VOL III - West Camp and Missoula

VOL III - West Camp and Missoula
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&M) Plan
for Butte Priority Soils Operable Unit
Volume III
West Camp Pump Station/Missoula Gulch Drainage
Atlantic Richfield Company
January 4, 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&M) Plan
for Butte Priority Soils Operable Unit
Volume III
West Camp Pump Station/Missoula Gulch Drainage
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 4, 2011
TABLE OF CONTENTS
Page
1.0
INTRODUCTION .............................................................................................................. 1
1.1
Purpose and Scope .................................................................................................. 1
1.2
System Background ................................................................................................ 1
1.3
Design Theory......................................................................................................... 2
1.3.1 Design Calculations .................................................................................... 3
1.3.2 Codes and Standards ................................................................................... 3
1.3.2.1 Mechanical Codes and Standards ................................................... 3
1.3.2.2 Instrumentation and Electrical Codes and Standards...................... 3
1.3.2.3 Civil/ Structural Codes and Standards ............................................ 3
1.3.3 Constituents of Concern .............................................................................. 3
1.3.4 Materials of Construction ........................................................................... 4
1.4
Owner and Contact Information ............................................................................. 4
1.4.1 Key Contacts / Emergency Information ..................................................... 4
1.4.2 Additional Emergency Contact Agencies ................................................... 4
1.4.3 Non-emergency Services ............................................................................ 4
1.5
Organization and Use of this O&M Plan ................................................................ 5
2.0
SYSTEM OVERVIEW ...................................................................................................... 7
2.1
General Facility....................................................................................................... 8
2.2
Extraction Well and Pumping System .................................................................... 8
2.3
Water Conveyance and Piping ................................................................................ 9
2.3.1 West Camp Pump (P-WCP-1) .................................................................... 9
2.3.2 Pressure Gauge (PI-WCP5013) and Flow Meter (FIT-WCP5006) .......... 10
2.3.3 Missoula Gulch Base Flow System .......................................................... 10
2.4
Monitoring and System Controls .......................................................................... 11
2.4.1 Water Level Monitoring ........................................................................... 11
2.4.2 Water Quality Monitoring......................................................................... 11
2.4.3 Flow Monitoring ....................................................................................... 12
2.4.4 Additional Monitoring Components ......................................................... 12
2.5
Electrical Systems ................................................................................................. 12
2.6
Backup Systems and Spare Parts .......................................................................... 12
3.0
SYSTEM CONTROLS ..................................................................................................... 13
3.1
Hydraulic Control ................................................................................................. 13
3.1.1 Pump Controls .......................................................................................... 13
3.1.2 Valving...................................................................................................... 13
3.1.3 Missoula Gulch Catch Basins, Weir Plates, and Bypass Structures and
Pipelines .................................................................................................... 13
3.1.4 Routine System Hydraulic Operations...................................................... 14
3.2
Electrical, Automation Control, and Monitoring .................................................. 14
3.2.1 Electrical Service Equipment .................................................................... 14
3.2.2 Automation Control Equipment ................................................................ 15
3.2.2.1 Wonderware HMI Data Management Software ........................... 15
3.2.3 Monitoring Equipment .............................................................................. 15
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3.3
3.4
3.2.3.1 Esterline KPSI Water Level Transducer (LT-WCP5001) ............ 15
3.2.3.2 McCrometer UltraMag® Flow Meter (FIT-WCP5006) ................ 15
3.2.3.3 Dwyer Pressure Gauge (PI-WCP5013) ........................................ 16
3.2.3.4 Detcon H2S Sensor (AIT-WCP5000) ........................................... 16
Instrumentation and Controls Operational Control Theory .................................. 16
Protective System Devices .................................................................................... 17
3.4.1 PSD List .................................................................................................... 17
4.0
SAFE OPERATING LIMITS ........................................................................................... 18
4.1
Pressure ................................................................................................................. 18
4.2
Temperature .......................................................................................................... 18
4.2.1 Groundwater ............................................................................................. 18
4.2.2 Pump House .............................................................................................. 18
4.2.3 Ambient..................................................................................................... 18
4.3
Flow Capacity ....................................................................................................... 18
4.4
Electrical ............................................................................................................... 18
4.4.1 Instruments ................................................................................................ 18
5.0
ROUTINE OPERATIONAL TASKS .............................................................................. 20
5.1
Normal Operation ................................................................................................. 20
5.1.1 Start-Up ..................................................................................................... 20
5.2
Routine Operations Tasks ..................................................................................... 21
5.2.1 Missoula Gulch Baseflow Collection System........................................... 21
5.2.2 West Camp Pump Station ......................................................................... 21
5.2.3 Routine Maintenance ................................................................................ 22
5.3
Site Vegetation and Access Maintenance ............................................................. 22
5.3.1 Site Vegetation Maintenance .................................................................... 22
5.3.2 Site Access Maintenance .......................................................................... 22
5.4
Routine Operations Duties and Responsibilities................................................... 23
5.4.1 West Camp Check – SOP-4 ...................................................................... 24
5.4.2 Water Level Measurement Procedure ....................................................... 25
5.4.3 Alarm Response Procedure ....................................................................... 25
5.5
Seasonal Flows...................................................................................................... 25
6.0
OPERATION DURING DISTURBANCES .................................................................... 26
6.1
System Disturbances ............................................................................................. 26
6.1.1 Electrical Disturbance ............................................................................... 26
6.1.2 Monitoring Equipment Disturbance ......................................................... 27
6.1.3 Control and Instrumentation Disturbance ................................................. 27
6.1.4 West Camp Pump Disturbance ................................................................. 27
6.1.5 Missoula Gulch Flow Disturbance............................................................ 28
6.2
Off-Site and Environmental Disturbances ............................................................ 28
6.3
Return From Disturbances .................................................................................... 29
7.0
MONITORING AND LABORATORY TESTING ......................................................... 30
7.1
Operator Observations .......................................................................................... 30
7.2
Monitoring Components ....................................................................................... 30
7.2.1 Water Level Monitoring ........................................................................... 31
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7.3
7.4
7.5
7.2.2 Pump Flow Rate........................................................................................ 32
7.2.3 AC Power .................................................................................................. 32
7.2.4 WCP-1 Pump Status ................................................................................. 32
7.2.5 H2S Concentration .................................................................................... 32
7.2.6 Routine Inspection and Calibration of On-Site Monitoring Systems ....... 33
Automatic Electronic Monitoring Data ................................................................ 33
Review of Monitoring Data for Operations .......................................................... 33
Routine Sampling Tasks ....................................................................................... 33
8.0
DATA MANAGEMENT.................................................................................................. 34
8.1
Data Management Plan ......................................................................................... 34
8.2
Automated Data Management .............................................................................. 34
9.0
OPERATIONS REPORTING AND RECORD KEEPING ............................................. 36
9.1
Daily Operations Report ....................................................................................... 36
9.2
Weekly Operations Report .................................................................................... 36
9.3
Monthly Operations Report .................................................................................. 36
9.4
Quarterly Operations Report ................................................................................. 36
9.5
Annual Operations Report .................................................................................... 36
9.6
Supplementary Data .............................................................................................. 37
10.0
ROUTINE INSPECTION AND MAINTENANCE GUIDELINES ................................ 38
10.1 Inspection and Maintenance Guidelines for Process Equipment .......................... 38
10.1.1 Scope and Organization ............................................................................ 38
10.1.2 Description of Access to Site Facilities .................................................... 38
10.1.3 Routine Maintenance Tasks ...................................................................... 38
10.1.3.1 Piping ....................................................................................... 39
10.1.3.2 Electrical Systems .................................................................... 39
10.1.3.3 WCP-1 Pump (P-WCP-1) ........................................................ 39
10.1.3.4 Valves (BFV-WCP5009) ......................................................... 40
10.1.3.5 Greenheck Exhaust Fan (EL-WCP107) ................................... 40
10.1.3.6 H2S Monitoring System (AIT-WCP5000) ............................... 40
10.1.3.7 Flow Meter and Totalizer (FIT-WCP5006) ............................. 40
10.1.3.8 Dwyer Pressure Gage (PI-WCP5013) ...................................... 40
10.1.4 Schedule of Task Performance ................................................................. 40
10.1.5 Equipment ................................................................................................. 40
10.1.6 Records and Record Keeping.................................................................... 41
10.2 Spare Parts Inventory ............................................................................................ 41
11.0
EMERGENCY PROCEDURES....................................................................................... 42
11.1 Alarm Response Notification................................................................................ 42
11.2 Alarm Conditions .................................................................................................. 42
11.2.1 Fire ............................................................................................................ 42
11.2.2 Electrical Lines Disturbances ................................................................... 43
11.2.3 H2S Alarm ................................................................................................. 43
11.2.3.1 H2S Alarm Site Response......................................................... 43
11.3 Emergency Shutdown ........................................................................................... 44
11.4 Waste Handling and Disposal ............................................................................... 44
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11.5
12.0
Emergency Back-up Pumping System.................................................................. 44
REFERENCES ................................................................................................................. 45
LIST OF FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
WCP and Missoula Gulch Site and Major Features
West Camp Water Flow Diagram
Corrective Action and Troubleshooting Decision Tree
Emergency Hospital Travel Route
LIST OF TABLES
Table 1
Table 2
Equipment and Spares Inventory
Alarm List
LIST OF APPENDICES
Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
Appendix G
Appendix H
Appendix I
Appendix J
Appendix K
System Design Drawings
System and Component Design Calculations
Administrative Order On Consent for West Camp/Travona System
Operator’s West Camp Reference Guide, BTL-LAO Operations Report
List of Equipment, PSDs
Standard Operating Procedures
Manufacturer’s Product Data
Johnson/US Filter Well Screen Information
Goulds Pump Model 250L15
Certa-LOK Pipe Literature
Variable Frequency Drive Pump Controller
MAASS Pitless Well Adapter
Chromolox Model HCH-251 Air Heater
Dwyer 2” SS Pressure Gage
McCrometer UltraMag® Flow Meter
Mueller LINESEAL® Butterfly Valve
Rosemount Water Level Measurement System
Detcon Model TP-624C H2S Monitor
Greenheck Exhaust Fan
Butte Remediation Evaluation System (BRES)
Seasonal Pumping Flow Rates
West Camp Retention Time/ Holding Capacity
Emergency Hospital Route from West Camp
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1.0
INTRODUCTION
The Draft Operation, Maintenance and Monitoring (O&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 Operation and Monitoring (O&M) Plan. This document, Volume III,
presents the West Camp Pump Station (WCP) and Missoula Gulch Discharge Systems
Operation, Maintenance and Monitoring (O&M) Plan. The information 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:
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•
•
•
•
•
•
•
•
•
•
1.1
Appendix A:
Appendix B:
Appendix C:
Appendix D:
Appendix E:
Appendix F:
Appendix G:
Appendix H:
Appendix I:
Appendix J:
Appendix K:
System Drawings;
System and Component Design Calculations;
Administrative Order On Consent for West Camp/Travona System;
Operator’s West Camp Reference Guide, BTL-LAO Ops Report;
List of Equipment, Protective Safety Devices (PSDs), and Alarms;
Standard Operating Procedures (SOPs);
Manufacturer’s Product Data;
Butte Remediation Evaluation System (BRES);
Seasonal Pumping Flow Rates;
West Camp Retention Time/ Holding Capacity; and
Emergency Hospital Route from West Camp.
Purpose and Scope
West Camp and Missoula Gulch are located within the Butte Mine Flooding Operable Unit
(BMFOU) of the Silver Bow Creek/Butte Area National Priorities Listing (NPL) Superfund Site.
The objective of this O&M Plan is to provide instructions for operating and maintaining the
West Camp groundwater extraction and conveyance system and the Missoula Gulch discharge
system. It contains key components for an O&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 9355.04A, Superfund Remedial Design and Remedial Action Guidance (EPA, 1986). Figure 1
identifies the entire site and major features within West Camp and Missoula Gulch. System
drawings are provided in Appendix A.
The following sections describe the treatment system, performance goals, routine operations,
record keeping and reporting requirements, routine inspection and maintenance programs, and
emergency procedures. All activities conducted in association with this document are to be
performed in compliance with the Butte Treatment Lagoons (BTL) and Lower Area One (LAO)
Site Specific Health and Safety Plan for Operation and Maintenance (O&M) Activities (Pioneer,
2010).
1.2
System Background
The design objectives of the WCP-1 groundwater extraction system, as stated in the Operations
and Maintenance Manual West Camp Pumping System Revision 1 (Atlantic Richfield Company,
2006a), were to reduce pumping costs by placing the system at a lower elevation, and to provide
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two options for discharging the water. The extraction system is constructed so that groundwater
can be routed to the BTL at LAO, or routed to the Butte-Silver Bow (BSB) Sewage Treatment
Plant via a pipeline directly connected to the BSB sewer system (currently abandoned and
capped). Normal, routine operation of the WCP-1 system discharges water to the BTL at LAO.
Because West Camp water is part of the BMFOU and contains elevated levels of arsenic, it is
necessary to treat the pumped water prior to discharge to waters of the State of Montana. Water
treatment occurs within the BTL system by means of chemical addition and physical settling
processes.
West Camp Pump Station (WCP-1) was implemented to maintain water levels below the critical
water level established at 5,435 feet above mean sea level (amsl) and prevent affected
groundwater from infiltrating into the alluvial water. Volume I contains more detailed
background information for this pumping station.
