QED AP4+ Operation Manual

Leaders in Environmental Compliance Products

OPERATIONS

Au

to

Pump

+

MANUAL

ATEX Version

602418-02 (doc # 602418 ) (Rev 12/10/12)

DURABLE, DEPENDABLE,

& DELIVERS

AutoPump Controllerless System

(For 4 inch wells or larger)

1-800-624-2026 (North America Only) (734) 995-2547 - Tele (734) 995-1170 - Fax info@qedenv.com - E-mail www.qedenv.com

QED Environmental Systems - P.O. Box 3726 / 2355 Bishop Circle W. Dexter, Michigan 48130-3726

QED Environmental Systems (West) - 1565 Alvarado Street San Leandro, California 94577-2640

1-800-537-1767 (North America Only) (510) 346-0400 - Tele (510) 346-0414 - Fax

Copyright QED Environmental Systems, Dec. 2012

Patents/Trademarks

The equipment in this manual is protected under U.S. and foreign patents issued and pending:

U.S. Patents:

AutoPump (AP)

"AP" is a Registered Trademark of "QED Environmental Systems" "AutoPump" is a Registered Trademark of "QED Environmental Systems"

The QED Environmental Systems logo is a Registered Trademark of "QED Environmental Systems" QED Environmental Systems is a Registered Trademark of "QED Environmental Systems"

5,004,405

Table of Contents

Introduction

Chapter 1: Safety

_________________________________________________

_______________________________

Safety

How to Contact QED

_______________________________

____________________________________________

A Partial List of Safety Procedures

Fire and Explosion Protection

_______________________________

Chapter 2: ATEX Certification Information

ATEX Certifications, Label Detail and Explanation

Chapter 3: Overview

Chapter 4: Equipment

Chapter 5: Installation

Chapter 6: Maintenance

Chapter 7: Troubleshooting & Repairs

_________________________________________

General Specifications

This is How it Works

_______________________________

________________________________________

Unpacking

Equipment List

Single Stage Filter/Regulator

_______________________________

_____________________________

Installation

Hose Bundling

_______________________________

______________________________________

Cleaning Pump Interior

Iron Build-up Cleaning Procedure

_______________________________

__________________________

Troubleshooting

Returning Equipment for Service

Equipment Cleaning Requirements

_______________________________

____________________________________________

_______________________________

1

2

3

5

8

9

10

13

20

22

Pump Specifications

_______

AP4+ Bottom Inlet Long

AP4+ Bottom Inlet Short

AP4+ Bottom Inlet Low Drawdown

AP4+ Top Inlet Long

AP4+ Top Inlet Short

AP4+ Top Inlet Low Drawdown

Terms, Conditions and Warranty

Figures:

Figure 1 -

Figure 2 -

Figure

Figure 12 -

Figure 13 -

ATEX Label Detail and Explanation

ATEX Label Location and Appearance

- 3

- 4

- 5

- 6

Examples of Well Caps

- 7

Hose Bundling

- 8

Exploded View of a Bottom-Loading AutoPump AP-4+ (Long & Short)

- 9

Exploded View of a Bottom-Loading AutoPump AP-4+ (Low Drawdown)

Exploded View of a Top-Loading AutoPump AP-4+ (Long & Short)

- 01

- 11

Exploded View of a Top-Loading AutoPump AP-4+ (Low Drawdown)

Exploded View of AP-4+ Lever Assembly

Exploded View of 1-Inch Brass Check Valve

_______________________________

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_______________________________

23

23 - 26

27 - 29

31 - 34

35 - 38

39 - 42

43 - 46

47

3

4

6

7

8

11

12

14

15

16

17

18

19

Introduction

Welcome to QED Environmental Systems’ AutoPump® (AP4+) manual.

To ensure the best operator safety and system performance, it is strongly recommended that the operators read this entire manual before using the system.

This manual reflects our many years of experience and includes comments and suggestions from our sales and service personnel and most importantly from our customers. The chapters, their contents and sequence were designed with you, the user and installer, in mind. We wrote this manual so it can be easily understood by users who may not be familiar with systems of this type or are using a QED system for the first time.

