Issue 1.2C Jan 06

ENVIRONMENTAL PUMPING SYTEMS

Art. no.: 12.60

O P E R A T I O N & M A I N T E N A N C E M A N U A L

PNEUMATIC PISTON PUMP FOR PRODUCT SKIMMING LNAPL & DNAPL RECOVERY TOTAL FLUIDS DISSOLVED PHASE RECOVERY LANDFILL LEACHATE LANDFILL GAS CONDENSATE GROUNDWATER PURGING INCORPORATING THE GEOSKIMMER

M2.12.60.E

P.O. Box 4, 6987 ZG Giesbeek Nijverheidsstraat 30, 6987 EM Giesbeek, The Netherlands T +31 313 880200 F +31 313 880299 E [email protected] I http://www.eijkelkamp.com

1.1 Manual Layout This1.2C operating Issue Jan 06 and maintenance manual is divided up into the following major sections, each dealing with specific topics as follows:-

SECTION 1

CONTENTS

SECTION 2

HEALTH AND SAFE TY General section which applies the specific Health and Safety issues applicable when using the PosiFlo (= art. no.12.60).

SECTION 3

INTRODUCTION Introduces the manual.

SECTION 4

GENERAL DESCRIPTION General description of the PosiFlo, how it works and an overview of the applications which it can be used for.

SECTION 5

INSTALLATION Instructions on how the PosiFlo should be installed including accessories and pipework systems.

SECTION 6

TYPICAL APPLICATIONS Use of the PosiFlo for Product Only Skimming, LNAPL recovery, Total Fluids. DNAPL & dissolved recovery, landfill leachate and condensate and groundwater monitoring.

SECTION 7

ADDI TIONAL EQUIPMENT Compressed air, dryers, air receiver and filters, fittings and accessories.

SECTION 8

MAINTENANCE At-a-glance guide to essential maintenance and repairs which may be required in the field.

SECTION 9

FAULT FINDING Information on how to identify faults in the PosiFlo.

SECTION 10

SPARE PARTS Full details of component parts including exploded diagrams to help identify any spare parts that may be required.

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Issue 1.2C Jan 06

1.2 SECTION CONTENTS

1 1.1 1.2

CONTENTS Manual layout Section contents

Page 2 2 3

2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2 2.6 2.6.1 2.6.2 2.7 2.7.1 2.8 2.9 2.10 2.11

HEALTH AND SAFE TY Control of substances hazardous to health (COSHH) Safety policy Conformity Markings Servicing and maintenance Disclaimer Operators and service engineers Hazard signals and signs Hazard signal words Hazard symbols used in the manual Risk a ssessment Risk a ssessment for working on contaminated land Safety specifications & precautions General introduction to groundwater remediation General introduction to landfill condensate & leachate Good working practices

5 5 5 6 6 6 6 6 7 7 7 8 8 9 10 10 11

SECTION

3

INTRODUCTION

12

SECTION

4 4.1 4.2

POSIFLO GENERAL DESCRIPTION How it works General specifications

12 12 13

SECTION

5 5.1 5.2 5.3 5.4 5.5 5.6

INSTALLATION Product/liquid depth measurement Preparing the pump Hose assembly Preparing air supply Check cycle Placing pump in well

14 14 14 15 15 15 15

SECTION

6 6.1 6.2 6.3 6.4 6.5

TYPICAL APPLICATIONS Product only skimming Total fluids Leachate - bottom filling Leachate - top filling Condensate

16 16 17 18 19 20

SECTION

7 7.1 7.2 7.3 7.4 7.4.1 7.4.2 7.5 7.6

ADDI TIONAL EQUIPMENT Compressed air Dryers Air receiver & filters Fittings Tubing & hoses Assembly of fittings & hoses Connecting to PosiFlo Accessories

21 21 21 21 22 22 22 23 24

SECTION

SECTION 2

Contd ov er

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Issue 1.2C Jan 06

1.2 SECTION CONTENTS contd

Page SECTION

8 8.1 8.2 8.3 8.6 8.7 8.8 8.9

MAINTENANCE Pump maintenance PosiFlo dis-assembly PosiFlo re-assembly Cleaning the cycle counter Maintaining compressed air supply Maintenance of air filter/regulator Maintenance schedule

25 25 26 27 30 30 30 31

SECTION

9

FAULT FINDING

32

SECTION

10 10.1

SPARE PARTS PosiFlo spares

33 33

SECTION

11 11.1 11.1.1 11.1.2 11.2 11.3 11.4

RETURN OF GOODS Returns procedure Chargeable Service & repairs Warranty Claim Packaging & carriage Transport & storage Limited Warranty

38 38 38 38 38 38 39

SECTION

12

APPENDIX

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Issue 1.2C Jan 06

2.0

HEALTH AND SAFETY Safety is very important when using any mechanical equipment and this section should be read by anyone installing or using the PosiFlo and associated accessories. This section applies to all areas of application that the PosiFlo is intended for particularly groundwater remediation and the pumping of landfill leachate and condensate. Included in this section are details on warning symbols, good working practices and information on the European Union (EU) legislation regarding “Control of Substances Hazardous to Health” (COSHH) and risk asse ssment of the working environment found in the above applications.

2.1

Control of Substances Hazardous to Health (COSHH) The EU legislation regarding the Control of Substances Hazardous to Health requires MGS Ltd to monitor and assess every substance entering or leaving their premises. Consequently any returned goods of whatever nature must be accompanied by a declaration form found on page 51of the index reference QF/038. Without this declaration MGS Ltd reserves the right not to handle the item.

2.2

Safety Polic y This section contains important information relating to all health and safety aspects of the PosiFlo. As such it should be read and understood by all personnel using the PosiFlo either as an operator or in a service capacity. EAE is committed to providing a safe working environment for its employees and all those who use any of its products and conducts its business responsibly, and in a manner designed to protect the health and safety of its customers, employees and the general public. EAE regularly reviews its operations to make environmental, health and safety improvements in line with UK and European Community legislation. The PosiFlo has been designed to be installed within a borehole. EAE cannot be held responsible for any damage, injury or consequential loss arising from the use of its PosiFlo for any other purposes or any unauthorised modifications made to the product.

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Issue 1.2C Jan 06

2.3

Conformity

The PosiFlo is supplied in a form that it complies with:Machinery Directive 98/37/EC Equipment intended for use in Potentially Explosive Atmospheres (ATEX) 94/9/EC Equipment description Make/Brand Models

Pneumatic pump PosiFlo PosiFlo 48 PosiFlo 46

Compliance with the essential health and safety requirements of the directives has been asse ssed by reference to the following harmonised standards: ♦ ♦ ♦

2.4

BS EN 809:1998 Pumps and pump units for liquids – Common safety requirements BS EN ISO 16330:2003 Reciprocating displacement pumps and pump units – Technical requirements BS EN 13463-1:2001 Non-electrical equipment for potentially explosive atmospheres – Part 1: Basic method and requirements.

