent. Although DO is not believed to have

any significant influence on system operations, testing the effluent and comparing it

against influent levels can determine if treatment results in any significant oxygen

depletion that could affect aquatic life at the outfall.

9.3.4 pH

PTS Effluent

• pH is a measured parameter of system influent. Although pH is not anticipated to change

significantly during treatment, testing the effluent pH can be done to ensure it is within

the proper pH range for aquatic life downstream.

9.3.5 Turbidity and Conductivity

Turbidity and conductivity are good indicators of the water source (i.e. groundwater or runoff).

These parameters can also be used as a marker or indicator of PCB concentrations, which allows

the operator to proactively manage system operation during storm events.

9.3.6 Temperature

Temperature may be measured at all of the sample locations listed. This can show how

temperature changes affect the treatment process at various stages and assist with

troubleshooting problems.

9.3.7 Percent Moisture Content

Filter Cake

• Evaluate effectiveness of the filter press.

• Determine appropriate filter cake management requirements.

• Minimize offsite disposal volume of filter cake by optimizing solids content.



9.3.8 Particle Size Distribution

• Determine the particle sizes that comprise TSS for troubleshooting.

• Determine how storm water flows affect particle size distribution. This could potentially

improve treatment system performance during storm events.

• Provide estimates of settling rates.



S E C T I O N 10 : E Q U I P M E N T M A I N T E N A N C E

This section summarizes recommendations for spare parts to keep on site and also

recommendations for routine preventative maintenance to be performed on the equipment.

10.1 SYSTEM COMPONENT CONTACTS

There may be instances when the operator cannot address a specific equipment malfunction,

even after review of the appropriate manufacturer manuals. Table 4 was compiled to provide a

system component contact list. The specified contact should be able to help resolve any

component problems in order to minimize potential system downtime.

10.2 SPARE PARTS

Refer to Table 5 for a list of spare parts originally developed by Earth Tech. The list was

intended to focus on parts that have a high potential for failure based on equipment vendor

manuals and guidance. Spare parts are generally stored on site when normal use typically causes

failure (e.g., filters bags), when failure would cause critical system components to be inoperable,

or when acquisition of a new part would take a long period of time. The presence of functional

backups for most process equipment is also taken into account when deciding whether or not to

stock certain spare parts. Critical spare parts are stored on site in an organized location and are

inventoried periodically.

10.3 PREVENTATIVE MAINTENANCE

An effective preventive maintenance program maximizes equipment reliability, increases

equipment life, and minimizes repair costs. Table 6 contains manufacturer-recommended

preventive maintenance schedules for major system components. The maintenance schedule

specifies all the recommended maintenance required to keep the equipment in good operating

condition. A permanent record is kept for all equipment inspections and maintenance. A backup

copy of this record is stored at the PSARA Bloomington office.



S E C T I O N 11 : R E P O R T I N G R E Q U I R E M E N T S

11.1 ROUTINE REPORTING

Routine reporting currently consists of a monthly summary report submitted to USEPA. The

report summarizes all critical data for the month, including:

• Precipitation amounts (monthly total and daily maximum);

• Volume of water treated (monthly total and average monthly flow rate);

• Weekly effluent sample PCB results (with volume of water treated on each sample date

and average flow rate for those days); and

• Summary of system O&M activities for the month.

11.2 NONROUTINE REPORTING

In the event of a nonroutine condition (system upset/bypass, effluent limit exceedance, etc.), the

operator notifies the Bloomington Branch Manager of PSARA Technologies and CBS

immediately. Appropriate information/data is compiled and evaluated to confirm the incident.

After confirmation, CBS provides an initial notification to USEPA immediately. A detailed

investigation of the incident is initiated and results are verbally reported to USEPA as they

become available. In addition, a summary written report is submitted to USEPA to address

potential causes and corrective actions. Any necessary follow-up actions are specified by

USEPA and are implemented as soon as possible.



S E C T I O N 12 : C O N T I N G E N C Y P L A N S

A comprehensive contingency plan is not required for the site; however, provisions have been

made for addressing various emergencies. Provisions have also been made for system bypass or

upset conditions that could recontaminate previously remediated areas.

12.1 FIRE AND SECURITY

The treatment system building is equipped with a fire alarm system. Smoke detectors are

strategically located throughout the building and are connected to the main control panel. The

fire alarm system is connected to a dedicated phone line for automatic call-out of alarm

conditions to both the operator and the Bloomington Fire Department. A private security

company monitors the system and performs a complete inspection annually.

The treatment building is surrounded by chain-link fencing with an entrance gate that is kept

closed and locked when the operator is not present. In addition, the SRS and treatment buildings

are kept closed and locked when the operator is not present.

12.2 EMERGENCY RESPONSE

Emergency response guidance was developed for the site by EFS, the original contract operating

company. This guidance addresses various emergencies and provides specific response

procedures. The operator was trained by EFS on these procedures, and they are still in use. A

copy of this guidance is maintained on file at the ICSTF building.

12.3 SYSTEM UPSET/BYPASS

In the event of a major system upset or bypass that causes untreated water to come into contact

with any area outside of the ICSTF buildings, USEPA will be notified immediately per Section

11.2 of this plan. Soil/sediment sampling will be conducted to determine if PCBs have

recontaminated the affected areas to levels exceeding the applicable cleanup criteria. CBS will

develop and submit a Sampling and Analysis Plan (SAP) for evaluating the affected areas. Upon

approval of the SAP, CBS will conduct the necessary sampling and submit a report of findings to

USEPA. In the event that PCB levels are found to exceed the applicable cleanup criteria,

USEPA will determine whether or not additional cleanup actions are necessary.



S E C T I O N 13 : A S - B U I L T R E C O R D D R A W I N G S

The as-built record drawings for the PTS and EFTS are maintained in the ICSTF building. The

drawings are annotated as necessary to note any significant changes, revisions, or corrections.

As-built sump and tank sketches, originally prepared by Earth Tech, are included in Appendix B

of this plan. System P&IDs are included in Appendix C of this plan for reference purposes.

Item Input Description Input Address Scaling Alarm Setpoints

16 Multi Media FilterFlowrate (FIT-103) I:5.3 0 to 1200 GPM

----------

----------

----------

15 Turbidity Meter(AIT-200) I:5.2 0 to 1000 NTU

14Tank T201 & T202

UnderdrainFlowrate (FIT-201)

I:5.1 0 to 2000 GPM

----------

12 Bag Filter 104BPressure (PIT-104B)

13 SpareInput I:5.0 Spare

I:4.3 0 to 75 PSI

High Alarm = 45 PSI

----------

----------

11 Bag Filter 104APressure (PIT-104A) I:4.2 0 to 75 PSI

10 Media Filter 103CPressure (PIT-103C) I:4.1 0 to 75 PSI

High Alarm = 45 PSI

8 Pump 201, 202 & 203Flowrate (FIT-200)

9 Media Filter 103BPressure (PIT-103B) I:4.0 0 to 75 PSI

I:3.3 0 to 5,500 GPM

High Alarm = 15.5 ftLow Alarm = 3.0 ft


----------

7Sludge Thickener

Tank-1Level (LIT-301)

I:3.2 0 to 10.0 Feet

6 Backwash TankLevel (LIT-400) I:3.1 0 to 15.0 Feet


4 SRS Influent Flow(FIT-000)

5 Filter Feed TankLevel (LIT-102) I:3.0 0 to 8.0 Feet

I:2.3 0 to 8000 GPM

High Alarm = 30.6 ft

High Alarm = 30.6 ft

----------

3 Storage Tank T202Level (LIT-202) I:2.2 0 to 31.5 Feet

2 Storage Tank T201Level (LIT-201) I:2.1 0 to 31.5 Feet

PLC Analog Inputs

1 Spring ReceivingSump Level (LIT-200) I:2.0 0 to 12.0 Feet High Alarm = 11.0 ft

Low Alarm = 0.8 ft

Illinios Central SpringFlow Treatment System

Table 2: Instrumentation Summary

1 of 11


PLC Analog Inputs




----------

----------

----------

31Feed Pumps101 & 102

Flowrate In (FIT-100)I:9.2 0 to 225 GPM

30Feed Pumps103 & 104

Flowrate In (FIT-101)I:9.1 0 to 900 GPM

----------

28Clarifier Output

Sludge Flow(FIT-300)


I:8.3 0 to 225 GPM

High Alarm = 35 PSI

High Alarm = 35 PSI

----------

27 GAC Filter 105BPressure (PIT-105B) I:8.2 0 to 75 PSI

26 GAC Filter 105APressure (PIT-105A) I:8.1 0 to 75 PSI

----------

24 Media Filter 103APressure (PIT-103A)

25Storage Tank

Feed Pump HeaderPressure (PIT-200)

I:8.0 0 to 60 PSI

I:7.3 0 to 75 PSI


----------

High Alarm = 45 PSI

23 Input Pressure toClarifier (PIT-100) I:7.2 0 to 40 PSI

22Sludge Thickener

Tank-2Level (LIT-302)

I:7.1 0 to 8.0 Feet

----------

20 SpareInput

21 Parshall FlumeFlowrate (FIT-102) I:7.0 0 to 4000 GPM

I:6.3 Spare

----------

----------

----------


18 Backwash WaterFlowrate (FIT-400) I:6.1 0 to 2000 GPM

----------17 SpareInput I:6.0 Spare

2 of 11


PLC Analog Inputs





33Process Water Sump

PumpFlowrate (FIT-301)

I:10.0 0 to 225 GPM

Comments

Signature: Date:

36 SpareInput I:10.3 Spare ----------

----------

----------

----------

3 of 11

Item Input Description Input Address Device Alarm Setpoints

7

8

9

10

11

12

2

4

5

6

13

15

16

14

Process Water FloorSump Low Low Level I:13/14

Process Water FloorSump Low Level I:13/15

Level Switch(LSLL-300)

6 in. abovepump intake **

12 in. abovepump intake **

Waste WaterSump High Level I:13/13 Level Switch

(LSH-500)

3 in. above top ofoverflow pipe **

----------

invert of sanitarysewer discharge **

SpareInput I:13/12

SpareInput I:13/10

Backwash TankHigh Level I:13/11

---------- ----------

Filter Feed TankHigh Level I:13/9

Filter Feed TankLow Level I:13/8 Level Switch

(LSL-103)

Level Switch(LSH-103)


SpareInput

Tank #104A HighDifferential Pressure I:13/7

I:13/6 ----------

Pressure Differential SwitchPDSH/PDI-101

----------

30 in. wc

ClarifierHigh Level I:13/4

SpareInput I:13/5

Level Switch(LSH-100F)

----------


----------

Waste WaterSump High High Level I:13/2

I:13/3

Level Switch(LSHH-500)

----------

Digital Inputs

1

3

SpareInput

Spring ReceivingSump Low Level I:13/0

Spring ReceivingSump High Level I:13/1



Level Switch(LSL-200F)

Level Switch(LSH-200F)

6 in. above top ofdischarge pipe **

Level Switch(LSL-300)

Level Switch(LSH-401)

----------

6 in. above pump intakes **

at bottom of overflow weir **

invert of overflowpipe to SRS **

----------

4 of 11


Digital Inputs



17 Process Water FloorSump High Level I:14/0 6 in. below

invert of overflow **Level Switch(LSH-300)

invert of overflowpipe to SRS **

----------

----------

----------

18 Process Water FloorSump High High Level I:14/1 Level Switch

(LSHH-300)

I:14/3 Digital input fromcompressor controller

19 SpareInput I:14/2 ----------

----------

21 Incomming ControlPower Lost I:14/4 Digital input from

control relay ----------

20 Air CompressorFault

23 Backwash TankLow Level I:14/6 Level Switch

(LSL-401)6 in. above top ofdischarge pipe **

22 SpareInput I:14/5

24 Tank #104B HighDifferential Pressure I:14/7 Pressure Differential Switch

PDSH/PDI-102

25 in. wc

25 Sludge ThickenerTank-1 High Level I:14/8 Level Switch

(LSH-301F)

30 in. wc

6 in. above overflowweir of tank **

6 in. above overflowweir of tank **

26 Tank #103C HighDifferential Pressure

27 Sludge ThickenerTank-2 High Level I:14/10 Level Switch

(LSH-302)

