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Vol IV BTL - Pioneer Technical Services, Inc.

1. 12 2 1 3 Lime Feeder System Screw Conveyor Failure Decision trees BTL DT 4 and BTL DT 5 located in Appendix F provide guidance in troubleshooting and maintaining the lime feed and screw conveyor systems The following sections provide potential causes and remedies for component operational failures Draft Butte Treatment Lagoon BTL Systems Page 76 of 85 Operation Maintenance and Monitoring Plan Potential Causes for Screw Conveyor Failure This status input detects the status of the screw conveyor The screw conveyor is associated with the Lime Feeder System Control Panel and operates at a constant speed Potential causes include 1 Lime Feeder Control Panel will automatically shut down the screw conveyor when these conditions exist e Screw conveyor motor failure and e Accurate Feeder motor failure 2 Power outage and 3 Tripped breaker due to overload caused by lime clog in the screw conveyor system Initial Review Screenings for Screw Conveyor Failure Verify screw conveyor status is not alarming on the HMI screen If status ON is displayed screw conveyor is operating normal but if status is alarming proceed to troubleshooting as described below Troubleshooting for Screw Conveyor Failure 1 Ensure the power is reaching the Lime Feeder System Control Panel by checking the lights on the front of the panel 2 Ensure Lime Feeder System Control Panel breaker is not tripped 3 Ensure the Accurate Feeder is ope
2. Assume a Lime Rate 130 Assuming a Routine Flow 1 200 gpm Known Silo Capacity 22 tons Theoretical lime usage calculation is as follows 130 0 001 1 454 1200 gpm 3 785 Meat 60 Vin 24 day 1 877 P aay 44 000 Ibs 1 day 1 877 Ibs 23 4 days Lime feed and actual usage is verified through computer a spreadsheet based calculation which uses field data and the difference in lime storage over a given period of time Calculations provide operators reliable projection of lime storage at current operating levels 6 2 3 2 Lime Delivery Lime deliveries are anticipated at a routine frequency of 5 to 7 days after placement of orders Deliveries are made in 24 to 30 ton trucks with pneumatic unloading capabilities Do not allow lime delivery personnel to unload more than the required amount of lime to fill the silo NOTE Overfilling the silo will create operational difficulties Draft Butte Treatment Lagoon BTL Systems Page 46 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Qperators must re order lime from the lime provider before lime level reaches 5 feet on the level indicator LI CAS 101 Lime order contact information Graymont Western US Inc Indian Creek Plant P O Box 550 4 12 miles west Indian Creek Road Townsend Montana 59644 Phone 406 266 5221 Contact Cindy Howard Alternate Contact Carla Corporate office Graymont Western US Inc S
3. CAS Building electrical service loss Poor communication line connection and Transmitter or receiver malfunction Pe Initial Review Screenings for CAS Building Communication Failure Verify CAS Building Communication Status is not alarming on the HMI screen If status NORMAL is displayed CAS Building communication is operating normal but if status is alarming proceed to troubleshooting as described below Troubleshooting for CAS Building Communication Failure Ensure the PLC is ON by checking the power lights Ensure main computer is ON by checking the monitor Ensure CAS Building has electrical service Ensure electrical and ethernet cables are connected firmly to the PLC Ensure cable is in good condition with no exposed wires and Ensure the operator s interface and PLC are communicating by checking transmit receive lights on the PLC located in the Treatment System Control Panel SAE Aa ie al al ae Corrective Procedures for CAS Building Communication Failure 1 Replace PLC electrical power fuse or replace electrical power supply 2 Replace communication cable and ensure cable is seated into correct port securely and 4 Reboot PLC to re establish communication Draft Butte Treatment Lagoon BTL Systems Page 75 of 85 Operation Maintenance and Monitoring Plan 12 2 1 2 CAS Building Electrical Service Failure The following subsections provide general guidance to troubleshoot electrical service failure at the CAS
4. alarm status such as loss of power pump failure instrument failure and high low level or flows Draft Butte Treatment Lagoon BTL Systems Page 12 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Data and site system status for all remote sites are collected by the CompactLogix PLCs and the Master PLC at the Operations Building then polls each site for the data 2 4 1 Hydraulic Control Channel The HCC shown on Figure 4 begins at the east side of LAO directly south of the BRW and flows west for approximately 5 000 feet to the west edge of the site where it discharges to Cell D4 The HCC was constructed during the Phase I LAO Expedited Response Action ERA construction to intercept the impacted alluvial groundwater in LAO This channel currently functions as an interception trench to collect impacted alluvial groundwater from Butte Hill and Missoula Gulch flow WCP 1 and MSD and prevents groundwater from impacting the reconstructed Silver Bow Creek channel and floodplain A high density polyethylene HDPE sheet pile terminates the HCC and prevents untreated flow to Silver Bow Creek The crest of the sheet pile is at 5 417 feet above mean sea level amsl A staff gauge located in the HCC near the HDPE sheet pile provides direct indication of the HCC water level The flow in the HCC is affected by the groundwater discharge and by wet weather flow in the Missoula Gulch watershed and MSD groundwater site Des
5. 2 to the east edge of Cell A2 or to the effluent pipeline through EL B Lagoon System C Flow into Lagoon System C is regulated with Weir Gate C located in the Distribution Tank Manual settings of the weir gate in OS 3 located in Cell C3 determine the water levels of Lagoon System C The initial target operating level of this system is 5 422 5 feet amsl Water can be discharged either to Cell A2 through a 12 inch discharge pipe which extends from the bottom of OS 3 to the southeast corner of Cell A2 or to the effluent pipeline through EL A Cell D2 During routine operations the initial target operating water level which should be checked visually of Cell D2 is 5 419 5 feet amsl and this pool elevation will be controlled with stop logs located in OS 6 The outlet structures will be checked and cleaned of debris if any Cell D3 During routine operations the initial target operating water level which should be checked visually of Cell D3 is 5 417 25 feet amsl and this pool elevation will be controlled with stop logs located in OS 8 The outlet structures will be checked and cleaned of debris if any Cell D4 Under routine conditions the water level at Cell D4 will be maintained at approximately 5 414 5 feet ams with only one influent pump will be in operation 3 2 6 System Flexibility and Adjustment Provisions have been made to enable operation of the BTL systems to respond to varying conditions and optimize overal
6. 4 Enclosure and Panel Heater and 120VAC Branch Circuit Breaker Panel 3 Cell A2 Station aoe soa rho 480VAC Distribution Breaker Panel Two Pump Hand Off Auto switches for control of 75 HP and 15 HP pumps Programmable Logic Controller Analog Interface Terminal for the following analog points name monitoring point and device A2 Level Feet Surge Protection for Line Power and Analog Isolation NEMA 4 Enclosure and Panel Heater Remote Radio Interface and 120VAC Branch Circuit Breaker Panel 4 Cell A3 Station a b 480VAC Distribution Breaker Panel and Two Pump Hand Off Auto switches for control of two 75 HP influent pumps 5 ASB at southern end of Cell A3 a Programmable Logic Controller b Analog Interface Terminal for the following analog points name monitoring point and device A3 Level feet CT EFF Flow gpm Cell D4 Level feet c Remote Radio Interface d Surge Protection for Line Power and Analog Isolation Draft Butte Treatment Lagoon BTL Systems Page 52 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product e NEMA 4 Enclosure and f 120VAC Branch Circuit Breaker Panel 6 Cell D4 Influent Pump Station a 480VAC Distribution Breaker Panel b Two Pump Hand Off Auto switches for local control of 75 HP pumps and c 120VAC Branch Circuit Breaker Panel 6 2 6 System Glossary HAND Hand or manual position of a Hand Off Auto c
7. 7124 219 545 4725 Pioneer Technical Dave Griffis 563 9371 ext 306 490 4210 Brad Archibald 497 8019 490 3032 494 6549 Pat Sampson 782 5797 490 0706 Brad Hollamon 782 5797 490 7678 782 3243 Steve Lubick 563 9371 490 7680 782 1702 Tan St John 782 5797 490 4900 Tara Schleeman 497 8026 490 8272 533 0913 EPA Sara Sparks 782 3264 949 4149 DEQ Joe Griffin 560 6060 1 4 3 Additional Emergency Contact Agencies Emergency Response 911 Disaster Emergency 406 497 6295 NorthWestern Energy Emergency 1 888 467 2427 Electrical Emergency 1 888 467 2353 1 4 4 Non emergency Services Police 406 497 1120 Mt Highway Patrol 406 494 3233 Fire Department 406 497 6481 Water Company 406 497 6500 Butte Silver Bow County 406 497 6515 Public Works Metro Sewer Plant 406 497 6550 NorthWestern Energy Connect and Repair 1 888 467 2669 Draft Butte Treatment Lagoon BTL Systems Page 6 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Qwest Comm 1 800 954 1211 Underground Utilities 1 800 424 5555 MT Department of 406 494 9600 Highways St James Hospital Butte 406 723 2500 Local Resources company names contact name phone numbers description of resources Oil Spill Response Contractors OSROs ATLATL Inc 406 723 7980 1 5 Organization and Use of this O amp M Plan This O amp M Plan contains information describing how to operate and maintain the lagoon treatment system In addition the
8. After enough time has been allowed for thorough lime addition throughout the mixing tank the operator must test the Al channel for the current pH Depending on the Channel pH the operator must adjust the Manual variable control knob until a desirable Channel pH is achieved 6 3 2 2 Slurry Feed Water SOP 7 1 Adjust the 10 inch main valve CAS GV 101 on the main influent pipe pipe number to be provided when finalized Closing the valve will create pressure on system to allow for flow into the online slurry tank 2 Direct flow to primary slurry tank under normal operating conditions The secondary mixing tank will be used when maintenance is required on the primary tank 3 Balance the pressure and flow of the feed water and main influent for maximum efficiency and range of flow 4 Ensure range of flow into slurry tank feed water 150 to 250 gpm 6 3 2 3 Slurry Mixers 1 Verify Tank 1 or Tank 2 being filled 2 Allow tank level to fill to 5 feet This point is beyond location of mixer impellers 3 Energize mixer motor locally by depressing the start button of the associated tank mixer Note Operating the mixer below the minimum level will result in damage to the mixer impeller or shaft Draft Butte Treatment Lagoon BTL Systems Page 55 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 6 4 Normal Shutdown Under normal operating conditions the CAS system will remain
9. Auger Status On Off Silo Level Feet Tank 1 Level Inches Tank 2 Level Inches Tank 1 Mixer Status On Off Tank 2 Mixer Status On Off Slurry Tank 1 Feed Water gpm Slurry Tank 2 Feed Water gpm A Cells Level Feet 2006 B Cells Level Feet 2017 C Cells Level Feet 2025 Lime Silo Control Panel Accurate Feeder Screw Motor Accurate Feeder Paddle Motor Dust Collection Fan Bin Discharge Screw Conveyor Slurry Tank Select and Slurry Tank Level 2 Cell Al Station a 480VAC Distribution Breaker Panel Draft Butte Treatment Lagoon BTL Systems Operation Maintenance and Monitoring Plan Confidential Attorney Work Product McCrometer Switch Yo Yo Meter Ultrasonic Ultrasonic Ultrasonic Ultrasonic Flow Meter Flow Meter Level Transducer Level Transducer Level Transducer Instrument Monitoring Definition name monitoring point device and identifier FIT LAO1059 TBD LT LAO1000 LT LAO1049 LT LAO1039 ZX LAO 1048 ZX LAO 1038 FIT LAO1049 FIT LAO1043 LI LAO 2000 2003 LI LAO 2015 2016 LI LAO 2021 2022 Page 51 of 85 b Three Pump Hand Off Auto switches for local control of 15 HP 5 HP and 5 HP pumps moa rho Programmable Logic Controller Analog Interface Terminal for the following analog points name monitoring point and device Al Level Feet B3 Level Feet C3 Level Feet Remote Radio Interface Surge Protection for Line Power and Analog Isolation NEMA
10. B3 should be discharged to Cell A2 to maintain water levels in Cell A2 and Cell A3 3 2 4 Alternate Flow Operations Effluent flow can either be parallel series flow in which flow is divided into A B and C lagoon flow as described above Each lagoon utilizes three cells in series to complete treatment before discharge to Silver Bow Creek Recirculation flow is attainable when additional treatment or retention time is required prior to discharge The following sections describe these flow operations Draft Butte Treatment Lagoon BTL Systems Page 36 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 3 2 4 1 Operation in Series An alternative flow path for routine conditions is the operation of the cells in series By diverting flows from Lagoon Systems B and C into Cell A2 the water will be passed in series throughout the lagoon system and ultimately discharged to Silver Bow Creek from Cell A3 Figure 2 shows the available flow path alternatives 3 2 4 2 Recirculation Flows If water does not meet the discharge criteria see Section 5 0 in one or any of the treatment cells there are several locations OS 3 OS 4 and OS 7 that allow water to be recirculated through the system for retreatment Structures OS 3 and OS 4 can divert flows from Cells A2 B3 and C3 into Cell D2 and eventually to Cell D4 where it can be recirculated through the system Structure OS 7 can be used to divert flows from Cell A3 int
11. BTL Systems Page 18 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product incorporated in the lime silo controls Lime is delivered at a dosage mg L set by the operator however mass delivery of lime is based on influent flow rate The incorporated control system provides variable lime feed to accommodate the influent flow rate fluctuations Supply Water Feed Lines These consist of two 4 inch PVC SCH80 lines which connect the influent pipeline with the slurry tanks Each supply water feed line is fitted with a butterfly valve to control the flow of water into the slurry tanks These feed lines provide makeup water for the continuous dry lime addition operations Slurry Tanks T CAS 101 T CAS 201 The slurry tanks consist of 2 identical tanks 5 foot diameter by 5 foot height constructed of s inch American Society of Testing and Materials ASTM A36 carbon steel rolled plate with a continuous seam weld welded flat bottom and fitted lid and 4 internal side baffles Baffles are symmetrical within the tank placed at 90 degree intervals Each tank has 730 gallon liquid capacity designed for atmospheric pressure The tanks are located in the west one half of the CAS Building The tanks were originally designed to allow batch mixing capabilities of lime slurry and are currently used for continuous addition of lime slurry During batching operation the south tank Tank 1 will be operated as a mixing vesse
12. BTL Weekly Operation Report and e Appendix I Sludge Production Estimate 1 1 Purpose and Scope This document Volume IV presents the BTL Systems at LAO System Operation Maintenance and Monitoring O amp M Plan located within the BPSOU It contains key components for an O amp M Manual as presented in the U S Environmental Protection Agency s EPA guidance Fact Sheet Operation and Maintenance in the Superfund Program OSWER 9200 1 37 FS EPA 2001 and Section 3 5 2 of OSWER Directive 9355 0 4A Superfund Remedial Design and Remedial Action Guidance EPA 1986 Figure 1 identifies the BTL LAO related system sites major features within LAO and remote monitoring locations Figure 2 identifies all components of the BTL systems The following sections describe the treatment system performance goals routine and transitional situation operations record keeping and reporting requirements routine inspection and maintenance programs emergency procedures and site health and safety associated with the BTL systems Activities associated with O amp M of the BTL LAO systems must be performed in accordance with the BTL LAO Site Specific Health and Safety Plan SSHASP for Operation and Maintenance Activities Pioneer 2010 The SSHASP provides guidance for the appropriate mitigation and controls to eliminate or reduce identified hazards and or risks associated with O amp M activities Draft Butte Treatment Lagoon BTL Systems Page 1 of 85 O
13. Building Appendix F also contains multiple troubleshooting decision trees Action beyond the steps provide require the assistance of a qualified electrician Potential Causes for CAS Building Power Failure This status input detects if the 480 Volt 3 phase electrical service is present Potential causes for a CAS Building Power Failure include 1 Power outage and 2 Tripped breaker due to overload Initial Review Screenings for CAS Building Power Failure Verify CAS Building Power Status is not alarming on the Operator interface screen If status NORMAL is displayed CAS Building communication is operating normal but if status is alarming proceed to troubleshooting as described below Troubleshooting for CAS Building Power Failure 1 Ensure the power is reaching the CAS Building by checking the lights in the building 2 Ensure Treatment System Control Panel breaker is not tripped 3 Ensure the cut out switch located on the north side of the CAS Building is not in the OFF position and 4 Ensure the main 480 Volt 3 phase breaker is not tripped Corrective Procedures for CAS Building Power Failure 1 Replace Treatment System Control Panel electrical power supply or blown power fuses 2 Try to reset tripped breakers if breakers trips again contact NorthWestern Energy or electrical contractor to perform further repair troubleshooting as necessary and 3 Turn ON the cut out switch located on the north side of the CAS Building
14. Cea 36 3 2 4 Alternate Flow Operations ssssseseseseseeesssesseessessseresseessseesseesseesseesseee 36 3 2 4 1 Ope rtati n In Seriesin ire nsn as eria 37 3 242 Recirculation FLOWS arran ein ea ETa aN 37 3 2 5 Routine Operations sses oiis ris TE ipai e iiS 37 3 2 6 System Flexibility and Adjustment cee ceeseceeceeceeeeeceeeeeceeeeeeeneeeees 38 32 Lagoon Retention TIMES n Gos E A EEE E en ea AEE R 39 AO SAFE OPERATINGLIMITS onnea e A tana 40 4 1 PROS SUNG sesinin si i n eri aas a ARE Ea SaS EEEE A EERE ES 40 AD VEMVBSL AWTS esi eh enint e e a a a e des e a e E SE 40 Draft Butte Treatment Lagoon BTL Systems Page iv of ix Operation Maintenance and Monitoring Plan Confidential Attorney Work Product AD SGround Water 22 5 sich eid bteisalits we HS avi a A SEATA 40 ADS PUMphoUS een canes sone scesecctna a N E N EAEE as 40 AD 3 AMen a cite onan ets arias a a a a eM 40 4 3 Flow Capacity ciscccsocssisiensiattvamnieiedeveaa aut a ada nes Te E Ea E EE Re Teat 40 AA Electricals nsns unne a t ae E e EESE 40 4 5 Protective Satety DEVICES aire E E E ance pee i eae 41 5 0 PERFORMANCE STANDARDS oirnn a a A E ates 42 6 0 ROUTINE OPERATION AND MAINTENANCE TASKS cccccccceceseceeeeeeeeeteeenaeens 42 6 1 Routine Operations Tasks yiiiciissiccisshacan sac jesacasessacansesdeanasuchadevsnnccats a s ia 42 6 1 1 Controls Outlet Structures Lime Feed Area and Cell D4 0 43 6 1 2 Missoula Gulch Groundwater
15. D4 The large amounts of influent water created from any of these situations can be stored by allowing the water level to rise in Cell D4 until it can be pumped down and treated Currently the normal operating water level in Cell D4 is 5 414 5 feet amsl and it can store inflow water by allowing the D4 level to rise to 5 417 feet amsl During periods of high flow each lagoon system receives additional flow proportional to the overall flow Additional provisions are not required Short term flows over the estimated 1 800 gpm designed maximum treatment system flow rate will be directed into Cell D4 where the water can fill the cell to 5 417 feet amsl and be stored until it can be pumped down 3 2 3 Low Flow Path During low flow conditions or flows less than 700 gpm routine operations are conducted with the following modifications e Minimum of 200 gpm is diverted into Lagoon System B from the Distribution Tank e Minimum of 200 gpm is diverted into Lagoon System C from the Distribution Tank e Remaining flow is diverted into Lagoon System A from the Distribution Tank e Flow from Lagoon System B is either diverted into EL B or Cell A2 If influent flow to Cell Al is below 300 gpm then flow from Cell B3 and or C3 should be discharged to Cell A2 to maintain water levels in Cell A2 and Cell A3 e Flow from Lagoon System C is either diverted into EL A Cell A2 or Cell D2 If influent flow to Cell Al is below 300 gpm then flow from Cell C3 and or
16. Pump Remote Stop Button is located on the Lime Feeder System Control Panel and is used to shut down the D4 pumps in an emergency situation If there is a communication failure between the CAS Building and the IPS radios for a period greater than 10 minutes the IPS PLC will shut the pumps off The control system is configured to shut down the lime feeder system when the influent pumps are interrupted for a period greater than 30 minutes The control system will also shut the influent pumps off when the lime feeder system is interrupted for a period greater than 30 minutes The IPS PLC transmits a signal to the CAS Building PLC to indicate the status of the D4 pumps When both pumps are off the CAS Building PLC program will shut down the lime system 2 7 Description of Monitoring Facilities 2 7 1 System Overview The BTL facilities include an extensive and varied information collection system Monitoring facilities include the following Draft Butte Treatment Lagoon BTL Systems Page 29 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product e Staff gauges and pressure transducers are installed at pond level at Cells Al A2 A3 B1 B3 C1 C3 and D4 e Monitoring of pump status 1 e on off and flow rate is performed at Cells Al A2 A3 B3 and C3 during pumping operations e Water quality monitoring sampling facilities are installed within the Automatic Sampler Building and within the CAS Buil
17. System cceesceeeeeeeceeeeeceeeeeeeeeeeeseeeeees 43 6 1 3 West Camp Pump Station ai g iscisscckiaisaceescaavesacdsuseeesanncsdanetedaedeauibecneneaeens 44 6 1 4 Metro Storm Drain Pump Station sseeesneeesseessensseesseeesseeesseesseesseesseeesseee 44 GALS Weekly Reportin Sanese esau t a K E haya E EERE 45 6 2 Lime Treatment at the CAS Building sssssssessessseseseeessseessresseesserssseeesseesseesseessee 45 OZ System OVCRVICW moisten a a E A a R 45 6 2 2 Lime Addition Control Mechanism cccccceeseeceeeeceeeeeceeeeeceeeeeseteeeees 45 6 2 3 Chemical Addition System Criteria ss esseesseessessseeesseessseessersseesseeesseee 46 623 l Eime DOSS ians i oes sae hr ghey oh a eau sstiees 46 6 2 3 2 Lame Delivery aian ein E E a A a L estas 46 6 2 4 Description of Control Settings sesesseeesseesseessessseesseeesseessesseesseeesseee 47 62AT Auto Sampin T n e E A A R EER 47 6 2 5 Control and Monitoring Device Summary s ssssesesssesssssessseessessesseeeeseee 50 6 2 0 System GIOSSA Y ccs ceiacacorighonnsnaebtensaes n n a a eaae e i 53 6 3 Normal Start Ups sisercdiass onor A E E A E a na 53 6 3 1 IPS StartUp SOP 0 zraneniami acct a a 53 63 2 CAS Star Upi n a a EE gh beta E eee aoe aaa ee 54 6 3 2 1 Lime Addition SOP 28 seseeseseeesssssssseseesesseserssseserssrseesesseseese 54 6 3 2 2 Slurry Feed Water SOP 7 sssessesssesssesessseesseessresseesserssseeesseessrese 55 6323n Slurry MIKE
18. and Maintenance in the Superfund Program OSWER 9200 1 37 FS May 2001 EPA 2002 Butte Mine Flooding Operable Unit Site Consent Decree CV OZ 35 Bu RFC August 14 2002 EPA 2006 Butte Priority Soils Operating Unit Record of Decision EPA 2006 Pioneer 2010 BTL LAO Site Specific Health and Safety Plan for Operation and Maintenance Activities February 2010 Draft Butte Treatment Lagoon BTL Systems Page 85 of 85 Operation Maintenance and Monitoring Plan srvw2k ArcoDatal Butte BPSOU 201 1 LAO O amp M Plan Vol IV_01 18 201 1 Vol IV BTL 0125201 1 docx
19. be either diverted into EL A Cell A2 or D2 Flow will be diverted from Cell C3 into EL A i e water quality at or near discharge standards and target water levels are achieved in the treatment cells e Flows entering Cell A2 can be diverted into D2 through OS 4 into Cell A3 or into the effluent line EL C at OS 5 Flow will not be diverted into Cell D2 during routine conditions Flows will be diverted through OS 5 to Cell A3 and will not be diverted to Cell D2 or EL C Water can be split between Cell A3 and EL C if water quality permits but a minimum of 400 gpm will be routed into Cell A3 to maintain required water levels and prevent exfiltration of impacted groundwater into this cell e Flows entering Cell A3 can be diverted into EL D or Cell D4 All flows will be diverted into EL D unless sample results at Cell A3 indicate water is not meeting discharge standards then flows will be diverted into Cell D4 All flow will be discharged from Cell A3 into EL D Draft Butte Treatment Lagoon BTL Systems Page 35 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 3 2 2 High Flow Path High flows are those influent flow rates between 1 500 gpm and the designed maximum treatment system flow rate of 1 880 gpm High flow situations could be related to high pump rates from WCP 1 MSD or high rates collected from the HCC High flow could also occur if a cell within the Lagoon System is drained and discharged in Cell
20. flow rates and pH for the influent and effluent stations and minimum maximum and average lime addition rates for the lime feeder system These data will be presented in graphs and tables to help visually explain the effectiveness of the BTL systems Also notes of maintenance activities on site possible upsets in operation and explanations for any elevated laboratory results will be included in the Quarterly Operations Report 10 4 Supplementary Data As necessary supplementary data may be collected for process control and system evaluation to assist the operator to improve the treatment effectiveness or optimize the BTL systems Record of these data will be included in the Quarterly Operations Report Draft Butte Treatment Lagoon BTL Systems Page 71 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 11 0 ROUTINE INSPECTION AND MAINTENANCE GUIDELINES Routine inspection and maintenance is performed as a component of daily system operation and maintenance Routine inspection involves an operator s use of sight sound and touch to identify maintenance items 11 1 Inspection and Maintenance Guidelines for Process Equipment The following subsections describe the routine inspection and maintenance tasks necessary for the process and monitoring equipment For the purposes of inspection and maintenance the following facilities contain process and monitoring equipment e CAS Building e ASB and e Cell D