Markings

In accordance with the above conformities the PosiFlo is labelled with the following information and symbols:-

• •

2.5

PosiFlo Serial number

Servicing

2.5.1 Disclaimer All service/repair work on the PosiFlo, its associated accessories and compressors should only be carried out by suitably trained personnel. EAE cannot be liable for damage, injury or consequential loss resulting from servicing from unqualified personnel. EAE will also not be liable for damage, injury or consequential loss re sulting from incorrect operation or modification of the PosiFlo.

2.5.2 Operators and Service Engineers A normal operator of the PosiFlo will not be trained in or qualified for service work on the equipment and may cause unnecessary damage/problems when trying to dismantle the pump especially if excessive internal deposits are present. EAE advises either that an authorised repairer is contacted to carry out such work or that the PosiFlo is returned to EAE for service/repair.

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Issue 1.2C Jan 06

2.6

Hazard signals and signs

2.6.1 Hazard Signal Words The two signal words are defined as:♦

CAUTION

Potentially hazardous situation or unsafe practice that, if not avoided could result in minor or moderate injury or damage to equipment.

♦

NOTE

Special attention should be made to ensure the correct operation or installation of the PosiFlo or accessories is carried out.

2.6.2 Hazard symbols used in manual Several hazard symbols are used within the manual to alert the operator to potential hazards associated with the installation, operation or servicing of the PosiFlo and their meaning is explained below:-

Note (refer to accompanying text)

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Issue 1.2C Jan 06

2.7

Risk assessment

2.7.1 Risk assessment for working on contaminated land and/or landfill sites Personnel working on remediation and/or landfill sites must appreciate that there are hazards associated with compressed air, contaminated groundwater, landfill gas, landfill condensate and leachate. Compressors or any other electrically operated equipment used must be either certificated intrinsically safe or located outside the hazardous zone.

ONLY SUITABLY TRAINED/QUALIFIED PERSONNEL SHOUL D CA RRY OUT WORK/SERVICE/REPAIRES TO PUMPING SYST EMS AND COMPRESSORS

WORK ACTIVITIES

SUBSTANCES INVOLVED

People involved in the installation, operation and monitoring of groundwater remediation, landfill leachate and condensate control systems. Contaminated groundwater - groundwater containing any type of material considered a danger to health. Landfill gas - asphyxiating & potentially explosive gas containing methane, carbon dioxide and minor contaminants. Condensate - liquid formed by cooling of LFG. High concentrations of dissolved organic matter and ammonia Leachate - liquid formed by rain percolating through waste. Depending on age, it contains high concentrations of dissolved organic matter and bacteria. Other major constituents are inorganic such as ammonia.

EXPOSURE

CONTROL MEASURES

!

Exposure to any of the above substances may occur when working on the pumping system. Direct inhalation of solvents, chemicals and landfill gas etc should be avoided where possible. If excessive inhalation occurs move quickly into an open area away from the source and seek medical advice. If direct skin contact with chemicals, condensate or leachate is likely, waterproof and/or chemical resistant gloves should be worn. Where a high level of exposure is anticipated, gauntlet style gloves, goggles, waterproof overalls or breathing apparatus should be worn.

ASSESSMENT OF RISK

The risk associated with this activity is low to high and site specific. Personnel should take the precautions necessary for each site.

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Issue 1.2C Jan 06

2.8

SAFETY SPECIFICATIONS & PRECAUTIONS

Safety information in this m anual is not intended to supersede local safety procedures, regulations, Perm it to Work or any other safety systems that m ay be in force.

The following hazards could potentially be present when operating groundwater remediation or landfill pumping systems. The information below is not a comprehensive list and is intended as a guide only. We recommend that full zoning and risk analysis be undertaken by the user. Fire and explosion due to ignition of flammable hydrocarbons, chemicals, solvents and landfill gas. This can be minimised by:1) Prohibiting smoking and the use or carrying of smoking materials on site. 2) Placing appropriate signs warning of the presence of flammable gas. 3) Preventing the use of spark or heat producing work. (e.g. welding, grinding etc). Hazards associated w ith hydrocarbons, chemicals, solvents and landfill leachate. This can be minimised by:1) Monitoring of air quality at the work location. 2) Wearing of appropriate protective clothing. 3) Never working on pumping systems when they are operating. Suffocation and biological hazards associated with the inhalation of hydrocarbons, chemicals, solvents and landfill gas. This can be minimised by:1) Monitoring of air quality at the work location. 2) Never work alone within confined spaces without the appropriate support equipment. 3) Always allow gas released during maintenance or monitoring to disperse before handling pumps or pipe work. Always stand upwind while gas disperses. 4) Always consider wearing an appropriate face mask. Hazards associated w ith compressed air. This can be minimised by:1) Designing and installing all systems in accordance with the United Kingdom Health & Safety Executive publication HS(G) 39 “Compressed air Safety” or other relevant National Standards. 2) Never allow a part of the body (e.g. hand) to interrupt a flow of compressed air even at low pressure. 3) Never open valves when under pressure and disconnected. Always think ahead and find a safe route for the discharge of compressed air. 4) Check the complete system regularly from time to time for air leaks and repair where necessary. 5) Always isolate the electrical supply before working on the compressor. 6) Avoid releasing large volumes of air quickly as icing may occur which will result in ice particles being expelled at high velocity. 7) Use eye protection when operating or servicing pneumatic equipment. 8) Wear protective gloves when performing maintenance operations that may involve contact with mineral oil lubricant.

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Issue 1.2C Jan 06

2.9 General introduction to Groundwater Remediation Groundwater remediation is a collective term used for several techniques where contaminants (typically refined hydrocarbon, solvents etc) are removed from groundwater as part of an environmental cleaning process. The PosiFlo is an inherently safe, pneumatic pump has been designed to safely pump contaminants found within groundwater as follows:LNAPL* recovery

When product thickness is large the intake can be positioned just above the oil/water interface for fast initial removal and then a skimmer can be used. *LNAPL is Light Non-Aqueous Phase Liquid

Total fluids

By placing the inlet just below the oil/water interface both LNAPL and water can be recovered. Advantages are that by drawing down the water level the maximum amount of product can be removed but it will need to go through an additional treatment process.

Dissolved

Water containing dissolved contaminants can be pumped out by positioning the pump intake strainer at the required level.

Groundwater remediation involves the pumping of m any different types of contam inants which can vary in viscosity, specific gravity and chem ical composition. The PosiFlo has been designed to be resistant to the majority of chem ical contam inants so far found w ithin groundw ater but there m ay be instances when new or unknown m ixtures of chem icals occur. Under these conditions, a full risk analysis should be carried out. For additional advice, please contact EAE.

2.10 General introduction to Landfill condensate and leachate Landfill condensate Landfill de-gassing systems create a liquid known as “condensate” which if not removed from the extraction pipe work causes blockages and failure of the gas extraction system. Condensate is typically removed by installing condensate knock-out pots (KOP) at low points within the gas extraction pipe work. These consist of HDPE vessels with an internal pipe into which the PosiFlo can be installed for pumping out of the condensate.