I:14/7 Pressure Differential SwitchPDSH/PDI-100

28 SpareInput I:14/11 ----------

----------

29 SpareInput I:14/12 ----------

----------

----------

----------

30 SpareInput

31 SpareInput I:14/14 ----------

I:14/13 ----------

32 SpareInput I:14/15 ---------- ----------

5 of 11


Digital Inputs



33 Pump 201Running I:15/0 Digital input

from field

----------

----------

----------

----------

35 Pump 203Running


from field

I:15/2 Digital inputfrom field


from field

18 in. wc

38 Tank #105A1 HighDifferential Pressure I:15/5 Pressure Differential Switch

PDSH/PDI-105

----------

18 in. wc

18 in. wc

39 Tank #105B1 HighDifferential Pressure

40 Tank #105A2 HighDifferential Pressure I:15/7 Pressure Differential Switch

PDSH/PDI-106

I:15/6 Pressure Differential SwitchPDSH/PDI-103

41 Tank #105B2 HighDifferential Pressure I:15/8 Pressure Differential Switch

PDSH/PDI-104

25 in. wc

42 Tank #103B HighDifferential Pressure I:15/9 Pressure Differential Switch

PDSH/PDI-107

18 in. wc

25 in. wc

I:15/11 Digital inputfrom field

I:15/10 Pressure Differential SwitchPDSH/PDI-10843 Tank #103A High

Differential Pressure

44 Running onGenerator Power

----------

----------

----------

Digital inputfrom field

SpareInput I:15/13 ----------

----------

48 SpareInput I:15/15 ---------- ----------

47 SpareInput I:15/14 ----------

46


from field

45 IncommingPower On I:15/12

6 of 11


Digital Inputs



51

52

53

61

62

49

58

59

60

54

55

56

57

---------- ----------

I:16/14SpareInput

Limit switchon valve V107


----------

Switch closes whenvalve is full open

Switch closes whenvalve is full closed

I:16/11T103C BackwashValve Closed

T103C BackwashValve Open I:16/10 Limit switch

on valve V102Switch closes when

valve is full open



64

Filter OutputValve Open I:16/12

SpareInput I:16/15

63

I:16/13Filter OutputValve Closed

T103C InputValve Open I:16/8

I:16/9





T103C InputValve Closed

I:16/7T103B BackwashValve Closed





I:16/5T103B InputValve Closed





T103A BackwashValve Closed I:16/3



T103A InputValve Open I:16/0 Switch closes when

valve is full open




Switch closes whenvalve is full closed50 T103A Input

Valve Closed I:16/1 Limit switchon valve V105

----------

T103A BackwashValve Open I:16/2

T103B InputValve Open I:16/4

T103B BackwashValve Open I:16/6

7 of 11


Digital Inputs



Signature: Date:

Comments

developed by the original engineer. Actual lnstallation of each level switch cannot be determined from within the PLC code.

** Actual installation elevation for all level switches must be field verified. This document references what was stated in the spread sheet

8 of 11

Item Pump Description Pump Tag No. Control Description

15 Filter Pumps P-105 & P-106Backwashing

Pump OnPump Off

14 Filter Pumps P-105 & P-106P-107 & P-108

OK to ActivateFilter Pumps

12

13 Filter Pumps P-105 & P-106P-107 & P-108 Filter Feed Tank Level OK

11 Clarifier Sludge Pumps P-301 & P-302 Timer Mode: Off SetpointTimer Mode: On Setpoint

10 Clarifier Sludge Pumps P-301 & P-302 OK to ActivateSludge Pumps

P-201 & P-202P-203

Lag Pump OnLag Pump Off8 Storage Tank Feed

Pumps

9

7 Storage Tank Feed Pumps

P-201 & P-202P-203

Lead Pump OnLead Pump Off

6 Storage Tank Feed Pumps

P-201 & P-202P-203

OK to Activate StorageTank Feed Pumps

P-103 & P-104 Pump OnPump Off4 Process Feed Pumps

5

5.0 ft1.0 ft

6.0 ft1.75 ft

1.) Incoming power is on2.) Clarifier not High Level3.) Filter Feed Tank less than 6.9 ft.4.) Filter Feed Tank not High Level

1.) Incoming power is on2.) Spring Receiving Sump Level OK

7.0 ft2.25 ft

8.0 ft2.75 ft

1.) Sludge Thickener Tank-1 not High Level2.) Sludge Thickener Tank-1 less than 9.0 ft.

3 Process Feed Pumps P-101 & P-102 Pump OnPump Off

2 Process Feed Pumps P-101 & P-102P-103 & P-104

OK to Activate ProcessFeed Pumps

Pump Control

1 Process Feed Pumps P-101 & P-102P-103 & P-104 Spring Receiving Sump Level OK

Setpoint / Condition

1.) Not Low Level2.) Level greater than 0.8 ft.

Illinios Central SpringExcess Flow Treatment System


240 minutes15 minutes


1.) Filter Feed Tank not Low Level2.) Backwash Tank less that 15.5 ft.3.) Backwash Tank not High Level4.) GAC Tank not high Differential Pressure

6.0 ft3.75 ft

9 of 11


Pump ControlSetpoint / Condition



30

28

29

27 Sump Pumps P-309 & P-310 Pump Off

26 Sump Pumps P-309 & P-310 Pump On

P-309 & P-310 OK to ActivateSump Pumps

24

25 Sump Pumps

23 Backwash Pumps P-401 & P-402P-403 Pump Sequence selected by operator

22 Backwash Pumps P-401 & P-402P-403 Pump Off

P-401 & P-402P-403 Pump On

P-401 & P-402P-403

OK to ActivateBackwash Pumps20 Backwash Pumps

21 Backwash Pumps

19 Backwash Pumps P-105 & P-106P-107 & P-108 Backwash Tank Level OK

18

P-107 & P-108 Pump OnPump Off

P-105 & P-106Not Backwashing

Pump OnPump Off

16 Filter Pumps

17 Filter Pumps

1.) Filter Feed Tank not less than 4.0 ft.and

2.) Backwash Tank Level greater than 6.0 ft.

8.0 ft2.75 ft


1.) P-101, 102, 103, 104 not Running2.) Filter Feed Tank not High Level.3.) Backwash Tank Level OK4.) Incoming Power is On

1.) Filter Feed Tank not greater than 6.5 ft.or

2.) Backwash Tank Level less than 3.0 ft.

1 = 1-2-32 = 2,3,13 = 3,1,2

1.) Filter Feed Tank greater than 6.9 ft.or

2.) Process Water Sump Low Level.

1.) Incoming power is on2.) Filter Feed Tank less than 6.5 ft.3.) Filter Feed Tank not High Level

1.) Filter Feed Tank less than 7.0 ft.and

2.) Process Water Sump not High Level.

5.75 ft2.0 ft

10 of 11


Pump ControlSetpoint / Condition



Comments

Signature: Date:

32

31

11 of 11

TABLE 3

ICS ALARMS LIST

HMI ALARM

IDENTIFIER

ICS TREATMENT SYSTEM

ALARM DESCRIPTION

ALARM

SETPOINT

ACTIVATE

ALARM HORN

ACTIVATE

ALARM LIGHT

CALL OUT

ON WIN-911

1 PROCESS FEED PUMP #101 FAILURE x x




5 STORAGE TANK FEED PUMP #201 FAILURE x x



8 FILTER FEED PUMP #105 FAILURE x x




12 BACKWASH FEED PUMP #401 FAILURE x x


14 PROCESS WATER SUMP PUMP #309 FAILURE x x

15 PROCESS WATER SUMP PUMP #310 FAILURE x x

16 BACKWASH FAILURE x x

17 GAC FILTER #105A HIGH PRESSURE 35 psi x x x

18 GAC FILTER #105B HIGH PRESSURE 35 psi x x x

19 SPRING RECEIVING SUMP LOW LEVEL x x x

20 SPRING RECEIVING SUMP HIGH LEVEL x x x

21 PIT-104A FAILURE x x

24 STORAGE TANKS HIGH LEVEL 30.6 ft or 31.2 ft x x x

25 EFFLUENT/BACKWASH TANK LOW LEVEL 3.0 ft x x x

26 EFFLUENT/BACKWASH TANK HIGH LEVEL 15.5 ft x x x

27 FILTER FEED TANK LOW LEVEL 1.25 ft x x x

28 FILTER FEED TANK HIGH LEVEL 6.9 ft x x x

29 WASTE WATER SUMP HIGH HIGH LEVEL x x x

30 CLARIFIER TANK HIGH LEVEL x x x

31 SLUDGE THICKENING TANK #1 LOW LEVEL 0.0 ft x

32 SLUDGE THICKENING TANK #1 HIGH LEVEL 9.0 ft x x x

33 SLUDGE THICKENING TANK #2 LOW LEVEL 0.0 ft x

34 SLUDGE THICKENING TANK #2 HIGH LEVEL 7.0 ft x x x

35 PUMP #101 AND #102 FAILURE x x x


37 PROCESS WATER FLOOR SUMP LOW LOW LEVEL x x x

38 STORAGE TANKS PUMPS ALL IN ALARM x x x

39 PROCESS WATER FLOOR SUMP HIGH HIGH LEVEL x x x


41 AIR COMPRESSOR ALARM x x

42 CONTROL POWER LOST x x x

43 BAG FILTER A HIGH DIFFERENTIAL PRESSURE x x x

44 BAG FILTER B HIGH DIFFERENTIAL PRESSURE x x x

45 SAND FILTER C HIGH PRESSURE 45 psi x x

46 SAND FILTER B HIGH PRESSURE 45 psi x x

47 SAND FILTER A HIGH PRESSURE 45 psi x x

48 GAC FILTER A1 HIGH PRESSURE x x x

49 GAC FILTER A2 HIGH PRESSURE x x x

50 GAC FILTER B1 HIGH PRESSURE x x x

51 GAC FILTER B2 HIGH PRESSURE x x x

52 VALVE #101 FAILURE x x x





Table 3: ICS Alarm List 1 of 2 May 2013

TABLE 3

ICS ALARMS LIST

HMI ALARM

IDENTIFIER

ICS TREATMENT SYSTEM

ALARM DESCRIPTION

ALARM

SETPOINT

ACTIVATE

ALARM HORN

ACTIVATE

ALARM LIGHT

CALL OUT

ON WIN-911



59 LIT-200 FAILURE x x x







66 FIT-200 FAILURE x x

67 PIT-103B FAILURE x x

68 PIT-103C FAILURE x x




73 AIT-200 FAILURE x x






79 PIT-100 FAILURE x x


81 PIT-200 FAILURE x x






87 SPRING RECEIVING SUMP FLOAT ALARM x x

88 WASTEWATER FLOOR SUMP FLOAT PROBLEM x x

89 FILTER FEED TANK FLOAT PROBLEM x x

90 BACKWASH TANK FLOAT PROBLEM x x

91 PROCESS WATER SUMP FLOAT PROBLEM x x

92 PUMP #107 AND PUMP #108 FAILURE x x x

93 PUMP #401 AND PUMP #402 AND PUMP #403 FAILURE x x x

94 GENERATOR ACTIVATED x x

97 CONTROL VALVE #206 MALFUNCTION x x x


Table 3: ICS Alarm List 2 of 2 May 2013

TABLE 4

SYSTEM COMPONENT CONTACTS

SYSTEM COMPONENTS COMPANY CONTACT(S) PHONE/MOBILE/FAX ADDRESS

Electrical Components A1 ElectRicks, Inc Rick Crouch (812) 332-6951

(812) 325-4737

P.O. Box 6462

Bloomington. IN 47407

Mechanical Components Bowen Engineering Corp. Jon Rauschkolb

Ron Hutchins

(317) 842-2626

(317) 841-4257

10315 Allisonville Rd.

Fishers, IN 46038

Yard Piping/ Site Work Crider & Crider Contractors Brad Bredeweg (812) 336-4452

(812) 287-2317

1900 Liberty Drive

Bloomington, IN 47403

Building Earth Tech, Inc. Chris Wilson (616) 975-4647

(616) 940-4397

5555 Glenwood Hills Parkway SE

Grand Rapids, MI 49588

Process Controls Frakes Engineering Dave Bash (317) 577-3000 ext 259

(317) 577-3005

7950 Castleway Drive, Suite 160

Indianapolis, In 46250

Clarifier Enprotec Don Bzdyl (606) 689-4300

(606) 689-4322

4465 Limaburg Rd.

Hebron, KY 41084

Multi-Media Filters Enprotec Don Bzdyl (606) 689-4300

(606) 689-4322

4465 Limaburg Rd.

Hebron, KY 41084

Bag Filters Werner-Todd Pump Company Mike Brown (317) 875-6900

(317) 452-4331

5381 West 86th Street


Carbon Adsorbers Calgon Corporation Ken McGuire

Vince Lamberti

(412) 787-5692

(412) 787-6749

400 Calgon Carbon Drive

Pittsburgh, PA 15205

Vertical Turbine Pumps BBC Pump & Equipment Jack Tinder (317) 636-1111

(317) 636-5467

1125, W. 16th St., P.O. Box 22098

Indianapolis, IN 46222

End Suction Centrifugal Pumps Werner-Todd Pump Company Mike Brown (317) 875-6900

(317) 452-4331



Filter Press US Filter JWI Scott Hardy (765) 737-6260

(317) 501-7128

11057 Allisonville Rd. #333


Air Compressor/ Air Dryer Tri State Compressor Air Systems (219) 533-8671

(219) 533-0711

1309 Eisenhower Drive South

Goshen, In 46526

Process Valves Bertsch Company Dan Foster (616) 452-3251

(616) 452-3707

1655 Steele, SW

Grand Rapids, MI 49507

Flow Meters/ Ultrasonic Level

Devices

Endress& Hauser Sara Croucher (317) 535-7138

(317) 835-8498

2350 Endress Place

Greenwood, IN 46143

Large Storage Tanks Kennedy Tank an d Manufacturing

Company

Brian Lunsford (317) 780-3544 833 East Sumner Avenue

Indianapolis, Indiana 46227

Filter Feed Tank Colombian Steel Tank Company Dave Davis

Curtis Crabtree

(913) 621-3700

(913) 621-2145

5400 Kansas Ave., P.O. Box 2907

Kansas City, Kansas 66110

Effluent/ Backwash Supply Tank Colombian Steel Tank Company Dave Davis

Curtis Crabtree

(913) 621-3700

(913) 621-2145

5400 Kansas Ave., P.O. Box 2907

Kansas City, Kansas 66110

Thickener Tanks Pekay Specialty Contracting, Inc. Jim Woelfel (920) 439-1001

(920) 439-1002

112 N. Military Rd., P.O. Box 266

Stockbridge, WI 53088

Emergency Generator McAllister Machinery Co., Inc. Marvin Barkes (317) 543-0405/

(317) 543-0433

7515 E. 30th Street

Indianapolis, IN 46219

Filter Press Feed Pumps Werner-Todd Pump Company Mike Brown (317) 875-6900

(317) 452-4331



TABLE 5

EQUIPMENT MAINTENANCE - SPARE PARTS LIST

SYSTEM EQUIPMENT EQUIPMENT SPARE PARTS LIST

PART

FAILURE =

SHUT

DOWN? Y/N

REPLACEMENT

SCHEDULE

SHUT DOWN

REQUIRED TO

REPLACE PART

TIME

REQUIRED TO

REPLACE

PART

PART

AVAILABILITY/

DELIVERY

SCHEDULE

STOCK QUANTITY

RECOMMENDED

BY COMPANY

MODEL #/

PART #

ORDERING INFORMATION /

CONTACT

Wet End Kit for pump model # EB2SM, TB3A N As needed N D / 3 weeks 1 476.065.360 Contact Don Bzdyl

CLARIFIER Air End Kit for pump model # EB3SM, TB3A N As needed N A 1 476.102.000 at: (606) 689-4300

Enprotec J600 3/4 Solenoid Valve for Air Station Y As needed Y A 1 8210G095

MULTI-MEDIA TRIAC ET 1300 120V Electric Actuator for 8" Actuated

ValveY As needed N* D / 1-3 weeks 1 already on site

Contact Don Bzdyl

FILTRATION SYSTEMTRIAC ET 2600 120V Electric Actuator for 10"

Actuated ValveY As needed N* D / 1-3 weeks 1 already on site

at: (606) 689-4300

Enprotec J3396-150 Differential Pressure Switch Y As needed N* 1-2 hours A 1

Swing Bolt, 3/4 10 UNC (SA193 B7 Steel) N* As needed N* A 12150286 Warner-Todd Pump Company

BAG FILTERS Pin (SA 193 B7 Steel) N* As needed N* A 12 350140 Contact Mike Brown

Strainrite Eye Nut, 3/4 10 UNC (SA 194 2H Steel) N* As needed N* A 12 150298 at: (317)875-6900

Vendor: Washer (Steel) N* As needed N* A 12 5X2X2

Warner-Todd Cover gasket N* 1 x per year N* A 12 150672

Basket gasket N* 1 x per year N* A 12 363

Basket (#10 woven wire cloth) N* As needed N* D / 3 weeks 2 350153

Filter Bags (10 micron) N* 24

Filter Bags (5 micron) N* 24

Filter Bags (0.5 micron) N*Regularly, when diff.

pressure = 25-30 psidN*

15-20 min. per

bagA 100 already on site

PE 1P25-530

Carbon Changeout N As needed N 0

GAC FILTERS Rupture Disk (pressure relief) Y As needed Y 1-2 hours 24-hour 1 already on site

Model 10 GAC

Rupture Disk

Contact Ken McGuire, (412) 787-

5692, or Mike Stenzel,

Calgon All other parts N As needed Varies 24-hour 0 Varies (412) 787-6809

Plate 1200 CGR LHV 32MM HH6 #1 INT 100 N As needed N 15 min. D / 8 weeks 1111 381 93 Contact Scott Hardy (H&T) at

FILTER PRESS Plate 1200 CGR LHV 32MM HH6 #3 INT 100 N As needed N 15 min. D / 8 weeks 1 111 381 94 (765) 737-6260

US Filter, F1200-100 Cloth 1200 CGR LHV 46409-4 END N As needed N 1-2 days D /4 weeks 2 115 280 14 (317) 501-7128

Cloth 1200 CGR LHV 46409-4 INT NEO NECK N As needed N 1-2 days D / 4 weeks 38 117 350 88

Filter Oil 0.75 FNPT SPIN-ON 25 MICRONS N As needed N 15 min. A 1 111 265 07

Filter Coalescing .25 Tube PARKER N As needed N 15 min. A 1 100 425 15

FILTER PRESS FEED PUMPS Fluid Section Sevice Kit N As needed Use back-up pump A1 637303-GG Warner-Todd Pump Company

Ingersoll-Rand Air Section Service Kit N As needed Use back-up pump A 1 637302 Contact Mike Brown

Model PD30A-AAP-GGG-B at: (317)875-6900

Air Filter Element Y As needed Y 1-2 hours A2 39588777 Tri State Copressor Air System

AIR COMPRESSOR Coolant Filter Element YEvery 2000 hours of

operation. **Y 1-2 hours

A 4 39907175 ph: (219) 533-8671

Ingersoll Rand SSR, Separator Element Y As needed Y 1-2 hours A 1 39831888 fx: (219) 533-0711

EP50-SE V-Belt 67" Y As needed Y 1-2 hours A 5 39160908

Rotary Screw Air Ultra Coolant, 5 gallon Y As needed Y 1-2 hours A 1 39433735

Compressor

IR250CHEE Filter Element Y As needed

Possible shut down

(depending on

location)

1-2 hours A

1 39240932

Start-Up Kit EP50-SE (Includes all of the above) As needed Y 1/2 day A 1 EP50-SE

INSTRUMENTATION Complete electronics for Promag N As needed Y 1/2 day D / 1-2 weeks0

33X MOD-

D21A

Jason Jones, ph: (317) 535-

7138, fx: (317) 535-1489

Endress+Hauser Complete shelf unit 1 N As needed Y 1/2 day D / 1-2 weeks0

FMU 860- R1E

1B8

Complete shelf unit 2 N As needed Y 1/2 day D / 1-2 weeks 0 PMC 731-051

P6M 12N1

Table 5: Spare Parts 1 of 3 May 2013

TABLE 5



PART

FAILURE =

SHUT

DOWN? Y/N

REPLACEMENT

SCHEDULE

SHUT DOWN

REQUIRED TO

REPLACE PART

TIME

REQUIRED TO

REPLACE

PART

PART

AVAILABILITY/

DELIVERY

SCHEDULE

STOCK QUANTITY

RECOMMENDED

BY COMPANY

MODEL #/

PART #


CONTACT

CENTRIFUGAL PUMPS

ITT A-C 3x2x9 2000 Impeller Trim 8.5" N As needed Use back-up pump D / 3-5 weeks0 52-226-001-229 Warner-Todd Pump Company

250 gpm filter feed pump Impeller Nut N As needed Use back-up pump D / 3-5 weeks 0 52-119-899-002 Contact Mike Brown

Impeller Washer N As needed Use back-up pump D / 3-5 weeks 0 CP-661-001-300 at: (317)875-6900

Shaft Sleeve N As needed Use back-up pump D / 3-5 weeks 0 52-118-010-001

Casing O-Ring N As needed Use back-up pump D / 3-5 weeks 0 CP-751-531-377

Slinger N As needed Use back-up pump D / 3-5 weeks 0 52-117-840-006

Mechanical Seal N As needed Use back-up pump D / 3-5 weeks 0 52-118-510-801

Spacer Sleeve N As needed Use back-up pump D / 3-5 weeks 0 52-105-350-001

Shaft N As needed Use back-up pump D / 3-5 weeks 0 52-226-500-001

Bearings N As needed Use back-up pump D / 3-5 weeks 0 CP-811-005-229

Bearing Caps N As needed Use back-up pump D / 3-5 weeks 0 52-121-337-001

Shaft Retention Ring N As needed Use back-up pump D / 3-5 weeks 0 CP-673-171-118

Retention Ring - OB N As needed Use back-up pump D / 3-5 weeks 0 CP-673-157-281

Retention Ring - IB N As needed Use back-up pump D / 3-5 weeks 0 CP-673-151-281

ITT A-C 4x3x9 2000 Impeller Trim (full) N As needed Use back-up pump D / 3-5 weeks0 52-226-091-229 Warner-Todd Pump Company

850 gpm filter feed pump Impeller Nut N As needed Use back-up pump D / 3-5 weeks 0 52-119-899-001 Contact Mike Brown













ITT A-C 6x6x13L 2000 Impeller Trim 11.4" N As needed Use back-up pump D / 3-5 weeks0 52-226-091-331 Warner-Todd Pump Company

1,000 gpm backwash feed pump Impeller Nut N As needed Use back-up pump D / 3-5 weeks 0 52-119-899-001 Contact Mike Brown














TABLE 5



PART

FAILURE =

SHUT

DOWN? Y/N

REPLACEMENT

SCHEDULE

SHUT DOWN

REQUIRED TO

REPLACE PART

TIME

REQUIRED TO

REPLACE

PART

PART

AVAILABILITY/

DELIVERY

SCHEDULE

STOCK QUANTITY

RECOMMENDED

BY COMPANY

MODEL #/

PART #


CONTACT

VERTICAL TURBINE

PUMPS

Peerless 16MC-1 stage None recommended N Use back-up pump BBC Pump & Equip.