21. fully open and not restricting flows Corrective Procedures for Influent Flow Alarms 1 Try to reset tripped breakers if breakers trip again contact NorthWestern Energy or electrical contractor to perform further repair troubleshooting as necessary 2 Procedure 10 in Appendix C summarizes the steps to startup flow at the IPS 3 Startup the lime feeder system equipment and primary PLC equipment located in the CAS Building and 4 Open all valves located on the influent line to ensure they are not restricting flows 12 2 2 Lagoon Systems Water Level Failure Alarm This section addresses alarm conditions at the lagoon systems and addresses likely causes and appropriate troubleshooting actions The operator interface panel located on the control and instrument panel displays the status of several system components Monitoring points associated with the lagoon systems are as follows Instrument Tag Number LT LAO 2000 LT LAO 2003 LT LAO 2006 LT LAO 2009 LT LAO 2011 LT LAO 2013 LT LAO 2015 LT LAO 2016 LT LAO 2017 LT LAO 2021 LT LAO 2022 LT LAO 2025 Description Pond A1 Level amsl Pond A2 Level amsl Pond A3 Level amsl Pond D2 Level amsl Pond D3 Level amsl Pond D4 Level amsl Pond B1 Level amsl Pond B2 Level amsl Pond B3 Level amsl Pond C1 Level amsl Pond C2 Level amsl Pond C3 Level amsl Callout Point HI LO HI LO HI LO HI LO HI LO HI LO HI LO HI LO HI LO HI LO HI LO HI LO Ca
22. leaving the lagoon systems The main reasons for this hydraulic overview are as follows e Effectiveness of treatment is likely to vary with hydraulic flows cell retention and water levels The operator may be able to increase system in effectiveness by modifying system operation For example cell level can be adjusted to change the retention time 8 7 Routine Sampling Tasks The operator is primarily responsible for collecting representative water quality samples for specific locations associated with the BTL Automatic samplers are provided to assist with this task The operator must perform various QC tasks to verify operation of monitoring instrumentation The following items are highlighted e Automatic composite samplers will be programmed to automatically start and complete a 24 hour composite sample collection on a twice weekly schedule that anticipates an operator visit shortly after completion of the compositing period e During each visit to collect composite samples the operator will use portable field measurement instruments to ensure the current parameter reading on the continuous measurement unit is within a specified deviation from the portable checking unit then the recent continuous measurement data will be reviewed and the instrument will be recalibrated if necessary If the deviation persists the continuous measurement unit will be checked and recalibrated or repaired according to manufacturer s instructions The perm
23. of 2004 Detailed as built drawings are available for the lagoons in Appendix A and also BTL Effluent System in the Draft Final As Built Drawings and Information for the Butte Treatment BTL Systems Atlantic Richfield Company 2006 The Effluent Pipeline System and outlet structures have been designed to discharge the maximum flows through each series of treatment lagoons as described in Section 3 2 2 without overtopping any of the berms or dikes separating the treatment lagoon cells while utilizing gravity flow only As a contingency to operating the system with gravity discharge electrical services pumps pump controls and the associated fittings flow meters and control valves are also installed The location size and maximum pump rate for each effluent pump within the BTL is presented in Table 2 The effluent pumps were installed to transfer treated water directly to the Effluent Pipeline System and ultimately Silver Bow Creek Treated water from the lagoons may be discharged to downgradient lagoon cells during differing operational situations as discussed in Section 6 0 During routine operations all effluent is discharged to Silver Bow Creek near sampling location CT EFS 7 shown on Figure 1 In addition to gravity discharge through the effluent pipeline and discharge of water by use of the effluent pumps direct discharge pipes from each of the outlet structures shown on Figure 8 will allow water to be discharged into downgradient treat
24. operating Normal shutdown sequences require redundant equipment to be brought on line following established SOPs Appendix C Once redundant equipment is operational flow must be diverted from primary systems to the back up systems After flow is established through redundant equipment primary equipment can be taken off line and maintenance performed 6 5 Routine Maintenance of IPS Operational maintenance of the IPS inlet screens is necessary to prevent large diameter solids from being passed through or sufficient blockage that could lead to lowered pump performance or impeller damage Screens will be cleaned daily using a plastic toothed rake The rake will be manually lowered to the screen and raked against the screens in an up and down motion across the entire width of the screen to remove accumulations of solids from the screen surface Influent Pump Station inlet screens will be maintained daily The screens must be removed periodically for a more thorough cleaning To remove the screens wall mounted articulated jib crane will be used Refer to the Site Specific Health and Safety Plan for Butte Treatment Lagoons BTL and Lower Area One LAO Operation and Maintenance O amp M Activities for any lifting operations protocol that must be adhered to prior to any lifting exercise 1 The hoist hook will be secured to the eye bolt of the screen 2 Remove the debris screen stabilizer clip and pin REF Drawing IP C 2 IP D 4 3 Util
25. operator as he she proceeds with routine activities Many of the routine operator activities and most of the unplanned activities involve other observations that should be documented for future reference Such observations may include the extent of lagoon ice cover movement of the ice sheets algal and aquatic plant density and range and other biological chemical or physical activities within and influencing the BTL The operator is responsible for generating and recording both types of observations on a daily basis This documentation provides a basis for report preparation and response to potential questions and or refinement of operations These operator observations are to be kept in an operator logbook maintained in such a way that another person can understand each entry Logbook entries are generally made in chronological order as the operator enters a site and begins routine tasks References to equipment should reference equipment numbers operating conditions and detailed description of any operational issues An example logbook page is shown below Date 9 21 2010 Site WCP Time 0921 Hrs General observations Site Normal uo disturbances Equipment System Status Dump running FE WC 101 225 GPM Operator Johu Operator Draft Butte Treatment Lagoon BTL Systems Page 65 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 8 2 System Generated Data Data collected
26. plan provides the operator the necessary background and overview of the BTL and how it is intended to function during various conditions Detailed documentation and instructions are provided to establish the necessary procedures for both routine operations and special circumstances Each section in the plan is described briefly in the following paragraphs e Section 2 0 System Description is presented in seven subsections An initial overview describes each major component of the system and its function The remainder of the section describes substantial detail for the design basis technical features and capabilities of each facility This section is designed to be the initial reference to the operator for optimization and is intended to fit into and contribute to the entire system e Section 3 0 Hydraulic Controls describes the system components and operational parameters to control water flows and levels associated with the BTL to keep the system operating efficiently It also describes how to use these components during various types of conditions in the BTL e Section 4 0 Safe Operating Limits describes the operating limits of the system components to prevent damage or failure of the system which could potentially impact worker safety of the environment This system provides safe operating pressure temperature and concentration limits as applicable to system components e Section 5 0 Performance Standards are organized and presented s
27. stored in the silo The Accurate Feeder then meters the lime into the screw conveyor at a regulated rate which is adjusted according to influent flow rates and current operating conditions The screw conveyor which has a constant speed then transfers the lime into the lime slurry tanks shown on Figure 6 Routine tasks for the lime feeder system components are presented in Appendix B 2 5 3 Lagoon System A Lagoon System A constructed during the 2004 modifications consists of the following 3 cells Al A2 and A3 see Figure 8 Cell Al provides primary settling of solids for the treated influent flows that enter Lagoon System A Treated influent water flows to the west end of the cell through a silt curtain The silt curtain in Cell Al manufactured by Gunderboom is approximately 50 feet wide and is used to filter the water and distribute the water over a greater area The water is then discharged into Cell A2 by means of Outlet Structure OS 1 The outlet structures act as flow control devices for each cell Section 3 1 1 presents a detailed description of their operation components and purpose Cell Al has a surface area of approximately 44 588 square feet ft at the average depth of 8 0 feet and a full pool volume of 181 386 cubic feet ft at 5 423 5 feet amsl the maximum operating water elevation see Table 1 Cell A2 is located directly downstream of Cell Al Cell A2 has a surface area of approximately 120 150 ft an average d
28. them from the treated water e Lime is added to the influent stream to adjust the pH level to a range between 9 5 and 11 e Lagoon cells are used as settling facilities for CaCO and metal precipitates resulting from pH adjustment through lime addition thereby removing the metals from the water prior to discharge into Silver Bow Creek and e As treated water moves to subsequent cells in the series the pH stabilizes or lowers from its initial range and additional retention time allows for additional physical settling treatment Draft Butte Treatment Lagoon BTL Systems Page 11 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 2 3 2 Primary Controls The opportunities for controlling the treatment processes involve two basic elements e Quantity of lime added to the influent stream and the resultant pH can be adjusted e Outlet structures can be altered so that the water surface elevations and volumes of Treatment Systems A B and C are raised or lowered In addition these structures can be used to route flows differently between cells and or Cells D2 and D3 Table 1 presents the average dimensions of each of the cells in the A B C and D systems 2 3 3 Secondary Controls The following controls can be used to make minor adjustments to the system e Adjust the influent rates temporarily and e Move re route treated water through various cells using different routes The following were factored
29. troubleshooting as described below Troubleshooting for Slurry Tank Discharge Failure 1 Ensure slurry tank feed water flow is present 2 Ensure the influent flow is present and 3 Ensure the discharge pipe is not built up with lime Corrective Procedures for Slurry Tank Discharge Failure 1 SOP 7 in Appendix C summarizes slurry tank feed water re establishment 2 SOP 6 in Appendix C provides required sequence for IPS startup and 3 SOP 39 in Appendix C provides required sequence for the slurry tank discharge cleaning 12 2 1 5 Lime Silo Level This status input detects the status of the Lime Silo level Potential causes for a Lime Silo level failure include 1 Bindicator GP 4 Yo Yo Failure Initial Review Screenings for Lime Silo Level Failure Verify Lime Silo level status is not alarming on the HMI screen If status is operating within the normal range the Lime Silo level is operating normal but if status is alarming proceed to troubleshooting as described below Draft Butte Treatment Lagoon BTL Systems Page 78 of 85 Operation Maintenance and Monitoring Plan Troubleshooting for Lime Silo Level Failure 1 Ensure Bindicator GP 4 Yo Yo meter breaker is not tripped OFF This breaker is located in the main CAS Building breaker panel 2 Ensure the meter is measuring 3 Ensure the sensor weight is correctly attached to the main unit located on top of the lime silo 4 Ensure the Bindicator GP 4 Yo Yo is c
30. 14 inch by 8 inch eccentric reducer A 4 foot straight section of 8 inch ductile iron pipe feeds directly into the pump suction intake The D4 Pump Control Panel has a Local Stop Button that shuts down both pumps immediately After the pumps stop operating the operator must follow the pump startup procedure and restart the sequence with the pump reset button In the case of a power failure or outage at the D4 Starter Cabinet the system will require an automatic pump start sequence to be initiated before starting pumps Operating status of the west and east pump ON or OFF is displayed on the HMI monitor 2 5 1 3 Influent Pipeline Piping from the discharge flange of the influent pumps to the CAS system makes up the CAS system influent piping Each pump has an independent discharge pipe with isolation valves and a tee pipe fitting which allows access to each pipe system from both pumps The original influent pipeline shown on Drawing IP C 7 consists of 2 400 feet of buried 10 inch diameter standard dimension ratio SDR 26 polyvinyl chloride PVC pipeline which transfers the untreated water from Cell D4 to the CAS Building This piping remains in place for use as an emergency alternative system Draft Butte Treatment Lagoon BTL Systems Page 16 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product The influent pipeline from the upgraded IPS contains parallel 14 inch SDR 17 HDPE lines which supply influent wate
31. 2 to 47 F 4 2 2 Pumphouse Temperature within the pump house is maintained in the range of 55 to 75 F 4 2 3 Ambient Ambient temperatures range from 40 to 110 F 4 3 Flow Capacity The maximum design flow for the influent system and associated components is 1 880 gpm 4 4 Electrical Electrical systems are rated for outdoor wet and dusty environment Type 4 NEMA enclosures are generally acceptable for these applications Draft Butte Treatment Lagoon BTL Systems Page 40 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 4 5 Protective Safety Devices The following protective safety devices PSDs are installed within the LAO and CAS systems Tag Number LT LAO3001 LT LAO3002 PS LAO1009 LT LAO1036 LT LAO1043 FCV LAO1019 FCV LAO1023 LT LAO1000 Device Level Transmitter Level Transmitter Pressure Switch Level Transmitter Level Transmitter Flow Control Flow Control Yo Yo Meter Draft Butte Treatment Lagoon BTL Systems Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Purpose Low level alarm of Vault D 4 1 prevents pump damage Low level alarm of Vault D 4 2 prevents pump damage Low pressure alarm of compressed air supply to actuated valves High low level alarm of Slurry Tank 2 protects lime supply to influent High low level alarm of Slurry Tank 1 protects lime supply to influent Controls lime feed to Slurry Tank 2 protects li
32. 20 8 1 gear reduction and provides a final mixer speed of 84 revolutions per minute rpm Wetted components are made of ASTM A240 Type 316 stainless steel and the mixer blades are chlorobutyl coated 1 4 inch thickness These mixers provide constant agitation to maintain thoroughly mixed lime slurry in each tank The mixers are mounted vertically in the top center of the tank bridge supported and provide continuous mixing of the fluid Draft Butte Treatment Lagoon BTL Systems Page 19 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Sluice Box T LAO 5 The 21 foot sluice box is made of 4 modular segments of uniform width 15 inches and varying lengths The box is constructed of 4 inch 316 stainless steel plate The sluice box slopes at 1 from the slurry tanks to the Distribution Tank It is elevated above the CAS Building floor by ASTM A240 Type 316 stainless steel prefabricated rectangular channel supports to maintain the appropriate elevation for gravity open channel flow to the distribution tank The sluice box is capable of carrying the maximum influent flow of 1 880 gpm Modular segments of the sluice box are fastened using s inch stainless steel ASTM A490 Type 3 bolts with nylon washers and bushings A diverter plate on the discharge end provides initial mixing and transfer of lime slurry and raw influent water from the CAS Building the Distribution Tank Distribution Tank T L
33. 4 pump station 11 1 1 Scope and Organization Manufacturer s literature Appendix B provides information that details the routine inspection and maintenance tasks including a schedule of task performance identification of required equipment maintenance and a discussion of records and reporting procedures Manufacturer s recommendations see Appendix B are used to establish the basis of routine maintenance requirements Maintenance repairs replacements and alterations are conducted under the requirements of Volume V Maintenance Plan The Maintenance Plan Volume V has been developed as a guide based on recommendations by various manufacturers of the process equipment Due to the local environmental dust extreme temperatures water etc and operating conditions frequent and infrequent use etc the maintenance program should remain flexible with maintenance tasks and intervals adjusted as necessary based on the actual operating conditions and experience 11 1 2 Description of Access to Site Facilities Routine operator use of the site roads is currently limited to the main entrance route to the CAS Building and along the main FCD road which divides the Silver Bow Creek floodplain from BTL systems Routine use of the divider dikes between the A Cells and D Cells and the cross dikes which separate the A Cells will be prohibited however these routes may be required during repair or improvement work The FCD road will be used to acce
34. 8 5 1 OmaSite PH Meters x sisssedcdsivesecs viacvedaiece seabavensdeded saesadadansedaeasenian eassbaarasastans 67 8 5 2 Lagoon Water Level Recorders ssc ccscsasssnessatveccasissces oto teeacde anaes 67 8 5 3 Slurry Tank Level Indicators eni uae oer astiente een ada 67 8 5 4 Lime Feeder System Equipment ccecscceesceceeneeceeeeeceeeeeeseeeeenteeeesaes 67 8 6 Review of Monitoring Data for Operations ce ceeceeeesceeeeeeeeseeeeceeeeeeeneeeenaeees 67 8 0 1 Lime Feed and Inventory Ancusdntinti eee alee eae aes 67 8 6 2 Lagoon Systems FloW Elevation ccccesscscesscecesececeeececeeececssececseeeeenees 68 8 7 ROUGE Sampling TASKS x csscss cuted ennienni a A 68 8 8 Laboratory Analysis eiin a e a a a iiaa E 69 8 9 Quality Assurance Quality Control ssesssessseeesseeesseesseesseesseeesseessseesseesseesseesseee 69 O DATA MANAGEMENT ntc a a a aaa a aaa ea 70 9 1 Data Management Plaisir teei e a E eE NE Rasas 70 92 Automated Data Management sicicdissccsstavessccisascascashes lt dtaspesnccessnceevasgecewadberaatebasents 70 9 3 Field Operator Collected Data onneoeneeneooeneoesesssoerssosesoereresssenssoevsoorssssessessserssoo 70 10 0 OPERATIONS REPORTING AND RECORD KEEPING ceceecceseeeteeneeeeeeeeeeeenaee 71 10 1 Daily Operations Report sseseessseeesseessessseesseesseeesstesseesseesseresseessresseesseesseeesseee 71 10 2 Weekly Operations Report sssssesssessessseesseesssstesstesseessees
35. AO 103 The distribution tank is located just outside the CAS Building within the CAS Building West Addition The tank is cast in place concrete The tank has an inside radius of 6 feet outside radius of 6 2 feet and a total wall height of 2 4 feet Tank internal volume is approximately 2 300 gallons Three prefabricated Fontaine weir gates are installed on flush surfaces of the distribution tank The weir gates are fabricated from ASTM A240 Type 316 stainless steel and act as downward opening rectangular weirs The stainless steel weir gate frames are separated from the concrete surface by EPDM gasket Each weir gate is capable of passing the maximum influent design flow of 1 880 gpm through the 14 inch wide by 15 inch deep openings Each weir gate is furnished with pre calibrated staff gauges for visual observation and electric displacement transducers networked to the instrumentation and control system Four inches of freeboard allows up to 11 inches of useable weir height Weir discharge flow rates are provided in Section 3 2 5 Flow entering the distribution tank is mixed and distributed by a prefabricated modular baffle constructed of 14 inch 316 stainless plate steel The 5 foot diameter baffle installed in the center of the Distribution Tank has a total height of 2 feet 9 inches making its height equal to that of the vertical walls of the distribution tank The baffle is oriented in a position to promote equal distribution of influent
36. Addition System Building ee eee eeececeeeeeceeeeeceteeeeeeeeees 10 2 2 6 Automatic Sampling Building 0 00 cee ce seeceseceeesececesecessseceeeseceeseeeees 11 2 3 Description of Treatment Processes and Controls eee eeseceeeeeeeeeeeeeaeeneeeees 11 2 3 1 Chemical Physical Treatment Processes ceescecesececeececeeeceeeteeeeeeeeeees 11 2 3 2 Primary Controls peera E E a EE A e a TRESS 12 2 3 3 Secondary Controls sssini nn ipase E E E E EEEE e SS 12 2 4 Description of Remote Facilities Influent Systems eseeeseeeeeseeeseeressereeresseeee 12 2 4 1 Hydraulic Control Channel sseseseeeeseseeeeesessresressersresreeseesresreesresseseessee 13 2 4 2 South Hydraulic Control System D Cells seeeseeeseseeeeeeeeesesesesressreerssee 13 2 4 3 Missoula Gulch Discharge icsscscecscssssaveteaviveessees avs cacagucegdasccsspedeucssaacnscesane 14 2A West Camp Pump Station acc nie audio nadia a a 14 2 4 5 Metro Storm Drain Groundwater Collection System cceeeeeeeseeeees 14 2 4 6 Silver Bow Creek Floodplain cee ceesceceencecesececeeececeeeeeceeeeeceseeeeseeeeees 15 2 4 7 Butte Reduction Works seeseseseseesessessresressessresresseesreseesseeseesreesreseseessee 15 2 4 8 Additional Monitored Sites seseeeeeseseseeeeesessresressersresressersreseresreseeseessee 15 2 5 Description of Butte Treatment Lagoon Facilities eeeeeeeeeeeeeeeeeesreerereesree 15 25 1 Influent System nicsen oer en t
37. Attorney Work Product Enter the Lime Silo and manually force the knife gate valve to the open position and lock the valve in the open position Locate the HMI panel and push STOP on the screen Move the feeder control switch to the Volumetric Manual position Locate the Silo control panel Move the Vibrator control switch to Volumetric Push the green Start Button on the OP1 Panel Push the red Auto Start button on the Silo Panel Set the Feed Rate on the OP1 Panel by turning the dial to the appropriate rate verify the rate displayed on the screen Verify channel pH and adjust lime dosage as needed and The routine setting for the Accurate Feeder is when the local panel control switch is in AUTO position and will run on a continuous basis c The routine setting for the Bin Discharge cycle is set to run for 15 seconds and then stop for 90 seconds before starting again 5 The Accurate Feeder will stop when any of the following conditions are satisfied Local panel control switch is in OFF position Breaker switch is tripped Main silo control panel and interlocked associated equipment is in correct state running or stopped dependent on piece of equipment 6 Screw Conveyor a The screw conveyor will start manually when all of the following conditions are satisfied Local panel control switch is in HAND position and Breaker switch is not tripped b The scr
38. Confidential Attorney Work Product Privileged Attorney Client Communication Prepared in Anticipation of Litigation BUTTE PRIORITY SOILS OPERABLE UNIT SILVER BOW CREEK BUTTE AREA SUPERFUND SITE Draft Operation Maintenance and Monitoring O amp M Plan for Butte Priority Soils Operable Unit Volume IV Butte Treatment Lagoon BTL and Chemical Addition Systems at Lower Area One LAO Atlantic Richfield ET January 27 2011 Confidential Attorney Work Product Privileged Attorney Client Communication Prepared in Anticipation of Litigation BUTTE PRIORITY SOILS OPERABLE UNIT SILVER BOW CREEK BUTTE AREA SUPERFUND SITE Draft Operation Maintenance and Monitoring O amp M Plan for Butte Priority Soils Operable Unit Volume IV Butte Treatment Lagoon BTL and Chemical Addition Systems at Lower Area One LAO Prepared for Atlantic Richfield Company 317 Anaconda Road Butte Montana 59701 Prepared by Pioneer Technical Services Inc P O Box 3445 Butte Montana 59702 January 27 2011 TABLE OF CONTENTS Page UO INFRODUCTION inni e Secu atone osha E ca ele cctv dete dacen ese 1 1 1 P rpose and Scopesserininnr nae a a a te e an 1 1 2 System Background insni a E N iiih 2 1 3 Desis M EMC ORY a a a A OAE 2 1 3 1 Remedial Action Objectives esseeeeesseeseesessesessressrserssressessrssressesnresreesesee 2 1 3 2 Capacity ocsi es A a E E E E E EE 3 1 3 2 1 Chemical Addition System ociccs
39. LE a rt E casa A E ERE 55 6 4 Normal Shutdown inn asana anaE aa r TTE e S EEES 56 6 5 Routine Maintenance of IPS seu socacs wecsicp thes gucaydussaagenceyeass gids duatoedeaanes acnenessineronas 56 6 6 Sludge Managementin sier as iei a E Esa EAEE E EE EEEE Ris 56 6 7 Site Vegetation and Access Maintenance es ssseesseesseessessseresseessseesseessresseeesseee 57 6 7 1 Site Vegetation Monitoring and Maintenance sesseseeeseeeeereseersreesrreresee 57 6 7 2 Site Access Maintenance eseeeeseseeseesessreseessessresressersresereseeseesreesreseeseessee 58 7 0 OPERATION DURING DISTURBANCES 00 ceccscescceseeeseceseceeeaceeaeeseeeseesaecnaeeneeees 59 7 1 SD IDISTUT ARC SA A E E EEE E EEE 59 7 1 1 Lime Feed System Disturbance 2s ne ie i i beeen Bees 59 7 1 2 Redundant Lime Peed System wive jssccisericee dbedeaasvesseoedecadassdeans edad easeseady 59 7 1 3 Lime Addition RES POnse aie jaicssseeceng sed sussdagtne salads even Sbssnss sacs daeadensnaetdadeneseas 59 7 1 4 CAS Building Electrical Service LOss 2 sui2aie steeds tae ei dnninice 60 7 1 5 Lime Feed Mechanical Failure vos 3 ies ush fetacodecbscadontsavsosesedeeostaiececens 60 7 1 6 Slurry Tank Feed Water Interruption eee eeeeeceeneeceeeeeceeeeeenteeeenaeees 60 Draft Butte Treatment Lagoon BTL Systems Page v of ix Operation Maintenance and Monitoring Plan Confidential Attorney Work Product TALL Note m thesia innnan sade vi chokea a ueged a cate vchees 61 7 1 8 Troubleshootin