1.3
Design Theory
As stated above, the objective of WCP-1 is to maintain water levels in the West Camp system
below the established critical water level of 5,435 feet amsl. West Camp Pump Station operates
to maintain the water level of this system approximately 10 feet lower than the critical water
level. To achieve this objective, the pumping system was designed to operate between 70 to 300
gallons per minute (gpm). Best efficiency pumping point is 250 gpm. Flow rate is dependent
upon the BTL capacity, and annual recharge rate. The pump was designed and selected to
operate continuously; therefore, a variable frequency drive (VFD) motor provides the ability to
control pump flow rate through speed control to maintain a nearly constant water level within the
well.
The extraction well, in which WCP-1 operates, was installed using air rotary drilling, and is
constructed of coupled 8-inch inside diameter (ID) schedule 80 polyvinyl chloride (PVC) blank
casing and 30 feet of 0.125-inch slot v-wire wrap, stainless-steel screen (Appendix G) positioned
from approximately 463 to 493 feet below surface grade. Stainless steel was chosen for the
screen material for its resistance to hydrogen sulfide (H2S) corrosion. The well screen was
designed to have an intake capacity of approximately 700 gpm. The above-ground wellhead is a
MAASS heavy duty steel well casing with vented cap. A MAASS Model NB stainless steel
pitless adapter is installed in the well casing to accommodate subgrade entry of the pump
discharge piping into the precast pump building.
From the pump discharge, 4-inch, Class 350, epoxy lined, ductile iron pipe fabricated in
accordance with AWWA C151 standards, is installed within the pump house. The piping system
is fitted with flanged connections designed in accordance with ANSI/AWWAC110/A21.10,
flanged valves are in accordance with ASME B16.1, Class 125# rating. Piping and associated
components transition from 4-inch ductile iron, to 4-inch PVC C900, then eventually to 6-inch
PVC SDR21 piping. The SDR21 piping existed at the time of the upgrade, and was therefore
utilized from the tie-in point to final termination at the Hydraulic Control Channel (HCC) or
BSB Water Treatment Plant. Refer to drawings sheets WCP-D-7 through D-11 located in
Appendix A.
Piping from the pump discharge was designed to convey fluid flow with a maximum velocity
less than 9 feet per second (ft/s). Normal fluid velocity is approximately 5 ft/s. The Piping
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Handbook defines acceptable fluid velocity range in “general water services” as 4 to 10 ft/s
(Piping Handbook, 6th edition, Nayyar, 1992).
The system was designed to continuous pumping operations over a 25-year service life. The
service life provides the basis of operating technologies selected and equipment cost
amortizations.
1.3.1
Design Calculations
Pump selection and pipe diameters are based upon recognized standard engineering calculations
and industry design principles. Supporting design calculations which provide justification of
equipment selection are located in the Appendix B.
1.3.2
Codes and Standards
The following codes and standards are followed throughout the design of system components.
Local jurisdiction and building code prevails in areas of conflicting terminology.
1.3.2.1 Mechanical Codes and Standards
Mechanical codes and standards include:
•
•
•
American Water Works Association (AWWA);
American National Standards Institute (ANSI); and
American Society of Mechanical Engineers (ASME).
1.3.2.2 Instrumentation and Electrical Codes and Standards
Instrumentation and electrical codes and standards include:
•
•
•
International Standards of Automation (ISA);
ISA-84 Process Safety Standards; and
National Electric Code (NEC).
1.3.2.3 Civil/ Structural Codes and Standards
Civil and structural codes and standards include:
•
•
American Association of State Highway and Transportation Officials (AASHTO); and
International Building Code (IBC) 2006.
1.3.3
Constituents of Concern
The primary Constituent of Concern (COC) is arsenic at an average concentration of 0.1
milligrams per Liter (mg/L). Other heavy metals including arsenic, cadmium, copper, lead,
mercury, and zinc may be present in this fluid stream. H2S may also be present in this flow stream
resulting in mildly corrosive liquid, H2S gas within contained areas.
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1.3.4
Materials of Construction
Precautions have been taken regarding the materials of “wetted” components. Metallic piping
materials are epoxy coated ductile iron to protect the metallic iron surface of the inside of the
pipe. Valves gates are epoxy coated. Non-metallic components are non-reactive and require no
additional treatments.
1.4
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&M may be tasked to a contractor, or
owner’s representative.
1.4.1
Key Contacts / Emergency Information
BP Incident Notification Center
1-800-831-8642
Atlantic Richfield Co.
Office (406)
Mobile (406)
Trey Harbert
723-1816
498-5749
Shannon Dunlap
723-1813
498-6630
Kevin Murphy
630-836-7124
219-545-4725
Pioneer Technical
Dave Griffis
Brad Archibald
Pat Sampson
Brad Hollamon
Steve Lubick
Ian St. John
Tara Schleeman
EPA
Sara Sparks
563-9371 ext. 306
497-8019
782-5797
782-5797
563-9371
782-5797
497-8026
782-3264
DEQ
Joe Griffin
1.4.2
494-6549
782-3243
782-1702
533-0913
949-4149
560-6060
Additional Emergency Contact Agencies
Emergency Response
Disaster-Emergency
NorthWestern Energy
Emergency
Electrical Emergency
1.4.3
490-4210
490-3032
490-0706
490-7678
490-7680
490-4900
490-8272
Home (406)
911
(406) 497-6295
1-888-467-2427
1-888-467-2353
Non-emergency Services
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Police
Mt. Highway Patrol
Fire Department
Water Company
Butte Silver-Bow County
Public Works
Metro Sewer Plant
NorthWestern Energy
Connect and Repair
Qwest Comm.
Underground Utilities
MT Department of
Highways
St. James Hospital (Butte)
(406) 497-1120
(406) 494-3233
(406) 497-6481
(406) 497-6500
(406) 497-6515
(406) 497-6550
1-888-467-2669
1-800-954-1211
1-800-424-5555
(406) 494-9600
(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&M Plan
This O&M Plan contains information describing how to operate and maintain the West Camp
and Missoula Gulch systems. In addition, the plan provides (the operator) the necessary
background and overview of the systems, and how they are intended to function during various
operating conditions. Complete system performance standards are presented in Volume I of the
BPSOU O&M Plan. 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:
•
Section 2.0: System Description is presented in six subsections. Each subsection provides
an overview of each major component of the system and its function. Substantial detail for
the design basis, technical features, and capabilities of each facility component are also
provided. This section is designed to be the initial reference to the operator for system
optimization.
•
Section 3.0: System Controls describes the system components and operational parameters
to efficiently control water flows and levels associated with West Camp and Missoula Gulch.
It also describes how to use these components during various types of conditions that may be
encountered at West Camp and Missoula Gulch.
•
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.
•
Section 5.0: 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 settings. Standard Operating
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Procedures will be referenced in this section as developed and subsequently appended as
operational experience is gained. All SOPs related to the operation of this system are located
in Appendix F.
•
Section 6.0: Operation During Disturbances identifies various types of upset conditions
that may occur. Alternative response/mitigation measures, approaches to identifying the
cause of problems, and sources of additional information and assistance are provided.
•
Section 7.0: Monitoring and Laboratory Testing defines the measurements and
observations required for West Camp and Missoula Gulch. 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 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 Volume I) and submit monitoring reports as
required (see Section 8.0).
•
Section 8.0: Data Management discusses the generation of automated monitoring data and
transfer of that data to the master database for storage.
•
Section 9.0: Operations Reporting and Record Keeping outlines the reporting
requirements, responsibilities, and intervals.
•
Section 10.0: Routine Inspection and Maintenance schedules for all pumping systems and
other system components are provided. Additional detailed maintenance requirements are
located in Volume V.
•
Section 11.0: Emergency Procedures are established for response to various alarm
conditions as well as the use of emergency/back-up equipment.
•
Section 12.0: References used to generate this West Camp/Missoula Gulch O&M Plan are
included in this section.
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2.0
SYSTEM OVERVIEW
Volume I provides a system background and overview of the O&M Plan for the water collection,
transfer, and treatment systems located within BPSOU and BMFOU.
Volume I includes the following:
•
•
•
•
System Performance Standards (Section 3.0);
Butte Treatment Lagoons (BTL) and Lower Area One (LAO)
Site Specific Health and Safety Plan for Operation and Maintenance (O&M) Activities
(Pioneer, 2010) (Section 5.0 discussion); and
Revisions and updates to the O&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 in the Butte Treatment Lagoon (BTL) Operation,
Monitoring, and Maintenance Manual (i.e., Volume II through Volume IV).
Volume III contains information relevant to the operations and routine maintenance tasks
associated with the West Camp including WCP-1. Historical background information is
provided in this volume where it provides guidance for operating the system. Legacy
background information is provided in Volume I. Equipment maintenance and overall haul
instructions are contained in Volume V, Maintenance Plan.
West Camp can be divided into six basic components:
•
•
•
•
•
•
General Facility;
Extraction Well and Pumping System (WCP-1);
Water Conveyance and Piping;
Monitoring and System Controls;
Electrical Systems; and
Backup Systems and Spare Parts.
The Missoula Gulch Base Flow Collection System can be divided into the following
components.
•
•
•
•
•
Catch Basin 8 (CB-8);
Catch Basin 9 (CB-9);
Bypass Pipelines and Overland Flow Channels;
Centennial Avenue Culvert; and
Diversion Channel Discharge.
System components, manufacturer’s information, model number, part number, purchase and
installation date, and contact information is located in Appendix G. Life expectancy, inspection
and maintenance interval is located in Volume V, Maintenance Plan.
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2.1
General Facility
The WCP-1 site is located at 526 Centennial Avenue in Butte. The facility is secured from
unauthorized entry by an 8-foot high, 36-foot by 36-foot, 9-gauge chain-link fence, with 2 locked
gates. The site is less than 1/10 acre, including a parking area located at the west gate. Refer to
Drawing WCP-C-1, West Camp Pump Station General Site Plan provided in Appendix A.
Storm water from the site is drained to the west and south through a riprap-lined channel. The
principal features of the facility within the locked compound include the groundwater extraction
well, the pump house, monitoring well, and emergency generator.
The Missoula Gulch Baseflow System extends from the inlet of CB-8 (located south of the Iron
Street/Excelsior Avenue Overpass) to the system discharge point at the diversion channel located
in Butte Reduction Works (BRW). The system is interconnected by a series of bypass pipelines,
overland channels, and culverts. Flow within the system is regulated by the capacities of CB-8
and CB-9 (located immediately north of Centennial Avenue), orifice weir plates, concrete by
pass structures, and spillways. Butte-Silver Bow is responsible for maintenance of the Missoula
Gulch Base Flow system. References to this system and associated catch basins are made to
capture the hydraulic flows of the entire West Camp subsurface hydraulic system.
2.2
Extraction Well and Pumping System
The drilling and construction of WCP-1 was conducted under the specifications of the Work Plan
for West Camp Groundwater Extraction System (AERL, 1998a). Construction of the system is
documented in Completion Report for the West Camp Extraction System, Butte Mine Flooding
Operable Unit (AERL, 1998b). Subsequent upgrades and modifications to the monitoring
equipment were documented in the Draft Butte Treatment Lagoons (BTL) Systems at Lower Area
One (LAO) Construction Completion Report (Atlantic Richfield Company, 2006b). Current
design modifications and improvements are per the specifications of the Butte Treatment
Lagoons (BTL) and West Camp Pump Station (WCP-1) Upgrades Design Report/Work Plan
(Atlantic Richfield Company, 2010).
Drawing sheets WCP-D-7 through D-13 provide West Camp piping, pump house, and
mechanical details. Site civil details are provided in Drawings WCP-C-1 through C-4, and D-1
through D-6. System electrical details are located in Drawings D46-15IN-023 through 029 (see
Appendix A).
The extraction well, WCP-1, is installed directly into the 800-foot sill of the Travona Mine, as
are monitoring well BMF96-1D and former well AMC-21. These wells have direct hydraulic
connection to West Camp. Well WCP-1 was installed following procedures that are consistent
with Clark Fork River Superfund Site Investigations (CFRSSI) SOP GW-3 (ARCO, 1992). The
borehole was advanced using air rotary drilling. The well was constructed using coupled 8-inch
inside diameter (ID) schedule 80 PVC blank casing and 30 feet of 0.125-inch slot v-wire wrap
stainless-steel screen (Appendix G). The well screen was designed to have an intake capacity of
approximately 700 gpm. The screened interval is positioned from approximately 463 to 493 feet
below ground surface (bgs). The well construction was completed on October 23, 1997.
Draft Volume III West Camp Pump Station/Missoula Gulch
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Following construction of the well, a 6-inch submersible, 15 HP, 480 volt, 3-phase Goulds pump
Model 250L15 (Appendix G) was installed on 4-inch Certa-Lock schedule 80 PVC (Appendix
G) and positioned at a depth of approximately 105 feet bgs. A VFD controller (Appendix G),
mounted on the south interior wall of the pump house, operates the pump. A new 12-inch
MAASS® Model MB stainless steel pitless adapter (Appendix G) was added to the extraction
well (2010) to accommodate West Camp upgrades described in Draft Final Butte Treatment
Lagoons (BTL) and West Camp Pump Station (WCP-1) Upgrades Design Report/Work Plan
(Atlantic Richfield Company, 2010).
