EPA542-R-13-013
May 2013
United States Office of Solid Waste and Emergency Response
Environmental Protection Office of Superfund Remediation and
9ency Technology Innovation
Optimization Review
French Gulch/Wellington-Oro Mine Site
Water Treatment Plant
Breckenridge, Summit County, Colorado
www.epa.gov/superfund/remedytech | www.clu-in.org/optimization | www.epa.gov/superfund/cleanup/postconstruction
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OPTIMIZATION REVIEW
FRENCH GULCH/WELLINGTON-ORO MINE SITE
WATER TREATMENT PLANT
BRECKENRIDGE, SUMMIT COUNTY, COLORADO
Report of the Optimization Review
Site Visit Conducted at the French Gulch/Wellington-Oro Mine Site
December 11,2012
May 16, 2013
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EXECUTIVE SUMMARY
Optimization Background
The U.S. Environmental Protection Agency's definition of optimization is as follows:
"Efforts at any phase of the removal or remedial response to identify and implement specific
actions that improve the effectiveness and cost-efficiency of that phase. Such actions may also
improve the remedy's protectiveness and long-term implementation which may facilitate progress
towards site completion. To identify these opportunities, regions may use a systematic site review
by a team of independent technical experts, apply techniques or principles from Green
Remediation or Triad, or apply other approaches to identify opportunities for greater efficiency
and effectiveness."'
An optimization review considers the goals of the remedy, available site data, conceptual site model
(CSM), remedy performance, protectiveness, cost-effectiveness and closure strategy. A strong interest in
sustainability has also developed in the private sector and within Federal, State, and Municipal
governments. Consistent with this interest, optimization now routinely considers green remediation and
environmental footprint reduction during optimization reviews.
An optimization review includes reviewing site documents, interviewing site stakeholders, potentially
visiting the site for one day and compiling a report that includes recommendations in the following
categories:
• Protectiveness
• Cost-effectiveness
• Technical improvement
• Site closure
• Environmental footprint reduction
The recommendations are intended to help the site team identify opportunities for improvements in these
areas. In many cases, further analysis of a recommendation, beyond that provided in this report, may be
needed prior to implementation of the recommendation. Note that the recommendations are based on an
independent review, and represent the opinions of the optimization review team. These recommendations
do not constitute requirements for future action, but rather are provided for consideration by the EPA
Region and other site stakeholders. Also note that while the recommendations may provide some details
to consider during implementation, the recommendations are not meant to replace other, more
comprehensive, planning documents such as work plans, sampling plans and quality assurance project
plans (QAPP).
EPA. 2012. Memorandum: Transmittal of the National Strategy to Expand Superfund Optimization Practices from Site
Assessment to Site Completion. From: James. E. Woolford, Director Office of Superfund Remediation and Technology
Innovation. To: Superfund National Policy Managers (Regions 1 - 10). Office of Solid Waste and Emergency Response
(OSWER) 9200.3-75. September 28.
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Site-Specific Background
The French Gulch/Wellington-Oro Mine Site is located near the town of Breckenridge in Summit County,
Colorado. Environmental contamination of surface water, groundwater, soil and sediment at the site
resulted from mining activities dating to the 1880s. Site investigations have concluded that the
underground workings (tunnels, adits, drifts, stopes and crosscuts) of the site constitute the largest source
of metals loading to groundwater and surface water. An on-site seep, FG-6C, is the primary conduit of
mine pool water into French Gulch. The surface water and groundwater remedy consists of the water
treatment plant (WTP), which treats acid rock drainage (ARD) collected by pumping FG-6C. The WTP
removes zinc and cadmium from FG-6C to improve surface water quality in French Gulch and the Blue
River.
Summary of CSM
The CSM for the French Gulch/Wellington-Oro Mine Site was not reviewed as this optimization review
focuses on the operations of the WTP.
Summary of Findings
Key findings from this optimization review include:
• Water from FG-6C flows year-round at a rate of approximately 50 gallons per minute (gpm). FG-
6C water is pumped from a pump box/diversion weir to a 9,000-gallon feed buffer tank at a
maximum rate of approximately 150 gpm for flow equalization and short-term storage. Any flow
in excess of 150 gpm entering the pump box flows over the weir directly to French Gulch without
treatment.
• Reagents used in the WTP include sodium hydrosulfide (NaHS), soda ash (Na2CO3) and
flocculent.
• Since startup in 2008, the WTP has experienced a series of mechanical problems (primarily
associated with the filters); these problems have caused frequent and extended periods of
shutdown and failure to meet the effluent standards for discharge to surface water. During 2012,
the WTP recycled partially-treated (99+ percent zinc removal) effluent to the mine for
approximately 50 percent of the time it was operating.
• The pressure filters do not appear to have adequate controls or back flushing capabilities for
proper upkeep of the media. Back flushing water is supplied from the effluent of other filters in
operation rather than from a dedicated supply pump; this approach cannot provide enough flow to
achieve effective back washing.
• The WTP building is compact and access around the equipment is severely constrained. In
addition, during the site visit, the interior space was cluttered with spare parts and miscellaneous
materials that were stacked due to a lack of storage space.
• During the site visit, the WTP building appeared to be poorly insulated and to have inadequate
ventilation. The ambient air in the WTP has low levels of hydrogen sulfide (H2S) from the
process units.
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• The WTP control system is a proprietary system provided by BioteQ Environmental
Technologies, Inc. (BioteQ); this requires WTP staff to contact BioteQ whenever any system
change is needed.
• There are level sensors on the tanks. However, during the site visit, there did not appear to be
adequate local indicators for operators to be aware of the conditions in the tanks and of the
processes to quickly monitor operating conditions. Therefore, tank levels are often unknown until
overflows occur.
• The WTP typically operates at less than 50 percent of capacity and could treat ARD from
additional seeps if they were identified.
• The WTP cannot meet the zinc standard (0.225 milligrams per liter [mg/L]) without filtration.
• Total annual operating costs (including equivalent labor costs) are $260,000. The major cost
components are $104,000 for labor (using typical, standard loaded operator labor rates); $80,000
for maintenance/subcontractors; $41,500 for chemicals; $24,500 for utilities; and $10,000 for
laboratory analyses. The maintenance costs are extremely high and represent a system that has
ongoing, non-routine operating problems associated with the filters, soda ash addition and the
overall building condition.
Summary of Recommendations
The following recommendations are provided to improve remedy effectiveness, reduce cost and provide
technical improvement:
Improving effectiveness.
• Consider alternative filters or improve existing filters:
o Consider retrofitting bag type filters to replace the existing pressure media filters to
reduce overall operator time associated with filter maintenance and allow the WTP to
operate at a much higher percent up-time. A simple test of bag filter capacity can be
performed to determine how frequently the bags would have to be replaced. If bag
replacement is infrequent, bag filtration will be more cost-effective than the multi-media
filters (with associated backwash and associated maintenance). A pilot test using a small
capacity filter could be conducted for approximately $5,000. If the pilot test indicates that
adequate metals removal can be achieved with reasonable bag filter use (for example
replacing the bag filters weekly or less frequently), conversion to a four-plex bag filter
system could be accomplished for approximately $30,000.
o If the existing filters are kept in service, several improvements should be considered:
• Provide individual differential pressure monitors on each filter.
• Install a pressure indicator upstream of the existing pressure maintaining valve to
help ensure that the valve is operating correctly.
• Consider adding orifice plates in the effluent lines from each filter for better flow
distribution between the filters.
in
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• Consider having a standby skid of four filters that are already charged with the
media; these would be available for immediate replacement if the inline filters
become clogged and require media replacement.
• Consider adjusting the pH after (rather than before) the filters. This may reduce
the potential for clogging the media.
• Continue using muriatic acid to clean the filter media on a routine basis.
Consider soda ash system changes:
o Consider using sodium hydroxide (NaOH; caustic soda) as an alternative for pH control
throughout the process. The existing soda ash system is a constant source of mechanical
problems related to pipe clogging or scaling. Also, daily flushing with hot water requires
considerable labor and energy expense. Adding a caustic soda system would include a
drum feed system and metering pumps. The existing soda ash solution piping could be
used to feed caustic soda. The cost for furnishing and installing a caustic soda feed
system would be approximately $10,000.
Develop a plan for meeting standards at the point of compliance:
o Determine if treating FG-6C is improving water quality in French Gulch and the Blue
River and to what degree based on surface water sampling results.
Reducing cost.
Provide natural gas service for heating. Natural gas heating would offer savings of approximately
80 percent compared to propane. The cost to provide service to the WTP should be investigated;
with long-term WTP operation likely, even a $25,000 or higher cost for a 5-year plus payback
period would be worthwhile.
Technical improvement.
• Improve tank level controls:
o Consider retrofitting the filter feed and backflush tanks with magnetic float type sight
glass level indicators to allow the operators a visual local indication of tank levels.
o Consider keeping the feed buffer tank in service during routine operation for surge
dampening.
• Improve building ventilation to reduce hydrogen sulfide (H2S) fumes:
o Consider modifying the ventilation system to bring outside air into the control room and
electrical room and discharge into the operations area to protect electrical gear.
o Consider installing individual in-line exhaust fans in the vent lines from each process unit
currently leaking H2S fumes to ensure a slight negative pressure in the headspace over
each unit. These vent lines would then feed the existing H2S scrubber system.
IV
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o Consider using nitrogen in the sodium hydrosulfide (NaHS) storage tank as originally
designed. This tank is likely the major source of H2S fumes.
o Consider improving heating in the chemical storage areas (insulating of the overhead
door was completed in the winter of 2013).
Standardize controls, maintenance, and parts:
o Make immediate efforts to use standard, readily available equipment wherever possible
and add or stock redundant parts. A high portion of operation and maintenance (O&M)
cost is for maintenance including subcontracted services and parts. In addition, the WTP
downtime is excessive.
o Make programming and engineering changes to automate the plant to switch from
"discharge" mode to "recycle to mine" mode. Operators currently manually change the
position on two valves when the plant goes out of compliance (pH primarily) to send
water from the discharge back to the feed buffer tank and to the mine. The "recycle to
mine" option would allow the WTP to operate while the problem is resolved instead of
shutting whole process down.
o Consider converting the control system to commercially available control software that
could be serviced or modified by local control system integrators and implement the
proposed control change to include automated recycle to the mine to improve system
operation.
o Standardize process equipment and chemical feed and control components (pumps,
probes, flow meters, level sensors, pressure sensors and switches, mixers) as feasible and
or have spares readily available. For example, the oxidation-reduction potential (ORP)
probes are indicated to be installed in a "hot tap assembly" for insertion and removal
from a full tank. Consideration should be given to providing a "hot-swappable"
arrangement so that another ORP probe can be immediately available at each location for
change out with the actively installed probe. This allows immediate and quick
replacement with no loss of signal.
Site closure.
No site closure recommendations are provided. The WTP operation is expected to continue indefinitely if
it is determined that treating FG-6C water is effective in meeting the site's remedial action objectives
(RAO). If treating FG-6C (and potentially adding a similar ARD source to be determined) is shown to
have little or no effect on French Gulch and Blue River, continued long-term operation of the WTP
should be reconsidered and source control alternatives should be re-examined.
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NOTICE
Work described herein including preparation of this report was performed by Tetra Tech for the U.S.
Environmental Protection Agency under Work Assignment #2-58 of EPA contract EP-W-07-078 with
Tetra Tech, Inc., Chicago, Illinois. Mention of trade names or commercial products does not constitute
endorsement or recommendation for use.
VI
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PREFACE
This report was prepared as part of a national strategy to expand Superfund optimization from remedial
investigation to site completion implemented by the EPA Office of Superfund Remediation and
Technology Innovation (OSRTI). The project contacts are as follows:
Organization
Key Contact
Contact Information
EPA Office of Superfund
Remediation and
Technology
Innovation
(OSRTI)
Kathy Yager
EPA
Technology Innovation and Field Services
Division (TIFSD)
11 Technology Drive (ECA/OEME)
North Chelmsford, MA 01863
yager.kathleen@epa.gov
phone: 617-918-8362
Tetra Tech, Inc.
(Contractor to EPA)
Jody Edwards, P.O.
Tetra Tech, Inc.
1881 Campus Commons Drive
Suite 200
Reston,VA20191
jody.edwards@tetratech.com
phone: 802-288-9485
Tetra Tech, Inc.
Doug Sutton, PhD, P.E.
Tetra Tech, Inc.
