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OPERATIONS & MAINTENANCEMANUALWATER TREATMENT SYSTEMS,SELLER AND PREISTERHOUSEHOLDS

For

LINDSAY MANUFACTURINGURS Job No. 33750799Revision 0September 29,2003

40175931

SUPERFUND RECORDS

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TABLE OF CONTENTS

1.0 BACKGROUND

20 SYSTEM DESCRIPTION

3 0 PERFORMANCE TESTING AND SYSTEM INSPECTION

4 0 ACTION ITEMS BASED ON PERFORMANCE TESTING4.1 CARBON FILTER REPLACEMENT4.2 LEAKS4.3 MICROFILTER CARTRIDGES

50 DOCUMENTATION

ATTACHMENTS

A Performance Testing and InspectionB U.S. Filter Technical NotesC Spent Carbon Profile FormD Example Purchase Requisitions

FIGURES

1 Water Treatment System Process Flow Schematic

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OPERATIONS AND MAINTENANCE MANUAL

WATER TREATMENT SYSTEMS AT THE BELLER AND PREISTER HOUSEHOLDS

1.0 BACKGROUND

In August 2003, whole-house water treatment systems were installed at the Beller Corporation(43721 460th St., Lindsay, NE) and the Preister household (45363 430th Ave, Lindsay, NE).The purpose of the systems is to remove volatile organic compounds (VOCs) from water usedfor household purposes. This manual includes a brief description of the systems installed,provides testing and system inspection requirements to ensure the systems are properly working,and outlines maintenance procedures.

2.0 SYSTEM DESCRIPTION

The system includes three carbon filters in series followed by microfilters (Figure 1). Onecarbon filter is required to meet the hydraulic sizing criteria. The second carbon filter isredundant and intended to prevent contaminant breakthrough. The third carbon filter is installedas an additional safety precaution for unforeseen circumstances or peak flows. Two microfiltersare installed in parallel after the third carbon filter to remove fines or sediment that mightpotentially pass the carbon filters. The number of operating microfilters during typical operationwill depend on the rate of sediment plugging and the pressure drop determined during startupand initial operations.

Each carbon filter is a tank constructed of fiberglass and has a volume of 81 gallons. The tankcontains 200 pounds of virgin granulated activated charcoal (GAC) and is 22 inches in diameter.One tank is suitable for a flow of approximately 16 gallons per minute (gpm). The estimatedGAC usage is 1.2 pounds per 1,000 gallons of water treated. The life of the GAC in each tank isestimated at approximately 167,000 gallons of water based on an average residential waterconsumption rate of 200 gallons per day and the maximum concentrations of VOCs detected inthe influent water at the Preister household from 1998 through 2002.

Routine maintenance of the system is not required. Maintenance is required only in response toreduced operating performance as indicated by performance testing or based on systemparameters described in Section 3. The system performance will be assessed by sampling theinfluent to and effluent from the lead carbon tank. Sampling and analysis results from the leadcarbon tank will be maintained by Lindsay Manufacturing in accordance with the procedures inSection 5. Additionally, the total flow through the system and the length of time in operationwill be monitored.

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3.0 PERFORMANCE TESTING AND SYSTEM INSPECTION

Performance testing and system inspection will be completed every three months concurrent withquarterly groundwater monitoring associated with the Lindsay facility. The Performance Testingand Inspection Form in Attachment A must be filled out each time the system is tested/inspected.After the inspection is completed, the system will be assessed to determine if maintenance orreplacement actions are necessary based on the guidance provided in Section 4. Itemsdesignated with an "(A)" in the Performance Testing and Inspection Form may require actionsdepending on the inspection results.

4.0 ACTION ITEMS BASED ON PERFORMANCE TESTING

4.1 CARBON FILTER REPLACEMENT

The lead carbon filter tank should be replaced if:

• the time since the last change (item 5) is greater than two years, or• the volume of water (item 8) is greater than 167,000 gallons or the volume

determined based on changes in VOC concentrations in the influent water.

Replacement includes: changing the carbon tank by removing the first tank in the series, movingthe second tank to the lead position, and moving the third tank to position number two. Thereplacement tank will be number three in the series.

The system must be shut down for the tank replacement. Twenty-four hours prior to the tankreplacement, remove the inlet and outlet plug, fill the tank with water, and replace the plugs.Notify the homeowner of the need to replace the filter and arrange a time that is convenientfor them to be without running water for one to two hours.

