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

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             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

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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

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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

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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

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Figure 5.  Pipe rack/dolly.
             20

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Figure 6.   Pipe and fitting rack/dolly
                  21

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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

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     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

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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

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        ^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.

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                                  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

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                                                      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.

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•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

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                                  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

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      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

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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

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       A.  Submersible pump dolly.
          i.  Cable reel dolly.
Figure 14.  Pump and cable reel dollies.
                   32

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         Note fittings in bin of pipe
         and fitting rack.   \
Figure 15.   Winch dolly.
            33

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     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

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                                  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

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Figure 18.  MSDS spill application.
                  38

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             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.

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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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