2 Paragon Way
Freehold, NJ 07728
doug. sutton@tetratech. com
phone: 732-409-0344
vn
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LIST OF ACRONYMS AND ABBREVIATIONS
Ag
AMD
ARD
As
Au
BioteQ
BMP
Btu
ccf
Cd
CdS
CERCLA
CDPHE
C02e
COC
CSM
Cu
DMR
EE/CA
EPA
ERT
Fe
ft2
GHG
gpd
gpm
H2S
HAP
HOPE
KW
kWh
LTM
Mg
mg/L
NaHS
Na2CO3
NaOH
Ni
NOx
NPDES
O&M
ORP
OSRTI
OSWER
percent
micrograms per liter
silver
acid mine drainage
acid rock drainage
arsenic
gold
BioteQ Environmental Technologies, Inc.
best management practices
British thermal unit
hundred cubic feet
cadmium
cadmium sulfide
Comprehensive Environmental Response, Compensation, and Liability Act
Colorado Department of Public Health and the Environment
carbon dioxide equivalents of global warming potential
contaminants of concern
conceptual site model
copper
discharge monitoring reports
Engineering Evaluation/Cost Analysis
U.S. Environmental Protection Agency
Emergency Response Team
iron
square feet
greenhouse gas
gallons per day
gallons per minute
hydrogen sulfide
Total Hazardous Air Pollutant Emissions
high-density polyethylene
kilowatts
kilowatt hour
long-term monitoring
manganese
milligrams per liter
sodium hydrosulfide
soda ash
caustic soda
nickel
nitrogen oxides
National Pollutant Discharge Elimination System
operation and maintenance
oxidation-reduction potential
Office of Superfund Remediation and Technology Innovation
Office of Solid Waste and Emergency Response
Vlll
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OU operable unit
Pb lead
PbS lead sulfide
P&T pump and treat
PM particulate matter
QAPP Quality Assurance Project Plan
RAO remedial action objective
RI/FS Remedial Investigation/Feasibility Study
ROD Record of Decision
RSE remediation system evaluation
SEFA Spreadsheets for Environmental Footprint Analysis
SOx sulfur oxides
S.U. standard units
TIFSD Technology Innovation and Field Services Division
TDS total dissolved solids
TSS total suspended solids
USGS United States Geological Survey
VFD variable frequency drive
wt weight
WTP water treatment plant
Zn zinc
ZnS zinc sulfide
IX
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TABLE OF CONTENTS
EXECUTIVE SUMMARY i
NOTICE vi
PREFACE vii
LIST OF ACRONYMS AND ABBREVIATIONS viii
1.0 INTRODUCTION 1
1.1 PURPOSE 1
1.2 TEAM COMPOSITION 2
1.3 DOCUMENTS REVIEWED 3
1.4 QUALITY ASSURANCE 3
1.5 PERSONS CONTACTED 4
2.0 SITE BACKGROUND 5
2.1 LOCATION 5
2.2 SITE HISTORY 5
2.2.1 HISTORIC LAND USE AND FACILITY OPERATIONS 5
2.2.2 CHRONOLOGY OF ENFORCEMENT AND REMEDIAL ACTIVITIES 5
2.3 POTENTIAL HUMAN AND ECOLOGICAL RECEPTORS 6
2.4 EXISTING DATA AND INFORMATION 6
2.4.1 SOURCES OF CONTAMINATION 6
2.4.2 GEOLOGY SETTING AND HYDROGEOLOGY 6
2.4.3 SOIL CONTAMINATION 6
2.4.4 SOIL VAPOR CONTAMINATION 7
2.4.5 GROUNDWATER CONTAMINATION 7
2.4.6 SURFACE WATER CONTAMINATION 7
3.0 DESCRIPTION OF PLANNED OR EXISTING REMEDIES 8
3.1.1 COLLECTION 8
3.1.2 WATER TREATMENT PLANT 8
3.2 REMEDIAL ACTION OBJECTIVES AND STANDARDS 10
3.3 PERFORMANCE MONITORING PROGRAMS 10
3.3.1 TREATMENT PLANT OPERATION STANDARDS 11
4.0 CONCEPTUAL SITE MODEL 12
5.0 FINDINGS 13
5.1 GENERAL FINDINGS 13
5.1.1 WTP PERFORMANCE 13
5.1.2 WTP MAINTENANCE 13
5.1.3 WTP CONTROLS 14
5.2 ARD COLLECTION AND RECYCLING 14
5.3 COMPONENTS OR PROCESSES THAT ACCOUNT FOR MAJORITY OF ANNUAL COSTS 14
5.3.1 UTILITIES 15
5.3.2 LABORATORY ANALYSIS 15
5.3.3 CHEMICAL COSTS 15
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5.3.4 LABOR 15
5.3.5 MAINTENANCE/SUBCONTRACTED SERVICES 16
5.4 APPROXIMATE ENVIRONMENTAL FOOTPRINT ASSOCIATED WITH REMEDY 16
5.4.1 ENERGY, AIR EMISSIONS, AND GREENHOUSE GASES 16
5.4.2 WATER RESOURCES 17
5.4.3 LAND AND ECOSYSTEMS 17
5.4.4 MATERIALS USAGE AND WASTE DISPOSAL 17
5.5 SAFETY RECORD 17
6.0 RECOMMENDATIONS 18
6.1 RECOMMENDATIONS TO IMPROVE EFFECTIVENESS 18
6.1.1 CONSIDER ALTERNATIVE FILTERS OR IMPROVE EXISTING SYSTEM 18
6.1.2 CONSIDER SODA ASH SYSTEM CHANGES 19
6.1.3 DEVELOP PLAN FOR MEETING STANDARDS AT POINT OF COMPLIANCE 20
6.2 RECOMMENDATIONS TO REDUCE COSTS 20
6.2.1 PROVIDE NATURAL GAS SERVICE FOR HEATING 20
6.3 RECOMMENDATIONS FOR TECHNICAL IMPROVEMENT 20
6.3.1 IMPROVE TANK LEVEL CONTROLS 20
6.3.2 IMPROVE BUILDING VENTILATION TO REDUCE H2S 21
6.3.3 STANDARDIZE CONTROLS, MAINTENANCE, AND PARTS 21
6.4 CONSIDERATIONS FOR GAINING SITE CLOSE OUT 22
6.5 RECOMMENDATIONS RELATED TO ENVIRONMENTAL FOOTPRINT REDUCTION 22
LIST OF TABLES
Table 1: Optimization Review Team Composition 2
Table 2: Persons Contacted During Optimization Review 4
Table 3: Current WTP Effluent Limits 11
Table 4: Summary of Annual Operating Costs 15
Table 5: Summary of Energy and Air Annual Footprint Results 17
Table 6: Summary of Recommendations and Associated Costs 22
APPENDICES
Appendix A: Select Figures from Site Documents and Process Flow Diagram
Appendix B: Informational Brochures - Rosedale Filters and Penberthy Magnetic Liquid Level Gages
XI
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1.0 INTRODUCTION
1.1 PURPOSE
During fiscal years 2000 and 2001, independent site optimization reviews called Remediation System
Evaluations (RSE) were conducted at 20 operating Fund-lead pump and treat (P&T) sites (i.e., those sites
with P&T systems funded and managed by Superfund and the States). Due to the opportunities for system
optimization that arose from those RSEs, the EPA Office of Superfund Remediation and Technology
Innovation (OSRTI) has incorporated RSEs into a larger post-construction complete strategy for Fund-
lead remedies, as documented in Office of Solid Waste and Emergency Response (OSWER) Directive No.
9283.1-25, Action Plan for Ground Water Remedy Optimization. Concurrently, the EPA developed and
applied the Triad Approach to optimize site characterization and development of a conceptual site model
(CSM). The EPA has since expanded the definition of optimization to encompass investigation stage
optimization using Triad Approach best management practices (BMP), optimization during design and
RSEs. The EPA's definition of optimization is as follows:
"Efforts at any phase of the removal or remedial response to identify and implement
specific actions that improve the effectiveness and cost-efficiency of that phase. Such
actions may also improve the remedy's protectiveness and long-term implementation
which may facilitate progress towards site completion. To identify these opportunities,
regions may use a systematic site review by a team of independent technical experts,
apply techniques or principles from Green Remediation or Triad, or apply other
approaches to identify opportunities for greater efficiency and effectiveness. " '
As stated in the definition, optimization refers to a "systematic site review", indicating that the site as a
whole is often considered in the review. Optimization can be applied to a specific aspect of the remedy
(for example, focus on long-term monitoring [LTM] optimization or focus on one particular operable unit
[OU]), but other site or remedy components are still considered to the degree that they affect the focus of
the optimization. An optimization review considers the goals of the remedy, available site data, CSM,
remedy performance, protectiveness, cost-effectiveness and closure strategy. A strong interest in
sustainability has also developed in the private sector and within Federal, State and Municipal
governments. Consistent with this interest, OSRTI has developed a Green Remediation Primer (www.clu-
in.org/greenremediation). and now routinely considers green remediation and environmental footprint
reduction during optimization evaluations.
The optimization review included reviewing site documents, visiting the site for one day and compiling
this report, which includes recommendations in the following categories:
• Protectiveness
• Cost-effectiveness
1 EPA. 2012. Memorandum: Transmittal of the National Strategy to Expand Superfund Optimization Practices from Site
Assessment to Site Completion. From: James. E. Woolford, Director Office of Superfund Remediation and Technology
Innovation. To: Superfund National Policy Managers (Regions 1 - 10). Office of Solid Waste and Emergency Response
(OSWER) 9200.3-75. September 28.
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• Technical improvement
• Site closure
• Environmental footprint reduction
The recommendations are intended to help the site team identify opportunities for improvements in these
areas. In many cases, further analysis of a recommendation, beyond that provided in this report, may be
needed prior to implementation of the recommendation. Note that the recommendations are based on an
independent evaluation, and represent the opinions of the optimization review team. These
recommendations do not constitute requirements for future action, but rather are provided for
consideration by the EPA Region and other site stakeholders. Also note that while the recommendations
may provide some details to consider during implementation, the recommendations are not meant to
replace other, more comprehensive, planning documents such as work plans, sampling plans and quality
assurance project plans (QAPP).
The national optimization strategy includes a system for tracking consideration and implementation of the
optimization review recommendations and includes a provision for follow-up technical assistance from
the optimization review team as mutually agreed upon by the site management team and EPA OSRTI.
Purpose of Optimization at the French Gulch/Wellington-Oro Mine Site - Water Treatment Plant
(WTP)
Environmental contamination of surface water, groundwater, soil and sediment occurred at the French
Gulch/Wellington-Oro Mine Site as a result of mining activities. The surface water and groundwater
remedy consists of the water treatment plant (WTP), which treats acid rock drainage (ARD) collected at
the site by pumping a natural seep named FG-6C. ARD is acidic metal-laden water that results from
oxidation of metal sulfides in rock surfaces exposed to air and water. Mining activities often expose
previously buried mineralized rock to air and water initiating the generation of ARD. Acid mine drainage
(AMD) refers to ARD strictly from mine disturbance. For the purposes of this report, the more general
term ARD is used. The WTP removes zinc and cadmium from FG-6C in an attempt to improve surface
water quality in French Gulch and the Blue River.
The site was selected by the EPA OSRTI for optimization review based on a nomination from the EPA's
Abandoned Mine Lands Team. The optimization review is focused on current WTP operational
effectiveness and efficiency. The optimization review includes discussion and evaluation of influent
sources, metals mass loading, discharge criteria, solids handling and an operating cost breakdown. Other
components of the site remedy are considered only as they relate to the WTP.
1.2 TEAM COMPOSITION
The optimization review team consisted of the following individuals:
Table 1: Optimization Review Team Composition
Name
Peter Rich
John Nemcik
Doug Sutton*
Carolyn Pitera*
Affiliation
Terra Tech, Inc.
Terra Tech, Inc.
Terra Tech, Inc.
Terra Tech, Inc.
Phone
410-990-4607
720-931-9307
732-409-0344
703-390-0621
Email
Peter.Rich@tetratech.com
John.Nemcik@tetratech.com
Doug. Sutton@tetratech.com
Carolyn.Pitera@tetratech.com
*Did not attend site visit.
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In addition, the following individuals from EPA Headquarters and the EPA Environmental Response
Team (ERT) participated in the optimization site visit:
• Steve Dyment, EPA Headquarters
• GaryNewhart, EPA ERT
Tom Kady, EPA ERT
1.3 DOCUMENTS REVIEWED
The following documents were reviewed in support of the optimization review. The reader is directed to
these documents for additional site information that is not provided in this report.
• Quantification of Metals Loading in French Gulch, USGS, July 1996
• Ecological Risk Assessment for French Gulch/Wellington-Oro Mine Site, EPA with Syracuse
Research Corporation, May 2002
• French Gulch Engineering Evaluation/Cost Analysis(EE/CA) Fact Sheet, EPA/State of Colorado,
June 3, 2002
• Action Memorandum, Victor Ketallapper, EPA, November 24, 2002
• Action Memorandum Addendum #1, Victor Ketallapper, EPA, November 30, 2004
• Applicable or Relevant and Appropriate Requirements Compliance Document, EPA and
Colorado Department of Public Health and Environment, July 13, 2005
• Consent Decree, EPA and State of Colorado, 2005
• Wellington-Oro Water Treatment Project Pre-Final Engineering Report, BioteQ/Lyntek, January
30, 2007
• Record Construction Drawings of the WTP, Stantec Engineering, 2007
• Operation and Maintenance Manual, BioteQ, February 14, 2009
• Discharge monitoring reports and table, 2008-2012
• Daily reports, 2012
• Town of Breckenridge cost data, 2008-2012
1.4 QUALITY ASSURANCE
This optimization review utilizes existing environmental data to evaluate remedy performance and to
make recommendations to improve the remedy. The quality of the existing data is evaluated by the
optimization review team before the data are used for these purposes. The evaluation for data quality
includes a brief review of how the data were collected and managed (where practical, the site QAPP is
considered), the consistency of the data with other site data and the use of the data in the optimization
review. Data that are of suspect quality are either not used as part of the optimization review or are used
with the quality concerns noted. Where appropriate, this report provides recommendations to improve
data quality.
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1.5 PERSONS CONTACTED
The following individuals associated with the site were present for the site visit:
Table 2: Persons Contacted During Optimization Review
Name
Joy Jenkins
Steve Dyment
Gary Newhart
Liz Fagen
Tom Kady
Mary Boardman
Carl Johnson
Gary Roberts
Dale Stein
Laura Lynch
Brian Lorch
Affiliation
EPA Region 8
EPA Headquarters
EPA Environmental Response Team (ERT)
EPA Region 8
EPA ERT
Colorado Dept. of Health and Environment (CDPHE)
Town of Breckenridge
Town of Breckenridge, Public Works, Water Manager
Town of Breckenridge, Public Works, Assistant Engineer
Town of Breckenridge, Public Works, Assist. Water Manager
Summit County, Open Space & Trails Director
Email
j enkins.j ovtgiepa. gov
dyment. stephengiepa. gov
newhart. gary @epa. gov
fagen. elizabethgiepa. gov
kadv.thomas(@,epa. gov
mary.boardman@state.co.us
carrj(@to wnofbreckenridge.com
garvr(@townofbreckenridge.com
dales(@townofbreckenridge.com
laural(@,to wnofbreckenridge.com
brianltgico . summit.co .us
The Town of Breckenridge operates the WTP, including all collection and conveyance systems and site
maintenance. Summit County funds the WTP operation jointly with the town. EPA and CDPHE oversee
WTP operation and EPA monitors site-wide environmental media.
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2.0 SITE BACKGROUND
This section is a summary based on information in the reviewed documents.
