Case study - Superfund site, water pump & treat system

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Courtesy of Anguil Environmental Systems, Inc.

Anguil Aqua Systems LLC was contracted as part of a team of companies to implement a ground water pump and treat system intended to remove trichloroethylene (TCE) from a local aquifer designated as a Superfund Site by the Environmental Protection Agency (EPA). Though the site is nestled between the buildings and roadways of an existing and operating industrial facility, the overall extent of the pump and treat system is expansive. Extraction wells are located over 1,000 ft. from the treatment building and there is an additional 1,200 ft. of separation to the injection wells. All the water treatment equipment and main control system was designed to be contained within the new treatment building, while control panels located at the extraction and injection areas were to provide local control and monitoring of the appropriate wells.

The 500 gallon per minute (GPM) pump and treat system, as well as the overall site plan, were designed by a large engineering, procurement and construction (EPC) firm working on behalf of the responsible party. A general contractor and dedicated installation sub-contractor were selected to prepare the site, drill the extraction and injection wells, install the underground conveyance piping, erect the pre-fabricated treatment building, install the treatment equipment and perform all the interconnecting piping.

Anguil was contracted for two phases of this project. During the design and approval portion, they were asked to review the electrical design and system controls. They also provided and reviewed the system controls specifications to facilitate approvals from the EPA and Army Corps of Engineers. For the construction phase, Anguil engineers were utilized to provide and manage the delivery of all the water treatment and water logistics equipment, including the control system and control panels. Furthermore, during the construction phase, Anguil field service engineers provided installation and shakedown assistance for the entire system. In regards to the equipment, Anguil’s scope of supply included all valves, process instruments and transmitters, water treatment equipment, the exhaust stack, storage tanks, pumps, chemical injection system, motor control system, main building control panel as well as two remotely located panels at the extraction and injection well sites. Further, to the largest extent possible, Anguil was directed to supply the equipment skid mounted, pre-plumbed and prewired.

Anguil was able to bring additional value to this project by successfully managing the multiple vendors of both the water treatment and controls equipment for the EPC. In particular, they were able to find low-cost, expedited options to meet the aggressive construction schedule mandated by the EPA penalty deadlines, in some cases cutting long lead times in half. Having a custom solutions integrator on this project was especially valuable when major, unforeseen factory delays occurred. By effectively communicating with the construction team, schedules and resources were adequately adjusted. Further, Anguil was able to manage discrepancies between the selected vendor’s products and customer specifications, achieving the design specifications without sacrificing performance.

Throughout the project, Anguil provided onsite engineering assistance suggesting inexpensive changes, such as relocation of instrumentation or alternate piping plans to the equipment, which improved operations and maintenance activities. From an engineering standpoint, they were able to recommend improvements to customer specifications based on operational experience. These improvements included recommendations to upgrade materials of construction, alterations to process instrumentation, upgrading the size of the control panel touch screen to effectively display control parameters, and addition of important safety features. Furthermore, elimination of the redundant vendor supplied control panels was accomplished by integration of logic into a Anguil supplied main system control panel. Lastly, because of site considerations, Anguil suggested substitution of the originally specified radio communications between the main control panel and remote injection well control panel with fiber optic connectivity. This ultimately resulted in a reduction of Anguil’s scope of supply, but greatly improved the system robustness and reliability.

As the project progressed, Anguil worked with the EPC engineer on several customer-driven change orders. Most significantly, they worked with the EPC to specify and source additional flow meters for the injection well piping that were capable of accurate operation within the space constraints (limited straight run) dictated by the pre-fabricated concrete well vaults. Additionally, Anguil managed ripple effect design changes including upgrading the effluent pump capacity, the motor control center and additional input/output cards for the local control panel – these changes were accomplished with no effect on the overall equipment delivery schedule.

In preparation of system start-up and shake down, Anguil on site personnel verified that all equipment was installed per manufacturer recommendations and was operating correctly. In several instances, they were able to identify equipment which had been installed improperly, delivered incorrectly or specified imprecisely. In most cases, these discrepancies were rectified quickly at no cost to the customer. As Anguil personnel accommodated continuing construction activities, PLC program operation was verified and altered as necessary to provide adequate system control. The final result was a turnkey system that meet customer requirements for their commissioning schedule and operational characteristics so the project could start on time and in budget.

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