EPA-600/2-81-,Z/7
September 1981
A MOBILE STREAM DIVERSION SYSTEM
FOR HAZARDOUS MATERIALS SPILLS ISOLATION
by
James V. Zaccor
Scientific Service, Inc.
Redwood City, California 94063
Contract No. 68-03-2458
Project Officer
Frank J. Freestone
Oil and Hazardous Materials Spills Branch
Municipal Environmental Research Laboratory—Cincinnati
Edison, New Jersey 08817
MUNICIPAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This report has been reviewed by the Municipal Envirorenental Research
Laboratory, U.S. Environmental Protection Agency, and approved for
publication. Approval does not signify that the contents necessarily reflect
the views and policies of the U.S. Environmental Protection Agency, nor does
mention of trade names or commercial products constitute endorsement or
recommendation for use.
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FOREWORD
The U.S. Environmental Protection Aqency was created because of
increasing public and government concern about the dangers of pollution to
the health and welfare of the American people. Noxious air, foul water,
spoiled land are tragic testimonies to the deterioration of our natural
environment. The complexity of that environment and integrated attach on the
problem.
Research and development is that necessary first step in problem
solution; it involves defining the problem, measuring its impact, and
searching for solutions. The Municipal Environmental Research Laboratory
develops new and improved technology and systems to prevent, treat, and
manage wastewater and solid and hazardous waste pollutant discharges from
municipal and community sources, to preserve and treat public drinking water
supplies, and to minimize the adverse economic, social, health, and aesthetic
effects of pollution. This publication is one of the products of that
research and provides a most vital communications link between the researcher
and the user community.
Some types of environmental accidents have dynamic aspects that can lead
to far-reaching as well as devastating consequences. This report describes a
system developed to respond to one class of environmental accident - the
spill of hazardous material into streams. Analyses and field experience have
been applied to produce and demonstrate a quick-response prototype mobile
stream diversion system to bypass normal stream flow around an isolated
section of contaminated stream while the latter is being restored.
Francis T. Mayo, Director'
Municipal Environmental Research Laboratory
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ABSTRACT
This program v\as undertaken to design and develop a practical prototype
mobile stream diversion system for quick diversion of a stream flow around a
contaminated area.
Spill scenarios ware analyzed to establish design criteria for a
completely self-contalined, independent system that would maintain flow
continuity around a region undergoing decontamination processing. The system
was designed to use stock items available nationwide, to be easily
maintained, and to be readily replaceable. To provide flexibility and
reliability, the system has been assembled as tvo totally independent units
mounted on trailers so that spills will be readily accessible via state or
interstate highvays. Components are fastened on the trailers so they can be
quickly unloaded for air shipment to more distant locations. Cnce onsite,
the system can be assembled and placed in operation by a crew of five in a
matter of hours.
Unit operation and ability to deliver a flow rate of 0.35 m /s (5,500
gpn) a distance of 0.3 km (1,000 ft) over unprepared ground were evaluated in
a shakedown test.
Alternative modes of operation have been defined and capabilities
indicated. The system can deliver a flow rate of 0.09 m /s (1,425 gpn) a
nominal distance of 1 km (3,280 ft) or a flow rate of 0.35 m /s (5,600 gpn) a
distance of 0.3 km (1,000 ft) .
This report was submitted in fulfillment of Contract Mo. 68-03-2458 by
Scientific Service, Inc. under the sponsorship of the U.S. Environmental
Protection Agency. This report covers the period September 7, 1976, to
August 31, 1977, and work was completed as of December 31, 1977.
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CONTENTS
Foreword iii
Abstract iv
Figures vi
Tables vii
1. Introduction 1
2. System Design 2
Design philosophy and approach 2
Performance specifications 2
3. Component Selection 4
Booster pumps 4
Submersible pumps 4
Generators 13
Pipes, hoses, and fittings 15
Crane 22
Transportation system 23
Lighting system 24
4. Trailer Layout and Site Preparation 26
5. System Operation 37
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FIGURES
Number Page
1 Submersible pump performance curve 10
2 Submersible pump auxiliary features 12
3 NEMA 3 service box 14
4 Generator circuit and control center features 16
5 Pipe rack/dolly 20
6 Pipe and fitting through one unit 21
7 Metered flow through one unit 22
8 Layout of components aboard trailer 25
9 Layout of components with pipe and fitting rack removed .... 27
10 Rear view of trailer with components aboard 28
11 Pipe and fitting rack unloading 29
12 Pipe and fitting rack rotation and wheel assembly 30
13 Completion of rack/dolly conversion 31
14 Pump and cable reel dollies 32
15 Winch dolly 33
16 Floodlight mounting stations 35
17 Quick-release retaining pins 36
18 MSDS spill application 38
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TABLES
Number Page
1 Major Components of Mobile Stream Diversion System 5
2 Major Component Alternatives Considered 9
3 Mobile Stream Diversion System (MSDS) Operational Modes 39
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SECTION 1
INTRODUCTION
The spill response experience of the Hazardous Spills Staff of the Oil
and Hazardous Materials Spills research qroup in Edison, N.J. have often
included spill cleanup scenarios involving contamination of small streams by
insoluble sinking hazardous materials. According to data from the
U.S. Geological survey, approximately 84% of the stream-miles in the
U.S. flow at 0.28 cubic meters per second (4,400 gallons per minute) or less.
Further, an analysis of the proposed list of designated "hazardous
substances" indicates that approximately 45% of the materials listed are
either insoluble sinkers or form insoluble precipitates on contact with
water.
Cleanup of insoluble sinkers from stream bottoms can be accomplished in
several ways such as hand vacuuming or dredging. These techniques often lead
to downstream spread of the contaminant due to resuspension of bottom muds
and silts. Further, there are significant problems associated with treatment
of the water-sediment slurry produced by the dredging. Another approach is
to dam the stream where possbile above the impacted area and bypass the
normal stream flow. This stream flow bypassing will permit the
spill-impacted segment to dry, thus facilitating cleanup either manually or
with mechanical earthmoving eauipment. The problems of sediment resuspension
and treatment of large volumes of contaminated dredge water are exchanged for
the retirements of pumping and piping to achieve the bypass.
Other spill experiences have pointed out the need for rapidly,
deployable pumping and piping to isolate a pond or boa that has been impacted
by soluble materials. The slow movement of these materials makes the
utilization of a diversion system practical.
For stream flows less than 0.0063 cubic meters per second (100 gallons
per minute), it is sometimes possible to achieve bypass by gravity flow.
Gravity bypasses, however, may have to be placed in the very stream bed that
is to be the subject of the cleanup. For those stream flows that require
pumping due to the combination of head and flow rate involved, suitable
pumping and piping systems are not always readily at hand and valuable time
is lost at the spill while attempting to engineer a system. Therefore, EPA's
Edison spills research group undertook a project to build a mobile,
pre-engineered pumping and piping system designed to bypass streams impacted
by spills of insoluble sinking hazardous materials, the product was to be a
completely self-contained, mobile system of submersible pumps, piping, and
accessories to provide the basic bypass capability.