2.1 LOCATION
The French Gulch/Wellington-Oro Mine Site is located near the town of Breckenridge in Summit County,
Colorado. The site is located approximately 2.2 miles upstream, east of the confluence of French Gulch
and the Blue River. The Blue River is a Trophy Water trout stream and extremely important to the
economy of Summit County. The French Gulch valley includes several abandoned mine and mill sites,
the largest of which was the Wellington-Oro mining complex. The site location and a schematic of the
French Gulch water treatment plant (WTP) with surface water sampling locations are shown on figures
included in Appendix A.
2.2 SITE HISTORY
2.2.1 HISTORIC LAND USE AND FACILITY OPERATIONS
The majority of mining activities at the Wellington-Oro site occurred between the 1880s and 1930s; with
some mining continuing until the 1970s. During those periods, lead (Pb), zinc (Zn), copper (Cu), silver
(Ag) and gold (Au) ores were removed from over 12 miles of tunnels, adits, drifts, stopes and crosscuts,
approximately half of which are below the elevation of the groundwater table. A 100-ton per day gravity
mill operated at the site from 1908 until 1929 to concentrate Pb, Zn and pyrite. A 50-ton per day roaster
and magnetic separation plant removed iron (Fe) and sulfur from the Zn ores from 1912 to 1927, when it
was replaced by a more economical flotation mill.
The French Gulch valley floor was mined and dredged from the late 1850s to the 1940s, altering the
valley topography and leaving behind large piles of boulders, cobbles and gravel.
2.2.2 CHRONOLOGY OF ENFORCEMENT AND REMEDIAL ACTIVITIES
The EPA and the Colorado Department of Public Health and Environment (CDPHE) began investigations
to determine the nature and extent of contamination at the Wellington-Oro Mine site in the late 1980s. An
Engineering Evaluation/Cost Analysis (EE/CA) that focused on surface wastes containing elevated levels
of Pb and arsenic (As) was completed in 1998. Subsequently, the EPA issued an action memorandum and
administrative order to consolidate and cap the roaster fines, mill tailings and waste rock; and the work
was performed in 1999. A second EE/CA that focused on the impact of metals being released from the
site on the water quality in French Gulch and the Blue River was completed in 2002. This second EE/CA
concluded that the underground workings (tunnels, adits, drifts, stopes and crosscuts) of the site constitute
the largest source of metals loading to groundwater and surface water and that a natural seep, FG-6C, is
the primary conduit of mine pool water into French Gulch. Zn and Cd were identified as the primary
contaminants of concern (COCs).
In May 2002, EPA completed an Ecological Risk Assessment and subsequently issued an Action
Memorandum in November 2002 and Addendum #1 in November 2004 to address water quality issues at
the site. The actions stipulated in these documents, collectively referred to as the "Action Memorandum"
are non-time critical response actions referred to as "Water Quality Action" providing for the collection
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and treatment of water at seep FG-6C. Removal actions and other stabilization measures were completed
at several of the other mine sites in the French Gulch valley in the 2000s.
2.3 POTENTIAL HUMAN AND ECOLOGICAL RECEPTORS
Dissolved metals in surface water in French Gulch downstream of the Wellington-Oro mine complex,
especially Zn and Cd, are acutely toxic to fish and invertebrates. Concentrations of metals exceed
benchmark levels in sediment associated with toxicity to benthic invertebrates. Groundwater is not used
for potable purposes in the area, and past studies and risk assessments have not identified any significant
human health risks.
2.4 EXISTING DATA AND INFORMATION
2.4.1 SOURCES OF CONTAMINATION
Drainage from flooded underground mine workings and seepage of leachate from surface tailings and
mine waste piles are groundwater contaminant sources which in turn are the source of metals loading into
French Gulch and the Blue River.
A 1996 United States Geological Survey (USGS) tracer test study concluded that the largest metals
loading to French Gulch was from springs affected by drainage from the Wellington-Oro mine where the
Bullhide Fault crosses the stream. Conflicting information exists regarding the relative contribution of
surface leaching of metals from the mine waste rock, roaster fines and mill tailings. The site team is
currently conducting studies to determine the relative contributions of the various sources.
2.4.2 GEOLOGY SETTING AND HYDROGEOLOGY
Local geology is comprised of bedrock ore with mineralized veins and metamorphic deposits associated
with the historical lode mining at the site, which contributes to the generation of ARD and the other
contaminant source materials listed in Section 2.4.1. Several north to northeast trending faults cut through
the site area, including the Oro Fault Block, Wellington Fault Block, Great Northern and "J" Faults,
Bullhide Fault and the 11-10 Fault.
At the western limit, the water level in the mine is above the level of French Gulch resulting in water
discharges from the mine to the valley: (1) through faults and fractures that discharge to the alluvium; (2)
as shallow alluvial groundwater flow; and (3) in the form of a series of springs which discharge mine-
pool water all year round and intermittent springs located in dredge tailings piles that line the French
Gulch valley floor.
Detailed discussion of the geology and hydrogeology of the site is beyond the scope of this review.
2.4.3 SOIL CONTAMINATION
Discussion of soil contamination at the site is beyond the scope of this review.
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2.4.4 SOIL VAPOR CONTAMINATION
No soil vapor contamination is expected because the site contaminants are ARD-related and do not
include volatile organic compounds.
2.4.5 GROUNDWATER CONTAMINATION
Groundwater impacted by ARD including metals negatively impacts the surface water quality in French
Gulch. The low pH typically associated with ARD is largely neutralized by limestone in the area. The
detailed nature of the groundwater flow and its interaction with surface water are beyond the scope of this
review.
Groundwater discharging at FG-6C is a key contributor to surface water contamination in French Gulch
and the Blue River at the confluence with French Gulch. The percentage contribution from FG-6C has not
been determined. The mass of Zn from the FG-6C seep is approximately 89 pounds per day (based on
approximately 48 gallons per minute [gpm] at approximately 154 milligrams per liter [mg/L] Zn
[averages from December 2008 to January 2012 discharge monitoring reports (DMRs)]).
2.4.6 SURFACE WATER CONTAMINATION
Surface water drainage through the French Gulch valley flows from east to west, discharging to the Blue
River. The Blue River then flows north for 10 miles, discharging to the Dillon Reservoir near the town of
Frisco.
Surface water in French Gulch downstream of the Wellington-Oro mine and in a portion of the Blue
River downstream of the mouth of French Gulch is impacted by levels of Zn and Cd that are toxic to
aquatic life.
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3.0 DESCRIPTION OF PLANNED OR EXISTING REMEDIES
The purpose of the Wellington-Oro Mine WTP is to treat a portion of the ARD collected at seep FG-6C,
which is considered to be the main contributor of acid mine seepage in the area. The treatment objective
is to reduce the Zn and Cd levels to the required effluent limits before discharging the effluent to French
Gulch. The water treatment process consists of a metal precipitation and recovery circuit where inorganic
sulfide is used as the precipitating agent. The WTP equipment components include a feed buffer tank, two
contactors, a flocculation tank, a sludge conditioning tank, a clarifier, a filter press, a filter feed tank, four
granular media pressure filters and a backflush tank. The process configuration is shown in a Process
Flow Diagram included in Appendix A.
The following sections describe water collection and WTP features and operations.
3.1.1 COLLECTION
Seepage from FG-6C is collected by an underground drain system and flows to the pump box/diversion
weir. From there it is pumped to the feed buffer tank in the WTP at a maximum rate of approximately 150
gpm. The feed buffer tank has a capacity of 9,000 gallons and provides some flow equalization and short-
term storage of the feed water. If the plant is down for any reason, the water from the pump box can be
pumped ("recycled") back to the mine. Any flow in excess of 150 gpm entering the pump box flows over
the diversion weir directly to French Gulch without any treatment. The FG-6C seep flows year-round at a
rate of approximately 50 gpm.
3.1.2 WATER TREATMENT PLANT
3.1.2.1. Chemical Additions
Reagents used in the WTP include sodium hydrosulfide (NaHS), soda ash (Na2CO3), and flocculent.
NaHS is delivered as a 35-44 percent solution and Na2CO3 and flocculent are prepared as solutions from
dry reagent of strength suitable for plant operation. Although the use of nitrogen was included in the
original design to minimize the release of hydrogen sulfide (H2S) into the atmosphere, that element of the
system was never constructed. All reagents are metered to the process using automated control systems.
3.1.2.2. Sludge Conditioning Tank, Contactors and Clarifier
The feed water is pumped to contactor TK-201 and flows by gravity to the second contactor, TK-200.
Each contactor has 1,845 gallons of working volume. Sludge from the clarifier is returned to the sludge
conditioning tank where the NaHS is added. The NaHS reacts with the recycled sludge and is available
for reacting with the influent Cd and Zn inTK-201. The sludge conditioning tank effluent combines with
the raw influent in the contactors. In the contactors, Zn reacts with dissolved sulfide supplied by NaHS to
form insoluble zinc sulfide (ZnS) precipitate. The Cd and Pb present in the feed water are precipitated as
cadmium sulfide (CdS) and lead sulfide (PbS). The feed rate of sulfide reagent is set by the operator to
maintain the oxidation reduction potential (ORP) in a set range. Na2CO3 is added to the effluent of TK-
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200 to neutralize the acidity generated by the precipitation reaction. The rate of Na2CO3 addition is
automatically controlled using pH sensors.
The ZnS slurry flows out of the contactors by gravity to flocculation tank TK-203 where flocculent and
Na2CO3 are added. Na2CO3 can be added to increase the pH above 6.5 standard units (S.U.), which is the
minimum discharge pH criterion. The slurry then flows by gravity from the flocculation tank to clarifier
TK-205 to settle out the ZnS solids. The clarifier is 16 feet in diameter with 8-foot high sidewalls.
3.1.2.3. Filtration, pH Adjustment and Discharge
The clarifier effluent flows by gravity to filter feed tank TK-501, which has a 650-gallon capacity.
Na2CO3 can also be added to TK-501 if the clarifier overflow pH is less than 6.5 S.U. Filtration is an
important final step in the process and is needed to meet the stringent discharge permit limits for Zn and
Cd. The filter effluent flows to the clear well or directly to the discharge.
The four filters operate in parallel and there is no apparent means for controlling the rate through any
given filter (rate of flow control valve or orifice plates). When the filters are returned to service following
a backwash there may be some minor maldistribution of flow, however, this probably is not a major
drawback. Granular media filters operate most effectively when their flow rate is equally distributed.
Excessive flows tend to prematurely blind the upper portion of the filter media resulting in shorter filter
runs and a need for more frequent backwashing. The filter effluent flows by gravity through an 8-inch
diameter high-density polyethylene (HDPE) outfall pipe to one of two injection wells installed in gravel
adjacent to French Gulch. The second injection well is used if the first injection well becomes plugged.
The final effluent flow meter is mounted in a vertical section of piping and full pipe flow is needed for
accurate flow measurement; this is achieved by a pressure sustaining valve. When the filters are not
functioning properly, the WTP is put in "recycle mode" with effluent pumped back to the mine pool. Zn
levels are typically approximately 1,000 micrograms per liter ((ig/L) (99+ percent removed) without
filtration. Other operating modes are "emergency shutdown" when FG-6C water is pumped directly to the
mine pool and "offline" mode when FG-6C water overflow and discharges to surface water.
One filter is backflushed (or backwashed) at a time each day while the other three remain in service. Each
filter is sequentially backflushed until all have been cleaned. The filtered effluent from the three filters in
service is diverted to the one filter being backflushed. The flow rate of backflushing is the WTP flow rate
at that time, but a flow-limiting valve installed on the backflush discharge line limits the flow to 42 gpm.
If the WTP is running at 40 gpm, the backflush flow rate is 40 gpm.
Each filter has an area of 3.15 square feet (ft2). At a backflush flow rate of 42 gpm, the rise rate in the
media is 13.3 gpm/ ft2 of media. Typically, the recommended backwashing rate for multimedia filters is
18 to 22 gpm/ ft2. The lower rate available for these filters may not be cleaning the media effectively.
However, the WTP operators have observed that at flows above 42 gpm the anthracite media begins
washing out of the filters, so the backflush rate cannot be increased.
The backflush water discharges to the backflush tank which is sized to contain the volume from one
complete wash cycle for the four filters. A small capacity, air-actuated diaphragm pump returns the
content of the backflush tank to the contactors. Once the backflush tank is full, it takes considerable time
for the tank level to be drawn down to allow another backwash cycle to begin. Normally, this is not a
problem, unless the clarifier is upset and discharging high concentrations of suspended solids to the
filters. Much more frequent backwashing would then be required, but the existing system will not allow
it. Under this circumstance, the WTP would have to go into recycle mode until the clarifier operation is
improved.
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3.1.2.4. Residual Solids
The ZnS solids collected in the clarifier are dewatered in a filter press (EQ-200) achieving a filter cake
with solids content of 35 to 50 percent weight (wt). The ZnS product is stored in one-ton plastic lined
sacks before being shipped to a smelter. The process generates no residuals that must be landfilled. The
process is intended to avoid Fe oxidation and precipitation since the presence of Fe in the final cake
product complicates the smelter's operation.
3.2 REMEDIAL ACTION OBJECTIVES AND STANDARDS
This site does not have a Record of Decision (ROD), so it does not have formal Remedial Action
Objectives (RAO) that would have been developed as part of a remedial investigation/feasibility study
(RI/FS) and then incorporated into the ROD. The remedy RAO as presented in the 2002 EE/CA fact sheet
is to limit the concentrations of dissolved Cd and Zn to 4.0 (ig/L and 225 (ig/L, respectively, in the Blue
River. The concentrations are temporary water quality standards set by the Colorado Water Quality
Control Commission and are also the remedy WTP discharge standards. The WTP only treats ARD from
one seep (FG-6C) and it has not operated effectively over a continuous period so that its effectiveness in
meeting the Blue River water quality standards cannot yet be evaluated. The Zn and Cd loading from
other sources are not known, however, they could be high enough that the WTP alone cannot meet the
stated objectives. Studies by the site team to determine if the RAO can be met by treatment of FG-6C
alone are ongoing (FG-6C is approximately 2 percent of French Gulch flow volume).
