Pilot Plant Troubleshooting

This section includes some minor issues the team has come across.

Note that there is always at least one operator at the treatment plant during regular hours. The operators are generally willing (and usually able) to help solve problems, so don't hesitate to ask if they're free to help out.

Starting the pilot plant

Check with the operators to see if it is permissible to run the pilot plant.
Check that all the cords, including the power strips, are plugged in.
Check with the plant operators to make sure they haven't turned off parts of the Filtration Plant for maintenance. The operators are also very helpful in figuring out what might be unplugged or turned off.

Starting the alum pump

If the alum pump has been switched on, but no alum is flowing (i.e., the corresponding box in the process controller reads "0" mg/L):

• Go to configuration in the process controller.
• In the top left corner there are methods, files, etc. buttons, and an icon that looks like an open folder. Click on the folder.
• Open the Fall 2008 folder (or a newer folder).
• Open Sept 9 2008 (or any configuration that may have been saved later).

Changing the alum dose

• Open process controller.
• Go to the Configuration tab.
• Click "Edit Rules."
• In the menu on the left-and side, go to "alum dose not increment" and change the value.

There is a leak

(/)Determine the source of the leak.

If it is a pipe:

• If the pipe connects the flocculator to the sed tank, plug the inlets with the screw caps already created. The benefit to this over just turning off the plant is that the flocculator can continue to run, since the water can leave through the weir in the flocculator which usually just handles excess flow.

Dry off the pipe with a towel. This is essential, as the caulk will not set properly if it is wet. Wait at least a few hours or a day to ensure that the surface is dry.

• Caulk the pipe, paying special attention to the bottom of the seal. The cure time is usually 24-48 hours. Leave the pipes plugged for this length of time.
• If water continues to leak, make sure that the leak is not coming from another location, and repeat the above steps if necessary.

If it is the plant leveling tank:

• Try to determine which component is causing the issue.
• Plug the pipes connecting the flocculator and the sedimentation tanks so that water stops flowing into the plant leveling tank.
• Ask Tom or one of the other nice plant operators if they could show you how to tighten the flanges of the connecting pieces.

Peristalic Pumps

It can be hard to tell which way to set the switch on a pump. If you're unsure, let a little air into part of the tubing and see which direction it goes. (That's the direction water is being pumped.)

*It likely that a pump isn't running if

• the power light is off,
• the motor isn't turning (i.e., the circle on the front of the unit isn't turning),
• water in the tubes doesn't seem to be going anywhere.

If the pump is plugged in and switched on, but still isn't running, try turning the dial or pressing the up arrow to increase the pump speed. If it still isn't working, the motor may be the problem. An immediate solution is to use one of the other pumps at the pilot plant if no one else is using it. (If the pump has more than one tube running through, you might need to label the tubes before taking them out so they can put back in the right order.) To take a tube out of a pump, lift the lever near the front of the pump and gently pull the beige tube out of the pump. You probably will not need to disconnect any tubes from one another.

Turbidity is unexpectedly high

Allow some time for measurements to stabilize. If this doesn't help, try cleaning the turbidimeter (see Maintenance.

Flocs look funny

If the flocs are white in color and float,
Check the flow rate into the pilot plant by looking at the digital monitor, located next to the wall facing Cornell University's Flocculator. If it is much lower than 23 gal/min:

• • Toggle the pump on and off. If this doesn't work:
  • The pump that drives the water through the plant may not be operating properly. There may be objects caught in the screen (e.g. leaves) or there may be electrical issues. Clean the screen on the pump or toggle the pump on and off a few times. (As always, ask one of the operators if you're unsure of what to do.)
• The turbidity of the incoming water may be fairly low, and the alum dose may be too high. Lower the alum dose slightly. (See above.)

If the effluent water is turbid and does not contain large flocs, but the water is not unsually white, the alum dose probably is not high enough. Increase the alum dose in Process Controller to account for the increased turbidity. (See above.) This is likely to occur if there has been a lot of rain.