1
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SECTION 2
SYSTEM DESIGN
DESIGN PHILOSOPHY AMD APPROACH
Underlying the EPA design strategy and specifications was a practical
philosophy that acquisition of a reliable and financially viable system would
require selection of components principally from commercial items that were
stocked and readily available nationwide. This philosophy would also
simplify system maintenance and repair. Using the specifications cited below
for the system and its components, and the basic philosophy, the design task
became one of sorting available products to achieve operational and space
compatibility while maintaining maximum operational flexibility at an
acceptable cost.
PERFORMANCE SPECIFICATIONS
Major performance specifications established in the contract defined a
system that would be:
1. Completely self-contained and capable of independent operation (with
liquid fuels supplied separately).
2. Self-propelled (via tractor-trailer) over interstate highways
without special permits (two trailers maximum) .
3. Able to be fully assembled onsite in 4 hours by five men.
4. Capable of diverting a volume flow rate of 0.35 m /s (5,600 gpm) a
distance of 0.3 km (1,000 ft), or a lesser flow volume a distance of
0.91 km (3,000 ft.) .
5. Continuously operable for 21 days (500 hrs) without dropping below
50% caoacity in the event of any single component failure.
6. Mounted for quick removal in case of air shipment of components.
Additional requirements for individual components are detailed below.
Submersible Pumps
1. Fifteen-m (50-ft) total dynamic head (TDH) at design capacity.
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2. Manual turndown to 0.009 m3/s (145 ppm).
3. Fittings for crane hoist lifting and for skidding.
4. Ability to operate 107 m (350 ft) from power source.
5. Electric or hydraulic drive with service line on storage reels.
6. Protected intake to exclude fish and debris.
7. High-level alarm to siqnal inadeauate pumping.
Booster Pumps (Suppl led try EPA)
* Two-stage centrifugal booster pumps with 0.09 m°/s (1,425 gpm) flow
volume and 84-m (275 ft) head capacity when used in the single-stage
Pi ping
1. Lightweight piping in sections weighing 45 kg (100 Ib) or less.
2. Quick-connect couplings.
3. Suitability for unprepared ground and for maximum pressure load of
booster.
Fittings (Quick Disconnect)
1. Flexible hose at submersible pumps.
2. Valves for control and isolation of components for repairs.
3. A selection of elbows for use where pipeline route is tortuous.
Accessories
1. Pipe dollies to distribute pipe quickly.
2. Tools for maintenance and repair.
3. Floodlighting.
4. Flow rate and flow totalizing meters.
5. Spare parts.
6. Weather covers for equipment (removable).
7. Spoilers to prevent stream bed erosion on return flow.
All these criteria have been met or exceeded in the system delivered.
3
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SECTION 3
COMPONENT SELECTION
An important factor in the selection analysis was compatibility of
components with one factor. Because the booster pumps were a qiven condition
of the system (they were provided by the government) this was an appropriate
starting point for the analysis. In this section, rationale is qiven for the
component selections made. A listing of those components selected is given
in Table 1. Discussion of those components considered and then rejected is
limited simply to the listing of such items and the brief comments in Table
2.
BOOSTER PUMPS
The entire operating mobile stream diversion system was built around
four each 0.09 m /s (1,425 gpm) GP-110-3 petroleum pumps produced by John
Reiner & Co. and provided by EPA. Each Reiner pump was powered by a
Continental R-602 six-cylinder gasoline engine which had the capacity to
deliver the rated flow under an 84-m (275 ft) head. (An 84-m [275 ft] head
corresponds to friction loss in 2,160 m [7,090 ft] of 203-mm [8-in.]
-diameter pipe). The units were designed to perform in any ambient
temperature from -15 C (5 to 122 F) and at altitudes from sea level to 1,500
m (5,000 ft). Because the pumped fluid supplied cooling, and pressure
reduced engine speed to idle whenever suction side conditions approached
cavitation, priming was a necessity.
SUBMERSIBLE PUMPS
Selection of a practical submersible pump array was based on supplying
the demand at the suction side of the four booster pumps. Flexibility and
reliability required that one submersible pump be provided to feed each
booster pump. (One submersible to feed more than one booster pump would
waste booster capacity if the submersible ceased to function.) With
one-to-one correspondence, the capacity of each submersible had to exceed the
booster demand to maintain suction side flow continuity (0.09 m^/s [1,425
gpm]) and avoid cavitation. There was also the possibility that debris might
choke off part of the flow field. Consequently, it was decided each
submersible pump should have a capacity (at the design head) that would
exceed the booster flow significantly; e.g., say a 25% areater capacity, and
be protected from debris entrainment by expanded metal screens.
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TABLE 1. MAJOR COMPONENTS OF MOBILE STREAM DIVERSION SYSTEM
Item
MFR/Model
Specifications
Tractor
2 ea.
Trailer
2 ea.
Submersible
Pump
4 ea.
Generator
2 ea.
Booster Pump
4 ea.
Crane
2 ea.
Mack Maxidine RL 795L5T
Fruehauf PF-F2-40
Peabody Barnes 6SEH4004
Electro Motion 125 T 6
Reiner, GP-110-3 (government-
furnished equipment)
International Crane
Model 309-4
325-HP diesel engine; 2 rear axles, tandem inter-
lock; 10:00 x 20 tires.
12.2-m (40-ft) trailer w/Budd wheels, 10:00 x 20
tires; 27,000-kg (60,000-lb) capacity.
29.8 kW (40 HP), 3 phase, 460 V, 0.8 PF, 152-mm
(6-in.) discharge, 0.12 m3/s (1,900 gpm), 15-m
(50-ft) head, 21-m (70-ft) #2 AWG 4-wire power
cable with 600-V, 100-A "Powertite" connector.
100 kW continuous duty (125 kW standby), 265/460/
575 volt, 3 phase; water-cooled Allis-Chalmers
Model 11000 diesel engine; Kurz & Root brushless
revolving field 100-kW generator.
Two-stage, 152 mm (6 in.), 0.09 m3/s (1,425 gpm),
8,370-cm (275-ft) head, gasoline-driven centrifugal
pump.
2,700-kg (6,000-lb) capacity
45 kN-m (33,000 ft-lb) electrical hydraulic, self-
locking winch; electric 2n radian continuous rota-
tion, 3.4 to 5.1-m lift (11 to 17 ft), 1.2 to 4.2-
m reach (4 to 14 ft).
(continued)
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TABLE 1 (continued)
Item
MFR/Model
Specifications
Pipe & Hose
(approx. 1 km
[3,000 ft])
ASC Mainline/Circle Lock
(C/L) Agricultural Irriga-
tion Aluminum Pipe w/
steel fittings
Pipe Fittings
ASC Mainline/Circle Lock
Connectors, B.F. Goodrich
Nylair 44 Hose and hose
patches
ASC Mainline/Circle Lock
Aluminum and Steel
203-mm (8-in.) tubing, 9.1-m (30-ft) length, 1.63-
mm (0.064-in.) wall, gaskets, quick connect coup-
lings and lock ring included with each length, 68
pieces (32.1 kg [70 lb]/length);
152-mm (6-in.) tubing, 9.1-m (30-in.) length, 1.47-
mm (0.057-in.) wall; gaskets, couplings, etc.,
24 pieces (21.7 kg [48 lb]/length)
203-mm (8-in.) tubing, selected lengths, 1.63-mm
(0.064-in.) wall; gaskets, couplings, etc., 18
pieces (various weights, less than 16 kg [35 lb]/
length).