For this review, the optimization review team assumed that updated sampling data will show that treating
FG-6C groundwater has a positive effect to meet the RAO, thus the focus of this review is on improving
the WTP effectiveness.
3.3 PERFORMANCE MONITORING PROGRAMS
The Discharge Monitoring Reports associated with the site's National Pollutant Discharge Elimination
System (NPDES) permit address requirements for:
• Daily flow and pH measurements;
• Weekly WTP effluent sampling with analysis for Cd, Zn and total suspended solids (TSS);
• Monthly WTP effluent sampling and analysis for hardness, total dissolved solids (TDS); and
• Quarterly WTP influent sampling with analysis for TSS, TDS, hardness, Cd, Zn and pH.
In the past, the site team had conducted influent sampling and analysis monthly instead of quarterly (they
switched to quarterly in January 2013). In addition, the site team collects monthly influent and effluent
samples for sulfate, Cu, Fe, manganese (Mg), nickel (Ni) and Ag analyses. Samples are also collected at
three surface water locations (BR1, BR2, FG-9 [see figure in Appendix A]) and analyzed for Zn and Cd
monthly.
In addition to the laboratory analyses above, the WTP operators maintain testing equipment on-site to
analyze influent and effluent daily for Zn, Fe and pH as indicators to provide immediate notification of
operating ineffectiveness. Samples at other process points are taken periodically. Additional surface water
sampling and analysis is conducted by others as part of continuing investigations of the sources of French
Gulch metals loading.
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3.3.1 TREATMENT PLANT OPERATION STANDARDS
The NPDES standards for discharging WTP effluent to surface water are listed in Table 3.
Table 3: Current WTP Effluent Limits
Parameter
Cd
Zn
Oil and Grease
TSS
pH
From NPDES DMRs (30-day average)
4ng/L
225 ng/L
lOmg/L
20mg/L
6.5 to 9.0 S.U.
When Zn and or TSS levels are above the effluent standards (or if any other parameter were above the
effluent standards), the WTP is put into recycle mode for discharge to the mine.
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4.0 CONCEPTUAL SITE MODEL
This optimization review focused on current ARD collection and WTP operations. Discussion of a CSM
including ARD sources, transport and fate are beyond the scope of this review.
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5.0 FINDINGS
The observations provided below are the interpretations of the optimization review team and are not
intended to imply a deficiency in the work of the system designers, system operators, or site managers,
rather they are offered as constructive suggestions in the best interest of the EPA and the public. These
observations have the benefit of being formulated based upon operational data not available to the
original designers. Furthermore, it is likely that site conditions and general knowledge of treatment have
changed over time.
5.1 GENERAL FINDINGS
5.1.1 WTP PERFORMANCE
Startup in 2008, the WTP has experienced a series of mechanical problems causing frequent and extended
periods of recycling of effluent to the mine pool. ARD or partially treated ARD has been diverted back to
the mine to avoid discharge of water directly from FG-6C. The primary mechanical difficulty appears to
be with the operation of the filters. These pressure filters do not appear to have adequate controls or back
flushing capabilities for proper upkeep of the media. Over relatively short periods of time, the media
becomes cemented together and must be replaced. Backflushing water is supplied from the effluent of
other filters in operation rather than from a dedicated supply pump. It is possible that inadequate
backflush flow is provided during winter months when the plant flow is below 40 gpm. The filter system
has been a continuous operational problem and is the primary reason for the WTP failing to meet the
effluent standards. Deficiencies in the backflushing system may be a contributing factor to the filter
problems.
5.1.2 WTP MAINTENANCE
The WTP building is compact and access around the equipment is severely constrained. The mixer motor
for the sludge conditioning tank (TK-220) is pressed against the underside of the ceiling of the building. It
will be a major problem for the operations staff to remove this mixer when service is needed. In other
cases, chemical feed pumps are located in building corners behind tanks, with limited access for
maintenance activities. There is no storage space in the building and spare parts and miscellaneous
materials are stacked throughout the building resulting in a cluttered and inefficient work environment.
The staff indicated that no additional buildings can be added on the site for storage or maintenance
because of zoning issues; however, the working conditions appear to be having a significant impact on the
ability of the staff to operate and maintain the building and its equipment effectively.
The process vessels and tanks are completely enclosed due to the need to contain fugitive H2S emissions.
As a result, the operators have limited information available concerning the operating conditions
occurring in the basins and tanks. Tank levels are often unknown until overflows occur. There are level
sensors on the tanks, but there did not appear to be adequate local indication for the operators to be aware
of the conditions in the tanks and processes to monitor the operating conditions quickly.
The building is poorly insulated and seems to have inadequate ventilation. The ambient air in the building
has low levels of H2S from the process units. Although the building is equipped with monitors and the
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level is maintained below the long-term exposure limits to H2S, air quality improvements should be
considered for human health and to minimize equipment corrosion.
5.1.3 WTP CONTROLS
The control system is a proprietary system provided by BioteQ Environmental Technologies, Inc.
(BioteQ), requiring the staff to contact BioteQ whenever any change in the system is needed. It seems that
it would be more efficient to convert the control system to commercially available control software that
could be serviced or modified by local control system integrators. There does not appear to be any benefit
at this stage in the life of the facility in continually relying on BioteQ to make changes to the system. The
proposed control change to include automated recycle to the mine would be useful to improve system
operation and BioteQ's proposed costs are reasonable; however, the many months required to work with
BioteQ to implement this change exemplifies the inefficiency of the current situation.
5.2 ARD COLLECTION AND RECYCLING
The system typically operates at less than 50 percent of capacity and could treat ARD from additional
seeps if identified. Surface water data were not provided to determine how higher flow rates affect metal
concentrations in French Gulch. Based on the limited data available it appears that Zn concentrations in
FG-6C are higher during times of high flow.
The WTP cannot meet the Zn standard (225 (ig/L) without filtration. At times, when filtration is not on-
line and at other times, when the system is not meeting standards, discharge is diverted to the mine with
no discharge limits. Without the filters operating, the WTP typically removes Zn to approximately 1 mg/L
(>99 percent removal). While this removal is significant, it does not meet the stringent water quality
discharge criteria established for the system. If the mine were inert, recycling the water to the mine would
be effectively diluting contamination. With ARD-generating material, however, the added exposure of
rock to water could generate ARD with higher concentrations and ultimately increase the Zn
concentration at the compliance point.
5.3 COMPONENTS OR PROCESSES THAT ACCOUNT FOR MAJORITY OF ANNUAL
COSTS
Table 4 provides a breakdown of the approximate annual cost estimates for operating this remedy based
on total costs provided by the site team and general averaging by the optimization review team.
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Table 4: Summary of Annual Operating Costs
Item
Project Management
and Labor
Maintenance/Subcontractors (repairs, parts, media replacement)
Process and Surface
Water In-house Laboratory Analysis
Outside Laboratory Analysis
Propane heat
Electricity
Telephone
NaHS
Soda Ash
Flocculent
Total
Total* (including equivalent labor cost)
Approximate Annual Cost
$104,000*
$80,000
$4,000
$6,000
$7,000
$17,000
$500
$23,000
$16,000
$2,500
$156,000
$260,000
5.3.1
UTILITIES
Electrical power costs are approximately $17,000 per year at an approximate rate of $0.082 per kilowatt
hour (kWh) from Xcel Energy representing a demand of approximately 24 KW. Large consumers of
electricity in the system include the process pumps and air compressor. Propane costs for building heat
total approximately $7,000 per year (approximately 2,100 gallons at approximately $3.35 per gallon).
Telephone service is approximately $500 per year. These are very low costs compared to similar WTPs.
Even though the building is poorly insulated, it is kept at a low temperature so that propane use is
minimized.
The site team reported problems with air compressor downtime. Air is used to operate four valves, four
pumps and the filter press. The site team is considering replacing the valves and pumps with electric-
powered alternatives to avoid the cost of an air dryer replacement, extend air compressor life and reduce
utility costs. Valve replacements would total approximately $5,000 and pump replacements
approximately $20,000. Potential power cost savings depend on pump run times but would be minimal;
costs saved in compressor maintenance and replacement would likely be exceeded by maintenance on
more expensive electric-powered pumps. Instead of the valve and pump replacements, the optimization
review team recommends consideration of a redundant compressor.
5.3.2
LABORATORY ANALYSIS
The combined $10,000 annual analysis cost is very low in comparison with similar WTPs. The analysis
conducted by the site team meets regulatory requirements and provides additional useful water quality
information.
5.3.3
CHEMICAL COSTS
Total chemical costs of approximately $41,500 annually are a major component of total operating costs
but they are consistent and dependent on the flow being treated as long as the WTP process remains the
same.
5.3.4
LABOR
The site team reports combined operating labor and management (including reporting) requirements of
approximately 40 hours per week. The operating labor requirements are quadruple what was estimated in
the 2007 Pre-Final Engineering Report prepared by BioteQ/Lyntek. At a $50 per hour loaded rate, the unit
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labor rate is equivalent to $104,000 annually. The labor costs alone are relatively comparable to other
WTPs, but when combined with the maintenance and subcontracted services costs, it is clear that the
system operation problems are increasing overall operating costs.
5.3.5 MAINTENANCE/SUBCONTRACTED SERVICES
The site team reported large subcontractor expenses in 2012, including:
• Cummins and Ingersoll Rand ~ $7,700:
o Combined for preventative maintenance for the generator and air compressor and repairs.
• Triangle Electric ~ $ 14,000:
o Installed heat tape and heater for NaHS line and tank to help prevent from freezing.
o Installed switch to enable exhaust fans to be turned off from outside of building.
o Installed pipe, wire, breaker for roof heat tape, replaced thermostat and repaired heaters.
o Installed additional outlets, troubleshoot chemical pump's variable frequency drive
(VFD) and installation of two new VFD chemical drivers.
o Annual Preventative Maintenance: check for loose wires and infrared scan, troubleshoot
Na2CO3 screw feeder overload.
• Arvada Pump ~ $29,000:
o Approximately one half from rebuilding the influent sump pumps that are in the FG-6C
vault. All four pumps (two in use and two spares) have been rebuilt with stainless steel
wear plates to prevent corrosion.
o Replaced the hose in the sludge reseed pump, replaced a leaking Na2CO3 pump and
rebuilt the leaking one.
o Replaced the filter feed pump and rebuilt the defective one, and performed annual
inspections and maintenance.
• Clearwater Cleanup ~ $7,500:
o Vacuumed out the media from the filters, vacuumed out and cleaned the Na2CO3 tank
(because of scaling), and cleaned out the septic tank.
• Various Parts ~ $24,500
These costs are extremely high for a WTP of this size and are similar to 2010 and 2011 costs. The high
maintenance costs represent a system that has ongoing, non-routine operating problems associated with
the filters, Na2CO3 and the overall building condition.
5.4 APPROXIMATE ENVIRONMENTAL FOOTPRINT ASSOCIATED WITH REMEDY
The following subsections describe the environmental footprint of the site remedy, considering the five
core elements of green remediation defined by the EPA (www.cluin.org/greenremediation).
5.4.1 ENERGY, Am EMISSIONS, AND GREENHOUSE GASES
The primary contributor to the energy footprint is the electricity usage of approximately 207,000 kWh of
electricity per year. XCel Energy is the electricity provider for the site, and based on a preliminary review
of Xcel Energy's 2011 Annual Report, it appears that approximately 50 percent of the electricity is
generated from coal, 22 percent from natural gas, 12 percent from nuclear plants, 10 percent from wind
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sources, 4 percent from hydroelectric plants and 2 percent from other sources (solar, biomass, oil and
waste). Based on this generation mix, the electricity is also a major contributor to greenhouse gas (GHG)
and other air emissions associated with WTP operation. The other largest contributor to GHG and other
emissions is associated with chemical manufacturing and transportation to the site and on-site propane use
(approximately 2,100 gallons per year).
The EPA Spreadsheets for Environmental Footprint Analysis (SEFA) were used to estimate the energy
and air footprints. The results for key energy and air footprint metrics are summarized in Table 5.
Table 5: Summary of Energy and Air Annual Footprint Results
Green and Sustainable Remediation Parameter
Greenhouse Gas Emissions (carbon dioxide equivalents [CO2e]
Total Nitrogen Oxides (NOx) + Sulfur Oxides (SOx) + Paniculate
Matter (PM) emissions
Total Hazardous Air Pollutant (HAP) Emissions
Total Energy Use
Voluntary Renewable Energy Use
Approximate Annual Value
220 tons
3,800 pounds
80 pounds
3,600 MMBtus
NA
Notes: CO^e = carbon dioxide equivalents of global warming potential
MMBtus = 1,000,000 Btus
Based on the assumptions made in SEFA, approximately 15 percent of the carbon dioxide equivalents of
global warming potential (CO2e) footprint is from chemical usage, 3 percent is from on-site propane use
for heat and approximately 74 percent is from electricity usage, 4 percent is for transportation of
chemicals and 4 percent is for personnel and subcontractor transportation. Other contributions are
negligible.
5.4.2 WATER RESOURCES
Relatively un-impacted site groundwater from well WO-01 is used for chemical batching and cleaning
purposes (500 to 1,000 gpd). Water that is intercepted as part of the remedy is discharged to surface
water, which would be the natural fate of the water in the absence of the remedy. Potable water is brought
to the site from outside sources and kept in two 250-gallon tanks for the washroom and safety shower;
very little potable water is used.
5.4.3 LAND AND ECOSYSTEMS
Operation of the remedy does not have secondary effects on local land and ecosystems.
5.4.4 MATERIALS USAGE AND WASTE DISPOSAL
The primary materials usage is the NaHS, Na2CO3 and flocculent. Residual solids from the WTP are sold
to a smelter for recycling.
5.5 SAFETY RECORD
The site team did not report any safety concerns or incidents. However, as discussed in Section 5.1.2, the
limited and cluttered space and low level H2S emissions inside the WTP building are safety concerns
noted during the site visit.
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6.0 RECOMMENDATIONS
This section provides several recommendations related to remedy effectiveness, cost control and technical
improvement. Note that while the recommendations provide some details to consider during
implementation, the recommendations are not meant to replace other, more comprehensive, planning
documents such as work plans, sampling plans and QAPPs.
