chilled water discharge plan

Revised November 2013

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Operating Procedure - ISU Utilities

Central Chilled Water System Discharge Identification and Correction

To be updated by Steve Mayberry

Purpose

To identify and minimize discharges from the central chilled water system.

Primary Authority / Coordinator

The Power Plant Shift Supervisor(phone 294-4926) will be the primary authority

coordinating activities until a discharge (leak) is found and corrected. The Power Plant

control room will act as the message center to receive and provide information to the

personnel responding to locate the discharge. Searches to locate the point of discharge

shall be continued until new direction is given from the Power Plant Shift Supervisor. If

needed, the Power Plant Shift Supervisor may arrange a meeting in the Power Plant with

the Departmental Contacts (see table in this document).

Background

The chilled water system is chemically treated. Molybdate had been the corrosion

inhibitor maintained in the system at concentrations near 5 PPM (3 -PPM molybdenum).

Molybdenum concentration in the university sanitary outfall is limited to 0.250 PPM by

the University / City of Ames Domestic Water Pretreatment Agreement. Therefore,

chilled water discharges into the sanitary sewer system needs to be managed to prevent

violations and fines. The Utilities Department manages the Domestic Water Pretreatment

Agreement for the University. The current chemical treatment program no longer uses

molybdate as the corrosion inhibitor; this treatment program eliminates chemical loading

concerns with the Ames treatment facility.

Approval of Discharges & Filling of the System Within Each Building

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Unavoidable discharges of chilled water shall be coordinated with Mike Murray (294-

8751). Randy Larabee (520-1503) is the backup coordinator. Approval of intentional

chilled water discharges may be granted provided discharge times, flow rates, and

quantities are pre-planned. Actual discharge information shall also be provided to the

coordinator when the discharge is completed.

Approval of Filling of the System Within Each Building

An organization planning an activity, which will cause chilled water make-up to occur,

shall contact the Power Plant Shift Supervisor (phone 294-4926) to notify when the

activity is to start and finish. This reduces the chance of having the Power Plant staff

misinterpret the planned maintenance activity as a leak.

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System Maintenance

Chilled water piping and coils are to be inspected regularly for leaks as part of routine

maintenance schedules. Maintenance personnel shall correct any detected leaks at the

time of the inspection. Un-repairable leaks shall be reported to the Power Plant Shift

Supervisor who will maintain an on-going file of current issues. The file will include

approximate flow rates and the expected repair date. Once repaired, the Power Plant Shift

Supervisor shall be notified.

Training

All ISU employees associated with the chilled water system shall be familiar with the

contents of this procedure. Departments should review this document as needed to

maintain familiarization.

Chilled Water Make-up Monitoring

The chilled water make-up is monitored by a metering installation in the Power Plant.

Chilled water make-up to the system should occur only in the Power Plant. Otherwise,

erroneous measured make-up quantities will occur. Potential make-up from other sources

shall be identified and removed. If makeup rates occur outside of established parameters,

the appropriate action plan listed within this document shall be followed.

Action Plan When Unplanned Losses Are Recognized

The action plan is based upon the flow rate magnitude as listed in the sections below.

The Power Plant Operator (phone 294-4926) will provide email instructions / updates.

The Power Plant Operator will communicate directly to the Departmental Contacts across

campus as shown in the table below. Communication and coordination within the

department will be the responsibility of the Departmental Contact. Information provided

by the Power Plant Operator shall include

when the situation started

average flow rate (gpm)

expected action including the urgency (dependant on flow rate)

when feedback is needed

provide web link to this written procedure at

http://www.fpm.iastate.edu/utilities/chw_system_discharge/

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http://www.fpm.iastate.edu/utilities/chw_system_discharge/

Helpful Tips to Assist in Locating a Leak

1) Process cooling loops sometimes have lines going to drains. These

locations are suspects and should be included in specific building

inspection checklists.

2) Locations where recent system modifications / construction have occurred

tend to increase the probability of a discharge.

3) Piping & coils exposed to extreme cold air conditions are suspect and

should be included in the specific building checklists. Examples include

air handlers with cooling coils that have outside air dampers. Accumulated

chilled water typically is present inside the air handler casing.

4) Gasketed joints in direct buried piping are subject to corrosion. The joints

are typically at hot tap valves. Removing the lids on direct buried valves

can sometimes show standing water that may be associated with an

underground leak.

A final update will be sent out to inform everyone that the situation has been corrected

along with information detailing what was found.

Departmental Contact Call List

Department Primary Contact (phone) Alternative Contact (phone)

Residence Randy Monthei

Randy cell (290-5504)

24 Hr Help Desk (294-3322)

6:00am to 7:00pm M-F

6:00 am to 4:30 pm Sat-Sun

(1) After hour Manager On-

Call pager

(515) 239-2801

(2) Randy Monthei (826-

3425) cell (290-5504)

(3) Richard Garrey

Work phone 294-6836

Home 515-382-8733

Ames Lab Mark Grootveld

Guard Desk 24/7 (294-3483)

(1)Mike Valcav (294-7891)

(2) Mark Grootveld (294-

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7895)

Soil Tilth Jerry Hatfield (294-5723) After hours

(1) xxxxx(xxx-xxxx)

(2) Ron Cochran (294-7515)

Memorial Union Ken Umbaugh (294-1147)

Ken Umbaugh Cell (460-

6800)

(1) Mark Turner (4-1449)

Turner cell (450-0401)

(2) After Hours

Main Desk (294-1031) for

call-in list

FP&M General University

Building Maintenance

Ron Cochran

Ron cell (460-8531)

Ron Home (597-2372)

Service Center (294-5100)

(1)Kenny Bollenbaugh(460-8533)(2) Don Hoffmann (733-

4437)

Hoffman cell (460-8534)


Utilities Mechanical

Distribution

Mike Murray (294-8751) Mike Murray ( 296-1015)

Randy Larabee (520-1503)

After Hour Call (294-5100)


Utility Production

Mike McGraw (294-8333) Jeff Witt (294-8286)


Construction

Administration

Dean McCormick (294-0563) After Hours Service Center

(294-5100)

Ron Cochran (597-2372)

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Actions will be taken based up the makeup flow rate as shown in the

sections below.

O GPM Makeup (unintentional) Make-up average over the a day is essentially 0

GPM and this condition is sustained for two consecutive days. The condition would

suggest that unintentional / un-metered make-up is occurring.

A) Departmental Contact:

a. Initial Contact: Power Plant Operator (phone 294-4926) will email

departmental contacts to have each department inspect their buildings /

systems within next two business days.

b. Departmental Action: The departmental contact shall reply by email to

the Power Plant Operator indicating receipt of the email message as soon

they receive it and follow up with any questions that they may have. The

departmental contact will distribute the information with the appropriate

departmental staff members. The departmental contact shall maintain an

internal check-off list of building systems and tasks to complete.

c. Departmental Response: The completed task list shall be emailed back

to the Power Plant Operator within two days after being notified. The task

list should indicate what actions were taken and describe anything out of

the ordinary.

B) Set Up Meeting: If the unintended make-up is not located within 4 business days

of being observed, the Power Plant Operator (phone 294-4926) will arrange a

meeting with the Departmental contacts to discuss what additional actions can be

taken. During the meeting, potential resolution of the situation will be discussed.

Potential actions may include:

a. Shutting down individual buildings while monitoring the makeup

b. Shutting down sections of the distribution piping while monitoring the

makeup

c. Recalibrate / test makeup meter.

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0.2 -2 GPM Makeup This is the expected make-up to the system under normal

operating conditions. No action is required.

2-10 GPM Makeup Make-up average over the day is greater than 2 gpm and less than

10 GPM and the makeup is sustained for two consecutive days.


a. Initial Contact: Power Plant Operator (phone 294-4926) will email


systems within next two business days.

b. Departmental Action: The departmental contact shall reply by email to

the Power Plant Operator indicating receipt of the email message as soon

they receive it and follow up with any questions that they may have. The

departmental contact will distribute the information with the appropriate

departmental staff members. The departmental contact shall maintain an

internal check-off list of building systems and tasks to complete.

c. Departmental Response: The completed task list shall be emailed back

to the Power Plant Operator within two business days after being notified.

The task list should indicate what actions were taken and describe

anything out of the ordinary. Specifically, actions taken that result in an

increase or decrease in the system make-up should be clearly noted in

detail.

B) Utility Operations Actions

a. Main Plant

1. Check the evaporator vents and drains on chillers 1,2,3 & 4 for any indication of leakage.

2. Check the primary pumps 1,2,3 & 4 and associated piping for any indication of leakage.

3. Check the supply and return header piping for any indication of leakage.

4. Check the filter, filter pump and associated piping for any indication of leakage.

5. Check the makeup controller and confirm set point 75 psi and note controlled variable.

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6. Check the 1 inch makeup valve and insure proper operation

b. North Campus Chiller Plant1. Check all chilled water piping for any indication of leakage.2. Check the evaporator vents and drains for any indication of

leakage.3. Check the primary pump and associated piping for any

indication of leakage.