A 4-inch check valve, installed directly above the pump, prevents impeller damage due to loss of
flow. A weep hole was drilled through the pipe above the check valve to allow the piping
system to drain back below ground surface. The pipe will automatically drain in the event that
the pump is shut down, and prevent water from freezing in the above-ground portion of the
piping. A performance curve for the pump is presented in Appendix G. The 4-inch ductile iron
discharge pipe is connected to the 6-inch SDR 21 PVC force main pipeline that discharges to
LAO. The 4-inch ductile iron pipe is installed from the WCP-1 pump house to the 6-inch SDR
21 PVC pipeline that discharges to the BSB sewer main.
A 10-foot by 12-foot precast concrete building is set on a 14-foot by 26-foot concrete pad
approximately 3 feet north of well WCP-1. The pump house is also equipped with 18-inch
Greenheck aluminum air circulation louver, an 18-inch Greenheck shutter mounted exhaust fan,
and heated with a Chromolox Model HCH-251 Air Heater (Appendix G) equipped with a
thermostatic control and upright position sensor. The fan and heater maintains pump house
temperature and provides ventilation.
Groundwater in West Camp contains H2S, which in certain concentrations is a highly toxic and
corrosive gas. All components of the extraction system that are in contact with West Camp
groundwater are designed to be resistant to H2S.
2.3
Water Conveyance and Piping
Missoula Gulch storm water is kept separate from the groundwater flows of the West Camp
system. The following is provided to describe the hydraulic relationship of each system as it is
introduced into the BTL-LAO treatment system.
2.3.1
West Camp Pump (P-WCP-1)
Groundwater is pumped from the collection well using a Goulds Model 250L15, 5-stage,
submersible, stainless steel turbine pump. The pump has an operating range from 70 to 300
gpm. Proper rotation is counter clockwise. Operation below the minimum recommended flow
rate increases motor amperage draw which could trip overload protection and cease pump
operation. A variable speed controller is used to control the pump discharge flow. The pump is
designed, rated and fabricated for continuous operation; however, the unit is also fieldserviceable. Once removed from the well, all parts can be dismantled should field service be
required.
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The manufacturer’s nomenclature (Goulds Pumps) provides the pump’s operating characteristics.
The initial number set (250) indicated the ideal discharge flow, the letter “L” indicates the pump
model, and the final number set indicates the nominal horsepower rating.
Per BP Site Remediation Technologies Engineering Integrity Manual (BP, 2009), Section 9.2
guidelines, all above ground piping is epoxy-coated ductile iron pipe, which is transitioned to
PVC C900 piping below ground. The 4-inch ID, ductile iron discharge line from well WCP-1 is
plumbed directly into a 48-inch precast manhole beneath the southwest corner of the precast
concrete building. A removable steel grate provides access to the manhole and plumbing. The
discharge line includes a 90-degree elbow upward into the precast operations building, and then
travels horizontally through the building until another 90-degre elbow directs the piping into
another manhole located in the northeast corner of the building (see Drawings WCP-D-7 through
D-10, provided in Appendix A).
2.3.2
Pressure Gauge (PI-WCP5013) and Flow Meter (FIT-WCP5006)
Inside the pump house, the discharge pipe features a Dwyer 2-inch SS Pressure Gage (PIWCP5013), 4-inch McCrometer® UltraMag flow meter (FIT-WCP5006), and 4-inch Mueller
butterfly valve (BFV-WCP5009) (Appendix G). A VFD controller is used to control the
discharge flow rate. The horizontal segment of discharge pipe, supported by Tolco pipe saddle
supports, also contains a 4-inch, 45-degree ductile iron wye with a capped end. This wye
provides an additional access point for maintenance or re-routing of flows if necessary.
Once past the flow meter, the 4-inch discharge pipe elbows down into the northeast manhole
where it leaves the building and continues below-grade to the east. The northeast manhole also
contains the 4-inch discharge line that leads directly to the BSB Sewage Treatment Plant. Each
pipe has been labeled for easy identification. Labeling is consistent with BP Integrity
Management (IM) standards, white lettering in blue background to indicate water conveyance
system. Both 4-inch pipelines connect to the 6-inch PVC pipelines east of the concrete pad at
WCP-1. The upper line (to BSB Sewage Treatment Plant) discharges through a 6-inch SDR 21
PVC force main. This line has been capped and is currently not in use.
The lower line (to the BTL) discharges through a 6-inch SDR 21 PVC force main. Each
discharge line is buried approximately 6 feet below grade to protect from frost damage.
The lines continue southeasterly for about 30 feet at a depth of approximately 6 feet bgs. The 2
lines turn south for approximately 21 feet and at that point the pipeline to the BSB-STP (east
line) discharges into manhole EW-1. Water is conveyed from EW-1 through a 12-inch, gravity
sewer pipe, beneath Centennial Avenue and the Silver Lake water line, and discharges to sewer
manhole EW-2 and then to the sewer main at manhole EW-3.
The 6-inch pipeline to the BTL tees into the 8-inch high density polyethylene (HDPE) Missoula
Gulch bypass pipeline north of Centennial Street. From that junction, water flows into a 15-inch
HDPE pipeline that discharges into the HCC. A complete system water flow diagram is
provided as Figure 2.
2.3.3
Missoula Gulch Base Flow System
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Storm water flow within Missoula Gulch is controlled by two reservoirs (CB 8 and 9). Catch
Basin 8 intercepts flow immediately south of the Iron Street/Excelsior Avenue intersection.
Weir orifice plates regulate flow from CB-8. The plates are generally set at a constant elevation
to retain as much flow as possible within the catch basin. If flow overtops the orifice plate, it is
transferred to a concrete bypass structure. The concrete bypass structure is screened to reduce
obstruction of the subsequent bypass pipeline. The bypass pipeline daylights immediately south
of CB-8 where it distributes flow on a riprap-lined apron. If flows exceed the capacity of the
concrete bypass structure and pipeline, they will crest the CB-8 spillway and disperse over the
aforementioned riprap apron immediately south of the reservoir. From this point, surface water
flow is channelized on the surface (with the exception of approximately 165 feet of buried
culvert) until it reachesCB-9.
Catch Basin 9 is located immediately west of West Camp, and north of Centennial Avenue.
Catch Basin 9 functions in the exact manner as CB-8 including the weir orifice plates, concrete
bypass structure and pipeline, spillway, and riprapped apron. Excess flow from CB-9 is
channelized until reaching the bypass line at Centennial Avenue. The bypass line passes under
Centennial Avenue and then discharges to the BRW diversion channel. The diversion channel
merges with the HCC, and the combined flow continues on to the BTL system.
2.4
Monitoring and System Controls
System monitoring is described in greater detail in Section 6.0 and in Section 8.1 of the Draft
Final Butte Treatment Lagoons (BTL) and West Camp Pump Station (WCP-1) Upgrades Design
Report/Work Plan (Atlantic Richfield Company, 2010).
Missoula Gulch is not regularly monitored with the exception of routine visual inspection to
ensure that the intake screens of CB-8 and CB-9 are free of debris and each is functioning
properly.
2.4.1
Water Level Monitoring
The objective of the pumping is to maintain water level in West Camp, as measured in the
Travona Shaft, below the critical water level of elevation 5,435 feet amsl. Two Esterline KPSI
Series 700 submersible level transducers and transmitters are installed in monitoring well
BMF96-1D. Each water level meter includes a digital readout in the WCP-1 pump house and
relays data to the Operations Building Control panel at LAO. The transducers utilize 4-20mA
signal to relay level alarms to the Operations Building. High level alarm is set at 5,430 feet amsl
and the low level alarm is set at 5,423 feet amsl. Data relays for the level transducers also include
power and communication status alarms.
The system operator must verify calibration quarterly against the water level in the Travona
Shaft (SOP pending, Appendix F).
2.4.2
Water Quality Monitoring
Water quality is monitored as a composite of the BTL influent. No independent monitoring is
performed on West Camp by BTL operations personnel.
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2.4.3
Flow Monitoring
A McCrometer UltraMag® electromagnetic model UM06, 4-inch flow meter (FE-WC101)
located in the WCP precast building measures instantaneous discharge flow rate and total flow.
Flow is checked two days per week by the site operator.
2.4.4
Additional Monitoring Components
Monitoring components associated with WCP-1 also include a Dwyer 2-inch SS Industrial
Pressure Gauge (PI-WCP5013)(Model # SGB-C0421N), a Detcon Model TP-624C H2S monitor
(AIT-WCP5000) (Appendix G), and an AC power (on/off) indicator.
2.5
Electrical Systems
Commercial 480 VAC 3-phase 100-amp underground electrical power supplies the system at the
southeast corner of the WCP-1 pump house. The power is used to directly power the pump
motor following a 30 AMP 480 VAC 3-phase isolation breaker panel (EL-WCP50101). A 10KVA transformer converts 480-volt 3-phase to 120-volt single-phase, which powers all other
electrical devices in the system (see Appendix A, Drawings D46-15IN-023 through 029).
2.6
Backup Systems and Spare Parts
A backup pump and variable speed drive, extra Certa-Lok pipe (used for the pump discharge
line), and other spare parts for both pump stations are stored at the BTL Operations Building
within LAO. Critical spare parts necessary to ensure the WCP-1 is not inoperable for an
extended period are stored at the BTL Operations Building within LAO. Based upon the
availability of replacement parts, and groundwater storage capacity available, a contingent backup system is not available. A spare parts list, including critical spares is included in Table 1, and
also maintained in Volume V, Maintenance Program.
2.6.1
Emergency Generator (U-WCP5010)
A Cummins (U-WCP5010) site-dedicated diesel generator provides emergency back-up
electrical service. The all season generator is located adjacent to the WCP-1 pump house on a
concrete pad and hard-wired directly to the electrical supply system. An automatic control
switch activates the generator in the event of a power outage. The transformer, automatic
transfer switch, and main meter base and service are mounted on the south exterior wall of the
building. All other electrical items, including the Cutler-Hammer panel board, are mounted on
the interior of the building. Wiring is protected within schedule 40 PVC (or greater) or liquid
tight flex conduit.
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3.0
SYSTEM CONTROLS
The following section provides information detailing the controls and methods available to
manage water level associated with West Camp.
3.1
Hydraulic Control
3.1.1
Pump Controls
A VFD mounted on the south wall of the WCP-1 pump house operates the extraction pump. The
pump runs on 3-phase, 480-volt, 60-hertz electrical power. Turning the main switch lever to the
“on” position and depressing the start button starts the pump. The controller is equipped with
heaters that break the circuit if there is too large an amperage draw. The controller has a reset
button that allows restarting the pump after an automatic or manual shutdown. The VFD
controller regulates the discharge flow from WCP-1. Programmable logic is used to control the
pump motor speed through the VFD. The logic allows frequency modulation to vary the
pumping rate slightly which in turn maintains nearly constant level in the well. Operator control
of the pump is not required. Control is achieved though changing the setpoint, or desired
operating level range within the well.
3.1.2
Valving
The only valve located in the pump house is the 4-inch Mueller LINESEAL® butterfly valve
(BFV-WCP-5009). This valve is located on the discharge pipe (4ʺ-UW-P2-WCP5001) that leads
to the BTL. The valves primary function is to isolate and stop flow from the pump to the BTL.
Primary flow control is achieved through controlling the speed of the pump using the VFD. In
the event of automated control failure, flow control can also be achieved through throttling of
valve BFV-WCP5009. Flow throttling is achieved through either opening or closing the valve to
set flow rate at the desired value indicated on the flow meter readout.
The submersible pump should never be operated with the gate valve closed, i.e. pumping against
“dead head,” as the flow of water past the pump cools the pump motor. The pump motor
manufacturer recommends a minimum discharge rate of 70 gpm, which will create a flow
velocity of approximately 0.75 feet/second around the motor, and will ensure proper cooling.
According to the manufacturer’s data, the best efficient pumping point is at discharge rate of 250
gpm (see Appendix G). The recommended operating range of this pump model is 70 to 300
gpm. This range is consistent with the actual pumping rates. The overall weight of the pump is
approximately 44 pounds.
3.1.3
Missoula Gulch Catch Basins, Weir Plates, and Bypass Structures and
Pipelines
Storm water flow within Missoula Gulch is controlled by two reservoirs (CB 8 and 9). Catch
Basin 8 intercepts flow immediately south of the Iron Street/Excelsior Avenue intersection.
Weir orifice plates regulate flow from CB-8. The plates are generally set at a constant elevation
to retain as much flow as possible within the catch basin. If flow overtops the orifice plate, it is
transferred to a concrete bypass structure. The concrete bypass structure is screened to capture
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debris and reduce obstruction of the subsequent bypass pipeline. The bypass pipeline daylights
immediately south of CB-8 distributing flow on a riprap-lined apron. If flows exceed the
capacity of the concrete bypass structure and pipeline, they will crest the CB-8 spillway and
disperse over the aforementioned riprap apron immediately south of the reservoir. From this
point, surface water flow is channelized on the surface (with the exception of approximately 165
feet of buried culvert) until it reaches CB-9.
Catch Basin 9 is located immediately west of West Camp, and north of Centennial Avenue.
Catch Basin 9 functions in the exact manner as CB-8 including the weir orifice plates, concrete
bypass structure and pipeline, spillway, and riprapped apron. Excess flow from CB-9 is
channelized until reaching the bypass line at Centennial Avenue. The bypass line passes under
Centennial Avenue, transects the BRW open areas, and eventually discharges to the BRW
diversion channel. The diversion channel merges with the HCC, and the combined flow
continues on to the BTL system.
