leachate management at landfills€¦ · forget to use seal-offs & not potting them • leave...

©2015 EPG Companies Inc.

Sump Drainer Why?

Efficiency-a. Air Release

Valve = Cooling

b. Screensc. Transducer d. Easy System!

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SSR Simple HorizontalApplication

Verticals Much the same :Transducer locationWheels

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Pump Curves Typical Curves

StagingFor Flexibility!!

No Mechanical seals to replace and monitor oils

Req. Submerged Running WHY?

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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

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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

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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 !

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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.

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Pressure Gauge Proper installation and location of the pressure gauge is important.

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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

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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

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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

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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?

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Controls …. Inspection & Housekeeping

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RE Installation and Maintenance !

Correctly Level & Secure Installation of Panel?

Inspect Gaskets Seal offs


Controls…Inspection & Housekeeping

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RE: Installation and Maintenance!When an event happens:What ?Why?

Don’t just treat symptoms


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

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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

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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

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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?

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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

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NEW Start-Up-Maintenance Checks Seal offs are to be installed in each conduit run between riser/sump and controller.

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NEW Start-Up - Maintenance Cutaway of typical seal off correctly potted.

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Control Panels Maintenance Panel info:

Compare

Voltage

Phase

Amps

SCCR

Pump Info

Enclosure Rating

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UL Panels Maintain Panel Integrity:

Site additions or changes

To remain ULNeed new drawings“A little engineering”

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Control Panels Maintenance UL Panel

Fast Fix may equal many problems

DocumentationDrawings“At least a little engineering”

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Site Maintenance 1. Gas effect:

a. Safetyb. Performancec. Maintenance

D. Come on!

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Pump Maintenance Encrustation Different types “Flubber”PolymersPreventive MaintenanceProgram

Muriatic Acid

Pump Sizing!

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Pump Maintenance Corrosives Corrosion

Aggressive leachate

May require 316SS

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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

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Force Main-Discharge lines -Mag meters Look at them-

Check once in a while –

Pump problems?

Buildup

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NEW Start-Up Maintenance Checks Your panel is unique. Identify the panel by the job number located on this label.

Document!

O&M’s

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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

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Vent Tube Check Valve

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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


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

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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

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• 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?

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Installation and MaintenancePhoto showing dryer connected at the end of cable to vent line.

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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-

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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.

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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

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What you see… May not be what you get.

Pollution Recovery MotorWell duty motor.6”-VS-4”½ the thrust

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NEW Installs -What you see… Don’t just kick the tiresLook under the hood!

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Installation and Maintenance Is control panel located safe distance from sump or riser?

Alerts?On going problems with Panel?Door pops open?Corrosion?

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Installation Maintenance

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Gas Infiltration:

Ignore it and it will lead to fires BOOM!


Installation , Site Maintenance Is control panel 3’ above grade?

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Makeshift breakout box?

a. Gas b. Ease of accessc. TransducerPressure -Vacuum



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Poor wiring.

a. Worn wiringb. Makeshift

Temporaryc. Corrosion

Low voltage

Arcing



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Quick fix ?

Not UL

Safety?

Performance?



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Concrete block support system.Look At your systems-has support worked loose?

GroundingLeaksPerformance


Installation-Maintenance A site visit resulted in this discovery:

A seal off which had not been potted.

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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!

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Installation and Maintenance Heavy corrosion on fuse blocks.

Indicates WHAT?

Performance

Safety

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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

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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.

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• 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

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• 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


2. Examine the reports and follow up

3. Form 200

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• 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.


2. Examine the reports and follow up

3. Form 200

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Future?New challenges!

Will require :Maintenance

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Thank You!

leachate management at landfills€¦ · forget to use seal-offs & not potting them • leave...

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