Draft - O&M Manual Presentation

Butte Priority Soils Operable Unit

June 7, 2011

EPA 540-F-01-004 Operation and Maintenance in the Superfund Program; Highlight 5 – Typical O&M Manual Sections, 2001

BP Engineering Integrity Manual; Section 22 – Operation and Maintenance Manual Requirements, 2009

Building Design Guide; Comprehensive Facility Operation and Maintenance Manual

Written sections of the O&M manual provide system background and operational justification for operating parameters, and allow for an operating range while maintaining safe operating limits of the system.

Volume I - System Overview

Volume II - Metro Storm Drain Pumping Station

Volume III - West Camp Pumping Station

Volume IV - BTL-LAO Treatment System

Volume V - Maintenance Plan

Volume I System Overview The Draft Operation, Maintenance and

Monitoring (O&M) Plan for Butte Priority Soils Operable Unit consists of multiple volumes (I through V). Each volume is used to describe specific aspects of the Operations and Monitoring (O&M) Plan. Volume I, presents project background information, an overview of the operating systems and associated components, and waste characterization.

Items provided in Volume I required by EPA Highlight 5 include the following:

•Remedy description•Staffing and Personnel Requirements•*Permits•Records

*(as written in the Final Consent Decree)

BP’s Site Remediation Technologies Engineering Integrity Manual, Section 22 provides requirements for Operation and Maintenance Manual preparation

The following provides clarification regarding where these items are found

BP Engineering Integrity Manual BTL-LAO O&M

I. Cover Sheet Volumes I – V

II. Table of Contents Volumes I – V

III. Purpose Volume I

IV. Equipment Description Volumes I – IV

V. Instrumentation and Protective System Devices Volumes I – V

VI. Safe Operating Limits Volumes I – IV

VII. System Operating Details Volumes II – IV

VIII. Sampling Volumes I – IV

IX. Equipment Lubrication and Maintenance Volume V

X. Waste Handling and Disposal Volumes II – V

XI. Drawings Volumes I – IV

BP Engineering Integrity Manual BTL-LAO O&M

XII. Equipment Manuals Volume V

XIII. Copy of Permits Volumes I – IV

XIV. Forms Volumes II– V

XV. Field Data Sheet Volumes II – IV; Daily Ops Report

XVI. Maintenance Schedule & Checklist Volume V

XVII.Maintenance Log Volume V

XVIII.PSD Checklist Volumes II– IV

1.0 INTRODUCTION 1.1 Purpose and Scope 1.2 Remedy Description 1.3 System Background 1.4 Waste Characterization 1.5 Treatment System 1.6 Treatment Method 1.7 Design Theory 1.8 Owner and Contact Information 1.9 Site Access 1.10 Operation and Maintenance

Manual Contents 1.10.1 Volume I System Overview 1.10.2 Volume II Metro Storm Drain 1.10.3 Volume III West Camp/Missoula

Gulch 1.10.4 Volume IV Butte Treatment

Lagoons and Lower Area One 1.10.5 Volume V Maintenance 2.0 SYSTEM OVERVIEW 2.1 Influent Characterization 2.2 Remedial Action Treatment

Objectives 2.3 Safe Operating Limits 2.4 Protective Safety Devices

(PSDs) 2.5 Description of

Facilities/Systems

2.6 Description of Remote Facilities/Influent Systems

3.0 PERFORMANCE STANDARDS 3.1 Groundwater 3.2 Surface Water 3.3 Operational Sampling and

Monitoring 3.4 Sampling by Others 4.0 OPERATION, MONITORING,

AND MAINTENANCE PLAN PURPOSE AND USE

5.0 HEALTH AND SAFETY PLAN 6.0 MANAGEMENT PLAN 6.1 Staffing and Personnel 6.2 Training 6.2.1 Start-up, Shutdown, Upset,

and Normal Operation 6.3 Records and Reporting 6.4 Transfer of Ownership,

Operation and Management 7.0 FUTURE REVISIONS AND

UPDATES TO O&M PLAN

Volumes II – IV are structured with a consistent Table of Contents format

Volumes II – IV provide operating and daily maintenance tasks associated with a specific system

Specific checklists, SOPs, drawings, etc. are contained within each specific volume

1.0 INTRODUCTION 1.1 Purpose and Scope 1.2 Project Background 1.3 Design Theory 1.0 INTRODUCTION 1.1 Purpose and Scope 1.2 Project Background 1.3 Design Theory 1.4 BTL-LAO Owner and Contact

Information 1.5 Organization and Use of this

Volume of the O&M Manual 2.0 SYSTEM OVERVIEW 2.1 General Facility 2.2 Electrical, Instrumentation and

Controls 2.3 Wet Vault Installation 2.4 System Monitoring 2.5 Electrical Systems 2.6 Backup Systems and Spare Parts 3.0 SYSTEM CONTROLS 3.1 Hydraulic Control 3.2 Electrical, Automation Control, and

Monitoring 3.3 Instrumentation and Controls –

Operational Control Theory

4.0 SAFE OPERATING LIMITS 4.1 Pressure 4.2 Temperature 4.3 Electrical 4.4 Protective Safety Devices (PSDs) 5.0 ROUTINE OPERATION AND

MAINTENANCE TASKS 5.1 Routine Operation 5.2 Site Vegetation and Access

Maintenance 6.0 OPERATION DURING DISTURBANCES 6.1 System Disturbances 6.2 Instrumentation and Control

Disturbance 6.3 Environmental Disturbances 7.0 MONITORING AND LABORATORY

TESTING 7.1 Operator Observations 7.2 System Generated Data 7.3 Automatic Electronic Monitoring Data 7.4 Field Measurement and Sample