40. SCO automatic composite water sampler is installed inside the ASB located near the southeast corner of Cell D4 Water quality monitoring parameters are under review at the time of this documents being written Draft Butte Treatment Lagoon BTL Systems Page 31 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 2 7 4 CAS Equipment Status Following is a brief description of the specific data items available from monitoring of facilities equipment at the CAS treatment facilities Influent flow The influent flow meter FIT LAO1059 is set to alarm when the flow is above or below set parameters e A high flow alarm indicates the amount of water being pumped is actually above the expected maximum flow Electrical equipment malfunction is a probable cause for this alarm e A low flow alarm may be an indicator that there is a loss of power or mechanical failure with the influent pump e Slurry Tank Levels Level transducers LT LAO1049 and LT LAO1039 installed in Slurry Tanks 1 and 2 located within the CAS Building When the liquid level in either of the tanks is above or below the set high and low level parameters an alarm is activated e High level alarms indicate there is a potential clog in the lime system preventing discharge from the tank e Low level alarms provide indicators that adjustments to flows entering the slurry tanks are required or a tank is running low on slurry and need
41. Section 2 4 5 is one of the 2 primary groundwater pumping stations to the BTL LAO system This system conveys captured impacted groundwater from the MSD subdrain to the BTL systems Flow rate is controlled via pump VFD to maintain a constant level in the MSD wet vault However flow cannot be redirected from MSD or interrupted for a prolonged period 3 1 6 West Camp Collection System The WCP 1 collection system as described in Section 2 4 4 is the primary pumping system to convey water from West Camp The groundwater extraction system pumps water from the WCP 1 pumping well and conveys it through a discharge line to HCC conduit The pump is equipped with a VFD which is used to control flow rate of the pump West Camp flow can be interrupted for prolonged periods up to 26 days due to available underground storage volume associated with the West Camp system 3 2 Description of System Hydraulic Operations The BTL systems are designed to provide maximum flexibility during anticipated various flow conditions depending on current water levels flow conditions and influent water chemistry The following sections describe scenarios of anticipated range of design flow conditions and how the system should be operated during each of those scenarios Contingency options are under evaluation at the time of this document being written Draft Butte Treatment Lagoon BTL Systems Page 34 of 85 Operation Maintenance and Monitoring Plan Confidenti
42. Tank Level Alarms Verify the slurry tank levels alarms are not alarming on the HMI screen If status is operating within the normal range the slurry tank levels are operating normal but if status is alarming proceed to troubleshooting as described below Troubleshooting for Slurry Tank Level Alarms 1 Ensure the breaker is not tripped OFF on the main CAS Building breaker panel 2 Ensure the breaker for the level indicators are not tripped OFF in the Slurry Tank Control Panel Draft Butte Treatment Lagoon BTL Systems Page 79 of 85 Operation Maintenance and Monitoring Plan 3 Ensure the level indicators sensors are not covered in lime dust 4 Ensure the measuring pipe is not clogged with lime slurry and 5 Ensure the slurry tank discharge pipe is free of lime buildup Corrective Procedures for Slurry Tank Level Alarms 1 Try to reset tripped breakers if breakers trips again contact NorthWestern Energy or electrical contractor to perform further repair troubleshooting as necessary 2 Clean level indictors and measuring pipe for lime buildup Procedure 12 summarizes the slurry tank discharge pipe cleaning 12 2 1 7 Influent Flow Rate Alarm This input measures influent flow with a 10 inch flow meter inside the CAS Building and alarms if the flow is above or below the set parameters Potential causes for high or low flow alarm 1 Influent pump s shut down e Power failure and e Pump failure maintenance issues 2 Flo
43. ach compressor has an 80 gallon vertical tank with 24 CFM capacity at maximum operating pressure of 175 pound force per square inch gauge psig Compressed air will travel to an Ingersoll Rand Model F71IG general purpose compressed air filter to remove any stream impurities prior to entering an Ingersoll Rand Model D72IN refrigerated dryer to remove any excess moisture from the process stream A second Ingersoll Rand Model F711G will be installed immediately following the refrigerated dryer to further purify the process air stream Each F71IG general purpose filter has 42 CFM capacity at maximum operating pressure of 250 psig and is capable of removing particulate matter to 1 Micron The 115 volt 60 amp single phase D72IN refrigerated dryer has a capacity of 42 CFM at a maximum operating pressure of 203 psig The D72IN has an ISO Class 6 dew point at 50 degrees Fahrenheit F 2 5 2 2 Description of Lime Feeder Systems Components and Controls Located inside the equipment area of the lime silo directly below the lime storage area is the bin discharge maintenance slide gate Accurate Feeder screw conveyor and air compressor see Figures 6 and 7 The bin discharge vibrates at a specified interval and prevents any lime from clogging within the cone and assists in keeping the Accurate Feeder supplied with lime The time on and time off for vibration of the bin discharge can be adjusted by the operator depending on density and volume of the lime
44. ag flow meter FIT LAO 1059 3 A portion 50 to 250 gpm of the influent stream is diverted into a slurry tank T CAS 101 or 201 to be mixed with lime from the screw conveyor SC LAO 1 and discharged back into the main influent stream 4 Lime is fed from the silo T CAS 102 via a rotary vane feeder and the screw conveyor SC LOA 1 to either slurry tank The rotary vane feeder is manually adjusted according to influent flow rate and current lime addition rate In the slurry tank lime is mixed with influent water and then discharged into the main influent stream 6 2 2 Lime Addition Control Mechanism As described in Section 2 5 the lime feed facility is designed to allow easy adjustment to the lime addition rate to meet treatment objectives established by the EPA State of Montana Department of Environmental Quality DEQ and agreed upon by responsible parties The primary control system is set up to relay various outputs back to the control screen The two most important factors for control of lime addition are influent flow rate and Accurate Feeder helix rpm The helix rpm will be set in accordance with the influent flow rate in order to maintain pH levels to a minimum of 9 5 standard units su but not exceed 11 0 su The pH is also monitored manually after lime addition As indicated on the BTL LAO Weekly Operations Report provided in Appendix H pH is monitored daily for influent and effluent flow Sample locations are also list
45. al Attorney Work Product 3 2 1 Routine Flow Path The following scenarios describe routine effluent flow paths Routine flow for the system indicate effluent flow meets established parameters for pH at the lagoons and criteria monitored at the ASB The routine flow path of water within the BTL will not require recirculation retreatment or series operation of the lagoon systems Routine flows are defined as those that range from a low flow of 700 gpm to the expected maximum flow of 1 880 gpm For the purpose of this operational scenario three routine operating flows were selected These flows include low flow average annual flow and the expected maximum flow Figure 3 presents a flow diagram for routine flow conditions outlined for the treatment system In order to get similar residence times in each lagoon system i e A B and C Systems the flows are be distributed as percentage of overall flow e Approximately 50 of the overall flow is diverted into Lagoon System A from the Distribution Tank e The remaining 50 is distributed between Lagoon System B and C from the Distribution Tank e Typically Lagoon System B and C each receive approximately 25 each e Flow exiting from Lagoon System B can be either diverted into EL B or Cell A2 Flow will be diverted from Cell B3 into EL B i e water quality at or near discharge standards and target water levels are achieved in the treatment cells e Flow exiting from Lagoon System C can
46. alarm set points and callout priorities 12 2 1 CAS Building This section addresses alarm conditions at the CAS Building and addresses possible cause and appropriate troubleshooting actions The operator interface panel located on the control and instrument panel displays the status of several system components The nine monitoring points associated with the CAS Building are as follows 1 CAS Communications Status ON OFF Normally ON alarm indication at OFF status Draft Butte Treatment Lagoon BTL Systems Page 74 of 85 Operation Maintenance and Monitoring Plan CAS Power Status ON OFF Normally ON alarm indication at OFF status Lime Auger ON OFF Normally ON alarm indication at OFF status Slurry Tank 1 Discharge ON OFF no alarm indication of status only Slurry Tank 2 Discharge ON OFF no alarm indication of status only Lime Silo HIGH LOW Level Alarm alarm indication at HIGH or LOW level Slurry Tank 1 HIGH LOW Level Alarm alarm indication at HIGH or LOW level Slurry Tank 2 HIGH LOW Level Alarm alarm indication at HIGH or LOW level and Influent Flow Rate HIGH LOW Flow Alarm alarm indication if out of acceptable range SO COA ON AE SoS 12 2 1 1 CAS Building Communication Status Potential Causes for CAS Building Communication Failure This status input detects if there is a communications problem between the device and the PLC e Potential causes for a communications failure include PLC malfunction
47. and or vegetation replacement may be necessary following unusual conditions or damage due to heavy equipment or other 1 The operator will note on a daily basis the overall health and appearance of the site vegetation 2 The operator will document any site erosion or vegetation damage due to storm events or mechanical work associated with the BTL Minor erosion will be documented and monitored for progression Major erosion or progressively eroded areas will require soil and vegetation replacement unless the site vegetation grows in and protects the existing soil from further damage 3 The operator will coordinate oversee and document weed control such as herbicide application and hand pulling Weed control tasks should be performed annually within LAO Additional guidance regarding weed control and vegetation areas within LAO is provided in Volume V Maintenance Plan 4 Reseeding and or fertilizer application may be required if the appearance or health of the site vegetation declines Seeding and fertilizer application may also be necessary following any mechanical disturbance of site soils due to process modifications or improvements Seeding Draft Butte Treatment Lagoon BTL Systems Page 57 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product and fertilizer application should be conducted to be consistent with the timing of application fertilizer types and rates and vegetation species already establish
48. anently installed continuous monitoring unit will be used for reporting purposes unless it has to be removed from service for repairs or replacement e Composite samplers will be checked on each visit to confirm proper function e Operator must collect the composite samples according to a specified routine designed to prevent contamination of the samples and to ensure that the collected sample or subsample is representative It will be properly preserved and labeled for subsequent transport to the laboratory Appendix C presents the standard procedures for collecting and preserving these composite samples e Water quality parameters that must be field analyzed will be analyzed following the Clark Fork River Superfund Site Investigations CFRSST SOPs ARCO 1992a Draft Butte Treatment Lagoon BTL Systems Page 68 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 8 8 Laboratory Analysis Sample analysis and analytical methods are included in Appendix G Butte Treatment System BTL Sampling and Analysis Plan Atlantic Richfield Company 2005 8 9 Quality Assurance Quality Control Water quality monitoring activities will be completed in accordance with QA QC requirements discussed in Appendix G Butte Treatment System BTL Sampling and Analysis Plan The SAP contains key elements quality control elements identified in the Clark Fork River Superfund Investigations Quality Assurance Project Plan ARCO 1992
49. are used to verify remotely logged data A blank report is provided in Appendix H Draft Butte Treatment Lagoon BTL Systems Page 70 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 10 0 OPERATIONS REPORTING AND RECORD KEEPING 10 1 Daily Operations Report The operator will record the parameters shown e Lime feed rate set point and actual feed rate and lime usage e Flow instantaneous and totalized e Cells pH and e Time date and relevant system notes The daily report is compiled and distributed to Atlantic Richfield Project Managers TREC and internal Pioneer personnel by close of business each working day 10 2 Weekly Operations Report The operator will record or log water levels lagoon parameters pH flow rates and any significant visual observations or systems modifications daily into the BTL LAO Weekly Operations Report see Appendix H Data in the Weekly Operations Report will be filed and stored for future reference and used to help determine trends or eliminate variables during troubleshooting and treatment performance evaluations These data are also transferred into an electronic version of the form and forwarded to the central database currently and managed by TREC Inc 10 3 Quarterly Operations Report Every 3 months a Quarterly Operations Report will be compiled and distributed This report will contain pertinent laboratory data from the BTL systems minimum maximum average
50. b Draft Butte Treatment Lagoon BTL Systems Page 69 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 9 0 DATA MANAGEMENT 9 1 Data Management Plan The BPSOU Data Management Plan outlines the methodology and associated contents relevant to efficiently obtaining documenting and presenting pertinent operational data The BPSOU Data Management Plan is currently under consideration at the time of this publication The BPSOU Data Management Plan will be included as an appendix upon completion 9 2 Automated Data Management The HMI includes data logging and historian software to log all desired system wide values and status points Data are logged at various time intervals and into separate files for each logging interval Data are saved in an appropriate format to match the data format now in use at other Atlantic Richfield treatment and process sites All data are transferred to Pioneer either daily or weekly for analysis and reporting purposes The Master PLC Allen Bradley ControlLogix located at the Operations Building at LAO polls all data points being monitored at the remote locations associated with the BTL The remote monitoring equipment records water levels flow rates and equipment process status in real time See Section 2 4 for a description of all of the locations monitored the equipment used and the data are collected The computer located in the Operations Building houses the Wonderware so
51. be maintained to prevent impacted groundwater from discharging to Silver Bow Creek The HCC is passively operated and adjustments are not routinely required The water level within each of the D Cells can be manipulated by installing or removing stop logs in their respective structures The following subsections describe the components and areas associated with each hydraulic control 3 1 1 Outlet Structures The outlet structures are located on several cells throughout the treatment system each excluding OS 6 and OS 8 utilize a weir gate downward opening slide gate as the main flow control component see Figure 8 These gates can be manually set at a desired position in order to maintain a target water elevation within each cell Outlet structures OS 6 and OS 8 contain stop logs in place of weir gates which are used to control water levels the same way by adding or removing the stop logs in order to achieve the desired cell water elevation Figure 8 presents details of each outlet structure including minimum and maximum operating levels and an associated schedule of stop logs required to achieve the desired operating level 3 1 2 Pumps In addition to the influent station auxiliary pumps stored within the site inventory location on site and are used as a backup for the outlet structures The pumps can be used as back ups if an outlet structure or an effluent system line is blocked clogged etc The pumps can also be used if an e
52. blem areas and critical facilities The items have been listed in a convenient order intended to facilitate an efficient step by step status check Although the checklist contains more detail in essence the operator must observe and document the following e Lime Addition Correct quantity of lime is being delivered into the influent stream 1 e the feeder is working correctly mixers operating discharge lines open and flowing freely e Water Flow There is no obstruction to the flow of water through the lagoon systems and e Monitoring Systems Monitoring and warning systems are functioning properly At the end of the operators Start of Day Status Check the operator should be confident that each of these components is operational and functional 6 1 2 Missoula Gulch Groundwater System The operator will perform a daily status check of the Missoula Gulch groundwater system which includes the following tasks Draft Butte Treatment Lagoon BTL Systems Page 43 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product e Ensure Base Flow Bypass Pipeline is free flowing and free of debris e Appropriate action has been taken or scheduled to resolve any problems Typical problems may include debris on the Bypass Pipeline inlet screen vandalism including closed valves broken pipe missing weir plates etc or damage resulting from unusually large high flow events Observations and actions are noted o
53. can detect trends and respond with appropriate changes in operation In addition the operator must review the monitoring data for compliance with performance standards see Section 4 0 and submit monitoring reports as required see Section 9 0 e Section 9 0 Data Management discusses the generation of automated monitoring equipment and transfer of data to the master database for storage e Section 10 0 Operations Reporting and Record Keeping outlines the reporting requirements responsibilities and intervals e Section 11 0 Routine Inspection and Maintenance of all treatment facilities and earthwork structures are provided A computerized scheduling and maintenance mechanism for the process equipment is provided so that scheduled activities automatically become part of the operator s daily activities Procedures for inspecting and maintaining the earthwork facilities are also provided e Section 12 0 Emergency Procedures are established for response to various alarm conditions as well as the use of emergency back up equipment e Section 13 0 Future Revisions and Updates are foreseen and a mechanism is established for periodic review and issuance of such revisions on a controlled and properly documented basis e Section 14 0 References used to generate this O amp M Manual are included in this section Draft Butte Treatment Lagoon BTL Systems Page 8 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Produc
54. d to collect data associated with the entire BTL systems therefore allowing performance to be optimized see Figure 1 2 2 General Facility Various systems are located and operated within the BTL LAO site Facility upgrades were made to the LAO site under Draft Final Butte Treatment Lagoons BTL and West Camp Pump Station WCP 1 Upgrades Design Report Work Plan Atlantic Richfield Company 2010a 2 2 1 Lower Area One Lower Area One is an operable unit OU located within BPSOU where the treatment lagoons CAS Building hydraulic control channel HCC and ASB and multiple open areas are located Lower Area One is the lowest topographic elevation of the OU All groundwater and surface flow is naturally directed to the LAO site Draft Butte Treatment Lagoon BTL Systems Page 9 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 2 2 2 Butte Treatment Lagoons The treatment lagoon system consists of multiple unlined open water cells Effluent is directed into a set of three cells referred to as A Cells B Cells and C Cells Each set contains three individual cells The first cell in each set is referred to and utilized as a sediment collection basin A silt curtain is deployed to mitigate sediment carryover to downstream cells The two following cells are referred to as ponds and used to increase retention time of the effluent water and polish or stabilize the pH prior to being introduced into Si
55. degradation of surface water Meet the more restrictive of chronic aquatic life or human health standards for surface water identified in Circular DEQ 7 through the application of B 1 class standards 1 3 2 Capacity Cell data are provided in Table 1 Maximum and minimum cell elevations are listed with the average storage capacity provided Residence time of the primary treatment system flow path is provided below Routine flow of approximately 1 200 gallons per minute is distributed to the lagoons based on the following percentage of total flow A system cells receive approximately 50 of the total flow and the remaining flow is split between the B and C Cells e Theoretical hydraulic residence time of the A system based on an average flow rate of 600 gallons per minute gpm is approximately 10 5 days e The hydraulic residence time of the B system based on an average flow rate of 300 gpm is approximately 5 days e The hydraulic residence time of the C system based on an average flow rate of 300 gpm is also approximately 5 days Contingency water management operations are discussed as an independent item 1 3 2 1 Chemical Addition System The Influent Pumping Station IPS is designed to deliver up to a maximum flow rate of 2 200 gpm The system is designed to accommodate steady state flow of 1 880 gpm and meet discharge performance standards referenced above The normal expected flow rate is 1 200 The lime storage silo capac
56. ding and e Lime feeder system equipment process status monitoring is done at the CAS Building Information developed by the above monitoring systems is used to provide e Input for control and adjustment of the lime feeder system e Activation of alarms to notify the operator of conditions that require attention and or correction action e Informational displays that provide the operator with an instantaneous overview of system status e Supplemental information that can be accessed by the operator to troubleshoot a problem or examine an aspect of system status in more depth and e Record documenting system performance relative to applicable performance standards The following paragraphs describe the monitoring system measurement technologies and the nature and availability of the data produced The information is presented from the broad scale to the more complex items in the following sequence e Water level and flow rate monitoring e Water quality monitoring and e Equipment process status monitoring 2 7 2 Water Level and Flow Rate Monitoring The cell levels and flow rates are monitored at a number of locations on the site Flow rates and cell levels can impact the effectiveness of the water treatment systems and therefore must be strictly monitored In several locations particularly relative to Lagoon Systems A B and C electronic pressure sensors measure water surface elevation Flow rates are monitored and recorded the efflue
57. dix C 4 Once the influent water has reached the CAS Building press the auto start button located on the System Control Panel to open the desired tank s 4 inch drop tube pneumatic valve This Draft Butte Treatment Lagoon BTL Systems Page 54 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product will ensure that any lime distributed through the screw conveyor will be discharged into the desired tank Tank or Tank 2 Using the OP1 Gravimetric Controller press the green Start button located on the OP1 Controller hand controls This step turns on the Accurate Feeder helix and paddle motors The speed of the agitation paddle motor can be manually adjusted using the Agitation variable control knob located on the right side of the OP1 Controller The helix speed can be controlled using the Manual variable control knob located on the left side of the OP 1 Controller To ensure the hopper within the Accurate Feeder receives proper lime flow the operator must operate the Silo Bin Discharge Silo Vibrator on a timer This is enabled by adjusting the hand control knob in the top left corner of the Silo Control Panel to the on or volumetric position This timer can be adjusted as required by using the hand control knob within the silo Two knobs control the following a Time the vibrator is off between cycles and b Time the vibrator is on during cycles
58. e establish the service the operator will contact NorthWestern Energy to have electrical service restored Once electrical service is restored the operator must adjust all affected equipment and ensure the lime feed system is in normal operations Treatment system settings will be changed according to operator parameters and the duration of the lime system disturbance as discussed above 7 1 5 Lime Feed Mechanical Failure Disruptions to the lime feeder system may include malfunctions with the Accurate Feeder screw conveyor massage paddles or bin discharge The operator will follow standard procedures detailed in SOP 3 see Appendix C to determine and correct the disturbance A decision tree is available in Appendix F to assist troubleshooting efforts of this system in the event disturbances are encountered 7 1 6 Slurry Tank Feed Water Interruption A portion of the influent flow is piped and discharged into the slurry tank were the lime addition occurs If interruption of the slurry tank feed water occurs lime addition interruption to the treatment system will also occur and the flow must be re established Standard Operating Procedure 7 provided in Appendix C summarizes the slurry tank feed water re establishment Draft Butte Treatment Lagoon BTL Systems Page 60 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 7 1 7 No Lime in the Silo Running out of lime stored in the silo will cause a disruptio