3.1.4
Routine System Hydraulic Operations
During routine system hydraulic operations, the groundwater level of the West Camp will remain
at or below 5,425 feet amsl. This level is established to maintain a 10-foot buffer elevation from
the critical water level of 5,435 feet amsl. Routine operations maintain the water level at or near
5,424 feet amsl. Pumping rates from WCP-1 average 180 gpm over the course of the year.
Discharge water is conveyed from WCP-1 and combines with base flow from Missoula Gulch
prior to discharging to the HCC. After reaching the HCC, the discharge water travels westward
where it eventually enters Cell D4 of the BTL system. It is then treated in the BTL and
eventually discharged to Silver Bow Creek. The WCP-1 level is maintained nearly constant
through the use of a VFD which controls pump motor speed based on well level. Operator
interaction, or manual throttling, is minimal under routine conditions.
The maximum baseflow from the Missoula Gulch is 75 gpm. Although this flow varies with the
conditions in the Missoula Gulch channels and intake screens, routine flows are approximately
50 gpm. Flow from the Missoula Gulch system discharge directly to the BRW diversion
channel, and later merge with the HCC prior to entering the BTL system.
3.2
Electrical, Automation Control, and Monitoring
This section of the O&M Plan provides a general description of the electrical systems at the
WCP pump house. The West Camp piping and instrumentation diagram (P&ID), Sheet I&C-C6, is located in the System Drawings in Appendix A.
3.2.1
Electrical Service Equipment
A schematic diagram of the main electrical system is provided in the System Drawings
(Appendix A). The 480-volt service panel contains circuit breakers to prevent overheating or
damage to the equipment in case of a short in the system. A 480-volt line runs directly to the
pump controller. The pump controller is used to start, run, or stop the 15-HP pump. The
controller also has “heaters” which will break the circuit if the wiring is beginning to overheat.
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A transformer converts the 480-volt, 3-phase power to 120-volt, single-phase power. The 120volt power is used to run the lights, fan, aeration blower, security system, water level monitors,
flow meter readout, and the data/communications system.
3.2.2
Automation Control Equipment
MSE Tetragenics automation control equipment is located on the east wall of the WCP-1 pump
house. The automation and control equipment includes an Allen-Bradley CompactLogix
Programmable Logic Controller (PLC) with distributed in/out and control base. Wonderware
operating software is utilized to provide operating control over the system. The interface logs all
data from the flow meter and pressure gauge and transmits that data to the BTL Operations
Building via the secure Federal Communications Commission (FCC) radio signal utilizing
Integra-H 900MHz wireless modem and Maxrad 900MHz Yagi Antennae.
3.2.2.1 Wonderware HMI Data Management Software
The Wonderware HMI System is installed on the computer located in the new Operations
Building at BTL-LAO, adjacent to the CAS Building. This system compiles all remote facility
location data in an electronic format that is readily available to the operator. The data can be
used to verify real-time performance and operation of the systems.
3.2.3 Monitoring Equipment
Monitoring equipment within the WCP-1 pump house is directly connected to the HMI
automation control equipment. This allows for data transmission to the BTL Operations
Building. The system is capable of notifying the operator of any upset conditions at WCP-1.
Monitoring equipment at WCP-1 includes two groundwater level sensors, the McCrometer
UltraMag® flow meter, Detcon H2S sensor, and power interruption/supply sensor. Local
indication of process conditions is available through the Dwyer pressure gauge installed within
the discharge piping, and local flow display on the flow meter. No water quality monitoring
devices are located within the WCP pump house. Water quality parameters are measured by
grab sample collection at West Camp on a quarterly basis.
3.2.3.1 Esterline KPSI Water Level Transducer (LT-WCP5001)
Digital submersible transducers and transmitters are installed in monitoring well BMF96-1D.
Each water level meter provides a digital readout in the pump house and data relays to the
Operations Building control panel. The level transducers utilize a 4-20 mA signal to relay level
alarms to the Operations Building; the high level alarm is set at 5,430.00 feet amsl and the low
level alarm is set at 5,423.00 feet amsl. Data relays for the level transducers also include power
and communication status alarms.
3.2.3.2 McCrometer UltraMag® Flow Meter (FIT-WCP5006)
West Camp flow is monitored using a McCrometer UltraMag® model UM06, electromagnetic
inline, full bore flow meter suitable for the measurement of electrically conductive fluids and
slurries. A magnetic flowmeter measures flow based upon Faraday's Law to measure flow in a
pipeline. A voltage induced across any conductor (fluid) as it moves at right angles through a
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magnetic field is proportional to the velocity of that conductor. Signal voltage is dependent on the
average liquid velocity, the magnetic field strength, and the length of the conductor (which in this
instance is the distance between the electrodes). A magmeter cannot distinguish entrained air from
the process fluid; therefore, air bubbles will cause the magmeter to read high. To remedy this, the
meter is installed horizontally, at a lower centerline than the centerline of the supply piping to ensure
the meter is constantly flooded. The meter is constructed of a 4-inch diameter body with 4-inch
flanged ends (ASME B16.5, Class 125, flat-faced), and installed directly in the pipeline. Instant
flow readout is available locally at the meter and remotely at the main panel in the BTL- LAO
Operations Building.
3.2.3.3 Dwyer Pressure Gauge (PI-WCP5013)
The pressure indicating gauge is a Dwyer SGB-C0421N model, constructed with 304 SS housing
and 316 SS wetted parts, glass lens, and a 1/8-inch MNPT process connection. The gauge is
suitable for process conditions of 0 to 60 pounds per square inch gauge (psig) operating pressure,
ambient temperatures of -4 degrees Fahrenheit (°F) to 140°F (60 degrees Celsius [°C]) and
process temperatures up to 356°F (180 °C). The face is a 2-inch diameter display with both
English and metric units. The unit enclosure rating is NEMA 3, rated to 125% of process
pressure, or 75 pounds per square inch (psi).
3.2.3.4 Detcon H2S Sensor (AIT-WCP5000)
The H2S sensor is a Detcon MicroSafe™ Model TP-624C, hydrogen sulfide sensor is a nonintrusive “Smart” sensors designed to detect and monitor H2S in the air. Ranges of detection are
user-settable between 0 to 20 parts per million (ppm), 0 to 50 ppm, and 0 to 100 ppm. The
automatic calibration feature guides the user through each step via instructions displayed on the
backlit LCD. The sensor features field adjustable, fully programmable alarms, relays for two gas
level alarms, and one for any fault condition. The sensor is equipped with both an analog 4-20
mA, and serial RS-485 output.
The sensor is packaged in a cast metal explosion proof enclosure, fitted with a threaded cover
that has a glass lens window. Magnetic program switches located behind the transmitter module
face plate are activated through the lens window via a hand-held magnetic programming tool
allowing non-intrusive operator interface with the sensor. All calibration and alarm level
adjustments can be accomplished without removing the cover or declassifying the area.
Electrical classification is Class I; Division 1; Groups B, C, D (explosion proof).
3.3
Instrumentation and Controls Operational Control Theory
The pump house is equipped with Allen Bradley CompactLogix PLC with distributed in/out and
control base to monitor and control sites process and/or monitoring equipment. The site PLC
provides local control such as pump control logic or flow control logic, and monitors 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 are collected by the Allen Bradley CompactLogix
PLC and transmitted via encrypted FCC radio to the Allen Bradley ControlLogix PLC at the
Operations Building. The Master PLC at the Operations Building polls remote sites for data at
regularly scheduled intervals. Polling intervals are programmable and can be set to meet data
acquisition requirements.
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3.4
Protective System Devices
Protective System Devices include any device installed to protect personnel, the environment, or
equipment. These devices act either independently or through control logic to shutdown
equipment, relieve pressure, or isolate energy. Such devices may include level and pressure
switches, relief valves, regulators, or instrumentation and control logic.
Protective System Devices protect the environment, system components, and personnel by
activating alarms and notifying personnel when process conditions are outside normal operating
parameters. If normal operations are upset and key parameters are out of range (e.g., power loss,
pump stoppage, water level elevation, high H2S in the building, etc.) the monitoring equipment
will transmit an alarm signal to the monitoring system at the BTL, which initiates an automatic
callout procedure to contact the operator.
3.4.1
PSD List
A list of protective safety devices for West Camp is provided below.
Type
Water lever
H2S monitor
Loss of power
Check-valve
Tag number
LT-WCP-5001
AIT-WCP-5000
TBD
VRV-WCP101
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Instrument Description
Level Indicator Controller
H2S Safety Area Monitor
Power Interruption/Supply Sensor
1" PVC Air Relief Valve
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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.
4.1
Pressure
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. Piping and components are rated to 200 psig at 100 °F. Instruments and gauges
installed in pressurized systems are rated to 75 psig (125% operating pressure) at 100 °F.
4.2
Temperature
4.2.1
Groundwater
Temperature of the groundwater is typically within the range of 42 – 47 ̊F.
4.2.2
Pump House
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
System flow capacity shall not exceed 300 gpm. Minimum flow will not be less than 70 gpm to
provide adequate cooling to the pump.
4.4
Electrical
The main electrical service line is rated to provide 100 amps. Major pieces of equipment are
powered on an independent circuit and protected with an over-current circuit breaker.
Electrical enclosures will be tested according to Underwriters Laboratories (UL), and rated to
meet National Electrical Manufacturers’ Association requirements. Enclosure types are listed
below for each instrument. Electrical wiring shall contain be THHN type insulation, rated for
maximum current overload at a temperature up to 194 °F.
4.4.1
Instruments
UltraMag UM06 flow meter operating range includes:
•
Temperature: 14 to 170 °F;
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•
•
Pressure: 0 to 150 psig (maximum allowable pressure); and
Enclosure: NEMA 4X.
DetCon H2S gas meter operating range includes:
•
•
•
Temperature: -40 to 175 °F;
Pressure: atmospheric; and
Enclosure: NEMA 7.
Dwyer pressure gauge operating range includes:
•
•
•
•
Temperature: 14 to 140 °F;
Pressure Range: 0 – 60psig;
Pressure Limit: 125% full scale range; and
Enclosure: NEMA 3.
WEG VFD operating range includes:
•
•
•
Ambient Temperature: 14 to 122 °F;
Altitude: No current de-rating required up to 13,100 feet (4,000 meters); and
Enclosure: NEMA 3R.
KPSI level transducers operating range includes:
•
•
•
Ambient Temperature: -4 to 140 °F;
Pressure: 10 – 200 feet H2O hydrostatic pressure head; and
Enclosure: NEMA 6P.
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5.0
ROUTINE OPERATIONAL TASKS
Routine operating functions and parameters are recorded by the operator on a log sheet. The
operator must obtain a new log sheet at the beginning of each week. Measurements are made
and recorded, and then the data are transferred to a database for retention. The log sheet also
serves as a punch list of operating activities that must be performed and when the activity must
be completed. Notes and observations of the systems and site are also made on this sheet. A
blank BTL-LAO Operations Log Sheet is available in Appendix D.
Proper system operation includes routine minor maintenance and inspection of the site,
equipment, and process parameters. Routine maintenance involves the use of sight, sound, and
touch. Operators must take the time to notice changes in system operating parameters, and
associated components. Operations logs and field notes are helpful in diagnosing system upsets.
Routine tasks are included in Appendix D. The operator’s reference guide provides items that
must be performed on a regular basis and scheduled intervals. Predictive and preventative
equipment maintenance tasks are discussed in Volume V, Maintenance. Topics included in
Volume V are equipment repairs, replacement, upgrades, maintenance schedules, and equipment
inventories. Non-routine maintenance procedures are also included.
5.1
Normal Operation
Under normal operations the objective of the groundwater extraction system is to maintain water
levels in the West Camp below an elevation of 5,425 feet amsl, which is the critical water level
(5,435 amsl) plus a 10-foot buffer. Normal operation of WCP-1 maintains water level at or near
5,423 feet amsl. During normal operations, an operator must visit the site twice weekly. During
site visits, the operator will record instantaneous flow reading, and totalized flow.
The pumping rate is controlled by the VFD to maintain a constant water level. The VFD
receives a signal based on well level to vary the pump motor speed in order to maintain a
constant level. Should the pump rate require manual throttling, the pump operates at full rated
capacity and the inline 4-inch butterfly valve will be adjusted to the following flow rates: during
non-recharge periods the pumping rate is typically set between 150 and 180 gpm; and during
periods of annual recharge the pumping rate is increased to between 200 and 240 gpm.
If normal operations are upset and key parameters are out of range (e.g., power loss, pump
stoppage, water level elevation, high H2S in the building, etc.) the monitoring equipment will
transmit an alarm signal to the monitoring system panel located at the BTL Operations Building,
which will ultimately notify the operator of the condition.
5.1.1
Start-Up
The following sequence is provided to initiate or restore pumping operations at P-WCP-1.
Upon arrival at the site and initial site inspection, and entry into the pumphouse:
1. Verify BFV-WCP5009 is open.
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2. Verify Panel EL-WCP-105 is energized. Main switch should be in the ON position.
3. Move pump power control Hand/Off/Auto (HOA) switch to the AUTO position.
4. Push and hold reset button for 1-second.
5. Push and hold START & BYPASS button to energize pump.
6. Verify the pump flow rate displayed on FE-WC-101.
7. Record the date, time the system is brought back online and flow rate of the system.
5.2
Routine Operations Tasks
Several scheduled tasks should be completed during routine operations to ensure continued
operational efficiency of the Missoula Gulch Groundwater System and West Camp. Routine
measurements are recorded on the BTL-LAO Weekly Ops Report, provided in Appendix D.