To shut down the system, perform the following: Before disconnecting the carbon tanks, lockoutthe well pump, depressurize the system using a sample valve port, and close the block valvesupstream of the lead carbon tank and downstream of the microfilters. After installing the newcarbon tank, follow the manufacturer technical notes for bed startup (Attachment B). During thebackflush, the water flow rate will decrease. When this happens, turn the backwash water off,open the drain and let the carbon bed relax and then repeat the backwash. It may take multiplerepetitions to clear the discharge water of fines.

After replacing the tank, the spent carbon profile form (Attachment C) will need to be completedby designated Lindsay personnel. The form will be sent to U.S. Filter and a new carbon tankwill be ordered. Once the spent carbon is profiled, U.S. Filter will inform Lindsay of thedesignated off-site facility which will be an EPA CERCLA off-site approved facility. Lindsaywill arrange all transportation and disposition.

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If the analytical results from the effluent sample of the lead carbon tank (item #17 on thePerformance Testing and Inspection Form) test positive for VOCs, the contaminantconcentrations along with other system performance data will be evaluated. Based upon thisassessment, a determination will be made to replace the lead carbon tank (GAC) or to continueusing it.

4.2 LEAKS

If leaks are noticed (item 16) during inspection, they must be repaired immediately.

4.3 MICROFILTER CARTRIDGES

The operating microfilter cartridge should be changed if the pressure drop calculated in item 14of the inspection is greater than 10 psi (item 15). If there is no pressure drop, only one cartridgemay be required on-line, but if the pressure drop increases during the inspection quarter, thenboth microfilter cartridges should be kept on-line. If the on-site stock of filters is less than two,or when the filters are replaced, contact the supplier to order a new filter stock. Spentmicrofilters will be taken back to the Lindsay facility and disposed with the facility solid waste.

Example purchase requisitions for U.S. Filter (carbon [GAC] tank supplier) and HarringtonIndustrial Plastic (microfilter cartridges) are provided in Attachment D.

5.0 DOCUMENTATION

Documentation associated with the whole-house treatment systems will be maintained in acentral file at the Lindsay facility. At a minimum, the following items will be maintained in thefile for a period of no less than 10 years:

• Complete Performance Testing and System Inspection Forms• Analytical Data (may be maintained with quarterly groundwater monitoring data)• Waste profiles and bills of lading, if required for spent GAC disposition

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33750799 12.cdr

Microfilter #1

From Wells V ^ To House

Microfilter #2

Sampling Port

Job No. 33750799

Figure 1Water Treatment System Process Flow Schematic

URS Lindsay ManufacturingLindsay, Nebraska

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ATTACHMENT A

Performance Testing and Inspection

IPerformance Testing and Inspection

1.

2.

3.

4.

5- (A)

6.

7.

8. (A)

9.

10.

11.

12.

13.

14. (A)

15.

16. (A)

17. (A)

Inspector:

Date:

Household:

Date of Previous Carbon Tank Change:

Time Since Last Tank Change (months):

Volume of Water Used To Date (gallons):

Volume of Water Recorded at Last TankChange (gallons):

Volume of Water Used Since Last TankChange (gallons) - Calculated = #6 - #7:

Microfilter Number One On-line (yes/no):

Microfilter Number Two On-line (yes/no):

Turn the water on (to drain) so that the flowthrough the system is approximately 16gallons per minute. Let the system operatefor 10 minutes.

Pressure Downstream of OperatingMicrofilter (psi):

Pressure Upstream of Operating Microfilter(psi):

Pressure Drop Across Microfilters (psi) -Calculated = #12 -#13:

Pressure Drop During Last Inspection (psi):

Inspect System for Leaks

Take Water Samples Downstream andUpstream of the Lead Carbon Tank andTest for Contaminants

Comments

ActionRequired

(Y/N)Action Taken/

Date

Inspector Signature Date:

Actions Completed, Signature Date:

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ATTACHMENT BI

U.S. Filter Technical Notes

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IMPORTANCE OF GAC BEDSTARTUP

Activated carbon is manufactured by the steam(steam/carbon dioxide) activation of a char producedfrom an appropriate starting raw material (coal,coconut shells, wood, etc.). The carbon's porestructure is formed during the activation process byremoving carbon atoms from the char, thusgenerating spacing between the graphitic plateletsthat made up the structure of the char.