Landfill leachate Rain passing down through landfill waste becomes contaminated with organic and inorganic substances and the resulting liquid is known as leachate. In order to minimise the risk of groundwater contamination the level of leachate in a landfill site must be kept to a minimum and therefore leachate is pumped out from vertical wells. The PosiFlo can be used to pump leachate from wells as deep as 60 metres. The composition of landfill leachate is very variable due to the wide range of materials placed within landfill site. The PosiFlo is constructed from leachate resistant materials to ensure minimum maintenance and maximum life. Under EU legislation the level of leachate should not exceed 1 metre above the basal sealing level and therefore the PosiFlo is an important tool to ensure that landfill sites remain within the EU environmental consent conditions.

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Issue 1.2C Jan 06

2.11

Good working practices

It is essential that good working practices are adopted at all times on site when installing, operating or servicing the PosiFlo and associated equipment. The following information is not intended as a complete guide to Good Working Practices, but is provided for information purposes to give an indication of the areas for consideration.

Some simple good practice rules are:♦

If in doubt, don’t

♦

If in doubt, ask

♦

Alw ays advise someone you are on site

♦

Alw ays turn off and isolate any electrical equipment before working on it

♦

Alw ays depressurise the compressed air lines before attempting to w ork on the PosiFlo

♦

Alw ays adhere to the local site safety rules & regulations

♦

Alw ays wear the correct PPE w hen w orking on site

♦

When handling liquids containing volatile organic compounds, alw ays wear suitable PPE and only w ork in a well ventilated area.

♦

Never enter a potentially confined space unless qualified and have adequate breathing apparatus

♦

Mop up any spillages immediately

♦

Dispose of substances in an appropriate m anner

♦

Use the correct tool for the job

♦

Keep a straight back and bend from the knees when lifting heavy objects

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Issue 1.2C Jan 06

3.0 INTRODUCTION This manual is intended for all users of the PosiFlo and provides information on the installation, operation and maintenance of the PosiFlo. Please note that the servicing and maintenance procedures should only be carried out by qualified service personnel and it is essential that all users should read the Health and Safety section of this manual.

4.0 POSIFLO GENERAL DESCRIPTION The Posi-Flo 48 is an automatic, inherently safe pneumatically operated piston pump which can be used for a wide range of applications including groundwater remediation and landfill where explosive environments exist. Since it can be used over such a wide range the specification for the pump and equipment will vary according to the application and site conditions (see section 5). It is important therefore to identify your particular application to ensure the correct installation specification and operation. Features ·

· · · · ·

The Posi-Flo is a positive displacement pump with an automatic pneumatic timer, to pulse at given intervals. The PosiFlo 48 has the timer in-built whereas the PosiFlo 46 has a separate timer housing which is mounted at the surface. Fully pneumatic operation with no electrical components. Manufactured from leachate resistant materials to provide reliability and longevity. Major components are manufactured from stainless steel, acetal, and viton. It is easy to take apart and clean in the field without the need for any special tools, making maintenance quick and easy. It can easily fit inside a 2” well.

4.1 HOW IT WORKS The pump is lowered into the liquid, which enters through the inlet screen via the bottom check valve into the pump body. A pulse of air, which is controlled by the automatic timer inside the pump operates the piston. This displaces the liquid up and through the top non return valve via the discharge pipe to the surface. The pulse of air is then exhausted, the piston then returns to its original position by a spring and the pump is then ready for the next stroke. The automatic timer cycle rate is factory set to operate at the optimum pulse for each application as follows:Product skimming

4 seconds

LNAPL & Total fluids

2 seconds

DNAPL

5 seconds

Landfill condensate

5 seconds

Landfill leachate

2 seconds

N.B The timer can be adj usted on site to suit application (see section X).

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4.3 GEOSKIMMER GENERAL DESCRIPTION The GeoSkimmer is a system designed to actively recover free floating hydrocarbon (LNAPL) from groundwater. It consists of a combination of floating intakes of either type HP or type RD. Both types of floats are interchangeable and can be easily changed on site to suit the application. It is used in combination with the PosiFlo 48.  FLOAT TYPE HP A hydrophobic intake screen which allows only hydrocarbon to pass through the filter and into the recovery pump. It can reduce the product layer down to a sheen (0.25 mm) depending on the viscosity and specific gravity.  FLOAT TYPE RD Specially designed float which allows product to enter and pass down the coiled flexible tube to the recovery pump. High recovery rates are achievable but depending on the specific gravity of the product may leave a residual layer up to 25 mm. The choice of floating intake will depend on the type of product being pumped and as many are often mixtures of several types the final choice may only be defined by site trials. Installing a GS50 GeoSkimmer

4.4 HOW IT WORKS  The GeoSkimmer has a floating intake that can follow any fluctuating water table level up to 1000 mm. Floating hydrocarbon enters through either the hydrophobic filter (HP) or through the intake (RD), down through a flexible tube, and is drawn up into the product pump. The product pump then pumps to a storage tank or suitable discharge point.  Active product recovery requires the GeoSkimmer to operate together with an automatic down-well Posi-Flo 48 product recovery pump which can recover product up to depths of 76 metres. The flow rate of the GeoSkimmer system can be altered to suit differing well yields.

4.5 GEOCANISTER GENERAL DESCRIPTION The GeoCanister is a passive, floating skimmer device designed to separate and recover light hydrocarbons (LNAPL) such as gasoline and diesel from groundwater. Featuring a floating hydrophobic filter buoy, the GeoCanister will automatically adjust to any water fluctuation up to 500 mm.

4.6 HOW IT WORKS It consists of two major components; a product GeoSkimmer and a collection canister. The GeoSkimmer collects the free product and it then passe s down the coiled tube into the canister below. Product is removed by removing the GeoCanister from the well and opening the drain on the bottom. Alternatively the 4” version can be upgraded in the field to an active system and coupled to a Posi-Flo 48 pump

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Issue 1.2C Jan 06

4.5 GENERAL SPECIFICATIONS - POSIFLO

MODEL

PosiFlo 48

PosiFlo 46

Autotimer 46

Pump type Fluid intake

Pneumatic Bottom fill

Pneumatic Bottom fill

Not applicable Not applicable

Max outside diameter Length

48 mm 800 mm

46 mm 400mm

48mm 320mm

Materials of construction

Stainless steel 316 Teflon Acetyl Viton Aluminium

Stainless steel 316 Teflon Acetyl Viton Aluminium

Stainless steel 316 Aluminium Viton

Air inlet/vent size

1/8” - 1/8” BSP

1/8” - 1/8” BSP

1/8” - 1/8” BSP

Fitting type

One-touch Compression Quick connect

One-touch Compression Quick connect

One-touch Compression Quick connect

Air supply tube OD*

6 mm

6 mm

6 mm

Air v ent tube OD*

6 mm

6 mm

6 mm

Discharge size

1” BSP

1” BSP

Not applicable

Discharge tube OD*

16 mm

16 mm

Not applicable

Average v olume/cycle

0.08 litres

0.08 litres

Not applicable

Max flow rate***

320 litres/min

28 litres/min

Not applicable

Max operating Pressure****

8 bar

8 bar

8 bar

Min operating pressure

3.5 bar

3.5 bar

3.5 bar

SG fluid range**

0.7 - 1.5

0.7 - 1.5

NA

Max operating noise level dB(A)