Routine inspection and maintenance tasks and frequencies are summarized in Operator’s West
Camp Reference Guide and West Camp Maintenance and Inspections Checklist, available in
Appendix D.
5.2.1
Missoula Gulch Baseflow Collection System
Butte-Silver Bow personnel are responsible for maintenance of the Missoula Gulch base
flow system. These tasks are listed here to provide an overview of all tasks associated with
West Camp. Routine operational tasks associated with the Missoula Gulch base flow system
include weekly site visits to inspect the condition weir orifice plates, base flow pipeline inlet
screen, concrete bypass structures, bypass pipelines, spillways, and containment dikes. Any
variance in the condition of site features that may result in upset operational conditions should be
documented and repaired immediately. When on-site, any debris that may have accumulated
around the weir, the debris screen, or on the spillway should be collected and removed from the
site. Surface channels should be walked and inspected yearly. Any obstructions (tree limbs or
trash) should be removed from the channel and the site. Exposed portions of the bypass pipeline
should be walked yearly to check for leaks, fissures, or other damage. Damage should be
documented, marked, and repaired as soon as practical.
5.2.2
West Camp Pump Station
The water level, flow rate, and system pressure is checked twice per week at WCP-1. It is
essential that the water level be maintained at or below the critical water level of 5,435 feet amsl.
The operator will physically record all values weekly and ensure that data loggers and
monitoring equipment are operating as designed and intended. These site visit intervals are
typically every Monday and Thursday. Site alarms necessitate additional site investigations. Site
alarms include: H2S detection, well level high and low, discharge flow out of range, and
generator alarms.
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5.2.3
Routine Maintenance
Routine operational maintenance items are listed on the BTL-LAO Operations Log sheet. Task
description and frequency is also available in Appendix D, the Operator’s West Camp Reference
Guide. The checklist is completed each day the operator visits the site. As previously stated, the
site is visited twice per week under normal operating conditions.
5.3
Site Vegetation and Access Maintenance
5.3.1
Site Vegetation Maintenance
The Butte Reclamation Evaluation System (BRES), contained in the Record of Decision Butte
Priority Soils Operable Unit Silver Bow Creek/Butte Area NPL Site (ROD) (EPA, 2006),
establishes the performance standard for site vegetation (see Volume I, Performance Standards).
The system was specifically designed for use in the upland environment of Butte, but may also
be re-evaluated, altered, and used appropriately for BPSOU and BMFOU. The BRES has
components that allow it to be applied to areas reclaimed as open space within this area.
Reclaimed areas, including cover soil caps, must achieve the proposed performance standards
described by EPA in the BRES document. This system is a site-specific tool to evaluate the
stability, integrity, and degree of human and environmental protectiveness afforded by response
actions initiated on lands impacted by mining within the OUs.
The BRES relies on routine inspections to assess the following reclamation characteristics:
•
•
•
•
•
•
Condition and diversity of vegetative cover;
Presence of erosion;
Condition of site edges;
Presence of exposed waste material;
Presence of bulk soil failure or mass instability; and
Presence of barren areas or gullies.
Based on the periodic monitoring (as observed by the operator and staff) and evaluation of
response action sites, the triggers noted above will prompt corrective action. Vegetated cover
must support a diverse plant community including native species to the extent that the
constituents of the vegetation cover are not incompatible with the remedy or overall performance
standards.
5.3.2
Site Access Maintenance
The West Camp is accessed via a gravel road from Centennial Avenue. The access road is
several hundred feet long. A chain-link fence with locked gates secures the West Camp facility.
The road and parking areas should be regularly maintained, including grading and addition of
surfacing materials when needed. Site drainage features (borrow pits) adjacent to the roadway
must also be maintained to promote the removal of excess surface water. This includes mowing
and removal of obstructions from the channels and from any culverts.
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The chain-link fence and locking gates must also be regularly checked to ensure site security. If
any damage or vandalism should occur to the fence or gates, immediate repair actions should be
undertaken to maintain site integrity.
5.4
Routine Operations Duties and Responsibilities
Routine Tasks: Perform the sampling and data gathering tasks listed on the BLT-LAO Weekly
Ops report at a frequency of twice per week. Tasks for the West Camp are typically performed
every Monday and Thursday. Complete West Camp Maintenance and Inspection Checklist
form, each day the site is visited.
Maintenance: Routine maintenance involves visual inspection and observation of the site upon
arrival. Inspection includes general observations of site security, fencing, gates, and locks. Also
included is basic observation of pipes, fittings, and equipment for signs of leakage or
degradation.
Weekly Inspection: Inspect back-up generator systems, fluid levels, hoses, and hour meter.
Record hour-meter readings to verify generator automatic start-up.
Bi-weekly Maintenance: Visual inspection/observation of pipe and fittings. Note signs of
leakage, and schedule repairs.
Monthly: Perform H2S low flow alarm test.
Quarterly Maintenance: Water level in WCP-1 must be manually verified and recorded on a
frequency of once per three-month interval, and a minimum of four times per calendar year.
Obtain, record, and compare water level reading to the reading of the display on the Wonderware
display monitor for the site.
Also included in the quarterly maintenance is inspection of site erosion, fencing, corners, pipe
and fittings. Critical inspection should be performed on of pipe and fittings that are exposed to
direct sunlight and ambient conditions. Look for signs of excessive deterioration, cracking, and
joint failure.
Protective System Devices must be inspected, tested, and recorded. A list of system PSDs is
provided in Appendix E.
Semi-annual: Perform preventative maintenance on building exhaust fan.
Annually: Look for signs of road and culvert maintenance needs, and weed control. Inspect all
electrical insulation, wire covering, conduit, junction boxes, etc. for signs of degradation. The
flow meter must be inspected and preventative maintenance performed annually. Refer to the
Maintenance Manual, Volume V, for meter calibration procedures.
The following subsections provide instructions for routine, recurring tasks associated with West
Camp. Operators are required to be appropriately trained on each procedure prior to performing
these tasks. Refer to the appropriate SOP for HSSE considerations, personal protective
equipment (PPE) requirements, required tools, and detailed work instructions (see Appendix F).
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5.4.1
West Camp Check – SOP-4
The West Camp pumping station requires a weekly Operations Check to insure every component
is working properly and information is accurately being gathered. During the weekly check, the
following tasks must be completed:
1. Check the HMI for indication of any alarm conditions. Alarms for the WCP-1 are also sent
via radio signal to the Wonderware system located in the CAS Building at the BTL. Alarms
monitored at WCP-1 are water elevation, electrical service status, and flow rate. If any
indication of alarms exists a further check at the WCP-1 is required to verify, identify, and
correct alarm.
2. Before entering site, visually inspect the condition of the security fence and gate and exterior
of WCP-1 pump house. If conditions appear normal, operator may enter site. If visual
inspection shows signs of damage or security gate is open, operator may notify the respective
pioneer contact or call 911 if needed.
3. Upon entrance of WCP-1 pump house, check the flow meter (FIT-WCP-5008), sound
emitting from flow in the 4-inch DI pipe (4ʺ-DI-WC001), and the Level Controller (LI-WCP5001). No flow, no sound emitted from water flowing through the 4-inch pipe (4”-DIWC001), or no light displayed on the Level Controller (LI-WCP-5001) indicates alarm
conditions; routine conditions are indicated by flow, sound emitting from the 4-inch DI pipe
(4”-DI-WC001), or light displayed on the Level Controller. If no alarm conditions exist
proceed with SOP-4, Step #5 and Step #6.
4. If electrical service has been disrupted the operator will determine if it is within operator
controls to restore power.
a. If within operator control operator will restore power; and
b. If not within operator controls, the operator will contact NorthWestern Energy to have
electrical service restored.
5. Once electrical service is restored, the pump must be reset to routine operation. A push
button reset switch located on the pump Control panel must be reset. Once reset, the pump
auto start button may be depressed.
6. Adjust flow rate as necessary to maintain, lower, or increase the water elevation in the West
Camp/Travona Mine complex. Flow rate is adjusted through modulation of the motor VFD.
7. Measure required daily parameters associated with WCP-1 and record accordingly on BTLLAO Operations Log.
The complete SOP-4 West Camp Check is available in Appendix F.
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5.4.2
Water Level Measurement Procedure
Manual water level measurements are required to verify level transducer readings. Operators
will place the manual level measurement device down the well until water level is reached.
Measurement is made by taking a level reading at the control mark placed on the north side of
the well casing. Record the level, and verify the automated measurement reading.
5.4.3
Alarm Response Procedure
The RACO auto-dialer provides notification to the operator upon prolonged upset conditions.
The dialer is pre-programmed to mitigate nuisance call-outs and prioritizes callouts to ensure
high impact conditions are corrected quickly. Upon notification the operator must initially
respond to the operator interface panel in the Chemical Addition System (CAS) building, at LAO
and investigate the nature of the alarm via the HMI terminal. The HMI monitor provides
indication of the alarm area, and nature of the alarm. The operator s then required to physically
investigate the local alarm area and physically correct the situation to remedy the alarm situation.
5.5
Seasonal Flows
Seasonal flow adjustments can be expected to account for precipitation events or non-typical
precipitation years. (A range of seasonal flow rates will be generated and placed in the
Appendices for adjustment guidance.)
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6.0
OPERATION DURING DISTURBANCES
This section describes the procedures to be implemented in the event that operation of the WCP1 is interrupted. Previous hydraulic recharge tests have been completed to estimate the amount
of downtime allowable before critical water level is achieved. Based on an operating water level
of 5,424 feet amsl, and normal recharge rate of approximately 150 gpm, WCP-1 can remain
inoperable for up to 12 days, resulting in an expected level increase of nearly 6 feet. After a 12day period water level would raise to approximately 5,430 feet amsl. The high level alarm
setpoint for this system is 5,430 feet amsl, which provides a 5-foot buffer below critical water
level. Normal recharge rate will cause water level to rise approximately .49 feet per day without
pump operation.
6.1
System Disturbances
Interruptions to the West Camp that would trigger the implementation of this contingency plan
include, but are not necessarily limited to the following:
1.
2.
3.
4.
5.
6.
7.
Loss of power;
Monitoring equipment disturbance;
Control and instrumentation disturbance;
Pump failure;
Missoula Gulch flow disturbance;
Subsurface changes that result in loss of effectiveness of well system; and
Pipeline damage between West Camp and the treatment lagoons.
System repairs and upsets will be considered and addressed on a case-by-case basis. Figure 3
West Camp Decision Tree, WCP-DT-1, presents the corrective actions for troubleshooting
various upset conditions at West Camp. During an interruption to the West Camp groundwater
extraction system, the following procedures will be implemented to address the system.
6.1.1
Electrical Disturbance
In the past the principal upset to the system has been shutdowns caused by the local utilities
electrical surges or outage. If a power outage occurs at the West Camp Pumping Station first
check to see if a breaker has been tripped. If a breaker has been tripped reset the breaker and
visually inspect all electrical systems to ensure that all wiring is in good condition. If a breaker
has not been tripped then notify the local utility of the power outage. Power outages should be
reported to NorthWestern Energy at 1-888-467-2353.
A Cummins site-dedicated diesel generator provides supplemental electrical service. The allseason generator with dual containment fuel tank is located adjacent to the south side of the
WCP-1pump house on a dedicated concrete pad and hard-wired directly to the electrical supply
system. The generator is activated by an automatic control switch in the event of power outages.
The automatic transfer switch continuously monitors line voltage from the utility. If line voltage
drops below a certain level (volts, or Δ phase) the transfer switch signals the generator to start
and then transfers power to the backup. The power switch takes approximately 10 seconds (need
data from Cummins). An uninterrupted power supply (UPS) system installed in all PLC panels
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accounts for this gap. The battery life for the CAS is 7 to 10 minutes at full load of about 7A.
The generator transfer will be monitored. If line power or backup power is not online an alarm
call out (primary) will take place. The transformer, automatic transfer switch, and main meter
base and service are mounted on the south exterior wall of the building.
In this manner, the water elevation in the extraction well will be maintained. Following utility
maintenance, the system is to be reconnected to the municipal power supply, brought back online
and the generator unit shutdown. Once electrical service is restored, the operator will ensure
WCP-1 returns to routine operating conditions.
6.1.2
Monitoring Equipment Disturbance
Upon discovery of the failure of the West Camp, the operator will initially check and record the
water level at the West Camp to verify the water level is below the critical water level of 5,435
feet. If water levels are below critical levels, begin troubleshooting (see Figure 3, WCP-DT-1) to
determine the cause of the West Camp failure and appropriate corrective action. Check and
record water levels daily during the failure until the system is repaired and operating normally
again.
(NOTE: Based on typical operating levels per this Manual, it is expected to take approximately
21-days for water levels to reach critical levels identified by BMFOU requirements. Continue to
monitor water levels.)
6.1.3
Control and Instrumentation Disturbance
If control and instrumentation devices are disrupted, begin manually recording data daily
(including water levels, flow rates, pressure readings, and H2S levels). Utilize BFV-WCP-5009
to control the pumping rate from WCP-1. The valve will be manually adjusted to achieve a
constant level in well BMF96-1D. Refer to the seasonal pumping rate chart (Appendix I) for an
initial flow range. Manual measurements will be obtained and recorded daily until the
disturbance is corrected.
Immediately contact MSE Tetragenics (406) 533-6800 to service the equipment and notify the
BTL-LAO Project Manager. Ensure that routine pumping and flow conditions are maintained by
performing manual adjustment if necessary. Following repair, ensure that all equipment is
functioning appropriately; including logging of data and transmittance to the HMI automated
data system at the Operations Building.