Platelets that are very close together (pore widths <50A) result in the highest energy adsorption sites andare called micropores. Mesopores (spacing 50 to 500A) and macropores (spacing >500 A) representprogressively lower energy sites. The largestmacropores serve mainly as transport pores, whichallow molecules to access the smaller micro- andmesopores where most of the adsorption occurs.

Initially the pore volume of the activated carbon isfilled with air. This air must be replaced with waterin order for the entire surface area of the carbon tobecome available for adsorption.

To effectively utilize all the carbons capacity, thefollowing operations must be included in theinitial processing or startup of the carbon bed.

1. The air within the carbon pores must be displacedby water.

2. The air bubbles that are produced by the out-gassing of the carbon need to be removed fromthe carbon bed.

3. Carbon fines need to be removed from the carbonbed.

4. The carbon bed needs to be either partially orcompletely stratified with respect to particle sizeand density. For repackaging bottle service(service D.I. water) applications, bedstratification is neither desirable nor applicable.

5. Water-soluble components that are leached fromthe inorganic ash present in the carbon's structureand alkalinity caused by the interaction of waterwith specific sites on the carbon surface need to

be flushed from the carbon bed, producing amore neutral pH for the effluent water.

Implementing all of these operations willsignificantly reduce carbon usage rates, provide forthe lowest system pressure drop and the highesteffluent water purity.

WETTING THE GAC BED

Figure 1 (data taken from the literature) indicates thatwhen activated carbon is added to water, at ambienttemperatures, the water very quickly displaces over80% of the air present in the carbon's pore structure.

The remaining air in the carbon pore structurediffuses out very slowly. It is important that most ofthis remaining air be removed before the carbon bedis put into service. Not doing so will significantlyreduce the amount of pore volume (and surface area)that is available for adsorption. When this trapped airis finally released, it can form micro-bubbles thatcling to the surface of the activated carbon particles.

These micro-bubbles can interfere with water flowaround and the diffusion of contaminates into thecarbon particles.

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Tech Notes No. 4

EFFECT OF TEMPERATURE AND FLOW RATE ON % BEDEXPANSION

Elevated temperatures accelerate the release of airfrom the carbon's pores but the use of hot water forbed soaking is seldom practical. U.S. Filter Westatesrecommends a 24-hour soak time be used before thefull backwashing procedure is initiated. This willinsure >90% of the pore volume will be available foradsorption and most of the air bubbles that areformed will be removed during the backwashing.

CARBON BED BACKWASHING

Carbon fines and air bubbles can be completelyremoved in a reasonable amount of time, if a bedexpansion of 10 - 30 % is achieved duringbackwashing. Figure 2 shows the % bed expansionthat can be obtained for KG-502 and AG-502aw as afunction of water flow rate and water temperature.

Proper bed expansion during backwashing alsoinsures that stratification of the bed by particle sizeand density will occur. A properly back washed andstratified bed will show a significantly lower pressuredrop when compared to a non-back washed bed. (seeFigure 3). A well-stratified bed also has less of atendency to mix if subsequent backwashing isrequired, thus improving the life and performance ofthe carbon bed.

US Filter Westates

For carbon repackaging operations (such as SDI), it isnot desirable to stratify the bed during backwashing.Stratification would cause some of the bottles beingfilled from a treated batch of carbon to contain adifferent particle size distribution than other bottles.

Backwashed & Stratified Bed

BASIC GUIDELINES FORUSING KG-502 AND AG-502aw1. The carbon should be soaked in clean water for at

least 24 hours before further processing of thebed takes place (the warmer the water the better).

2. After the initial soak period, the carbon bedshould be back washed at such a rate as toachieve at least 10 — 30% bed expansion.• For KG-502 the backwashing rate should be

between 5-11 gpm/ft2.• For AG-502aw the backwashing rate should

be 8 - 16 gpm/ft2, depending on thetemperature of the water being used.

3. Backwashing should be continued until theeffluent water is clear, i.e. free of carbon finesand air bubbles, and shows the required pHand/or electrical conductivity.

4. Backwashing times will vary depending on anumber of factors. These factors include:• Water backwashing flow rate• Properties of the water such as its

temperature and for pH control the ionicstrength, and the amount of dissolved oxygenpresent in the water

August, 19992

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Tech Notes No. 4

• The purity of the effluent water that needs tobe achieved.

5. In that KG-502 and AG-502aw 12x40 are of alarger mesh size when compared to the smallermesh size Calgon TOG 20x50, a higherbackwashing rate will be required for the 12x40mesh carbon to achieve the desired 10 - 30 %bed expansion.

For facilities where sufficient water flow is notavailable to achieve 10 - 30 % bed expansion, thefollowing operational changes should be considered:1. A reasonable soak time and the maximum water

flow rate available should be used forbackwashing.

2. Unless the bed is expanded and mixed duringbackwashing, complete removal of fines is verydifficult even when long backwashing times areused. To aid in expanding and mixing the bed,air can be sparged into the bottom of the carbonvessel. The rising air bubbles cause the bed toexpand and aid in carrying carbon fines to the topof the bed and out. The volume of air required toproperly sparge the vessel will depend on thefollowing and will need to be determinedexperimentally by each facility:• Water flow rate being used• Water temperature• The number of points at which air is being

introduced into the vessel and the size of theair bubbles being generated

3. The rising air bubbles from the spargingoperation have a tendency to carry even fairlylarge particles to the top of the adsorber. Ameans such as back flushable outlet screens forkeeping these larger particles in the adsorberwithout retaining the carbon fines needs to beused.

WATER pH and ITS CONTROL

When KG-502 (like most virgin activated carbons)and to a lesser extent AG-502aw are added to water,an alkaline pH will result. This pH can be as high as10 and often requires a large amount of backwashwater to reduce it to an acceptable value. There aretwo main causes for the alkaline pH of activatedcarbon leachate:

US Filter Westates

1. Hydroxide ions produced by the ion exchange ofanions present in the water with active sites onthe carbon surface.

2. The presence of alkaline and alkaline earthmetals (mainly sodium, potassium, calcium andmagnesium salts) in the mineral matter thatmakes up a portion of the activated carbon.

Of these factors No. 1 above appears to be by far themost important. The interaction of water with thecarbon surface can be described as an ion exchangetype of phenomenon. The carbon surface absorbsanions present in the water with the release ofhydroxide ions. The resulting pH increase appears tobe independent of the raw material used for theproduction of the activated carbon, e.g. anthracite,bituminous, lignite, wood, coconut shell, etc. SimilarpH excursions can occur with virgin, reactivated andthoroughly dried acid washed carbons.

Water with a higher ionic strength (increasedhardness) will reduce the backwashing time while theuse of high purity water for backwashing willsignificantly increase the time required for pH controlof the carbon. When wet activated carbon is allowedto come in contact with oxygen, these surface sitesundergo oxidation and their ability to increase the pHof the water decreases.

The mineral matter present in an activated carbon canto a limited extent contribute to its ability to producealkaline pH water. The high quality coals used in themanufacture of KG-502 and AG-502aw contain acertain amount of naturally occurring mineral matter(commonly referred to as the ash content of theactivated carbon). This mineral matter is composedmainly of calcium and magnesium aluminates,silicates and aluminosilicates plus iron containingcompounds and trace amounts of half dozen or soother elements. Even though these inorganiccompounds show a low solubility in water, they canbe leached very slowly from the carbon. Thebackwashing process quickly removes the moresoluble salts, significantly reducing the rate ofleaching of these compounds and consequentlyreducing their concentration in the effluent water toacceptably low levels.

James R. Graham, Ph.D.Technical Director, US Filter Westates

August, 19993

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ATTACHMENT C

g Spent Carbon Profile Form

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USFilter WestatesPARKER FACILITY

2523 Mutahar Street • P.O. Box 3308Parker, AZ 85344

(928) 669-5758 • FAX (928) 669-5775EPA ID: AZD 982 441263

GENERATOR INFORMATION

1. a) Generator:

Mailing Address:

c) Contact Name:

e) Phone No:

CONSULTANT INFORMATION

2. a) Consultant:

c) Phone No:

RED BLUFF FACILITY11711 Reading RoadRed Bluff, CA 96080

(530) 527-2664 • FAX (530) 527-0544EPA ID. CAR 000 058 784

SPENT CARBON PROFILE FORM

b) Site:Address:

d) EPAID#:

f) Fax No:

b) Contact:

d) Fax No:

PROPERTIES AND COMPOSITION OF THE SPENT CARBON3. Provide a specific description of the process generating the spent carbon including constituents being treated.

(Please note if potable -water or food processing application).