Cost estimates provided in this section have levels of certainty comparable to those done for
Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) Feasibility
Studies (-30 to +50 percent), and have been prepared in a manner generally consistent with EPA 540-R-
00-002, A Guide to Developing and Documenting Cost Estimates During the Feasibility Study, July,
2000. A summary table of the recommendations with associated capital cost and changes in operating
costs is included as Table 6.
6.1 RECOMMENDATIONS TO IMPROVE EFFECTIVENESS
6.1.1 CONSIDER ALTERNATIVE FILTERS OR IMPROVE EXISTING SYSTEM
The existing filters are a frequent cause of WTP shut down. During the site visit, the potential benefit of
retrofitting bag type filters in lieu of the existing pressure media filters was discussed. Bag filters are a
simple means of providing polishing filtration and could reduce overall operator time associated with
filter maintenance and could allow the WTP to operate at a much higher percentage up-time. While cost
reduction is possible, the more important improvement would be to WTP effectiveness.
Many long-term operating treatment systems with flows exceeding 100 gpm use bag filters instead of
granular media filters. However, the bags must be removed and replaced manually. While this is not a
major issue, this labor requirement must be factored into the decision to make this change. It is
recommended, therefore, that bag filters be pilot tested before a final decision is made. If bag filters are
installed, adequate hose down and drain facilities should be available and a suitable lifting system for the
bag filters could be considered. A brochure for an example of this type of filter (Rosedale multi-bag
filters) is included in Appendix B.
A simple test of bag filter capacity can be performed to determine how frequently the bags would have to
be replaced. If bag replacement was infrequent, bag filtration would be more cost-effective than the multi-
media filters with their costs for backwash and associated maintenance. A pilot test using a small capacity
filter could be conducted for approximately $5,000. If the pilot test indicates that adequate metals removal
can be achieved with reasonable bag filter use, conversion to a four-plex bag filter system could be
accomplished for approximately $30,000.
One of the major benefits of the bag filter system is that backflushing is not required. The limitations of
the existing backflushing system have been described earlier in this report. With a dual bag filter system,
one set of bag filters could be replaced while the other side of the filter remained in service with no
interruption in plant operation. The bags would be a new, but small, volume/mass waste stream.
18
-------
If the existing filters are kept in service, consideration should be given to making several improvements:
• Provide individual differential pressure monitors on each filter.
• Install a pressure indicator upstream of the existing pressure maintaining valve to be sure that
valve is operating correctly.
• Consider adding orifice plates in the effluent lines from each filter for better flow distribution
between the filters.
• Consider having a standby skid of four filters already charged with media that would be
available for quick replacement if the inline filters become clogged and require media
replacement.
• Consider adjusting the pH after rather than before the filters. This may reduce the potential
for clogging the media.
• Continue the use of muriatic acid for cleaning the filter media on a routine basis.
• Install a level indicator/switch to prevent backflush from happening if TK-551 is too high.
These changes could be implemented for approximately $25,000.
Another option would be to provide a complete replacement skid of filters that could be quickly installed
in place of the online filters if the media becomes completely clogged. With the current operation it takes
approximately a month for a complete change media replacement operation. During that time, the plant is
in "recycle to mine" mode with the treatment system in operation (minus the filters) with 99% of the zinc
removed. The cost of the existing filters was approximately $16,000.00.
6.1.2 CONSIDER SODA ASH SYSTEM CHANGES
During the optimization site visit, the plant staff reported that the Na2CO3 system has also been a
significant operations and maintenance problem. Currently the Y-strainer before the centrifugal pump is
cleaned Monday, Wednesday and Friday to keep the flow of liquid at a constant pressure. Even though
the Na2CO3 is at an 8 percent dilution and should not drop out of solution based on solubility graph
information, the Y-strainer always contains un-dissolved Na2CO3. Calcium deposits are also building up
in the Y-strainer after only approximately 4 months of cleaning the tank. The Na2CO3 pump seal has been
replaced after only 8 months of use. The WTP staff is currently running hot water through the pump
during the hot water flush. The original BioteQ programming stopped the pump during a hot water flush
(this has been changed so the pump continues to run). This may help to remove any kind of deposit where
the seal is sporadically leaking and could lengthen the life of the pump seal. The valve that controls the
Na2CO3 feed rate to maintain the pH set point has to be replaced more than once a year due to a part of
the valve leaking likely due to wear and tear. The Na2CO3 loop is flushed daily with hot water in an
attempt to keep up the operation. It may help to add a VFD to the pump drive to control the flow of
Na2CO3 into the process. The WTP staff has expressed a concern that VFD may slow the existing pump
to such a low flow rate that the Na2CO3 may settle in the piping. Caustic soda (NaOH) may be an option
to reduce the potential for pipe clogging since no solids are involved.
A caustic soda system would include a drum storage and feed system and chemical metering pumps.
Caustic is normally delivered at 50 percent concentration and diluted at the site to approximately 25
percent concentration. There is limited space for a drum and feed pumps, however, several locations
could be made available. If the feed tank had to be located in a tight location, incoming caustic could be
transferred via pumping to the fixed feed tank. A simple plastic tank containment could be provided for
the feed tank if it had to be located outside the existing containment area. The cost for such a system
would be approximately $10,000.
19
-------
Another minor improvement for the existing Na2CO3 system would be to provide a seal water system for
the Na2CO3 pumps to get longer service life out of the pump seals. This is an inexpensive improvement
and could easily be performed by WTP maintenance staff. Following the site visit, the WTP staff
implemented this improvement.
6.1.3 DEVELOP PLAN FOR MEETING STANDARDS AT POINT OF COMPLIANCE
Determine whether and to what degree the treatment of the FG-6C seep is improving French Gulch water
quality based on surface water sampling results. The mass balance had indicated that standards would be
met at the point of compliance once the WTP was in operation. The optimization review team
recommends determining:
• If the mass balance analysis is reasonable, or if it is not, then update it.
• If treating FG-6C is improving French Gulch substantially but not enough to meet standards,
identify, capture and treat other sources, if possible.
• If no significant improvement in French Gulch is indicated, reevaluate FG-6C capture and
operating system, and consider other alternatives.
This effort has been started by the site team.
6.2 RECOMMENDATIONS TO REDUCE COSTS
6.2.1 PROVIDE NATURAL GAS SERVICE FOR HEATING
The site team reported that natural gas service is available in the vicinity of the WTP. Natural gas heating
would offer savings of approximately 80 percent compared to propane (based on $3.35/gallon propane
and $0.80 per hundred cubic feet (ccf) natural gas and 1 ccf natural gas = approximately 1.1 gallons
propane heating value). At the current propane usage rate, approximately $5,500 per year could be saved
if natural gas was provided at the WTP. The cost to provide service to the WTP should be investigated;
with long-term WTP operation likely, even an upfront cost of $25,000 with a 5-year payback period
would be worthwhile.
Improving ventilation systems and weatherproofing the building (see Section 6.3.2) are not likely to
reduce the heating costs because current practice has the building kept at a low indoor temperature.
6.3 RECOMMENDATIONS FOR TECHNICAL IMPROVEMENT
6.3.1 IMPROVE TANK LEVEL CONTROLS
Plant influent is discharged to the Feed Buffer Tank (TK-101) which has a 9,000-gallon capacity. This
tank acts as a storage reservoir in the event of a WTP shutdown so that the influent pumps can continue to
run while the problem is resolved. This tank, the filter feed tank and the backflush tank should be
retrofitted with magnetic float type sight glass level indicators to allow the operators visual local
indication of the tank level. This type of indicator includes a dual standpipe to isolate the stored liquid
from the viewing standpipe to isolate the fouling that normally occurs in the viewing standpipe and is
offered by Penberthy/Tyco Model MG; a brochure for this type of level indicator is provided in Appendix
B. During the site visit, the operators noted that they were often hampered by a lack of ready knowledge
of the levels in the tanks. The only way to find out the level is for staff to go to the control stations in the
electrical room and look at the readings on the control screens. The installed cost per tank would be
approximately $2,500 for a site level gage.
20
-------
The WTP operation and maintenance (O&M) manual indicates that feed buffer tank is normally off-line
and only brought into service during a shutdown. This tank could provide benefit to control surges into
the WTP and even out the flow. Consideration should be given to keeping this tank in service (and
changing the system programming to allow it) during routine operation for surge dampening.
6.3.2 IMPROVE BUILDING VENTILATION TO REDUCE H2S
The building is poorly insulated and ventilated. At a minimum, the following should be considered to
reduce H2S in the building to provide a better work environment and improve electrical/mechanical
system lifespans:
• The ventilation system should be modified to bring outside air into the control room and electrical
room and discharge into the operations area to protect electrical gear.
• Individual in-line exhaust fans should be installed in the vent lines from each process unit
currently leaking H2S fumes to ensure a slight negative pressure in the headspace over each unit.
These vent lines would then feed the existing H2S scrubber system.
• Consider venting the NaHS storage tank to the outside. This tank is likely the major source of
H2S fumes.
• The overhead door should be insulated (implemented winter 2013) and heating in the chemical
storage areas should be improved.
The costs of these improvements may vary greatly depending on the degree of improvement, but will
likely be at least $50,000. While annual maintenance costs are expected to be reduced, the amount of
reduction cannot be quantified. With long-term, possibly indefinite, WTP operation likely, improvements
to the building are warranted and a major renovation should be considered.
6.3.3 STANDARDIZE CONTROLS, MAINTENANCE, AND PARTS
A high portion of O&M cost is for maintenance including subcontracted services and parts.
The most fruitful improvement in this category would be to convert the control system to commercially
available control software that could be serviced or modified by local control system integrators and
implement the proposed control change to include automated recycle to the mine to improve system
operation. The site team should obtain proposals from vendors to accomplish this change.
Many process equipment and chemical feed and control components (pumps, probes, flow meters, level
sensors, pressure sensors and switches and mixers) should be standardized as feasible and or have spares
readily available. For example, the ORP probes are indicated to be installed in a "hot tap assembly" for
insertion and removal from a full tank. Consideration should be given to providing a "hot-swappable"
arrangement so that another ORP probe can be immediately available at each location for immediate
change out with the actively installed probe. This allows immediate and quick replacement with no loss of
signal.
Consideration should also be given to programming and engineering changes that automate the WTP to
switch from "discharge" mode to "recycle to mine" mode. Operators currently have to manually change
the position on two valves when the plant goes out of compliance (pH primarily) to send water from the
21
-------
discharge back to the feed buffer tank and to the mine. The "recycle to mine" option would allow the
WTP to run while the problem is resolved instead of shutting whole process down. The Town of
Breckenridge indicated that this automation change was considered in 2012 and a proposal from BioteQ
was received. However, implementation was postponed until the five-year review and optimization
review were completed.
6.4 CONSIDERATIONS FOR GAINING SITE CLOSE OUT
The WTP operation is expected to continue indefinitely if it is determined that treating FG-6C water is
effective in meeting the site RAO. If treating FG-6C (and potentially adding a similar ARD source, to be
determined) is shown to have little or no effect on French Gulch and Blue River, the site team should
reconsider continued long-term operation of the WTP and re-examine source control alternatives
If the WTP operation is indefinite, the site team should make significant efforts to achieve consistent,
cost-effective WTP operation. The optimization review team does not have further recommendations
regarding site close out.
6.5 RECOMMENDATIONS RELATED TO ENVIRONMENTAL FOOTPRINT
REDUCTION
The above recommendations are likely footprint neutral given the level of accuracy of current footprinting
methodologies. Significant footprint reductions would be associated with reducing electricity use and
chemical use. A combined heat and power unit (likely rated between 50 and 100 kW) could provide
electricity and heating from natural gas more efficiently and with lower emissions than grid electricity
and propane or natural gas heat. However, the optimization team does believe there would be a favorable
financial payback for the capital investment.
Table 6: Summary of Recommendations and Associated Costs
Recommendation
6.1.1 Consider Alternative Filters or Improve Existing
6.1.2 Consider Soda Ash System Changes by adding Caustic
Soda Feed System
6.1.3 Develop Plan for Meeting Standards at Point of
Compliance
6.2.1 Provide Natural Gas Service for Heating
6.3.1 Improve Tank Level Controls
6.3.2 Improve Building Ventilation to Reduce H2S
6.3.3 Standardize Controls, Maintenance, and Parts
Reason
Effectiveness
Effectiveness
Effectiveness
Cost Reduction
Technical Improvement
Technical Improvement
Technical Improvement
Cost Change
$30,000
$10,000
Not Quantified
($5,500)/year
$2,500 per tank
$50,000+
Not Quantified
22
-------
APPENDIX A
SELECT FIGURES FROM SITE DOCUMENTS
&
PROCESS FLOW DIAGRAM
-------
Pile
t Hill
Figure 1-1
Location of the French
Gulch/Wellington-Oro Mine Site
Ecological Risk Assessment for the
French Gulch/Wellington-Oro Mine Site
Breckenridge, Colorado
-------
Map not to scale
Dillon
Reservoir
BR-ADMS
Brecenridge
654
Expanded View of North Branch
KDS/
FG-6A
TS-4
North Branch
/
' i
I Extenuate
| Site
Wellington-Oro \
Mine ' Sf
McLeod
Tunnel
FG-3
South Branch
Figure 2-1
Sampling Location Map
Ecological Risk Assessment
French Gulch Wellington-Oro Mine Site,
Breckenridge, Colorado
-------
FG6C
WELLINGTON ORO
MINE DRAINAGE
NaHS&
SODA ASH
FEED WATER
FEED
BUFFER
TANK
D
NaHSAND
SODA ASH
1£
TK-200
CONTACTOR
TK-201
CONTACTOR
Q
UJ
Q
O
e
CL
TK-220 SLUDGE
CONDITIONING TANK
SODA ASH AND
FLOCCULANT
TK-203
FLOCCULATION
TANK
TK-205
CLARIFIER
ZnS/CdS PRODUCT
TO SMELTER
EQ-200
FILTER PRESS
FLOCCULANT
TK-501
FILTER
FEEDTANK
EQ-500 MIXED
MEDIA FILTERS
g
CL
n
o
IT
TK-509
CLEAR
WELL
FERRIC
CHLORIDE
FINAL DISCHARGE
TO OUTFALL 1
O
UJ
I
O
CO
O
CO
CO
UJ
o
o
a:
Q.