33 sections flexibile hose couplings, 50 m (165 ft)
total.
48 pieces:
203-mm (8-in.) elbow, 90°, -16 each
203-mm (8-in.) valves -5 each
203- by 152-mm (8- by 6-in.) reducer -3 each
152- by 203-mm (6- by 8-in.) expander -5 each
305- by 203-mm (12- by 8-in.) reducer -3 each
305-mm by 1.5-m (12-in. by 5-ft) long, flanged
meter-input - 3 each
305-mm by 0.3-m (1- by 1-ft) long, flanged meter-
output - 3 each
152-mm (6-in.) flange to C/L coupler -5 each
203- by 203- by 305-mm (8- by 8- by 12-in.) Tee
-3 each -with gaskets, couplings and lock
rings
152- by 305- by 305-mm (6- by 12- by 12-in.)
spoiler tee - 2 each.
(continued)
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TABLE 1 (continued)
Item
MFR/Model
Specifications
Winch
1 ea.
Water Meter
2 ea.
Rack/Dolly
2 ea.
Rack/Dolly
2 ea.
Control Center
2 ea.
Ramsey DC 12-8
McCrometer, Model M C 0500
305-mm (12-in.) meter
Scientific Service, Inc.
Scientific Service, Inc.
Scientific Service, Inc.
Cable Reels
4 ea.
Hannay C 3034-24-26
2,700-kg (6,000-lb), 12-volt DC portable electric
winch, SSI dolly mounted.
0.01 to 0.2 m3/s range (150 to 3,000 gpm).
2.4 m wide by 5.4 m long by 0.5 m to 0.7 m deep
(8 ft by 17 ft, 8 in. by 20 to 28 in.) telescoping
pipe rack with 2 pr wheels and drawbar to convert
to pipe dolly.
2.4 m wide by 5.4 m long by 0.6 m deep (8 ft by
17 ft, 8 in. by 2 ft) pipe and fitting rack with
2 pr wheels and drawbar to convert to pipe dolly.
200-ampere, 600-volt, 3-phase Service Box with:
100-ampere, 480-volt, 3-phase circuit breaker
- 2 each
30-ampere, 277-volt, 1-phase circuit breaker
- 3 each
15-ampere, 120-volt, 1-phase convenience
circuits - 2 each;
100-ampere, 480-volt, 3-phase Cutler-Hammer
starter relays with remote start-stop and hold-
ing relay - 2 each;
High/low water level switches.
High water level alarm.
107-m (350-ft) storage capacity for #4 AWG 4-wire
cable.
(continued)
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TABLE 1 (continued)
Item
MFR/Model
Specifications
Cable, electric
Floodlight
4 ea.
Tool Box
1 ea.
Cereske Cable #4 AWG
600-volt SO cable
Sylvania 1500 T 3Q/CL
277 volt
12-gauge steel box with
SSI-selected tool
complement
4 each, #4 AWG 4-wire, 86-m (280-ft) power cables
with 100-ampere, 600-volt AC Appleton Electric
"Powertite" cable connectors.
127° horizontal by 98° vertical dispersion; 1,500
watts, 34,400 lumens, 61% efficiency.
50-piece selection of maintenance and repair tools,
and controllers.
oo
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TABLE 2. MAJOR COMPONENT ALTERNATIVES CONSIDERED
Item
Tractor
MFR/Model
Ford LNT 900
Ford C 8000
International F1850
Type
Gasoline
Diesel
Diesel
Comments
Operating cost too high.
Inadequate off-highway.
First cost too high.
Trailer
Submersible
Pump
Utility Brute
MAI
Pacific Construction
Flygt B2151
Flygt C53200
Crisafulli High Head
Inside frame
Platform
TX 40 platform
Centrifugal
Light weight no cost advantage;
first cost too high .
First cost too high.
First cost too high.
Requires daily lube.
Restrictive low-side flow.
First cost too high; restrictive
low-side flow.
Generator
Crane
Fittings &
Pipe
Onan 115 Owa Diesel
Electro Motion 125HG800 Gasoline
Hiab 345
Hiab 550
R 0 Products TC 40 1A
Fiberglas Resources
Corporation
Electric/Hydraulic
Kwiklok
Fiberglas
First cost too high.
Operating cost too high.
Not equipped with winch.
No winch; first cost too high.
First cost too high.
Pipe too heavy; first cost
excessive.
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Figure 1 is a performance curve of capacity versus head for the Peabody
Barnes centrifugal pump Model 6SEH 4004 selected. Each pump is powered by a
480-volt, 3-phase motor that draws 61 amperes at rated capacity and has, a
271-ampere locked rotor startup current. The pump will deliver 0.12 irTYs
(1,900 gpm) at the design total dynamic head (TDH) of 15m (50 ft) or 0 09
m /s (1,425 opm) (the booster flow) at 22-m (72.5-ft) head. The 22-m head
corresponds to the friction loss in 573 m (1,900 ft) of 203-mm (8-in.) pipe
at 0.09 m /s (1,425 gpm). Thus, over level ground, each submersible pump can
deliver 0.09 m /s (1,425 gpm) at a distance of nearly 0.6 kilometers (2,000
ft) provided the output from each pump flows through its own 203-mm (8-in.)
pi pe.
36
24
12
.01 .02 .03 .04 .05 .06 .07 .08 .09 .10 .11
~"i ow Rate (m'/s ^
Figure 1. Submersible pump performance curve.
10
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At the lower limit, the pipe flow can be turned down to 90CL cm /s (14
gpm) without overheating the pump motor. To ensure a 900-cm /s (14-gpm)
cooling flow through each submersible pump, a 6-mm (0.236-in.) hole has been
drilled in the flanged fitting attached.
Submersible Pump Cables and Cable Storage Reel s
Power cable requirements for the submersible pumps were determined by
the continuous duty demand at the pumps' maximum operating capacity, by the
voltage drop that could be tolerated in 107 m (350 ft) of cable, and by
safety requirements. These requirements were 61 amperes, something less than
20 volts, and an internally grounded (4-wire) power cable system,
respectively.
National Electric Code specifies 70 amperes as allowable current
carrying capacity of #4 AWG 4-wire cable with utility-grade insulation (such
as RW, T, TW, UF. S, SO) in 3-phase continuous service at ambient
temperatures of 30 C (86 F). With increased ambient temperature, the
allowable continuous service current-carrying capacity of a given conductor
must be reduced. This will become 64 amperes at 35 C (95°F), 57 amperes at
40 C (104°F), and 50 amperes at 45°C (113°F) for the specific cable cited.
An ambient temperature condition outdoors which equals or exceeds the latter
temperature will be extremely unusual and will occur only in the heat of the
day. It is a simple matter to compensate, should this occur, simply by
turning flow volume down slightly during periods of high ambient temperatures
above ~35°C (95°F). Moreover, the voltage drop in 107 m (350 ft) of this
cable drawing 61 amperes in 3-phase service is less than 10 volts.
