TRAINING SUPPORT PACKAGE (TSP)

TSP Number TSP Title Task Number(s) / Title(s) Effective Date Supersedes TSP(s) TSP Users Proponent Comments / Recommendations

77W12G01 End Of Course Review

01 Oct 1999 None MOS 77W10 Water Treatment Specialist The proponent for this document is Quartermaster Center and School. Send comments and recommendations directly to: DEPARTMENT OF THE ARMY TRAINING DIRECTORATE ATTN: ATCL-AT 401 First Street Suite 227 Ft. Lee, VA 23801-1511 This product has been reviewed by the product developers in coordination with the U.S. Army Combined Arms Support Command foreign disclosure authority. This product is releasable to military students from foreign countries on a case-by-case basis.

Foreign Disclosure Restrictions

PREFACE
Purpose

This Training Support Package provides the instructor with a standardized lesson plan for presenting instruction for:

This TSP Contains

TABLE OF CONTENTS PAGE Preface ............................................................................................................................................. 2 Lesson Section I Administrative Data ..................................................................................... 4 Section II Introduction.................................................................................................. 6 Terminal Learning Objective - Ask questions to clear up any remaining difficulties with the course. ................................................... 6 Section III Presentation ................................................................................................ 8 Section IV Summary................................................................................................... 61 Section V Student Evaluation .................................................................................... 63

77W12G01 version TATS / End Of Course Review 01 Oct 1999

SECTION I. All Courses Including This Lesson Task(s) Taught(*) or Supported Reinforced Task(s) Academic Hours

ADMINISTRATIVE DATA
Course Number Course Title

720-77W10
Task Number

77W10, WATER TREATMENT SPECIALIST, AIT COURSE

Task Title

Task Number

Task Title

The academic hours required to teach this TSP are as follows:

ADT Hours/Methods

Test Test Review Total Hours:

Prerequisite Lesson(s) Clearance Access References
Number Lesson Number

1.5 / Conference / Discussion .0 .0 1.5

Lesson Title

None

Security Level: Unclassified Requirements: There are no clearance or access requirements for the lesson.
Title Date Additional Information

Student Study Assignments Instructor Requirements

None

One primary instructor and one alternate per class if conference.

Additional Support Personnel Requirements Equipment Required for Instruction Materials Required

None

Name

Quantity

Expendable

None INSTRUCTOR MATERIALS:

Training Support Package VGT (1-7) Lite Pro Projector (P 16312)

Projector Video Data (P 18230) Viewing Screen

STUDENT MATERIALS:

Notepad Pen/Pencil Trainee Guide

Classroom, Training Area, and Range Requirements Ammunition Requirements Instructional Guidance GENERAL INSTRUCTION BUILDING

Name

Student Qty

Misc Qty

None NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material.

Ensure facilities and materials are ready prior to class time.

Proponent Lesson Plan Approvals
Name Rank Position Date

Mr. Harold A. Williams James Keener

GS-13 Major

Chief, QM-PWD, TD Chief, WTD

SECTION II.

INTRODUCTION Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:18 Time of Instruction: 0 hrs 5 mins Media: Group-paced Instruction

Motivator

The ability of the water treatment specialist to perform water analysis testing, maintain mobile water supply equipment, and operate military wells, the 600-GPH and the 3,000-GPH ROWPUs, the 150,000-GPD ROWPU, the TWDS, and other water distribution, storage, and transportation equipment is a very important skill in the production of potable water. NOTE: Show VGT 01.

Terminal Learning Objective

NOTE: Inform the students of the following Terminal Learning Objective requirements.
At the completion of this lesson, you [the student] will: Action: Ask questions to clear up any remaining difficulties with the course. Conditions: Given a course review. Standards:

Proficiency will be determined by achieving a score of 70% or higher on the written examination.

Safety Requirements

1. No smoking in the classroom. 2. Keep aisles clear for hasty exits. 3. Identify and point out primary and alternate fire exits. 4. Observe all safety precautions.

Risk Assessment Level Environmental Considerations

Low

Army Regulation 200-1 delineates TRADOC responsibilities to integrate environmental requirements across DTLOMS and ensure all training procedures, materials, and doctrine include sound environmental practices and considerations. The Army's environmental vision is to be a national leader in environmental and natural resource stewardship for present and future generations as an integral part of all Army missions. This Training Support Package meets this standard. Refer students to the Student Evaluation Plan. This review will provide you with the opportunity to ask questions to clear up any remaining difficulties with installing, operating, and maintaining equipment used in

Evaluation Instructional Lead-In

Lead-In

the production, storage, and distribution of potable water.

SECTION III.

PRESENTATION

1.

Learning Step / Activity 1. Discuss risk assessment and safety considerations Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Show VGT 02. a. No smoking in the classroom. b. Keep aisles clear for hasty exits. c. Identify and point out primary and alternate fire exits. Conference / Discussion 1:18 1 hrs 15 mins Group-paced Instruction

d. Observe all safety precautions. NOTE: 2. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 2. Review Water Treatment Specialist course information for the End of Course Comprehensive Test (EOCCT). Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Show VGT 03. a. Identify water sources and treatment processes (A02). 1) Water is characterized in four different ways. 2) Contaminated water contains disease-producing organisms, poisonous substances, or nuclear, biological, and chemical (NBC) agents which make it hazardous and, therefore, unfit for human consumption or domestic use. Water may be contaminated but not necessarily polluted. 3) Polluted water contains substances such as garbage, sewage, industrial waste, or mud, which makes it objectionable because of appearance, taste, or odor. Polluted water is usually contaminated and may be easily detected. 4) Palatable water is significantly free from color, turbidity, taste, and odor, and is cool and aerated. Although palatable water tastes good, it may not be potable. 5) Potable water is free from disease-producing organisms, NBC agents, and organic and inorganic poisonous substances. Potable water has been treated to the degree required, and therefore, is safe for human consumption. Conference / Discussion 1:18 0 hrs Group-paced Instruction

b. Determine pH value of a water sample (A03). 1) The pH value is determined by measuring the degree of acidity or alkalinity of water. The pH value influences the corrosiveness of water, the amount of chemical dosages needed for disinfection, and the ability of an analyst to detect contaminants. 2) The pH value expresses its tendency to accept or donate hydrogen ions. The pH value represents the instantaneous hydrogen ion activity, while alkalinity and acidity expresses the total reserve amount. 3) The pH values range from 0 to 14. A pH value less than seven indicates acidity and more than seven alkalinity. A value of seven is neutral. 4) Most natural waters fall within the ranges of 0 to 9. Most waters are slightly basic due to carbonates and bicarbonates. Changes can be caused by the entry of strong acids or industrial waste. 5) Color comparator determines the pH value with simple numbers conforming to the hydrogen ion scale. A pH color disk contains nine permanent values. The test is made by comparing the color of a measured amount (colored with reagent) with the standard disk. 6) Once a water point has been established, a pH test is performed on the raw water source at least once a day or anytime you move to a new source. The pH tests of product water should be performed every half hour. 7) If NBC contamination is possible, a pH test of the raw water should be performed every half hour. 8) c. According to Technical Bulletin (TB) MED 577, water produced by water purification units must fall between 5.0 to 9.0 units.

Determine the chlorine residual of a water sample (A04). 1) Chlorine residual is the amount of un-reacted chlorine left at a specified time after the chlorine compound is added. Chlorine in a solution is highly unstable. It may change under many conditions, including the presence of other elements or compounds. 2) During normal conditions, water purification personnel will add enough chlorine to treated water to produce a chlorine residual of at least 5.0 ppm after 30 minutes contact time at a pH between 6.5 and 7.5. 3) The potable water chlorine residual at the point of consumption (such as water trailers, collapsible fabric drums, or lister bags) will be at least 1 ppm or at a higher level if prescribed by the command surgeon.

4) The chlorine residual will be measured every hour of the operating day at water purification points and at least two times a day at water distribution points. 5) The chlorine residual of water contained in water trailers, fabric drums, and lister bags will be measured at least two times a day to ensure adequate disinfection. 6) Gather water samples at production sites from the product water tank after 30 minutes of contact time. Gather water samples from all stored water after circulating the water for the period of time that accommodates the volume of water contained. d. Determine the amount of color in a water sample (A05). 1) Color. a) Organic color is primarily caused by the decomposition of natural organic matter. b) Oxidized, metallic ions (such as iron) produce non-organic color. c) Color usually increases during spring runoff and again in the fall from surface sources. d) Color removal deserves consideration due to the colloidal particles. e) These particles are the smallest of the turbidity-causing particles that generally have diameters of about 0.003 microns, as compared to clays of about 1.0 microns. f) In addition, these particles are negatively charged with the strength of the charge depending on the pH.

g) The charge is part of the molecule, rather than absorbed on the surface as with clays. 2) Color Removal. a) The mechanism of color removal is the direct formation of an insoluble chemical compound with a metallic coagulant (such as ferric chloride). b) This presents a problem for most reverse osmosis equipment because these systems employ charge neutralization (polymers) for turbidity removal. c) The color may neutralize the polymer and allow it to pass through the filtration processes of media filters and cartridge filters and become attached to the reverse osmosis elements. d) This would render the RO elements ineffective and would require the elements to be cleaned.