< 65

< 65

< 65

Weight Kg

2.5

2.0

0.5

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Issue 1.2C Jan 06

4.6 GENERAL SPECIFICATIONS - GEOSKIMMERS

MODEL

GS-50-500

GS-50-1000

GS-100-500

GS-100-1000

Max outside diameter

45 mm

45 mm

45 mm

45 mm

Ov erall length

750 mm

1640 mm

750 mm

1600mm

Materials of construction

Stainless steel 316 Nylon PVC Polyethylene

Stainless steel 316 Nylon PVC Polyethylene

Stainless steel 316 Nylon PVC Polyethylene

Stainless steel 316 Nylon PVC Polyethylene

Fitting type

Quick connect

Quick connect

Quick connect

Quick connect

Float range

500 mm

1000 mm

500 mm

1000 mm

Minimum water depth required for operation

570 mm (HP) 554 mm (RD)

570 mm (HP) 554 mm (RD)

488 mm (HP) 463 mm (RD)

488 mm (HP) 463 mm (RD

Weight Kg

2.5

3.0

3.5

4.0

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Issue 1.2C Jan 06

5.0 INSTALLATION Since the PosiFlo can be used over such a wide range of environments and in a number of different applications, the specification for the pump and equipment will vary according to the application and site conditions. It is therefore important to identify your particular application to ensure the correct installation specification and operation as detailed in section 6.0.

PRIOR TO INSTALLATION THE DEPTH TO PRODUCT(LNAPL) AND THE DEPTH OF PRODUCT (LNAPL) AND/OR THE DEPTH TO LIQUID SHOULD BE MEASURED 5.1 Product and/or Liquid Measurement LNAPL (non conductive liquid) - measured using an Oil/Water Interface Probe 1. Lower the probe into the well. 2. When the probe reaches the top of the product (LNAPL) a single audible buzz will be heard and a green light will show . 3. Note the depth to the top of product on the graduated tape on the Oil/Water Interface Probe. 4. Continue to lower the probe down through the LNAPL until a two-tone buzzer is heard and both the red and green lights show. 5. Note the depth at which the two-tone buzzer starts. Subtract this value from the above to get the thickness of LNAPL. 6. Where the two-tone buzzer starts is also the depth to the product/water interface. CONDUCTIVE LIQUID (leachate, condensate, water) - measured using a Water Lev el Meter 7. Lower the probe into the well. 8. When the probe reaches the top of the water a single audible buzz is heard and a red light shows. 9. Note the depth on the graduated tape on the Water Level Meter.

5.2 Preparing the Pump 5.2.1 Dry test Irrespective of which application the PosiFlo is to be used for (see section 6.0) before installing it is advisable to carry out the following dry test:1. Connect the air supply and apply 4 bar (58 psi) to the inlet (IN) on the top of the pump (PosiFlo 48) or top of the Autotimer (PosiFlo 46). 2. Check pulsing operation of the autotimer to achieve a pumping cycle to suit the application (see 4.1) between 1 and 6 seconds. If necessary alter the timer as shown

5.2.2 Cycle volume check Once the dry test has been done place the PosiFlo into a suitable vessel filled with water, connect the discharge pipe and check the pumping volume Approximate v olume per stroke should be between 80 to 90 mls.

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Issue 1.2C Jan 06

POT ENTIALLY EXPL OSIV E ENVIRONMENT ─ WE RECOMMEND FULL ZONING AND RISK ANALYSIS BE UNDERTAKEN BY T HE USER PRIOR TO INSTALLATION. Installation should be carried out in accordance with directions in Section 5.0

6

TYPICAL APPLICATIONS

6.1

LNAPL (LIGHT NON AQUEUS PHASE LIQUID) RECOVERY The Posi-Flo 48 can be used to recover LNAPL by placing the intake just above the product/water interface. If any fluctuation of the water level occurs both water and product (total fluids) will be pumped. Alternatively the Posi-Flo 48 can be repositioned so that it is just above the interface. If product only is needed then the PosiFlo 48 must be used with a GeoSkimmer (see 6.4)

5

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

1 2

6

3 4

Air filter regulator (auto drain) Pressure gauge Air supply in 5 micron filter Cycle counter (optional) Fluid discharge 50 mm ID well or larger Air exhaust (above liquid level) Posi-Flo 48 Fluid intake & NRV

7

INSTALLATION 8

9

floating hydrocarbon LNAPL

10

groundw ater

17

1.

Make sure the maximum and minimum water fluctuation levels are known.

2.

Take product & water level readings with an oil/water interface probe.

3.

Calculate the depth that is required to position the top of the intake screen just above the oil/water interface.

4.

Lower the Posi-Flo 48 into the well.

5.

Turn on the pump and check to see if product only is being pumped. If water is being pumped raise the Posi-Flo 48 until no more water is pumped.

6.

If the water level fluctuates then the intake position will need to be adjusted.

Issue 1.2C Jan 06

POT ENTIALLY EXPL OSIV E ENVIRONMENT ─ WE RECOMMEND FULL ZONING AND RISK ANALYSIS BE UNDERTAKEN BY T HE USER PRIOR TO INSTALLATION. Installation should be carried out in accordance with directions in Section 5.0

6.2

TOTAL FLUIDS The PosiFlo can be used to remove total fluids by placing the intake below the product/water interface.

5

1 2

6

3 4

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Air filter regulator (auto drain) Pressure gauge Air supply in 5 micron filter Cycle counter (optional) Fluid discharge 50 mm ID well or larger Air exhaust (above liquid level) Posi-Flo 48 Fluid intake & NRV

7

INSTALLATION 8

9

floating hydrocarbon LNAPL SG1

12

Impermeable layer

19

1.

Take DNAPL level reading.

2.

Calculate the depth that is required to position the DNAPL intake screen so it rests on the bottom of the well.

3.

Mount the Autotimer vertically on a suitable post & connect air supply and air exhaust pipes to PosiFlo 46 and to the Autotimer

4.

Lower the PosiFlo 46 into the well.

5.

Turn on the pump and check to see if DNAPL is being pumped. N.B. it may take several minutes for the DNAPL to fill the hose and reach the surface.

6.

Adjust the timer to maximise flow against yield of well.

Issue 1.2C Jan 06

POT ENTIALLY EXPL OSIV E ENVIRONMENT ─ WE RECOMMEND FULL ZONING AND RISK ANALYSIS BE UNDERTAKEN BY T HE USER PRIOR TO INSTALLATION. Installation should be carried out in accordance with directions in Section 5.0

6.4 ACTIVE PRODUCT ONLY RECOVERY Product Only recovery is carried out using the combination of a Posi-Flo 48 with a GeoSkimmer (RD or HP type) where the GeoSkimmer is placed at the interface and at its mid point of travel so that no water can be pumped.

6 12 5

1 2 3

11

4

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Air filter regulator (auto drain) Pressure gauge Air supply in 5 micron filter Cycle counter (optional) Fluid discharge 50 mm ID well or larger Air exhaust (above liquid level) Posi-Flo 48 Geo-Skimmer RD/HP Product recovery tank Tank full sensor

7

INSTALLATION 1. 8

2. 9

10

Floating hydrocarbon LNAPL

Make sure the maximum and minimum water fluctuation levels are known. Take product & water level readings with an oil/water interface probe.

3.

The GeoSkimmer is designed to allow the floating buoy to be placed at the mid-point of its travel to allow for water table fluctuations in both directions.

4.

Lower the Posi-Flo 48 & GeoSkimmer into the well. The GeoSkimmer will be at the bottom of its travel length. From the oil/water interface reading adjust the depth (mm) as below so that the GeoSkimmer is placed at its midpoint

GeoSkimmer 50-500 100-500 50-1000 100-1000

Groundwater

20

High +250 +250 +500 +500

Low -250 -250 -500 -500

THE RD TYPE SKIMMER CAN LEAVE UP TO 25 mm OF PRODUCT DEPENDING ON ITS SPECIFIC GRAVITY.

Issue 1.2C Jan 06

POT ENTIALLY EXPL OSIV E ENVIRONMENT ─ WE RECOMMEND FULL ZONING AND RISK ANALYSIS BE UNDERTAKEN BY T HE USER PRIOR TO INSTALLATION. Installation should be carried out in accordance with directions in Section 5.0

6.4

LEACHATE Leachate can be extracted by installing the PosiFlo 48 into a leachate well or combined gas & leachate well (illustrated below).

6

5

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

1 2

7 3

8 9

4

Air filter regulator (auto drain) Pressure gauge Air supply in 5 micron filter Cycle counter (optional) Fluid discharge Air exhaust (above liquid level) Wellhead Extraction well connection Extraction well casing Posi-Flo 48 Non return valve Intake screen

10

INSTALLATION - LEACHATE WELL 1.

2. 3. 11

Leachate 4. 5.

6. 12

7. 8.

13

9.

21

Measure depth to bottom of well and check if there is any silt in the bottom of the well. Check depth to leachate From the depth measurement attach sufficient pipe and support rope length to position the intake screen 150 mm above the bottom or silt level. Connect air supply to Posi-Flo 48 and check dry operation of the pump. With the Posi-Flo 48 working slowly lower it into the well to the final position. Set air pressure at required pressure for system operation and open supply valve. Check liquid is being pumped and exhaust is vented outside the well. If Posi-Flo 48 is pulsing but not pumping suspect that the intake screen is blocked. Remove pump, check and/or clean intake screen and replace.

Issue 1.2C Jan 06

POT ENTIALLY EXPL OSIV E ENVIRONMENT ─ WE RECOMMEND FULL ZONING AND RISK ANALYSIS BE UNDERTAKEN BY T HE USER PRIOR TO INSTALLATION. Installation should be carried out in accordance with directions in Section 5.0

6.5

CONDENSATE The PosiFlo 48 can be used to control condensate levels in knockout pots with an internal pipe of 63 mm ID or larger.

6 7

1 5

2 3

8 4

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Air filter regulator (auto drain) Pressure gauge Air supply in 5 micron filter Cycle counter (optional) Fluid discharge Air exhaust (above liquid level) Knock-out pot access Knock-out pot drilled well Knock-out pot body Posi-Flo 48 Non return valve Intake screen

INSTALLATION - KNOCK-OUT PO T (PKOP) 9

1. 2. 10

4. 11

5. 6.

7.

12

8. 13

9. Condensate

22

Measure depth to base of PKOP. From above measurement attach sufficient pipe and support rope length to position the Posi-Flo 48 at the base of the PKOP. Connect air supply to Posi-Flo 48 and check dry operation of the pump. With the Posi-Flo 48 working slowly lower it into the well to the final position. Set air pressure at required pressure for system operation and open supply valve. Check liquid is being pumped and exhaust is vented outside the well. If Posi-Flo 48 is pulsing but not pumping suspect that the intake screen is blocked. Remove pump, check and/or clean intake screen and replace.

Issue 1.2C Jan 06

6.6

GROUNDWATER PURGING & SAMPLING The Posi-Flo 48 can be used for purging and sampling of groundwater up to depths of 76 metres. It is ideally suited to be used within 50 mm wells to reduce the amount of purging volume required.

5

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

1

7 2 6

3 4

Air filter regulator (auto drain) Pressure gauge Air supply in 5 micron filter Cycle counter (optional) Fluid discharge Air exhaust (above liquid level) Extraction well casing Posi-Flo 48 Non return valve Intake screen

8

INSTALLATION - MONITORING WELL 1. 2.

4. 5. 9

6.

7. 8. 10

9.

Check depth to groundwater From the depth measurement attach sufficient pipe and support rope length to position the intake screen at the depth required. Connect air supply to Posi-Flo 48 and check dry operation of the pump. With the Posi-Flo 48 working slowly lower it into the well to the final position. Set air pressure at required pressure for system operation and open supply valve. Check liquid is being pumped and exhaust is venting. If Posi-Flo 48 is pulsing but not pumping suspect that the intake screen is blocked. Remove pump, check and/or clean intake screen and replace.

11

Ensure that the rope is secure.

23

Issue 1.2C Jan 06

Com pressed air can be dangerous and work should be carried out only by trained personnel

7.0 ADDITIONAL EQUIPMENT The PosiFlo requires compressed air to operate. Whilst the pump itself can operate with virtually any quality of compressed air the provision of a correctly designed air supply is important to ensure maximum performance and reliable operation.

7.1 Compressed Air The follow ing is prov ided for information only and it is the customer’s responsibility to ensure the prov ision of air is appropriate for the site conditions. We recommend that full zoning and risk analysis be undertaken by the user to ensure that the compressor is suitable for use in the relevant zone. There are two basic types of compressor and Table 1, below, outlines some of the advantages/disadvantages. Table 1

COMPRESSOR TYPE

ADVANTAGES

Reciprocating

Rotary Screw

DISADVANTAGES

Low cost capital Good availability w orldw ide

Low efficiency Poor air quality

High efficiency/low running cost High air quality

High cost capital

7.2 Dryers Condensate build up within the air line can cause problems and limit the efficiency of the system and include:-

• Freezing of condensate in air lines if not insulated • Hydraulic locks at low spots For long term reliability it is therefore recommended that an air dryer is incorporated within a pneumatic pump system. Air dryers should be matched with the corresponding compressor to ensure adequate cooling of the air (check with manufacturers recommendations).

7.3 Air receiver and filters In order to provide a sufficient reservoir of air so that the compressor is not working continuously, a suitably sized receiver should be provided. Correctly sized and lengths of pipe work should be designed into the compressor house to ensure correct velocities of air. In addition automatic draining valves together with filters should be installed to minimise maintenance requirements and produce problem free air (see fig 7).

4

2

1

3

5

1. 2. 3. 4. 5. 6. 7.