Consequently, a #4 AWG 4-wire SO cable is adequate for field service. (SO is
a utility-grade, waterproof, oil- and acid-resistant insulation for outdoor
use).
The Peabody Barnes pumps selected came equipped with 21 m (70 ft) of #2
AWG 4-wire SU cable rated at 66 amperes at 45 c'(114°F). (SU is equivalent
to SO with the additional property of abrasive resistance.) To meet the total
requirements for 107 m (350 ft) of cable per pump unit, an additional 86 m
(280 ft) of #4 AWG 4-wire SO cable was provided for each pump and mounted on
Appleton "Powertite" 100-ampere internally grounded connector (see Figure 2A,
C, D) that served as a safety disconnect as required by the National Electric
Code.
For easy access onsite, the pump service lines were required to be
stored on reels (Item 5 of the performance specifications for submersible
pumps). For this purpose, four Hannay Reels, Model C-3034-24-26 were
selected. They had hand cranks for rewinding and a capacity of 100 m (330
ft) of #4 AHG 4-wire SO cable. Each of these reels was used to store 86 m
(280 ft) of service cable extensions. Two cable reels were mounted on a
dolly designed to allow the cable to be paid out directly off the storage
reel to minimize dragging.
11
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Powertite
connector
Crossarrn
securing pipe
racks and pump
floats
Figure 2. Submersible pump auxiliary features,
12
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Float Switches
Remote automatic switches to start and stop the submersible pumps and to
warn of high water conditions were specified as part of the operating system.
To comply with retirements, three mercury switches (each enclosed in a
float) were provided. Float orientation, controlled by water level, actuated
them. Two of the switches controlled one of the pumps on each unit ("on" at
low water in the catch basin and "off" at high water) and the third switch
sounded an alarm if the water rose above the high-water pump switch control
(for example, in case of a pump failure), the pump control switches were
linked to the pump starter relay via a 107-m (350 ft) #14 AWG 3-wire SO
cable, and the high-water alarm switch was linked to a claxon via a 107-m
(350-ft) #18 AWG 2-wire SO cable. The latter was connected to the 24-volt DC
battery supply on the generator and the former was connected to the 480-volt
AC output.
Mounting of the float switches is depicted in the sequence of
photographs in Figure 2. Figure 2 shows a pump pinned in place on the deck
of a trailer (A); one of the multiple crossarms being inserted into the
square tubing that is part of the pump skid (B); the pair of float switches
that turn the pump on and off remotely (C); and a second position for the
float switch that turns the pump on at high water (0).
GENERATORS
Selection of the generators was based on the power demands of the oumps
and on the damands for the floodlighting and convenience circuits used for
battery chargers, power tools, comfort heaters, etc. Continuous duty demands
were set by the submersible pump requirements, the remaining requirements
could be covered by standby capability of a generator. The continuous duty
demands on the generator were 97 kW, to power the submersible Dumps at their
rated capacity. The remaining demand was likely to be less than 10 kW so
that a standby capacity of 110 kW would ordinarily by sufficent. However,
the largest single power requirement was the startup load of the submersible
pumps. Careful analysis of this requirement indicated that a 125 kW standby
capacity would be sufficient to start both submersible pumps, provided the
two pumps were started sequentially.
Cost benefit analysis indicated that a diesel generator would be
preferable. This preference was based on the trade-off between the
incremental first cost of the diesel generator over a gasoline generator of
comparable size and the differential fuel costs for gasoline over diesel
fuel. The trade-off favored diesel after 1,000 hr of operation. Hence, each
unit was equipped with an Electro-Motion 125 T6 Diesel Generator assembled
from an All is Chambers turbocharged Model 11000 water-cooled diesel engine
and a Kurz & Root reconnectable brush! ess revolvina field four-pole
generator.
13
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Control Center
The generator was equipped with a built-in main circuit breaker rated at
600 volts, 200 amperes, and with an adjustable temporary overload delay.
National Electric Code required that each power take-off circuit be protected
against continuous overload and that such protection be mounted in a NEMA 3
service box if it were outdoors. A simple 600-volt, 200 ampere "fusible and
motor starter panelboard" from Cutler-Hammer was selected (Figure 3} for this
purpose. In it were installed two 480-volt, 100-ampere, 3-phase breakers to
service the two submersible pumps, and three 277-volt, 20-ampere, 1-phase
breakers to service each of the two 277-volt floodlights and a
277-volt/120-volt 3-kW transformer providing two 120-volt convenience outlets
for power tools, trouble lights, heaters, etc. Each of the three 277-volt
breakers provided service from a different leg of the generator, to
distribute the load. The service panelboard also provided the "Lockout"
capability specified in the National Electric Code as a safety requirement in
Figure 3. NEMA 3 service box.
14
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cases where the service panel would not be visible from the motor being
serviced. (A complementary Code safety feature reauired a valid disconnect
within sight of each motor. The "Powertite" cable connectors that terminated
each cable were selected to provide this disconnect feature.) The panelboard
served principally as a distribution service box that divided the power
output of the generator into appropriate voltages to service the various MSDS
components and protected each of these and the generator with a circuit
breaker. As it was not likely that access to the service box would be needed
often, it was located in front of the generator control panel, but hinged to
the protective pipe-framework so it could be swung clear to gain access to
the generator control center (Figure 4), when necessary.
The generator control center was mounted inside the weather housing that
covered the generator. Also under this housing were the starter relays
needed to activate and protect the sumbersible pumps. Each starter relay was
equipped with a fusible link (matched to the continuous duty current draw) to
protect the pump in case of an overload, but which would pass the temporary
"locked-rotor" current required for startup. A remote-start circuit was also
provided, and a holding relay was supplied to override short-term signal
changes (such as would occur if a float-actuated switch were to ride up and
over a wave). To assure reliability, the starter relays were enclosed
separately to protect them from damange in a dusty operating environment.
Cutler-Hammer relays were 480-volt, 100 ampere, 3-phase units mounted in NEMA
3R (dustproof) enclosures. For each leg of the 3-phase circuit, 61.3 to
64.9-ampere heater coils (fusible links) were used to protect the submersible
pump motors. Each pump was wired for local start and stop at the control
center and one pump on each trailer was operated from remote start and stop
via the float switches at the submersible pump. (The rationale for only one
remotely controlled pump per unit was that it would be adequate to preclude
either overflowing or draining of the pump catch-basin whenever two pumps
were used, or else one pump would be sufficient.)
The generator control center was equipped with low oil pressure, high
water temperature, overspread, and overcrank automatic shutdown and audible
(siren) alarm circuits. These were augumented by a separate high water
audible (claxon) alarm. The generator-fuel high/low-level alarm was
connected on the same panel (and claxon). All these circuits were equipped
with "acknowledge" switches to deactivate the alarms, in particular where the
passage of time (high water-temperature) or an action (add oil) would be
required before reset was possible. The alarms were selected to operate
either by 12-volt DC or by 24-volt DC (rather than generator AC) so that
shutdown notification would be ensured.