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e) Color removal is affected by pH and should be carried out under acid conditions (pH 4 to 6). Raising the pH for other processes before removing color may cause color fixation to take place. f) This makes color removal (even at optimum pH) more difficult. Water treatment personnel do not attempt to remove color by this process.

g) Instead, when the turbidity is less than 8 NTU and the color is greater than 10 color units, polymer is not used as part of the treatment process. e. Determine the temperature and turbidity of raw water (A06).
1) Turbidity is a muddy or unclear condition of natural raw water caused by contamination being held in suspension. The turbidity test is used to show the amount of suspended matter present in natural raw water. Turbidity occurs in most surface waters as the result of suspended clay, silt, finely divided organic and inorganic matter, plankton, and other microorganisms. The removal of turbidity is very important to the production capability of Army water purification equipment. In removing turbidity, contaminating substances are reduced. The degree of turbidity affects the time between back washing multi-media filters and has an impact on the frequency of cartridge filter replacement. The less turbid the water source, the less operational maintenance will be required and smaller amounts of chemicals will be needed to treat equal amount of water.

2)

f.

Determine the total amount of dissolved solids in a water sample (A07). 1) Dissolved Solids. The total dissolved solids (TDS) test is used to determine the categories of water sources. The categories are fresh, brackish, and saline. It also determines if product water from saltwater sources are within the acceptable standards for treated water. 2) Fresh water: 0 to 1,500 parts per million (ppm). 3) Brackish water: 1,500 to 15,000 ppm. 4) Salt water: 15,000 ppm or greater.

g. Conduct a lewisite test (A08). 1) The purpose of the lewisite test is to detect and identify harmful amounts of C.W. agents present in a raw or treated water sample. 2) It is important when monitoring the raw water to determine whether C. W. agents are below MPC levels. If the C.W. agents are above MPC levels, the water must be subjected to additional treatment processes. 3) It is also important to know whether the treated water has been made safe to drink after treatment.

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h. Conduct a nerve agent test (A09). 1) The nerve agent test uses the M272 Chemical Agent Water Test Kit from the WQAS-P. 2) In this test, NO COLOR CHANGE ON THE WHITE PATCH MEANS AGENT IS PRESENT. 3) A blue patch matching or bluer than the test color means - SAFEno nerve agent present. i. Conduct a cyanide and mustard test (A10). 1) The cyanide and mustard tests also use the M272 Chemical Agent Water Test Kit from the WQAS-P. 2) Cyanide test. a) Blue beads mean - DANGER - cyanide. b) All white beads mean - safe - no cyanide. 3) Mustard test. a) Purple beads mean - danger - mustard. b) All white beads mean - safe - no mustard. j. Conduct a radiological test (A11). 1) When monitoring equipment, supplies, or a water source for radiation contamination use the AN/VDR-2. 2) The protective cover on the probe must be open to detect beta particles. 3) Open the shield of the probe and take a background reading. 4) Leaving the shield open, hold the probe about one inch from the item being monitored. 5) Hold the probe perpendicular to the surface and move it along the surface with a slow, steady motion. 6) If the reading is twice background or higher, contamination is present; record the reading using the correct unit of measurement. 7) Report the results to your supervisor. NOTE: Show VGT 04. k. Conduct water reconnaissance (A14). 1) An air reconnaissance will precede a ground reconnaissance when time and equipment permit. An air reconnaissance is a rapid

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means of securing information about water sources and potential storage and distribution sites over a large area. An air reconnaissance is limited by adverse weather and security considerations. Helicopters are the best aircraft to use to conduct an air reconnaissance because of their versatility. Factors to consider are as follows: a) Terrain features. b) Routes of communication. c) Cover and concealment. d) Protection from encirclement, infiltration, and avenues of attack. e) Air and ground recon can be done at the same time to provide quick and timely results. f) Limiting factors are weather and security.

2) Ground reconnaissance is the only positive way of getting accurate information to select a water point or storage and distribution site. Detailed information is the most important factor. This information must be accurate. The decision of whether or not to use this water source is going to be based on the information that is recorded on the water reconnaissance report. The person that will be making the decision probably has never seen the water source, so you must provide him or her with enough information to give him or her a good idea of what exists at the site. l. TAMMS and PMCS (B01). 1) Preventive maintenance checks and service or PMCS. The PMCS section lists the services which are to be performed by the operator or crew. They are performed within the interval shown and in numerical sequence within each interval as indicated by item number. There are six different designated interval checks. 2) Before-operation PMCS. These are checks performed by the operator/crew per the -10 TM PMCS tables. The tables identify faults which prevent the performance of the mission and must be corrected prior to the start of the mission. All other faults are corrected or, if above operator/crew authorization to correct, reported during or after the mission. 3) During-operation PMCS. These are checks performed by the operator/crew per the -10 TM PMCS tables. These tables monitor and identify faults in equipment performance during the mission. Faults which render the equipment not mission capable (NMC) require immediate correction. All other faults are corrected or, if above operator/crew authorization to correct, reported during or after the mission. 4) After-operation PMCS. These are checks and services performed per the -10 TM PMCS tables. The tables immediately at the

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conclusion of the mission are used to identify and correct faults which will prevent the next mission and to maintain the equipment to -10/20 standard. Faults which render the equipment NMC must be corrected prior to the start of the next mission. All other faults are corrected or, if above operator/crew authorization to correct, reported to unit maintenance before the next mission. 5) Periodic operator/crew PMCS. These are checks and services performed by the operator/crew per the -10 PMCS tables. These tables show the items to be checked column and identify faults which must be corrected to maintain equipment to -10/20 TM standard. Faults requiring correction beyond operator/crew level will be reported to unit level maintenance for correction. 6) Fault. A fault is a defect in a piece of equipment that does not prevent the operation of the equipment, but must be corrected as soon as possible. The "/" status symbol is entered on DA form 2404 to indicate a fault exists. 7) Deficiency. A deficiency is a fault in a piece of equipment so severe that it causes the equipment to be not mission capable (NMC). The "X" status symbol is entered in the status column on DA Form 2404 to indicate a deficiency. m. Operate a well (B02). 1) Hydraulics of Wells. Before being pumped, the level of water in a well is the same as the level of the water table. This is called the static level in the well. The depth from the ground surface to the static water level is measured in feet. Thus, if the water in a well is 25 feet below ground, the static water level is said to be 25 feet for this well. 2) When a well is pumped, the water level drops. After several hours of pumping at a constant rate, it stabilizes itself in a lower position. This is called the pumping level or dynamic water level for this rate of pumping. 3) The distance that the water is lowered by pumping is called drawdown. It is the difference between the static level and the pumping level. The drawdown in the well, resulting from the pumping, lowers the water pressure in the well, but the surrounding water-bearing ground retains its original pressure. In response to this difference in pressure, water flows out of the pores of the ground into the well. 4) The ground does not give up its water all at once to the pumped well. The flow of water into the well is held back by the resistance of the ground to the flow of water through the pores. This resistance varies in every well. It follows from this that the rate of flow, or time required to refill the well to the static level, depends on the resistance to flow in the ground. The term used to describe this is recovery. Recovery is expressed as a percent of the wells total water. As an example, a well contained 100 feet of water and was pumped for four hours to a pumping level of 75 feet. Two hours after it stopped pumping, the water level rose back to 100 feet. In

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this case the recovery rate is 100% in two hours. Another example might be a well containing 200 feet of water that was pumped for four hours to a pumping level of 100 feet. Two hours after it stopped pumping, the water level rose back to 175 feet. In this case the recovery rate is 88% in two hours. Wells that do not totally recover after four hours should be avoided as they could be pumped dry and never recover. n. Operate the 30-kiloWatt generator (C01). 1) Start the generator. a) Ensure that the battle short switch is in the OFF position. b) Push in the DC control circuit breaker button. c) Flip start/run/stop switch to run. d) Flip battle short switch on. e) Test fault indicator light. f) Flip battle short switch off.

g) Check air cleaner, circuit breaker, and battle short indicator lights. h) Push the circuit breaker switch down to the OPEN position. i) Rotate the voltage adjustment knob to the extreme left.

CAUTION: Do not crank engine in excess of 15 seconds. Allow the starter assembly to cool at least 15 seconds between cranking. j) Hold the start-run-stop switch in the START position until the engine oil pressure reads 30 psi.

k) Release the start-run-stop switch to the RUN position. l) Ensure the volts-amp transfer switch is in the L3-L1 position.

m) Adjust the engine speed adjustment knob so that a frequency of 60 Hz is indicated on the frequency meter. n) Rotate the voltage adjustment knob until 208 volts AC is indicated on the AC voltmeter. o) Manually close circuit breaker. NOTE: If any of the indicator lights illuminate, press the TEST or RESET switch. If the lamp continues to illuminate, stop the generator and notify organizational maintenance. p) Observe the engine and generator instruments for normal indications according to the appropriate technical manual.

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NOTE: Frequency adjust gage may decrease; to increase voltage, adjust manual speed control knob. 2) Operate the generator. a) Observe engine for normal indications. b) Observe generator instruments for normal indications. c) Refuel and add oil to generator as required; annotate on DA Form 2404. 3) Shut down the generator. a) Set the generator circuit breaker switch on the generator control panel to OPEN. b) Allow the generator set to operate approximately three minutes with no load applied. Decrease engine speed to idle. c) Set the START-RUN-STOP switch to STOP. d) Pull out the DC control circuit breaker button. NOTE: If an emergency shutdown is required, pull out the DC control circuit breaker button. o. Set up the 600-GPH ROWPU (C03). Install the ROWPU, tanks, and pumps. 1) Position the ROWPU trailer on the pre-selected site. a) Choose a site as nearly level as possible; clear site of rocks and vegetation. Be sure surface is firm enough to support the trailer-mounted ROWPU. b) Maneuver trailer into position with towing vehicle. Be sure all sides of trailer and all fittings and controls for the ROWPU are easily accessible. 2) Disconnect the trailer from the prime mover. a) Drop all four leveling jacks to vertical position, pull jacks out and away from trailer, and rotate jack down to vertical position. b) Disconnect electrical connector from towing vehicle. Stow connector in stowage clip on trailer drawbar. c) Release the pintle. d) Remove the safety pin and crank handle from the rear of the jack support bracket. e) Position the crank handle on the jack and turn the handle clockwise to the lower jack pad. Continue to lower both of the

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front jacks until the weight of the trailer rests on the jacks instead of on the towing vehicle, and the lunette is clear of pintle. f) Replace the crank handle on the rear of the jack support bracket and install the safety pin.

g) Disconnect the air hoses from the towing vehicle. The parking brakes are now set. Stow air hoses on the dummy couplings provided on the trailer drawbar. h) Disconnect the trailer safety chain from the towing vehicle. Place the trailer safety chain in the stowed position on the trailer drawbar. i) Ensure the ROWPU is level. Level the ROWPU by standing approximately 5 feet from the unit and visually inspecting the unit for levelness. If the unit is not level by visual inspection, use the four leveling jacks to level the unit.