6.1.4
West Camp Pump Disturbance
After establishing that groundwater levels are below specified action levels, the operator will
begin troubleshooting to identify the cause of the West Camp system failure. Refer to Figure 3,
Corrective Action and Troubleshooting Decision Tree for troubleshooting assistance. It will take
approximately 3 weeks for groundwater levels to rise above action levels, therefore the operator
will strive to identify and fix the cause of the failure before groundwater reaches this level.
The most difficult upset condition to manage would be caused by excessive water level rise
resulting from above average annual precipitation and/or recharge in West Camp. The extraction
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system’s output capacity is limited by the its pumping capacity and the amount of water that can
be treated at the BTL. West Camp has the capacity to deliver up to 300 gpm to BTL.
According to the Sampling and Analysis Plan for Field-Scale Treatability Study Base Flow and
West Camp Water Work Plan (AERL, 2001), the BTL is expected to accept approximately 180
gpm from WCP-1. The piping in the BTL system is designed to handle more than 400 gpm from
WCP-1. The maximum acceptable flow rate from WCP-1 is based on treatment capacity of
LAO.
Discharge from WCP-1 to LAO is best managed by using the best available predictions of the
regional water balance, much the same as is done with reservoir management. During years
when the winter and spring snow pack are well above normal the regional recharge will be high.
During these conditions the water levels in the West Camp should be drawn down to increase the
buffer from 10 to up to 20 feet (elevation 5,215 feet amsl). This will provide added storage in
the aquifer and underground mine system. Climatic predictions can be accessed through the
Natural Resource and Conservation Service to aid in long-term planning of the West Camp pump
rates. Appendix I contains seasonal pumping capacity recommendations.
In the event of pump failure, a redundant pump and variable speed drive is maintained in the
West Camp equipment inventory (see Appendix E). In the event of pump failure, the operator
will initiate the steps required to replace the pump with the pump located in inventory. This
replacement will be a replacement-in-kind.
6.1.5
Missoula Gulch Flow Disturbance
Butte-Silver Bow personnel are responsible for maintenance of the Missoula Gulch base
flow system. These tasks are listed here to provide an overview of all tasks associated with
the West Camp. Missoula Gulch Flow may be disturbed during abnormally high flow
conditions, failure of flow regulation devices or containment structures, or plugging of discharge
piping. During high flow conditions water will accumulate within and eventually overtop the
spillway of CB-8. The excess flow will then travel downhill to CB-9 and eventually discharge to
the BRW diversion channel.
Immediate dewatering efforts must be implemented should a breach occur in either containment
dike of CB-8 or CB-9. Water may be discharged directly to the Missoula Gulch drainage.
Damage is then to be assessed and corrective reconstruction measures implemented.
In the event that flow control structures fail or malfunction, they will be repaired or replaced as
needed. If plugging of discharge piping occurs, attempt to physically remove the obstruction in a
safe manner. If the operator is unable to safely remove the obstruction proceed to mechanical
pigging or flushing actions.
Maintenance of the Missoula Gulch bypass should be completed as needed. Including repairing
any leaks or needed replacement of any corrugated metal pipe segments.
6.2
Off-Site and Environmental Disturbances
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Possibilities exist that off-site or environmental disturbances may impact routine operations of
West Camp and Missoula Gulch. Off-site disturbances may include nearby civil or residential
construction, including utility installation, road improvements, and residential development.
Additional off-site disturbances may include the disturbance or failure of other water collection
and treatment systems associated with West Camp and Missoula Gulch, including the BTL,
Metro Storm Drain (MSD), or CAS. General off-site construction will likely be foreseen or
known of prior to it beginning. The operator will assess the possible impacts of the off-site
event, and prepare for any foreseeable operational disturbances. The operator must coordinate
efforts with the entity performing off-site construction/disturbance in order to fully address the
situation. Accounting for possible disturbances and implementing the appropriate system
adjustments will help in maintaining successful operation of the system.
Environmental factors that may affect routine operations include significant storm events, spring
run-off, freeze and thaw events, and extreme drought. These events are generally unpredictable.
The operator has the ability to vary WCP-1 pumping rates and to vary the amount of water
retained or released from Missoula Gulch. Prior to increasing pumping rates (if groundwater
levels are nearing the critical water level) or releasing excess water from Missoula Gulch, the
operator must ensure that receiving facilities (BTL and/or BSB Sewage Treatment Plant) have
sufficient capacity to accommodate the increased flow. The operator will return the systems to
routine conditions as soon as practical following an environmental disturbance.
6.3
Return From Disturbances
After prolonged periods of shutdown, the accumulated water level must be returned to normal
operating conditions. The pumping rate from WCP-1 is dependent upon the current operating
levels and capacity at LAO. The estimated time required to return West Camp to normal
operating level is also provided in Appendix I. The information in Appendix I provides an
estimate of the length of time it may require to return to normal operating based on pre-shutdown
pumping rate. To mitigate operational issues at LAO, the post-disturbance pumping rate can be
selected moderate treatment capacity at LAO.
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7.0
MONITORING AND LABORATORY TESTING
The following sections describe monitoring equipment utilized to collect and relay operating data
to the BTL Operations Building. Also discussed are operator duties and responsibilities. On a
weekly basis, the operator will obtain a new BTL-LAO Weekly Operations worksheet and obtain
the appropriate measurements from the designated locations. This referenced worksheet serves as
the basis for daily, routine operation of the LAO system. The referenced worksheet contains data
to be collected from locations outside of West Camp. This section describes data and monitoring
equipment associated with West Camp.
7.1
Operator Observations
To facilitate data generation and minimize data gaps, collected data will be sorted into the
following categories:
•
•
•
•
Operator observations;
Control system generated data;
Automatic electronic monitoring data; and
Water level, flow, and quality data.
Many of the routine activities involve data forms or checklists that the operator completes as
he/she proceeds. Many of the routine operator activities and most of the unplanned activities
involve observations that should be documented for future reference. Such observations may
include general site condition and appearance, pressure and flow readings, and H2S levels and
other biological, chemical, or physical activities within or influencing West Camp. 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 easily understand each entry.
7.2
Monitoring Components
Operation and performance of WCP-1 is monitored to ensure efficient operation, react to upsets,
and to meet regulatory obligations.
System monitoring is broken into two sections as follows:
1. Individual Monitoring Components at the WCP-1; and
2. HMI System at the BTL Operations Building
The following monitoring components are a part of the WCP-1 monitoring system within the
WCP pump house:
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TAG
NUMBER
TYPE
DESCRIPTION
AIT-WCP-5000
AI
H2S Sensor
LI-WCP-5001
AI
West Camp Well Level
HS-WCP-5004
DO
West Camp VFD Hand Control
SIC-WCP-5003
AO
West Camp VFD Speed
FI-WCP-5008
AI
West Camp Station Flow
ZA-WCP-5010
DI
West Camp Generator Alarm
ZI-WCP-5011
DI
West Camp Generator Run Status
ZS-WCP-5012
DI
West Camp Transfer Switch Status
A= Analog; D = Discrete; I = Input; O = Output
7.2.1
LOW
HIGH
UNITS
TBD
0
NA
0
50
NA
NA
NA
TBD
35
NA
100
350
NA
NA
NA
ppm
Feet
NA
%
gpm
NA
NA
NA
Water Level Monitoring
Water level in the Travona shaft is measured quarterly with an electric depth-to-groundwater
tape. Water levels are measured from the measuring point marked on the north side of the steel
casing by Montana Bureau of Mines and Geology (MBMG).
Water level at WCP-1 is monitored automatically in the vicinity of WCP-1 in BMF96-1D with
an Esterline KPSI 700 (LI-WC101) level measurement system, which consists of two Series 700
submersible transmitters and pressure transducers. Water level is measured to the hundredth of a
foot and referenced to elevation in feet amsl. Refer to Appendix G for the Manufacturer’s
Installation, Operation and Maintenance Manual.
The submersible transducers and transmitters are attached to the transmitter with 120 feet of
polyurethane shielded electrical cable. The cable extends from the Esterline transducer, out of
the pump house and into monitoring well BMF96-1D. The transmitter is set approximately 30
feet below the water level in BMF96-1D. The water level in BMF96-1D is approximately 40
feet below the measuring point on the well casing. Thus the transmitter is suspended in the
monitoring well by approximately 70 feet of cable. Note that any kinks or nicks in the cable may
allow water to seep into the cable, shorting out the transmitter. Also, the surface ends of the
cable provide the transmitter with a reference to atmospheric pressure therefore they should not
be sealed.
The water level elevation that is displayed on the transmitter (LI-WC101) (see Drawings for
location) is adjusted to be equivalent to the water level elevation in the Travona Mine Shaft, not
the water level in BMF96-1D. This is accomplished by adding 0.66 feet to the water level
reading of the transmitter during calibration.
Readout display is four digits and is set to read to two decimal places. The water level elevation
is determined by adding 5,400 to the readout. For example, when the display reads 24.75 it
should be interpreted as a water level elevation of 5,424.75 feet amsl. Associated water level
alarms are transmitted to the HMI System located at the BTL for further logging and notification
to the BTL system operators.
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7.2.2
Pump Flow Rate
Flow rate from WCP-1 is measured by a 4-inch UltraMag® Flow Meter (FE-WC101). The H2S
resistant flow meter measures flow through the system in gpm and total flow in hundreds of
gallons. The flow meter is designed to accurately measure flows between 50 and 500 gpm.
Flow through the system is recorded, stored and transmitted to the HMI computer. The flow rate
and total flow through the system are checked and recorded manually during weekly inspections.
7.2.3
AC Power
Automated monitoring equipment within the WCP-1 pump house monitors the AC power
supply. A “com fail” alarm detected by this system and transmitted to the HMI within the BTL
will signify that AC power is not reaching the building. The RACO alarm dialer will then notify
the operator via the alarm dialer.
7.2.4
WCP-1 Pump Status
WCP-1 pump status is monitored by the automated monitoring equipment. The flow rate from
the WCP-1 is transmitted continuously to the HMI computer. A “low flow” alarm will notify the
operators when the flow from the WCP-1 pump is below 70 gpm.
7.2.5
H2S Concentration
The H2S concentration inside the pump house is monitored by a Detcon Model TP-624C H2S
Sensor (U-WC101) installed on the south wall inside the pump house. A Detcon alarm light is
installed on the southeast exterior corner of the pump house near the mandoor which allows
access to the pumphouse. Refer to Drawing WCP-D-8 for sensor location in Appendix A. This
location provides visual warning indication of the presence of H2S gas prior to entry into the
pump house. Refer to Appendix G for the Detcon User’s Manual.
At the time of installation, the H2S sensor was calibrated per the instructions in the Detcon
User’s Manual. Once installed, the unit should be calibrated every six months.
**Note: The H2S sensor must be powered up for two hours prior to calibration.**
The Detcon H2S Sensor is equipped with an internal alarm that will sound if the H2S
concentration inside the building is equal to or greater than 10 ppm. The acceptable ceiling
concentration for an 8-hour exposure of H2S is 20 ppm and the acceptable maximum above the
ceiling is 50 ppm. The LEL for H2S is 4.0% (40,000 ppm) and the UEL is 44.0%, both by
volume.
**Note: For reference, hydrogen sulfide levels monitored in the aeration stripper tank between
June and October 1999, were found to be between 3 and 7 ppm. Additional monitoring
conducted on November 11, 2008, resulted in no H2S being detected within the pump house.**
If the alarm triggers, a beacon light mounted above the pump house provides a visual alarm of
the excessive H2S levels in the building.
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7.2.6
Routine Inspection and Calibration of On-Site Monitoring Systems
The accuracy of the electronic monitoring systems requires inspections and regular calibration
checks to ensure proper operation of the monitoring equipment. Operator attention to proper
functioning of instruments is essential in order to provide accurate information on important
West Camp 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 as described in their individual O&M Manuals, which are
included as appendices. Volume V also contains maintenance schedules and intervals.
7.3
Automatic Electronic Monitoring Data
Data such as flow rates, water levels and various other inputs are recorded on the treatment
system computer located within the BTL Operations 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 water collection
and treatment effectiveness and to improve understanding of the factors that affect performance.
Procedures for emergency conditions and troubleshooting guidance are included in Section 11.0.
7.4
Review of Monitoring Data for Operations
Monitoring data must be reviewed daily to ensure that the systems are operating appropriately
and that the physical and chemical properties are within historic operational ranges. If
significant variations are observed within the monitoring data the operator should determine the
necessity of performing system maintenance or altering pumping rates and/or the treatment
process.
7.5
Routine Sampling Tasks
Routine sampling tasks are conducted by others. For further information, refer to the Montana
Bureau of Mines and Geology Sampling and Analysis Plan (MBMG, 2004) which was prepared
under the Butte Mine Flooding Consent Decree #02-35-BU-SHE, Docket # CERCLA-VII-96-19
(EPA, 2002).
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8.0
DATA MANAGEMENT
Data are generated from automated data loggers and manual field measurements. Data
management for each type data collection is discussed.
8.1
Data Management Plan
The BPSOU Data Management Plan will outline the methodology and associated contents
relevant to efficiently obtaining, documenting, and presenting pertinent operational data. The
BPSOU Data Management Plan is under development as a separate document.