The generator control center included voltmeter, ammeter, frequency
meter, running-time meter, oil pressure and water temperature qauges, and
field (circuit) breaker. A phase selector switch enabled voltaqe and current
in each leg to be measured so that lighting and convenience circuits could be
balanced, or continuous-duty overload conditions determined. An "emergency
stop" switch was mounted prominently on the weather cover (above the service
submersible pumps) to provide the safety of a total shutdown (see Figure 4)
capabil ity.
15
-------
II Submersible
StartSstop
Emergency,
AH stopj
*!
#2 Submersible
lltaftfStop]
Service box
277 volt -
lighting
circuit ,
outlets ,
Generator control
center access
Figure 4. Generator circuit and control center features.
16
-------
PIPES, HOSES, AND FITTINGS
A practical system of piping and fittings that could be rapidly
distributed and assembled at any site had to satisfy many retirements. Pipe
needed to be lightweight, provided in manageable sections with strength
sufficient to withstand the 84-meter (275 ft) pressure head, be riqid enough
to take the weight when laid over unprepared ground, be flexible at pump
connections, have a sufficient complement of valves to enable pump components
to be isolated for repairs without necessitating equipment shutdown, and be
supplied with a complement of elbows to enable direction changes to be made
in the pipeline where needed. Finally, friction loss in the pipe could not
exceed available pumping head for the volume flow rate and pipe length
required and all had to be packaged to fit together compactly for transport
to a site.
Fortunately, because many of these requirements apolied also to
agricultureal irrigation systems, a good many of the desired qualities for
the MSDS pipe were available in a commercial product. Thus, it was necessary
only to select a complement of irrigation pipe size(s) and lenaths to meet
the requirements for rigidity, pressure rating, limited friction loss,
acceptable weight per section, total line length, efficient storage, and
distribution and assembly and valves and fittings sufficient for completing
assembly in the field. A fair number of tradeoffs were involved,
nevertheless, Moreover, the industry discouraged the notion of "nesting" any
small-diameter pipe inside larger pipe to save space. Two reasons were
given: sliding one pipe into or out of another had been found to wear pipe
out physically, and the process was reported to become tiring very quickly.
Commensurate with all these demands, it was concluded that the 203-mrn
(8-in.) pipe was the largest practical diameter, as determined by the
pressure head requirements. At the uoper range of volume flow rates desired,
the next smaller size of irrigation pipe readily available (152 mm [6 in.])
was adequate but there would be about four times the head loss .,per unit
length of smaller pipe. System potential for delivery of 0.09 m /s (1,425
gpm) could be enhanced over longer distances by the use of 203-mm (8-in.)
pipe (that is, the range would be four times that with 152-mm (6-in.) pice).
In anticipation that incidents could occur that would require very rapid
response to supply water (for example, nuclear water coolant loss; bypassing
a contaminated community water supply) where a long run of pipeline might be
an important factor selection of pipe and fittings was weighted heavily in
favor of the 203-mm (8-in.) diameter.
With regard to fittings, rigid elbows were acquired for the pump and
metering hookup and flexible elbows for every three lengths of pipe in the
line. The flexible elbows were made up of short (0.7 and 1.5-m [2.3 and
5-ft]) lengths of B.F. Goodrich Nylair 44 hose, clamped to quick-connect
couplings by means of stainless steel bands applied with a Band-it tool. The
couplings used were of a standard agricultural irrigation coupler-pair, each
welded to a section of standard Goodrich serrated steel hose-patch which
ensured a good grip on the hose. With these flexible elbows and the
additional flexibility provided at each pipe joint by virture of the unique
gasketing, a pipeline could be constructed through a forest, if necessary.
17
-------
Moreover, the flexible joints would also preclude transmission to the pump
mounting of therma-l stresses developed as temperatures in the metal pipe
changed.
Flexibility was provided at the submersible pump discharge by means of
3-m (10 ft) lengths of 152-mm (6-in.) hose and couplinas. A 152- by 203-mm
(5- by 8-in.) expander-fitting enabled each 152-mm (6-in.) pump hose to be
connected to the 203-mm (8-in.) mainline pipe. Where this line was connected
to the booster pumps, a yoke, or manifold, was bolted on each intake (and
exhaust) to provide a auick-connect 203-mm (8-in.) coupling that joined the
pipeline to the two 152-mm (6-in.) flanged fittings on the suction and
discharge lines of each pump.
One 203-mm (8-in.) valve on the discharge side of each booster pump
controlled the flow volume manually, when desired, and isolated a pump unit
for repair when necessary. The potential for cavitation and/or bearing
damage precluded use of flow valves on the intake (or suction) side of the
booster pumps; hence, four valves (and a spare) constituted an adeouate
supply.
A spoiler fitting supplied with each unit prevented stream erosion at
the downstream return point. The spoiler comprised a 305-mm (12-in.) section
of pipe, open at both ends, welded to a centrally connected 152-mm (6-in.)
quick-connect coupler. The spoiler reduced pipe flow at discharqe to 2.5 to
3 km/hr (1.6 to 1.9 mi/hr), so that a plastic sheet spread over a 5- by 5-m
(16- by 16-ft) section of stream bed would preclude erosion.
Distrubution and assembly of the pipe and fittings was analyzed in
detail to determine requirements imposed on packaging. Estimates indicated
that, to be able to distribute and assemble the entire system and have it
operating onstream in 4 hours with the five-man crew, the distribution and
assembly of the entire pipe complement could be allocated no more than 2 to 3
hours. Consequently, an evaluation of pipe distribution and assembly options
was conducted.
Pipe Racks and Dollies
A simple evaluation of the total distance covered in travel along the
pipeline was made assuming distribution of 914 m (3,000 ft) of 9.14-m (30-ft)
lengths of 152-mm (6 in.) pipe, one at a time, by hand. (This oipe length
was selected to be manageable bv one person, as each unit weighed under 22.7
kg [50 lb]).
Each time a crew member delivered a length of pipe to the end of the
pipeline, the total line length would be traversed twice (round trip). Thus,
total travel required to deliver 100 lengths was calculated as:
L = [(1 + 100)72] x 100 x 9.14 - [100 x (9.14/2)1 x 2 = 91.4 km
or an average of 18.3 km (12 mi) per crew member (with a 22.7-kg (50-lb) load
18
-------
half the time). Clearly, it would take over 4 hours under ideal conditions
for the five-man crew to do more than deliver even this small size pipe along
the pipe! ine.
A calculation similar to the one above showed that the minimum distance
travelled with a 3-pipe dolly would be 30.5 km (19 mi), or 61 man kilometers
(two-man operation). Divided among the five-man crew, the task would average
12.2 km (7.6 mi) per crew member (though without the burden and cumbersome
task of handcarrying) . Nevertheless, it was estimated that just delivering
the pipe along the line would reguire 2 to 3 hours, so that a larger dolly or
a larger crew would be reguired. The larger dolly was considered practical,
provided the idea was kept in mind that it would be inefficient to transfer
pipe at the site; that is, the pipe should arrive at the site already loaded
on the do! ly.
The combination rack and dolly that appeared mandotory to meet the time
specifications was not available as a commercial item. Adjustable rack and
dolly units of maximum practical size had to be designed for pipe and for
pipe and fittings to carry out the pipe distribution operation. (Details of
the system are given in Figures 5 and 6.)