6

7

Fig 7

24

Compressor Water separator Air receiver General purpose air filter Air dryer High efficiency air filter Condensate management system

Issue 1.2C Jan 06

7.4 Fittings The PosiFlo can be fitted with several types of fittings to accommodate a wide range of tubing and hoses as follows:

Fitting type

Air supply

Air vent

Discharge

One-touch

6mm

6,10 mm

10,12,16 mm

Compression

16,20,25 or 32 mm

Quick connect HK

1/4”/3/8”/1/2”/3/4”/1”

Quick connect ST

1/4”/3/8”/1/2”/3/4”/1”

Hose tail

1/4”/3/8”/1/2”/3/4”/1

7.4.1 Tubing and hoses To complement the above types of fittings the following range of tubes and hoses are available:-

Fitting type

Air supply

Air vent

Discharge

One-touch

Nylon, PE

Nylon, PE

Nylon, PE

Compression

PE

Quick connect HK

SBR

Quick connect ST

Polyflex

Hose tail

Nylon, PVC, SBR,

7.4.2 Assembly of Fittings and Hoses The type of fittings and accessories will depend on the application (please refer to section 6) and it is important to ensure that the correct equipment is used. Different types of fittings work in slightly different ways:1

ONE TOUCH - Pipe pushes directly into the hole on the top. Push until a ‘click’ is felt as the pipe locates into the internal seal. To remove push in blue release ring (1) and pull out pipe. Fig 8

QUICK CONNECT HK - Spring operated ball and socket type coupling with automatic positive shut off on disconnection preventing all chances of fluid escape.

Fig 9

HK type

To connect simply pull back the spring loaded sleeve (female) and push the ring (male) on to the plug. The sleeve then snaps forward to lock the coupling.

To disconnect just pull the sleeve back to unlock the coupling. QUICK CONNECT S T - same as the HK range but a straight through type without self sealing. Connects and disconnects the same as the HK.

ST type

Fig 10

25

Issue 1.2C Jan 06

7.4.2 PE COMPRESSION FITTINGS - used with metric PE pipe.

Assembly instructions 1. 2. 3. 4. 5.

Cut pipe to length ensuring end is straight. Place threaded nut on to pipe. Place split ring on to pipe. Push pipe into body through internal ‘O’ ring as far as it will go. Tighten nut firmly.

7.5 CONNECTING TO POSI-FLO The top of the PosiFlo is clearly shows the position of the inlet (IN) and exhaust (EX) ports to which the tubing should be fitted. Ensure that the tubing or hoses are connected to the correct positions as shown below.

1. AIR IN (IN) - always 6 mm to the top of the well. 1

2. DISCHARGE - will vary on application. 2

4

3

3. EXHAUST (EX) - normally 6 mm and the end must be ABOVE the liquid level. If deeper than 3m then it must be increased to 10 mm. If installed within a vacuum well the exhaust should be vented outside the well.

Top of Posi-Flo 48

Cycle time can be adjusted through the exhaust port. 4. BLANKED PORT - DO NOT REMOVE

26

Issue 1.2C Jan 06

7.6 Accessories In addition to the items described in items 7.1 to 7.5, further accessories are available for the PosiFlo to provide extra safety and other operational benefits.

♦

Air filter/regulator - To provide the PosiFlo with a reliable source of air, it is recommended that a float-operated auto drain air filter/regulator is used at each well. The auto drain should be able to drain even under pressure and not need the compressed air system to be de-pressurised. It should be fitted with a 5 micron replaceable filter, metal bowl and be rated up to 250 psi (17 bar).

♦

Tank full sensor - pneumatic sensor which turns off the pump if the discharge tank is full.

♦

Cycle counter - counts the number of times the pump cycles

♦

Well caps - range of PVC & HDPE caps for any size of well. Standard push-on or vacuum sealed types are available.

♦

Support rope - nylon or stainless steel support ropes.

Air filter regulator and cycle counter

Tank full sensor

CHECK THE AIR/FILTER REGULATOR IS A TRUE AUTO DRAIN

27

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.0 MAINTENANCE 8.1 Pump maintenance The PosiFlo has been designed for minimum maintenance but will depend on the type of liquid being pumped. Below is an indication of maintenance requirements dependent on application:Product skimming

- very low maintenance

Total fluids

- low maintenance - some iron or calcium encrustation on inlet screen may occur.

Dissolved

- low maintenance.

Landfill condensate

- low maintenance - some encrustation around float may occur.

Landfill leachate

- medium maintenance - will vary greatly between different wells and sites. Scaling likely to occur around float, inside of casing and around inner stem. Wearing items (non return valves) may require replacing if leachate has high solids content.

Any pump operating under the harsh conditions found within groundwater remediation and/or landfill will inevitably require some maintenance and even repair of wearing parts. The PosiFlo has been designed to allow maintenance and repair to be carried out easily and without the need for any special tools. The PosiFlo pump-end can easily be stripped down, cleaned, repaired and reassembled in the field.

AS THE POSIFLO USES COMPRESSED AIR IT IS IMPORTANT THAT THE COMPRESSOR AND THE AIR QUALITY IS REGULARLY M AINTAINED.

28

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.2 ADJ USTING THE CYCLE TIME If it is necessary to adjust the cycle time of the Posi-Flo 48 it can be done as follows:1. 2.

Remove the exhaust pipe from the top of the pump. Insert the small flat head screwdriver provided (3 mm diameter x 150 mm long) through the exhaust fitting to reach the adjustment screw on top of the autotimer (see Fig 1below). clockwise = slow er anticlockw ise = faster

TOP NON RETURN VALVE WILL HAVE TO BE REMOVED TO ENABLE THE CYCLE TIME ADJ USTMENT TO BE MADE.

Fig 1

8.3

AIR PRESSURE

Depending on the system it may be necessary to alter the air pressure to the pump by altering the filter/regulator. Look at which way the arrow is facing on the regulator and turn the knob in the direction required to increase or decrease the pressure (see fig 2) as follows:1. 2.

Pull the top knob upwards. A click will be heard. Turn adjustment handle to alter the air pressure.

anti-clockw ise to decrease pressure Fig 2 clock-w ise to increase pressure 4.

Once pressure is adjusted push down knob until click heard.

ABOVE ADJ USTMENTS RELATE TO THE STANDARD FILTER REGULATOR PROVIDED BY MGS. OTHER MANUFACTURERS MAY DIFFER. PLEASE REFER TO INDIVIDUAL MANUFACTURER.

29

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.4 CONVERTING TO USE WITH GEOSKIMMER In order to use the PosiFlo 48 with a GeoSkimmer or upgrading a GC100 GeoCanister to an active the following conversion will be needed:-

Remove the intake strainer from the bottom of the PosiFlo 48 non return valve. Fig 3

Fig 3 The GeoSkimmer is supplied with an adaptor for use with the PosiFlo 48. Undo the Quick Release coupling on top of the GeoSkimmer which is attached to the 1” BSP adaptor. Fig 4

Fig 4

Screw the 1” BSP adaptor into the bottom of the PosiFlo 48 non return valve assembly and attach to top of GeoSkimmer by reconnecting the Quick Release coupling Fig 5

Fig 5

30

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.5

CHANGING FLOAT ON A GEOSKIMMER Depending on the type and thickness and type of product (LNAPL) it may be required to change the GeoSkimmer float. The GeoSkimmer floats are totally interchangeable and can be changed easily on site as follows:1. Undo Quick Connect plug from the top of the GeoSkimmer fig 6. Fig 6

2. Remove Quick Release fitting from top of GeoSkimmer central stem. 3. Using a 3mm Allen key loosen the socket set screw (grub screw) and remove the top disc from the GeoSkimmer stem fig 7. Fig 7

4. Cut the tie wrap or clip which holds the tube onto the hose tail on the underside of the GeoSkimmer float and remove the end of the coiled tube from the hose tail fig 8. 5. Slide the float off the inner stem.