5. Foreign Material: O Yes O No(rocks, dirt, sand, etc.)

4. Type of Spent Carbon: O Aqueous O Vapor O Impregnated

6. Handling: O Bulk O Drum O Adsorber O Bulk Bag O Other

7. Free Liquid Range: O 0 a 1 - 15% 8. Liquid Flashpoint: O < 140°F O >140°F ON/A Vapor

9. pH Range: O<2 a 2-4 04.1-10.5 O>10.5

10. Is Spent Carbon Generated at a SubpartFF Facility? (Benzene NESHAP) a Yes ONoa) If yes, total benzene analysis is also required.

11. Strong Odor? O Yes a No If yes, please describe_

12. DOES THE SPENT CARBON CONTAIN ANY OF THE FOLLOWINGA. Polychlorinated Biphenyls (PCBs) OYes DNoB. Dioxins and/or Furans O Yes O NoC. Dibromochloropropane (DBCP) a Yes ONoD. Sulfide or Cyanide OYes ONoE. Explosive, Pyrophoric and/or Radioactive material O Yes O NoF. Infectious material O Yes O NoG. Shock Sensitive material OYes ONoH. Oxidizer OYes ONoI. Heavy Metals OYes ONo

Page 1 of 2

GENERATOR CLASSIFICATION

13. Is the Spent Carbon a RCRA Hazardous Waste? DYes ONoRCRA Hazardous Waste requires "II RCRA "Analysis.If yes, list waste code(s) below:

14. Is the Spent Carbon a State Hazardous Waste? OYes ONoIf yes, list waste code(s) below:

15. Is this Waste Subject to the Land Disposal Restriction Notification? OYes ONo

16. If this is a Renewal, Provide the Existing Profile Approval Number:

17. Estimated Annual Carbon Usage:

GENERATOR CERTIFICATION

I hereby certify that all information on this and all attached documents are true and that this information accuratelydescribes the subject spent carbon. I further certify that all samples and analyses submitted are representative of thesubject spent carbon in accordance with the procedures established in 40 CFR 261 Appendix I or by using anequivalent method. All relevant information regarding known or suspected hazards in the possession of the generatorhas been disclosed. I authorize USF/Westates to obtain a sample from any waste shipment for purposes of confirmationor further investigation. If I am a consultant signing on behalf of the generator, I have their proper approval.

Printed Name Signature

Title Date

For Internal Use Only:

Profile Approval Number

Valid Through

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ATTACHMENT D

Example Purchase Requisitions

•PURCHASING DEPT. USE ONLY

ORDER DATE8/27/03

^ VENDOR• US Filter Westates Carbon• P.O. ORDER NO.

99779APPROX. SHIP DATE NEED BY DATE

• Bv 9/10• EQUIP # MODEL #

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PARTS AND MATERIALREQUISITION

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REQUISITIONED BY Bdb13»iot!

REQUISITION nftDATE Ob-27-03

92DEPT. NO

SERIAL* 1 WORK ORDER* CUSTOMER ORDER #

, -. ••-•-.£- • - i , . •>• v. . • .- -•;.• v * ;Nf tfc ,'•"'.• •v'^.x-'-^"'- •-- t /WTor1

iilSI?}iXi*» , >-:-i: '-^: te^S3B§lfcC •• ' fil; • '•••«-• <-,A •••;.. ;.^r^A1.-t- . . , - .?.-•- .••• .• .. it. • • • : • • -.--.v, ,w •-< - . (Kjgi,

HP200-1-AC 1240AW Carbon filters 1 Q75 ga

Top fill and top withdraw

Backup for Seller's and Preister's whole housefiltration units.

Previously Ordered on PO # 97106

Please request delivery within 3 weeks.

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DELIVER TO

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PROJECT #807

^LINDSAY/^ MANUFACTURING CO.

•PURCHASING DEPT. USE ONLY

ORDER DATE

^ VENDOR• Harrington Industrial PlasticV P.O. ORDER NO.

APPROX. SHIP DATE

• EQUIP #

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NEED BY DATE

MODEL #

PARTS AND MATERIALREQUISITION

APPROVED BY

REQUISITIONED BY

SERIAL #

Bob Jacobson

B.plf3aeobs5rl: . .: -

REQUISITION „„ ^DATE 08-27-03

92DEPT. NO

WORK ORDER # 1 CUSTOMER ORDER #

DGD-2501-20Dual Gradient Filter 20" long25 micron to 1 micron

Previously ordered on PO# 96716

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27.55 ea.

DELIVER TO

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PROJECT #807

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