2,500 gpm storage tank feed pump Jack Tinder

ph: (317) 636-1111

Peerless 12LD-1 stage None recommended N Use back-up pump fx: (317) 636-5467

1,000 gpm process feed pump

Peerless 8LB - 3 stage None recommended N Use back-up pump

200 gpm process feed pump

Peerless 7LB - 5 stage None recommended N Use back-up pump

Process water sump pump

Ingersoll-Rand Fluid Section Sevice Kit N As needed Use back-up pump637303-GG Tri State Copressor Air System

Model PD30A-AAP-GGG-B Air Section Service Kit N As needed Use back-up pump 637302 ph: (219) 533-8671

Filter Press Feed Pumps Spacer N As needed Use back-up pump 92876 fx: (219) 533-0711

MISCELLANEOUS

EQUIPMENT

Generator Fuel Filter 2 1R0749 MacAllister Engine Power

Oil Filter 2 1R0716 Marvin Barkes

Air Cleaner 2 7E1571 ph: (317) 543-0405

Fan Belt Set 1 6N9158

Safety Switches Bussman Fuse for Pump P-101, P-102 2 FRS-R-15 A1 ElectRicks, Inc

Bussman Fuse for Pump P-103, P-104 2 FRS-R-50 Rick Crouch

Bussman Fuse for Pump P-105, P-106 2 FRS-R-60 ph: (812) 332-6951

Bussman Fuse for Pump P-107, P-108, P-201, P-202, P-

203 2 FRS-R-200 fax: (812) 325-4737

Bussman Fuse for Pump P-301, P-302 2 FRS-R-40



Control Panel Control Relay 2 AB700-PK400A1

Fuse 2 LPS-RK-20SP

Fuse 2 FNQ-20

Fuse 5 FNQ-4

Fuse 5 FNQ-1

PLC Power Supply 1 1746-P4

PLC 13-Slot Chassis 1 1746-A13

PLC Processor 1 1747-L553

PLC Rio Scanner Card 1 1747-SN

PLC Analog Input Card 1 1746-NI4

PLC Analog Output Card 1 1746-NO4

PLC 120V Input Card 1 1746-IA16

PLC 120V Output Card 1 1746-OA16

VFDs

Level Float Switches 2 already on site

NOTES:

Part Availability A = Available, delivery anticipated to be within a week * Stock basket for Bag Filtration System only if system is used for rough duty.

D = Delayed availability ** Replace the air compressor coolant filter element after the first 150 hours of operation (1-2 weeks), then every 2000 hours after that.

N = No Y= Yes

N* = No shut down, send all flow to other filters


TABLE 6

PREVENTIVE MAINTENANCE SCHEDULE

TIME INTERVAL (1)

EQUIPMENT ID / PART ID ACTION

RUNNING

HOURS (1)

ONE

DAY

ONE

WEEK

ONE

MONT

H

THREE

MONTH

S

SIX

MONTH

S

YEARL

Y

TWO

YEARS

THREE

YEARS

Ingersoll Rand Air Compressor

Coolant level Inspect Weekly X

Discharge air temperature Inspect Weekly X

Separator element differential Inspect Weekly X

Air filter Delta P (at full load) Inspect Weekly X

Coolant filter Replace 150X (initial

only)

Temperature Sensor Check 1,000 X

Hoses Inspect 1,200 X

Coolant filter Replace 2,000X (after

initial)

V-belt/Belt tension Inspect 2,000 X

Separator scavenge screen and orifice Clean 4,000 X

Cooler Cores Clean 4,000 X

Air filter Replace 4,000 X

Separator Element Replace when delta P is 3X the initial delta P or max delta P of 12 PSI at full load or upon warning display

SSR coolant Replace 6,000 X

Ultra coolant Replace 8,000 X

Starter contactors Inspect 8,000 X

Drive motor lubrication Service - See Section 5.15 of O&M Manual

AirCel Air Dryer

Refrigerant gauges Check X

Condensate drain separator Check/clean/drain X

Valve Positions Inspect X

Condenser Coils Clean X

Gauge Readings Check X

Oil Removal Filter (Coalescer) Check/replace as nec. X

Hot Gas Bypass Check X

Table 6: Preventative Maintenance Schedule 1 of 6 May 2013

TABLE 6


TIME INTERVAL (1)


RUNNING

HOURS (1)

ONE

DAY

ONE

WEEK

ONE

MONT

H

THREE

MONTH

S

SIX

MONTH

S

YEARL

Y

TWO

YEARS

THREE

YEARS

Caterpillar Emergency Generator

Insulation Check X

Grease for bearing lubrication Add X

Grease for bearing lubrication Replace X

Clutch Check/adjust 125 X

Valve Lash Check/adjust 250 (initial)

Engine Crank Case - Before starting engine Check/ add oil X

Cooling System - Before starting engine Check/ add coolant X

General walk-around - Before starting engine Inspection X

Air Cleaner Indicator - Before starting engine Check X

Belts - Before starting engine Inspection X

Batteries - Before starting engine Clean 250 X

Block Heater -Before starting engine Check X

Governer - Before starting engine Check/ add fluid X

Gauges condition of - Before starting engine Inspection X

Air System (if equipped) - Before starting engine Check X

Control Panel - Before starting engine Inspection X

Generator - Before starting engine Inspection X

Generator space heaters - Before starting engine Check X

Oil pressure gauge - While engine running Check X

Fuel pressure gauge - While engine running Check X

Engine Crank Case - While engine running Check/ add fluid X

Frequency - While engine running Check X

Generated voltage - While engine running Check X

Generator louvers - While engine running Check X

Generator air inlet filter - While engine running Check X

Leaks and noises - While engine running Check X

Starter Winding Temp. - While engine running Check X

Bearing Bracket Temp. - While engine running Check X

Automatic Switch Positions - Engine stopped Check X

Fuel Tank - After engine stopped Check/ fill X

Battery charger amps- After engine stopped Check X

Malfunction Report - After engine stopped Document X

Walk Around Inspection - Before starting engine Check X

Cooling System Element - Before starting engine Replace X


TABLE 6


TIME INTERVAL (1)


RUNNING

HOURS (1)

ONE

DAY

ONE

WEEK

ONE

MONT

H

THREE

MONTH

S

SIX

MONTH

S

YEARL

Y

TWO

YEARS

THREE

YEARS

Fuel System - Before starting engine Drain water & sed. 250 X

Air Cleaner Element - Before starting engine Clean/Replace X

Engine Crank Case - Before starting engine Check/ add oil X

Crankcase Breather - Before starting engine Clean 250 X

Valve Lash - Before starting engine Check/adjust X

Linkages - Before starting engine Check/adjust/lube 1,000 X

Engine Protective Devices - Before starting engine Check/test 1,000 X

Batteries - Before starting engine Clean/check X

Engine - Before starting engine Wipe down/clean X

Generator - Before starting engine Check/clean X

Generator bearing/bracket - Before starting engine Inspect/lube X

Generator Start Check X




Engine Mounts - While engine running Inspection X


Load Test - While engine running Perform X


Bearing Bracket Temp. - While engine running Check X

Walk Around Inspection - After engine stopped Inspection X

Scheduled Oil Sampling - After engine stopped Collect 250 X

Engine oil and Filter - After engine stopped Change/replace 250 X

Generator Air inlet filter - After engine stopped Clean/recharge X

Fuel Tank - After engine stopped Check/fill X


Automatic Switch Positions - Engine stopped Inspection X

Space heater - Before engine started Inspection X

Generator - Before starting engine Inspection X

Cooling System - Before starting engine Drain/clean/replace X

Hoses and belts - Before starting engine Replace X

Batteries - Before starting engine Replace X

Turbocharger - Before starting engine Inspect/check 3,000 X

Engine - Before starting engine Adjust-tune up X

Generator bearing/bracket - Before starting engine Inspection X


TABLE 6


TIME INTERVAL (1)


RUNNING

HOURS (1)

ONE

DAY

ONE

WEEK

ONE

MONT

H

THREE

MONTH

S

SIX

MONTH

S

YEARL

Y

TWO

YEARS

THREE

YEARS

Generator Start Inspection X




Exhaust System - While engine running Leak check/repair X


Load Test - While engine running Perform X


Walk Around Inspection - After engine stopped Inspection X

Scheduled Oil Sampling - After engine stopped Sample X

Engine oil and filter - After engine stopped Change/replace X

Coolant analysis - After engine stopped Sample X

Fuel Tank - After engine stopped Check/fill X


Automatic Switch Positions - Engine stopped Inspection X

Coolant/Antifreeze SAC Test/add SAC 250

Fuel System - Clean primary filters Clean 250

Fuel System - Replace final filters Replace 250

Belts/ Hoses/ Clamps Inspect/replace 250

Fan drive bearing (if equipped) Lube 250

Radiator fins/ aftercare Inspect/check 250

Coolant/Antifreeze Drain/clean/replace 3,000

Thermostats Replace 3,000

Crankshaft vibration damper Inspect 3,000

Valve lash, valve bridge, valve rotators Check/adjust 3,000

Fuel ratio control, set point and low idle Check/adjust 3,000

Fuel injection nozzles Test/exchange 5,000

Alternator, air compressor Inspect/exch. 5,000

Water pump, starter, turbocharger Inspect/exch. 5,000

Overhaul Perform 10,000


TABLE 6


TIME INTERVAL (1)


RUNNING

HOURS (1)

ONE

DAY

ONE

WEEK

ONE

MONT

H

THREE

MONTH

S

SIX

MONTH

S

YEARL

Y

TWO

YEARS

THREE

YEARS

U.S. Filter / JWI Filter Press

Cylinder Boot Inspect/repair/replace X

Electro-Hydraulic Power Unit - Clamp pressure Check/adjust X

Electro-Hydraulic Power Unit - Oil level Check/ add fluid X

Electro-Hydraulic Power Unit - Relief valve Check/adjust X

Electro-Hydraulic Power Unit - Hydraulic oil & filter Change/replace X

Process Manifold - Plumbing Inspect X

Process Manifold - Process Valves Inspect X

Process Manifold - Process Valves Remove/inspect seals X

Plate shifter - Lift Cylinder Clean X

Plate shifter - Push cylinders Clean X

Plate shifter - Lift Cylinder Operate w/o plates X

Plate shifter - Push cylinders Operate w/o plates X

K/M Specialty Pumps/ Filter Press Feed Pumps

Flush Sludge Pumps with Water Between Uses

Invert Pump Prior to Dissassembly To Drain Prior To Servicing

Keystone Valve Electric Actuator

Fixing Screws Check X

Wiring Terminal Block Screws Check X

Wiring Disconnect Terminations Check X

Torque and Travel Limit Switch Operating Cams Check X

Electrical Compartment Check X

Cover O-ring Check X

Indicator Shaft O-ring Check X

Ground Terminal Check X

ITT End Suction Centrifugal Pumps

Bearing Temperature Check X

Bearing Grease Check/replace X

Packing Check/replace X

Shaft/shaft sleeve (scoring of) Check X

Pump Alignment Check X

Motor Alignment Check X

Rotating Elements Inspect X

Wearing clearances Check X


TABLE 6


TIME INTERVAL (1)


RUNNING

HOURS (1)

ONE

DAY

ONE

WEEK

ONE

MONT

H

THREE

MONTH

S

SIX

MONTH

S

YEARL

Y

TWO

YEARS

THREE

YEARS

Stuffing Box Piping Clean Out X

Total dynamic suction and discharge head Measure/record X

Peerless Vertical Turbine Pumps

Water Flow to Pump Seats Check X

Hach Surface Scatter 6 Turbidimeter

Standardization Check Check X

Calibration Perform X

Calgon Model 10 GAC System

Backwash Perform backwash before the differential pressure across a vessel reaches 20 psi.

Vessel Internal Parts Inspection X

Carbon Transfer Perform as needed

Enprotec Multi-Media Filters

Backwash Perform/Record DP X

Top Media Level Inspection Add media as needed X

Wash Media Perform as needed

Media Transfer Perform as needed

Enprotec Clarifier

Inspect Clarifier Monthly X

Clean Plates by Draining and Powerwashing Annually X

Remove and Clean Plates Individually Perform as needed

Flush Sludge Pumps with Water Between Uses

Sludge Pump Check Valve Inspect/Repair As Nec.

Sludge Pump Diaphragm Inspect/Repair As Nec.

Pekay/Alstor - Thickeners

Vessel Integrity Inspection Empty/clean/inspect X

Earth Tech - Bar Screen (North of RR)

Flow Through Screen Inspect/Clean X

Clean Screen of Obstructions Clean X

NOTES:

(1) Maintenance task should be performed in accordance with the indicated time interval or the specific "Running Hours" time period, whichever occurs first.

(2) Plumbing and HVAC equipment were not evaluated for preventive maintenance purposes.