With this system, the pipe was readily unloaded while still in the
racks, and the racks were converted to dollies in 15 minutes. Five men could
lay 1 km (3,280 ft) of pipe in 1-1/2 to 2 hours over reasonable terrain, and
with the dolly hitched to the tractor, two men could lay 1 km (3,280 ft) of
pipe in 5 hours (and in an emergency, one man alone could lay pipe this way).
Metering
Once the pipe and pumps were in place and operating, the pumping system
could be made to operate more efficiently by adjusting it to pump at a nearly
continuous flow rate, rather than leaving it to cycle off and on according to
High/Low float switches. The current could be less at lower flow rates, the
generator would not have to work as hard, and a corresponding lower fuel
consumption, operating cost, and air pollution would result.
Metering provided an effective means for empirical determination of an
appropriate flow rate to match stream flow. With High/Low switches a fixed
distance apart, one needed only to time the periods between activation of the
switches from high to low (At^l ) and from low to high (At-|h) and to record
the pump flow volume, q , during the pump "on" cycle, to define the stream
volume flow, q . That flow volume could be calculated as:
Clearly, with the stream flow, q , defined, one could simply close down the
valve (on the pump discharge] until the new flow registered on the meter.
Thereafter, little cycling would occur because the Dump rate would equal the
stream flow rate. Though a perfect match would be unlikely, the pumpinq
period would be extremely long, the off period relatively short, and the
19
-------
Figure 5. Pipe rack/dolly.
20
-------
Figure 6. Pipe and fitting rack/dolly
21
-------
operational efficiency near a maximum,
Th i s wa s
0.18 M /s continuously.
A "McCrometer MC 0500-12 inch" flowneter and totalizer was furnished for
the smallest size meter capable of monitoring a flow
nuously. The unit was purchased with a special
required to enable the meter to operate at this flow
At the low flow rate extreme, the meter could read down
(The meter, shown in Figure 7, is graduated in hundreds
head can be purchased for remote
each unit.
volume of
heavy-duty bearing,
volume continuously.
to 9 1/s (145 gem).
of gallons per minute. An electronic
readout, control, or warning signal.)
Because the meter was bulky and heavy, and required a 1.5-m (5-ft)
straight section of 305-mm (12-in.) steel pipe upstream and 0.3 m (1 ft) of
305-mm (12-in.) steel pipe downstream (steel was reauired in this size to
meet internal pressure requirements), this entire section of 305-mm (12-in.)
pipe, with meter, was mounted under the trailer, protected in the lee of the
landing gear from major road hazards.
CRANE
The maximum load imposed by items that would be unloaded onsite was
computed as something less than 1,700 kg (3,800 Ib) (the pipe and fitting
rack) with a lever arm of less than 2.4 m (8 ft) required. Maximum moment,
therefore, would be under 45 kN-m (33,000 ft-lb) . A crane with a cable hoist
was necessary in order to meet the specification for direct drops of
submersibles 15 m (50 ft) from a bridge into the stream below, should that be
reauired.
Figure 7. Metered flow through one unit.
two submersibles through 273 m (900 ft)
(Note this flow rate is for
of 203-mm (8-in.) pipe.)
22
-------
The crane selected was a Model 309-4, manufactured by International
Crane Corporation, which had 22 m (70 ft) of cable, a 45 kN m (33,000 ft-lb)
maximum moment, and a 2,700 kg (6,000 Ib) maximum load capacity. This crane
provided 360 continuous rotation^capabil ity and a telescopilnq boom that was
hydraul ically operated (112 kg/cm [1,600 Ib/in ]) and electrically powered
(12 volt DC). A 12-volt DC system was selected over a 24-volt system so that
in an emergency the crane could be powered by the tractor's heavy-duty
12-volt system using a set of jumpers specially made of 4/0 welding cable and
provided with each unit.
TRANSPORTATION SYSTEM
An analysis of the deck space requirements for the major components
(booster pumps, generators, submersible pumps, crane, pipe- with pipe stacked
to maximum practical height) indicated a total load area almost equal to the
deck area of the largest trailer allowable on interstate highways. When area
was added to account for the spacing reauired between components to ensure
adequate cooling of engines, working space for personnel to unload
components, and clearance space needed to operate one on-board crane, the
total deck area required became considerably greater than that available on a
single trailer. Because there appeared to be no alternative to a two-trailer
system, added flexibility, reliability, and practical ity were provided by
designing two totally independent units. With this kind of redundancy,
should one unit get delayed or lost in an accident, it would not affect the
operation of the other unit. Moreover, on spills into small streams the
second unit could become standby and be dispatched elsewhere, should the
situation warrant.
Perhaps the greatest benefit of the two-unit system was that it enabled
a design approach to be used that would result in units that could have
access to state as well as interstate highways without special permit.
Information on state vehicle code weight and dimension limits for each state
was obtained from the California Trucking Association. These data defined
certain constraints on the MSDS transport system if it were to have access to
all state and interstate highways without restriction. The most stringent
conditions of allowable semi-tractor height and trailer dimensions and
weights were used to establish the following criteria for design of the MSDS
transport system:
Maximum height above roadway: 3.81 m (12.5 ft)
Maximum width: 2.44 m (8 ft)
Trailer length: 12.19 m (40 ft)
Total length: 16.76 m (55 ft)
Single axle load limit: 8,164 kq (18,000 Ib)
Tandem axle: 11,794 kg (26,000 Ib)
GVW (5 axle): 26,762 kg (59,000 Ib)
23
-------
Trailers
The array of components shown in Figure 8 favored a trailer with inside
frame to provide support for the concentrated loads along the centerline. A
steel frame trailer was selected over aluminum because the higher cost of
aluminum could only be offset by the payload weight saved on a high regular
annual mileage hauling schedule, which would be inappropriate to the intended
use. The steel frame also enabled a steel welded crane mount to be used. A
PF-F2-40 Fruehauf steel platform trailer with 12.19 m (40 ft) bed-length was
selected because it was a stock item and had the lowest bid price of
acceptable trailers. Moreover, its 27,000-kg (60,000 Ib) capacity was more
than adequate for the estimated 16,000-kg (35,000-lb) payload (20,500 kg
[45,000 Ib] total load) and the excess capacity provided the additional
flexibility of last-minute relocation of load.
Tractors
The single axle load limit in the state vehicle
important constraint. To meet this load requirement,
among the following: a special wheel and tire size;
axle; or tandem axles. The policy
eliminated the first option. Though dual
axle would enable specification of a
provide four drive wheels. Becuase
specification, a tandem rear axle tractor
LIGHTING SYSTEM
codes imposed another
a choice had to be made
dual wheels on one
of rejecting special purchase items
wheels were acceptable, the tandem
tandem interlock system that would
off-highway use was another
was selected.
