Leachate management at landfills€¦ · Forget to use seal-offs & not potting them • Leave...
Transcript of Leachate management at landfills€¦ · Forget to use seal-offs & not potting them • Leave...
UPMI
©2015 EPG Companies Inc.
Sump Drainer Why?
Efficiency-a. Air Release
Valve = Cooling
b. Screensc. Transducer d. Easy System!
2
©2015 EPG Companies Inc.
SSR Simple HorizontalApplication
Verticals Much the same :Transducer locationWheels
3
©2015 EPG Companies Inc.
Pump Curves Typical Curves
StagingFor Flexibility!!
No Mechanical seals to replace and monitor oils
Req. Submerged Running WHY?
4
©2015 EPG Companies Inc.
Do…• Tailor specifications to each job• Use qualified and experienced installers &
electricians• Establish good electrical ground• Adhere to color coding of wiring• Design properly sized force main • Include air release valves in force main• Install pressure gauge in pump discharge line
Installation and Preventive Maintenance Overview
5
©2015 EPG Companies Inc.
Don’t…• Over size pumps
• Excessive flow rate creates high velocity in sump, pulling in fines
• Excessive pump head can lead to overload and vibration
• Place control panel too close to riser or sump • Forget to use seal-offs & not potting them • Leave excess cable and hose in sump or riser
Installation and Maintenance Learn to :Document data over timeTrack performanceUse your toolsFlow meterLevelElapsed timeCycle Counter
6
©2015 EPG Companies Inc.
Purpose
• Monitor and verify pump health• Normal pressure and flow determined
by pump performance curves
• Best if used in conjunction with a flow meter
• Document and record over time.
Pressure Gauge Inexpensive !
7
©2015 EPG Companies Inc.
Pressure Gauge
What can it tell you?
• Low Pressure / Low Flow• May indicate a worn pump• Starved suction – little or no liquid• Dry running
• High Pressure / Low Flow• Plugged pipe
Around $80.00 ea.
8
©2015 EPG Companies Inc.
Pressure Gauge Proper installation and location of the pressure gauge is important.
9
©2015 EPG Companies Inc.
A pressure gauge reads the system pressure loss from the point where the gauge is located to atmosphere.
It is not reading pump discharge pressure unless it is mounted directly at the pump discharge.
Pressure Gauge
10
11
©2015 EPG Companies Inc.
Dry Running and Maintenance
Running a pump with no liquid is termed “dry running”.
Dry running will lead to damage of:• Bearings• Seals• Motor
Clogged Inlets =
Pump called for and starved
12
©2015 EPG Companies Inc.
Dry Running and Maintenance Checks
Dry running can be caused by:
• A plugged sump drainer (screen)• Incorrect meter settings• Faulty meter or sensor• Plugged discharge line (dead head)• Gas effect; positive or negative pressure from
LFG or extraction system leads to false readings.
Pump starvedUnderload Overcurrent monitorMotor not doing work
13
©2015 EPG Companies Inc.
Check Valves and Maintenance
Check valves are used to:• Prevent back flow
• Back flow in some applications can turn the pump backwards. A pump starting at this time can damage the pump or cause premature wear of the bearings.
• Prevent air lock
Check valves can be located directly in the pump, or in the discharge line or in the force main.
Frozen Discharge Lines
Drilled check Valve In Pump?
14
©2015 EPG Companies Inc.
Controls …. Inspection & Housekeeping
15
RE Installation and Maintenance !
Correctly Level & Secure Installation of Panel?
Inspect Gaskets Seal offs
©2015 EPG Companies Inc.
Controls…Inspection & Housekeeping
16
RE: Installation and Maintenance!When an event happens:What ?Why?
Don’t just treat symptoms
©2015 EPG Companies Inc.
NEW Start-Up and Maintenance ChecksController:• Use and replace Corrosion inhibitors.• Use and correctly replace Desiccant dryers.• Make sure the door is straight, level, and not bent to
maintain a good seal and keep closed at all times.• Check to assure that there are no crushed, cut or damaged
wires. • Examine and Test all fuses.
e.g. Form 200
17
©2015 EPG Companies Inc.
NEW Start-Up and Maintenance ChecksController:• Test all indicating and warning lights.• Test level meter and IS barriers.• Configure meters and OCS with the sensors.• Test as a system with other panels.• Test “Tank Full” shut down.• Test level sensor circuit –set points correct?• Test alarming - leak detection circuit –vault, tank?
Form 200
18
©2015 EPG Companies Inc.
NEW Start-Up and Maintenance ChecksController (cont.):• Visually inspect inside of enclosure looking for signs of
moisture, bugs, loose wires, and burnt or discolored parts• Plug, or seal-off any holes in the control panel• Measure incoming voltage – Note: document it record it.• Verify flow meter is working by using a hand simulator if
pump is not running
e.g.Form 200
19
©2015 EPG Companies Inc.