Safety

Safety has been a cornerstone of our design which has been proven out in building and shipping systems throughout the world. Our high level of performance is achieved by using quality components, building in redundancies or backup systems, and not compromising our commitment to quality manufacturing. The net result is the highest quality and safest pneumatic pump recovery system on the market. We feel so strongly about safety, based on years of working

with the hydrocarbon industry, that it is the first section of all our manuals

How to Contact QED

If for any reason you are unable to find what you need in this manual feel free to contact the QED Service Department at any time. We encourage you to use following communication methods to reach us at any time:

San Leandro Service Center

1565 Alvarado Street San Leandro, California 94577-2640

( (510) 346-0400 — Tele. (510) 346-0414 — Fax

QED can be reached 24 hours a day

Service Department

QED Environmental Systems

www.qedenv.com

ylnO aciremA htroN — 7671-735 )008

Ann Arbor Service Center

PO Box 3726 Ann Arbor, Michigan 48106-3726

2355 Bishop Circle W.

Dexter, Michigan 48130

(800) 624-2026 — North America Only (734) 995-2547 — Tele. (734) 995-1170 — Fax info@qeden

v.com — E-mail

We welcome your comments and encourage your feedback regarding anything in this manual and the equipment you have on-site.

Thank you again for specifying QED equipment.

1

Chapter 1: Safety

Safety has been a prime consideration when designing the AutoPump System. Safety guidelines are provided in this manual, and the AutoPump System safety features are listed below. Please do not attempt to circumvent the safety features of this system.

We have also listed some possible hazards involved when applying this system to site remediation. Nothing will protect you as much as understanding the system, the site at which it is being used, and the careful handling of all equipment and fluids. If you have any questions, please contact the QED Service Department for guidance.

As you read through this manual, you will encounter three kinds of warnings. The following examples indicate how they appear and lists their respective purposes.

Highlights information of interest.

Note:

Caution:

Warning:

Highlights ways to avoid damaging equipment. Highlights personal safety issues.

A Partial List of Safety Procedures

WARNING:The air compressor and any other electrical equipment used with this pneumatic system must be positioned outside of any area considered hazardous because of possible combustible materials.

These safety procedures should be followed at all times when operating QED equipment on or off site, and should be considered as warnings:

Wear safety goggles when working with the AutoPump System to protect eyes from any splashing or pressure

•

release.

•

Wear chemically resistant rubber gloves, boots, and coveralls when handling the AutoPump and fluid discharge hose to avoid skin contact with the fluid being removed

•

Point tubing/hoses away from personnel and equipment when connecting or disconnecting.

•

Always ensure that the fluid discharge line is connected before the air line to prevent accidental discharge.

The AutoPump System minimizes the potential for accidents with the following safeguards:

Fire and Explosion Protection

Almost all of QED underground fluid extraction systems are pneumatic. This offers many inherent fire and explosion protection features.

2

Chapter 2 ATEX Certifications, Label Detail and Explanation

Equipment with an ATEX label similar to the example in Figure 1, is ATEX certified. Equipment without the label is not ATEX certified. Figure 1 explains the ATEX label, Figure 2, (following Page) shows the label location and appearance.

Figure 1

This equipment has been certified to Hazardous Area Classification:

1725

CE

Symbol

Code No. of Notified

Body Certifying

Quality Management

System

of Manufacturer

Equipment Model:

= 2-inch AutoPump

AP2

= 3-inch AutoPump

AP3

= 4-inch AutoPump

AP4

= 4-inch AutoPump

AP4+

= Genie Pump

GNE

= Bladder Pump

BP

= 2-inch Specific

SPG2

Gravity Skimmer = 4-inch Specific

SPG4

Gravity Skimmer = 2-inch Selective

SOS2

Oil Skimmer = 4-inch Selective

SOS4

Oil Skimmer

X

3

Indicates That

the Equipment

May Be Used in

a Hazardous Area

Group

Catagory

Atmosphere*

*G=Gas D=Dust

II

1

G D G D G D

Manufacturer, Zip Code, Country

1

G

II 2

TL EX DIS IN

AP4+

FM

APPROVED

Approving Entity

II

c

B

Protection Method is by Construction

The Equipment

May be Located

Where Flammable

Gases and Vapors

3

MAXIMUM PRESSURE

of Group IIB May

QED, 94577-2640, USA

1725

YEAR

PAT. 5004405,

5641272, 5495890, 5358038

6T

be Present

X

3

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1

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Maximum Operating Pressure

as Appropriate and as Noted

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Certificate Number

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*Serial Number May be

LocatedOutside the Label

II

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6

9.0 BAR (130 PSI)

13.8 BAR (200 PSI)

Year of Manufacture

Patent Number(s)

Serial Number*

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Allowable Ambient

Temperature Range

for Equipment

Minimum Auto

Ignition Temperature

of Surrounding

Substance by Class

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450° C 300° C 200° C 135° C 100° C

85° C

X

3

Figure 2 ATEX Label Location and Appearance

Figure 2

Bottom Loading

A

M

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AutoPump

Top Loading

Pump Serial Numbers

Located on the Pump’s Head

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4

Chapter 3: Overview

The AutoPump® fills and empties automatically, and is very easy to install, use, and maintain.