59. e manual override button on the far south end of the valve By pressing this button the valve manually closes thereby ensuring a loss in weight position by separating the weight of lime in the silo from the weight of lime inside the Accurate Feeder 2 The hopper then must be emptied by placing the lime delivery system into volumetric mode and increasing the helix speed to expedite the empting process 3 Once the hopper is emptied the Accurate Feeder must be cleaned of as much lime as possible to ensure an accurate calibration 4 Press the calibrate button on the Accurate Feeder display and follow the step by step process provided Note Objects of a known weight for the calibration process are located next to the Accurate Feeder in the lime silo 5 Once the calibration process is complete the pneumatic knife valve must be opened by depressing the upper button on the air actuating control solenoid located on the end of the knife gate 6 The system can then be returned to gravimetric mode Draft Butte Treatment Lagoon BTL Systems Page 61 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product QUpon completion of lime feed calibration the operator will monitor a several loading cycles to verify load rates are accurate A troubleshooting decision tree is available in Appendix F to assist in identifying problems with the lime feed system 7 2 Influent Flow Disturbance An influen
60. ed on the Weekly Operations Report Additional more frequent readings may be required following significant Draft Butte Treatment Lagoon BTL Systems Page 45 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product changes in flow rate and or lime addition rate adjustments in order to maintain general understanding of how pH is changing as water flows through the Lagoon Systems A B and C and of how the BTL systems are performing 6 2 3 Chemical Addition System Criteria The lime treatment facilities located in and around the CAS Building are the primary components for managing the water treatment process Figure 6 provides a detailed schematic of the lime treatment facilities The design criteria of the CAS Building and lime treatment facilities were based on two major factors e Lime addition is to be sufficient to maintain pH levels in to a minimum of 9 5 su but not exceed 11 0 su and the target inflow pH is 10 2 when measured in the distribution tank and e Lime addition is to be effective at both minimum and maximum design flows Target lime rate is based on treatability studies and historic data on cell performance and may be adjusted based on experience gained and any changes in influent water quality Lime dosage ranges from 130 to 1805 1 6 2 3 1 Lime Dosage At the current dosage of 1305 4 lime is delivered rate is approximately 1 5 pounds of dry lime per day per gpm influent flow lb day gpm
61. ed with LAO 6 7 2 Site Access Maintenance Site access maintenance will be required periodically to ensure efficient and unobstructed access to the O amp M equipment associated with the BTL Primarily access maintenance tasks will be performed as follows 1 Spring summer and fall maintenance will consist of periodic road grading along the main entrance road to the CAS Building the ASB and the IPS at the southwest corner of Cell D4 Generally grading of the access routes will be conducted following large storm events or snow melt events 2 Winter maintenance will consist mainly of plowing and removing snow to provide obstructed access to the same site locations Winter maintenance will also provide safer access to these sites by minimizing operator exposure to cold conditions and increasing visibility of the access routes Draft Butte Treatment Lagoon BTL Systems Page 58 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 7 0 OPERATION DURING DISTURBANCES This section addresses operational responses to potential upset conditions that may develop during operation of the BTL systems A decision tree is presented in Appendix F which shows suggested actions for upset conditions In general potential conditions which may be investigated during operation upsets include e High or low pH e Impacts of WCP 1 and MSD influent water quality and quantity e Lack of lime treatment because of malfunctioning
62. eecseccecseeceeeeeeeeeteeeesaes 29 2 6 2 3 Influent Pump Station Automation Control ee eeeeeeeeeeeeeeeee 29 2 7 Description of Monitoring Facilities ceeseeeseceececeecceceeeeeceeeeecsneeeenteeeenaeees 29 Dhl System VEL VICW eneeier e a R Rere EE 29 2 7 2 Water Level and Flow Rate Monitoring eesesseesssesssssessseesseesseesseeesseee 30 2 7 3 Water Quality Monitoring eseseseesessesssesrerseesresressessresresseesreseeesreseeseessee 31 2 7 4 CAS Equipment Status oeeeseeeeseneeeeeseseesseersrerseesseeeseseeseeessressresseeeseeee 32 3 0 HYDRAULIC CONTROLS pinitos an talni Seal aei ia gea aa aeS 33 3 1 Description of Hydraulic Controls eeseeeeeseeeseseesseseesresseseresressessresressersresreeseese 33 3 lT Outlet SUCHE i onn a E ia n ep ET T TA 33 kg PUMPS enna e a E aes ad tock E A a R 33 3 1 3 Hydraulic Control Channel jciccssiccdisssestaavesatdesesccteanvccaatasstevedesuncatennecegn 34 3 1 4 Groundwater Interception Areas eessseeseeesseesseesseeesseeesseessresseesseeesseee 34 3 1 5 Metro Storm Drain Collection System sssesseeseeesseeeeseeesseesseessessseeesseee 34 3 1 6 West Camp Collection System siiijs cdssccidsasdesiaacisunscesusidesatasecsaasednnceueanecsad 34 3 2 Description of System Hydraulic Operations sesssesessseesseesseesseeeseeessseesseesseessee 34 32 1 Routine Flow Pathirana E E NE 35 S22 AO ON Pathe EEEE A E A 36 3 2 3 Low Flow Pathi rtia a ands E E EE
63. em is interrupted for a period greater than 30 minutes The following is a system overview of components involved in the influent pump control and lime feeder system process e The CAS Building contains the primary PLC computer multiple monitors radio telemetry base station and the lime addition system e The ASB contains a secondary PLC with a control program for operating the influent pumps and radio telemetry communication with the CAS Building e The Influent Pump Control Panel contains four operator interface switches for local pump control with wiring interface to the ASB and the influent pump Starter Cabinet and e The influent pump Starter Cabinet located on the D4 Electrical Service Rack contains the pump starter units and 480 VAC 3 Phase power to operate the pumps The starter unit for each pump contains a HAND OFF AUTO switch for operating the pumps in manual off or automatic configurations Automated components under design revision at the time of this document being written Revisions are TBD Draft Butte Treatment Lagoon BTL Systems Page 28 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 2 6 2 2 Lime Addition Rate Automation The Accurate Feeder lime rate HAND OFF AUTO HOA switch on the Lime Feeder System Control Panel controls the automation or manual adjustment of lime rate addition AUTO MODE While the Accurate Feeder lime rate switch is in the AUTO or automatic
64. epth of 7 5 feet and a full pool volume of 525 013 ftat5 422 75 feet amsl the maximum operating water elevation Once water from Cell Al reaches Cell A2 it Draft Butte Treatment Lagoon BTL Systems Page 21 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product flows west to OS 4 located on the west end of the D2 Dike or OS 5 located on the west bank of Cell A2 Outlet structure 4 diverts water into Cell D2 and OS 5 has the ability to divert water to Effluent Line EL C or Cell A3 Diversion of flow to these different locations depends on volume of flow lagoon water elevation and quality of water leaving Cell A2 Cell A3 is the final cell in Lagoon System A Water from Cell A2 is discharged on the east end of Cell A3 from OS 5 and flows west to OS 7 Here water is diverted to either Cell D4 if retreatment is necessary or EL D to be discharged to Silver Bow Creek Cell A3 has a surface area of 157 440 ft an average depth of 8 feet and a full pool volume of 540 559 ft at the maximum operating water elevation of 5 422 5 feet amsl 2 5 4 Lagoon System B The 3 original treatment lagoons which make up treatment Lagoon System B have been utilized for water treatment since their construction in 1997 Lagoon System B is located within the central portion of the treatment lagoon area directly west of the CAS Building see Figure 8 During the 2001 improvements Cell B1 was expanded to the east approximately 60 fee
65. equipment e Lack of influent flow and e High or low lagoon water levels The above conditions are primarily of concern relative to the treatment lagoons and lime feed system However they can be significant in regards to emergency bypassing or recirculating of partially treated water which does not meet the performance standards as described in Section 5 0 7 1 System Disturbances 7 1 1 Lime Feed System Disturbance Lime feed system disturbances stop the addition of lime to the influent flow Disturbances in the additions of lime may be attributed to CAS Building electrical service loss Accurate Feeder failure screw conveyor failure lime blockage running out of lime in the silo slurry tank feed water failure and loss of flow from the IPS 7 1 2 Redundant Lime Feed System In the event of a failure in the primary lime feed system a back up lime feed system will be available The back up lime feed system is modular and must be moved into position prior to use 7 1 3 Lime Addition Response Lime feed system disturbances are separated into three stages to identify and reconfigure the treatment system as necessary for each stage The three stages and the corresponding operator responses are listed below from minimal to significant Draft Butte Treatment Lagoon BTL Systems Page 59 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product e Stage 1 0 to 6 hours After the cause of the lime feed disturbance is de
66. er controls power at all A3 Area locations The ASB is located on the south end of A3 Area The 480 volt service feeds the ASB where 240 120 volt loads at this area are served by a 7 5 KVA transformer 2 6 1 3 D4 Area Service A 3 phase bank of pole mounted transformers rated 75 KVA provide this area with 480Y 277 volt power The overhead service supplies the D4 Area Service Rack with a 100 amp electrical service The meter base service disconnect is located on a utility pole and the 100 amp main breaker controls power at all D4 area locations via underground conduit A 5 KVA transformer serves all 240 120 volt loads at this area 2 6 1 4 Control and Monitoring Device Electrical Summary The BTL LAO control system utilizes Allen Bradley ControlLogix for the primary control and master polling PLC located at the Operations Building This primary PLC controls and monitors the lime addition process and associated systems and polls each secondary PLC located at remote sites for data Total polling time to contact and receive data from the remote sites does not exceed 30 seconds using a CalAmp Viper FCC licensed Ethernet data radio operating in the 400MHz range The encrypted FCC licensed radio to radio communication is capable of transmitting data up to 128 kilobytes per second kbps at 10 watts of effective power Data that have been transmitted back to the Operations Building it is displayed on the operators HMI Invesys Wonderware InTouch softwa
67. er switch is not tripped and Slurry level is outside the specified range below 9 inches c The routine setting for Slurry Mixer is to run continuously 8 Slurry Mixer 2 a The slurry mixer will run when all of the following conditions are satisfied Local panel control switch is in ON position Breaker switch is not tripped and Slurry level is detected within the specified range 11 inch minimum 48 inch maximum b The slurry mixer will not run when all of the following conditions are satisfied Local panel control switch is in OFF position Breaker switch is not tripped and Slurry level is outside the specified range below 9 inches c The routine setting for Slurry Mixer 2 is to run continuously 6 2 5 Control and Monitoring Device Summary The following information is a preliminary description of the control and monitoring devices at the BTL Additional information will be provided when instrumentation and controls I amp C upgrades are finalized Draft Butte Treatment Lagoon BTL Systems Page 50 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 1 CAS Building a Operator Interface HMI Computer and Screen PLC Master Radio Interface Process Set Points and Alarms System Trends and Historical Logging Alarm Dialer Uninterruptible Power Supply and Surge Protection for Line Power and Analog Isolation Influent Flow GPM Lime
68. ew conveyor will start automatically when all of the following conditions are satisfied Local panel control switch is in AUTO position Auto Start button on the Local panel is depressed Breaker switch is not tripped and Main silo control panel and interlocked associated equipment is in correct state running or stopped dependent on piece of equipment c The screw conveyor will stop when all of the following conditions are satisfied Local panel control switch is in OFF position Breaker switch is tripped and Draft Butte Treatment Lagoon BTL Systems Page 49 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Main silo control panel and interlocked associated equipment is in correct state running or stopped dependent on piece of equipment d The routine setting for the screw conveyor is when the local panel control switch is in AUTO position and the rotation direction toggle is in the FORWARD position The screw conveyor will run continuously 7 Slurry Mixer 1 a The slurry mixer will run when all of the following conditions are satisfied Local panel control switch is in ON position Breaker switch is not tripped and Slurry level is detected within the specified range 11 inch minimum 48 inch maximum b The slurry mixer will not run when the following conditions are satisfied Local panel control switch is in OFF position Break
69. flow toward each Fontaine weir gate and subsequent distribution channels Weir gates provide final mixing and flow control to direct the mixed influent water and lime slurry to each of the distribution channels Distribution Channels Three independent concrete distribution channels extend from each Fontaine weir gate of the concrete distribution tank The initial portion of each distribution channel is constructed as cast in place concrete continuous with the Distribution Tank vertical walls until they exit the CAS Building West Addition through the building s concrete footings The initial cast in place portion of each distribution channel slopes away from the distribution channel at 2 until reaching the transition to precast rectangular channels Distribution Channels A B and C Type A riprap discharge aprons installed at the end of each channel dissipate flow energy in the primary cell to mitigate erosion effects Draft Butte Treatment Lagoon BTL Systems Page 20 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Air Compressors Two Ingersoll Rand Model 2475N7 5FP electric driven 230 volt 60 amp single phase two stage compressors with integrated pressure switches will be installed in the storage room of the new Operations Building The redundant compressors will provide compressed air to various components of the lime feed and distribution system located in and adjacent to the CAS Building E
70. ftware which collects and displays the values on the HMI screen from the remote monitoring devices The Wonderware software is the master monitoring device that polls all data points being monitored at the remote locations associated with the BTL This information is updated on the HMI screen at 3 second intervals All data logged are stored on the HMI computer The software averages each of these input values over a 30 second period then the average values are attached to a file ARC year month day _A3S csv located on the local hard drive and are sent via a DSL link to Pioneer s Butte office server This server hosts the BTL website www lao lagoons com that displays the 30 second average data from each of the remote monitoring devices The 3 second interval data are also averaged over a 1 hour period These 1 hour average values are attached to a file ARC year month day _A1H csv on the local hard drive and sent via a DSL link to the Pioneer s Butte office server The 1 hour average data are distributed to TREC Inc for data management and analysis Data are saved in an appropriate format to match the data format now in use at other Atlantic Richfield treatment and process sites All data are transferred to Pioneer either daily or weekly for analysis and reporting purposes 9 3 Field Operator Collected Data Key process parameters are recorded on the BTL LAO Weekly Operations Report These data
71. g Wimies Peed ii x ci9 Sacacs2s a sannc aac causecatsyorgeantidvectuaeaceaasas 61 K2 influent Flow Disturbance niea ina E E a 62 7 2 1 Influent Pump Station Electrical Service Loss eeeeseeeeereeeeerererrse 62 7 2 2 Influent Pump Station Pump Failure eee eeeeeceeeceeeeeeeceeeeeenteeeenaeees 63 7 3 Monitoring Equipment Disturbance 2 2 10 Laake ai eed 63 7 3 1 Electrical Service Loss to CASB s c c542 src as eee ets ioee hd eames 63 7 3 2 Monitoring Control Failure ics saccesesess dusseadgucssads Seces wecedusgaaes cats dbadnessecadansens 63 74 Off site Disturbances 22 4 s2cisives a ieaenel dace e dace eae eu eae ee Tiaa 64 7 4 1 West Camp Pump Station and MSD Pump Station Electrical Service Loss i ee aac tee I Nie N lth OES Cait ia lat TA E he ered ta 64 7 4 2 West Camp Pump Station and MSD Pump Failure ee eeeeeeee 64 7 4 3 West Camp Pump Station and MSD Monitoring Equipment Failure 64 7 5 E vironme tal Disturbances noei e E A E aii 64 8 0 MONITORING AND LABORATORY TESTING Qu ccecsscssecseeteeeeessecssecnaeeeeeeeeeeees 65 8 1 Operator ODSErvVatiOns ssrdsn iieii e a Ee ETA ETA ER 65 8 2 System Generated D ta isise r E E a A a a S 66 8 3 Automatic Electronic Monitoring Data ce eesesscecssceesseceessccessscceessceeeeseees 66 8 4 Field Measurements and Sample Collection cee cecseeeeeeceeececeeeeeceeeeeesneeeenaes 66 8 5 Routine Inspection and Calibration of On Site Monitoring Systems 66
72. g stations 12 2 3 Effluent Flow Rate Alarm This input measures influent flow with a 14 inch McCrometer UltraMag flow meter FIT LAO 4000 located near station 0 02 Potential causes for high or low level alarm Flow rate is above or below set parameters Malfunction of flow meter Debris covering flow meter sensor Outlet structure s clogged with debris or ice ASB Communication status failure and Malfunction of outlet structure s Dy Ge Initial Review Screenings for Effluent Flow Alarms Verify the effluent flow rate status is not alarming on the HMI monitor If status is operating within the normal range the cells are operating normal but if status is alarming proceed to troubleshooting as described below Troubleshooting for Effluent Flow Alarms 1 Visually check to verify that water is discharging into the effluent system Cells A3 B3 and C3 2 Visually check flow through the outlet structure weirs to verify the alarm is not false Draft Butte Treatment Lagoon BTL Systems Page 82 of 85 Operation Maintenance and Monitoring Plan 3 Ensure all valves located on the effluent line are fully open and not restricting flows 4 Check for debris or ice in outlet structures and the effluent line to be sure they are not restricting flow 5 Visually check for flows out of the effluent discharge CT EFS7 located south of the ASB and 6 Ensure flow meter is operating Corrective Procedures for Effluent Flow Alar
73. gular basis Figure 2 shows the locations and alignments of the Treatment Lagoons and distributions channels 2 5 2 1 Description of Chemical Addition System Components General descriptions of the CAS components are outlined in the following paragraphs Lime Silo T CAS 102 The lime silo consists of a 22 ton capacity silo with equipment and controls to transfer dry hydrated lime to the lime transfer auger In addition the silo is fitted with a fill tube bag house and controls to accommodate filling the silo by a pneumatic truck and monitoring equipment to determine the quantity of lime in the silo The lime silo is positioned directly outside of the CAS Building on the east side of the building A skirt support structure allows access to the bottom of the silo and houses lime feed components such as the lime hopper Accurate Feeder U CAS 106 knife gate valve and screw conveyor U CAS 102 These components and assemblies are discussed below Accurate Feeder U CAS 106 and Screw Conveyor U CAS 102 The Accurate Feeder controls the amount of dry lime from the bottom of the lime silo that passes directly to the screw conveyor The screw conveyor then transfers lime to either of the slurry tanks Selection of which slurry tank is in operation during continuous feed operations and which tank is receiving lime from the screw conveyor is made on the lime silo control panel Controls for this auger are Draft Butte Treatment Lagoon
74. h the Influent System is approximately 4 3 mgd 3 000 gpm Additional storage or surge capacity is available especially when water levels exceed 5 414 feet amsl in the lower end of the HCC 2 5 1 1 Cell D4 Cell D4 is the main influent water collection area of the influent system located at the west end of the site This collection area as stated in Section 2 4 2 is fed by the HCC and serves as the main influent water source Cell D4 is designed to operate at an elevation of 5 414 5 feet amsl with a minimum and maximum pool elevation of 5 413 5 feet amsl and 5 417 feet amsl respectively 2 5 1 2 Influent Pump Station The IPS is located in Cell D4 Pumping capabilities are provided by 2 electric driven 75 HP Godwin Dri Prime Model CD225M Automatic Self Priming centrifugal pumps with 316 stainless steel pump ends and two 75 HP VEDs which are designed to interact with one another for synchronized start and stop capabilities The pump system is capable of pumping flows ranging from 800 gpm up to 2 100 gpm A primary pump will operate at approximately 1 200 gpm with a back up pump offering 100 redundancy The pumps are skid mounted with a central lifting bracket and securely housed above grade in the IPS building Each pump is supplied by independent suction piping from the influent sump located in Cell D4 Suction piping consists of a 14 inch ductile iron piping vertical riser suspended into the sump The riser makes a 90 degree turn into a
75. he IPS and CAS Building to provide emergency power at each site 2 6 1 Electrical Services Equipment Descriptions NorthWestern Energy is the operating electric utility that supplies power to this area The BTL system has a total of 5 electrical services all fed by NorthWestern Energy overhead distribution lines operating at 15 000 volts The pole mounted transformers are protected on the primary side by a set of distribution fuse cutouts These cutouts are sized to protect the transformer from internal transformer faults The utility company may manually cut out the fuses to isolate the transformer from the distribution circuit The fuses will melt in response to abnormal current flow in the transformer coils Each service has a main breaker that controls protects the electrical system at that location The main breaker and subsequent breakers will be found in one of 3 positions 1 ON 2 OFF or 3 TRIPPED All breaker panels located within the BTL have panel schedules inside the door and indicate the load served and circuit breaker number 2 6 1 1 Chemical Addition System CAS Building Service A 3 phase bank of pole mounted transformers rated 150 kilovolt ampere KVA provide the CAS Building with 480Y 277 volt power The underground service supplies the building with a 200 amp electrical service A 480 volt breaker panel supplies power to the 100 amp filter press and to a 30 KVA 3 phase 480 volt to 240 120 volt transformer that feeds the buildi
76. ibution Tank T LAO 103 to the distribution channels which then transfer the mixed slurry and influent water to the BTL The 22 ton lime silo feed system and associated equipment were installed during the spring of 2002 The operating instructions maintained within the CAS Building contain detailed information for this equipment see Appendix A The equipment documentation contains manufacturer s information dimensions and capacities electrical diagrams and operating information for the silo and related equipment A maintenance schedule for all operating equipment associated with the lime feeder system is located in Volume V Maintenance Plan Based upon the range of operating conditions listed above the lime silo T CAS 102 is expected to provide continuous lime feed to the system as described below Lime Consumption Rate e Minimum 1 095 lbs day 40 days e Maximum 3 440 lbs day 13 days and e Initial Target 1 877 lbs day 23 days The distribution channels downstream of the CAS Building are cast in place utility trench boxes extending to the initial riprap aprons of each primary cell of the treatment lagoon system The distribution channels require little maintenance during routine operations This maintenance will consist of annual removal of a small amount of precipitated calcium carbonate that accumulates within the channels less than 50 cubic yards In addition Cells Al B1 and or C1 require sediment removal on a re
77. ign flow within the HCC is a summation of flows from WCP 1 Missoula Gulch flow MSD BRW and LAO groundwater Groundwater flows may vary throughout the year The base design flow of the HCC is 1 880 2 4 2 South Hydraulic Control System D Cells The Groundwater Interception Areas Cells D2 and D3 shown on Figure 4 function to create a gradient away from Silver Bow Creek Cells D2 and D3 can also act as a recirculation route for water from Cells A2 B3 and C3 to be routed back to Cell D4 In the event of a need to re circulate water Cells D2 and D3 can be utilized as a recirculation circuit e The C lagoons can be discharged to either D2 or A2 for increased retention time or back to D2 for recirculation and B lagoons can be diverted to A2 for increased retention time or from A2 to D2 for recirculation e Cell D2 will be used as a recirculation bypass to Cell D3 for water discharged from Cell C3 and e Cell B3 and Cell D3 will be used as a recirculation bypass to Cell D4 for water discharged from Cell D2 During routine operations no flow from the Treatment Lagoons treated water will be discharged into D2 however intercepted groundwater will be directed down gradient to Cell D3 No flow from the Treatment Lagoons will be discharged into Cell D3 however flow from intercepted groundwater will be directed into Cell D4 Draft Butte Treatment Lagoon BTL Systems Page 13 of 85 Operation Maintenance and Monitoring Plan Confiden