8.2
Automated Data Management
Selected data from the remote stations and from the CAS Building is logged and archived on 30second and 1-hour intervals by the HMI. The recorded points are placed into a comma delimited
file format and delivered to Pioneer. The 30-second file is then used to update the LAO Lagoons
website and the 1-hour data are used for records back-up. 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
Pioneer’s Butte office server. The 1-hour average data are distributed to TREC, Inc. for data
management and analysis. See Section 2.0 for a description of all of the locations monitored, the
equipment used, and the data that are collected.
Data that are transmitted back to the Operations Building are displayed on the operators’ 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.
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
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 Allen Bradley ContolLogix
Master PLC at the Operations Building which polls each remote site for the data.
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.
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The HMI system also provides alarms for any alarm state within the entire process and
monitoring system. Alarm states are made available to the RACO Catalyst alarm dialer to notify
any off-site operators or personnel of the alarm event or events. Alarms are broken down into
several alarm severity categories and the call out are made according to severity logic. The
RACO alarm dialer also has a separate battery power supply internal to the unit to ensure an
alarm call out in the event that none of the backup systems come online after a power loss.
The HMI data management system monitors and logs data for the four following West Camp
parameters.
1. Groundwater level in well BMF96-1D (as adjusted to the Travona water level) is logged
hourly;
2. System flow rate that is being extracted from the West Camp is logged hourly;
3. Power is monitored by sending a “com fail” alarm to the operators indicating power loss at
the West Camp pump house and is logged at the time of initial failure; and
4. H2S is monitored and an alarm status will be logged and operator(s) notified callout via
RACO alarm dialer.
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9.0
OPERATIONS REPORTING AND RECORD KEEPING
Reporting and record keeping will be the responsibility of the system operator. Quantitative
records such as water quality, water levels, and discharge rates should be maintained in
electronic format, either Excel spreadsheet or Access database. Refer to SOP-4 West Camp
Check (Appendix F) for additional guidance.
9.1
Daily Operations Report
Under normal, routine operating conditions, West Camp does not require a daily inspection. The
site is visited and inspected at a frequency of twice per week. Data collected in the field during
routine inspection are recorded on the BTL-LOA Weekly Ops Report on the day the inspection
was conducted. A blank BTL-LOA Weekly Ops Report is available in Appendix D. Routine
inspections are typically conducted every Monday and Thursday.
9.2
Weekly Operations Report
All field measurements, system maintenance and site visits will be recorded in the BTL-LAO
Weekly Ops Report. A blank report is provided in Appendix D for reference. Entries
documenting site visits will include at a minimum, time and date of observations, observations or
site conditions, and field personnel numbers and each page will be signed and dated by the field
personnel or logbook reviewer. All entries will be made in permanent black ink.
9.3
Monthly Operations Report
The ROD (EPA, 2006) requires monthly reporting of water levels in the West Camp. In
addition, the total volume of water discharged to the water treatment facility and the results of
any water quality analysis that was performed during the month are reported. These data are
maintained as part of the permanent record for the site.
9.4
Quarterly Operations Report
Any problems or system upsets, including a summary of monthly reports, are reported quarterly
in the TREC, Inc. LAO/WC Groundwater Treatability Study, Quarterly Operations and
Maintenance Report. Copies of the quarterly report are distributed to the PRPs, EPA, Montana
Department of Environmental Quality (DEQ) and BSB Planning Department (for public
distribution).
9.5
Annual Operations Report
The ROD (EPA, 2006) requires that DEQ coordinate an annual report for the entire BMFOU.
All data and records collected by the operator will be supplied to the project manager for DEQ in
the TREC, Inc. LAO/WC Groundwater Treatability Study, Quarterly Operations and
Maintenance Report.
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9.6
Supplementary Data
The operation and performance of the system should be reviewed every five years. The five-year
review report should summarize and include the following:
•
•
•
•
•
•
•
•
Changes to the system;
Significant problems or emergencies encountered;
Summary of water quality trends;
Hydrographs of West Camp water levels;
Summary of pumping history;
Recommendation for changes to the program including monitoring and reporting;
Equipment inspection results and foreseeable replacement recommendations; and
Addendum or update to this O&M Manual.
The information presented in the five-year review report will be consistent with the requirements
of the Clark Fork River Superfund Site Investigations – Standard Operating Procedures (ARCO,
1992a), Laboratory Analytical Plan (ARCO, 1993) and Quality Assurance Project Plan (ARCO,
1992b).
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10.0
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.
A copy of this O&M Manual and the West Camp Inspection and Maintenance Checklist
(Appendix D) should be maintained by the system operator and kept in the WCP-1 pump house.
A log that specifies the date, time, flow rate and flow totals of each site visit will be maintained
in the BTL-LAO Weekly Operations Report.
If replacement parts are needed or portions of the system require design changes and
construction, the operator will notify Atlantic Richfield of the need and request approval to
complete the modification or improvement. A Work Order is submitted to perform these types
of activities. Details of the Work Order system are discussed in Volume V, Maintenance Plan.
Specific procedures are provided for routine maintenance on specialized pieces of equipment.
Refer to the procedures located in Volume V, Maintenance Manual for detailed instructions,
specialized tool requirements, and protective measures.
10.1
Inspection and Maintenance Guidelines for Process Equipment
Inspection and maintenance guidelines for routine, operational maintenance is provided in this
section. Detailed maintenance procedures are provided in Volume V, Maintenance Manual. The
Maintenance Manual should be referenced for items out of scope as discussed below.
10.1.1 Scope and Organization
The following sections describe the routine inspection and maintenance tasks necessary for the
site, process, and monitoring equipment. Appendix D provides information that details the
routine inspection and maintenance tasks, including a schedule of task performance, and a
discussion of records and reporting procedures. Major equipment maintenance is discussed in
Volume V, Maintenance Manual.
10.1.2 Description of Access to Site Facilities
West Camp is located at 526 Centennial Avenue in Butte. West Camp is accessed via a graveled
road from Centennial Avenue. The graveled road is approximately 360 feet in length and
approximately 20 feet wide. The site also includes a parking area adjacent to the West Camp.
The parking lot area includes a 60-foot turnaround area. An 8-foot, 9-gauge chain-link fence
with two 12-foot locked gates secures West Camp.
10.1.3 Routine Maintenance Tasks
Much of the maintenance of West Camp can be performed through visual inspection of the
system and associated components. Routine visual inspection enables operators to schedule
maintenance tasks before emergency maintenance is required.
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On a bi-weekly basis the following general site tasks will be performed:
1. A general visual inspection of the West Camp area will be performed;
2. Check for signs of trespass or vandalism including breaches in the fencing, gate or building
locks;
3. Check for building damage due to trespass, vandalism or natural occurrences;
4. Check for signs of damage to any well-heads;
5. Check for any obvious signs of theft;
6. Check for signs of drainage erosion; pick up trash from the site and access road;
7. Assure that the site signs (H2S Warning and Site Contact) are not damaged or stolen and
replace them as necessary; and
8. Road and culvert maintenance and weed control will be performed annually.
10.1.3.1
Piping
On a bi-weekly basis the following task will be performed:
1. Make a visual inspection of all piping (4ʺ-DI-WC001) at the WCP-1 looking for leaks,
cracks, or breaks in the piping system.
10.1.3.2
Electrical Systems
The following tasks are performed bi-weekly:
1. Make a visual inspection of all electrical systems at West Camp; and
2. Confirm that all electrical systems (meters, alarms, etc.) are being supplied with power.
Annually:
1.
Inspect all exposed cords and wiring for breaches in the protective insulated covering; and
2.
Inspect all conduit, junction boxes, etc. to ensure proper condition and function.
10.1.3.3
WCP-1 Pump (P-WCP-1)
The Goulds submersible pump requires no scheduled maintenance. In fact, it should be left in
place unless obvious signs of malfunction occur.
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10.1.3.4
Valves (BFV-WCP5009)
Visually inspect valve connection, stem and packing at the valve handle, and valve body for
obvious signs of leakage. Every five years, remove and inspect seats, seals, and gate for
excessive wear and corrosion on the 4-inch Mueller LINESEAL® Butterfly Valve (BFVWCP5009). Repair or replace as necessary.
10.1.3.5
Greenheck Exhaust Fan (EL-WCP107)
Every six months, the exhaust fan should be inspected. Lubricate the motor sleeve bearings,
using S.A.E.>20 non-detergent oil (Appendix G). In addition, clean accumulated dirt off the
propeller, motor guard, and shutter.
10.1.3.6
H2S Monitoring System (AIT-WCP5000)
On a monthly basis, perform the low flow alarm test described in the Detcon H2S Sensor User’s
Manual (Appendix G). This instrument is listed on the PSD checklist.
Every six months calibrate the H2S meter as described in the Detcon H2S Sensor User’s Manual
(Appendix G).
10.1.3.7
Flow Meter and Totalizer (FIT-WCP5006)
After two years of use the initial maintenance should be performed, including inspection of the
flow meter. The frequency of subsequent maintenance inspections can be determined by the
condition of the meter upon the initial inspection.
After five years of use, inspect the complete meter for wear and corrosion. See the McCrometer
UltraMag® Flow Meter Operation and Maintenance Manual (Appendix G) for complete
maintenance details.
10.1.3.8
Dwyer Pressure Gage (PI-WCP5013)
The Dwyer stainless steel pressure gauge should be inspected monthly for verification of proper
operation and evidence of leakage around and near seals and couplings. The pressure gauge
should be maintained according to the user’s manual (Appendix G).
10.1.4 Schedule of Task Performance
Routine operational maintenance is based on daily, weekly, bi-weekly, monthly, quarterly, and
semi-annual intervals. Intervals longer than those listed are considered non-routine. Non-routine
maintenance items are discussed in Volume V, Maintenance Manual. The inspection and
maintenance program will be updated when new inspection and maintenance tasks are defined as
the result of on-going operations.
10.1.5 Equipment
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Individual equipment manuals and other documentation provided by the manufacturers’ are
included as supplements to this O&M Plan. A listing equipment and equipment datasheet
documentation is provided in Appendix E. Appendix G contains manufacturer’s equipment data,
which will be maintained and stored within the WCP-1pump house. Specific instructions related
to maintenance, replacements, or repairs are provided in the Maintenance Manual. Refer to the
Maintenance Manual, Volume V, for additional information.
10.1.6 Records and Record Keeping
The current date, time, flow rate, and totalized flow should be recorded in the WCP Weekly
Operation and Field Parameter Record at the time of any flow adjustments or pump tests. The
maintenance records are kept and maintained at the BTL Operations Building.
10.2
Spare Parts Inventory
Spare parts kept for West Camp are maintained in a dedicated location at LAO. Critical spare
parts are also identified in Volume V, Maintenance. A spare pump and variable speed drive are
maintained in inventory to allow timely replacement of the pump at West Camp.
Items retained in spare parts inventory are available in Table 1.
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11.0
EMERGENCY PROCEDURES
In case of injury to personnel at the site, please refer to the BTL Site Specific Health and Safety
Plan (SSHASP) (Pioneer, 2010). The quickest route to the hospital is included in Appendix K,
and should be reviewed and understood by all site personnel. To contact ambulance, fire,
rescue or police call 911. Provide the address “526 Centennial Avenue.” Contact personnel
and notification information is located in Section 1.4 of this document and also in the SSHASP.
11.1
Alarm Response Notification
Alarms associated with most of the inputs monitored at West Camp notify the operator(s)
immediately after an upset, malfunction, or maintenance issue occurs. These alarms 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 (PRIMARY OR SECONDARY).
•
PRIMARY alarms dial out a notification if the upset, malfunction, or maintenance issue
continues after 2 minutes (120 seconds); and
•
SECONDARY alarms dial out until after 10 minutes (600 seconds) of the upset, malfunction,
or maintenance issue.
Callout priority for each alarm is shown in the Alarms List located in Table 2. 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
addressed on the next operator visit.
11.2
Alarm Conditions
Alarm conditions have been established as part of the automatic control system located at the
BTL Operations Building. Table 2 provides a list alarm conditions that may be encountered at
West Camp. Instruments and alarm set points are also provided in Volume I.
11.2.1 Fire
A 5-pound ABC fire extinguisher is located within the pump house at West Camp. The
extinguisher is effective on wood, electrical, and chemical fires.
If a fire occurs at the West Camp Pumping Station an attempt should be made to extinguish the
fire if it is of manageable size. If the main power switch can be reached safely, the power should
be shut off immediately. Extinguish the fire with the ABC fire extinguisher located on site.
Remain at the site until it is certain that the fire has been completely extinguished. Secure the
site as necessary and notify proper personnel.
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If the fire is not of manageable size, the fenced perimeter should be vacated and the local fire
department should be contacted by dialing 911. If the main power switch can be reached safely,
the power should be shut off prior to evacuating the site. To leave the fenced perimeter, exit
through either of the two gates located at the west and east walls of the fence. The gates lock
from the outside, therefore personnel must leave through the gate that has been opened to allow
entry. Under no circumstances should both gates be locked with personnel inside the
fencing. To evacuate the area walk quickly, taking the most direct route to the open gate. Once
outside the perimeter fence and at a safe distance from the fire, dial 911 to notify the local fire
department of the fire. Give the address as “526 Centennial Avenue, Butte.”
11.2.2 Electrical Lines Disturbances
If an overhead electrical line is down at West Camp, do not approach the electrical line. Do not
attempt to enter the fenced area and do not approach the fence. Remain well away from the
electrical line; dial 911 to notify proper officials. Give the address as “526 Centennial Avenue,
Butte.”