APPENDIX A

Standard Operating Procedures

Index of SOPs

1 SRS Spring Diversion……………………………………………….…………………1

2 SRS Atmospheric Testing…………………...…………………………………………5

3 SRS Cleaning…………………………………………………………………………10

4 SRS Pump Change Out………………………………………….……………………17

5 SRS Daily Flow Report…………………………………….…………………………24

6 PTS Clarifier Sludge Pump Settings……….…………………………………………27

7 PTS Bag Filter Change……………………………..…………………………………29

8 PTS Carbon Backwash A1 and B1 Lead…...…………………………………………31

9 PTS Carbon Backwash A2 and B2 Lead…………………...…………………………33

10 PTS Decanting Thickeners……………………………………………………………35

11 PTS Filter Press……………………………………….………………………………37

12 PTS Carbon Exchange Procedure………………………………………………….....40

13 2500gpm SRS Pump Back Flush Procedure……………………………………….....44

- 1 -

ICSTF Standard Operating Procedure (SOP)

Spring Diversion

(Revised June 2011)

- 2 -

Purpose

The purpose of this procedure is to prevent spring water from flowing into the Spring

Receiving Sump (SRS). This will facilitate entry into the sump for maintenance and cleanup

activities. Spring waters will be diverted from the SRS inflow

Summary

The spring inlet pipe immediately upstream of the SRS must be blocked to prevent inflow of

spring water into the SRS while personnel are performing work inside the sump. Spring water

will be captured and diverted to the main Illinois Central Spring Treatment Facility (ICSTF)

building for treatment. Water must be pumped from the spring inlet pipe manhole to the floor

sump in the main building.

Preparations and Planning

Scheduling and Prerequisite Conditions

For safety and in consideration of limited pumping capacities, spring diversion operations

should be scheduled to occur during minimum spring flow periods and when no storm events

are likely. Spring flow rates no greater than 100 gpm are required for this spring water

diversion procedure. When favorable conditions are obtained, work may proceed. For

routine quarterly inspections or as-needed removal of accumulated sediment and debris from

the SRS, no subcontractors will be needed.

Safety

The spring inlet pipe manhole is a permit required confined space. A four-gas meter will be

used to confirm adequate oxygen level before entry into the manhole. Entry into the manhole

will conform to the PSARA Standard Operating Procedure for Confined Space, SP-012.

Testing to determine PCB concentration in the manhole atmosphere will be performed prior to

implementation of this procedure. Adequate breathing protection will be used as needed

based on the results of testing. It is anticipated that adequate ventilation will obviate the need

for respirators.

Equipment and Materials List

a. 3-inch gasoline powered trash pumps or pneumatic diaphragm pump, 2 (1 for backup).

b. 3-inch discharge hose with cam-lock fittings, 500 feet.

c. 3-inch suction hose, 2, each at least 20 feet in length.

d. 1-inch air hose with Chicago fittings, 500 feet, for diaphragm pump, if used.

e. Two panels of ¾-inch plywood laminated with compressible gasket material for sealing

off the spring water inflow to the SRS (see sketch, Figure 1).

f. Mounting hardware (4-anchor bolts with nuts, u-channel or flat bar)

g. Four-gas meter.

h. Fuel, if using gas-driven pumps.

i. PPE, Level B; plus waders and nitrile gloves.

- 3 -

j. Rotary hammer drill (only needed for initial panel hardware installation)

k. Electric extension cord (to be used with ground fault interrupter)

Note: Pumps and hoses must be tested and verified operational and leak-free prior to use in

this procedure.

Procedure

1. Conduct safety briefing with all personnel involved in the Spring Diversion

operations. Review permit-required confined space operations as described in PSARA

SP-012, and assign entrant and attendant duties to appropriate personnel.

2. Lay out hoses from main ICSTF floor sump to the spring inlet pipe manhole and

connect to main diversion pump. Position the back-up pump where it can most

quickly be put into use if needed.

3. Remove manhole cover from spring inlet pipe. Measure oxygen level. If oxygen level

safe, proceed to insert suction hoses from both the primary and the backup pumps into

the manhole.

4. Start main diversion pump.

5. Entrant will then enter the manhole and attendant will pass him the first panel section

to cover the lower half of the spring inlet pipe leading into the SRS.

Note: Prior to diverting water for the first time, the hardware to secure the panels in

place must be installed. This involves marking and drilling holes into the concrete

face wall of the SRS inlet opening and installation of anchor bolts. Then the panels

and securing hardware must be test fitted and adjusted as necessary.

6. Entrant positions the first panel, secures in place, observes for effective sealing, then

confirms effective pumping as water depth increases to cover the pump intake.

7. Second panel is passed to the entrant, who mounts and secures it in position to

completely cover the inlet opening into the SRS.

requires the presence of an attendant.

9. A single person will be required to constantly monitor pumping operations and water

levels within the spring inlet pipe manhole until spring diversion is no longer needed.

If the primary pump fails, the attendant will quickly disconnect the discharge line from

the primary pump and connect it to the backup pump. The backup pump will be

started and normal operations resumed. A backup pump type that does not require

priming is highly desirable.

8. Entrant then exits the confined space. Note: Any re-entry into the confined space

- 4 -

10. After completion of all work within the SRS Sump, permit-required confined space

entry procedures will be used to enter the manhole for removal of diversion panels.

11. After all personnel have exited the manhole, pumping will be terminated, suction hose

will be removed and the manhole cover replaced.

12. Remove all tools and equipment from area.

- 5 -


Spring Receiving Sump (SRS)

Atmospheric Testing

(Revised June 2011)

- 6 -

Purpose

Atmospheric testing for the presence of Polychlorinated Byphenols (PCBs) of the ICSTF

Spring Receiving Sump (SRS) is to be performed to determine proper level of personal

protective equipment (PPE) needed to perform various actions within the sump. This

procedure should be undertaken initially and whenever modifications to the sump system are

made or when changes in the PCB content of the incoming water are detected. This procedure

and attachments detail the steps necessary for safe testing of the atmosphere inside the SRS.

Summary

The SRS Sump atmospheric testing procedures described herein detail the preparations for

procedural setup, safe entry, sample collection, sample analysis and result interpretation.


Scheduling

For safety and in consideration of limited pumping capacities, all SRS atmospheric testing

operations should be scheduled to occur during minimum spring flow periods and when no

storm events are likely. Spring flow rates no greater than 100 gpm are required for

implementation of this procedure.

Safety

Personnel involved with atmospheric testing activities will be OSHA HAZWOPER and

confined space trained. The Spring Receiving Sump is a permit-required confined space. A

four-gas meter will be used to confirm adequate oxygen level before entry into the SRS. Air

monitoring will be performed every 15 minutes while workers are in the SRS. Entry into the

SRS will conform to PSARA Technologies’ Standard Operating Procedure for Confined

Space, SP-012. Please see attached copy.


a. PSARA Confined Space Entry Permits

b. PSARA Air Monitoring Forms

c. Level C PPE with organic vapor cartridges

d. Flashlight

e. Tripod and harness system for fall arrest

f. Two-way radio communication system

g. Multi-RAE (or similar) real time gas monitor

h. Dry-Cal flow calibrator (or similar)

i. Two SKC low flow personnel pumps (or similar) and associated tubing

j. 100mg/50mg Florisil media and 13mm glass fiber filter media suitable for NIOSH

Method 5503

k. Two pump stands or tripods

l. Plastic pool or similar

m. Garbage bags

- 7 -

Procedure

1. Conduct safety briefing with all personnel involved in the sump atmospheric testing

operations. Assign entrant and attendant duties to appropriate personnel.

2. Initiate spring water inflow diversion. See Spring Diversion Procedures.

3. Pump SRS Sump to lowest level by SRS Process Pumps.

4. Set pump controls to manual operation at PLC panel (plant operator)

5. Set disconnect(s) to off position at main motor control panel(s) in SRS building. (See

table 1 for disconnect locations for each SRS pump)

6. Follow Lock Out Tag Out (LOTO) procedures in accordance with ICSTF HASP to

safely isolate the SRS pumps/motors from all potentially hazardous energy sources.

7. For each process pump, close and lock out butterfly valve located closest to the

effluent side of the pump flange. (See Table 2 for valve number) This is to prevent the

inadvertent or unexpected release of backflow and/or back flush water from the main

pump line leading to the main ICSTF plant. Lock Out/Tag Out required.

8. Remove sump access cover located in northwest corner of SRS building.

9. Set up Tripod and harness system over the access point.

10. Use four-gas meter to determine oxygen levels. Do not enter until safe levels are

obtained. Confine Space Entry required. First entrant will use oxygen meter to

confirm adequate oxygen at working level in the sump before any other personnel

enter the SRS. Oxygen level monitoring will be performed every 15 minutes while

personnel are present inside the sump area.

11. One entrant wearing level C PPE and organic vapor cartridges will be in the sump

working to set up and remove monitors as needed. One attendant will be continually

observing the entrant for safety monitoring.

Baseline Testing (no ventilation)

12. Calibrate and assemble two personnel pumps for use according to the procedures in

NIOSH Method 5503 for Polychlorobiphenyls.

a. Set flow by opening waste gate and adjusting gross controls to approximately 1

L/min; place low flow adapter and media in line and adjust the fine control

until desired flow rate is reached.

- 8 -

b. Flow rates should be set to close to 0.2 L/min for an approximate total volume

of 36 L for a 3 hour sample. Do not exceed 0.2 L/min.

c. Initial flow rate should be recorded as the average of 3 readings with no

adjustments made.

13. Lower both stands into the sump area and place them at a wide interval within the

sump area.

14. Position the two pumps on the stands at approximately 5 feet above floor level and

start them.

15. Allow the pumps to sample for a total of three hours, recording the start and stop times

of each pump.

16. Stop and remove the pumps.

17. Prepare the samples for shipment.

a. Use the air flow calibrator to read the current flow rate 3 times, average this

and then again with the initial readings to determine average flow rate for the

entire sample period.

b. Multiply the total time in minutes that the pump ran by the average flow rate to

determine total volume of the sample.

c. Cap the florisil tube ends and place the filter media in a glass vial with clean

forceps.

Ventilated Sampling

18. Turn on the SRS ventilation system and allow it to run for a minimum of one hour

before continuing to the next step.

a. Allow the ventilation system to continually run throughout the next sampling

procedure.

19. Calibrate and assemble two personnel pumps for use according to the procedures in

NIOSH Method 5503 for Polychlorobiphenyls as outlined in step 12.

20. Position the sampling pumps as before and allow them to sample for three hours,

recording the start and stop times for each pump.

21. Stop and remove the pumps.

- 9 -

22. Prepare the samples for shipment to the lab as outlined in step 16.

23. Label and catalog all samples on PSARA Air Monitoring Forms.

24. Submit one unused set of florisil and glass fiber filter media to the lab as a blank.

25. Ship all samples to an ACGIH accredited lab for analysis by Gas Chromatography and

Electron Capture Detection as detailed in NIOSH 5503.

26. Final PCB concentration is determined by dividing the lab data result by the sample

volumes obtained in steps 17 and 22.

27. Remove all equipment from the SRS sump.

28. Upon exiting from the SRS sump, personnel will step into a plastic wading pool and

remove PPE. Used PPE and dirty disposable materials will be collected and disposed

in the rolloff in the main building. Contaminated tools and rubber boots will be

decontaminated in a designated area over the floor sump in the main facility.

29. Remove all tools, equipment and other cleanup materials from the SRS building area.

30. Recover from LOTO condition - Remove lock(s) from pump power supply at

electrical panel. Remove locks and open discharge butterfly valves at each previously

locked out pump.

31. Halt spring water inflow diversion. See Spring Diversion Procedures.

32. Reset pump(s) to automatic mode at the PLC panel.

33. The plant operator will restart the treatment system and verify normal plant operations.

- 10 -


Spring Receiving Sump (SRS) Cleaning

(Revised June 2011)

- 11 -

Purpose

Cleaning of the ICSTF Spring Receiving Sump (SRS) is performed as needed and determined

by periodic inspection. This procedure and attachments detail the steps necessary for the

removal of foreign materials from the SRS.

Summary

The SRS Sump cleaning procedures described herein detail the preparations for SRS cleaning,

safety measures, SRS process pumps shutdown and foreign material removal, as well as the

preparations for pumps restart.


Scheduling

For safety and in consideration of limited pumping capacities, all SRS cleaning operations

should be scheduled to occur during minimum spring flow periods and when no storm events

are likely. Spring flow rates no greater than 100 gpm are required for implementation of this

procedure.

Safety

Personnel involved with sump cleaning activities will be OSHA HAZWOPER and confined

space trained.