NOTE: If sloping is a problem and the ROWPU cannot be leveled, site improvements must be implemented. If capabilities for site improvement are unavailable, the water point noncommissioned officer in charge (NCOIC) must determine if the water point should be moved to a site that is satisfactory for operation. j) Unload All Equipment from the ROWPU Trailer. (1) Roll the canvas cover up and over the ROWPU frame and fasten it with tie-back straps. (1) Roll the canvas cover up and over the ROWPU frame and fasten it with tie-back straps. (2) Remove the two-frame cross-braces. Store them on top of the ROWPU canvas. Release the cargo straps by loosing the saw tooth (ratchet) holders. Unsnap the hooks on the bottom of the straps. Roll up the cargo straps and put them on top of the ROWPU canvas. (3) Remove from the ROWPU the float, chemical pails, brine tank, two product water tanks, tank ground cloths, and covers. Also remove the paddle, sledge hammer, hard rubber hoses, canvas hoses, and storage boxes No. 2 and 3 (remove, but do not unpack). (4) Inspect the storage boxes to ensure they contain all items. (5) Release the hold down straps over the two raw water pumps. Remove canvas covers. Lift both of the raw water pumps off the ROWPU. (6) Release the straps over the backwash pump and remove the cover. (7) Remove the backwash pump from the ROWPU.

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(8) The distribution pump is fastened to the rear platform of the ROWPU trailer. It is packaged for two men to carry (portable). Release the hold down straps, remove the ladder and canvas cover, and then remove the distribution pump from trailer. 3) Set up the product water storage tanks on the pre-selected site. a) Assemble each onion tank on a pre-selected site. b) Place tanks on ground cloth. 4) Set up the brine/backwash tank and the raw water pumps on the pre-selected site. a) Position the pumps on a pre-selected site. b) Place the raw water pumps and distribution pump in place (use two students to lift these pumps). c) Place the backwash pump, and attach the strainer to the discharge side (use four students to lift this pump). p. Operate the 600-GPH ROWPU (C04). 1) Turn Off the Emergency Stop Button. Push in emergency stop button if any of the following conditions exist to avoid injuries to personnel or damage to the ROWPU if it is allowed to run. a) The blue high-pressure lamp associated with the RO pump comes on but the RO pump does not automatically stop. b) The blue low-pressure lamp associated with RO pump comes on but RO pump does not automatically stop. c) Some other serious trouble or malfunctions are indicated by noise, vibration, and large water leaks. 2) Reverse Osmosis Element Cleaning Method. It will be necessary to clean the RO elements to improve TDS rejection and reduce operating pressure.There are two methods for cleaning the elements. One method, used most often on saltwater operation, is to feed citric acid solution through the vessels. The second method, used most often on freshwater operation, circulates Triton X-100 soapy cleaning solution through the vessels. a) If any of the following conditions exist, the RO elements must be cleaned: (1) Whenever the pressure shown on the RO pressure indicator rises to above 960 psi for seawater or 500 psi for freshwater. (2) When the product water output drops several gallons per minute on the product water flow indicator with no change in the raw water temperature.

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(3) When brine flow increases noticeably, and the adjustment of the regulate product flow valve does not correct the brine flow indication. (4) When the RO vessels pressure increase by 20 percent over the initial reading. b) If any of the above conditions exist, perform the following procedures for the citric acid method: (1) Backwash the multimedia filter before doing an RO element cleaning. (2) Adjust the brine water level in the brine tank to 7 inches. You may have to drain water from the tank or operate the ROWPU normally until you obtain 7 inches. (3) Check for a 7-inch brine water level with telescoping aluminum mixing paddle. Paddle has a 7-inch mark for checking the brine depth. (4) Remove the backwash hose from the outlet on the discharge side of the backwash pump and connect vent vessels hose to outlet of the backwash pump. (5) Add 1 pound of citric acid to water (for a 1500-gallon tank) in the backwash water tank and mix with an aluminum mixing paddle for one minute. (6) Check to see that the valve on the bottom of the backwash water tank is fully open. (7) Remove the product water hose from the product water tank and allow the hose from the ROWPU to drain on the ground. Leave the brine water hose in the backwash water tank. (8) Start element cleaning. Push the element cleaning switch up to the start position. Release the switch. The switch automatically goes to the run position. The backwash starts. (9) Ensure that the brine flow indicator shows a flow of 16 GPM or more. (10) Allow the citric acid solution to circulate for 45 minutes. NOTE: The temperature of the solution will rise during element cleaning. At no time should it exceed 120 degrees. Check the temperature of the water at the end of the brine line as it enters the brine tank. If the temperature exceeds 120 degrees, stop re-circulating the citric acid solution. After the element cleaning, the system will rinse for 5 minutes during normal operation. CAUTION: A pH below 3.5 will damage the RO elements. Constantly monitor the pH level of the water re-

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circulating out of the brine line as it enters the brine tank. The pH during element cleaning should read 3.5; if not, add 1 pound of citric acid to the brine tank every five minutes. Stir solution until the pH reaches 3.5. Add more water to the brine tank if the pH should fall below 3.5 to raise the pH level. (11) Stop re-circulation by pushing the element cleaning switch down to off. (12) Remove the vent vessels hose from the outlet of the backwash pump and connect the backwash water hose to the backwash pump outlet. (13) Drain the citric acid solution into a shallow man-made lagoon a reasonable distance away from the unit or sanitary drain system. Close the valve after the discharge of brine water tank. NOTE: Ensure that you do not place the product water line and brine line in the tanks at this time. (14) Allow the ROWPU to operate for 10 minutes with the regulate product flow valve fully open to rinse the RO pressure vessels. (15) Adjust the regulate product flow valve until the product water flow gage reads under 16 GPM on freshwater or 12 on seawater, and RO pressure psi reads under 500 for freshwater or 960 for seawater.

(16) Allow the ROWPU to run 3 minutes, and check product water TDS. After obtaining TDS level under 1000, place product water line back into product water tank, above water level, and place brine line back into the brine water tank. c) During freshwater operations, Triton X Detergent is the best method for cleaning the elements because of suspended matter found in freshwater sources. When the Triton X Detergent method is used, perform the same procedures for citric acid method with the following exceptions: (1) Instead of subparagraph b)(5) above for citric acid, use 800 milliliters of surfactant (Triton X detergent) for a 1500gallon tank and 2160 milliliters for a 3000-gallon tank if used. (2) Instead of subparagraph b)(14) above for rinsing, continue to rinse the elements until you can no longer see suds in the rinse water. q. Shut down the 600-GPH ROWPU (C05). 1) Perform after-operations PMCS.

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a) Inspect the general appearance of the unit, paying particular attention to the words on identification markings and the condition of the paint. Inspect for rust, especially on weldments. b) Inspect tools and toolbox. (1) Good shape. (2) Clean. (3) All there. (4) In proper place. (5) Box mounts solid. (6) Box closes properly. c) Check vent and drain lines/connections. (1) Solid. (2) Any damage. (3) No obstructions. d) Frame and equipment. (1) Remove oil, grease, mud, chemical spills, and other matter from all parts of the ROWPU. Use clean cloths. (2) Wash the floor with product water. e) Multimedia filter. (1) Inspect for leaky gaskets and loose mountings. (2) Notify organizational maintenance if you find trouble. (3) Check multimedia gage readings. Should read within 5 psid of initial log reading, and in no case should exceed 10 psid. f) Gages and flow indicators. (1) Inspect for broken glass. (2) Look for loose mountings and tube connections. g) Frames: ROWPU backwash pump, distribution pump, raw water pumps. (1) Inspect for damaged or bent frames, loose mounting bolts, and missing or broken tie downs and frame pins.

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(2) Inspect cross members and beams for cracks and breaks. (3) Tighten loose mounting bolts. (4) Report breaks, misfits, cracks, damaged framework, or missing hardware to organizational maintenance. h) Hoses, tanks, piping, tubing, fittings, strainers, and nozzle. (1) Inspect for leaks. (2) Look for hose or pipe blockages. (3) Are parts cracked or broken. i) Chemical feed equipment: containers/rack, plastic pails, tubes, and strainers. (1) Inspect containers/rack, pails and tubes for cuts, cracks or holes. (2) Inspect strainer for clogging. (3) Clean containers/rack, pails, tubes, and strainers. j) Chemical feed pump. (1) Inspect for loose mounting nuts. (2) Inspect for cracked or broken fitting. (3) Add oil as necessary. 2) For normal shutdown, use the following order of shutdown steps to prevent damage to the ROWPU: a) Place chemical feed pump valves to prime position. Set chemical feed control knobs to 8.5. b) Open the regulate product flow valve. c) Open the vent product water valve. CAUTION: After opening the regulate product flow valve fully, wait 5 minutes before opening vent vessels valve. d) Open the vent vessels valve. e) Open the three vent valves on the control panel. (1) Open the vent cartridge filter valve. (2) Open the vent pulse dampener valve. (3) Open the vent multimedia filter valve.