If an electrical line should drop while personnel are inside the fenced perimeter, stay away from
the downed line. If the line is across the fence do not attempt to leave the fenced perimeter. Dial
911 to notify proper officials. Give the address as “526 Centennial Avenue, Butte.” Wait for
emergency response personnel to arrive and provide assistance.
11.2.3 H2S Alarm
In the unlikely event that H2S levels in the pump house exceed 10ppm, dial 911 to notify
officials of the nature of the alarm (elevated H2S concentrations), so that responders will be
equipped with proper PPE. Personal protective equipment for high H2S atmospheres consists of
a self-contained breathing apparatus (SCBA). Responders should also be prepared to deal with
an explosive atmosphere. Although it is possible to monitor the H2S remotely through the HMI
system at the BTL, a site visit remains necessary to determine/confirm actual H2S
concentrations. Excessive H2S concentrations can be lethal and explosive, therefore under no
circumstances should the site be entered until emergency responders have determined that it is
safe.
11.2.3.1
H2S Alarm Site Response
If upon arriving at West Camp the H2S alarm is activated, evacuate the site immediately by
moving upwind. Refer to site windsock for current wind direction.
** NOTE: At high H2S concentrations, the sense of smell is lost, thus it is not a reliable
indication of safe conditions. **
After evacuating the area, immediately dial 911 to notify proper officials. Inform officials of the
alarm and of the high H2S condition (high H2S concentrations) so that responders will be
equipped with proper PPE. Under no circumstances should the site be entered until emergency
responders have determined that it is safe.
If the H2S alarm is activated while inside the West Camp pump house, immediately open the
door and check the digital readout on the H2S meter. If the readout is below 20 ppm the area is
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safe, but keep the door open. Reset the alarm. If the readout on the H2S meter is above 20 ppm
evacuate the site immediately by moving upwind. Dial 911 to notify proper emergency response
personnel. Inform officials of the alarm and of the high H2S condition. Under no circumstances
should the site be entered until emergency responders have determined that it is safe.
11.3
Emergency Shutdown
In the event of the need to shutdown pumping at West Camp due to piping failure, fire, or other
cause, pumping operations will be suspended through remote operations located at the
Operations Building at LAO. There is no need to enter the site to initiate emergency shutdown
procedures. Normal shutdown sequence will be followed through remote, computer controlled
operation. Refer to SOP-42 step #3b (Appendix F) and set the pump status to OFF. Continue to
monitor West Camp level for the duration of the shutdown.
11.4
Waste Handling and Disposal
West Camp is essentially a transfer pumping station utilizing WCP-1. No chemicals are used,
added, or stored at this location. Associated equipment requires minimal amounts of lubricants
or additional compounds to be used in maintenance of the equipment. These fluids are typical of
industrial equipment (oil, coolant, etc.). Waste generated at this site is expected to be associated
with data verification tasks such as litter, paper, etc. Waste at this site shall be collected and
placed in an appropriate receptacle and finally transported to the landfill. Material Safety Data
Sheets (MSDS) for all compounds used or stored at West Camp is located in the SSHASP.
In the event that controlled waste is used, found, or generated at this site, contact the Atlantic
Richfield Project Manager, Pioneer Project Manager, and Pioneer Safety Officer for further
instructions. Refer to Section 1.4 for contact personnel.
11.5
Emergency Back-up Pumping System
In the event of loss of pumping capabilities at WCP-1, and water level rising to a level that
would meet or exceed 5,435 feet amsl, the Travona pumping system can be utilized to provide
short-term pumping capability. The Travona pumping system has a submersible pump already
submerged to operating depths and electrical provisions made to the pump. Electrical provisions
must be completed at the electrical disconnect to make the pump operable. In addition,
temporary piping modifications, and a water truck must be available at the site in order to
operate this system. All water pumped from the Travona system will be captured and treated at
the BTL-LAO treatment system. Groundwater will not be routed to the BSB Water Treatment
Plan. Operation of this system will be made available, and placed on stand-by status, when
modifications are made to WCP-1. Operation of the Travona system will be implemented when
water level of the West Camp reaches 5,434 feet amsl. Refer to Figure 3, WCP-DT-1, West
Camp Decision Tree, for guidance when to implement the Travona pumping system.
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12.0 REFERENCES
AERL, 1998a. Work Plan for West Camp Groundwater Extraction System.
AERL, 1998b. Completion Report for the West Camp Extraction System, Butte Mine Flooding
Operable Unit.
AERL, 2001. Sampling and Analysis Plan for Field-Scale Treatability Study Base Flow and
West Camp Water Work Plan, AERL, 2001.
ARCO, 1992a. Clark Fork River Superfund Site Investigations (CFRSSI) Standard Operating
Procedures (SOPs). September 1992.
ARCO, 1992b. . Clark Fork River Superfund Site Investigations (CFRSSI) Quality Assurance
Project Plan (QAPP).
ARCO, 1993. Clark Fork River Superfund Site Investigations (CFRSSI) Laboratory Analytical
Plan.
Atlantic Richfield Company, 2006a. Operations and Maintenance Manual West Camp Pumping
System Revision 1. September 22, 2006.
Atlantic Richfield Company, 2006b. Draft Butte Treatment Lagoons (BTL) Systems at Lower
Area One (LAO) Construction Completion Report. April, 2006.
Atlantic Richfield Company, 2010. Draft Final Butte Treatment Lagoons (BTL) and West Camp
Pump Station (WCP-1) Upgrades Design Report/Work Plan. September 9, 2010.
BP, 2009. Site Remediation Technologies Engineering Integrity Manual. January 2009
EPA 1986. Superfund Remedial Design and Remedial Action Guidance, OSWER Directive
9355.0-4A, June 1986.
EPA, 2002. Butte Mine Flooding Operable Unit Site Consent Decree, CV O2-35-Bu-RFC.
August 14, 2002.
EPA, 2006. U.S. EPA Record of Decision for the Butte Priority Soils Operable Unit, Silver Bow
Creek/Butte Area NPL Site. September 2006.
MGMB, 2004. Montana Bureau of Mines and Geology Sampling and Analysis Plan, Butte
Priority Soils Operable Unit, 2004
Pioneer, 2010. Butte Treatment Lagoons (BTL) and Lower Area One (LAO)
Site Specific Health and Safety Plan for Operation and Maintenance (O&M) Activities,
February, 2010.
Piping Handbook 1992, 6th Edition, Nayyar, Mohinder L.
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Tables
Table 1.
Table 2.
Equipment and Spares Inventory
Alarm Notification Callout Priority
Figures
Figure 1.
Figure 2.
Figure 3.
Figure 4.
WCP and Missoula Gulch Site and Major Features
System Water Flow Schematic
Corrective Action and Troubleshooting Decision Tree, WCP-DT-1
Emergency Hospital Route from West Camp
List of Appendices
Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
Appendix G
Appendix H
Appendix I
Appendix J
Appendix K
System Design Drawings
System and Component Design Calculations
Administrative Order On Consent for West Camp/Travona System
Operator’s West Camp Reference Guide, BTL-LAO Operations Log
List of Equipment, PSDs
Standard Operating Procedures
Manufacturer’s Product Data
Johnson/US Filter Well Screen Information
Goulds Pump Model 250L15
Certa-LOK Pipe Literature
Variable Frequency Drive Pump Controller
MAASS Pitless Well Adapter
Chromolox Model HCH-251 Air Heater
Dwyer 2” SS Pressure Gage
McCrometer UltraMag® Flow Meter
Mueller LINESEAL® Butterfly Valve
Rosemount Water Level Measurement System
Detcon Model TP-624C H2S Monitor
Greenheck Exhaust Fan
Butte Remediation Evaluation System (BRES)
Seasonal Pumping Flow Rates
West Camp Retention Time/ Holding Capacity
Emergency Hospital Route from West Camp
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Appendix A – System Drawings
Drawing
Number
Drawing Title
Originator/
Company
Date
WCP-C-1
WEST CAMP PUMP STATION GENERAL SITE PLAN
PIONEER
3/25/2010
WCP-C-2
WEST CAMP ACCESS UPGRADES PLAN AND PROFILE
PIONEER
3/25/2010
WCP-C-3
WEST CAMP EXISTING CONDITIONS
PIONEER
3/25/2010
WCP-C-4
WEST SIDE SOILS, HAUL ROUTES
PIONEER
3/25/2010
WCP-D-1
WEST CAMP ROAD UPGRADES CROSS SECTIONS; STATIONS 0+00 THRU 0+75
PIONEER
3/25/2010
WCP-D-2
WEST CAMP ROAD UPGRADES CROSS SECTIONS; STATIONS 1+00 THRU 1+75
PIONEER
3/25/2010
WCP-D-3
WEST CAMP ROAD UPGRADES CROSS SECTIONS; STATIONS 2+00 THRU 2+75
PIONEER
3/25/2010
WCP-D-4
WEST CAMP ROAD UPGRADES CROSS SECTIONS; STATIONS 3+00 THRU 3+98
PIONEER
3/25/2010
WCP-D-5
WEST CAMP ROAD UPGRADES TYPICAL CROSS SECTIONS
PIONEER
3/25/2010
WCP-D-6
WEST CAMP ENGINEERED STORM WATER CHANNEL DETAILS
PIONEER
3/16/2010
WCP-D-7
WEST CAMP PUMP STATION FACILITY UPGRADES PLAN VIEW
PIONEER
3/25/2010
WCP-D-8
WEST CAMP PUMP STATION ELECTRICAL UPGRADES PLAN VIEW
PIONEER
3/25/2010
WCP-D-9
WEST CAMP PUMP STATION PLUMBING AND PIPE HOUSING DETAIL
PIONEER
3/25/2010
WCP-D-10
WEST CAMP PUMP STATION PIPE, FOOTINGS, AND SLAB DETAIL
PIONEER
3/25/2010
WCP-D-11
WEST CAMP PUMP STATION PITLESS ADAPTER AND MANHOLE DETAIL
PIONEER
3/25/2010
WCP-D-12
WEST CAMP PUMP PREFABRICATED CONCRETE BUILDING DETAILS
PIONEER
3/25/2010
WCP-D-13
WEST CAMP PUMP PREFABRICATED CONCRETE BUILDING DETAILS
PIONEER
3/25/2010
I&C-C-7
MSD PIPING AND INSTRUMENTATION DIAGRAM
PIONEER
12/22/2010
I&C-C-8
BRW DRYING BED PIPING AND INSTRUMENTATION DIAGRAM
PIONEER
12/22/2010
I&C-C-9
TYPICAL REMOTE STATION PIPING AND INSTRUMENTATION DIAGRAM
PIONEER
12/22/2010
I&C-G-3
BPSOU MONITORING LOCATIONS SITE MAP
PIONEER
12/22/2010
I&C-G-4
BTL-LOA PROCESS FLOW SCHEMATIC
PIONEER
12/22/2010
I&C-G-5
PROCESS INSTRUMENTATION AND CONTROL COMMUNICATION PATH
PIONEER
12/22/2010
D46-15IN-023
LAO, WEST CAMP STATION ONE LINE DIAGRAM & CONDUIT SCHEDULE
MSE/ TG
8/16/2010
D46-15IN-024
LAO, WEST CAMP STATION POWER GENERAL ARRANGEMENT
8/16/2010
D46-15IN-025
LAO, WEST CAMP STATION SCADA PANEL LAYOUT
MSE/ TG
MSE/ TG
D46-15IN-026
LAO, WEST CAMP STATION TERMINAL BLOCK LAYOUT
D46-15IN-027
LAO, WEST CAMP STATION POWER DISTRIBUTION
D46-15IN-028
D46-15IN-029
LAO, WEST CAMP STATION I/OMODICON #1 PIN LAYOUT
LAO, WEST CAMP STATION I/OMODICON #2 PIN LAYOUT
D46-40IN-001
LAO CHEMICAL ADDITION SYSTEM BUILDING SCADA PANEL
D46-40IN-002
LAO REMOTE SYSTEM SCADA PANEL
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
MSE/ TG
MSE/ TG
MSE/ TG
MSE/ TG
MSE/ TG
MSE/ TG
Page 47 of 45
8/17/2010
8/18/2010
8/19/2010
8/20/2010
8/21/2010
12/15/2010
12/15/2010
Appendix B – System and Component Design Calculations
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 48 of 45
Appendix C – Administrative Order on Consent; West Camp / Travona
Shaft System
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 49 of 45
Appendix D – Operator’s West Camp Reference Guide
BTL-LAO Weekly Ops Report
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 50 of 45
Appendix E – Equipment Inventory,
Equipment Data Sheets
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 51 of 45
Appendix F – West Camp Standard Operating Procedures (SOPs)
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 52 of 45
Appendix G –Manufacturer’s Data
Johnson/US Filter Well Screen Information
Goulds Pump Model 250L15
Certa-LOK Pipe Literature
Variable Frequency Drive Pump Controller
MAASS Pitless Well Adapter
Chromolox Model HCH-251 Air Heater
Dwyer 2” SS Pressure Gage, Model SGB
4” McCrometer UltraMag Flow Meter
4” Mueller LINESEAL® Butterfly Valve
Rosemount Water Level Measurement System
Detcon Model TP-624C H2S Monitor
Greenheck Exhaust Fan
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 53 of 45
Appendix H – Butte Remediation Evaluation System
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 54 of 45
Appendix I – Seasonal Pumping Rates
Under development
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 55 of 45
Appendix J –West Camp Retention Time/Holding Capacity
Under development
Draft Volume III West Camp Pump Station/Missoula Gulch
Operation, Maintenance, and Monitoring Plan
Page 56 of 45
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