Start-Up and MaintenancePUMPS:• Measure voltage and amperage while pump is running.• Megger motor lead by disconnecting it at control panel
(Do not megger low voltage equipment).• Log run time and number of cycles run if controller has
these features.• If possible, visually inspect pump discharge. Try and find
a point you can use to see if material is precipitating out of the leachate (decrease in flow rate or signs of precipitation are indications that the pump should be pulled and cleaned.
• Record pump discharge pressure readings. ( w/date )• Document: Complete a event record e.g. form 200
Qualified Personal
What has changed?
Startup note: Water in sump?
HDPE, PVC,Solids, fines?
20
©2015 EPG Companies Inc.
Vent Valve KitOn a sealed Sump Drainer…Failure of the vent valve to operate properly allows air or gases to enter the drainer while pumping causing it to accumulate at the top of the housing. This prevents effluent from entering the pump and likely lead to failure.Dry run
Start-Up -Maintenance Approx. $40.00
21
©2015 EPG Companies Inc.
NEW Start-Up-Maintenance Checks Seal offs are to be installed in each conduit run between riser/sump and controller.
22
©2015 EPG Companies Inc.
NEW Start-Up - Maintenance Cutaway of typical seal off correctly potted.
23
©2015 EPG Companies Inc.
Control Panels Maintenance Panel info:
Compare
Voltage
Phase
Amps
SCCR
Pump Info
Enclosure Rating
24
©2015 EPG Companies Inc.
UL Panels Maintain Panel Integrity:
Site additions or changes
To remain ULNeed new drawings“A little engineering”
25
©2015 EPG Companies Inc.
Control Panels Maintenance UL Panel
Fast Fix may equal many problems
DocumentationDrawings“At least a little engineering”
26
©2015 EPG Companies Inc.
Site Maintenance 1. Gas effect:
a. Safetyb. Performancec. Maintenance
D. Come on!
27
©2015 EPG Companies Inc.
Pump Maintenance Encrustation Different types “Flubber”PolymersPreventive MaintenanceProgram
Muriatic Acid
Pump Sizing!
28
©2015 EPG Companies Inc.
Pump Maintenance Corrosives Corrosion
Aggressive leachate
May require 316SS
29
©2015 EPG Companies Inc.
Site Maintenance area Set up a maintenance area for your pumps and keep it clean and ready for business.
Spare pump endsSpare motorsSpare TransducerMisc parts
30
©2015 EPG Companies Inc.
Force Main-Discharge lines -Mag meters Look at them-
Check once in a while –
Pump problems?
Buildup
31
©2015 EPG Companies Inc.
NEW Start-Up Maintenance Checks Your panel is unique. Identify the panel by the job number located on this label.
Document!
O&M’s
32
©2015 EPG Companies Inc.
Start-Up ..AND Maintenance Checks
• Verify that equipment and supply voltage match.• Inspect equipment, look for shipping damage, dirt
and rough handling.• Control panel should be mounted in secure way at
least 15’ from riser or sump and 36” above grade to bottom of control panel.
• Inspect inside of control panel. Look for items which may have come loose during shipping.
• Test level sensor in bucket of water. Does it return back to zero? Form 200
33
Vent Tube Check Valve
34
©2015 EPG Companies Inc.
NEW Start-Up Maintenance ChecksFasten motor lead and sensor cables to discharge line every 5’ to 7’ with straps or plastic wire ties. Motor lead and sensor cable are to be on opposite sides of the discharge line; use padding between cables and any metal straps.
CAUTION: Do not fasten stainless steel safety cable with other cables as this will snap off straps or ties when pulling pump. Fasten it independently with separate ties.
35Motor Lead
Sensor Cable
S.S. Safety Cable
©2015 EPG Companies Inc.
Installation and Maintenance
• Run pump down riser s-l-o-w-l-y using stainless steel suspension wire as hold back.
• Make sure motor lead and sensor cable are slack as you lower pump.
• Take Ohm reading of each motor lead wire to wire and compare the values in table 13 of the Franklin Electric motor manual for 1Ø and table 22 for 3Ø.
Pump re-install
Document
36
©2015 EPG Companies Inc.
Installation And Maintenance• Be sure to add wire resistance value to value from
tables 13 & 22. Call your MFG. with questions!
• Check insulation resistance as pump is lowered down riser.
• Resistance may drop gradually as pump and cable enter liquid, but any sudden drop indicates a problem.
Pump re-install
37
©2015 EPG Companies Inc.
Installation and Maintenance
• Run sensor leads and power cables in separate conduits to control panel.
• USE breakout junction boxes.
• If you have to remove dryer from end of transducer lead to pull lead through fittings or conduit, seal end of the vent tube with a piece of tape. Reinstall dryer as soon as possible.
Separate low Voltage
Maintenance:Check BJB’sDes. Dryers Pink?
38
©2015 EPG Companies Inc.