The AutoPump is a pneumatic fluid extraction pump that pumps in pulses. It handles any liquid which flows freely into the pump and is compatible with the component materials and with the connecting hoses. The AP4+ is intended for vertical operation in well casings with a 3.75-inch or greater internal diameter. It can pump particles up to 1/8-inch in diameter.

The AutoPump is very versatile and available in a wide range of lengths, valve arrangements, and materials of construction to meet particular site specifications.

Equipment will vary by application and site specifications. (See Chapter 3)

General Specifications

Pump Diameter:

Pressure Range:

High Pressure Option:

Flow Ranges:

3.6 inch (91 mm) 5 - 120 psi (0.4 - 8.5 Kg/cm²)

5 - 200 psi (0.4 - 14.1 Kg/cm²) 0-14 gallons per minute (0-53 liters per minute)

This is How it Works

The AutoPump is a submersible compressed air-driven pump which fills and empties automatically. It also controls the fluid level in a well automatically. The pump fills (See Figure 1) when fluids enter either the top or bottom check valve. Air in the pump chamber exits through the exhaust valve as the fluid fills the pump. The float inside the pump is carried upwards by the fluids rising in the casing until it pushes against a stop on the control rod, forcing the valve mechanism to switch to the discharge mode.

The switching of the valve causes the exhaust valve to close and the air inlet valve to open. This causes the pump to empty (see Figure 1) by allowing compressed air to enter the pump. This pressure on the fluid closes the inlet check valve and forces the fluids up the discharge line and out of the pump through the outlet check valve. As the fluid level falls in the pump, the float moves downward until it pushes against the lower stop on the control rod, forcing the valve mechanism to switch to the fill mode. The outlet check valve closes and prevents discharged fluids from

re-entering the pump. The filling and discharging of the pump continues automatically.

NOTE: The figures shown here are simplified schematics.

5

Figure 3 - How it Works

Pump FillingPump Emptying

Pivoting Lever

Tipped Upward

By Rising Float

Compressed Air

Flowing Into

Pump

As Pump Empties,

Float Descends

Air Exhausting

From Pump

Upper

Float Stop

Pivoting Lever

Tipped Downward

By Descending

Float

Lower

Float Stop

Check Valve Seated

Sealing Inlet

As Pump Fills,

Float Rises

Lower

Float Stop

Check Valve

Unseated

Allowing

Liquid into

Pump

6

Figure 4 - Overview of the AP4+ System

AP4+ System provides everything required for pumping fluid from a well.

Air Supply From Compressor

8

0

6

1

0

0 4 0

1

2

0

2 0

www.qedenv.com

1

4

0

1

6

0

Filter/Regulator

Cycle Counter

999999

111111

000000

Easy Bolt

Fluid Discharge

Easy Bolt

Note: Support Harness, Rope, and Tubing Sheath Omitted for Clarity

Wellhead

Air Exhaust

Tubing

Easy Fittings

pmuPotuA

Pump

7

Chapter 4: Equipment

Unpacking

During the unpacking procedure, check for the following:

• All parts on the packing list have been included in the box

• All fitting openings are unobstructed

• The equipment has not been damaged in shipment

Equipment List

The equipment list will vary depending on site specifications, but the following list is a typical configuration

1. Top-Loading or Bottom-Loading AP-4 with support harness

2. Single stage filter/regulator with:

•

5 Micron filter with auto drain tap

•

Pressure regulator with gauge

•

Maximum operating pressure 120 P.S.I. (8.4 Kg/cm²)

3. Pump Cycle Counter (PCC)

4. Pump support system:

• pac lleW

• epor eriw SS ro ylbmessa knil-kciuq htiw epor troppus enelyporpyloP

(Alternate materials as required)

Single Stage Filter/Regulator

A single stage 5 Micron particulate air filter/regulator has a manual or an optional automatic drain and is installed on the system air supply line. The filter/regulator removes particles and water droplets from the air passing to the AP4+.

NOTE: Too much air pressure can result in low pump efficiency

Figure 5 - Single Stage Filter/Regulator with Quick-Connects

Part # 302468

For Standard Systems

Maximum operating pressure 120 P.S.I. (8.4 Kg/cm²)

Part # 302470

For Systems with Pump Cycle Counter

8

Chapter 5: Installation

1. Cover the pump tubing/hose ends with tape if they are to be pulled through trenches or laid on the ground. This is to prevent debris from entering the lines.