The design criteria used for the lighting system were based upon typical
lighting levels used in auditorium, theatre, and hotel lobbies as 200 to 250
Im/m (19 to 23 fc) . (Such lighting levels would be slightly below the
requirement for general classroom and reading activity.) Selection was made
from floodlights that operated at 277 volts and had an output per unit area
compatible with the design requirement and commensurate with illumination
geometry. At a height of 3.7 m (12 ft) off the ground, a^floodlight with an
127 dispersion in one direction and 98 in the other'would deliver light
over an area approximately 15 x 8 m (50 x 25 ftl*. Each trailer was provided
with two floodlights. These floodlights were rated at 1,500 watts and
produced 22,000 1m each, about 180 Im/m (17 fc).
One 107 m (350 ft) #14 AWG 3-wire SO power cable, terminated at each
with a Woodhead Safety Yellow water-resistant connector, was provided with
each trailer unit for operating one floodlight at a range eguivalent to the
maximum distance at which the submersible pumps could be operated from the
trailer.
* Baumeister, T., Anallone, E. A., and Baumeister, T. Ill,
Handbook for Mechanical Engineers," McGraw-Hill, NY., NY.,
; "Mark's Standard
p. 12-126, (1978).
24
-------
^Submersible Pump
/ .8 in. Inlet Manifold
Cable Reel
Rack/Dolly
8 in. Outlet Manifold
/ X8 in. Outlet Manifold
Submersible Pump
7
8 In. Inlet Manifold
Pipe
Wheel and Fittings
Storage
Hose and Short
Pipe Fittings
Side View
Figure 8. Layout of components aboard trailer.
-------
SECTION 4
TRAILER LAYOUT AND SITE PREPARATION
The general arrangement of the Table 1 components on a unit is shown in
Figure 8. Figure 9 is a typical elevation view with the pipe and fitting
rack removed. Noted in Figure 9 is the reach of the crane and its main body
clearance requirements. For most response operations, only the pipe,
submersible pumps, and power cables need be unloaded, appropriately
distributed, and assembled. Because time is of the essence, each of the
racks converts to a wheeled dolly - the dolly wheels are stored in the
expanded metal section of the pipe and fitting rack (see Figure 8) - to
simplify and speed setup of the system. Figures 10 through 13 depict the
unloading sequence for the pipe and fitting rack and its conversion to a
dolly. Figures 5 and 6 show features of the pipe and the pipe fitting rack.
An isometric view of a typical wheel assembly and mode of attachment is
illustrated in Figure 5. Drawbar pins are used to secure those major system
components to the trailer which will be unloaded onsite (in order to
facilitate guick release on arrival and/or when air trans-shipment is
necessary), and to assemble various dollies used to distribute items onsite.
The wheel assemblies used to convert the pipe, and pipe and fitting
racks to dollies to distribute pipe are also used again to deliver the
sumbersible pumps and distribute power cables. Figures l^A and 14B are
photographs of a submersible pump dolly and a cable-reel dolly, respectively.
Both dollies can be moved by hand over smooth and nearly flat terrain, or
they can be hitched to one of the tractors. Should the region between the
off-highway staging point and the stream be inaccessible by tractor, a
portable winch with 2,700 kg (6,000 Ib) capacity is available. This winch
and its battery can be easily carried by two men, or fitted with wheels (see
Figure 15) and dragged to a vantage point from which to winch a submersible
pump into place (using successive staging points for the winch by tyinq it to
a tree, or to a ground anchor) . Such a winching procedure might be required
for operating in a woods, over steep or roiling terrain, or down an
embankment. Finally, should access to a stream be precluded except by a
vertical drop, for example, off a bridge the trailer can be parked on the
bridge, the crane boom extended 4 m (14 ft), and the submersible pumps
lowered 15 m (50 ft), by rerigging the crane cable to operate with a single
winch line. (If it is necessary to operate the pumps and remain within the
single winch-line load-limit. However, with two winch lines, both
submersible pumps can be suspended by one crane if limited to a reach of 3.3
m (10 ft) and a drop of 10 m (33 ft).)
26
-------
Cable Reel Rack/Dolly
jniersible Pump (2 each)
f 'H in. Inlet Manifold Limit of Crane A
| / , ' ' Reach \
*'(
((
Rear Booster O
v^r^i l
\)rs / v 1 \
V I I \
B in. Outlet fvin i foi d
\ I
Pipe Rack \ /
x _s
Generator
^
ok
•A
S Too
/ Sto
L^\
I"
i *•• V J
I V Circle
' V Inrk Rinn
8 in. Outlet ^ ^CK Klng Vfi00dHght Storage
Manifold
Storage
3 in. Inlet Manifold
Travel Height Limit
200 AMP, 480 Volt Service Box
Side View
Figure 9. Layout of components with pipe and fitting rack removed.
-------
•ftFrr
_ . . _
-
r-.'n.irr
TRAVEL
BOOM EXTENDED TO PICK
UP PIPE AND FITTING
RACK
.'( f: ! it
Figure 10. Rear view of trailer with components aboard.
28
-------
BOOM ROTATED TO CLEAR
TRAILER DECK; TELESCOPED IN,
TO LONER RACK
ALONGSIDE
TRAILER, CABLE UNREELED
TO SET RACK ON GROUND
(ATTACH DRAWBARS)
f
\-.
h'.'.l-'
OOQ
i , . i i • • rf
-
-
OOQ.
Figure 11. Pipe and fitting rack unloading.
29
-------
1E3L LJJJLUT _1^__. „
BOOM EXTENDED, ALTERNATED WITH DOHN CABLE, TO ROTATE RACK
NINETY DECREES
coo
AFTER TURNOVER, BOOM LOWERED, WHEELS ATTACHED, AND TOUCHED
TO GROUND
Figure 12. Pipe and fitting rack rotation and whee] assembly.
30
-------
QOjQ
• T^f-iTi
. ...
PO.Q,
I^IILGT
1
li
f
L
£&£&&•$&
BOOM RETRACTED AND HOOKED TO OPPOSITE SIDE, RACK RAISED,
AND SECOND PAIR OF WHEELS ATTACHED
Figure 13. Completion of rack/dolly conversion.
31
-------
A. Submersible pump dolly.
i. Cable reel dolly.
Figure 14. Pump and cable reel dollies.
32
-------
Note fittings in bin of pipe
and fitting rack. \
Figure 15. Winch dolly.
33
-------
For setting up the system at night, each unit is equipped with two
1500-watt floodlights (see Fiqure 16). These floodlights mount on the shear
wall stanchions welded to the booster skids (see Figure 17B) that are used to
secure the pipe and pipe and fitting racks (both fore and aft) in transit.
On site, the crossarms (already removed from the rear stanchion in Fiqure 178)
that secure each of these racks to the stanchions may be removed, turned 90°,
and by means of adapters (carried in the tool box) mounted to the stanchion
to provide an additional 1.2 m (4 ft) of height above the trailer deck for
the lights. The floodlights are mounted with two degrees of freedom in
rotation so that lights can be provided in any direction.
A 107-meter (350-ft) service cord for one flood!iqht enables it to be
moved anywhere between the staging point and the stream, so that whenever
difficult terrain is encountered in night operations, ample lighting will be
available for setting up the submersible pumos, .power cables, upstream
piping, and pump on-off and alarm switches.