Collection 7.5 Routine Inspection and Calibration of

On- Site Monitoring Systems 7.6 Review of Monitoring Data for

Operations 7.7 Routine Sampling Tasks

4.0 SAFE OPERATING LIMITS 4.1 Pressure 4.2 Temperature 4.3 Electrical 4.4 Protective Safety Devices (PSDs) 5.0 ROUTINE OPERATION AND

MAINTENANCE TASKS 5.1 Routine Operation 5.2 Site Vegetation and Access

Maintenance 6.0 OPERATION DURING DISTURBANCES 6.1 System Disturbances 6.2 Instrumentation and Control

Disturbance 6.3 Environmental Disturbances 7.0 MONITORING AND LABORATORY

TESTING 7.1 Operator Observations 7.2 System Generated Data 7.3 Automatic Electronic Monitoring Data 7.4 Field Measurement and Sample

Collection 7.5 Routine Inspection and Calibration of

On- Site Monitoring Systems 7.6 Review of Monitoring Data for

Operations 7.7 Routine Sampling Tasks

8.0 DATA MANAGEMENT 8.1 Data Management Plan 8.2 Automated Data Management 8.3 Monitoring, Alarm, and Data

Logging System 9.0 OPERATIONS REPORTING AND

RECORD KEEPING 9.1 Daily Operations Report 9.2 Weekly Operations Report 9.3 Monthly Operations Report 9.4 Quarterly Operations Report 9.5 Annual Operations Report 9.6 Supplementary Data 10.0 ROUTINE INSPECTION AND

MAINTENANCE GUIDELINES 10.1 Inspection and Maintenance

Guidelines for Process Equipment 11.0 EMERGENCY PROCEDURES 11.1 Alarm Response Notification 11.2 Alarm Conditions 11.3 Emergency Shutdown of Pump

Station 12.0 REFERENCES

Volume V provides maintenance requirements beyond daily operational maintenance tasks

Work order system Inspection schedules, maintenance

logs, seasonal maintenance, etc.

1.0 INTRODUCTION1.1 Purpose1.2 Scope1.3 Updates2.0 EQUIPMENT TRACKING2.1 Equipment List2.1.1 Equipment Numbering2.1.2 Equipment Data Sheets2.2 Maintenance Procedures2.3 Work Permits – HSSE Requirements2.4 Risk Assessments2.5 Training2.5.1 Re-certifications2.6 Work Order System2.6.1 Work Order2.7 Prioritizing Work Requests2.8 Labor Usage2.9 Spare Parts Inventory and Inventory Control2.10 Manufacturer’s Manuals Usage2.11 Schedule of Tasks Performed3.0 INSPECTION, DOCUMENTING AND REPORTING

4.0 SYSTEM OVERVIEW INSPECTION4.1 Inspection Log4.2 Equipment Maintenance Logs4.3 Protective Safety Devices Maintenance4.3.1 PSD Testing and Maintenance Log4.4 Work Orders4.5 Incident Investigations 5.0 PREVENTATIVE MAINTENANCE TASKS5.1 Inspections5.2 Cleaning5.3 Lubrication 6.0 PREDICTIVE MAINTENANCE7.0 SEASONAL MAINTENANCE8.0 HSSE AND SPECIALIZED TOOLING REQUIREMENTS9.0 PROCESS DESCRIPTION10.0 MAINTENANCE REQUIREMENTS (BY SYSTEM)

10.1 CAS10.2 BTL10.3 LAO SITE

14.0 REGULATORY REQUIREMENTS15.0 WASTE AND WASTE DISPOSAL16.0 MATERIAL SPECIFICATIONS17.0 INSTRUMENTATION18.0 LESSONS LEARNED19.0 UPGRADES and UPDATES

Checklists

Tables

Forms

Schedules

Drawings

BTL-LAO Ops Report

West Camp

MSD

LAO

CAS Building

*Protective System Devices

* Denotes Integrity Management required items

*PSD Safe Chart Cause and Effect

• *Instrument Device• Valves

Decision Trees• Operating • Maintenance

Registers• *Device Register• Equipment Register• Interface Register

Line List

* Denotes Integrity Management required items

Equipment Data Sheet Work Orders *Inspection Logs *Maintenance Logs * Denotes Integrity Management required items

*Quarterly Overview Inspections *PSD Inspections Valve Cycling Lubrication Cell Dredging/Waste Removal

* Denotes items required by BP Integrity Management

*Site Plot Plan Process Flow Diagram Construction As-Built Drawings Equipment Layout

• Well Details – West Camp• Equipment Interface Details

*Piping and Instrumentation Diagrams (P&IDs)

Electrical One Line – upon completion of upgrades

• Provide specific purchase information

• Document specific equipment details

• Should be completed for all equipment when purchased/installed

• Retired when equipment is removed/replaced

Provide method for tracking maintenance

Ensure CoW practices are followed

Require dual verification of work completed

Standard Operating Procedures (SOPs)• Currently 43 SOPs written• Standard format

Scope, HSSE , PPE, MSDS, Reference Drawings, Work Instructions

Manufacturer’s Specific O&M Manuals• Included in specific Volume Appendices• Referenced for minimum maintenance

requirements

System Upgrades Transition from Manual

to Program Maintenance

• Schedules• Procedures• Detailed equipment files

Operations• Additional SOPs• Updated SOPs

IM Compliance• Monthly

compliance focus

Line Lists Coordinate

• Contingency Operation Plans

• Construction Completion Reports