2. Blow out all water and particles from compressed air conduits (including downwell pump air supply lines) and fluid lines for at least 10 seconds after the water and particles exit before connecting them to the system.

3. Slip clamps over appropriate tubing/hose prior to connecting the tubing/hose to the pump barbs.

4. Push tubing/hose down flush with the fitting's nut if possible; cover at least three barbs if three or more are present (Note: when installing tubing in freezing weather, tubing can be dipped in warm water for a few seconds to soften the nylon).

5. Attach pump support rope/cable to the pump.

6. Attach pump air supply and liquid discharge lines to the well cap. Attach the air exhaust line to the well cap if the pump air is to exhaust outside the well (Note: the liquid discharge line is always the largest diameter of the three lines, and the air supply line is always the smallest diameter).

7. Connect the pump air supply and liquid discharge lines to the appropriate surface lines/headers.

8. Turn on the air pressure to the pump (minimum of 0.5 psi per foot of vertical static head).

Caution: Submerging the pump before supplying it with air will result in fluid entering the exhaust tubing/hose. Those fluids will be discharged from the exhaust tubing/hose during the first few cycles of the pump. If this discharge will not be confined to the well; i.e., if the air exhaust line is routed outside the well*, it is important to make sure that the air exhaust line is not directed such that equipment/ personnel could be splashed by the discharged fluid when air is turned on to the pump.

Note: Submerging the pump before supplying it with air can also result in fluid entering the air supply line.This fluid from the well can contain particles, which could interfere with operation of the pump's air valve.

9. Lower the pump to the desired depth in the well.

10. Secure the pump by tying off the pump support line or by placing the well cap (or flange) on the well.

11. Increase the air pressure to the pump until the pump is pushing the fluid out at the desired rate. With sufficient air pressure (at least 10 to 15 psi higher than the vertical static head), the pump will gradually draw down the fluid level in the well to the level of the pump. The time required for this draw down varies with the yield of the well as compared to the flow rate of the pump. The maximum recommended pump operating pressure is 120 psi.

Note: If the well environment is such that deposition occurs on stainless steel parts, the operator

may wish to raise the pump above the water level during a shutdown of the system.

* Routing the air exhaust in vacuum wells:

QED controllerless pumps automatically control the liquid level in the well. Under normal conditions, the liquid level will be maintained at a point approximately one foot below the top of a bottom load pump (this is the pump's actuation point). The pump will automatically start and stop as needed to maintain the level at this actuation point.

When QED controllerless pumps are used in wells that are under vacuum, and the exhaust air is routed into the well, the well level will be maintained at this normal actuation point. If, however, the well is under vacuum and the exhaust air is routed outside of the well (to atmospheric pressure), the actuation point of the pump will be higher than the normal actuation point by a distance equal to the amount of vacuum applied to the well (expressed in "inches of water column"). Please note that the pump will still function normally and maintain the liquid level, albeit a higher level.

9

Chapter 5: Installation

Hose Bundles

Hose bundling or the use of jacketed tubing reduces equipment entanglement at the well surface, and aids the removal of the pump from the well. Bundling also assists in positioning the pump and down-well hose assembly against one side of the well casing. Maximum space is created for other items, such as probes, to be periodically placed inside the well.

Follow these instructions to create a hose bundle:

1. Lay the equipment on the ground and make all of the necessary hose connections. (See Figure 5).

2. If a well cap is supplied, install it on the hoses. (See Figure 4).

3. Connect the quick-link assembly on the support rope to the eyebolt on the AP4+ and lay the support rope out along with the hoses. Make sure that none of the hoses or support ropes are crossing over each other (See Figure 5).

Note: To make the next step easier, pull the support rope and the hoses taut.

4. Starting at the AutoPump end of the hose, put a tie-wrap through the center of the braided support rope just above the uppermost quick-connect or barb on the AutoPump (See Figure 5).

5. Pulling the rope taut, put the tie-wrap around the fluid discharge hose with the rough surface outwards. Cross the ends and complete the connect the tie-wrap make sure it is straight and is not kinking the hoses (See Figure 5).

Note: After completing this step, the fluid discharge hose will be attached to the support rope and the exhaust hose. At this point the air supply hose is still lying free.

6. Place the next tie-wrap two feet towards the well cap from the first. Secure the air supply hose rather than the exhaust hose.