34
-------
SECTION 5
SYSTEM OPERATION
Efficient application of the stream diversion system will require
experience, and attention to development of standard management strategies as
a backlog of experience is acquired. Until that experience is acauired, some
discussion of approaches to efficient application and to pumping options is
included here. Figure 18 illustrates the deployment of the MSOS in a typical
spill scenario.
Assuming notification of a soil! has been received, an effective
management approach would be to dispatch the foreman to the site by the
fastest means in order to select and mark the staging area for the drivers
and to identify any existing or potential problems. The foreman of the MSDS
should also provide decision information on selection of sites for catch
basins, etc. Under ideal conditions, only the stream velocity, elapsed time
from spill to completion of the downstream dam, and the margin for error
allotted to these two estimates will determine the length of stream to be
isolated. However, because a catch basin cannot be infinite, the length to
be isolated will be affected by how rapidly the upper basin (above the
isolated region) fills. Hence, isolated length also depends on the volume
rate of flow of the stream and the choice of catch-basin site (i.e., on
catch-basin volume). It should be the MSDS foreman's task to temper site
selection by knowledge of the time it will take to get the MSDS in operation,
taking local conditions into account, as well as which mode of operation
should be employed.
To help in the decision process, the capability of MSDS under different
conditions (modes) of operation must be known. Table 3 lists a number of
operational modes for the system. These have been computed based on the
assumption that the pipe is laid over level ground and that the pump pressure
acts only against head loss in the pipe. Under such circumstances the
booster pumps are not required for the system to deliver a flow volume of
0.35 m /s (5,600 qpm) a distance of 0.3 km (1,000 ft) as this is within the
capability of the submersible pumps. Under these assumption, it is also
within the capability of the system to deliver 0.07 m /s (1,100 gpm)3 a
distance of 0.9 km (3,000 ft) with just the submersible Dumps (0.09 m /s
[1,425 qpn] with one submersible and one booster pump).
There are definite benefits to be gained if a mode can be selected which
eliminates the requirement for a booster pump (because the boosters on each
unit use four times the fuel required to operate the submersibles). Thus, a
judicious choice of operational mode can save fuel, reduce operational costs,
37
-------
Figure 18. MSDS spill application.
38
-------
TABLE 3. MOBILE STREAM DIVERSION SYSTEM (MSDS) OPERATIONAL MODES
- —
1.
2.
3.
4.
5
6
7.
8.
Vo 1 ume
Rate 0
Mode (mVs)
@ .„
V_- 22
(sj •'"
Q .
.35
G)
CO
(M?J--10
GHIH20
CHlT'1"
0-ffl
0-iT]
Dow Volume Flow Volume How
.3 km Rate @ .6 km Rnte @ .9 km
q o_ o
(gpm) (mVs) (gpm) (mVs) (gpm)
1 ,750 .09 1 ,425 .06 950
3,500
2,900 .10 1,600 .07 1,100
5,600
1,600 .10 1,600 .09 1,425
3,200
2,900 .18 2,900 .11 1,750
5,600
If Series Staged With WdftTonal Pipe
Pipe
0 Ranne Required
Stages (mVs) (gpm) km ft km ft
4 .09 1,425 2.4 7,900 2.4 7,900
2 .18 2,900 1.2 3,900 2.4 7,900
1 .10 1,600 0.6 2,000 1.2 3,950
4 .09 1,425 11 36,000 11 36,000
2 .10 2,900 5 16,400 11 36,000
1 .35 5,600 1.1 3,600 2.2 7,200
Note: Submersible pumps (?) and booster pumps [3] may he used singly or jointly, in series or parallel, with
individual or common pipelines. The mode symbols used are descriptive of such arrays. Volume rate of
flow for the system has been indicated for the two specified and one intermediate distance in the left-
hand columns, possible future options in the right.
-------
and cut down on air pollution. Where it is necessary to deliver flow up a
hill or at a great distance (and high frictional head loss) the booster pumps
maybe absolutely necessary. However, an alternative to hiqher pumpinq
pressure is to stage several pumps along the pipeline. This requires that
small reservoirs, e.g., inflatable swimming pools (not part of the present
system), be provided as sumps, one for each successive submersible pump. A
pool about 1.5 m (5 ft) in diameter and 0.5 m (1.5 ft) high is sufficient.
With this artifice, total dynamic-head capabil ity of the submersible pumps
alone becomes 73 m (250 ft) at" 0.9 rrT/s (1,425 gpm) and TDH of the entire
system becomes 408 m (1,350 ft) at this volume flow rate. To achieve the
maximum TDH, each prior stage booster would fill the reservoir supplying the
next stage submersible pump, with one sumbersible servicing each booster. (A
staged system of this sort could actually deliver 0.09 m /s (1,425 gpm) a
distance of 11 km (7 mi), or 0.18 m /s (2,900 gpm) a distance of 5 km (3 mi)
over level ground.) Without staginq, the present TDH capability is 102 m (334
ft) at 0.09'rrr/s (1,425 gpm) .
40
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing]
1. REPORT NO.
EPA-600/2-81-;^
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
A MOBILE STREAM DIVERSION SYSTEM FOR
HAZARDOUS MATERIALS SPILLS ISOLATION
5. REPORT DATE
September 1981
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
James V. Zaccor
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Scientific Service, Inc.
1536 Maple Street
Redwood City, California 94063
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
Contract No. 68-032458
12. SPONSORING AGENCY NAME / "ID ADDRESS
13. TYPE OF REPORT AND PERIOD COVERED
Municipal Environmental Research Laboratory - Cin.,OH
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, OH 45260
Final Report
14. SPONSORING AGENCY CODE
EPA/finn/ia
15. SUPPLEMENTARY NOTES
Project Officer: Frank J. Freestone (201)321-6632
16. ABSTRACT
A program was conducted to design and develop a prototype mobile system for quick
diversion of a stream flow around a contaminated area.
Spill scenarios were analyzed to establish design criteria for a self-contained,
independent system that would maintain flow continuity around a region undergoing
decontamination. The design utilized stock items available nationwide, to provide
easy maintenance and replaceability. To provide flexibility and reliability, the
system was assembled as two independent units, mounted on trailers so that spills
would be readily accessible via state or interstate highways. A quick unloading fea-
ture provided capability for air shipment to more distant locations. Once onsite,
the system could be assembled and placed in operation by a crew of five in a matter
of hours.
3
Unit operation and ability to deliver a flow rate of 0.35 m /s a distance of
0.3 km over unprepared ground were evaluated in a shakedown test.
Alternative modes of operation have^been defined and capabilities indicated.
system can deliver a flow rate of 0.09 m /s a nominal distance of 1 km, or a flow
rate of 0.35 m /s a distance of 0.3 km.
The
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATl Field/Group
Stream Diversion, Mobile,
Pumping and Piping, Self-contained,
Independent, Modular,
Redundant,
System
Stream Pollution Control
Hazardous Materials
Spills
13B
13. DISTRIBUTION STATEMENT
RELEASE TO PUBLIC
19. SECURITY CLASS (This Report)
UNCLASSIFIED
21. NO. OF PAGES
49
20. SECURITY CLASS (This page)
UNCLASSIFIED
22. PRICE
EPA Form 2220-1 (9-73)
41
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