The Spring Receiving Sump is a permit-required confined space. A four-gas meter will be

used to confirm adequate oxygen level before entry into the SRS. Air monitoring will be

performed every 15 minutes while workers are in the SRS. Entry into the SRS will conform

to PSARA Technologies’ Standard Operating Procedure for Confined Space, SP-012. Please

see attached copy. Ventilation to reduce PCBs in the SRS atmosphere below levels requiring

entrants to wear respirators with organic vapor cartridges may be possible. PSARA

Technologies defines this limit as 0.125 mg/m3, which is more stringent than the OSHA

permissible exposure limit of 1 mg/m3. Testing to determine adequate ventilation will be

designed and performed prior to implementation of these SRS cleaning procedures.


a. 1.5-inch discharge hose with cam-lock fittings, 200 feet

b. 1.5-inch suction hose, 5 feet

c. 1.5-inch pneumatic diaphragm pump

d. air hose, 200 feet, for diaphragm pump

e. air hose Y-adaptor if using another diaphragm pump as spring diversion backup

f. 1.5 inch discharge hose for diaphragm pump, 200 feet

g. 50 feet garden hose with spray nozzle

h. 8-12 plastic 5-gal buckets

i. 2 flat blade shovels

j. pool skimmer net

- 12 -

k. 2-3 30-gallon garbage cans

l. 30 feet rope

m. Tripod for confined space rescue

n. Safety harnesses for all entrants, 3 minimum

o. Four-gas meter

p. Pickup truck with lift gate

q. Two-wheel dolly

r. PPE, Level D (Level C if organic vapor breathing protection is needed) with Tyvek

overalls, protective gloves and waterproof boots

s. Plastic wading pool

Note: Pumps and hoses must be tested and verified operational and leak-free

prior to use in this procedure.

SRS Inspection

Entry into the SRS for cleaning provides the opportunity to inspect the SRS and equipment in

it for problems and general condition. An Inspection Checklist is attached.

Procedure

1. Conduct safety briefing with all personnel involved in the sump cleaning operations.

Assign entrant and attendant duties to appropriate personnel.

2. Initiate spring water inflow diversion. See Spring Diversion SOP.

3. Pump SRS Sump to lowest level by SRS Process Pumps.

4. Set pump controls to manual operation at PLC panel (plant operator).

5. Set disconnect(s) to off position at main motor control panel(s) in SRS building. (See

table 1 for disconnect locations for each SRS pump).

6. Follow Lock Out Tag Out (LOTO) procedures in accordance with ICSTF HASP to

safely isolate the SRS pumps/motors from all potentially hazardous energy sources.

7. For each process pump, close and lock out butterfly valve located closest to the

effluent side of the pump flange. (See Table 2 for valve number) This is to prevent the

inadvertent or unexpected release of backflow and/or back flush water from the main

pump line leading to the main ICSTF plant. Lock Out/Tag Out required.

8. Remove sump access cover located in northwest corner of SRS building.

9. Turn on SRS Sump ventilation fan; the switch is located on north wall next to ISCO

equipment. PSARA Technologies’ Standard Operating Procedure for Confined Space,

SP-012, section IV Preparation for Entry will be followed. Pre-entry ventilation

- 13 -

duration will be determined by specific testing in the SRS, and may be longer than the

30 minutes rule-of-thumb specified in SP-012.

10. Use four-gas meter to determine oxygen levels. Do not enter until safe levels are

obtained. Confine Space Entry required. First entrant will use oxygen meter to

confirm adequate oxygen at working level in the sump before any other personnel

enter the SRS. Oxygen level monitoring will be performed hourly for the duration of

sump cleaning activities.

11. Lower garden hose into sump and spray upper sump floor sediment into the lower

sump area.

12. Remove any live animals, e.g. turtles, frogs, snakes, etc. using pool skimmer net.

Release animals at some distance away from SRS building.

13. Position the 1.5-inch pneumatic diaphragm pump inside the sump. Connect both

discharge and suction hoses, then the air supply hose to the diaphragm pump and use

pump to move remaining water from SRS to the spring diversion manhole. Once all

standing water has been evacuated from the sump, work to remove sediment and

debris can begin.

14. One or two people will be in the sump working to remove sediment and debris using

shovels and buckets. One attendant will be continually observing the entrant(s) for

safety monitoring.

15. Additional staffing needed: One person will be constantly monitoring the spring

diversion pumps. Two people will be involved in manually raising buckets of sediment

out of the SRS by rope and placing material in the 30-gallon garbage cans. The

garbage cans will be transported to the disposal rolloff in the main facility building

using a truck with lift gate. Excess water will be decanted out of the rolloff by the

plant operator when needed. It is not anticipated that solidification will be required.

16. Prior to personnel leaving the SRS sump the following should be inspected: sump

lighting, pump assembly columns, pump intake screens, debris accumulation

characteristics, float switches, and sump floor & walls for cracks. An inspection form

(attached) should be completed by the plant operator or on-site field supervisor.

17. Upon exiting from the SRS sump, personnel will step into a plastic wading pool and

remove PPE. Used PPE and dirty disposable materials will be collected and disposed

in the rolloff in the main building. Contaminated tools and rubber boots will be

decontaminated in a designated area over the floor sump in the main facility.

- 14 -

18. Remove all tools, equipment and other cleanup materials from the SRS building area.

19. Recover from LOTO condition - Remove lock(s) from pump power supply at

electrical panel. Remove locks and open discharge butterfly valves at each previously

locked out pump.

20. Halt spring water inflow diversion. See Spring Diversion Procedures.

21. Reset pump(s) to automatic mode at the PLC panel.

22. The plant operator will restart the treatment system and verify normal plant operations.

- 15 -

Table 1

SRS Pumps Electrical Disconnect Locations

Pump/Motor # Pump HP Pump Size Disconnect Location Panel/Breaker Number

# P-101 5 200 GPM SRS building west wall # MMC P-101

# P-102

5 200 GPM SRS building west wall # MMC P-102

# P-103


# P-104





Table 2

SRS Pumps Butterfly Valve Number

Pump/Motor # Butterfly Valve Number

# P-101 # 3VY1 100A

# P-102 # 3VY1 100B

# P-103 # 6VY2 100A

# P-104 # 6VY2 100B

# P-201 # 10VY2 100A

# P-202 # 10VY2 100B

# P-203 # 10VY2 100C

- 16 -

ICSTF SRS Inspection Checklist

Item

OK

or

Note #

Check for:

Lighting Broken or dead bulbs, condition of fixture

Debris Accumulation, unusual materials

Float switches (2) Free movement, general condition

Pump assembly columns Looseness, corrosion, general condition

Pump intake screens Looseness, corrosion, holes, obstruction by debris

Sump floor and walls Cracks, any other signs of deterioration

Notes

Inspected by:

Date:

- 17 -


Spring Receiving Sump (SRS) Pump Change-Out

(Revised June 2011)

- 18 -

Introduction and Background

The Illinois Central Spring Treatment Facility (ICSTF) receives influent flow from the spring

emergence area via a 24-inch below ground pipe which gravity discharges directly into the

Spring Receiving Sump (SRS). The SRS is a rectangular, poured concrete pit, approximately

20 feet in depth and measuring 24 x 38 feet in outside dimension. It is covered by a standard

metal frame protective structure, the SRS building.

The SRS building houses 7 vertical turbine pumps (SRS Pumps) which pump water to the

process feed tank in the main ICS treatment plant or to the two large outside storage tanks.

The 7 pumps (2 each 5 HP 200 GPM, 2 each 25 HP 800 GPM, and 3 each 100 HP 2500

GPM) are controlled automatically by the Programmable Logic Controller (PLC) in the

ICSTF control room. The pump operating parameters may be varied by operator input at the

PLC and may also be switched to manual operation mode. Switching to manual mode

overrides automatic control of the pumps, provides for flexibility in configuration and permits

safe maintenance activities.

Purpose

Routine preventive maintenance of the SRS pumps is performed in accordance with the

ICSTF Operations and Maintenance Plan and with pump manufacturer’s installation,

operation and maintenance manuals. However, occasional non-routine maintenance of one or

more of the SRS pumps may be necessary and may require the physical removal of the

pump(s) from the SRS.

Summary

This procedure details the steps necessary for the removal and re-installation of the SRS

pumps. It details work preparations, system shutdown, skylight removal, motor disconnect

and removal, pump removal, pump and motor re-installation, safety measures, and system

restart.

Pump removal and replacement is described herein as a two day procedure. On Day 1, pumps

to be removed are disconnected and preparations are made for Day 2 activities. The crane

arrives on Day 2. Also on Day 2, the replacement pumps are delivered, accompanied by the

pump manufacturer’s representative. Existing pumps are removed and temporarily placed on

the ground. The new pumps are taken by the crane directly from their shipping skids and

installed in position in the SRS building. The pumps just removed are placed into the

shipping skids by the crane and returned to the pump dealer for inspection and service as

needed.

The plant operator completes installation, adjustment and restart of the new pumps according

to Peerless Pump Company’s Vertical Turbine Pump Installation, Operation and

Maintenance Manual, Publication B-263319 (Rev. 11/08) and guidance of the pump

manufacturer’s representative.

- 19 -


Prerequisite Conditions

Pump removal operations can be performed during conditions of moderate spring flows, i.e.

less than 100 gpm. Do not schedule pump removal operations during high flow events, i.e.

storm periods or during typical high flow periods of the year, unless absolutely necessary.

The duplicate pump of the same capacity as the pump being removed should be in good

working order.

Contact subcontractors and obtain necessary parts and equipment

a. Contact and schedule all subcontractors, i.e. crane service, aerial lift rental source, pump

manufacturer’s representative, etc. at least 4 weeks prior to the anticipated work date.

b. To minimize pump down time, obtain or confirm availability of all necessary repair and

replacement parts before scheduling the work date.

Safety

a. The plant operator and one or two PSARA technicians will perform all work involving

contact with potentially contaminated equipment. These personnel all are OSHA

Hazwoper trained.

b. Lock Out / Tag Out procedures in accordance with ICSTF Health And Safety Plan

(HASP) will be followed as needed to safely isolate pumps, motors and valves from

energy sources.

c. Fall Protection measures will be followed as needed in accordance with ICSTF HASP.

d. The crane contractor will be responsible for operating in compliance with OSHA

guideline 29 CFR Part 1926.550.

Equipment and Materials

1. Pressure washer and hose

2. Replacement pump assemblies

3. Gaskets, packing and other small pump and piping parts

4. Plastic sheeting

5. Wooden blocks & chocks

6. Rental crane & operator; crane must be capable of lifting 1100 lb., 20 ft. long pump

assembly 35 feet vertically to clear the roof opening.

7. Rental aerial lift

8. Safety harness and lanyard

9. Lock Out/Tag Out (LOTO) supplies

10. PPE, Level D, with Tyvek suits, and nitrile gloves

- 20 -

Procedure

Day 1

1. Conduct safety briefing with all personnel involved in the pump removal operations.

Pumps to be removed will be tagged by the plant operator to clearly identify pumps to

be locked out and to distinguish them from the pumps that will remain in service.

2. At the main PLC panel, operator will set SRS pump controls to MANUAL operating

mode for the pump(s) to be repaired/removed. All other pumps will remain in normal

or AUTO operating mode.

3. At main motor control (MMC) panel(s) in SRS building, set disconnect(s) to OFF

position. (See table 1 for disconnect locations for each SRS pump).

4. Lockout power to SRS pump motor(s) to be removed. Lock Out/Tag Out required.

5. Disconnect wiring and conduit from motor housing of pump(s) to be removed. Label

each wire as it is disconnected. This assures proper spin direction when the motor is

re-connected.

6. Remove motor shaft assembly, then remove motor mounting bolts. Manually remove

the motor body and place on the floor or on a pallet nearby. These weigh

approximately 20-50 pounds, not too heavy to handle but require careful handling and

safe lifting technique.

7. Close and lock out butterfly valve located closest to the effluent side of the pump

flange. (See Table 2 for valve number) This hydraulically isolates the pump from the

rest of the system. Lock Out/Tag Out required.

8. Disconnect pump from discharge piping.

9. Place appropriately sized wooden block inside top of housing and secure in place to

prevent shaft from moving longitudinally when the pump assembly is removed and

transported.

10. Stage pressure washer for use on Day 2.

Day 2

11. Conduct safety briefing with all personnel, including contractors, involved in the pump

removal and installation operations.