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f) Stop the RO pump. g) Stop the booster pump. h) Stop the chemical feed pump. i) Stop the raw water pump Number 2. j) Stop the raw water pump Number 1. 3) If the shutdown is due to preparation for movement, then backwash the multimedia filter next. 4) When the ROWPU is shut down while operating during cold weather, remove the RO elements. Store the elements inside sealed bags in a tent where the temperature is above freezing. Ensure that all water is drained from the ROWPU according to the appropriate technical manual. r. Dismantle the 600-GPH ROWPU (C06). 1) Backwash ROWPU multimedia filter, and clean the RO elements. 2) Shut off ROWPU for normal shut down. 3) Drain ROWPU pipes, filters, and connections. a) Open the seven drain valves. b) Open the five vent valves. 4) Drain the RO pump after water stops flowing out of the drains. a) Set the RO pump jog switch to jog. Hold it there for three to five seconds to force the water from the pump. Repeat the operation of the RO pump with the jog switch until no more water comes from the drain pulse dampener drain. b) Disconnect the plastic tubing from the bottom of the RO vessels so they can drain. Reconnect the tubing when the vessels are fully drained. c) Disconnect the six plastic connectors holding the plastic lines on the backwash timer on the multimedia filter and allow the lines to drain. After draining the lines, reconnect them to the timer valve assembly. 5) Drain the booster pump. a) Run the booster pump for no more than five seconds and set the switch to stop. b) Repeat this process until no more water comes from the cartridge filter drain.

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6) Drain the chemical feed pumps. The chemicals used for operating the ROWPU can be fatal. The chemicals alone or in a mixture can be dangerous. Always wear protective clothing and make sure the area is well ventilated. a) Empty and rinse all chemical utility containers and fill them with brine water. b) Set chemical pump valves to prime and all control knobs to their maximum settings. Run the pump motor to rinse chemical pumps. c) Remove intake hoses from all chemical containers and allow the pump to run for five to ten seconds to empty the water from the chemical pumps. d) Stop the pump motor and empty the chemical containers. e) Set the chemical pump valves to the off position and remove all hoses from the pump and drain each hose. 7) Drain product water tanks and pump. a) Start the distribution pump and run it until all water is drained from both product water tanks. b) Shut off the distribution pump and roll up the electrical cord onto the holder on the pump. Do not disconnect the cord from the ROWPU. 8) Drain the backwash water tank and backwash pump. a) Start and run the backwash pump by using the element cleaning switch. Run the backwash pump until all the water is drained from the brine water tank. Do not use the start backwash switch because the unit will go into the automatic backwash cycle. b) Close the backwash water tank shutoff valve and disconnect the backwash suction hose at the backwash pump. c) Unscrew the drain plug on the bottom of the backwash pump. Drain the pump and the backwash strainer. Disconnect the strainer and strap the backwash strainer to the pump frame. d) Replace the drain plug on the pump, roll up the electrical cord, and place it into the holder on the pump. Do not disconnect the cord from the ROWPU. 9) Drain raw water pumps Numbers 1 and 2 and the distribution pump. a) Open the pump vent valves and the drain valves on all pumps. b) Run the pumps until all the water is out and shut off the pumps.

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c) Disconnect the hoses, strainer, and float. d) Disconnect and roll up the electrical cords on the pumps. 10) Shut off the generator unit according to proper procedures. 11) Prepare hoses, pumps, and tanks for movement. a) Disconnect all hoses from the ROWPU panel and install caps on the panel hose connections. b) Remove the hoses from the pumps and separate hoses. c) Remove all hose adapters and the distribution nozzle. Put adapters and nozzle into the storage box. d) Roll all rubber hoses and connect the ends. e) Drain and roll the canvas hoses. Start with the male end to avoid damage to the threads. f) Put caps on all the openings of the portable pumps.

g) Remove the covers from all the water storage tanks. Fold the covers. Take apart all three of the water storage tanks, remove the valve from the backwash tank, and cover the tank openings. If any water remains in the tanks, tip the tanks and drain the water. Dry the tanks before folding. Fold up the tanks and ground cloths. h) Disconnect the grounding cable from the units grounding stud and from the clamp on the grounding rod. Pull out the grounding rods with a slide hammer, unscrew the rod into its three sections, and store them on the ROWPU control panel. i) Disconnect the two input lines from the TDS monitor on the control panel and replace the cover caps. Remove the safety key and slide monitor from left to right and place in-line with the TDS monitor in the proper storage box.

12) Refer to the loading plan attached to each storage box lid and pack accessories as indicated. 13) Install pumps, storage boxes, pails, hoses, sledge hammer, aluminum paddle, and tanks on the ROWPU. s. Operate the 60-kiloWatt generator (D01). 1) Starting the 60-kW generator. a) Crank engine by placing START-RUN-STOP switch in the start position. CAUTION: Do not crank more than 15 seconds at a time. Allow at least 15 seconds to elapse between crankings.

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b) When air temperature is below plus 40 degrees Fahrenheit, engine ether primer may be required. To use ether primer, momentarily place engine primer switch in the ON position and release while cranking the engine. Each time the switch is cycled, one metered shot of ether is injected into engine air intake system. c) After engine starts, continue to hold START-RUN-STOP switch in start position until oil pressure gage reading is above 20 psi and main generator voltage is normal. AC voltmeter should indicate 208/416 volts if amps-volts selector switch is set at L1L2, L2-L3, or L1-L3. d) Position voltage adjust rheostat as required to obtain proper voltage output (440 VAC). e) Adjust manual throttle control to obtain 60 Hz on frequency meter. f) Allow engine to warm up to normal operating temperature (100 degrees Fahrenheit to 150 degrees Fahrenheit) with no load applied.

CAUTION: To prevent engine carbon deposits, do not run enginegenerator sets for more than five minutes at governed speed without load. g) Reset fault indicator lights by pressing test or reset switch. If fault indicators are extinguished after being reset, proceed with step h. If any fault indicator lights up, the indicated fault must be corrected before proceeding. h) Close main AC contactor by momentarily placing CKT BKR switch in CLOSE position. Momentarily placing CKT BKR switch in OPEN position will open the AC contactor. 2) Operating the 60-kW generator. a) Observe engine for normal indications. b) Observe generator instruments for normal indications. c) Refuel and add oil to generator as required; annotate on DA Form 2404. 3) Shutting down the 60-kW generator. a) Open main AC contactor by momentarily placing CKT BKR switch in OPEN position. b) Allow three minutes to elapse after performing step a, and place START-RUN-STOP switch in STOP position. c) After engine stops, remove DC control power by opening DC CONTROL CIRCUIT BREAKER.

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t.

Set up the 3,000-GPH ROWPU (D03). 1) Preparation for Use. a) As you position the trailer, the raw water source must be to the right of the truck cab. Move the trailer into a position at the work site which will allow the front end to be slightly lower than the rear for water drainage. Position the trailer so that there is no more than a 2 percent side-to-side grade. b) Place wheel chocks under the wheels to prevent trailer movement. c) Place load boards under the landing gear. Lower the loading gear and unhook the trailer from the tractor. d) Using the bubble level mounted on the ROWPU, adjust the landing gear so that the front of the trailer is 1/2 bubble lower than the back of the trailer. 2) Deploy the raw water intake system. a) Use the shoulder straps to pull the raw water pump into place. Make sure pump location is within limits and upstream of cyclone separator if water source is a river or has prevailing flow. b) Carry intake strainer, raw water suction hose sections, anchor tie down rope, and anchor to raw water pump location. WARNING: Never use potable water hoses to handle raw water or raw water hoses to handle potable water. Mixing hoses could cause contamination of water resulting in serious illness. Hoses are labeled.

NOTE: Two people will be required to deploy intake strainer. Work as near to the shore line as possible. c) Attach the snap to the anchor eye and double back so that rope length from anchor to free ends is at least 100 ft. NOTE: Inspect hose ends and gaskets before connecting hose sections. Replace damaged gaskets. d) Connect lengths of suction hose required to reach intake point. Attach one end of hose to intake strainer. Keep sand and dirt out of connectors. Be sure gaskets are in place, and connectors are tight. e) Tightly cap raw water pump end of hose so air is trapped inside hose. f) Snap the end of the rope to intake strainer eye and tie the free end to the suction hose.

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g) Carefully coil rope to prevent tangling when anchor is deployed. h) Deploy anchor. i) Untie the free end of the rope from the suction hose. One crew member pulls free end of rope as another feeds out intake strainer and suction hose into water. When intake strainer is in desired position, uncap last hose. Hose will sink. Tie free end of anchor rope to raw water pump frame to secure the anchor.

j)

k) Connect or disconnect remaining suction hose sections as required to obtain proper length. Connect raw water suction hose to raw water pump. l) Install pump tee to raw water pump discharge.

m) Connect raw water pump discharge hoses to the pump tee and lay out to location selected for the separators. n) Uncoil and connect electrical cable sections from raw water pump to raw water pump power outlet. o) Set up the cyclone separator. NOTE: Show VGT 05. u. Operate the 3,000-GPH ROWPU (D04). 1) First Start-Up or Start-Up from secured or drained condition. a) Initial Polyelectrolyte Set-Up. NOTE: Polyelectrolyte is not used in low turbidity which contains moderate to high color. Make sure the speed controls on all three chemical injection pumps are in the off position. The polyelectrolyte tank and chemical bottles are identified by a triangle symbol. b) Establishing Water Flow. c) Chemical System Final Set-Up. d) Direct Potable Water to Storage. NOTE: During first start-up with new RO elements continue to direct the product water to waste for at least 30 minutes to flush out preservative. e) Clean/Flush Tank Set-Up. f) Hypochlorite Pump Adjustment. When storage tanks have at least 1 ft of water, check chlorine level in product water.