Note: It is important to put the tie-wraps approximately two feet apart to keep a proper discharge hose/support rope bundle. Experience has shown that spreading the tie-wraps further apart than two feet increases the probability for hose kinking.

7. Continue to alternate the air exhaust and the air supply tie-wraps every two feet, stopping about five feet from the wellhead.

8. Being careful not to leave any sharp edges, cut the excess from the tie-wraps.

You now have a down-well bundled hose assembly that supports both the hoses and the down-well equipment.

10

Figure 6 - Examples of Well Caps

11

Figure 7 - Hose Bundling

Air Exhaust Tie-Wraps in Between Air Exhaust Tie-Wraps Every 4 Ft. (122 Cm)

Support Harness

Quick Link Assembly

Support Rope

Fluid Discharge Hose (Black)

Air Exhaust Hose (Blue)

AutoPump® Air Hose (Green)

Tie-Wrap Detail

Thread Tie-Wraps Through Support Line

Air Exhaust Tie-Wraps in Between Air Hose Tie-Wraps Every 4 Ft. (122 Cm)

Air Exhaust Tie-Wrap

Fluid Discharge Hose (Black)

Support Rope

Air Exhaust Tie-Wrap

Air Hose Tie-Wrap

Fluid Discharge Hose (Black)

AutoPump Air Hose (Green)

Air Exhaust Hose (Blue)

AutoPump Air Hose (Green)

Figure 8 Tie-Wrap Layout

12

Support Rope

Air Hose Tie-Wrap

Air Exhaust Hose (Blue)

Chapter 6: Maintenance

Removing the Pump’s Casing

1. Remove the bolt at the bottom of the pump which holds the inlet screen in place (bottom loading pumps only).

2. Remove the three bolts at the bottom of the pump which hold the inlet in place. (See Figures 6,7,8,and 9)

3. Remove. the inlet from the pump’s casing by pulling it out.

4. Twist and slide the casing down off the pump’s frame.

Cleaning Pump Interior

The inner workings of the pump should now be exposed for inspection and cleaning. (See Figures 6 Through 11)

Note: A Scotch Brite® abrasive pad is useful for cleaning debris from the pump components.

.1 Gently brush off built-up solids from the float, the discharge line, the pump casing and the control rod guide.

2. The pump can be steam cleaned without damage.

3. Remove thick deposits of hardened scale on the discharge tube by using a handbrush or by lightly tapping the

discharge tube with a small hammer. Be careful not to strike any pins or other components, since they may be damaged.

Iron Build-up Cleaning Procedure

After the casing has been removed from the AutoPump please follow the procedure below:

1. The bottom “spider” should be removed by unthreading it from the pump’s discharge pipe. (See Figures 6,7,8,and 9)

2. Visually inspect the 1 inch stainless steel fluid discharge pipe for scale build-up or debris. Also, do the same with the float

that rides up and down on the SS discharge pipe.

3. Should there be scale deposits on either or both the discharge pipe or float, then remove the float from the SS fluid discharge pipe as follows . (See Figures 6,7,8,and 9)

Remove the small SS hairpin from the bottom spring cup. Removing the hairpin and spring cup will allow you to remove the spring, sliding stop and float from the SS discharge pipe.

4. The 1 inch stainless steel fluid discharge pipe can now be cleaned using either a ScotchBrite pad, a wire brush or a wire wheel on either a drill or a grinding machine. After removing the scale/debris, it is recommended the pipe be water rinsed.

Both the internal and external surfaces of the float will generally require cleaning. The cleaning material choices include a Scotch Brite pad, and a light grade 150 sandpaper.

The plates are removed to ease cleaning, they should be replaced on the same float end from which they came. That is, the plates should maintain their original top and bottom positions.

5. The white plastic square Control Rod is the next component to be cleaned. The control rod is the item that fits through the smaller hole in the float and is adjacent to the SS discharge pipe in the assembled pump. To Clean use the Scotch Brite pad or a razor or Exacto knife (not sandpaper).

6. The final component to be cleaned is the outer AP4+ casing. The fastest and most effective way to clean out the inside surface of the pump casing is to use a three-stone honing tool. The technique is to move the hone in and-out, a half dozen times or so through, each end of the casing. The time for the casing cleaning should take no longer than 5 minutes.

The AutoPump is now ready for re-assembly by following the steps above in reverse order.

Note: Before threading the bottom “spider” onto the pump’s discharge pipe, be sure to wrap the discharge pipe’s threads completely with Teflon tape.

13

QED AP4+ Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual