QED AutoPump AP-3 Manual de usuario
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AutoPump Controllerless System
(for 3-inch wells or larger)
AP-3 AutoPump®
Document No. 602234 03
1565 Alvarado Street
San Leandro, California 94577-2640
(800) 537-1767 — North America Only
(510) 346-0400 — Tele.
(510) 346-0414 — Fax
PO Box 3726
6095 Jackson Road
Ann Arbor, Michigan 48106-3726
(800) 624-2026 — North America Only
(734) 995-2547 — Tele.
(734) 995-1170 — Fax
info@qedenv.com — E-mail
www.qedenv.com
Copyright QED Environmental Systems, April 2009
Environmental Systems
The equipment in this manual is protected under U.S. and foreign patents issued and pending:
U.S. Patents:
Selective Oil Skimmer (SOS) 4,497,370
Specic Gravity Skimmer (SPG) 4,663,037
AutoPump (AP) 5,004,405
Specic Gravity Skimmer (SPG) Product Sensing 5,474,685
Vacuum/Pressure Hydrocarbon Recovery System 4,761,225
SPG PSR technology 5,474,685
AP-2 5,641,272
Genie System 5,704,772
Canada Patent:
Specic Gravity Skimmer (SPG) 1,239,868
"AP" is a Registered Trademark of "QED Environmental Systems"
"AutoPump" is a Registered Trademark of "QED Environmental Systems"
"SOS" is a Registered Trademark of "QED Environmental Systems"
"Genie" is a Registered Trademark of "QED Environmental Systems"
"SPG" is a Registered Trademark of "QED Environmental Systems"
"AutoSkimmer" 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"
Page i
AP-3 Manual Table of Contents
Revision 3 - April, 2009
Table of Contents
Introduction_________________________________________________1
Safety .......................................................................................................1
ATEX Certication ...................................................................................1
How to Contact QED................................................................................4
Chapter 1: Safety ____________________________________________5
A Partial List of Safety Procedures ..........................................................5
Fire and Explosion Protection ..................................................................6
Personal Protection ...................................................................................6
Spill Protection .........................................................................................6
Chapter 2: Overview _________________________________________7
General Specications ..............................................................................7
This is How it Works ................................................................................8
Major AutoPump Features........................................................................8
Special Operating Conditions ................................................................... 10
Cold Weather .....................................................................................10
Actions To Take .................................................................................10
Flow induced freezing .......................................................................12
The well is under a vacuum...............................................................12
Abrasive particles in the well ............................................................12
Hard pipe air supply connection to the pump....................................12
Options and Accessories ...........................................................................13
QED Environmental Systems
AP-3 Manual
Page ii
Chapter 3: Equipment________________________________________14
Unpacking.................................................................................................14
Equipment List..........................................................................................14
Tools..........................................................................................................15
Parts List ...................................................................................................15
AP-3 AutoPumps ......................................................................................15
Bottom-Loading AP-3/BL ................................................................15
Top-Loading AP-3/TL ......................................................................15
Specications.....................................................................................18
Component Materials ........................................................................18
Performance and Air Use Curves ...................................................... 18
Leachate Screens ...............................................................................19
Optional “WYE” Fitting....................................................................20
Short Top Loading Cup .....................................................................21
Long Top Loading Cup......................................................................22
Single Stage Filter/Regulator....................................................................23
Hoses and Fittings.....................................................................................24
Hose and Tubing Color Code Table................................................... 24
Volumes Pumped Per Cycle......................................................................25
Pump Support System...............................................................................25
Chapter 4: Assembly & Installation_____________________________26
Cautions ....................................................................................................26
Compressed Air Supply ............................................................................27
Component Assembly...............................................................................27
Quick-Connects/Hose Barbs .............................................................27
AutoPump Assembly .........................................................................27
Dry Test.....................................................................................................33
Pump Support System and Hose Bundling Assembly..............................34
AutoPump Installation..............................................................................39
AP-3 Manual Table of Contents
Revision 3 - April, 2009 Page iii
Chapter 5: Start Up and Operation _____________________________41
Start Up Checklist.....................................................................................41
Observation of System Operation.............................................................42
Downwell Testing of the AutoPump.........................................................42
AutoPump Shutdown while Submerged...................................................42
AutoPump Removal Technique (optional) ...............................................42
Chapter 6: Maintenance ______________________________________43
General Maintenance ................................................................................ 43
Maintenance Table....................................................................................44
Air Quality Check.....................................................................................44
Single Stage Filter/Regulator Maintenance.......................................44
AutoPump Service .................................................................................... 46
AutoPump Shutdown and Removal from Well .................................46
For Bottom-loading pumps................................................................46
For Top-loading pumps ......................................................................46
Removing Pump Casing .................................................................... 47