78. includes data from remote sensing devices as described in Section 2 4 alarms logs generated and operator actions associated with the BTL For example when the operator adjusts set points of an input or acknowledges an alarm the software maintains a record of that occurrence that can be retrieved later Section 9 2 summarizes the data management system 8 3 Automatic Electronic Monitoring Data Facilities described in Section 2 3 generate large amounts of data on flow rates water levels and various other inputs These data are recorded on the treatment system computer located within the CAS Building The data can be accessed as necessary via telephone computer connection for routine operation and troubleshooting However the predominant use of the data will be for review and analysis of the BTL s effectiveness and to improve understanding of the factors that affect performance Procedures for emergency conditions and troubleshooting guidance are included in Section 12 0 The accuracy of the electronic monitoring systems requires inspections and regular calibration checks to ensure proper operation of the monitoring equipment see Section 8 5 8 4 Field Measurements and Sample Collection Electronic monitoring facilities are available for collecting only a portion of the project s water data Other data are derived from field measurements of water levels or flow and from composite and grab samples The samples require both field and or labo
79. ineia naasa a PEA E 15 2DE CAU DA niiret oa aa eie aaia gi aa 16 Draft Butte Treatment Lagoon BTL Systems Page iii of ix Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 2 5 1 2 Influent Pump Station assein nasisi 16 21 3 Mame 5 08 tte 110 Pipeline pres nenne e ea Perse eter tr ce ces Chretien Setter 16 2 5 2 Chemical Addition System CAS jaca staeciasotanedieterecnasaaeaactsancadesdapvastetens 17 2 5 2 1 Description of Chemical Addition System Components 18 2 5 2 2 Description of Lime Feeder Systems Components and Controls 21 De Lagoon System Aae 0 eet il de en eae edie e ia e aea 21 23 4 Lagoon System B eenn ode aia er e aaa a A EE O R 22 DENY Lagoon System Cirerer e a a E R 22 2 0 Effluent System sinire i a p iR E i 23 2 6 Electrical Automation Control and Monitoring Description ceeeeeeeeeee 24 2 6 1 Electrical Services Equipment Descriptions sssssesesseesseesserssersseeesseee 24 2 6 1 1 Chemical Addition System CAS Building Service 24 26 L2 ALAT a SEV Ce ei e a E A EAEE SAN 24 DORI SIA ATS ay Servi Eea E E E E NN 25 2 6 1 4 Control and Monitoring Device Electrical Summary 0 25 2 6 2 Lime Addition Rate and Influent Pump Station Automation 28 2 6 2 1 Interruption Interval vsiaicuigesasss seadicdesccecastesadeves soaaes snteen ss desecaeastetans 28 2 6 2 2 Lime Addition Rate Automation cee eee
80. ing water elevation given in the table Draft Butte Treatment Lagoon BTL Systems Page 39 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 4 0 SAFE OPERATING LIMITS The following provides maximum allowable limits of process conditions to prevent damage to process equipment personnel and subsequent release to the environment Line classes are established by safe operating pressure and temperature based upon the pipe material and size The BTL LAO system operates under two distinct operating environments The system is a pressure rated system from IPS to the lime slurry tanks From the discharge of the lime slurry tanks the system operates as an open channel flow system 4 1 Pressure Maximum discharge pressure at the IPS is 60 pounds per square inch gauge psig System operating pressure will not exceed 60 psig Low pressure will not be less than atmospheric Pressure components are not rated to maintain vacuum or pressure less than atmospheric The BTL operates as an open water system Open channel flow and open water cells are subjected to atmospheric pressure and pressure head created by water depth 4 2 Temperature Ambient temperature for the region is acceptable for the BTL system Temperature range is 40 to 100 degrees Fahrenheit F Temperature of the groundwater is typically within the range of 42 to 47 F 4 2 1 Groundwater Temperature of the groundwater is typically within the range of 4
81. ing Electrical Service Failure 0 0 eee eeeeeeeeeeeeeeeee 76 12 2 1 3 Lime Feeder System Screw Conveyor Failure cceeeeeeeeee 76 12 2 1 4 Slurry Tank Discharge Failure secsiui seis acstiees Ae caciccaricn de a eases 77 122 15 Lime Silo Levels sinini ene 78 12 2 1 6 Slurry Tank Level Alarms 24 2 4 22 siioecce daa 79 1221 7 Influent Flow Rate Alarms oeno e e a E anes 80 12 2 2 Lagoon Systems Water Level Failure Alarm 81 12 2 3 Effluent Flow Rate A lari st ccc 045 ota ta de ead can idler ict ee oe A ee 82 13 07 REVISIONS AND UPDATES 242 65 BENE SEG EE OGL EE 84 14 0 REFERENCES anaana a a aE E N a as ccna ceidstus stone ccali tae cian nadidetuas 85 Draft Butte Treatment Lagoon BTL Systems Page vii of ix Operation Maintenance and Monitoring Plan Confidential Attorney Work Product LIST OF FIGURES Figure Butte Treatment Lagoon BTL Remote Facilities Monitoring Locations and Influent Sources Figure 2 Butte Treatment Lagoon BTL Systems Components Figure 3 BTL LOA System Flowsheet Figure 4 Lower Area One LAO Hydraulic Control Channel HCC and Cells D2 D3 Figure 5 Outline Butte Treatment Lagoon BTL Sampling Locations Figure 6 Butte Treatment Lagoon BTL Schematic of Lime Feed Facilities Figure 7 Lower Area One LAO Underground Utilities Figure 8 Butte Treatment Lagoon BTL Treatment Lagoon and Outlet Structure Configurations Figure 9 Butte Treatment Lagoon BTL ASB Sample Station Detail Figu
82. ing levels of Cell A3 are 5 419 and 5 422 5 feet amsl respectively In the event that lower operating levels are required the auxiliary pump can be operated to lower the water level to approximately 5 416 feet amsl Treatment System B Treatment System B water levels may be changed by manually adjusting the weir gate in OS 2 The routine minimum and maximum operating levels of Cell B3 are 5 421 and 5 423 5 feet amsl respectively In the event that lower operating levels are required the auxiliary pump can be operated to lower the water level to approximately 5 416 feet amsl Treatment System C Treatment System C water levels may be changed by manually adjusting the weir gate in OS 3 The routine minimum and maximum operating levels of Cell C3 are 5 421 and 5 423 5 feet amsl respectively In the event that lower operating levels are required the auxiliary pump can be operated to lower the water level to approximately 5 416 feet amsl South Hydraulic Control Cell D2 water level can be changed by manually removing or adding stop logs in OS 6 The minimum and maximum operating levels of Cell D2 are 5 414 and 5 420 feet amsl respectively Cell D3 water level can be changed by manually removing or adding stop logs in OS 8 The minimum and maximum operating levels of Cell D3 are 5 414 and 5 417 5 feet amsl respectively 3 2 7 Lagoon Retention Times The BTL retention times are provided in Table 6 Volumes are based on an average operat
83. into the BTL systems design basis e Operation of the treatment system must accommodate removal of multiple metals e Mixing evenly distributes the lime throughout the influent stream thereby achieving the pH adjustment and precipitation reaction in the lagoon systems This is facilitated by the mixing baffle located inside the Distribution Tank and the distribution channels The mixing then continues in the first cell of Treatment Systems A B and C e Building of the precipitate into particles which will drop out of solution This begins immediately following addition of lime and is facilitated by the mixing described above e Settling of the particles begins upon entry of the flow into Cells Al B1 and C1 The other cells in the treatment systems provide additional polishing sedimentation Under ideal conditions settling would depend simply on particle size weight and the upflow velocity flow rate divided by surface area of the cell Hydraulic barriers and flow patterns were designed to eliminate obvious short circuiting The following subsections present a detailed description of each of the facilities of the BTL 2 4 Description of Remote Facilities Influent Systems All remote sites are equipped with Allen Bradley CompactLogix PLCs to monitor and control any of the remote sites process and or monitoring equipment The remote PLCs provide local control such as pump control logic or flow control logic and monitor the local process for any
84. ipment and distribution tank Additional detailed information is provided below The Operations Building is located on the east side of the CAS Building as an addition The Operations Building is a 1 054 square foot building which houses all updated hardware controls and monitoring equipment The Operations Building also includes an operations room with a desk computer additional monitoring equipment sample preparation room and restroom All system monitoring device signals are displayed and accessible to operators in this room Draft Butte Treatment Lagoon BTL Systems Page 10 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 2 2 6 Automatic Sampling Building Effluent flow is monitored and automatically within the ASB through the ISCO 3700 automatic sampler housed within the ASB The ASB is an 11 by 13 foot engineered precast concrete building which houses sampling equipment effluent piping and associated valves interior panel mounted heaters and exhaust fan 2 3 Description of Treatment Processes and Controls The BTL water treatment system is an active lime treatment system which utilizes a series of lagoons to precipitate metals The BTL system treats Missoula Gulch base flow entering the HCC West Camp Pumping System WCP 1 groundwater and groundwater collected and pumped from the MSD The addition of lime or an equivalent amendment is the primary treatment Lime product is added to the inf
85. ithout requiring operator interface In the event that the influent flow rate changes the automation adjusts the lime addition rate to maintain the target lime rate and if lime addition is interrupted for a set time period the influent system will shut down to prevent flow of untreated water through the lagoon cells Alarms and callouts are provided according to priority within the system The automation regulates the IPS and lime addition rate system during interruptions To prevent influent water from receiving inadequate or zero lime addition during lime feeder system interruptions the controls for the IPS shuts down the pumps To prevent excessive lime addition to the slurry tank during influent flow rate interruptions the lime system is brought offline automatically All interruptions to the treatment system are monitored alarmed and the operator s automatically notified Once the interruptions are corrected the operator must manually restart the treatment system and perform the daily routine checks to ensure that the startup was successful and all initial system settings are appropriate The following sections describe the equipment settings and operation of the lime addition and IPS automation equipment 2 6 2 1 Interruption Interval The control system is configured to shut down the lime feeder system when the influent pumps are interrupted for a period greater than 30 minutes The influent pumps are shutoff when the lime feeder syst
86. ity is 44 000 pounds of hydrated lime CaOH z The target lime feed rate is 130 milligrams mg of lime per liter of influent The design flow and feed rate allows up to 15 days of continuous runtime 1 3 3 Codes and Standards The buildings were designed and reviewed under International Building Code IBC 2006 edition and International Energy Conservation Code IEEC 2003 edition as discussed in the following subsections Draft Butte Treatment Lagoon BTL Systems Page 3 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 1 3 3 1 CAS Building International Building Code e Occupancy F 1 e Occupant Load 100 ft occupant 1 273 ft 13 occupants maximum e Construction Type V B e Maximum 8 500 ft per 1 story e All walls must maintain 30 feet from property lines no fire rating is required e Class C finishes at interior allowed e One exit required 3 have been provided and e Class C roof allowed Class B provided International Energy Conservation Code 2009 e Per IECC Silver Bow County is in Zone 16 ceilings require R 25 walls require R 11 minimum and less than 10 exterior wall windows or door glazing 1 3 3 2 Operations Building Operations Building constructed adjacent to the existing CAS Building e Occupancy F 1 e Occupant Load Industrial areas allow 100 square feet per occupant With 1 054 square feet the Operations Building can have 11 occupants e Cons
87. ize the hoist to lift the screen from the grating support structure and 4 Rotate the jib crane to allow placement of the screen at grade level Once appropriate cleaned the screen can be replaced by reversing sequence listed above 6 6 Sludge Management Sludge produced from lime addition and metals precipitation is managed using a dredging operation A dredge is used to remove the sediment for the floor of each primary cell and then the sediment is pumped to a drying bed area located within the BRW area Dredging operations are conducted up to 3 events per calendar year Each event takes approximately 30 to 40 working days to complete The material is allowed to naturally dewater before it is transported to the mine waste repository for long term disposal Dewatering time is dependent on the efficiency of the dredging operation but can take between four to six weeks The volume of material pumped during dredging activities is dependent upon operator skill and the dredging practices followed Sludge production is estimated based on influent flow rate lime feed rate and retention time Estimated sludge calculations are provided in Appendix I to assist operations personnel in planning sludge removal Draft Butte Treatment Lagoon BTL Systems Page 56 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product A floating dredge system consisting of a 4 inch submerged pump 8 2 foot wide cutter head and multi directiona
88. l during routine continuous dry lime addition If desired the north slurry tank Tank 2 will provide storage for the backup batch of high concentration approximately 20 by weight lime slurry Each tank is fitted with two discharge ports near the bottom of the tank and a 4 inch overflow port and discharge line near the top One 4 inch discharge port on each slurry tank is located at the invert of the tank This port is generally reserved for completely draining the tank should maintenance of the tank or mixer become necessary or complete removal of debris or lime slurry from the tank is required The second discharge port on each tank is located approximately 20 inches above the invert of the tank and is 4 inches in diameter This is the port generally utilized during routine operation of the CAS Each of the discharge ports is fitted with a pinch valve and PVC line which can discharge to the Sluice Box The overflow port located approximately 50 inches above the invert of the tank is fitted with a discharge line to direct influent water and slurry to the Sluice Box should one or both of the tanks become over filled or if flow of influent water exceeds the flow rate of lime slurry through the discharge port s Slurry Mixers M LAO1037 and M LAO1046 An APPCOR model CYB 100 elastomer coated mixer with on off controls 1 5HP electric motor and gear reducer is mounted on the top of each of the slurry tank The S M Cycle Gear Reducer provides
89. l hoist winch system is capable of removing sludge deposits up to 12 inches deep and 7 2 feet wide per pass The overall cutting depth range is from 1 foot above water level to 16 feet below water level Dredged material is pumped through a 6 inch SDR 17 HDPE pipeline to the multi cell drying bed facility The drying facility is designed with a storage capacity of 3 378 000 gallons total dredged material This allows multiple sludge management activities to occur simultaneously 6 7 Site Vegetation and Access Maintenance All vegetation and access routes within LAO must be routinely checked and maintained throughout the year to ensure safe unobstructed access to the operating BTL equipment and provide an attractive aesthetic site appearance Operator attention to the health of the site vegetation is essential to maintain the quality of the site appearance In addition the operator must ensure that the site access routes are maintained to efficiently complete the other routine tasks necessary to maintain the BTL systems The following paragraphs discuss the site access and vegetation items which require periodic maintenance 6 7 1 Site Vegetation Monitoring and Maintenance The following routine site vegetation monitoring and maintenance tasks will be used to ensure the site vegetation remains healthy and continues to grow This brief task list is provided to guide the operator in maintaining the site vegetation on a routine basis Additional tasks
90. l treatment performance The possible adjustments are summarized in the following paragraphs with a brief description of the purpose and effect of each adjustment Some possible reasons for operating cells at their minimum operating level might include anticipated increased flows into the system or maintenance of the system The maximum operating level might be utilized for retention of treated water to facilitate maintenance of downstream components Cell A1 Cell Al water level may be changed by manually adjusting the weir gate in OS 1 The routine minimum and maximum operating levels of Cell A1 are 5 421 and 5 423 5 feet amsl respectively In the event that lower operating levels are required the auxiliary pump can be operated to lower the water level to approximately 5 416 feet amsl Draft Butte Treatment Lagoon BTL Systems Page 38 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Cell A2 Cell A2 water level may be changed by manually adjusting the weir gate in OS 5 The routine minimum and maximum operating levels of Cell A2 are 5 420 and 5 422 75 feet amsl respectively Water levels also may be changed by manually adjusting the weir gate in OS 4 This structure will be used to divert water into D2 when necessary In the event that lower operating levels are required the auxiliary pump can be operated to lower the water level to approximately 5 416 feet amsl Cell A3 The minimum and maximum operat
91. ll begin notifying the operator of the electrical service loss An onsite generator is capable of providing long term electrical supply The CAS Building back up generator is equipped with an auto transfer switch 7 3 2 Monitoring Control Failure In the event of an electrical service loss to the remote monitoring equipment NorthWestern Energy will be contacted to restore electrical service Once electrical service is restored the operator will make sure the monitoring equipment returns to routine conditions A signal loss from one of the remote stations A1 A2 or A3 may be caused by a radio failure or an electrical service loss at one or more of the stations A malfunction with the radios will cause a disruption with the transfer of data from the monitoring equipment to the monitoring system and initiate the alarm callout Draft Butte Treatment Lagoon BTL Systems Page 63 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 7 4 Off site Disturbances 7 4 1 West Camp Pump Station and MSD Pump Station Electrical Service Loss In the event of an electrical service loss to the West Camp or MSD electrical supply will resume with the automatic transfer of power provided by the on site emergency back up generator The operator will verify WCP 1 or MSD returns to routine operating conditions A signal loss from one of the remote stations West Camp or MSD may be caused by a radio failure or an electrical service los
92. llout Priority NYVNNNNYNNNNNYNDN LY Cells B3 C3 A2 and A3 Levels All the inputs for the listed lagoon cells were installed with identical level loggers therefore causes for alarms and troubleshooting will be the same for each installation throughout the system Potential causes for a slurry tank level alarm include 1 Water level in slurry tank is above or below set parameters 2 Ice or debris blockage of discharge system Draft Butte Treatment Lagoon BTL Systems Operation Maintenance and Monitoring Plan Page 81 of 85 3 Malfunction with level logger 4 Debris interfering with level logger reading and 5 Communication with the PLC failure Initial Review Screenings for Water Level Alarms Verify the individual cells level status for alarming conditions on the HMI monitor If individual cell status is operating within the normal range the cells are operating normal but if status is alarming proceed to troubleshooting as described below Troubleshooting for Water Level Alarms 1 Visually ensure water levels are within operation range to verify the alarm is not false and 2 Ensure communication to remote monitoring stations Corrective Procedures for Water Level Alarms 1 Remove pressure transducer to ensure debris algae is not prohibiting the correct level 2 Replace pressure transducer with spare transducer to isolate the problem and 3 Reset remote radio to ensure communication to the remote monitorin
93. luent at the CAS Building The targeted lime addition rate which ranges from 80 to 180 mg of amendment for each liter of water is based on lowering metal solubility in the water to form a low volume solid that is chemically and physically stable that will eventually settle out of the water Immediately following the lime addition optimal pH is 9 5 to 11 0 Multiple treatment lagoons are used to allow variable functionality of the system and increase retention time as needed The lagoon systems are made up of three parallel retention systems A B C each containing three lagoons A1 A2 A3 etc located in series resulting in a 3 by 3 array of cells Outlet flow from the distribution tank is directed to the three primary lagoons in each system Interconnecting piping and outlet structures are in place to allow water flow diversions throughout the array The treatment lagoons are unlined allowing a small volume of treated water to infiltrate into native groundwater while the majority of the water discharges to Silver Bow Creek as surface water All water whether infiltration or surface flow is treated metals precipitated and eventually enters the Silver Bow Creek aquifer 2 3 1 Chemical Physical Treatment Processes The basic treatment processes which remove metals from the influent water in the BTL systems are two fold e Formation of CaCO which then precipitates and falls through the water column adhering with other solids and removing
94. lver Bow Creek The cells are separated by earthen berms with outlet structures in place to allow outflow to the next successive location Cell D4 is the lowest pond elevation of the lagoon system All influent flow is conveyed through HCC and discharged to Cell D4 ultimately for transfer to the treatment process 2 2 3 Hydraulic Control Channel The HCC is utilized as a groundwater boundary which directs groundwater to the IPS located within Cell D4 In addition flow from all remote pumping stations is directed to the HCC This flow is ultimately conveyed to Cell D4 and the IPS to be treated as influent flow The HCC begins on the eastern boundary of LAO immediately west of Montana Street and continues to the western boundary of LAO paralleling the northern site boundary 2 2 4 Butte Reduction Works Open Areas Previous remediation and waste removal efforts have resulted in open areas and depressions in the landscape These areas are susceptible to natural filling due to groundwater and precipitation events Minor O amp M tasks are associated with this area Butte Reduction Works open areas are utilized for drying bed locations with associated outlet structures and decant water routing to the HCC 2 2 5 Chemical Addition System Building The CAS consists of lime storage feed and slurry equipment and associated automated controls The CAS Building houses all lime feed slurry tanks and associated equipment monitoring and control equ
95. m the remote sites does not exceed 30 seconds using a CalAmp Viper Federal Communications Commission FCC licensed Ethernet data radio operating in the 400MHz range The encrypted FCC licensed radio to radio communication is capable of transmitting data up to 128 kilobytes per second kbps at 10 watts of effective power Data that have been transmitted back to the Operations Building is displayed on the operators human machine interface HMI Invesys Wonderware InTouch software screen in the control room The Wonderware software monitors all local statuses for the CAS and the status of all remote stations The HMI also accepts operator set points and alarm set points Graphical display screens with data trending capabilities are available for all process areas and show all process variables equipment status or state system set points and alarm history A dedicated desktop computer located in the Operations Building control room has the HMI software installed The computer has two monitors One monitor is provided to display the lime addition process and local system instrument readings and set point The additional monitor is dedicated for the remote sites A hard drive capable of logging all system data for an extended time period is also provided An optional client version of the Wonderware software is also installed directly in the CAS Building process area on the existing panel mounted BSI computer to allow operator monitoring of levels flo
96. me supply to influent Controls lime feed to Slurry Tank 1 protects lime supply to influent Indicates Silo lime level ensure lime availability to treat influent flow Page 41 of 85 5 0 PERFORMANCE STANDARDS Performance standards established within the Butte Mine Flooding Operable Unit Site Consent Decree CV OZ 35 Bu RFC EPA 2002 or administrative order for BPSOU will be attained These standards are included in this report as Appendix D Evaluation of current performance is conducted in quarterly reports Montana Numeric Water Quality Standards DEQ 2010 are shown in Table 7 6 0 ROUTINE OPERATION AND MAINTENANCE TASKS The purpose of this section is to define the routine conditions and operator activities for the BTL systems The definitions given are a starting point based on available design information and experience gained during the previous treatability studies Routine operations are described as readily identifiable planned tasks that must be performed on a known interval Standard operating procedures are a set of written instructions which provide detailed instructions to perform a specific task following a specified method have been risk assessed controls identified to mitigate risks and allow repeatable performance of the task Routine operations regularly incorporate one or more SOPs Appendix C contains SOPs for the BTL LAO systems In addition Appendix F contains several troubleshooting and decision trees to retur