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g) Polyelectrolyte Optimization. After the first hour of operation, if polyelectrolyte is being used, adjust polyelectrolyte, as soon as other set-up tasks are complete. CAUTION: It is essential that the amount of polyelectrolyte be optimized to provide the lowest turbidity with the least amount of polyelectrolyte. Failure to carry out this procedure will result in insufficient filtration and rapid accumulation of dirt on the RO elements. This dirt (fouling) will decrease the amount of product water produced or will lead to early failure of the RO elements, and failure to complete the assigned mission. h) Enter Data Log information for start-up. i) Once Polyelectrolyte in feed water and chlorine level in product water are correctly set the ROWPU is fully operational. It will keep on working with very little attention. Only routine tasks, and special jobs indicated by warning lights and the alarm horn, will need to be done. NOTE: During a typical filter run (i.e. time between backwashes) the turbidity will usually continue to decrease with time. On occasion it will increase after some time, indicating that the filter is so loaded with dirt that it can no longer remove dirt efficiently and it requires backwashing. j) If allowed by mission demands, backwash media filter after optimization. 2) Routine Operation. Perform the following services as indicated by the number of operating hours, or by the warning horn and yellow warning lights. a) Backwash media filter. b) Check filter performance and keep optimized if polyelectrolyte is being used. c) Clean basket strainer. NOTE: When basket strainer is blocked or needs cleaning, the basket strainer pressure drop sensor will turn on warning horn and yellow STRAINER PLUGGED light. d) Replace cartridge filter elements. NOTE: When cartridge filters are dirty, the cartridge filter pressure drop sensor will turn on warning horn and yellow CARTRIDGE FILTER PLUGGED light. e) Refill chemical tanks. When a tank reaches low level, the sensor will turn on the warning horn and yellow light. Tank must be refilled within 30 minutes. Routinely observe tank levels to assure steady drop in level relative to tank markings. f) Conduct during operation PMCS as directed.

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g) Conduct routine RO element detergent cleaning procedure every 200 hours when operating on sea water and every 100 hours for other waters. Use the high pressure pump hour meter to monitor hours. h) Complete Data Log. v. Shut down the 3,000-GPH ROWPU (D05). 1) Shut down to Standby when the 3,000-GPH ROWPU is to be shut down for 3 hours or less. a) Fully open system pressure control valve. b) Push HIGH PRESSURE PUMP STOP. c) After the feed flow drops below 60 gpm, push BOOSTER PUMP STOP. d) Push CHEMICAL PUMP STOP. e) Push RAW WATER PUMP STOP. 2) Shut down to Temporary Secured Status the 3,000-GPH ROWPU when the ROWPU is to be shut down for 3 hours to 3 days. a) Backwash Media Filter with product water in the clean/flush tank. NOTE: 525 gallons of potable water will be used in this procedure. Be sure water is available. Before shutdown, be sure that the 5-gallon can is filled with product water to use in the polyelectrolyte tank during the next start-up. (1) Fill clean/flush tank with potable water. (2) Backwash. Do not forward flush the media filter. b) System Flush. Flush with potable water. (1) Make sure MAIN circuit breaker is ON and SYSTEM MODE switch is in SYSTEM ON position. (2) Set OPERATION MODE switch to SYSTEM CLEAN. (3) Push INITIATE. (4) Close feed valve. (5) Open cleaning bypass valve. (6) Close potable water shut-off valve. (7) Open product utility hose valve. (8) Fill clean/flush tank with potable water.

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(9) Flush. (10) Bisulfite sanitizing cleaning. NOTE: Bisulfite sanitizing cleaning is required as part of short term and long term shutdown to secured status to prevent bacterial growth within the RO elements. NOTE: This procedure leaves the RO vessels full of the sodium bisulfite sanitizing solution. Drain only if the ROWPU will be subject to freezing. c) Hypochlorite Flush. When shutdown periods exceed 2 days, clean hypochlorite tank and pump as follows: NOTE: Control panel must be set up in FILTER NORMAL operation for following flush. (1) Water flush. (2) Air purge. d) Secure Equipment. (1) Open all drain valves, EXCEPT THOSE AT THE RO VESSELS. Turn MAIN circuit breaker to OFF, and secure generator. Drain distribution system when appropriate. (2) Operating near or below 32 degrees F (0 degrees C) the winter kit must be used. NOTE: Take special care of the ROWPU in cold weather. Parts of the ROWPU will be damaged if they freeze. (3) If moving, the support items are packed into four separate boxes. e) Perform after-operations PMCS. (1) Log all actions/deficiencies on DA Form 2404. (2) Give form to supervisor at the end of each shift. 3) Shut Down to Long-Term Secured Status when the 3,000-GPH ROWPU is to be shut down for more than 3 days. a) Clean-Up. (1) Use product utility hose to wash down the ROWPU floor with product water while still producing water. (2) Clean-up inside ROWPU as time permits during following period. b) Backwash media filter. Do not forward flush media filter.

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c) Water flush hypochlorite system. NOTE: When water flush is complete, add water as needed to leave 9 gallons in the tank. d) Backwash media filter again with potable water in the clean/flush tank. (1) Fill clean/flush tank with potable water. (2) Backwash media filter. Do not forward flush after backwash. e) Flush piping (seawater and brackish water operation only). f) RO element cleaning. (1) Cleaning procedures when operating with polyelectrolyte. (a) Backwash media filter (do not forward flush). (b) Replace cartridge filters. (c) Preliminary flush. (d) Set-up to clean. (e) Citric acid clean. (f) Flush RO elements two additional times. (g) Heat up to 80 degrees F but not over one hour. (h) Set-up to clean. (i) Detergent clean. (j) Return to normal operation. (2) Cleaning procedures when operating without polyelectrolyte. (a) Backwash media filter. (b) Clean strainer basket. (c) Replace cartridge filter elements. (d) Refill chemical tanks. (e) Data log. (f) Routine RO element cleaning. (3) Continue with bisulfite sanitizing cleaning.

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g) Flush chemical tanks. h) Secure equipment. i) Perform after-operations PMCS. (1) Log all actions/deficiencies on DA Form 2404. (2) Give form to supervisor at the end of each shift. w. Dismantle the 3,000-GPH ROWPU (D06). Pack the system components. Pack the ROWPU in the following order: 1) Place all tools in boxes. 2) Place storage box on accessory table, and set heat lamps on top with cords in between lights. NOTE: Ensure that the strap hooks are properly attached to the floor brackets. Ensure straps are tightened securely. 3) Hook strap #9 in position. 4) Thread strap through handles of box and heat lamps and tighten strap. NOTE: Make sure RO element pusher under table is in its storage position, secured by J-bolts under the accessory table. 5) Hook strap #8 in position. 6) Place storage boxes on accessory table. Set adjustment kit on top of box. 7) Thread strap #8 through handles of boxes and tighten strap. NOTE: Make sure eyewash station is secured by its mounting straps. 8) Place filter boxes in place behind control panel. 9) Place detergent jugs and chemical bottles next to filter boxes behind control panel. 10) Place raw water and distribution pump covers on top of storage box and between storage boxes as shown. 11) Install gate on accessory table. 12) Hook strap #13 in position. 13) Place distribution pump skid upside down on table. 14) Place raw water pump skid right side up on top of distribution pump skid. 15) Coil and store four raw water discharge hoses on skids.

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16) Coil and store six waste out hoses on raw water discharge hoses. 17) Coil and store auxiliary hose on suction hoses. 18) Coil and store cleaning heat-up jumper hose on suction hoses. 19) Coil and store raw water and distribution pump drain hoses on top of auxiliary hose. NOTE: Route strap #13 over hose end of strainer assembly, not over top of strainer. 20) Coil and store two distribution hoses with nozzle on top of suction hoses. 21) Store strainer assembly on top with hose end over cleaning heatup jumper hose. 22) Secure both stacks of hoses with strap #13. 23) Hook strap #10 in position. NOTE: Connect straps to front loop nearest RO elements first. 24) Coil and store the following hoses: a) Ten raw water suction. b) Four product water to storage and one storage tank hose. c) Two distribution pump suction hoses. d) Two raw water pump discharge hoses. e) Two distribution pump suction hoses. f) NBC operating hose 41.50 in.

g) NBC operating hose 71.50 in. 25) Store the following inside hoses: a) Raw water T-pipe. b) Distribution pump discharge pipe. c) Storage tank connection tee. d) Product out adapter pipe. e) Priming pitcher. f) Primer pump assembly.

g) Waste out adapter. h) Separator adapter.