Cleaning Pump Interior .....................................................................49
Iron Build-up Cleaning Procedure.....................................................56
Installing Pump Casing .....................................................................57
Checking Volumes Pumped Per Cycle .....................................................58
Chapter 7: Troubleshooting & Repairs __________________________59
Troubleshooting ........................................................................................ 60
Returning Equipment for Service .............................................................63
Equipment Cleaning Requirements ..........................................................64
Hoses and Fittings .............................................................................64
AutoPumps ........................................................................................64
QED Environmental Systems
AP-3 Manual
Page iv
Appendix A: Performance Curves_______________________________65
Appendix B: Air Consumption Curves ___________________________79
Appendix C: AP-4 Conversions _________________________________93
Appendix D: Vacuum on Well __________________________________100
Terms, Conditions, and Warranty _______________________________105
AP-3 Manual Table of Contents
Revision 3 - April, 2009 Page v
Figures:
Figure 1 - ATEX Label Detail, Example and Explanation ................................ 2
Figure 2 - AP-3 ATEX Label Location and Appearance ................................... 3
Figure 3 - How it Works..................................................................................... 9
Figure 4 - Overview of the AutoPump System .................................................. 11
Figure 5 - Long and Short Bottom-Loading (AP-3/BL)................................... 16
Figure 6 - Long and Short Top-Loading (AP-3/TL) .......................................... 17
Figure 7 - Long and Short AP-3 Bottom Loading with Leachate Screen.......... 19
Figure 8 - Short AP-3 Top Loading with Optional Brass “WYE” Fitting ......... 20
Figure 9 - Short AP-3/TLC and Short AP-3/TL Comparison............................ 21
Figure 10 - Long AP-3/TLC and Long AP-3/TL Comparison ............................ 22
Figure 11 - Single Stage Filter/Regulator 60 with Quick-Connects ................... 23
Figure 12 - Locking Quick-Connects .................................................................. 28
Figure 13 - Two-Ear Clamp and Hose Barb Assembly Instructions.................... 29
Figure 14 - Worm Drive Clamp and Hose Barb Assembly Instructions.............. 30
Figure 15 - AP-3 Assembly: Well Cap with Holes .............................................. 31
Figure 16 - AP-3 Assembly: Well Cap with Hose Barbs..................................... 32
Figure 17 - Examples of Well Caps ..................................................................... 35
Figure 18 - Hose Bundling: Part 1 of 2................................................................ 37
Figure 19 - Hose Bundling: Part 2 of 2................................................................ 38
Figure 20 - Removing AP-3 Pump Casing .......................................................... 48
Figure 21 - Internal View of a Bottom-Loading and Top-Loading AP-3............. 50
Figure 22 - Exploded View of a Top-Loading Long AP-3................................... 51
Figure 23 - Exploded View of a Bottom-Loading (Long & Short)...................... 52
QED Environmental Systems
AP-3 Manual
Page vi
Figure 24 - Exploded View of AP-3 Lever Assembly.......................................... 53
Figure 25 - Exploded View of a Top Loading Short AP-3................................... 54
Figure 26 - Bottom Intake Check Valve Assembly.............................................. 55
Figure 27 - Long AP-3/BL Performance Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 67
Figure 28 - Long AP-3/BL Performance Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 68
Figure 29 - Long AP-3/BL Performance Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 69
Figure 30 - Long AP-3/TL Performance Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 70
Figure 31 - Long AP-3/TL Performance Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 71
Figure 32 - Long AP-3/TL Performance Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 72
Figure 33 - Short AP-3/BL Performance Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 73
Figure 34 - Short AP-3/BL Performance Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 74
Figure 35 - Short AP-3/BL Performance Curves::
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 75
Figure 36 - Short AP-3/TL Performance Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 76
Figure 37 - Short AP-3/TL Performance Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ........... 77
Figure 38 - Short AP-3/TL Performance Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 78
Figure 39 - Long AP-3/BL Air Consumption Curves::
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 81
Figure 40 - Long AP-3/BL Air Consumption Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ........... 82
AP-3 Manual Table of Contents
Revision 3 - April, 2009 Page vii
Figure 41 - Long AP-3/BL Air Consumption Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNIT............... 83
Figure 42 - Long AP-3/TL Air Consumption Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 84
Figure 43 - Long AP-3/TL Air Consumption Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 85
Figure 44 - Long AP-3/TL Air Consumption Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 86
Figure 45 -Short AP-3/BL Air Consumption Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 87
Figure 46 - Short AP-3/BL Air Consumption Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 88
Figure 47 - Short AP-3/BL Air Consumption Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 89
Figure 48 - Short AP-3/TL Air Consumption Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 90
Figure 49 - Short AP-3/TL Air Consumption Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 91
Figure 50 - Short AP-3/TL Air Consumption Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 92
Figure 51 - Conversion from Top-Loading to Bottom Loading........................... 95
Figure 52 - Conversion from Bottom Loading to Top-Loading........................... 97
Figure 53 - Conversion from Short Bottom-Loading to Short Top Loading ....... 99
Figure 54 - AP-3/BL with Vacuum In the Well and Pump Exhaust
Outside the Well ................................................................................ 101
Figure 54 - AP-3/BL with Vacuum In the Well and Pump Exhaust
In the Well ......................................................................................... 102
Figure 56 - AP-3/TL with Vacuum In the Well and Pump Exhaust
Outside the Well ................................................................................ 103
Figure 57 - AP-3/TL with Vacuum In the Well and Pump Exhaust
In the Well ......................................................................................... 104
Page 1
AP-3 Manual
Revision 3 - April, 2009
Introduction
Welcome to QED Environmental Systems’ AutoPump® (AP-3) 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 reects 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 rst 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 rst section in all of our
manuals.
ATEX Certications
Equipment with an ATEX label similar to the example on Figure 1, page 2 is ATEX certied.
Equipment without the label is not ATEX certied.
Figures 1 and 2 explain the ATEX label, the label location and appearance.
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