97. me time 6 3 2 CAS Start Up Proper CAS start up requires multiple procedures to be followed The following provides specific instructions to perform start up In addition refer to the references SOP for HSSE personal protective equipment PPE drawing etc references to fully perform the procedure Operating personnel must also complete procedure training and demonstrate a full understanding of the process and steps 6 3 2 1 Lime Addition SOP 28 1 Ensure screw conveyor is operating properly by visual inspection through the port in the screw conveyor cover or manually checking the switch located on the system control panel Two switches control the screw conveyor One will operate screw conveyor in forward or reverse The second switch will operate the screw conveyor in automatic or manual mode and the third position will turn it off Proper operation of the screw conveyor requires the two switches to be in the forward and manual positions 2 Ensure the 10 inch Salina Vortex pneumatic knife valve is in the open position This valve is located inside the silo above the Accurate Feeder If in the closed position the valve must be opened using the manual override button on the far south end of the valve By pressing this button the valve manually opens thus ensuring continuous lime flow 3 The operator will then restart both pumps located at the D4 pumping station by using steps described in SOP 6 Influent Pump Station Start Up Appen
98. ment lagoon cells or to Cells D2 and D3 by use of gravity These direct discharge pipes will allow water to be routed to the next downstream treatment cell for additional treatment increasing flow to downstream cells to maintain treatment effectiveness in these cells or routing of treated water that does not meet discharge criteria to Cell D4 for retreatment through the entire BTL treatment system recirculation Table 3 presents general location and operational information for each of the effluent pipelines within the BTL Table 4 presents dimensional information for each discharge pipe within the BTL The ASB houses the ISCO automatic sampler U ASB 101 peristaltic pump P ASB 101 Rosemount water level probe LT ABS 101 heater U ASB 102 and main electric box for the IPS EL ASB 103 see Figure 9 This sampling point is located on the southeast end of Cell D4 Draft Butte Treatment Lagoon BTL Systems Page 23 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product see Figure 4 The automatic sampler is placed in a 10 by 12 foot building For maintenance and operation refer to the ISCO owner s manual maintained in the CAS Building Appendix B 2 6 Electrical Automation Control and Monitoring Description The following subsections provide a general description of the electrical systems at the BTL Site dedicated back up generators provide back up power to the site Back up generators are located at t
99. ms 1 Remove flow meter sensor to ensure debris algae is not prohibiting correct flow rates 2 Configure valves to divert water into effluent pipeline and 3 Remove debris that is preventing flow into the effluent pipeline Draft Butte Treatment Lagoon BTL Systems Page 83 of 85 Operation Maintenance and Monitoring Plan 13 0 REVISIONS AND UPDATES Procedures and protocol which address revisions and updates to this manual are discussed in detail in Volume I Water Collection and Treatment Systems Section 7 0 The O amp M will be revised as necessary when there are changes to any of the following e Program operation or system components e Updates of manufacturers recommended practices for the system or equipment e Change in regulatory or compliance requirements e Deviations from operating boundaries physical damage or loss of containment e Changes in operating conditions e Physical alterations to equipment e New knowledge and experience of deterioration mechanisms or other parameters that could affect the equipment integrity or reliability or e Alterations or modification of the system or system equipment Each update package will contain the necessary update information a summary sheet listing the changes and any instructions that may be necessary and a revised listing of all previous updates Each page in the update will include the date on which the update was made as well as the update number The procedure
100. n in the lime feed This will occur if the operator does not monitor the amount of stored lime and enough lime is used to completely empty the silo To minimize the potential for this condition the operator will order lime when approximately 8 tons of lime remains in the silo and schedule the delivery to occur when approximately 4 tons remain Lime delivery information is contained in Section 6 2 3 2 Lime may also get blocked bridged in the lime silo causing a disruption of lime to the Accurate Feeder hopper The bin discharge motor was installed to run automatically to prevent this from occurring and installed to run manual to dislodge the lime bridge Investigate silo vibrator function if the Yo Yo meter LT LAO 1000 indicates lime level is sufficient but no lime flow 7 1 8 Troubleshooting Lime Feed To initiate troubleshooting of the lime feed system evaluate the lime feed trend line on the OP1 screen An erratic trend line jumps up and down sharply is an indication that the feeder has lost its calibration point and should be re calibrated Empty the feeder hopper and recalibrate the feeder To recalibrate refer to SOP 35 provided in Appendix C The following instructions will be followed to perform re calibration 1 Ensure the 10 inch Salina Vortex pneumatic knife valve FCV LAO 1004 is in the closed position This valve is located inside the silo above the Accurate Feeder If in the open position the valve must be closed using th
101. n systems back to routine status 6 1 Routine Operations Tasks The operator s normal routine will include several standard tasks These tasks include e As described in SOP 1 CASB Initial Arrival located in Appendix C start of day status check for the controls outlet structures lime feed area and Cell D4 e Check of WCP 1 SOP 4 West Camp Check twice per week and e Daily check of MSD Pump Station and discharge The specific subtasks and activities in each of these routine tasks are detailed in the following subsections Checklists provided in Appendix D identify routine tasks performed by the operator on weekly monthly bi monthly and quarterly intervals Daily monitoring of cell levels pH and flows are conducted by the operator Instantaneous field data measurements and recordings are transferred to a computer system at the end of each work day Daily recordings are used to verify lime feed rates and influent flow rates These field data are also used to generate a daily operations report as described in Section 10 0 Final performance standards are pending agency agreements and the Final Consent Decree Until the final performance standards are established Montana DEQ 7 standards will be met Draft Butte Treatment Lagoon BTL Systems Page 42 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 6 1 1 Controls Outlet Structures Lime Feed Area and Cell D4 Upon arrival at the project
102. n the operators log sheet Observations and areas of concern regarding Missoula Gulch and associated catch basins will also be directed to BSB Director of Public Works for remedy Periodic inspection of catch basin outlet structures is required to ensure hydraulic controls are set properly orifice plates at catch basin outlets are in place or bypass pipeline valves are open These inspections coincide with seasonal maintenance activities Refer to Volume V Maintenance Plan for additional information 6 1 3 West Camp Pump Station The operator will perform a check of the WCP 1 twice per week Pump operating status and flow are available at the main panel in the Operations Building Refer to Volume III West Camp Pump Station WCP and Missoula Gulch Discharge Systems for additional information This provides the operator with firsthand knowledge that includes e West Camp pump is operational e Well levels are within minimum and maximum operating limits and e Site security and integrity is maintained 6 1 4 Metro Storm Drain Pump Station The operator will perform a daily status check of the MSD pump station Refer to Volume IL Metro Storm Drain MSD Collection System for additional information Pump operating status and flow are available at the main panel in the Operations Building This provides the operator with real time system status that includes e MSD pumps are operational and e Water levels in the pumping vault are wi
103. nd infiltration are also utilized to dewater dredged material prior to solids being transported to the waste repository 2 4 8 Additional Monitored Sites Multiple sites identified on Drawing Sheet I amp C G 5 located in Appendix A are also equipped with monitoring equipment and data transmitted to the data logging system in the CAS via FCC radio 2 5 Description of Butte Treatment Lagoon Facilities 2 5 1 Influent System Historical operations of the Influent System have determined that the optimum operating level for Cell D4 is approximately 5 414 5 feet amsl Short term up to 2 days high flows may increase the operating level of Cell D4 to 5 417 feet amsl Short term high flows may result from construction dewatering or increases in pumping rates from storm water surges Long term fluctuations due to multiple storm water surges or snowmelt events may require the normal operating level to be raised for a longer period The influent system design flow rate is 1 800 gpm The pumps described in Section 2 5 1 2 are sized to provide adequate capacity to maintain Cell D4 at or below the target water level during routine operating conditions The maximum flow rate that can be produced with 1 pump in Draft Butte Treatment Lagoon BTL Systems Page 15 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product operation is approximately 3 mgd 2 200 gpm when both pumps are in operation the maximum flow rate expected throug
104. ndary tank receives approximately 50 to 100 gpm Manual actuation of the tank discharge valves BV LAO 1038 or BV LAO 1040 allows the liquid level in each tank to be adjusted to the desired level A liquid level is maintained in the secondary tank to allow seamless switching of slurry tanks as needed Dry lime feed is switched through operation of the inline knife gate valves FCV LAO 1019 or FCV LAO 1023 from the primary tank to secondary tank Liquid is maintained in both tanks therefore no downtime is incurred when lime delivery is diverted between slurry tanks Dry lime is added to the primary tank at the dosage described below In general the following operating ranges are expected to be seen in relation to the CAS Influent Water Flow Rate e Minimum 0 58 mgd 700 gpm e Maximum 2 59 mgd 1 800 gpm and e Average 1 73 mgd 1 200 gpm Lime Usage Rate e Minimum 1 095 pounds per day Ibs day e Maximum 3 440 lbs day and e Initial Target 1 877 lbs day The continuously mixed slurry will then be constantly discharged from the active slurry tank and directed to the Sluice Box for initial mixing and transfer of raw influent water and lime slurry to the Distribution Tank located directly west of the CAS Building Combined influent water and Draft Butte Treatment Lagoon BTL Systems Page 17 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product lime slurry is then discharged from the Distr
105. ng s 100 amp panel All 240 volt and 120 volt loads in the CAS Building are fed from this 100 amp panel Caution this 100 amp 240 120 volt panel contains 208 volts from phase C to ground 2 6 1 2 A1 Area Service A 3 phase bank of pole mounted transformers rated 26 1 KVA provide this area with 480 volt power The overhead service supplies the Al Area Service Rack with a 50 amp electrical service The meter base service disconnect is located on a utility pole and the 50 amp main breaker controls power at all Al Area locations via underground conduit A 5 KVA transformer serves all 240 120 volt loads at this area A2 Area Service A 3 phase bank of pole mounted transformers rated 75 KVA provide this area with 480 Y 277 volt power The underground service supplies the A2 Area Service Rack with a 100 amp electrical service The meter base service disconnect is located on the service rack and the 100 amp main breaker controls power at all A2 Area locations A 5 KVA transformer serves all 240 120 volt loads at this area Draft Butte Treatment Lagoon BTL Systems Page 24 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product A3 Area Service A 3 phase bank of pole mounted transformers rated 75 KVA provide this area with 480Y 277 volt power The underground service supplies the A3 Area Service Rack with a 100 amp electrical service The meter base service disconnect is located on the service rack and the 100 amp main break
106. nt station the CAS Building WCP 1 and MSD pump station The software then logs the input data at 30 second and 1 hour intervals into separate files The measurement Draft Butte Treatment Lagoon BTL Systems Page 30 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product stations established for the system all report data back to the monitoring system located at the Operations Building The systems are summarized below Metro Storm Drain flow is measured with a 10 inch McCrometer UltraMag flow meter MSD FIT 6019 installed at the MSD pump station discharge West Camp flow is measured by the McCrometer UltraMag flow meter FIT WCP 5006 installed in WCP 1 discharge piping Lagoon Water Surface elevations are measured by an electronic pressure transducer installed in a round stilling well fastened to the wing wall of the primary outlet structure in Cells Al A2 A3 B1 B3 C1 and C3 The stilling basin is provided to minimize the effect of wave action and ice formation on the cell Typical stilling well construction is shown on Figure 10 Operating elevation and structure height schedule are also provided Influent Flow is measured with a 10 inch McCrometer UltraMag FIT LAO 1059 flow meter installed on the influent pipeline within the CAS Building Effluent Flow is measured by a Greyline Area Velocity Flow Meter AVFM FI LAO 110 attached near the outlet to the invert of EL A The AVFM measures the dep
107. ntenance tasks are defined as the result of on going operations 11 1 5 Equipment Individual equipment manuals and a listing of the equipment documentation provided by the manufacturers are included in Appendix B which will be maintained and stored within the CAS Building 11 1 6 Records and Record Keeping A maintenance log located in Volume V is used to provide written record of all maintenance performed Additional information and instructions is provided in Volume V Section 2 0 Routine maintenance activity notes and identification of maintenance are also included in weekly operations reporting described in Section 10 2 Draft Butte Treatment Lagoon BTL Systems Page 73 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 12 0 EMERGENCY PROCEDURES This section discusses alarm conditions and response actions for each alarm In case of injury to personnel at the site please refer to the Site Specific Health and Safety Plan for Butte Treatment Lagoons BTL and Lower Area One LAO Operation and Maintenance O amp M Activities SSHASP Pioneer 2010 To contact ambulance fire rescue or police call 911 Provide the address Centennial Avenue Lower Area One adjacent to Metro Treatment Plant Contact personnel and notification information is located in Section 1 4 of this document and also in the SSHASP 12 1 Alarm Response and Notification Alarms associated with most of the input
108. o Cell D4 where it can be recirculated through the system The decision tree BTL DT 8 is located in Appendix F and provides decision making guidance when recirculation is considered 3 2 5 Routine Operations Routine operations of each component of the BTL systems are described in the following paragraphs Table 1 presents the operating range and target operating levels of each cell in the treatment system The BTL systems data for routine operations is summarized in the BTL Weekly Operations Report provided in Appendix H Distribution Tank T LAO 6 The weir gates on the Distribution Tank will be adjusted to maintain a minimum freeboard of 4 inches while still allowing flow to be distributed as necessary to each of the Lagoon Systems A B and C The Table 5 provides guidance when setting the weir height to establish flow into the cells Cell A1 Under routine conditions a majority of flow regulated with Weir Gate A which is located in the Distribution Tank is diverted through Cell A1 to the outlet structure Initial target water level for this cell is 5 423 feet amsl and the weir gate in OS 1 can be adjusted accordingly to achieve this water level range of operations of 5 421 to 5 423 5 feet amsl From OS 1 there are two 15 inch discharge pipes that extend from the bottom of OS 1 to the northeast corner of Cell A2 that allow flow to be dispersed into Cell A2 Cell A2 Water levels in Cell A2 can be regulated with either OS 4 or OS 5 Du
109. o that the operator can clearly understand the performance requirements and how they must be addressed on a day to day basis This section presents the O amp M requirements relevant to maintaining high water quality performance This section must be used in conjunction with Section 8 0 on monitoring requirements and Section 9 0 reporting requirements e Section 6 0 Routine Operations provides a description of routine system monitoring and oversight Also provided are details for routine operational conditions for the various facilities and procedures for establishing verifying or changing these settings Standard Operating Procedures will be referenced in this section as developed and subsequently appended following the Shakedown Period Draft Butte Treatment Lagoon BTL Systems Page 7 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product e Section 7 0 Operation During Disturbances identifies various types of upset conditions that may occur in the lagoon treatment system Alternative response mitigation measures approaches to identifying the cause of problems and sources of additional information and assistance are provided e Section 8 0 Monitoring and Laboratory Testing defines the measurements and observations required for the BTL This includes both monitoring for operation and process control and monitoring required by regulatory agencies A method is provided for summarizing the data so that the operator
110. on The programmed sampling start time is set appropriately initially set at 10 00 a m The START button is depressed and The sampling pump is operating properly 2 Effluent Sample Pump a The effluent automatic sampler will start automatically when all of the following conditions are satisfied Breaker is not tripped The ON OFF key is in ON position The programmed sampling start time is set appropriately initially set at 10 00 a m The START button is depressed Peristaltic pump is turned on the day prior to sampling day and The sampling pump is operating properly 3 Lime Feeder Lime is fed to the screw conveyor and finally to the slurry tanks automatically when all of the following conditions are satisfied Locate operator interface terminal panel EL CAS 112 in the Operations Building at LAO Position the lime feeder switch in Gravimetric position Push the green start icon on the OP1 screen and Set the appropriate dosage in mg L indicated on the screen display Locate the Main Silo Control Panel Set the screw conveyor switch to HAND the ensures the screw conveyor is operating and Set Silo Vibrator to Gravimetric 4 Bin Discharge a The lime feed system will be operated manually when all of the following conditions are satisfied b To operate in HAND Volumetric mode Draft Butte Treatment Lagoon BTL Systems Page 48 of 85 Operation Maintenance and Monitoring Plan Confidential
111. onfigurations a Manual Startup Position For operation of the influent pumps in manual mode the operator must have the switch in the HAND position To avoid pumping system problems the pumps must not be started Draft Butte Treatment Lagoon BTL Systems Page 53 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product simultaneously Therefore in the manual operation mode the operator must ensure that both pumps are not started simultaneously b Automatic Startup Position For operation of the influent pumps in the automatic mode the operator must have the switch in AUTO position and use the D4 Pump Control Panel for pump startup The D4 Pump Control Panel contains a local emergency stop button reset button east pump start and west pump start For pump start up sequence the operator must first depress the pump reset button on the D4 Pump Control Panel The pump reset button s function is to start the PLC program and the automation After resetting the pump sequence the operator must depress either the D41 or D42 Pump Start Button to start the pump The IPS PLC program will begin a 30 second timer that will not allow the second pump to start until 30 seconds have elapsed After 30 seconds have passed the operator can depress the second pump that needs to be started if necessary To avoid pumping system problems the PLC 30 second timer programming prevents the operator from starting both pumps at the sa
112. onfigured correctly Corrective Procedures for Lime Silo Level Failure 1 Try to reset tripped breakers if breakers trips again contact NorthWestern Energy or electrical contractor to perform further repair troubleshooting as necessary 2 Manually measure the lime by depressing the manual measure button on the Bindicator display located in the lime silo 3 Remove the main measurement device located on the top of the lime silo and observe for any abnormal operations Refer to the Bindicator GP 4 Yo Yo User s Manual 4 Refer to the Bindicator GP 4 Yo Yo User s Manual for re configuration of the parameters for the measuring device 12 2 1 6 Slurry Tank Level Alarms This status input detects the status of the slurry tank alarm A level indicator located on the top of slurry tanks measures the slurry level in the tank and alarms personnel if the level is above or below the set parameters Potential causes for a slurry tank level alarm include 1 A clog in the discharge line restricting or preventing slurry discharge from the tank This will raise the level in the tank to the emergency overflow port and cause a high level alarm 2 The level indicator and measuring pipe may be in need of maintenance This will cause inaccurate readings and create false alarms 3 The amount of water entering the slurry tank is greater than that being discharged eventually creating a high level alarm Initial Review Screenings for Slurry
113. ontrol or selector switch When in this position the device is under manual control OFF Off position of a control or selector switch When in this position the device is turned off AUTO Auto position of a Hand Off Auto control or selector switch When in this position the device is under automatic control by the control system ON On position of a control or selector switch When in this position the device is turned on OPERATOR INTERFACE This is a personal computer running an industrial control software package which acts as HMI It allows the operator to view the process status and alarms of the entire system It allows graphic depiction of the system and provides access to all required set points and operator adjustable values and alarms Table 8 provides a list of instruments alarms and set points for LAO systems 6 3 Normal Start Up The IPS start up is dependent upon CAS system status If CAS slurry equipment is off line for longer than 30 minutes IPS enters auto shutdown status 6 3 1 IPS Start Up SOP 6 1 The IPS control panel located near the Cell D4 electrical service controls the 75 HP IPS pumps and provides control to the auxiliary temporary pump when needed For each pump a HAND OFF AUTO switch controls the status of each pump The pumps do not operate in the OFF position The IPS pumps can be operated in two different configurations Manual or Automatic Below describes the procedures to start pumps in both c
114. ow single pump operation during routine conditions parallel pumping operation to meet increased capacity demand and redundant pumping capability to ensure treatment capabilities can be met 1 3 1 Remedial Action Objectives The remedial action objectives RAOs established in order to meet the requirements of the Record of Decision ROD EPA 2006 for groundwater and surface water include Groundwater Prevent ingestion of or direct contact with contaminated groundwater that would result in unacceptable risk to human health Prevent groundwater discharge that would lead to violations of surface water ARARs and remedial goals for the BPSOU Prevent degradation of groundwater that exceeds current standards Surface Water Prevent ingestion or direct contact with contaminated surface water that would result in an unacceptable risk to human health Return surface water to a quality that supports its beneficial uses Prevent source areas from releasing contaminants to surface water that would cause the receiving water to violate surface water ARARs and remedial goals of the operable unit Draft Butte Treatment Lagoon BTL Systems Page 2 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product and prevent degradation of downstream surface water sources including during storm events Ensure that point source discharges from any water treatment facility meet ARARSs Prevent further
115. peration Maintenance and Monitoring Plan Confidential Attorney Work Product 1 2 System Background The BTL system is a result of multiple demonstration projects implemented to determine the best method of treating the waste associated with BPSOU Some demonstration projects were conducted in parallel to one another As a result multiple lagoon and cell systems were constructed As additional influent flows were introduced into the system and a final remedy identified the system utilized multiple lagoons and effluent cells as part of the final remedy The governing purposes of the BTL are to protect adjacent surface water systems Blacktail and Silver Bow Creeks through capture and treatment of impacted groundwater and effectively remove heavy metals copper cadmium and zinc and arsenic under a variety of anticipated conditions 1 3 Design Theory The BTL effluent system consists of multiple cells operating in parallel Each system consists of 3 cells The first cell is an unlined open water cell The primary purpose of this cell is sediment collection The additional cells are referred to as ponds Each pond is also an open water unlined cell for the purpose of increasing residual time and allowing final pH adjustment The series of cells are separated by highly conductive earthen walls Floating silt curtains are used to mitigate solids carry over from the primary cell to downstream ponds The influent pumping station is designed to all
116. position the rate of lime addition is controlled automatically The WonderWare control screen allows the operator to enter a value to decrease or increase the lime rate Once a value is set the Accurate Feeder motor speed determines the amount of lime that is fed into the system Therefore the amount of lime that enters the system is automatically increased or decreased in direct proportion to the influent flow rate HAND MODE While the Accurate Feeder lime rate switch is in the HAND or manual position the operator manually controls the lime rate In manual operation the operator adjusts the feed rate knob on the Lime Feeder System Control Panel to change the speed of the Accurate Feeder motor A transducer mounted on the outside of the motor gear shaft sends a value to the digital panel meter display located on the front of the Lime Feeder System Control Panel The panel meter displays the rpm of the motor shaft with a 9 25 gear ratio offset While operating in the HAND position the operator must manually measure and confirm the lime addition rate on a routine basis see SOP 8 provided in Appendix C 2 6 2 3 Influent Pump Station Automation Control The CAS Building PLC has input parameters that are directly related to continued D4 pump operation If the influent flow rate drops below 400 gpm for a period greater than 10 minutes the CAS Building PLC program sends a signal to the IPS PLC to shut the pumps off The D4
117. r from the IPS at Cell D4 to the CAS Building Each pipeline is approximately 2 400 feet of buried pipeline Pump discharge piping is 14 inch ductile iron pipe which exits the IPS Building below grade and transitions to 14 inch SDR 17 HDPE The 14 inch HDPE influent lines will then follow the flood containment dike FCD road alignment and parallel the existing 10 inch PVC influent line en route to the CAS Building Mueller resilient wedge gate valves and curb boxes will be installed on each of the 3 lines prior to entering the proposed CAS Building addition The two 14 inch HDPE lines and the existing 10 inch line transition to a single consolidated 14 inch ductile iron pipe immediately following the aforementioned gate valves The 14 inch ductile iron pipe enters through the floor of the southwest corner of the proposed CAS Building addition and continues directly to the existing sluice box 2 5 2 Chemical Addition System CAS During routine operations raw influent water is directed to both slurry tanks through the 4 inch PVC feed water supply lines to the top of the slurry tanks Flow is throttled using inline 4 inch butterfly valve BFV LAO 1037 or BFV LAO 1044 Flow rate to each respective tank is provided from an UltraMag flow meter FIT LAO 1039 or FIT LAO 1045 located upstream of the valves A continuous flow of raw influent water is directed to each tank The primary tank receives approximately 200 gpm of raw influent water while the seco
118. rams per Liter mg L The WCP 1 is operated and maintained in accordance with the requirements of the Volume III West Camp Pump Station WCP and Missoula Gulch The pumping rate from WCP 1 is controlled through the use of a variable frequency drive VFD to maintain the water level at approximately 5 425 amsl under routine conditions Operating WCP 1 in this manner minimizes the potential of the water level to rise above the required critical water level of 5 435 feet ams 2 4 5 Metro Storm Drain Groundwater Collection System The MSD pump station and pipeline constructed in the second quarter of 2004 is 1 of the 2 primary groundwater pumping stations to BTL LAO This system shown on Figure 1 conveys captured groundwater to the BTL A pump in the vault at the bottom end of the MSD subdrain transfers impacted groundwater from the subdrain to the upper end of the HCC in LAO at an average flow of 0 65 mgd 450 gpm and is expected to range from 0 32 mgd 225 gpm and 1 18 mgd 820 gpm The outlet of the MSD pipeline is located at the east end of the HCC where the discharged flow mixes with on site ground and surface water collected within the BTL from the HCC WCP 1 and Missoula Gulch groundwater flow The operation of the MSD station is conducted in accordance with Volume II Metro Storm Drain Collection System Draft Butte Treatment Lagoon BTL Systems Page 14 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Prod
119. rational and 4 Ensure screw conveyer is not clogged by lime Corrective Procedures for Screw Conveyor Failure 1 Ensure Lime Feeder System Control Panel is properly configured Procedure 2 in Appendix C summarizes the Screw Conveyor Cleaning and 3 Try to reset tripped breakers if breakers trips again contact NorthWestern Energy or electrical contractor to perform further repair troubleshooting as necessary 12 2 1 4 Slurry Tank Discharge Failure Decision tree BTL DT 7 located in Appendix F provides guidance in troubleshooting and maintaining the lime slurry feed system Draft Butte Treatment Lagoon BTL Systems Page 77 of 85 Operation Maintenance and Monitoring Plan Potential Causes for Slurry Tank Discharge Failure This status input detects the status of the slurry tank discharge Slurry Tanks 1 and 2 discharge inputs are configured in the Allen Bradley PLC to only call if both inputs alarms are active This prevents false alarms at the discharge stage of lime feeder system during tank inactivity Potential causes for a slurry tank discharge failure include 1 Slurry tank feed water interruption 2 Influent flow interruption and 3 Lime buildup in the slurry tank discharge pipe Initial Review Screenings for Slurry Tank Discharge Failure Verify slurry tank discharge status is not alarming on the HMI screen If status OPEN is displayed slurry tank discharge is operating normal but if status is alarming proceed to
120. ratory analyses Subsequent receipt use and data management storage are also necessary Documentation of water levels flow and water quality data are particularly important to verify regulatory performance Specific monitoring and analytical requirements are detailed in the Draft Butte Treatment Lagoons BTL Systems at Lower Area One Sampling and Analysis Plan SAP Atlantic Richfield Company 2005 Refer to Appendix G Additional field measurements or samples may be collected by the operator as necessary to aid in optimizing water treatment Figure 5 shows sample locations for the BTL system 8 5 Routine Inspection and Calibration of On Site Monitoring Systems Monitoring instrumentation must be routinely checked to verify their accuracy and to ensure proper calibration and operation Operator attention to proper functioning of instruments is essential in order to provide accurate information on important BTL operating parameters The following paragraphs discuss various types of instrumentation common problems associated with their operation and attention required by the operator to ensure proper function Monitoring equipment will also require periodic routine recalibration and maintenance Appendix C also contains SOPs for instrument recalibration tasks Draft Butte Treatment Lagoon BTL Systems Page 66 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 8 5 1 On Site pH Meters The on site pH meter
121. re screen in the control room The Wonderware software monitors all local statuses for the CAS and the status of all remote stations The HMI also accepts operator set points and alarm set points Graphical display screens with data trending capabilities are available for all process areas and show all process variables equipment status or state system set points and alarm history A dedicated desktop computer located in the Operations Building control room has the HMI software installed The computer has two monitors one for the lime addition process and local system and one for the remote sites and a hard drive capable of logging all system data for an extended time period An optional client version of the Wonderware software is also installed directly in the CAS Building process area on the existing panel mounted BSI computer to allow operator monitoring of levels flows set points and alarms for the lime process The following information is a summary of the electrical devices for control and monitoring at the BTL 1 CAS Building a Operator Interface The following devices are located in the Treatment Control Panel located on the southeast corner of the CAS Building Draft Butte Treatment Lagoon BTL Systems Page 25 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product HMI Computer and Screen PLC Master Radio Interface Process Set Points and Alarms System Trends and His
122. re 10 Butte Treatment Lagoon BTL Stilling Well Detail Figure 11 Butte Treatment Lagoon BTL Outlet Structure Pump Plumbing Details LIST OF TABLES Table 1 Treatment Lagoon General Information Table 2 General Effluent Pump Information Table 3 General Effluent Pipeline Information Table 4 Effluent System Discharge Pipe Information Table 5 Distribution Tank Weir Gate Settings Table 6 BTL Cell Retention Times Table 7 Montana Water Quality Standards DEQ 7 Table 8 Lower Area One LAO Alarm Conditions Draft Butte Treatment Lagoon BTL Systems Page viii of ix Operation Maintenance and Monitoring Plan Confidential Attorney Work Product LIST OF APPENDICES Appendix A System Drawings Appendix B Equipment Inventory and Manufacturer s Data Appendix C Butte Treatment Lagoon BTL Standard Operating Procedures Appendix D Butte Treatment Lagoon BTL Performance Standards Appendix E Butte Treatment Lagoon BTL Op Report Appendix F Butte Treatment Lagoon BTL Systems Operation Decision Tree BTL DT 1 Cell pH Based Decisions BTL DT 2 Influent Pump Station BTL DT 3 under development BTL DT 4 Screw Conveyor BTL DT 5 Lime Feed System BTL DT 6 Accurate Feeder BTL DT 7 Slurry Tanks BTL DT 8 Cell Recirculation BTL DT 9 Electric Motors Appendix G Butte Treatment Lagoon BTL Systems Sampling and Analysis Plan SAP Appendix H Butte Treatment Lagoon BTL Weekly Operation Report Appendix I Sludge Production Estimate Draft Butte Trea
123. ring routine conditions OS 4 will be closed raised to the full upright position and all flows will be regulated with OS 5 which diverts water to Cell A3 or EL C Manual settings of the weir gate in OS 4 located in Cell A2 determine the water levels of the cell The initial target operating level of this cell is 5 421 25 feet amsl Water can be discharged either to Cell A3 through a 24 inch discharge pipe which extends from the bottom of OS 5 to the east edge of Cell A3 or to the effluent pipeline through EL C Draft Butte Treatment Lagoon BTL Systems Page 37 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product Cell A3 Water levels in Cell A3 can be regulated with OS 7 Manual settings of the weir gate in OS 4 located in Cell A3 determine the water levels of the cell The initial target operating level of this cell is 5 420 5 feet amsl Water can be discharged either to Cell D4 through an 18 inch discharge pipe which extends from the bottom of OS 7 to the east edge of Cell D4 or to the effluent pipeline through EL D Lagoon System B Flow into Lagoon System B is regulated with Weir Gate B located in the Distribution Tank Manual settings of the weir gate in OS 2 located in Cell B3 determine the water levels of Lagoon System B The initial target operating level of this system is 5 422 5 feet amsl _ Water can be discharged either to Cell A2 through a 12 inch discharge pipe which extends from the bottom of OS
124. s A malfunction with the radios would cause a disruption with the transfer of data from the remote monitoring equipment to the primary PLC located in the CAS Building and initiate the callout NorthWestern Energy will be contacted to restore electrical service 7 4 2 West Camp Pump Station and MSD Pump Failure Pump failure at WCP 1 is confirmed by completing troubleshooting procedures described in Volume II West Camp Pumping System and Missoula Gulch Pump failure at WCP 1 or MSD may be caused by normal wear electrical failure or other mechanical factors A pump failure at WCP 1 longer than 2 to 3 days refer to Volume III West Camp Pumping System and Missoula Gulch A pump failure at MSD may be limited to one pump or both pumps within the vault A temporary pump will be used to bypass the pump vault to allow for access and pump replacement 7 4 3 West Camp Pump Station and MSD Monitoring Equipment Failure Monitoring equipment failures at the West Camp level meter and flow meter or MSD float switch in the wet vault and pump status are detected in the local monitoring system The operator will be notified by the primary PLC in the CAS Building via automatic callout Following notification and troubleshooting the operator will correct the disturbance as needed 7 5 Environmental Disturbances If a large precipitation or snowmelt event occurs while the influent pumps at Cell D4 are running at maximum pump rate and Cell D4 is at full capaci
125. s for revising or updating this manual are outlined below e An update revision package will be sent to all individuals on the distribution list e Recipients will add replace the necessary pages e Recipients will replace the Listing of Previous Updates in the front of the Volume and e Recipients will place the Update Summary Sheet for future reference purposes Draft Butte Treatment Lagoon BTL Systems Page 84 of 85 Operation Maintenance and Monitoring Plan 14 0 REFERENCES ARCO 1992a Clark Fork River Superfund Site Investigations Standard Operating Procedures September 1992 ARCO 1992b Clark Fork River Superfund Investigations Quality Assurance Project Plan ARCO 1992 Atlantic Richfield Company 2005 Draft Butte Treatment Lagoons BTL Systems at Lower Area One Sampling and Analysis Plan SAP Atlantic Richfield Company 2006 BTL Effluent System in the Draft Final As Built Drawings and Information for the Butte Treatment BTL Systems May 5 2006 Atlantic Richfield Company 2010a Draft Final Butte Treatment Lagoons BTL and West Camp Pump Station WCP 1 Upgrades Design Report Work Plan September 9 2010 Atlantic Richfield Company 2010b BLT LAO Water Management Contingency Operations March 10 2010 DEQ 2010 Circular WQB 7 Montana Numeric Water Quality Standards August 2010 EPA 1986 OSWER Directive 9355 0 4A Superfund Remedial Design and Remedial Action Guidance June 1986 EPA 2001 Operation
126. s monitored at the BTL were installed to notify the operator s immediately after an upset malfunction or maintenance issue occurs These alarms will assist the operator s in maintaining consistent treatment and prevent unsafe conditions to human health or the environment The automatic control system is equipped with a dialer that can deliver up to 15 distinct messages set up according to priority Alarms deemed primary dial out a notification if the upset malfunction or maintenance issue continues after 120 seconds while the those notifications deemed secondary do not dial out until after 600 seconds of the upset malfunction or maintenance issue Callout priority for each alarm is shown in Table 8 Depending on the severity of the alarm the operator is expected to respond to an alarm situation as soon as practicable Dialer notification is designed to advise the operator of appropriate needs while minimizing nuisance alarms that could ultimately nullify the use of the system When no immediate effect on system performance is probable dialer notification will not be made and the alarm will be dealt with on the next operator visit Alarm response procedures are under development at the time of this revision release Future revisions will contain appropriate instructions to alarm response 12 2 Alarm Conditions Alarm conditions have been established as part of the automatic control system located at the CAS Building Table 8 provides
127. s to be taken off line and refilled e Silo Level A Bindicator GP 4 Yo Yo Meter LT LAO1000 installed in the lime silo The meter indicates the volume of lime stored in the silo will activate an alarm if the level is above or below the set parameters e Lime auger An on off switch installed on the Accurate Feeder U CAS 120 activates an alarm if the auger is not turning e Air compressor Redundant skid mounted air compressors provide service air to pneumatically actuated valves and baghouse pulse jet system A pressure switch located after the air filtering and drying unit activates an alarm if the pressure level is below the set parameters Various additional monitoring instruments provide real time indication of system operational status such as lagoon levels flows and equipment run ON OFF status Draft Butte Treatment Lagoon BTL Systems Page 32 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 3 0 HYDRAULIC CONTROLS 3 1 Description of Hydraulic Controls Most hydraulic controls at the BTL are manually operated These include e Weir gates e Canal gates Waterman Canal Gates e Stop logs Fiberglass Reinforced Polyester FRP Stop Logs and e Pumps The hydraulic controls have one routine operation setting which is not to be changed by the operator until after consultation and approval from Atlantic Richfield Project Manager Groundwater hydraulic gradients must
128. scdsecscsessecesssssvenstiecresaeenscedacteeannass 3 1 33 Codesand Standards nnie a E E E E E E 3 Seek CAS B ildins crano aa T EE AaS 4 1 3 3 2 Operations Building oees cq sunsets secs sane steacd ved aaddaesdetey ansoasmanesgeacsaesecee 4 WW3 3 5 Electrical viv c icsici orate eeinOe ecard weed 4 ISA MOTOR TCO Yi 2 cc cs aced eces A E tastes paeeeoav ase 5 1 4 BTL LAO Owner and Contact Information 0 cee eeeseeeeneeceeeeeeeeeeeceeeeeesteeeesaes 5 1 4 1 Owner and Contact Information 00 0 0 ee eee eeseceseeeeeeeeseecnaecneeseeeeeaeeeaeens 5 1 4 2 Key Contacts Emergency Information 0 0 0 0 eeesceceeneeeeeeeeeeeneeeeneeeesaes 6 1 4 3 Additional Emergency Contact Agencies eeececeeseecesececeeeeeceeeeeeeteeeesaes 6 1 4 4 Non emergency Services scs5ccccsy eee eas eases vcs seecusacss aeasecaceenybeaveotnaed eousbaaeee 6 1 5 Organization and Use of this O amp M Plann cece ceeseeceenceeseececeeeeeceeeeecseeeeesteeeesaes 7 207 SYSTEM OVERVIEW waseus tees ces taatepeasdapesaria caus a a a a deena 9 2 1 OSC VS score en a A E A 9 2 2 Gremeral ei A E AE E A E 9 2 21 Lower Area O sonnir a e r ESE 9 2 2 2 Butte Treatment Lagoons iss ceccscivssjecesssccadadesscee suaede teasgeaaeasvanaceedeeddaessdeoden 10 2 2 3 Hydraulic Control Channel os csc eaycattat ac ahaedesvaccuasspcandoneaaanctsactanevacenadues 10 2 2 4 Butte Reduction Works Open Areas 0 ceeccecesececeeeeeceeeeeceeeeeceteeeeseeeees 10 2 2 5 Chemical
129. seeesseessseesseesseesseeesseee 71 10 3 Quarterly Operations Report sssesssessssseesseeessstesseesseesseesseeessseessresseesseesseeesseee 71 1045 Supplementary Data Le oa a EEEE E a GE T EE che ed ene 71 11 0 ROUTINE INSPECTION AND MAINTENANCE GUIDELINES 0 cccecceeeseeeteees 72 11 1 Inspection and Maintenance Guidelines for Process Equipment eeeeeee 12 WL ASL Scope and Organization conic a ee e a a tases 12 11 1 2 Description of Access to Site Facilities ee ceecccsscesssceceeeceesseceeeseceees 12 Draft Butte Treatment Lagoon BTL Systems Page vi of ix Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 11 1 3 Description of Routine Maintenance Task ceeeeeeesecsneceeeeeeeeeenees 73 11 1 4 Schedule of Task Performance seis fo c0t5 2 svacos so ccstetaseedade ocandi ecm 73 HELS EQUIPMENT 22555 ctise case a e a lati eal eet des iene ete 13 11 1 6 Records and Record Keeping i ciscccenvicsscessgecncesd hesasheveaes eteaeteasstanneeavans 73 12 0 EMERGENCY PROCEDURES x 21 i0e i28 sietedeths eaves eedaecl tects stab dence Wedded pean 74 12 1 Alarm Response and Notification c isss9accals ocusestes ea geaessasqaensseaccadseniaeoestbasesseereeuaiess 74 122 Alarm Conditions 4 4 0 0 ates pie heeded Sache h arco en 74 12 2 1 CAS Building s 22 s2cccts si eteiestn cece elena aieds 74 12 2 1 1 CAS Building Communication Status 000 eee eeseeeeeeeereeenees 75 12 2 1 2 CAS Build
130. site each weekday the operator will check alarms and current monitoring data on the HMI screen EL CAS 112 This is to provide the operator with a quick overview of the facility and operating conditions so he she can give immediate attention to major problems if any The Daily Ops Report presents an initial checklist for this task The operator will review the previous day s monitoring data As described in Section 8 0 graphical records are to be developed that plot daily summary indicator data for the following categories of information e Lime Operations daily use average mg L e Hydraulics daily flow rates of influent and effluent and water levels and e pH daily readings of influent and effluent These data will be reviewed to detect trends within the previous 1 to 2 weeks and seasonal variations over the past several months as compared with previous year or typical years Some operational modifications may warrant making operating adjustments due to subtle changes in the treatment system performance that the operator detects during this review Circumstances may occur when quick response is required However it will be much more usual for changes to develop over several days which may warrant consultation between the operator and Atlantic Richfield prior to performing any modifications to current operations During daily routine monitoring the operator will complete a tour of inlet area facilities to check potential pro
131. ss the IPS and the ASB As vegetation becomes established around the BTL cells access to the IPS and ASB will transition to the north dike road adjacent to the HCC This transition will also coincide with the anticipated construction of the Silver Bow Trail along the main FCD road throughout the LAO site Following completion of the Silver Bow Trail routine use of this route by the operator will be prohibited Draft Butte Treatment Lagoon BTL Systems Page 72 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 11 1 3 Description of Routine Maintenance Tasks Inspection and maintenance for the process equipment includes preventative maintenance both scheduled and unscheduled corrective maintenance and emergency maintenance and repair tasks Inspection and maintenance tasks are based on maintenance manuals and related documentation submitted with the installed equipment 11 1 4 Schedule of Task Performance Routine visual inspections are conducted weekly to ensure the equipment is operating to meet process requirements General inspection notes are maintained within the site logbook A schedule of inspection intervals is provided in Volume V Maintenance Plan to inspect key components for evidence of wear As experience is gained in operation of the facilities and maintenance systems these schedules will be adjusted as necessary The inspection and maintenance program will be updated when new inspection and mai
132. stem C is constructed much like Lagoon System B and consists of 3 treatment lagoons operated directly south of Lagoon System B adjacent to the reconstructed Silver Bow Creek floodplain The total volume of these lagoons is approximately the same as the Lagoon System B This lagoon system has been utilized for water treatment since 2001 Treated influent water enters Cell C1 on the east bank and travels west through a 50 foot silt curtain for approximately 300 feet to TW C1 these treatment walls aid in filtration of suspended Draft Butte Treatment Lagoon BTL Systems Page 22 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product solids much like the treatment walls in Lagoon System B but are constructed of 6 to 9 inch rock After water filters through and over TW C1 it enters Cell C2 and continues to travel west for approximately 200 feet until it reaches TW C2 which was constructed the same as TW C1 Once water enters Cell C3 which is the final cell much like Cell B3 it flows approximately 175 feet to OS 3 located on the west bank of Cell B3 Outlet structure 3 has the ability to divert flows to either Effluent Line A EL A Cell A2 or D2 depending on lagoon elevation volume of flow and water quality leaving Cell C3 Maximum water elevations and full pool volumes for the C System can be found in Table 1 2 5 6 Effluent System Original construction of the BTL Effluent System was completed during the fall
133. t 2 0 SYSTEM OVERVIEW Volume I provides a system background and overview of the O amp M Plan for the water collection transfer and treatment systems located within BPSOU and BMFOU Volume I includes the following e System Performance Standards Section 3 0 e The BTL LAO Site Specific Health and Safety Plan for Operation and Maintenance O amp M Activities Pioneer 2010 Section 5 0 discussion and e Revisions and updates to the O amp M Plan Section 7 0 Figures showing emergency routes to the hospital from each site are included in their own respective volumes as separate appendices This Volume contains information relevant to the O amp M tasks associated with the BTL CAS and Automatic Sampling Building ASB Historical background information is provided in this Volume where it provides guidance for operating the system System background and evolution of the system provided in Volume I Overview Major maintenance instructions are contained in Volume V Maintenance Plan 2 1 Objective The objective of the BTL is to achieve the performance based water quality discharge targets for BPSOU through a collection and lime treatment process Influent sources are illustrated on Figure 3 LAO Flow Sheet The BTL system treats impacted groundwater from West Camp Metro Storm Drain MSD Butte Reduction Works BRW open areas and within LAO and discharges treated water to Silver Bow Creek Several monitoring facilities are utilize
134. t and the floor was excavated to approximately 5 416 feet in elevation An additional 1 foot of depth was excavated on the eastern one third of Cell A1 to create an accessible area for sediment collection and removal The floors of Cells B2 and B3 remain in their original configurations sloping from an elevation of 5 418 feet amsl on the north side of each cell to 5 416 feet amsl on the south side Treated water from the Distribution Tank flows through Distribution Channel B to Cell B1 and first enters Cell B1 on the east bank and travels west through a 120 foot silt curtain for approximately 200 feet until it reaches Treatment Wall TW B1 which separates Cells B1 and B2 and is constructed of 3 to 6 inch rock The treatment walls act as filters for the suspended solids created from the chemical reaction of the hydrated lime once it mixed with the influent stream Water flows through and over the treatment wall Once the water enters Cell B2 it travels west approximately 150 feet until it reaches TW B2 where further filtration of any solids that may have migrated through TW B 1 occur After water travels through TW B2 it then enters Cell B3 which acts as the final polishing cell in Lagoon System B Water travels west to OS 2 where it can be diverted to either Cell A2 located directly to the west or into Effluent Line B EL B Maximum water elevations and full pool volumes for the B system can be found in Table 1 2 5 5 Lagoon System C Lagoon Sy