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26) Secure by tightening strap #10. WARNING: Each storage tank weighs 130 lbs. (59 kg). Three people are required to carry each tank. NOTE: Hook strap to front loop nearest actuated valves. 27) Store two storage tanks and hook straps #11 and #12 to foot loop. WARNING: Make sure load hook is attached at or near balance point of any load being moved. Failure to do so could result in violent swinging or dropping of load. This could result in serious injury and damage to equipment. WARNING: Crewmember on ground should stand clear of pump frame to avoid being hurt in event pump falls or is released too quickly. WARNING: Check chains on hoist for link damage or wear regularly. Damaged or worn chains must be replaced immediately to prevent accident. Notify unit maintenance. 28) Disassemble access ladder, distribution side. 29) Hook straps (#11 and #12) in position. 30) Attach chain hoist to eyebolt over distribution side access door and to eyebolt on distribution pump. Using chain hoist, lift the distribution pump into van and position distribution pump with drain pipe facing door. 31) Disconnect chain hoist hook and take down chain hoist from eyebolt and rehook at front door. 32) Using generator ladder, store anchor, anchor rope and stool (upside down) on top of distribution pump. 33) Secure by tightening strap #12. 34) Close and secure door (product side). 35) Put handrail on raw water side of the ISO shelter door into position for movement. 36) Hook strap #####14 in position. 37) Store separators and secure with strap #14. 38) Coil sump drain hoses and store beside control panel. NOTE: If movement is short term and the unit is to be operational, fill the jug with product water. Do not fill if under freezing conditions. 39) Place 5-gallon jug between NBC tank and sump drain hoses.

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40) Store funnel assembly next to 5-gallon jug. 41) Place storage tank along side hoses. 42) Disassemble access ladder. Follow step 28). NOTE: One crewmember must be inside van, two crewmembers outside. 43) Hook straps in position. 44) Store access ladder, separator frame and sandwich in ground rods, ground wire, slip hammer, and ground rod clamp. 45) Secure by tightening strap. Keep pads over corner of ladder and separator frame. 46) Hook two straps (#10) in position. 47) Store electrical cables on top of raw water pump. Keep eyebolt accessible. 48) Hook chain hoist in eyebolt, hoist raw water pump through door and rotate 90 degrees with caution plate facing door. 49) Place storage tank in front of control panel. 50) Secure tank and raw water pump with straps (#10). 51) Store remainder of chain in hoist bag and tie closed. 52) Secure van door. 53) Using generator ladder, store hand rails (2 long ones first then 4 short) and secure with straps. 54) Zip cover closed down past second door strap and secure top two straps. 55) Deflate stable level air bags and secure both 3 in. straps. 56) Connect rope to ladder using snap hook. 57) Hoist ladder and secure rope using snap hook in eyebolt. 58) Secure ladder with strap in cross pattern. 59) Zip cover all the way closed and secure lower strap. x. Set up the 150,000-GPD ROWPU (E02). 1) Site selection. Each of the assemblies must rest on a level, solid surface. The site must allow for easy drainage away from the assemblies.

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2) Deployment. Arrange assemblies. Raw water pump assembly should be located near water source and within 500 ft. of boost pump assembly. y. Operate the 150,000-GPD ROWPU (E03). Perform during-operations PMCS. 1) Raw water pump assembly. a) Hose assemblies. (1) Check all hose connections. (2) Tighten loose quick-disconnect, grooved pipe, couplings, and threaded connections. (3) Check hoses for leaks. If hose leaks, notify your supervisor. (4) Check strainer in raw water pump inlet for dirt and debris. If needed, remove ring and strainer and rinse strainer. (5) Equipment is not ready/available if hose connections are loose or hose leaks. b) Pump. (1) Wipe off any oil, grease, mud, or other foreign matter. (2) Check for cracks, leaks, and loose or missing nuts and bolts. (3) If pump is cracked or leaking, or if nuts or bolts are loose or missing, notify your supervisor. c) Gauges. (1) Check for cracked or broken lenses and proper operation. (2) If lenses are cracked or broken or gauge is inoperable, notify your supervisor. 2) Boost pump assembly. a) Hose assemblies. (1) Check all hose connections. (2) Tighten loose quick-disconnect, grooved pipe coupling, and threaded connections. (3) Check hoses for leaks. If hoses leak, notify your supervisor. b) Pump. (1) Wipe off any oil, grease, mud, or other foreign matter.

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(2) Check for cracks, leaks, and loose or missing nuts and bolts. (3) If pump is cracked or leaking, or if nuts or bolts are loose or missing, notify your supervisor. c) Gauges. (1) Check for cracked or broken lenses and proper operation. (2) If lenses are cracked or broken or gauge is inoperable, notify your supervisor. 3) Pretreatment assembly. a) Hose assemblies. (1) Check all hose connections. (2) Tighten loose quick-disconnect, grooved pipe coupling, and threaded connections. (3) Check hoses for leaks. If hoses leak, notify your supervisor. b) Pipes and tubing. (1) Check pipes and tubing for cleanliness. (2) Wipe off any oil, grease, mud, and other foreign matter. (3) Check for leaks. If pipes or tubing leak, notify your supervisor. c) Chemicals, chemical metering, pump, and tubing. (1) Check empty supply indicator on pump. If indicator is red, replenish coagulant aid or scale inhibitor as required. (2) Verify that pump is operating. (3) Check for leaks or cracks in tubing and tube connections. If needed, tighten connections. (4) If pump is not operating or if tubing leaks, notify your supervisor. d) Flowmeter (FI-1). (1) Check for cracks, leaks, and proper operation. (2) If cracks or leaks are present, or the meter is inoperable, notify your supervisor. e) Control box indicators.

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(1) Check indicator lights for cracked or broken lenses and burnt out bulbs. (2) If lenses are cracked or bulbs burnt out, notify your supervisor. f) Gauges. (1) Check for cracked or broken lenses and proper operation. (2) If lenses are cracked or broken or gauge is inoperable, notify your supervisor. 4) Multimedia filters Hose assemblies. a) Check all hose connections. b) Tighten loose quick-disconnect, grooved pipe coupling, and threaded connections. c) Check hoses for leaks. If hoses leak, notify your supervisor. 5) High pressure pump assembly. a) Hose assemblies. (1) Check all hose connections. (2) Tighten loose quick-disconnect, grooved pipe coupling, and threaded connections. (3) Check hoses for leaks. If hoses leak, notify your supervisor. b) Pump. (1) Wipe off any oil, grease, mud, or other foreign matter. (2) Check for cracks, leaks, and loose or missing nuts and bolts. (3) If pump is cracked or leaking, or if nuts or bolts are loose or missing, notify your supervisor. c) Gauges. (1) Check for cracked or broken lenses and proper operation. (2) If lenses are cracked or broken or gauge is inoperable, notify your supervisor. d) Oil (high pressure pump diesel engine). (1) Check oil level on dipstick. Oil level should be between L and F lines on ENGINE STOPPED side of dipstick.

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(2) Run engine at idle and check oil level on dipstick. Oil level should be between L and F lines on LOW IDLE side of dipstick. If needed, add oil. (3) Equipment is not ready/available if oil level is low. e) Air cleaner service indicator (high pressure pump diesel engine). Check window for red piston. If red piston is visible, service air filter. 6) Reverse osmosis block assembly. a) Hose assemblies. (1) Check all hose connections. (2) Tighten loose quick-disconnect, grooved pipe coupling, and threaded connections. (3) Check hoses for leaks. If hoses leak, notify your supervisor. b) Gauges. (1) Check for cracked or broken lenses and proper operation. (2) If lenses are cracked or broken or gauge is inoperable, notify your supervisor. c) Pressure tubes. (1) Check for damage, leaks, and loose attaching parts. (2) If damage or leaks are present or parts loose, notify your supervisor. 8) Log all actions/deficiencies on DA Form 2404. 9) Give form to supervisor at the end of each shift. z. Shut down the 150,000-GPD ROWPU (E04). 1) Push in high pressure pump engine throttle lock button. Slowly push in throttle until engine runs at low idle. CAUTION: To prevent damage to turbocharger, let engine run for 5 minutes at low idle before shutdown. 2) Run engine at low idle for 5 minutes. Push in KILL START lever to shut down engine. 3) Turn OFF COAGULANT PUMP (P2) and INHIBITOR PUMP (P4). 4) Idle engines for a few minutes. 5) Flip boost pump control switch down. Engine will stop.

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6) Flip raw water pump control switch down. Engine will stop. Shutdown is now completed. aa. Conduct system maintenance on the 150,000-GPD ROWPU (E05). 1) Multimedia filter backwash. When a pressure differential between gauges PI-1 and PI-2 exceeds 35 psi, backwash of the multimedia filters is required. The backwash procedure uses filtered water from two of the filters to backwash the third one. During this procedure, both chemical feed pumps and the high pressure pump are turned off. The raw water and the boost pumps are used as required to establish the flow required. The backwash procedure includes slow backwash, fast backwash, slow backwash again, and finally back to service. The backwash and rinse flow rates are adjusted by valve V-6. The exact amount required depends on the water temperature indicated on TI-1: The cooler the water, the less flow is required; the warmer the water, the higher the flow required. 2) Reverse osmosis membrane cleaning. When the pressure of gauges PI-4 and PI-5 increases/decreases 10 psi over initial readings or pressure differential of 15 psi between PI-4 and PI-5 exists, RO membrane cleaning is required. The following procedure must be performed if the ROWPUs output deteriorates to an unacceptable level because of reduced membrane efficiency. These step-by-step cleaning procedures are performed on an operating system which has been producing potable water. 3) Cartridge filter elements replacement. When the differential pressure between PI-2 and PI-3 exceeds 12 psi, cartridge filter element replacement is required. 4) Reverse osmosis membrane element replacement. When RO membrane cleaning does not improve efficiency of the membranes, replacement is required. The following is the installation of the RO membrane elements. ab. Dismantle the 150,000-GPD ROWPU (E06). 1) Movement of the 150,000-GPD ROWPU depends on prior planning. 2) Perform normal shutdown of the ROWPU. 3) Backwash multimedia filters. 4) Remove control box cable from socket on high pressure pump. Store cable on pretreatment assembly. 5) Remove filler cap and feeder tube from each 55-gallon chemical drum. Store on pretreatment assembly. 6) Install cover caps on each 55-gallon chemical drum. 7) Disconnect any auxiliary fuel tanks.