Fig 8

6. Slide the new float over the central stem. 7. Replace the tube onto the hose tail and fit new tie wrap. 8. Replace the top disc and Quick Connect plug.

Fig 9

Install as per section 6.4 31

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.6 DIS-ASSEMBLY 8.6.1

8.6.2

If pump is not already clean, clean with appropriate liquid (normally water) and inspect for any obvious problem or damage. Remove intake strainer (fig 10).

Fig 10

8.6.3

With suitable tool e.g. screwdriver, short bar or piece of pipe lift bottom non return valve plunger/ball to empty any liquid inside the pump (fig 11).

8.6.4

Check for debris and free movement of the non return valve plunger/ball. If necessary remove non return valve and clean thoroughly. If the ball shows sign of wear replace.

8.6.5

Fig 11

Using 2 mm “Tommy bar” support lower pump casing with one hand and undo the bottom head ( fig 12).

Fig 12

32

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.7.6

Remove bottom head and place safely on work surface (fig 13).

Fig 13

Fig 14 8.7.7

Remove spring and piston fixed stop (figs 14 & 15).

Fig 15

33

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.7.8

Carefully unscrew pump outer casing in an anti-clockw ise direction and remove completely. (fig 16)

8.7.9

Carefully remove piston from casing.

8.7.10 Clean all parts with a suitable cleaning agent and soft cloth. 8.7.11 Inspect pump discharge pipe outer surface for excessive wear, scratches etc. 8.7.12 Inspect external and internal piston seals for wear and/or damage. Replace as necessary. 8.7.13 Inspect pump casing internal surface for excessive scour. Replace as necessary. 8.7.14 Check condition of spring. Replace as necessary. 8.7.15 Check ‘O’ ring for damage during disassembly and replace as necessary.

8.80

Fig 16

RE-ASSEMBLY Fig 17 shows the components parts of the Posi-Flo 48.

1

Re-assembly is basically a reverse of the dis-assembly (see 5.3.1 to 5.3.10 on next page).

2

1.

Auto-timer casing

2.

Discharge pipe

3.

Piston

4.

Pump casing

5.

Bottom stop

6.

Spring

7.

Bottom head

3

4

5

6

7

Fig 17

34

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.8.1 Grease the pump discharge bottom thread with a silicone based grease* 8.8.2

Carefully screw, in a clockw ise direction, the piston over the bottom thread of the pump discharge pipe (fig 18).

8.8.3

Grease the piston seals with silicone based grease*

Fig 18 8.8.4

Place pump casing over discharge pipe and carefully push over piston (fig 19).

8.8.5

Push pump casing until a “snap” is heard as it locates over the top ‘O’ ring.

8.8.6

Place piston fixed stop into pump casing (fig 20). Fig 19

*Lubeserv PA4000 or equiv alent

Fig 20

35

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.8.7

Replace spring (fig 21).

Fig 21 8.8.8

Replace and tighten bottom head. (fig 22) ! Do not ov er tighten.

8.8.9

Replace bottom non return valve, inlet screen or quick release fitting.

8.8.10 Once the pump is complete carry out the following dry test:Connect the air supply and apply 4 bar (58 psi) to inlet port in the outer head. Check pulsing operation of autotimer to achieve a pumping cycle to suit the application between 1 and 6 seconds. Adjustment is via a screw in end of vibrator (fig 23). (clockwise = slow , anticlockw ise = fast)

Fig 22

Once the dry test has been done place the Posi-Flo 48 into a suitable vessel filled with water, connect discharge pipe and check pumping operation. Approximate volume per stroke should be betw een 80 to 90 mls.

Fig 23

36

Issue 1.2C Jan 06

Where appropriate, PPE should be used. If in doubt, use PPE.

8.9

Cleaning the Cycle Counter IF THE COUNTER STOPS OPERATING IT MAY BE BLOCKED BY DEBRIS OR SCALE AND MAY NEED CLEANING.

1. 2. 3. 4. 5. 6. 7.

8.10

Remove air in & out pipes. Remove the end hexagon connector . Remove the spacer, spring and magnet spool assembly and clean as necessary. Inspect the inside of the counter tube and clean as necessary. Once cleaned reassemble . Replace cycle counter into system and refit air pipes. Check operation as outlined in 4.4.

Maintaining Compressed Air Supply Maintenance of the compressor and supply system should be carried out in accordance with the manufacturers recommendations. PosiFlos are part of a system which incorporates the compressor, air filtration equipment and the compressed air supply pipe work. It is important to ensure that all components of the air system are regularly maintained to prevent damage to the PosiFlo.

DEPRESSURISE SYSTEM BEFORE DISCONNECTING ANY FITTINGS

8.11 Air Filter/Regulator Maintenance To ensure that reliable air is continuously supplied to the PosiFlo the air filter/regulator should be periodically inspected and the internal filter element changed. Remove the metal bowl by pulling down on the locating button (see arrow) and twisting the bowl in either direction and pulling downwards. Inspect the bowl and clean. Inspect the filter and internal float and replace as necessary. Check auto drain by filling the bowl, reconnecting to the regulator and pressurising with the air. The water inside should drain out. If air is heard escaping around the top flange it is likely that the internal diaphragm needs replacing. Contact EAE for advice.

37

Issue 1.2C Jan 06

8.12

GEOSKIMMER The GeoSkimmer has been designed for minimum maintenance but the amount of maintenance will depend on the type of GeoSkimmer and individual site conditions. TYPE HP The GeoSkimmer HP consists of a hydrophobic filter element which is mounted on the top of the floating buoy. The element has a fine micron mesh which, after time may become clogged with fine particles or biological growth. If a noticeable reduction in flow rate occurs although there is plenty of product in the well it is likely that the screen has become clogged. If the flow reduces and the product thickness reduces then it is likely that this is the maximum flow achievable from the GeoSkimmer. The special hydrophobic filter is designed to be disposable and therefore should be replaced rather than cleaned as follows:1. 2. 3. 4. 5. 6. 7.

Undo the Quick Connect fitting between the Posi-Flo 48 pump and the GeoSkimmer. Unscrew and remove the Quick Connect on top of the GeoSkimmer. Undo the socket set screw in the side of the support disc & remove disc. Unscrew filter cap and remove the filter. Replace with new filter element and re-assemble. Check the free movement of the buoy and the condition of the coiled tube. Clean and replace in well.

TYPE RD The GeoSkimmer RD consists of a direct intake mounted on top of the float which can be easily cleaned by hose, power washer, steam cleaner or scrubbed by hand. Care should be taken during the cleaning not to damage or bend the central stem as this will stop the float from operating correctly. Check the condition of the coiled tube and that product passes down the tube and that there are no leaks.