Project No.: 133-01298-12002
Designed By:
JSIM
Drawn By:
JLC
Checked By:
JSN
PFD-1
Bar Measures 1 inch
-------
APPENDIX B
INFORMATIONAL BROCHURES:
ROSEDALE MULTI-BAG FILTERS
&
PENBERTHY MAGNETIC LIQUID LEVEL GAGES
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MULTI-BASKET STRAINERS AND MULTI-BAG FILTERS
Multi-Basket Strainers
and Multi-Bag Filters
These multi-basket strainers and bag filters
offer a wide range of flow capacities and
contaminant-holding capabilities. They
contain from 2 to 23 baskets.
To serve as a strainer, a unit is ordered
with perforated stainless steel baskets
(mesh-lined if desired). When ordered as
a filter, it's fitted with perforated stainless
steel baskets designed to hold disposable
or cleanable filter bags. Industry-standard
size bags are used: the standard 30 inch
baskets accept bag size 2, the optional 15
inch baskets take size 1.
The standard pressure rating for all models
is 150 psi. All housings can be supplied
with an ASME code stamp, if required.
Features
- NSF61 listed
• Multiple housing styles available (standard,
quick access, low profile, hinged)
• Permanently piped housings are
opened without tools and without
disturbing the piping
• Machined cover gasket groove
provides positive O-ring sealing
• Carbon steel, 304 or 316 stainless
steel construction housings
• Large-area, 30 inch deep, heavy-duty,
9/64 inch perforated baskets
• Easy to clean
• Low pressure drop
• Four cover seal materials: Buna N,
Ethylene Propylene, Won®, and Teflon®
• Pressure rating 150 psi
• Flanged connections for 2
through 12 inch pipe
• Vent, drain and gage connections
Options
• ASME code stamp
• Higher pressure ratings
• Corrosion allowances
• Steam jackets
• Special connection locations
• Bag hold down assembly (standard
on QTi design)
• Inner baskets for dual-stage straining or filtering
• Cleanable wire mesh lined or perforated
strainer baskets
• Special alloy materials
• Hydraulic cover lifting assembly
• Sanitary fittings
• Differential pressure indicators
Duplex Systems
All multi-basket models described here are also
available as duplex systems. Two units come
piped together with valves to permit continuous
use of either unit while servicing the other. One
lever actuates all valves simultaneously or it can
be ordered for automatic service. See page 65.
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MULTI-BASKET STRAINERS AND MULTI-BAG FILTERS
Choose Housing Style
Designed to suit your requirements
The versatility of Rosedale Products provides a
choice of several different designs.
• Standard Housing Design (STD) is
durable and economic. It includes a davit arm
and handwheel to facilitate cover removal.
It is our most versatile housing design offering
a variety of options, including our low profile
design.
• Spring Access Cover Design (HLP) opens
and closes without effort. Simply loosen the
swing bolts and lift the cover up to open.
An automatic cover stop is provided. See
page 37 for details.
• Quick Access Cover (QTI) features a unique
counter weight design that makes opening,
closing, and change-out, fast, easy, and simple.
This will significantly reduce change-out time and
lower operating costs. The QAC is rated to
150 PSI and constructed to meet ASME code
requirements. Built-in safety features ensure that
the cover cannot be opened unless the internal
pressure is first released. The QTI is offered with
our low profile design making bags more
accessible and easy to remove.
• Low Profile Design (SLP) Housings are
compact and space saving, allowing for ease of
bag change-out. Standard operating height is
reduced, resulting in a safe design by eliminating
platforms and ladders. The SLP is manufactured
in any housing version, including our standard
davit arm cover, QAC design, and spring assisted
hinged cover.
Standard Davit Arm
Spring Access Cover
QII Quick Access Cover
Low Profile Design
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MULTI-BASKET STRAINERS AND MULTI-BAG FILTERS
Choose Baskets
That Strain or Filter
Whatever your needs dictate
Strainer baskets are cleanable, reusable.
A seal is supplied on any strainer basket.
It forms a seal between basket and
housing to prevent dirty fluid bypass.
Choose between various perforation sizes
or wire mesh. Strainer baskets have flat,
non-perforated bottoms and contain
heavy-duty handles.
Filter bag baskets hold disposable filter bags.
Filter bags have an interference fit between
the bags top rim and the housing causing
a positive seal to prevent fluid bypass. Filter
bag baskets have flat perforated bottoms.
Filter bags are available in a wide variety
of felt, micro-fiber, monofilament and
multifilament mesh materials. They are
detailed completely on pages 134.
DUAL-STAGE- Dual-stage action will
increase strainer or filter life and reduce
servicing needs. This straining/filtering
action can be achieved by
ordering a second, inner basket.
It is supported on the top flange
of the outer basket. Both
baskets can be utilized as
strainers (with or without
wire mesh linings), filter bag
baskets, or a combination of
strainer and bag basket.
Basket Data
Surface area of each 30 in. basket: 4.4 sq. ft.
Volume of each 30 in. basket: 0.6 cu. ft.
Basket Construction
For cleanable strainer baskets, choose from
the following perforation diameters: 1 /4,
3/16, 9/64, 3/32, or 1/16 inch (for other
not shown consult factory).
Any perforated basket can also be
ordered lined with wire mesh. Stainless steel
wire is used in mesh sizes 20, 30, 40, 50, 60,
70, 80, 100, 150, or 200.
Filter bag baskets, have standard 9/64 inch
diameter perforations that are 51 % open area.
A wire mesh can also be utilized with bag
baskets for two advantages:
1. Fiber migration is minimized.
2. In the unlikely event of bag
rupture, the wire mesh better
contains the contaminant.
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MULTI-BASKET STRAINERS AND MULTI-BAG FILTERS
SAFETY VALVE
MECHANISM
COUNTER
BALANCED COVER
HANDWHEEL
OPERATION OF
TURNBUCKLE
MECHANISM
ELEMENT/BAG
RETAINING DEVICE
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MULTI-BASKET STRAINERS AND MULTI-BAG FILTERS
.
MODEL Pipe Leg Bolt
NUMBER Sizes Circle
& Dim. A B Dia.
16 2 14.0
3
4
18 2 16.0
3
4
22 2 20.0
3
4
6
24 2 22.0
3
4
6
30 2 28.0
3
4
6
8
36 3 34.0
4
6
8
10
42 4 40.0
6
8
10
12
48 4 46.0
6
8
10
12
C D
10.9 40.1
42.5
44.9
11.9 40.5
42.9
45.3
14.0 41.4
43.9
46.2
50.4
15.0 41.7
44.1
46.5
50.7
18.0 42.8
45.2
47.6
51.9
56.4
21.0 46.4
48.8
53.1
57.6
62.1
24.0 50.0
54.3
58.8
63.3
68.0
27.0 51.0
55.4
60.0
64.4
69.2
Standard 1
E
57.1
59.5
61.9
58.0
60.4
62.8
60.0
62.4
64.7
69.0
60.7
63.1
65.5
69.7
63.3
65.7
68.1
72.4
76.8
68.4
70.8
75.1
79.6
84.1
73.5
77.8
82.3
86.8
91.5
76.0
80.4
85.0
89.4
94.2
F
4.50
5.25
6.00
4.50
5.25
6.00
4.50
5.25
6.00
7.00
4.50
5.25
6.00
7.00
4.50
5.25
6.00
7.00
8.25
5.25
6.00
7.00
8.25
9.50
6.00
7.00
8.25
9.50
11.0
6.00
7.00
8.25
9.50
11.0
G
10.5
12.3
14.0
11.1
12.9
14.6
11.9
13.7
15.4
18.9
13.1
14.8
16.6
20.1
15.2
17.0
18.7
22.2
25.7
18.8
20.6
24.1
27.6
30.6
22.6
26.1
29.6
32.6
36.1
24.8
28.3
31.8
34.8
38.3
Weight, Ib
(Approx)
400
425
450
450
475
500
485
500
515
560
675
700
725
750
635
650
665
705
850
840
860
870
1010
1150
1840
1870
1960
2070
2200
2015
2075
2200
2350
2530
^^^^^^HTffB
H
37.9
38.3
N/A
39.6
40.0
N/A
39.5
40.0
39.5
N/A
41.2
41.6
41.1
N/A
41.3
41.8
41.3
41.2
N/A
43.3
43.2
43.2
43.2
N/A
45.9
45.9
45.9
45.8
N/A
46.5
46.4
46.4
46.4
N/A
I
54.9
55.3
N/A
58.5
58.9
N/A
58.0
58.5
58.0
N/A
61.6
62.0
61.5
N/A
61.9
62.4
61.9
61.8
N/A
64.5
64.5
64.4
64.4
N/A
70.7
70.6
70.6
70.5
N/A
71.5
71.4
71.4
71.4
N/A
J
8.00
9.00
N/A
8.00
9.00
N/A
8.00
9.00
9.00
N/A
8.00
9.00
9.00
N/A
8.00
9.00
9.00
10.0
N/A
9.00
9.50
10.5
11.5
N/A
9.50
10.5
11.5
12.5
N/A
9.50
10.5
11.5
12.5
N/A
K
15.0
17.0
N/A
15.0
17.0
N/A
15.0
17.0
19.0
N/A
15.0
17.0
19.0
N/A
15.0
17.0
19.0
17.0
N/A
17.0
19.0
17.0
17.0
N/A
19.0
17.0
17.0
17.0
N/A
19.0
17.0
17.0
17.0
N/A
L
13.0
14.0
N/A
14.0
15.0
N/A
16.0
17.0
18.0
N/A
17.0
18.0
19.0
N/A
20.5
21.0
22.5
23.0
N/A
24.0
25.0
26.0
27.0
N/A
28.0
28.0
29.5
30.0
N/A
32.0
32.0
32.5
33.0
N/A
Dimensions (IN)
(30-inch deep basket)
Dimensions are reference only and
should not be used for hard plumbing.
Consult factory for certified drawings.
I-
JT
-B
:
• L
— G Typ. -H (4) 7/8 DIA. HOLES
Standard
L Typ. H (4) 7/8 DIA. HOLES
Low Profile
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MULTI-BASKET STRAINERS AND MULTI-BAG FILTERS
NUMBER Circle
& Dim. A Dia.
& 16.0
22.0
22.0
28.0
A
18.0
24.0
24.0
30.0
Size
B
2
3
?
3
4
2
3
4
2
| Qll Low Profile
c
40.0
40.4
41.5
41.9
41.4
41.5
41.9
41.4
43.0
D
53.2
53.6
56.2
56.6
56.1
56.2
56.6
56.1
59.2
E
8.00
9.00
8.00
9.00
9.00
8.00
9.00
9.00
8.00
F
15.0
17.0
15.0
17.0
19.0
15.0
17.0
19.0
15.0
G
14.0
15.0
16.0
17.0
18.0
17.0
18.0
19.0
20.5
^^IH Model Selection (For all housings) 1
H
35.5
35.5
38.5
41.5
Model
No.
16
18
22
24
30
36
42
48
Number
of
Baskets
2
3
4
6
8
12
17
23
Straining,
Filtering
Area, ft2
8.8
13.2
17 6
26 4
35.2
52.8
74.8
101.2
Nominal
Flow Rate
lgpm|"
200
300
400
600
800
1200
1700
2300
Inlet/
Outlet
Size (in)
2,3,4*
2,3,4*
2346*
2346*
2,3,4,6,8*
2,3,4,6,8,10*
2,3,4,6,8,10,12*
2,3,4,6,8,10,12*
Dimensions (IN)
1/2 COVER VENT VALVE -\
CLAMP
HAND
WHEEL
GTyp
7/8 DIA HOLES (4)
1/2 NPT SAFETY VALVE -,
Dimensions are reference
only and should not be
used for hard plumbing.
Consult factory for
certified drawings.
* Not available on SLR HLR and Qll styles.
** Nominal flow rate is based on water @ 1 psi AR
For optimum filtering effectiveness, a maximum
fluid velocity of 10 ft/sec should be maintained.
Pressure Drop Data
Basket strainers and bag filters are usually selected so
that the pressure drop does not exceed 2 psi, when they
are clean. Higher pressure drops may be tolerated
when contaminant loading is low.
Determining housing pressure drop:
The pressure drops shown on the graph are reliable
for all multi-basket housings, including strainer baskets or
bag filter (perforated only or mesh lined). The pressure
drop of any housing is governed by the size of the inlet
and outlet, not the vessel itself.
1. Using the desired pipe size and approximate flow rate,
determine the basic pressure drop from the graph.
2. Multiply the pressure drop obtained in step 1 by the
viscosity correction factor found in the accompanying table.
3. You now have the pressure drop for a clean multi-basket
unit. If bag filters are employed, you must add the pressure
drop they incur to get a true pressure drop for the assembly.
Note: Filter bags are specified separately.
See pages 134.
500 1000 1500 2000 2500 3000 3500 4000
FLOW, GPM
Recommended flow rates are based on housing only.
Fluid viscosity, filter bag used, and expected dirt load should
be considered when sizing a filter.
QJI Low Profile
Viscosity Factors
i
(H20|
.65
50
.85
100
1.00
CPS
200
1.10
MUM
400
1.20
BER
600
1.40
800
1.50
1000
1.60
2000
1.80
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Previous
INDEX
Next
MULTI-BASKET STRAINERS AND MULTI-BAG FILTERS
How To Order
Build an ordering code as shown in the example
Housings
Options
SLP-24-30-4F -1-150-C- B -S -M-20- C-
HOUSING STYLE
Standard (std| = No Symbol
Standard Low Profile = SLP
Quick Access Cover = Q
MODEL NO.
16=16 30 = 3O
18=18 36 = 36
22 = 22 42 = 42
24 = 24 48 = 48
BASKET DEPTH
15-in.