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8) Disconnect all hoses. 9) Remove cartridge filter elements and discard. Perform cartridge filter replacement. 10) Install all hose connection covers. 11) Clean all external surfaces with warm soapy water and a stiff-bristle brush. Clean control box by wiping with a clean lubricated cloth. Remove any corrosion, and touch up paint as required. CAUTION: Reverse osmosis membrane elements must be packed within a short time after removal to prevent damage from dehydration. Organizational maintenance is responsible for packing elements and must be notified before they are removed from pressure tubes. 12) Prepare RO block assembly for movement by removing RO membrane elements from the pressure tubes. 13) Replace all components into original crates. 14) Maintain reports/logs/forms. ac. Lay out the Tactical Water Distribution System (TWDS) hose line (F02). 1) Ground profile and pump spacing triangle. a) A ground profile (drawn on graph paper) and a pump spacing triangle can be utilized to determine the location of each boost pumping station. Proper construction and use of the ground profile and pump spacing triangle will ensure that the installed TWDS will perform within its optimal range. b) Ground profile construction. To construct a ground profile, first obtain a topographical map or other source material providing accurate information concerning terrain along projected hose line route. Then, using this information, draw a ground profile of the hose line route on graph paper. c) Pump spacing triangle construction. To construct a spacing triangle, obtain a piece of paper, transparent sheet, or cardboard thick enough to be used as a straight edge. Then prepare the pump spacing triangle. d) Determine location of first boost pumping station. Using ground profile graph and pump spacing triangle, determine first boost pumping station as follows: (1) Place pump spacing triangle on ground profile graph. (2) Align vertical side of pump spacing triangle with vertical (elevation) side of ground profile graph. Ensure zero mark of pump spacing triangle is on lead pumping station mark of ground profile graph.

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(3) Ensure horizontal side of spacing triangle is exactly parallel with horizontal base of ground profile graph. Horizontal space on both the pump spacing triangle and ground profile graph should be exactly aligned. NOTE: If level of ground profile is below base of pump spacing triangle, extend pump spacing triangle hypotenuse line until it crosses the ground profile. (4) Mark point at which the hypotenuse (long side of pump spacing triangle) crosses ground profile. This will be the first boost pumping station location. e) Determine location of second boost pumping station. To determine second boost pumping station location, place pump spacing triangle zero mark on the first boost pumping station mark on ground profile graph. Mark point at which pump spacing triangle hypotenuse crosses ground profile. This identifies second boost pumping station location. Locations of successive boost pumping stations are determined using the same procedure. f) Determine location of pressure-reducing valve assembly. (1) After locations of pumping stations have been plotted, check ground profile for any sharp declines in elevation along hose line route. An excessive drop in elevation will significantly increase water pressure as water flows downhill. CAUTION: To prevent damage to TWDS components, do not allow water pressure to exceed 225 psig. (2) If pressure builds to 225 psig, hose line can rupture and equipment failure will result. Therefore, when a sharp elevation drop along hose line route is indicated by the ground profile graph, a pressure-reducing valve assembly must be installed in the hose line. To determine pressurereducing valve assembly location, refer to ground profile graph. 2) Lay and install hose. NOTE: Remove caps or packaging material from ends of hose. a) Remove 6-inch grooved pipe coupling from leading ends of hose assemblies in flaking boxes. b) Connect leading end of hose in flaking box four to trailing end of hose in flaking box three with 6-inch grooved pipe coupling. CAUTION: Install swivel joint after every 1,000 feet of hose line, 2 hose line segments. Failure to install swivel joint every 1,000 feet may result in damage to equipment. NOTE: Newer flaking boxes contain 1,000-foot sections of hose.

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c) Connect swivel joint to leading end of hose in flaking box three with 6-inch grooved pipe coupling. d) Connect trailing end of hose in flaking box two to swivel joint with grooved-end pipe quick disconnect coupling. e) Connect leading end of hose in flaking box two to trailing end of hose in flaking box one with 6-inch grooved pipe coupling. f) Connect swivel joint to trailing end of hose in flaking box four with 6-inch grooved pipe coupling.

g) Connect leading end of hose assembly in flaking box one to pressure relief valve on discharge hose at lead pumping station. Attach leading end of hose with grooved-end pipe quick-disconnect coupling clamp. h) Deploy hose assembly. i) j) Continue to lay hose until hose line in all four boxes has been flaked. Repeat steps a through i (leaving out step g) to connect each truckload of hose line to sections already laid. Be sure to install swivel joints at every 1,000 feet in hose line.

k) Connect hose line to each boost pumping station and storage assembly as those installation sites are reached. l) Retain empty flaking boxes, tailgates, and breakaways for reuse.

ad. Operate the 600-GPM PUMP (F03). 1) Characteristics. The Model 609-A Pumping Assembly is a diesel engine driven centrifugal pump mounted on a two wheel trailer. The trailer has two tail lights that are controlled by the towing vehicle. The trailer is equipped with an inertia-actuated hydraulic brake system. It also has a manually operated park brake for each wheel. Control of each park brake is independent of the other. The trailer has two jacks at the rear and a tongue jack at the front. The jacks prevent the trailer from tipping when disconnected from the towing vehicle. 2) Position and connect the pumping assembly. 3) Manual mode. Before starting Model 609-A, make sure that the pump has been primed. Start, operate, and shut down the pump as follows: a) Perform before-operations PMCS. b) Pull out MODE SWITCH to unlock and set to MANUAL THROTTLE position. c) Turn MANUAL THROTTLE clockwise until it is fully in.

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d) Turn FUEL RACK handle counterclockwise to UNLOCK position. Pull handle fully out and turn clockwise to LOCK position. WARNING: To avoid hearing loss, hearing protection must be worn by personnel standing within 50 feet of operating pumping assembly. CAUTION: To prevent damage to starter, allow 3 minutes between start attempts. NOTE: Engine alarm will sound if engine does not start within 30 seconds after ENGINE SWITCH is set to START position. e) Push ENGINE SWITCH to START position and hold for no more than 30 seconds or until engine starts. When engine starts, release ENGINE SWITCH. Engine will run at idles speed (1,000 revolutions per minute [rpm]). WARNING: If pump fails to take suction, pump can overheat. Overheated pump can cause severe burns. f) Turn MANUAL THROTTLE counterclockwise until pump takes suction, as indicated by pressure reading on PUMP SUCTION gauge or decrease in engine speed as indicated on ENGINE TACHOMETER/HOURMETER. If pump fails to take suction after 3 minutes, shut down engine by setting ENGINE SWITCH to off position. Notify unit maintenance.

CAUTION: Down line pumping assemblies can be damaged if suction pressure falls below 10 pounds per square inch (psi). Any pumping assemblies may be damaged if discharge pressure rises above 150 psi. NOTE: Suction and discharge pressures will vary depending on operating conditions and engine speed. g) Monitor suction pressure on PUMP SUCTION gauge. Also monitor discharge pressure on PUMP DISCHARGE gauge. If suction pressure falls below 10 psi on any down line pumping assemblies or discharge pressure rises above 150 psi on all pumping assemblies, reduce engine speed to regain proper pressure as follows: (1) Turn MANUAL THROTTLE clockwise to decrease engine speed. Decrease engine speed until reading on PUMP SUCTION gauge and reading on PUMP DISCHARGE gauge are within proper pressures. (2) If required, reduce engine speed to idle (1,000 rpm on ENGINE TACHOMETER/HOURMETER) until problem is corrected. h) If required, use MANUAL THROTTLE to control pump output by adjusting engine speed. Pump output is related to

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discharge pressure. Observe PUMP DISCHARGE gauge and use MANUAL THROTTLE to adjust engine speed. Turn MANUAL THROTTLE counterclockwise to increase speed and discharge pressure. Turn it clockwise to decrease speed and discharge pressure. i) Perform during-operations PMCS.

CAUTION: Engine can be damaged if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). NOTE: Engine alarm will sound if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). j) If engine alarm sounds: (1) Check ENGINE COOLANT TEMPERATURE gauge and ENGINE LUBE OIL PRESSURE gauge. If engine temperature or oil pressure is not within proper limits, shut down engine (step 11 below). (2) Reset engine alarm by pushing ENGINE ALARM reset button. (3) Notify unit maintenance. CAUTION: To prevent damage to engine, DO NOT shut down engine suddenly from full-load running. k) To stop engine, turn MANUAL THROTTLE clockwise to fully in position. Let engine idle for 2 or 3 minutes. Push engine switch left to OFF position. Engine will shut down. l) Turn FUEL RACK handle counterclockwise and release.

m) Perform after-operations PMCS. 4) Electric manual mode. Before starting pumping assembly 609-A, make sure that the pump has been primed. Start, operate, and shut down pump as follows: a) Perform before-operations PMCS. b) Turn PRESSURE REGULATOR SWITCH counterclockwise to START position. c) Turn ELECTRIC SPEED CONTROL counterclockwise to IDLE position. d) Pull out MODE SWITCH and set to PRESSURE REGULATOR (NORMAL) position. e) Turn MANUAL THROTTLE clockwise until it is fully in.

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f)

Turn FUEL RACK handle left to UNLOCK position. Push handle fully in and turn right to LOCK position.