38

Issue 1.2C Jan 06

Posi-Flo Check for operation Check cycle rate Check hoses & fittings Replace seals * Replace spring

yearly

6 monthly

4 monthly

monthly

The schedule below is only a recommendation and individual site applications may demand more frequent intervals. If in doubt please contact MGS for advice.

weekly

MAINTENANCE SCHEDULE

daily

8.13

X X X X X

GeoSkimmer HP or RD Check for operation Check coiled tube Check hydrophobic screen (HP type) Change hydrophobic screen** Change coiled tubing

X X X X X

Cycle counter Check reading Clean

X X

Compressor Condensate drain Check oil level Check emergency stop operation Replace oil filter Replace air filter Replace oil Check drive belt condition & tension

X X X X X X

Air filter/regulator Check operation Check auto drain Check pressure gauge Check filter Replace filter

X X X X X

Pipe work Check for leaks Check valves for operation

X X

* this may alter if a high degree of solids are being pumped ** dependent on individual site conditions

39

Issue 1.2C Jan 06

9.0

FAULT FINDING - POSIFLO

Problem No discharge

X

Reduced flow

X

X

X

X

X

X

X

X

X

X

X

X

Slow pulsing rate No pulse

X X

X

X

Air from exhaust Liquid from exhaust

X

X

X

X

X

e

f

g

h

j

k

Piston spring broken

Piston seal failure

Auto-timer blocked with liquid

Air line contamination

Discharge blocked

d

System head greater than air pressure

c

Inlet & outlet valves open

b

Suction intake blo cked

a

Low air pressure

X

No air supply

Possible Cause

Remedy Letter

X

Remedy a

Establish air supply

b

Increase air pressure

c

Remove non-return valve, clean, inspect for damage & replace. Check pump operation

d

Remove suction intake, clean, inspect for damage & replace. Check pump operation

e

Clean as in c & d above

f

Maximum air pressure is 10 bar. For greater discharge head refer to EAE

g

Refer to section 5.0 and follow steps 5.2.1 to 5.2.7. Re-assemble following 5.3.1 to 5.3.10

h

Refer to section 5.0 and follow steps 5.2.1 to 5.2.15. Re-assemble following 5.3.1 to 5.3.10

j

Refer to section 5.4

k

Refer to sections 5.5 & 5.6

40

Issue 1.2C Jan 06

9.1

FAULT FINDING - GEOSKIMMER

Problem No discharge

X

Reduced flow

X

X

X

X

X

X

X

X

X

X

X

X

Slow pulsing rate No pulse

X X

X

X

Air from exhaust Liquid from exhaust

X

X

X

X

X

e

f

g

h

j

k

Piston spring broken

Piston seal failure

Auto-timer blocked with liquid

Air line contamination

Discharge blocked

d

System head greater than air pressure

c

Inlet & outlet valves open

b

Suction intake blo cked

a

Low air pressure

X

No air supply

Possible Cause

Remedy Letter

X

Remedy a

Establish air supply

b

Increase air pressure

c

Remove non-return valve, clean, inspect for damage & replace. Check pump operation

d

Remove suction intake, clean, inspect for damage & replace. Check pump operation

e

Clean as in c & d above

f

Maximum air pressure is 10 bar. For greater discharge head refer to EAE

g

Refer to section 5.0 and follow steps 5.2.1 to 5.2.7. Re-assemble following 5.3.1 to 5.3.10

h

Refer to section 5.0 and follow steps 5.2.1 to 5.2.15. Re-assemble following 5.3.1 to 5.3.10

j

Refer to section 5.4

k

Refer to sections 5.5 & 5.6

41

Issue 1.2C Jan 06

10 SPARE PARTS 10.1 PosiFlo 48 & 46 Please note that illustration is for PosiFlo 48 only but all items are Interchangeable with the PosiFlo46. PLEASE QUOTE SERIAL NUMBER WHEN ORDERING SPARE PARTS

Item

Part number

Description

Qty

1

-

Discharge pipe (size varies)

-

2

-

Connector (size varies)

1

3

K10-005

Air supply tubing

-

1

2 Discharge connector

3 Air in

4

PO261

Lifting eye

1

5

E10-009

Non return valve assembly

1

6

K10-006

Air vent tube

-

7

P0113

Outer head

1

8

K11-025

1/4” BSP x 6mm connector

2

9

P0117*

Autotimer & casing assembly 1

6

Air vent

5 4

8

9 7

10 11

10

P0085

Top head

1

11

L10-003

‘O’ ring

2

12

P0127

Pump casing

1

13

E10-007

Piston - c/w seals

1

14

P0089

Spring

1

15

P0090

Fixed stop

1

16

P0088

Discharge pipe

1

17

P0087

Bottom head

1

18

N12-027

1” BSP non return valve

1

19

P0368

1” BSP intake strainer

1

12

13

14

15

16

11 17

* The autotimer assembly is only available as a complete assembly and only to EAE authorised companies.

42

19

18

Issue 1.2C Jan 06

10 SPARE PARTS 10.2

GeoSkimmer GS-50

PLEASE QUOTE SERIAL NUMBER WHEN ORDERING SPARE PARTS

1 2 3 4

Item

Part number

Description

Qty

1

R18-001

Quick connect coupling

1

2

G0035

Support ring

1

3

G0021

Filter cap

1

4

G0027

Hydrophobic filter

1

5a

G0011

Float type GS-50-HP

1

5b

G0023

Float type GS-50-RD

1

6

K21-001

hosetail

2

7

G0014A

Coiled tube GS-50-500

1

G0014D

Coiled tube GS-50-1000

1

8

G0034

Spacer tube

1

9

G0013A

SS central tube GS-500

1

G0013D

SS central tube GS-1000

1

10

G0028

Support disc

1

11

G0012

Manifold

1

5a

6

7

6 8

9

10 11

43

5b

Issue 1.2C Jan 06

10 SPARE PARTS 10.3

GeoSkimmer GS-100

PLEASE QUOTE SERIAL NUMBER WHEN ORDERING SPARE PARTS 1 2 3 4 5b

Item Part number

Description

Qty

1

R18-001

Quick connect coupling

1

2

G0033

Support ring

1

3

G0018

Filter cap

1

4

G0020

Hydrophobic filter

1

5a

G0016

Float type 100-HP

1

5b

G10-001

Float type 100-RD

1

6

K21-002

Hose-tail

2

7

G006A

Coiled tube GS-100-500

1

G006D

Coiled tube GS-100-1000

1

8

G0031

Spacer tube

1

9

G0009A

SS central tube GS-100-500

1

G0009B

SS central tube GS-100-1000 1

10

G0005

Manifold

1

11

K21-005

Hose-tail

1

5a 6

7

8

9

10 11

44

Issue 1.2C Jan 06

10.4 Spares - Cycle Counter

2 3 12

11

10

9

8

7

6

4 1

5

Item Part number

Description

Qty

1

P0099

Tube

1

2

M11-001

Socket cap screw

2

3

Q21-001

Counter

1

4

P0100

Collar

1

5

M14-011

Socket set screw

1

6

P0105

Locking screw

1

7

P0106

Magnet

1

8

P0104

Spool

1

9

P0103

Spring

1

10

P0101

Spacer

1

11

L10-007

‘O’ ring

1

12

P0102

End connector

1

*

E13-001

Cycle counter assembly

1

* Not illustrated

45