C) Mechanical Distribution System Actions:

a. Sewer Sampling: Utility Mechanical Distribution staff will take a grab

sample from the sanitary sewer manhole SA11D10 (City # 739) located at

the intersection of Beach Avenue and Lincolnway within one business

days after being notified. The sample(s) shall be retained for testing to

identify molybdate levels should the sustained make-up present a sewer

effluent violation potential based upon discussions with the City of Ames

Water Pollution Staff (see external notification section).

b. Surface Check: The Mechanical Distribution staff will also survey the

ground surface over buried distribution piping to locate water that may be

coming out the ground.

c. Valve Box Check: After the initial surface review, each valve box shall

be check within two business days after being notified to see if water is

accumulating in the box. Accumulated water shall be tested in the Power

Plant water lab to verify if molybdate is present which would tend to

indicated a chilled water leak.

D) Set Up Meeting: If the leak is not located within 4 business days of being

observed, the Power Plant Operator will arrange a meeting with the Departmental

contacts to discuss what additional actions can be taken. During the meeting,

potential resolution of the situation will be discussed. Potential actions may

include:



makeup

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c. Monitoring the storm and sanitary sewer effluent to measure molybdenum

concentrations in trunk lines across campus that potentially could focus

the search to specific locations on campus.

d. Recalibrate / test makeup meter.

In Excess of 10 GPM Makeup Make-up average over a four hour period is greater

than 10 GPM. Each department shall maintain their staff on-site looking for the leak

unless the Power Plant Operator provides different instructions.


a. Initial Contact: Power Plant Operator (phone 294-4926) will call the


systems after the four hour period. After hour call in lists will be utilized

by the Power Plant Operator if needed to personally contact each

departmental contact. The Power Plant Operator will also send out an

email to document relevant information.

b. Departmental Action: The departmental contact will distribute the

information with the appropriate departmental staff members. The

departmental contact shall maintain an internal check-off list of building

systems and tasks to complete.

c. Departmental Response: The departmental contacts shall email the task

list back to the Power Plant Operator within 4 hours after being notified

and follow-up with an email. The task list should indicate what actions

were taken and describe anything out of the ordinary. Specifically, actions

taken that result in an increase or decrease in the system makeup should

be clearly noted in detail.

B) Utility Operations Actions

a. Main Plant

i. Check the evaporator vents and drains on chillers 1,2,3 & 4 for any indication of leakage.

ii. Check the primary pumps 1,2,3 & 4 and associated piping for any indication of leakage.

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iii. Check the supply and return header piping for any indication of leakage.

iv. Check the filter, filter pump and associated piping for any indication of leakage.

v. Check the makeup controller and confirm set point 75 psi and note controlled variable.

vi. Check the 1 inch makeup valve and insure proper operation

b. North Campus Chiller Planti. Check all chilled water piping for any indication of leakage.

ii. Check the evaporator vents and drains for any indication of leakage.

iii. Check the primary pump and associated piping for any indication of leakage.

C) Distribution System Actions:

a. Sewer Sampling: Utility Mechanical Distribution staff will take a grab

sample from the sanitary sewer manhole SA11D10 (City # 739) located at

the intersection of Beach Avenue and Lincolnway within 4 hours after

being notified. The sample(s) shall be retained for testing to identify

molybdate levels should the sustained make-up present a sewer effluent

violation potential based upon discussions with the City of Ames Water

Pollution Staff (see external notification section).

b. Surface Check: The Mechanical Distribution staff will also survey the

ground surface over buried distribution piping within 4 hours after being

notified and follow-up with an email to locate water that may be coming

out the ground.

c. Valve Box Check: After the initial surface review, each valve box shall

be checked within 4 hours after being notified to see if water is

accumulating in the box. Accumulated water shall be tested in the Power

Plant water lab to verify if molybdate is present which would tend to

indicated a chilled water leak.

d. Confirming Task Completion: Upon completion of the sewer sampling,

surface check, and valve box check; an email shall be sent to the Power

Plant Operator.

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D) Set Up Meeting: If the leak is not located within 4 hours, the Power Plant

Operator (phone 294-4926) will arrange a meeting with the Departmental

contacts to discuss what additional actions can be taken. This meeting would be

set up even if this search is occurring outside the normal working hours. During

the meeting, potential resolution of the situation will be discussed. Potential

actions may include:



makeup

c. Monitoring the storm and sanitary sewer effluent to measure molybdenum

concentrations in trunk lines across campus that potentially could focus

the search to specific locations on campus.

d. Recalibrate / test makeup meter.

E) External Notification: If the discharge exceeds 10 gpm for 15 hours, External

Notification procedures will be followed. Mike Murray (alternate – Randy

Larabee) will be responsible for notifying the City of Ames Water Pollution

Control Facility of planned and accidental chilled water discharges. If directed by

the City of Ames Water Pollution Control Facility, a continuous wastewater

sampler may be needed at sanitary sewer manhole SA11D10 (City # 739) located

at the intersection of Beach Avenue and Lincolnway.

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chilled water discharge plan

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