Installation and MaintenancePhoto showing dryer connected at the end of cable to vent line.
39
©2015 EPG Companies Inc.
Installation -Maintenance
• Megger motor leads. Resistance must be 1 Megohm or greater.
• Connect pump to control panel, complying with local and national codes.
• Controller terminal strips, motor leads, and sensor leads are all color coded to simplify connections.
Maintenance Notes-Form 200-
40
©2015 EPG Companies Inc.
InstallationSeal offs are to be installed in each conduit run between riser/sump and controller.
The proper use of thread seal tape on electrical conduit connections to prevent gas migration DOES eliminate the conduit as a ground.
A separate, dedicated ground wire must be pulled to insure a good ground.
41
©2015 EPG Companies Inc.
Questions for Installer• Were sensor and power cable tied or strapped to discharge line?• On what kind of spacing?• What is the as-built length of riser pump? Were cables long
enough? There should be 3 or more feet of slack in the cables.• What size cable was run for supply power.• What is the distance from power supply transformer to pump
control panel? • How did they verify that pump was down into sump?• Test level sensor prior to installing?• Test pump prior to installing or prior to your arrival?
Form 200
42
©2015 EPG Companies Inc.
What you see… May not be what you get.
Pollution Recovery MotorWell duty motor.6”-VS-4”½ the thrust
43
©2015 EPG Companies Inc.
NEW Installs -What you see… Don’t just kick the tiresLook under the hood!
44
©2015 EPG Companies Inc.
Installation and Maintenance Is control panel located safe distance from sump or riser?
Alerts?On going problems with Panel?Door pops open?Corrosion?
45
©2015 EPG Companies Inc.
Installation Maintenance
46
Gas Infiltration:
Ignore it and it will lead to fires BOOM!
©2015 EPG Companies Inc.
Installation , Site Maintenance Is control panel 3’ above grade?
47
©2015 EPG Companies Inc.
Installation and Maintenance
48
Makeshift breakout box?
a. Gas b. Ease of accessc. TransducerPressure -Vacuum
©2015 EPG Companies Inc.
Installation Maintenance
49
Poor wiring.
a. Worn wiringb. Makeshift
Temporaryc. Corrosion
Low voltage
Arcing
©2015 EPG Companies Inc.
Installation and Maintenance
50
Quick fix ?
Not UL
Safety?
Performance?
©2015 EPG Companies Inc.
Installation Maintenance
51
Concrete block support system.Look At your systems-has support worked loose?
GroundingLeaksPerformance
©2015 EPG Companies Inc.
Installation-Maintenance A site visit resulted in this discovery:
A seal off which had not been potted.
52
©2015 EPG Companies Inc.
Installation Maintenance Corrosion allowed the VFD to separate from the panel. Note the condition of the circuit board and terminal block.
Maintenance: A program to check on it all!
53
©2015 EPG Companies Inc.
Installation and Maintenance Heavy corrosion on fuse blocks.
Indicates WHAT?
Performance
Safety
54
©2015 EPG Companies Inc.
After running first few days:• Check that adequate grounding remains• Check voltage• Look for signs of power surges (lightning)• Installation problems may be traced back to:
• Poor connections• Mishandled parts• Pump flow rate too high for sump design
• Pumps clogged with HDPE chips or sand
Installation Maintenance Documentation
Call your MFG for Grounding requirements
55
©2015 EPG Companies Inc.
After several months of service:• Check that adequate grounding remains• Check voltage• Look for signs of power surges (lightning)• Do pumps perform as expected?• Is there noticeable Gas Effect in play (unreliable
level readings)?
Installation - Maintenance Documentation Good RecordsTo maintain a healthy system over time.
56
©2015 EPG Companies Inc.
• 1. Preventive Maintenance and Maintenance are both important tools at your sites.
• 2. Setting up a program is cost effective, needs a commitment –however from the top.
• 3. Look at how you can work it in to existing conditions and do it.
• Cycles, runtimes, flows, gas, levels, • Equipment integrity, leaks.
Maintenance 1. Have a person with a little training take a walk periodically
2. Form 200
57
©2015 EPG Companies Inc.
• 4. The indications of pressure changes, cycle and run time changes, blown fuses, low flows-overtime.
• Follow up and follow through-correct problems in early stages.
• Cost effective• Efficient• Safe • Responsible
Maintenance 1. Have a person with a little training take a walk periodically
2. Examine the reports and follow up
3. Form 200
58
©2015 EPG Companies Inc.
• Follow up and follow through-to correct problems in early stages, with a Maintenance Plan
• Is Cost effective• Is Efficient• Is Safe • Is Responsible• To your fellow workers, your site,
the environment and you.
Maintenance 1. Have a person with a little training take a walk periodically
2. Examine the reports and follow up
3. Form 200
59
©2015 EPG Companies Inc.
Future?New challenges!
Will require :Maintenance
60
Thank You!