30-in. (std)
15
30
PIPE SIZE (FLANGED1)
2-in. (Std.SLRHLPl 6-48 / Qll 18 & 24) = 2F
3-in.(Std, SLP, HLP 16-48 / Qll 18 & 24] = 3F
4-in. (Std I 6-48 / SLP, HLP 22-48 / Qll 24) = 4F—I
6-in. (Std 22^8 / SLR HLP 30-48) = 6F
8-in. (Std 30-48 / SLR HLP 36-48) = 8F
10-in. (Std 36-48 / SLR HLP 42 & 48) =1 OF
12-in. (Std 42, 48) = 12F
OUTLET STYLE
In-line, bottom (std) = 1 —
Side inlet/outlet (SLP, HLR Qll) = 2
Side inlet/outlet, same side (SLR HLR Qll) = 4
PRESSURE RATING2
150 psi (flanged) = 150
HOUSING MATERIAL
Carbon steel = C
304 stainless steel = S
316 stainless steel = S316
* COVER SEAL
Buna N (N/Aon Q housing) = B
Ethylene Propylene (N/A on Q housing) = E
Viton® = V
Teflon® Encapsulated Vlton® (N/A on Q housing) = TEV
Teflon® (solid white) (N/A on Q housing) = TSW
BASKET SEAL
No seal = N
Seal (only on strainer housings) = S
1. Flanges provided with the housing match the pressure rating of the vessel.
Housings rated 150 psi have 150 class flanges. Housings rated 300 psi
have 300 class flanges. Other styles and classes available. ANSI Bl 6.5
Pressure-Temperature rating tables determine flange class for ASME code
housings. Consult factory.
2. Higher pressure ratings available. Consult factory.
•Note: Because of its unique Quick Access Cover, the Q (QE)
housing style is available only with a Viton cover seal.
OPTIONAL
INNER
BASKET
2P 1/16
OPTIONAL INNER
BASKET, MEDIA SIZE
Perforation diameters (for type 2P
baskets)
-1/4, 3/16, 9/64, 3/32, 1/16
Mesh sizes (for type 2M & 2BM
baskets)
20, 30, 4O, 50, 60, 70, 80,
100, 150, or 200
OPTIONAL INNER
BASKET, TYPE
2B = Filter bag basket,
9/64 perforations
2P = Strainer basket
perforated metal
2BM = Filter basket, mesh lined
2M = Strainer basket,
perforated, mesh lined
ASME CODE STAMP
C = Code
NSF = NSF6I listed
BASKET, MEDIA SIZE No
symbol if type B basket was
selected
Perforation diameters (for type P
baskets)
1/4, 3/16, 9/64, 3/32, 1/16
Mesh sizes (for type M & BM
baskets)
20, 30, 4O, 50, 60, 70, 80,
100, 150, or 200
BASKET, TYPE
PB
BM
M
HWM
Filter bag basket,
9/64 perforations
Strainer basket,
perforated metal
Filter bag basket,
perforated, mesh
iined
Strainer basket,
perforated, mesh
lined
Filter bag basket,
heavy wire mesh
-------
Section 4000
Bulletin 4200
Issued 10/04
Replaces 7/99
-
l---d
-------
Worldwide Leadership in
Liquid Level Monitoring!
Penberthy has long been recognized as a world leader in manufacturing products for liquid
level monitoring. Whether it is direct reading level gages, eductors or sight flow indicators,
Penberthy is known for superior products at competitive prices. Penberthy continually
strives for excellence in product quality, customer service and on-time deliveries.
It would be easy for a company that has achieved this reputation to become
complacent. Not at Penberthy! With the new century in view, Penberthy has made a
renewed commitment to striving for excellence, both In product quality and customer
support and service. Through the course of many years of research and development,
product testing both in the lab and in the field, and monitoring product performance,
Penberthy has acquired a vast pool of knowledge...knowledge that has been passed on
to our customers in the form of superior products.
This commitment to excellence is the core of Penberthy's business philosophy. For
many years, Penberthy has recognized that the only way to truly control product quality
is to "do it yourself." Therefore, all components of every product are manufactured to
Penberthy's strictest specifications. Along with this single-source responsibility also
comes renewed vigor in making certain that process industry needs are met in the most
expedient way possible. Penberthy has a proactive business philosophy...anticipate
customer needs, offer technical advice, help solve problems. That is today's Penberthy.
With this vision in mind, Penberthy offers its MULTIVIEW™ Magnetic Liquid Level Gage
product line to the process industry. These liquid level gages offer more versatility, greater
durability, more features and more options than any other system on the market today.
See why MULTIVIEW™ is the magnetic gage of choice for liquid level monitoring in today's
modern processing operations.
tl/CO
m
PENBERTHY
Tyco Valves
& Controls
-------
Typical Process Applications
• Sodium Hypochlorite
• Boiler Feedwater Tank
•Hydrochloric Acid
• Stop Oil
•LPG
• Interface
• Dowtherm®
•Su If uric Acid
• Hydrogen Sulfide
• Oil/Water Separator
• Sodium Hydroxide
• Liquid Nitrogen
• Flare Drums
• Phosgene
•Ammonia
• Butane
• Seal Oil Pots
• Black Liquor
• Drip Pot
• Boiler Steam Drums
• Glycol
• Propane
• Hydraulic Oil
• Feedwater Heaters
• Extreme Flashing
• Hydrazine
•Caustic Chemicals
• Fuel Oil
•Hydrofluoric Acid
• Jet Fuel
• Molten Sulfur
•Sour Oil
• Diesel Fuel
• Deionized Water
• Sumps
• Freon
• Liquid Ethylene
• Water
• Underground Storage
• Benzene
•Asphalt Settler
• Acetic Acid
• Liquids & Slurries
Typical Tank Configurations
Top-Mounted Indicator
Boiler Feedwater Tank
Indicating
Scale
Follower-Type
Indicator
Sodium Hypochlorite
Oil/Water Separator
Liquid Nitrogen
- 4 to 20 mA
Transmitter
• High Level
Alarm
• Insulation
Blanket
Thermostat
Hydrochloric Acid
Sodium Hydroxide
-------
Choice of Indicators
Flag-Type
Follower-Type
Fluid Contained in
Standpipe Chamber
Rugged, Versatile
Options for a Wide
Range of Applications
Penberthy MULTIVIEW™ Magnetic Liquid Level Gages
can be built to serve practically any process industry
situation. From the simplest operation to the most severe,
corrosive environment, Penberthy can construct a system
to best suit your company's requirements. As pioneers in
magnetic gage level indication and as creators of the unique
concentric magnet design, Penberthy has the expertise to
know what design, specifications and options best fit any
given application. Contact a Penberthy representative to
discuss specific duty requirements in your operation.
Magnetic Float
Conventional Follower
Penberthy Anodized Gold
-------
Vessel Connection
Magnetic
Coupling
Indicator Showing
Liquid Level
Hermetically-Sealed
Glass Tube
Vessel Connection
-------
MULTIVIEW™ Magnetic
Liquid Level Gages utilize
a standpipe constructed
of 2-1/2" pipe which is
connected to the process
tank with either side or end
connections. A float with
a self-enclosed magnet is
custom sized and weighted
to float at the surface of
the process liquid to be
monitored. The float is then
installed in the standpipe.
In MG Follower-Type
models, the unit consists
of a hermetically-sealed
tube in a protective view
housing. Within this
tube is a gold anodized
aluminum follower which
will mirror level changes
in the process tank. This
entire assembly is attached
to the standpipe where the
follower is magnetically
coupled with the float.
Because the follower and
float are magnetically
linked, liquid level changes
in the process tank will
cause both float and
follower to rise and fall in
unison. The result is a
precise indication of the
liquid level within
the vessel.
The anodized gold
follower can withstand
extreme heat up to 800° F
without adverse wear and
discoloration. Follower-type
monitoring is suitable for
most applications, except
where violent changes in
level can cause the follower
to de-couple from the float.
In these types of
applications, flag-type
indication is recommended.
-------
Model MG
Flag-Type
MG Flag-Type monitors
provide a more secure
link between indicator and
float. The view housing
is sealed and consists of
a single column assembly
of aluminum flags within
an extruded aluminum
channel. These flags are
anodized with black on one
side and gold on the other.
Each flag houses a small
magnet and is assembled
on a single, individual axle.
As the float in the standpipe
rises and falls, the magnetic
interaction between float
and flag magnets cause the
flags to rotate 180°. These
changes are shown through
contrasting colors - black
above and gold below the
liquid level.
Follower-Type and
Flag-Type indicators are
both available with stainless
steel housings.
To insure trouble-free
operation, Penberthy's flags
are magnetically interlocked
and utilize mechanical
stops. This prevents
over-rotation. Penberthy's
redundant axle system
prevents binding, with each
flag allowed to rotate on
the axle and each axle free
to rotate in the channel.
This method of indication is
always accurate, regardless
of the speed of process
level change or vibration.
Installation of a point-
level switch can provide
highly accurate, non-
intrusive high/low point
monitoring. For continuous
level monitoring from a
remote location, a level
transmitter can be installed
on either model as well.
For more information
on switches and
transmitters, see pages
14 and 15, or contact a
Penberthy representative
for specific details.
-------
Conventional Corrugated
Magnetic Ring
Penberthy
Concentric Magnet
Corrugated Ring
Stiffening Ring
More
Consistent
Magnetic
Strength
Weak Areas in
Magnetic Field
Float Design
Conventional floats have 12 to 15 small magnets
contained by a corrugated stainless steel ring
as shown above. To provide internal support
necessary to operate at higher pressures, a
typical float contains stiffening rings throughout.
It is not possible to place an effective stiffening
ring within the corrugated ring design. In other
words, there is no internal support in the part of
the float containing the magnets. This can cause
the float to collapse under higher pressure. Also,
the magnetic field in the corrugated magnet
design has weak areas, causing float and
follower to lose magnetic contact. And, if a switch
or transmitter is mounted in-line with a low point,
the magnetic field may not be strong enough to
actuate these devices.
The concentric magnet design of
MULTIVIEW™ allows for the use of stiffening
rings. This means strong internal support to
prevent collapse when operating in higher
pressure applications. It also allows for
more consistent magnetic strength than the
conventional designs.
Other float types offered in the MULTIVIEW™
product line include standard ANSI Class 150,
300, 600, 900 pressure/temperature rated floats,
Super Magnet floats with > 6 times the B-H
product for high vibration or other environments
and Vented floats. Also available are Interface
floats designed so that 50% of the float's length
rides in the heavier of the two liquids; 50% in the
lighter liquid. At least 0.2 difference in specific
gravity is required.
Standpipe Design
Professionals in the process industry realize
the importance of solid construction in their
containment vessels. That applies not only to
the tank, but to the level monitoring equipment
as well. Level gages must be built to withstand
the rigors of continuous use, often in less than
ideal conditions.
Penberthy's answer to these customer
demands is to design and build equipment that
meets the highest construction standards. That
is why all metallic MULTIVIEW™ standpipes are
rated to the ANSI/ASME Boiler and Pressure
Vessel Code and ANSI/ASME B31.1 and B31.3,
making them perfect for use in all kinds of
storage and pressure vessel applications in the
most extreme duty conditions. These metallic
standpipes are constructed of 2-1/2" Schedule
10 or 40 pipe and are available in a wide array
of materials and/or linings (see chart on next
page). Weldneck flanges, weldolets, threadolets,
sockolets, 3000# threaded process couplings,
and other plumbing options are offered to meet
specific vessel connection requirements.
Additionally, Penberthy offers PVC and
CPVC versions constructed of 2" Schedule 40
pipe for low pressure applications where cost-
effectiveness and corrosion-resistance are of
primary concern. These varied options make
Penberthy MULTIVIEW™ products some of the
most versatile on the market.
8
-------
Construction Materials Available
• 304/304L STS
•316/316L STS
•Alloy-20
1 Monel
•Titanium
• Hastelloy-C
•PVC
•CPVC
•PVDF
1 Tefzel® Lined
• Halar® Lined
Float Minimum Specific Gravity
Float Material
31 6/31 6L STS
304/304L STS
Titanium
Monel
Alloy-20
Hastelloy-C
PVC
CPVC
Other
Min. Specific Gravity
0.49
0.49
0.37
0.51
0.47
0.53
0.79
0.86
Consult Factory
Stated Specific Gravity is for metallic ANS1150 Schedule 10 extended length float except
for polymers.
Standard Chamber Lengths
Side
Connection
End
Connection
Minimum
Maximum
Minimum
Maximum
Overall (mm)
20-7/16" (519)
258- 15/1 6" (6577)
20-7/16" (519)
254- 15/1 6" (6475)
Vessel
Centers (mm)
4-1/4" (108)
236" (5994)
4-1/4" (108)
236" (5994)
Consult the factory for lengths outside of stated maximum or minimum.
Temperature Ranges
Float/Standpipe
Material
Metallic
PVC
CPVC
Minimum Temp. °F
(°C)
-325°F(-198°C)
-20°F (-28°C)
-20°F (-28°C)
Maximum Temp. °F
(°C)
750°F (400°C)
140°F(60°C)
200°F (93°C)
Note: Specification data subject to change without notice.
Pressure Ratings (Float Limited)
Float/Standpipe
Material
316/316LSTS
304/304L STS
Titanium
Monel
Alloy 20
Hastelloy -C
PVC
CPVC
Other
Standpipe
Schedule 10
psig @ 100°F
(kPag @38° C)
1270(8756)
1270(8756)
915(6309)
1400(9653)
1240(8549)
1480(10204)
N/A
N/A
Standpipe
Schedule 40
psig @ 1 00° F
(kPag @38° C)
2200(15168)
2200(15168)
1580(10894)
2430(16754)
2140(15444)
2560(17651)
250(1724)
250(1724)
Consult Factory
Float @
100° F
ANSI/psig
900#/2160
900#/2160
900#/1800
900#/1800
900#/1800
900#/2250
150 psig
150 psig
Metallic Standpipe based on:
P =
2SEt Stresses from ANSI B31.1 or
D-2yt ASME Section II-D
These pressure ratings assume that all fittings are equal to or exceed the Standpipe ratings.