12. Verify LOTO are still in place.

- 21 -

13. Access roof of SRS building by aerial lift and remove skylight(s) as necessary for

access and removal of SRS pump(s). Fall Protection required.

14. Coordinate with crane operator to setup crane in correct position for pump removal.

15. Pumps delivery vehicle moves into position.

16. Plastic sheeting is spread and secured on the lay-down area where pulled pumps will

be temporarily placed after removal and prior to loading onto the transport vehicle.

17. Lower crane lifting rig through skylight access and attach securely to pump to be

removed.

18. Slowly raise pump turbine and housing assembly while power washing external

components to remove silt and accumulated grime, etc. Wash water will be directed

back into the sump through the floor opening.

19. Remove pump from building through skylight access and place in the temporary lay-

down area. Chock as necessary to prevent accidental movement.

20. The crane crew will then lift the new pump from its shipping skid on the pump

transport vehicle and lower into position in the SRS building.

21. The pump earlier removed is then lifted by crane, placed into the shipping skid on the

pump transport vehicle and secured for transport.

22. Repeat for second or subsequent pump(s).

23. Verify power source to pump motor is still off and butterfly valve closed and both are

in locked configuration. Lock Out/Tag Out required.

24. Re-connect pump discharge to effluent pipe. Important: Before re-connecting,

inspect inside piping for foreign objects.

25. Re-install motor and pump shaft assembly per pump manufacturer’s IOM manual

(Peerless Pump Co. publication B-2633119).

26. Re-connect wiring/conduit to motor consistent with wire labeling applied when pump

was originally disconnected.

27. Remove lock(s) and open discharge butterfly valve.

28. Remove lock(s) from pump power supply at Main Motor Control (MMC) panel.

29. Check for correct motor spin direction (counter-clockwise when looking down from

above). At the pumps Variable Frequency Drive (VFD) control box (interior north

- 22 -

wall of SRS building), press the JOG button to briefly send power to the pump motor.

The spin direction should be observable by watching the exposed shaft or the top of

motor fins, if the motor cover is still off.

30. If OK, move to the PLC panel in the main building and check for expected pump

yield. With pump mode still set to MANUAL, turn pump ON and observe flow rate

displayed on PLC panel. Flow rate readings should be equal to or greater than the

nominal pump rating, 200 gpm or 800 gpm.

31. The plant operator and pump manufacturer’s representative should return to the SRS

building while the newly installed pump is running and check for unusual or excessive

noise or vibration. If no problems are detected, the pumps can be set to AUTO

operating mode at the PLC.

32. If all systems operating normally, release crane crew.

33. Re-install skylight covers. Fall Protection required.

34. Remove all tools and equipment from area.

Table 1

SRS Pumps Electrical Disconnect Locations

Pump/Motor # Pump HP Pump Size Disconnect Location Panel/Breaker Number


# P-102


# P-103


# P-104





- 23 -

Table 2

SRS Pumps Butterfly Valve Number

Pump/Motor # Butterfly Valve Number

# P-101 # 3VY1 100A

# P-102 # 3VY1 100B

# P-103 # 6VY2 100A

# P-104 # 6VY2 100B

# P-201 # 10VY2 100A

# P-202 # 10VY2 100B

# P-203 # 10VY2 100C

- 24 -


Daily Flow Report

(Revised June 2011)

- 25 -

Summary

This procedure covers daily SRS flow calculations, which are done in Microsoft Excel based

on an equation developed by Earth Tech (now AECOM). It calculates the SRS influent flow

based upon level and flow data collected by system instrumentation.

Procedure

1. Open Microsoft Excel program

2. Open File Folder in My Documents

3. Open EFS ICS Folder

4. Open ICS-SRS Flow Rate

5. Open Current Calendar Year

6. Open Current Month

7. Open Last Flow Rating

8. Enable Macros (If an error occurs ensure network connections are correctly set, see

Internet and Network Operations SOP for set up)

9. Click on Tools to Run Macros

a. Click on run:

i. Click on TAG to pick Column Name:

1. SPRING FLOW RATE Time ( Never Changes)

2. SPRING RECEVING SUMP LEVEL Value (FT)

3. FLOW FROM PROCESS FEED PUMPS #101 & #102 Value (GPM)

4. FLOW FROM PROCESS FEED PUMPS #103 & #104 Value (GPM)

5. TOTAL FLOW FROM SRS TO CLARIFIER Value (GPM)

6. FLOW TO SRS STORAGE TANKS Value (GPM)

7. TOTAL FLOW OUT OF THE SRS Value (GPM)

8. FLOW FROM SRS STORAGE TANKS TO SRS Value (GPM)

9. SPRING FLOW RATE Value (GPM)

10. SRS RATE (GPM) Self Calculate and do not move

11. SRS 15 MIN AVG (GPM) Calculate and do not move

ii. Click on to change Date From (for date or dates need) and Time (12:00 AM)

iii. Click on to change Date To (for date or dates need) and Time (11:59 PM)

- 26 -

iv. Click on Get Data to gather Data for each column

10. Click on Chart 1 on bottom of spread sheet

a. Double Click on Date and Time at bottom of Chart

b. Click on Scale and add 1 to both the minimum and maximum numbers

c. Click OK to change date on chart

11. After gathering Data for each column and changing date, do a SAVE AS to save data and

chart for that date

- 27 -


Primary Treatment System (PTS)

Clarifier Sludge Pump Settings

(Revised June 2011)

- 28 -

Summary

This procedure covers adjustments to clarifier sludge pump timer settings that are required

after storm events. Sediment loading increases with increasing flow, so solids will need to be

pumped out of the clarifier more frequently after storm events. The Operator should make the

necessary setting changes within 2 hours after the start of a storm event.

Procedure

1. Can use either PLC screen. Starts with screen F9.

2. Once screen F9 is displayed selects Function F6.

3. To change length of time pump is on, select F1.

(a) Once blue bar appears, use #s keys to enter the time you want pump to be on.

(b) Press the “enter” arrow below the “0” key to enter new value.

(c) Press the “cancel” key to reset screen.

4. To change the length of time the pump is off, select F2.

(a) Once blue bar appears, use #’s keys to enter the time you want the pump to be off.

(b) Press the “enter” arrow below the “0” key to enter new value.

(c) Press the “cancel” key to reset screen.

5. Press key F9 to return to original screen on PLC.

Note: All changes in time are in minutes (i.e. 1 hour = 60 minutes)

Suggested settings based on spring flow:

Flow of Spring

(gpm)

Time ON

(min)

Time OFF

(min)

<50 10 360

<100 10 240

100-300 20 120

300-500 20 60

500-1000 15 30

>1000 15 15

Water flowing in clarifier should look like “weak tea” when settings are correct. Operator

should be able to see circles in bottom of weir.

- 29 -



Bag Filter Change

(Revised June 2011)

- 30 -

Summary

Change out of bag filters is a manual procedure. Each vessel contains 12 bags with a pore

size of 0.5 micron. The bag filter inventory should not be allowed to drop below 50 bags

without placing an order for more. It takes almost 1 month for the vendor to manufacture and

ship 100 bags. The system alarm for the bag filter units is set at a differential pressure of 22

psi or a head pressure of 35 psi (report given over MMI is head pressure).

Safety

Operator must wear Tyvek suit, gloves, and safety glasses. Footwear needs to be washable or

dedicated to the job. Respirators are not required.

Procedure

1. Upon receiving alarm condition or operator determining that change out is needed,

influent and effluent valves are closed to isolate vessel.

2. The vessel bottom drain valve is opened to allow water to drain into containment.

3. After water has drained (20-25 minutes), the lid of vessel is unbolted. A chain hoist is

used to lift lid and it is swung aside.

4. Holding ring is unbolted and removed. Ring is set aside inside containment area.

5. Bags are removed and placed inside containment area to allow drainage of any water.

6. Once all bags are removed, new bags are installed. Personnel should make sure that

the plastic seal ring on each bag seats in each basket. New bags can be found in gray

cabinets or on pallet next to cabinet.

7. After bags are installed, holding ring is put back in place.

8. Lid of vessel is put in place. Ensure that o-ring seal is in place on vessel before

lowering lid. Lid might stick and operator will have to push it down. Lids sometimes

will “free fall”. Ensure all hands and fingers are back prior to handling lid. Once lid

is in place, tighten bolts.

9. Bottom drain valve is closed. Influent and effluent valves are opened.

10. Air is bled off through the pressure relief valve.

11. Used bags are transferred into the PCB roll-off box under press for disposal. Work

area is washed down with water and squeegee used to dry.

12. PPE is placed in roll-off for disposal.

- 31 -



Carbon Filter Backwash

A1 and B1 Vessels Lead

A2 and B2 Vessels Lag

(Revised June 2011)

- 32 -

Summary

Granulated Activated Carbon (GAC) filter backwashing is a manual operation. This SOP

outlines the correct way to accomplish a backwash of the vessels when A1 and B1 are in the

lead position (A2 and B2 in the lag position). Differential pressures will read approximately

25 psi when backwash of GAC is needed.

Procedure

1. The operator needs to ensure that system will only run at 200 gpm by putting the 800

gpm SRS pumps and 900 gpm filter feed pumps in “MANUAL” mode by highlighting

each pump and then pressing key F19 on screens F9 and F11.

2. Once the larger pumps are in “MANUAL” mode, locate and access valves 8VY2-400,

8VY2-402 (B vessels) and 8VY2-403 (A vessels). Valve 400 is normally open and

needs to be closed. Valves 402 and 403 are normally closed and only one needs to be

opened depending on which vessel is being backwashed (A or B).

3. Go to gray valves between GAC vessels. Need to close all valves IN ORDER V-1, V-

3, and then V-10).

4. Once valves are closed, open the “Backwash Inflow” valve (V-8 for vessel A1/B1 and

V-7 for vessel A2/B2).

5. Now open the “Backwash Outflow” valve (V-5 for vessel A1/B1 and V-6 for vessel

A2/B2).

6. Return to office area and select PLC screen F14.

7. Highlight backwash pump P-401, P-402, or P-403. Once highlighted, press key F19 to

place in manual mode.

8. Use pump in manual mode to backwash the GAC at 600 gpm by key F20 to start the

pump and F21 to stop it.

9. Once the operator completes backwashes, close all gray valves.

10. Open valves IN ORDER V-10, V-3, and then V-1.

11. Open valve 400 and close valve 402 (B vessels) or 403 (A vessels) depending on

which vessel is being backwashed.

12. Return to PLC screens and place all pumps in auto mode by highlighting the pumps

put in “MANUAL” mode and pressing key F17.

Length of backwash is 30 minutes for each vessel.

- 33 -



Carbon Filter Backwash

A2 and B2 Vessels Lead

A1 and B1 Vessels Lag

(Revised June 2011)

- 34 -

Summary

Granulated Activated Carbon (GAC) filter backwashing is a manual operation. This SOP

outlines the correct way to accomplish a backwash of the vessels when A2 and B2 are in the

lead position (A1 and B1 in lag position). Differential pressures will read approximately 25

psi when backwash of GAC is needed.

Procedure

1. The operator needs to ensure that system will only run at 200 gpm by putting the 800

gpm SRS pumps and 900 gpm filter feed pumps in “MANUAL” mode by highlighting

each pump and then pressing key F19 on screens F9 and F11.

2. Once the larger pumps are in “MANUAL” mode, locate and access valves 8VY2-400,

8VY2-402 (B vessels) and 8VY2-403 (A vessels). Valve 400 is normally open and

needs to be closed. Valves 402 and 403 are normally closed and only one needs to be

opened depending on which vessel is being backwashed (A or B).

3. Go to gray valves between GAC vessels. Need to close all valves IN ORDER V-2, V-

4, and then V-9).

4. Once valves are closed, open the “Backwash Inflow” valve (V-8 for vessel A1/B1 and

V-7 for vessel A2/B2).

5. Now open the “Backwash Outflow” valve (V-5 for vessel A1/B1 and V-6 for vessel

A2/B2).

6. Return to office area and select PLC screen F14.

7. Highlight backwash pump P-401, P-402, or P-403. Once highlighted, press key F19 to

place in manual mode.

8. Use pump in manual mode to backwash the GAC at 600 gpm by key F20 to start the

pump and F21 to stop it.