135. t flow disturbance prevents the flow water through the treatment process and into the treatment cells Disturbances in the influent flow may be attributed to IPS electrical service loss pump failure pipe line malfunction valve malfunction and pump intake screen failure Cell D4 is capable of storing water for a flow disturbance until water crests the sheet pile at an elevation of 5 417 0 feet amsl Influent flow disturbances are separated into three stages to identify and reconfigure the treatment system as necessary for each stage The three stages and the corresponding operator responses are listed below from minimal to significant e Stage 1 0 to 6 hours After the cause of the influent flow disturbance is determined and the system is brought back to normal operations a disturbance of 0 to 6 hours will require no changes to the lime feed system After the pump s are brought back on line pumping will be increased to account for the increase in the water level of Cell D4 Treatment system and sample results will be monitored e Stage 2 6 to 12 hours After the cause of the influent flow disturbance is determined and the system is brought back to normal operations a disturbance of 6 to 12 hours will require a decrease in the lime feed rate by an amount determined by the volume of lime added to the slurry tank during the disturbance After the pump s are brought back on line pumping will be increased to account for the increase in the water le
136. termined and routine conditions are re established a disturbance of 0 to 6 hours will require no changes to the lime feed system Treatment system and sample results will be monitored e Stage 2 6 to 12 hours After the cause of the lime feed disturbance is determined and routine conditions are re established a disturbance of 6 to 12 hours will require an increase in the lime feed rate by an amount determined by the volume of water that was untreated during the outage Procedure 9 Lime Addition Recovery in Appendix C summarizes recovery of inadequate or zero lime addition e Stage 3 gt 12 hours After the cause of the lime feed disturbance is determined and routine conditions are re established An electrical service loss greater than 12 hours will require an increase in the lime feed rate similar to a Stage 2 disturbance and the treatment system flows will be changed according to operator parameters Procedure 6 in Appendix C summarizes recovery of inadequate or zero lime addition The decision tree BTL DT 5 is provided in Appendix F to aid in making process based decisions to ensure effluent meets discharge standards during non routine conditions 7 1 4 CAS Building Electrical Service Loss In the event of an electrical service loss to the CAS Building operation of the lime feeder system will be disrupted Once an electrical service loss is identified during trouble shooting procedures and it is not within the operator s ability to r
137. th and velocity of EL A and calculates a flow rate that is transmitted to the Allen Bradley ControlLogix Master PLC and recorded 2 7 3 Water Quality Monitoring Several approaches to water quality monitoring are used depending on the purpose of the data The measurement stations and facilities that have been established and the parameters to be measured are described in the following paragraphs Detailed sampling and analysis procedures are specified in Appendix G Additional information regarding field measurements and routine calibration tasks are discussed in Section 8 4 Monitoring station locations are shown on Figure 4 Influent water quality is monitored in order to provide baseline information for influent flows that enter the treatment facilities and to aid in determining lime addition rates for the CAS The influent water sample point Cell D4 Influent is located within the CAS Building and utilizes an ISCO automatic composite water sampler In addition the operator takes manual measurements of influent water temperature pH dissolved oxygen DO and specific conductivity SC on a daily basis Measurements are recorded in the Field Parameter Logbook maintained in the ASB Effluent water quality is monitored at ASB Sample Station CT EFS7 to evaluate the effectiveness of treatment Lagoon Systems A B and C A stilling well is constructed from the invert of EL A at Station 0 60 see Figure 10 for water sampling monitoring An I
138. thin the operating range In addition to the daily status check the following items will be inspected on a monthly basis e MSD channel is free of debris and vegetation is in good condition and e MSD subdrain cleanout pipes are free of debris and end caps are intact Draft Butte Treatment Lagoon BTL Systems Page 44 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 6 1 5 Weekly Reporting At the end of each week a completed Weekly Operation Report is submitted to Atlantic Richfield This report will contain information regarding water elevations influent and effluent flow rates lime rates and lagoon cell field water quality parameters see Table 8 Any changes to routine system O amp M issues related to potential performance upsets are also noted within this report The specific approach and format for these reports is outlined in Section 9 0 6 2 Lime Treatment at the CAS Building 6 2 1 System Overview The following description outlines the routine operational tasks to be used at the CAS Building This brief system overview is provided to complement the subsequent Description of Control Settings in Section 6 2 4 Figure 2 presents an overall site view depicting the expected path of flow during routine operating conditions 1 Untreated influent water enters the CAS Building from the IPS P LAO D41 or P LAO D42 at Cell D4 2 The influent flow rate is monitored with a 14 inch McCrometer UltraM
139. tial Attorney Work Product 2 4 3 Missoula Gulch Discharge Missoula Gulch drainage modifications were completed in the spring of 2004 The base flow discharging groundwater from the upper portion of the Missoula Gulch drainage exits the storm sewer system just south of Iron Street into the Missoula Gulch base flow diversion basin and pipe The basin and pipe collect and convey base flow into the Missoula Gulch channel directly below Catch Basin CB 9 immediately north of Centennial Avenue see Figure 1 This groundwater eventually discharges to the HCC see Section 2 4 1 along with other BTL groundwater Storm events or abnormally high base flows fill CB 8 when water goes over the base flow spillway structure During a high flow event Missoula Gulch runoff first enters CB 8 When CB 8 fills completely it begins to discharge to CB 9 After the high flow event dewatering procedures for CB 8 and CB 9 may begin 2 4 4 West Camp Pump Station The WCP 1 is located directly north of Centennial Avenue adjacent to the BRW The pump station and pipeline identified on Figure 1 transfers bedrock groundwater from the West Camp Complex to the BTL at an average flow of 0 26 million gallons per day mgd 180 gpm Flow rates from the WCP 1 Groundwater Collection System range from a minimum of 0 23 mgd 160 gpm to a maximum of 0 46 mgd 300 gpm The primary Constituent of Concern COC from this source is arsenic at an average concentration of 0 1 millig
140. tine conditions Treatment system configurations will be changed according to operator parameters and the duration of the lime system disturbance as discussed above Refer to Appendix C for IPS startup procedure 7 2 2 Influent Pump Station Pump Failure Pump failure may include but is not limited to the electrical wire deterioration on the pumps impeller failure and pump control failure Pump failures and normal wear events may degrade flow rates or cause zero influent flows In the event of one pump failing during base flow conditions from the influent sources Cell D4 can store water for approximately 120 hours while the other pump continues to operate If both pumps were shut down Cell D4 can store water for approximately 24 hours The WCP 1 should be shutdown to reduce the influent flow until IPS is restored and functioning normally The BRW stop logs should be installed to mitigate influent The MSD has a very short retention capacity and therefore should remain operating Refer to the BLT LAO Water Management Contingency Operations Atlantic Richfield Company 2010b for available retention times associated with the BTL LAO systems 7 3 Monitoring Equipment Disturbance 7 3 1 Electrical Service Loss to CASB In the event of an electrical service loss to the monitoring equipment located in the CAS Building a Universal Power Supply UPS will provide uninterrupted electrical services for approximately 15 minutes The alarm call out system wi
141. tment Lagoon BTL Systems Page ix of ix Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 1 0 INTRODUCTION The Draft Operation Maintenance and Monitoring O amp M Plan for Butte Priority Soils Operable Unit consists of multiple volumes I through V Each volume is used to describe specific aspects of the Operations and Monitoring O amp M Plan This document Volume IV presents the Butte Treatment Lagoons BTL and Lower Area One LAO Systems Operation Maintenance and Monitoring O amp M Plan The information is provided to allow proper operation and routine maintenance of the system Background information and characterization for Butte Priority Soils Operable Unit BPSOU is provided to allow proper operation and routine maintenance of the system Ancillary information which is useful to this manual is provided in the appendices section of this manual The following list of appendices is provided for additional reference e Appendix A System Design Drawings e Appendix B Equipment Inventory and Manufacturer s Data e Appendix C Butte Treatment Lagoon BTL Standard Operating Procedures e Appendix D Butte Treatment Lagoon BTL Performance Standards e Appendix E Butte Treatment Lagoon BTL Ops Report e Appendix F Butte Treatment Lagoon BTL Systems Operation Decision Tree e Appendix G Butte Treatment Lagoon BTL Systems Sampling and Analysis Plan SAP e Appendix H Butte Treatment Lagoon
142. torical Logging Alarm Dialer Uninterruptible Power Supply UPS and Surge Protection for Line Power and Analog Isolation Lime Feeder System Control Panel The following devices are controlled by the Lime Feeder System Control Panel located on the northeast corner of the CAS Building Accurate Feeder Screw Motor Accurate Feeder Paddle Motor Dust Collection Fan Bin Discharge Screw Conveyor Tank Selector and Air Compressor Slurry Tank Control Panel The following devices are monitored or controlled by the Slurry Tank Control Panel located on the south side of the CAS Building Tank 1 and 2 Levels and Tank 1 and 2 Mixers 2 Al Area Station se m moan 480 Volt Alternating Current VAC Distribution Breaker Panel Three Pump Hand Off Auto switches for local control of optional effluent 15 HP 5 HP and 5 HP pumps PLC Remote Radio Interface Surge Protection for Line Power and Analog Isolation NEMA 4 Enclosure and Panel Heater and 120 VAC Branch Circuit Breaker Panel 3 A2 Area Station monogs 480 VAC Distribution Breaker Panel Two Pump Hand Off Auto switches for control of optional effluent 15 HP pumps PLC Surge Protection for Line Power and Analog Isolation NEMA 4 Enclosure and Panel Heater Remote Radio Interface and Draft Butte Treatment Lagoon BTL Systems Page 26 of 85 Operation Maintenance and Monitoring Plan Confidential A
143. truction Type V B e CAS and Operations Buildings are considered one building under 503 1 2 Total square footage of the combined building is 2 327 The maximum allowed is 8 500 square feet per one story e All exterior walls are 30 feet from property lines no fire resistance rating is required e Class C finishes at interior allowed e One exit required two have been provided e Class C roof allowed Class B provided e Per IECC Silver Bow County is in Zone 16 ceilings require R 30 walls require R 13 minimum less than 10 exterior wall windows or door glazing 1 3 3 3 Electrical All electrical service components including the generator panel board pad mounted transformer double throw safety switch neutral assembly automatic transfer switch weather shields lug kits pull breakers and safety switches have been selected designed and are in compliance with National Electric Code NEC 2009 edition Draft Butte Treatment Lagoon BTL Systems Page 4 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 1 3 4 Control Theory The BTL LAO control system utilizes Allen Bradley ControlLogix for the primary control and master polling programmable logic controller PLC located at the Operations Building This PLC is considered the primary PLC which controls and monitors the lime addition process and associated systems and polls each remote site for data Total polling time to contact and receive data fro
144. ttorney Work Product g 120VAC Branch Circuit Breaker Panel 4 A3 Area Station a 480VAC Distribution Breaker Panel and b Two Pump Hand Off Auto switches for control of optional 15 HP effluent pumps 5 ASB Station at southern end of A3 Area PLC Remote Radio Interface Surge Protection for Line Power and Analog Isolation NEMA 4 Enclosure and 120VAC Branch Circuit Breaker Panel eae oE 6 D4 Area Influent Pumping Station a 480VAC Distribution Breaker Panel b Four Pump Hand Off Auto switches for local control of two 75 HP influent pumps and c 120VAC Branch Circuit Breaker Panel 7 WCP 1 a 480 VAC Distribution Breaker Panel b VFD Pump Control Panel c PLC d Remote Radio Interface e Surge Protection for Line Power and Analog Isolation f NEMA 4 Enclosure and Panel Heater and g 120 VAC Branch Circuit Breaker Panel 8 MSD Pump Station a 240 120 VAC Single Phase Distribution Breaker Panel b VFD Pump Control Panel c PLC d Analog Interface Terminal for future analog points e Remote Radio Interface f Surge Protection for Line Power and Analog Isolation and g NEMA 4 Enclosure and Panel Heater Draft Butte Treatment Lagoon BTL Systems Page 27 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 2 6 2 Lime Addition Rate and Influent Pump Station Automation The lime addition rate and IPS controls are automated to accommodate changes in the system w
145. ty water may breach the crest of the sheet pile weir located directly below HCC 07 Reducing flow rates from WCP 1 and MSD to accommodate the excessive precipitation or snowmelt events will minimize the potential impacts to Silver Bow Creek Refer to the BLT LAO Water Management Contingency Operations Atlantic Richfield Company 2010b for available retention times associated with the BTL LAO systems Draft Butte Treatment Lagoon BTL Systems Page 64 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 8 0 MONITORING AND LABORATORY TESTING The purpose of this section is to define the routine monitoring activities required of the site operator with respect to system control and performance reporting Monitoring sites and facilities are described in Section 2 4 The frequency and location of water quality sampling at the BTL is presented in the Weekly Operations Report provided in Appendix H 8 1 Operator Observations To facilitate data generation and minimize data gaps collected data will be sorted into the following categories e Operator observations e Control system generated data e Automatic electronic monitoring data and e Manual water level flow and quality data Routine operation of the BTL systems involves a number of operator activities some of which are routine or planned activities and others that are not Many of the routine activities involve data forms or checklists completed by the
146. uct 2 4 6 Silver Bow Creek Floodplain The Silver Bow Creek floodplain is located on the southern most portion of LAO and was reconstructed in 1997 see Figure 2 The original Silver Bow Creek was diverted around the tailings impoundment from the Colorado Smelter During the initial cleanup of LAO in 1996 1997 the Silver Bow Creek floodplain was reconstructed to its original state by utilizing historical data for the design and flows were then directed back into the reconstructed Silver Bow Creek channel which was constructed at an elevated gradient within the floodplain The elevated channel minimizes the potential of Silver Bow Creek to collect impacted groundwater within LAO The D Cells and the HCC protect Silver Bow Creek from impacted groundwater by creating a gradient away from Silver Bow Creek and directing the flow of impacted groundwater to Cell D4 2 4 7 Butte Reduction Works The open areas of BRW can result in the accumulation of surface water mainly the by product of precipitation events Outlet structures are used to control outflow from BRW to the HCC These open areas are unlined therefore seepage from the open area infiltrates to the groundwater flow which ultimately is collected by the HCC and treated as influent flow This area is also utilized for sludge de watering and drying beds Free standing water is decanted over the outlet structure and directed to the HCC through channel flow Natural processes such as evaporation a
147. uite 301 3950 South 700 East Salt Lake City Utah 84107 6 2 4 Description of Control Settings This section of the O amp M lists the electrical and control requirements for operation of each item of the lime treatment equipment This information provides an example of routine operations Information for each item is presented in the following categories e Conditions required for the equipment item to start manually e Conditions required for the equipment item to start automatically e Conditions under which the equipment item will automatically stop operation and e Settings for routine mode of control Where appropriate additional information pertinent to understanding of the control mode or necessary auxiliary piping or valve alignment conditions is provided Supplemental information regarding the use of standby redundant equipment the alarm conditions response is presented in Section 12 0 Emergency Procedures Section 2 6 provides additional understanding description of the process function of the control system and the conditions under which alternative modes of control should be employed 6 2 4 1 Auto Sampling 1 Influent Sample Pump Draft Butte Treatment Lagoon BTL Systems Page 47 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product The influent automatic sampler will start automatically when all of the following conditions are satisfied Breaker is not tripped The ON OFF key is in ON positi
148. up the lime build up Refer to the manufacturer s instructions for proper maintenance and recalibration These instructions are maintained within the CAS Building 8 5 4 Lime Feeder System Equipment It is necessary to calibrate the lime feeder system once per week for accuracy in order to track lime usage rates monitor current lime inventory monitor wear etc on the operating equipment and ensure proper lime addition is occurring A 10 minute test will be conducted to verify the amount of lime the feeder is conveying Refer to SOP 9 located in Appendix C Corresponding data sheets correlating the feeder rpm with influent flow rate to achieve appropriate lime rates will require adjustment also 8 6 Review of Monitoring Data for Operations 8 6 1 Lime Feed and Inventory The operator needs to maintain knowledge of the amount of lime used and the remaining amount on hand e Lime inventory must be monitored and controlled so that shortages are avoided Draft Butte Treatment Lagoon BTL Systems Page 67 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product e Major deviations in lime usage need to be detected so that troubleshooting activity can be initiated either to explain why such usage is appropriate or to correct the problem and e Lime rate and total usage must be reviewed daily 8 6 2 Lagoon Systems Flow Elevation The operator needs to maintain a record of the amount of water entering retained in and
149. used for daily monitoring will be calibrated each day before use This instrument is a portable meter used for various measurements throughout the site For required maintenance and probe replacement refer to the manufacturer s specifications maintained within the BTL CAS Building 8 5 2 Lagoon Water Level Recorders Rosemount water level recorders and transmitters are installed within 6 cells of the BTL systems These level recorders send a 4 to 20 mA signal back to the primary PLC and the Operator Interface then displays a water level for each corresponding cell The level recorders are installed inside a PVC stilling pipe to prevent inaccurate readings created from rough water or debris that might be in the cell The stilling pipes are installed on the wing walls of the associated outlet structures located within each cell For required maintenance and recalibration refer to the manufacturer s specifications provided in Appendix B Manufacturer s specifications are also maintained within the BTL CAS Building 8 5 3 Slurry Tank Level Indicators One ultrasonic level indicator is located in each of the two slurry tanks located within the CAS Building Lime has been known to build up on the sides of the slurry tanks and cause inaccurate level readings Periodically the tanks will require cleaning and or the indicators will need to be recalibrated and cleaned To clean the tanks the indicator is removed and a 1 inch PVC pipe is used to break
150. vel of Cell D4 e Stage 3 gt 12 hours After the cause of the influent flow disturbance is determined and the system is brought back to normal operations An electrical service loss greater than 12 hours will require and decrease in the lime feed rate similar to a Stage 2 disturbance and the treatment system flows will be changed according to operator parameters After the pump s are brought back on line pumping will be increased to account for the increase in the water level of Cell D4 Disturbances of longer duration than the stages listed above require implementation of Water Management Contingency Operations to prolong water storage capabilities until the disturbance can be remedied Refer to the BLT LAO Water Management Contingency Operations Atlantic Richfield Company 2010b for additional instructions and diversion strategies 7 2 1 Influent Pump Station Electrical Service Loss In the event of an electrical service loss to the IPS the influent flow will be disrupted Once an electrical service loss is determined and it is not within the operator s ability to re establish the service the operator will contact NorthWestern Energy to have electrical service restored Once Draft Butte Treatment Lagoon BTL Systems Page 62 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product electrical service is restored the operator will adjust all affected equipment and ensure the IPS operation has returned to rou
151. w meter malfunction and 3 Low water level in Cell D4 due to base flow conditions Initial Review Screenings for Influent Flow Alarms Verify the influent flow rate is not alarming on the HMI screen If status is operating within the normal range the influent flow rate is operating normal but if status is alarming proceed to troubleshooting as described below Troubleshooting for Influent Flow Alarms 1 Ensure all breakers associated with the IPS are not tripped OFF 2 Ensure the Lime Feeder system is in operation power is on and screen display is visible 3 Ensure the ASB has electrical service ASB maintains the PLC for the influent pump control automation electrical equipment is functional 4 Ensure no damage to influent pipeline has occurred visibly inspect the pipe for damage 5 Ensure the intake self cleaning screens are operational visibly inspect screens for signs of clogging 6 Visually check flow pumped through CAS Building to verify the alarm is not false This includes checking the readout mounted on the McCrometer flow meter checking whether the communication wire is disconnected damaged etc and looking for water in the distribution channel Draft Butte Treatment Lagoon BTL Systems Page 80 of 85 Operation Maintenance and Monitoring Plan 7 Ensure water level in Cell D4 is operating above the minimum operating 5 414 feet level and 8 Ensure all valves located on the influent line are
152. ws set points and alarms for the lime process All remote sites are equipped with Allen Bradley CompactLogix PLCs to monitor and control any of the remote sites process and or monitoring equipment The remote site PLCs considered secondary PLCs provide local control such as pump control logic or flow control logic and monitor the local process for any alarm status such as loss of power pump failure instrument failure and high low level or flows Data and site system status for all remote sites are collected by the CompactLogix PLCs The Master PLC at the Operations Building then polls each site for the data Polling intervals are programmable and can be set to meet data acquisition requirements 1 4 BTL LAO Owner and Contact Information 1 4 1 Owner and Contact Information Atlantic Richfield Company Atlantic Richfield is a Potentially Responsible Party PRP of the BTL LAO water treatment system Operation and maintenance of the system is the responsibility of the PRP Duties associated with proper O amp M may be tasked to a contractor or owner s representative Draft Butte Treatment Lagoon BTL Systems Page 5 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 1 4 2 Key Contacts Emergency Information BP Incident Notification Center 1 800 831 8642 Atlantic Richfield Co Office 406 Mobile 406 Home 406 Trey Harbert 723 1816 498 5749 Shannon Dunlap 723 1813 498 6630 Kevin Murphy 630 836
153. xtremely high flow is being pumped through the system and the gravity flow system will not carry it Figure 11 shows how they are integrated into the Effluent System and where they are located Table 2 also gives a description of each pump for each installation location Operation of these pumps is intended for use during upset non routine conditions Draft Butte Treatment Lagoon BTL Systems Page 33 of 85 Operation Maintenance and Monitoring Plan Confidential Attorney Work Product 3 1 3 Hydraulic Control Channel The HCC as described in Section 2 2 3 is a groundwater collection channel which runs nearly the entire length of the LAO site As previously stated the HCC is passively operated and adjustments are not routinely required The HCC can be isolated from Cell D4 with a canal gate which is installed at the west end of the 36 inch corrugated metal pipe CMP that connects the facilities There are five weirs used to control flow in the HCC and are located throughout the HCC 3 1 4 Groundwater Interception Areas Cells D2 and D3 as described in Section 2 4 2 create a hydraulic gradient for groundwater away from Silver Bow Creek and also act as an alternate recirculation route for the Treatment Lagoons Water levels in Cells D2 and D3 are controlled with outlet structures that utilize stop logs for flow control devices as described in Section 3 1 1 3 1 5 Metro Storm Drain Collection System The MSD collection system as described in

Vol IV BTL - Pioneer Technical Services, Inc.

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