For Halar®/Tefzel® lining and other float materials, contact the factory for details.
Flag-Type
with Transmitter
& Switch
• .
Follower-Type
with Transmitter
& Switch
-------
The MULTIVIEW™ Vapor
Bypass Magnetic Liquid
Level Gage is designed
for processes where
flashing may occur.
Standard magnetic liquid
level gages fail in these
types of processes. When
flashing occurs, the vapor
build-up beneath the float
cannot escape quickly
enough due to the limited
clearance between the
float and the chamber wall,
causing the float to rocket
to the top of the chamber,
where it is crushed or
damaged. The Vapor
Bypass variation of the
Penberthy MULTIVIEW™
Magnetic Liquid Level Gage
features a large chamber in
combination with a unique
cage system which confines
the float to one side of
the chamber. This allows
maximum area for vapor
to bypass the float and
ensures proper magnetic
coupling to the indicator.
No more crushed floats!
The unique guide cage
design of the MULTIVIEW™
Vapor Bypass Magnetic
Liquid Level Gage eliminates
the risk of crushed floats
due to flashing vapors.
-------
An Effective Solution For
Gauging Flashing Liquids!
Features - MGVB Vapor Bypass
Larger chamber and unique
internal float cage
Magnetically interlocked flag
type indication
Custom weighted magnetic float
Designed in accordance with
ASMEB31.3
Easy installation
Virtually maintenance-free
Optional transmitter or switches
Illustration Key
1
2
3
4
5
6
7
Standpipe
Vessel Connections
Internal Guide Cage
Clamp
Magnetic Float
Flag Indicator
Indicator Scale
Typical Applications
This magnetic liquid level gage provides
benefits when used in the following
applications:
• Light Hydrocarbons
• Liquid Nitrogen
• Propane
• Methane
• Carbon Dioxide
• Anhydrous Ammonia
or any pressure liquefied gas
Technical Data
Constructed of 4" NFS
Schedule 40 pipe
Size Range: Vessel Centers: 4.25" - 236"
[108 mm -5994 mm]
Minimum specific gravity of 0.47*
Upto300#ANSI rating
Temperature range: -325°F - 750°F
[-198°C-400°C]
Refer to previous pages in this bulletin
for other features shared with the
standard MULTIVIEW™.
"Based upon Titanium float
11
-------
Top Mount
Magnetic Gage (TMMG)
lOdelTMMG Top Mount
Model MMG Mini Mag
Mini Magnetic
Gage (MMG)
When side-mounted level
monitoring is not feasible
or impractical, Penberthy
offers the MULTIVIEW™
Top Mount Magnetic
Gage (TMMG). TheTMMG
features the same trouble-
free method of operation
as a standard MULTIVIEW*
Magnetic Liquid Level Gage.
A stilling well is
recommended for protecting
against both float and tube
damage... the primary
cause of top mount failure.
In vessels where large
particulates can become
trapped between float and
stilling well, Penberthy's
unique guide system limits
the contact area, virtually
eliminating the chance that
particulates will clog and
hinder float movement.
In applications where
monitoring will operate
at or near ambient
temperature, the Mini
Magnetic Gage (MMG)
is recommended. This
system reduces initial
customer cost without
sacrificing performance and
is perfect for applications
such as air conditioning
and refrigeration, filter
manufacturers, waste water
treatment, oil/chemical
storage, skid system and
tank manufacturers, and
boiler feedwater tanks.
Only flag-type level
indication is offered with
both the TMMG and MMG.
-------
Features -TMMG Top Mount
The TMMG float is located in the containment
vessel while the magnet assembly is at the
opposite end of a tube in the standpipe. As
the float level changes, so does the magnetic
position. The level change is visually conveyed
to the operator via the indicator mounted to the
standpipe.
Options-TMMG Top Mount
Both point level and continuous
electronic level indication can
be added by using Penberthy's
third party approved switches
and transmitters
Optional stilling well can be
installed for additional protection
of both float and tube
Unique guide system can be
added to minimize the risk of
particulatematter/crystalization
adversely affecting float operation
Guide System
Float Minimum Specific Gravity
Float Diameter (mm)
3.5"
4.5"
6"
8"
10"
(89)
(114)
(152)
(203)
(254)
Min. Specific Gravity
0.50
0.32
0.21
0.20
0.15
Specific Gravities are based upon multiple ANS1150# Titanium floats. Your actual minimum
specific gravity will be application-based.
Minimum Vessel Opening Requirements
Float Diameter (mm)
3.5"
4.5"
6"
8"
10"
(89)
(114)
(152)
(203)
(254)
Min. Flange Conn. Req.
4"
5"
6"
8"
10"
Features - MMG Mini Magnetic Gage
MMG Mini Magnetic Gages feature a nominal
1" Schedule 10 standpipe with flag-type level
indication. Because of the smaller float diameter,
the MMG features a conventional 6 magnet
configuration with a magnetic field similar to
other MULTIVIEW™ models. The MMG carries
a true 150# ANSI rating. Standard material of
construction for the standpipe is 316/316L STS,
although 304/304L may also be specified. Float
material of construction is 316/316L STS.
Options - MMG Mini Magnetic Gage
• 1 Amp Point Level Switch available for
level control
• Penberthy's standard third party approved
Transmitter can be added for continuous
level monitoring
MMG Specifications
Materials of Construction
Standpipe Diameter
Minimum Specific Gravity
Maximum C-C Dimension
(Indication Length)
Pressure Rating
Temperature Rating
Standpipe: 31 6/31 6L STS
304/304L STS
Float: 31 6 STS
Nominal 1" Schedule 10
Standard Length: 0.70
Extended Length: 0.65
222-5/8"* (5655mm)
150#ANSI (PN 16/25)
Determined by chosen
design of flag-type indicator
* Indication lengths greater than this require a staggered bridle arrangement.
Consult factory for additional information.
Note: Specification data subject to change without notice.
Minimum connection sizes assume the use of a schedule 10 stilling well equal to the flange
size. If a higher schedule or Penberthy's guide system is used, consult factory for sizing.
Construction Materials Available -TMMG
304/304L STS
31 6/31 6L STS
Titanium
Monel
Inconel 625
Alloy-20
Hastelloy-C
Other -Consult Factory
Standpipe
•
•
•
Float
•
•
•
13
-------
Both point level control
and/or continuous level
measurement are available
with MULTIVIEW™. These
options can be ordered with
your magnetic gage or can
be added to existing units.
MGS Switches provide
non-intrusive point-level
control and contain no
mercury. They allow you
to be environmentally safe
without sacrificing accuracy.
• MGS-314:
SPOT (Form C) 5A service
• MGS-314D:
DPDT (2x Form C)
10A service
• MGS-314L:
SPOT (Form C) 1A service
Used with standard
MULTIVIEW™
• MGS-314M:
SPOT (Form C) 1A
service
Used with either
TMMGorMMG
• MGS-314P:
A latching
pneumatic switch
MGT Transmitters
provide continuous
level indication to remote
locations via 4 to 20 mA
loop-powered transmitters.
• MGT-362:
* A reed switch based
unit available in
& integral and remote
mounting styles
• MGT-362B or C:
An in-tank reed
switch based unit. The
MGT-362B is an NPT-
mounted assembly. The
MGT-362C is a flange-
mounted assembly. Both
are available in integral or
remote mounting styles.
• MGT-367:
A magnetostrictive
transmitter available with
HART protocol.
MGT-367-HART
-------
MGS-314 Switch Specifications
FM-Approved/
CSA-Certified Ex d
Explosion-Proof:
FM-Approved/
CSA-Certified Exi a
Intrinsically Safe:
Enclosures:
Output:
Repeatability:
Response Time:
Deadband:
Operating
Temperature:
MGS-314/314D*
Division 1 ,2
Class I: Groups B,C,D
Class II: Groups E,F,G
Class I II: Type 4
When installed in accordance with
Penberthy Drawing »7E741 -009
Division 1 , 2
Class I: Groups A,B,C,D
Class II: Groups E,F,G
Class I II: Type 4
When installed in accordance with
Penberthy Drawing (7E742-009
Watertight (Type 4)
Explosion-Proof
cast aluminum
MGS-314:
SPOT
(Form C)
5A@
125/250/
277 Vac
non-
inductive
load
MGS-314D:
DPDT (2x
Form C)
10A@
125/250
Vac non-
inductive
load
Better than 0.032"
(0.8mm)
<1 00 milliseconds
0.5" (12.7mm) of float
movement
-400Cto185°C(-40°F
to 365°F) with third
party approvals
-162°Cto340°C
(-260°F to 645°F)
without third party
approvals
MGS-314LV314M*
Division 1,2
Class I: Groups B,C,D
Class II: Groups E,F,G
Class I II: Type 4
When installed in accordance with
Penberthy Drawing *7E741-009
Division 1 , 2
Class I: Groups A, B,C,D
Class II: Groups E,F,G
Class I II: Type 4
When installed in accordance with
Penberthy Drawing *7E742-009
Watertight (Type 4)
Explosion-Proof STS
SPOT (Form C)
1A@130Vac/dc
non-inductive load
Better than 0.032"
(0.8mm)
<1 00 milliseconds
0.5" (12.7mm) of float
movement
-400Cto107°C(-40°F
to 225°F)
"Third party approvals pending
MGS-314P Switch Specifications
Operating Medium:
Enclosures:
Operating Pressure
Range:
Air Consumption:
Connections:
Deadband:
Operating
Temperature:
Filtered Plant or Instrument Air
Watertight (Type 4) STS
17to100psig(117to690kPaG)
1.4scfm @ 100psig
1/4" NPT-F
0.5" (12.7mm) of float movement
-198°C to 232°C (-325°F to 450°F)
MGT-362 / 362B / 362C Transmitter Specifications
FM-Approved/
CSA-Certified Ex d
Explosion-Proof:
FM-Approved/
CSA-Certified Ex d
Intrinsically Safe:
Enclosures:
Loop Voltage:
Output:
Resolution:
Response Time:
Operating
Temperature:
Division 1,2
Class I: Groups B,C,D
Class II: Groups E,F,G
Class I II: Type 4
When installed in accordance with Penberthy Drawing »18F51-009
Division 1 , 2
Class I: Groups A, B,C,D
Class II: Groups E,F,G
Class I II: Type 4
When installed in accordance with Penberthy Drawing (18F52-009
Watertight (Type 4)
Explosion-Proof cast aluminum
11 toSOVdc
4 to 20 mA continuous;
22 mA failure indication
0.375"
<30 milliseconds
-400Cto70°C(-400Fto160°F)
transmitter
-162°C to 125°C (-260°F to 257°F)
sensor (unprotected)
MGT-367 Transmitter Specifications
FM-Approved/
CSA-Certified Ex d
Explosion-Proof:
Enclosures:
Loop Voltage:
Output:
Repeatability:
Hart Protocol:
Operating
Temperature:
Division 1 , 2
Class I: Groups B,C,D
Class II: Groups E,F,G
Class I II: Type 4X
Watertight (Type 4X)
Explosion-Proof cast aluminum
10.5 to 36.1 Vdc
4 to 20 mA continuous
0.01 %FS. or 0.01 5" (0.381 mm)*
Base HART Command Capability
-340Cto70°C(-300Fto160°F)
electronics
-340Cto149°C(-300Fto300°F)
sensor
"Whichever is greater
Note: Specification data subject to change without notice.
15
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Optio
Sanitary MULTIVIEW™
To meet sanitary requirements
necessary in the production of
food, beverage, dairy, biomedical
and pharmaceutical products and
in other sanitary applications,
Penberthy recommends the
Sanitary MULTIVIEW™. Designed
to 3A standards, this system is
constructed of standard 316L SS
materials with other construction
materials available. Fittings and
clamps meet industry sanitary
regulations and allow for quick
disassembly and cleaning.
Explosion-Proof
(XP) Illuminator
To improve visibility in low-light
environments, an Explosion-Proof
Illuminator can be a valuable
addition to many level monitoring
situations. This option also works
well when an insulation blanket is
in use. The illuminator is
FM-Approved/CSA-Certified for
explosion-proof usage: Class
1 Groups B, C, D, 125/250
Vac, maximum 25 or 60 watts,
depending on the length required.
isulation Blankets
enberthy Insulation Blankets can
ithstand temperatures ranging
Dm-3000Fto750°F(-184°C
1400° C). Flexible blankets are
/ailable in thicknesses of 1/2", 1"
• 2". Materials available include
)erglass cloth coated with either
TFE Teflon® or silicone rubber.
igid blankets in thicknesses of
' -12" are available in other
laterials on request.
Thermal Tracing
MULTIVIEW™ Magnetic Liquid
Level Meters can be equipped
with electrical heat tracing or piped
for either refrigerant use or steam
use. To determine the temperature
differential, subtract the minimum
expected ambient temperature
from the desired maintenance
temperature. An insulation blanket
is highly recommended in cases
such as these.
tt/co
Tyco Valves
& Controls
:rost-Free Extensions
i super-frigid applications such as
quid nitrogen or liquefied ethylene,
:rost-Free Extensions should be
itilized. Both types of monitoring
ystems can be equipped with
>MMAfrost-free features. This
)w-coefficient thermal transmitting
naterial resists frost buildup to
naintain clear visibility. With
widths ranging from 2" to 12",
lese extensions can be paired
/ith virtually any thickness of
isulation blanket.
Drum Level Indicator
Combining MULTIVIEW™
monitoring with an integrally-
mounted armored gage,
Penberthy's Drum Level
Indicator offers improved safety,
convenience and versatility,
meeting ASME Boiler Code,
Section 1, PG-60 requirements for
Water Level Indicators.
By adding the MGS-314 switch
and MGT-362 transmitter, remote
level measurement transmission
and precise control capability
is possible.
f/f
fff
PENBERTHY
Tyco reserves the right to change product design and specifications without notice.
Copyright © 2005 by Tyco International Ltd. All rights reserved.
Penberthy is a registered trademark of Tyco Valves & Controls LP
Form No. PEN07210045M © 2005 Tyco International Ltd.
Printed in USA
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