9. Once the operator completes backwashes, close all gray valves.

10. Open valves IN ORDER V-9, V-4, and then V-2.

11. Open valve 400 and close valve 402 (B vessels) or 403 (A vessels) depending on

which vessel is being backwashed.

12. Return to PLC screens and place all pumps in auto mode by highlighting the pumps

put in “MANUAL” mode and pressing key F17.

Length of backwash is 30 minutes for each vessel.

- 35 -



Decanting Thickeners

(Revised June 2011)

- 36 -

Summary

Decanting water in Thickener T-301A and T-301B after sedimentation is a manual operation

that must be carefully managed to prevent the thickeners from being full when a storm event

is in progress. Thickener T-301A is fed by the removal of sludge from the clarifier or

cleaning of the SRS sump. Thickener T-301B receives backwash waste from the Multimedia

and GAC filters. Both thickeners have manual decant valves which are identical, so this SOP

works for both.

Procedure

1. Use either PLC screen to determine fluid levels in thickeners. Use F13 function to

select screen with thickener levels.

2. Open top decant and drain. Ball valve on drain pipe should be open no more than 30%

due to Process sump pump can not keep up with drain flow.

3. Once water has drained, you can close the valve and open the next valve below.

4. Steps 1 thru 3 are repeated until the water level in the thickener is at its lowest stage.

Thickener 301A will have a water level of 2.3 ft. and Thickener 301B water level of

0.5 ft.

Thickener #1 (T-301A) has capacity of 19,802 gal. It can hold the clarifier sludge pump

discharge at a rate of 10 gpm for 12 hrs.

Thickener #2 (T-301B) has a capacity of 36,320 gal. It can hold 3 multi-media filter

backwashes or 2 GAC filter backwashes.

- 37 -



Filter Press

(Revised July 2012)

- 38 -

Summary

Operation of the filter press / pressing sludge is a mostly manual process that takes an entire

week. The filter press does have an internal PLC that automatically controls the dewatering

cycle.

Safety

Personnel should wear tyvek suits, gloves, safety glasses, and dust masks while handling lime.

Procedure

Day 1

1. Fill lime mixing tank with 300 gal. of water. Turn on mixer. Slowly add lime to tank.

8 bags of lime can be mixed at once.

2. Use small pneumatic pump to transfer lime slurry from mixing tank to thickener to be

pressed.

3. If any lime is still present in the tank, add additional water and repeat step 2.

4. Open valve at base of thickener to allow air to mix thickener.

5. Clean up area were lime dust is. This will consist of washing down floor and

equipment. Squeegee floor dry.

6. Hang plastic sheeting around base of press so “slop” will be contained when filter cake

falls.

Day 2

7. Start filter press. Shut off air mixing prior to pressing. Follow prompts on processor

screen on press. Press is programmed and runs an automatic cycle which last 1.5 to

2.5 hrs. Shuts off automatically.

8. After press shuts off, open valve and bubble sludge in thickener. Personnel need to

wear Tyvek suit, gloves, safety glasses, and washable/dedicated boots.

9. Open press and allow filter cake to fall off. Cake sometimes needs to be scraped

loose. If it free falls, check edges of plates and clean off any cake in corners or along

edges.

- 39 -

10. Ensure that all hands are clear before using spreader to move plates.

11. Repeat steps 9 & 10 until all plates are clean (42 plates).

12. Close press & Repeat step 7.

A total of 3 pressings a day can be completed. Repeat steps 7 through 12 until all sludge is

processed.

After all sludge is pressed, the filter cake and miscellaneous PCB-contaminated filtration

equipment are analyzed for the parameters necessary to generate the appropriate, current

waste profile for the disposal vendor. Plastic sheeting is placed in roll-off and tarp cover

replaced. Press area is to be washed down and squeegee dry.

Prior to transporting full roll-off boxes off-site, an additional dewatering step is taken. A

small submersible pump attached to a screened PVC tube is placed in the north side of the

roll-off box and used to pump out any remaining free water.

- 40 -

Illinois Central Springs Treatment Facility

PTS Carbon Exchange Procedures

(Revised June 2011)

- 41 -

Purpose

The carbon adsorption units filter PCBs and other contaminants from the influent water

stream. When adsorptive capacity of the carbon is exhausted, the spent carbon must be

removed and replaced. This procedure and attachments detail the steps necessary for the

carbon exchange.

Summary


Scheduling

a. All carbon exchange operations should be scheduled to occur during minimum spring

flow periods. Do not schedule carbon exchange operations during high flow periods, i.e.

storm periods or during typical high flow seasons of the year.

b. Develop a contingency schedule should a high flow “storm” event occur or be forecast

just prior to or during the scheduled carbon exchange.

c. Verify that the roadway to the Illinois Central Spring Treatment Facility (STF) is capable

of supporting the carbon tanker and the waste disposal roll-offs.

d. Obtain a waste disposal approval for the spent carbon (pending analysis) at both Heritage

and Southside landfills. Note: Final approval can only be received after the samples are

analyzed, which can only be accomplished after the carbon change. However, we wish to

ship promptly upon receipt of analytical results, so a profile should discussed and

submitted in advance.

e. Arrange for delivery to the site of five 25 cubic yard de-watering roll-off boxes and five

filter liners. Three boxes may be adequate if carbon exchange is performed on one vessel,

and the boxes are used for transport, returned to the site and re-lined before the second

vessel carbon exchange is performed.

The carbon exchange procedures described herein detail the preparations, safety measures,

system shutdown, carbon removal and replacement, and the post-operations checks for system

restart. The carbon vendor (Calgon) will deliver new carbon, empty the carbon vessel, inspect

the carbon vessel and repair if necessary, then charge the vessel with new carbon and

collaborate with the plant operator to put the vessel back in service. This procedure does not

specifically describe those portions of the operation that will be performed by Calgon. It is

presumed that they have their own procedures. Rather, this document addresses their utility

and support requirements which will be handed by PSARA. This include providing sufficient

compressed air and water, providing an adequate number of de-watering boxes, capturing and

treating drainage water, and disposal of the spent carbon.

- 42 -

Contact subcontractors and obtain necessary parts and equipment

a. Contact and schedule all subcontractors necessary for the performance of carbon

exchange. These include Calgon, the filter box supplies, and he transporter and disposal

facility(ies).

.

Review Safety Requirements

a. Review all necessary safety requirements anticipated for carbon exchange and assure that

all scheduled work personnel and contractors have the necessary training, equipment, and

documentation required to perform the scheduled tasks.

b. Required training and equipment should all be obtained and verified prior to start of

project.

c. Proper personnel protective equipment (PPE) MUST be worn due to the possibility of

contact with PCBs or other contaminants.

d. Inspect the roll-off to insure that tailgate seals are in good condition and that the bed is

lined to prevent liquid from leaking out of the roll-off.

Equipment Required

a. Approximately 200 foot of 4-inch discharge/suction hose.

b. 100 feet of garden hose for wash-down.

c. Five 25 cubic yard de-watering roll-off boxes (for two vessels).

d. At least two manway gaskets to replace the ones being removed. (by Calgon as necessary)

e. An air supply system capable of 100 cfm at 90 psig. A fitting should be available to

connect air to the carbon delivery truck.

f. 50 feet of two-inch suction hose for spent water return

g. 150 feet of two-inch lay flat discharge hose for spent water return

h. A two-inch gasoline trash pump and adequate fuel for 8 hours use

Calgon Requirements (to be provided by PSARA)

Calgon will deliver the new carbon via a carbon transfer service vehicle, available with

capacities for one or two complete carbon vessel exchanges. Equipment specifications

required for the use of the Calgon carbon trailer include:

a. Flat area to support the trailer

b. Water line, 4-inch male Kamlock connector, 100 gpm at 15 psig max

c. Air line, 3/4-inch male Kamlock connector, 100 scfm at 90 psig max

d. Drain and transfer line, 4-inch male Kamlock connection, 20 ft. long

- 43 -

Procedure

PSARA Activities:

1. Conduct safety briefing prior to the procedure with all maintenance and contractor

personnel involved in the carbon exchange operation.

2. Locate the required roll-offs outside the Illinois Central Spring Treatment (see

attached map) Facility and set up necessary pumps and hose to transfer so that any

water in the carbon can be drained into the plant floor drain for processing.

3. Set Plant Process pump controls for P-107 and P-108 to manual operation at PLC

panel to prevent automatic start (plant operator).

4. Set disconnect(s) to off position at main motor control panel(s) next to the Plant

Process pumps P-107 and P-108. Lock Out/Tag Out required.

5. Connect the 4-inch suction hose from the vessel discharge pipe to the roll-off. Secure

the cam lock fittings to prevent an accidental release of the carbon/water.

6. Run the 2-inch water hose from the filter box through the trash pump and on to the

sump at the west end of the plant. Set this up with the two-inch trash pump. Be sure

the exhaust from the pump is not vented into the building.

7. Install filter liners in all filter boxes.

8. As the carbon is transferred to the filter boxes, pump the excess water from beneath

the filter fabric back to the plant sump using the trash pump.

9. When the first box is nearly full, transfer the discharge to the second filter box. Each

vessel is expected to fill between two and two-and-a-half filter boxes.

10. Collect a composite sample of the spent carbon for waste characterization analysis.

Submit the sample to Heritage Laboratories for the quickest turnaround available.

11. Removal all possible water from the filter boxes.

12. Tarp the boxes.

13. Submit the analytical results to the appropriate disposal facility (Heritage for TSCA

waste, Southside for non-TSCA waste), and complete the profiling process.

14. Prepare appropriate manifests, and ship the spent carbon to the appropriate facility.

15. Decontaminate the filter boxes at the ICS facility and return them to the supplier.

Note: This procedure does not address the actual carbon change process, as that process

will be performed by Calgon, using their own procedure. This procedure presumes that

Calgon will return the vessels to a ready condition, including wetting the carbon and

removing any entrained air.

- 44 -

Illinois Central Springs Treatment Facility

2500 gpm SRS Pump Back Flush Procedure

(Revised July 2012)

- 45 -

Purpose

The 2500 gpm SRS pumps are provided to help the PTS handle spring flows over 1000 gpm,

usually associated with a rainfall event. Because these pumps are infrequently used, they

require regular maintenance in order to ensure continued successful operation. One of these

maintenance activities includes back-flushing each pump to remove any solids that have

accumulated on the pump screen. This procedure details the steps necessary to perform this

task.

Procedure

1. Determine the pump that needs to be back flushed and select the appropriate pump to

provide flow for back flushing. If pump P-201 or P-203 need to be back flushed, P-

202 should be used to provide flow. If pump P-202 needs to be back flushed, either P-

201 or P-203 may be used to provide flow.

2. Manually open the valve connecting the back flushed pump and the flowing pump

approximately 1/8th

of the way.

3. Turn on the flowing pump.

4. Gradually open the valve between the two pumps until it is fully open to provide back

flushing flow to the designated pump.

5. Allow flow to continue for five minutes to ensure that all debris is removed from the

pump screen.

6. Turn off the flowing pump.

7. Return the valve between the two pumps to a closed position.

APPENDIX B

As-built Sump and Tank Sketches

APPENDIX C

System Piping and Instrumentation Drawings

PR

OC

ES

S &

INS

TRU

ME

NTA

TIO

N D

IAG

RA

M

DRAWING 9 OF 34 DRAWINGS

PR002

DESIGNED BY: AWB/OAGDRAWN BY: CSH/CWLCHECKED BY: RLVDATE CHECKED: 07/10

A

B

C

D

1 2 3 4 5 6

C0850030

NOTE: DIMENSIONAL DATAIS NOT TO BE OBTAINED BY SCALING ANY PORTION OF THIS DRAWING.

DATE REVISION

PROJECT No.

DRAWING No.

PROJECT TITLE

DRAWING TITLE

125 WEST CHURCH STREETCHAMPAIGN, IL 61820PHONE : 217.373.8900FAX : 217.373.8923

ENGINEERS

ILLI

NO

IS C

EN

TRA

L S

PR

ING

BLO

OM

ING

TON

, IN

EX

CE

SS

FLO

WTR

EA

TME

NT

SY

STE

M

07/10 BID SET09/10 FOR CONSTRUCTION07/11 RECORD DRAWING

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