WARNING: To avoid hearing loss, hearing protection must be worn by personnel standing within 50 feet of operating pumping assembly. CAUTION: To prevent damage to starter, allow 3 minutes between start attempts. NOTE: Engine alarm will sound if engine does not start within 30 seconds after ENGINE SWITCH is set to START position. g) Push ENGINE SWITCH right to START position and hold for no more than 30 seconds or until engine starts. When engine starts, release ENGINE SWITCH. Engine will run at idle speed (1,000 rpm). h) Turn MANUAL THROTTLE counterclockwise until it is fully out. i) Set PRESSURE REGULATOR SWITCH to ELECTRIC position.

WARNING: If pump fails to take suction, pump can overheat. Overheated pump can cause severe burns. j) Turn ELECTRIC SPEED CONTROL clockwise until pump takes suction, as indicated by pressure reading on PUMP SUCTION gauge or decrease in engine speed as indicated on ENGINE TACHOMETER/HOURMETER. If pump fails to take suction after 3 minutes, shut down engine (step 15). Notify unit maintenance.

CAUTION: Down line pumping assemblies can be damaged if suction pressure falls below 10 psi. Any pumping assembly may be damaged if discharge pressure rises above 150 psi. NOTE: Suction and discharge pressures will vary depending on operating conditions and engine speed. k) Monitor suction pressure on PUMP SUCTION gauge. Also, monitor discharge pressure on PUMP DISCHARGE gauge. If suction pressure falls below 10 psi or discharge pressure rises above 150 psi, reduce engine speed to regain proper pressure as follows: (1) Turn ELECTRIC SPEED CONTROL counterclockwise to decrease engine speed. Decrease engine speed until reading on PUMP SUCTION gauge or reading on PUMP DISCHARGE gauge are within proper pressures. (2) If required, reduce engine speed to idle (1,000 rpm on ENGINE TACHOMETER/HOURMETER) until problem is corrected.

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l)

If required, use ELECTRIC SPEED CONTROL to control pump output by adjusting engine speed. Pump output is related to discharge pressure. Observe PUMP DISCHARGE gauge and use ELECTRIC SPEED CONTROL to adjust engine speed. Turn ELECTRIC SPEED CONTROL clockwise to increase speed and discharge pressure. Turn ELECTRIC SPEED CONTROL counterclockwise to decrease speed and discharge pressure.

m) Perform during-operations PMCS. CAUTION: Engine can be damaged if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). NOTE: Engine alarm will sound if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). n) If engine alarm sounds: (1) Check ENGINE COOLANT TEMPERATURE gauge and ENGINE LUBE OIL PRESSURE gauge. If engine temperature or oil pressure is not within proper limits, shut down engine (step 15 below). (2) Reset engine alarm by pushing ENGINE ALARM reset button. (3) Notify unit maintenance. CAUTION: To prevent damage to engine, DO NOT shut down engine suddenly from full-load running. o) To stop engine, turn ELECTRIC SPEED CONTROL counterclockwise to idle position. Let engine idle for 2 or 3 minutes. Push ENGINE SWITCH to OFF position. Engine will shut down. p) Turn FUEL RACK handle counterclockwise and release. q) Perform after-operations PMCS. 5) Electric automatic mode. Start, operate, and shut down Model 609-A as follows: CAUTION: During startup, all pumping assemblies should be operated in manual or electric manual modes. a) Perform before-operations PMCS. b) Turn PRESSURE REGULATOR SWITCH counterclockwise to START position. c) Turn ELECTRIC SPEED CONTROL counterclockwise to IDLE position.

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d) Pull out MODE SWITCH and set to PRESSURE REGULATOR (NORMAL) position. e) Turn MANUAL THROTTLE clockwise until it is fully in. f) Turn FUEL RACK handle left to UNLOCK position. Push handle fully in and turn right to LOCK position.

WARNING: To avoid hearing loss, hearing protection must be worn by personnel standing within 50 feet of operating pumping assembly. CAUTION: To prevent damage to starter, allow 3 minutes between start attempts. NOTE: Engine alarm will sound if engine does not start within 30 seconds after ENGINE SWITCH is set to START position. g) Push ENGINE SWITCH right to START position and hold for no more than 30 seconds or until engine starts. When engine starts, release ENGINE SWITCH. Engine will run at idle speed (1,000 rpm). h) Turn MANUAL THROTTLE counterclockwise until it is fully out. i) Set PRESSURE REGULATOR SWITCH to ELECTRIC position.

WARNING: If pump fails to take suction, pump can overheat. Overheated pump can cause severe burns. j) Turn ELECTRIC SPEED CONTROL clockwise until pump takes suction, as indicated by pressure reading on PUMP SUCTION gauge or decrease in engine speed as indicated on ENGINE TACHOMETER/HOURMETER. If pump fails to take suction after 3 minutes, shut down engine (step 14). Notify unit maintenance.

k) Turn PRESSURE REGULATOR SWITCH clockwise to AUTO position. Engine speed is now automatically controlled by the pressure regulator. The pressure regulator provides 150 psi discharge pressure at suction pressures of 20 to 120 psi. l) Perform during-operations PMCS.

CAUTION: Engine can be damaged if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). NOTE: Engine alarm will sound if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). m) If engine alarm sounds: (1) Check ENGINE COOLANT TEMPERATURE gauge and ENGINE LUBE OIL PRESSURE gauge. If engine

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temperature or oil pressure is not within proper limits, shut down engine (step 14). (2) Reset engine alarm by pushing ENGINE ALARM reset button. (3) Notify unit maintenance. CAUTION: To prevent damage to engine, DO NOT shut down engine suddenly from full-load running. n) To stop engine, turn ELECTRIC SPEED CONTROL counterclockwise to idle position. Let engine idle for 2 or 3 minutes. Push ENGINE SWITCH to OFF position. Engine will shut down. o) Perform after-operations PMCS. NOTE: Show VGT 06. ae. Operate the Tactical Water Distribution System (TWDS) hose line (F04). CAUTION: Do not attempt to operate other pumping stations when one unit fails. The bypass hose assembly is used only to keep down line pumps primed. Enough pressure will not exist to operate down line pump, even at a partial rate. CAUTION: If suction pressure falls below 10 psi or if discharge pressure rises above 150 psi, damage can result to pump. 1) When packing hose line, monitor suction and discharge pressure on pumps. If pressure is too low or too high, IMMEDIATELY shut down pumps. Notify supervisors on hose laying crews and operators at other pumping stations who are packing hose line. Cease operation until problem is corrected. CAUTION: Trapped air can cause hose line to collapse and pressure at down line pumping stations to fall below 10 psi. To prevent damage to pump, take precautions to vent air from hose line. 2) As hose laying crews connect major components, prepare the TWDS for operation by packing hose line. As soon as lead pumping station and first boost pumping station are installed and connected by hose line, perform the following steps: a) Turn petcock on boost pump discharge elbow to the left, until fully opened. This will allow air trapped inside the hose line to be vented as water column moves forward. b) Notify operator(s) on lead pumping station to begin pump operations. c) Observe hose line for visual indications of approaching water. Listen for air escaping from petcock.

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d) Close petcock on discharge elbow when water begins to flow out of petcock. e) Notify operator(s) on lead pumping station to shut down pump operation. f) Close butterfly valve on boost pump discharge hose to contain water.

3) Begin moving water again when next down line station is installed and connected by hose line. Open butterfly valve on boost pump discharge hose and repeat steps a) through f) above. Start up lead pump and first booster pump. When water column reaches second boost pumping station, close petcock on discharge elbow, shut down pumps, and cease operation of system. Close butterfly valve on second boost pump discharge hose to contain water column. 4) Continue packing hose line as each boost pumping station is installed and connected. NOTE: Before storage tanks are filled, or complete operation of system begins, flush hose line of sediment and debris. 5) To protect hose from damage in high winds, do not begin filling storage tanks until hose line is packed. When system is ready for operation, fill the storage tanks. 6) Complete operation of the TWDS can begin as soon as all pumping stations, storage assemblies, and distribution points have been installed and connected. 7) During startup of the complete system, run all pumps in manual or electric mode. After startup, boost pumping stations can be operated in electric automatic mode. However, the lead pump should always be operated in manual mode. 8) When 20,000 gallon pillow tanks are approaching the maximum holding capacity, reduce speed on lead pump to decrease rate of down line water flow. If operating in electric mode, rate of boost pumps should decrease automatically. When 20,000 gallon pillow tanks are filled to maximum capacity (height of tank reached 5-1/2 feet), close 4-inch gate valve on each storage assembly. 9) Operation of distribution points can begin when storage tanks contain enough water to allow a normal discharge rate. Pumping rates during operation will vary, depending on amount of water being discharged at either distribution points, large storage and distribution units, or both. Pumping stations operate at intervals long enough to refill 20,000 gallon pillow tanks if discharge rate is minimal. When water is pumped on a continual basis and boost pumping stations are operating in electric automatic mode, perform during-operation PMCS on trailer mounted pump assemblies at a minimum of every three hours.

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10) During all phases of operation, operators at pumping stations and storage assemblies must be in communication with each other. Any unusual situations or difficulties must be reported immediately. a) Since pumps are operated in manual or electric manual modes during startup, operators must monitor suction and discharge pressure and take corrective action immediately. b) Storage assembly operators should report beginning and completion of tank filling operations. c) Operators at lead pumping station should track status of advancing water column during packing operation. During startup they should monitor overall performance of system. d) Once operation of complete system begins, operators on each pumping station must continue to monitor suction and discharge pressures. They must report low suction pressure or high discharge pressure and take corrective action immediately. af. Shut down the Tactical Water Distribution System (TWDS) hose line (F05). 1) Maintaining reports/logs/forms. a) Record all operations data, such as chemical dosages and pressure and flow gage readings on DA Form 1714-R. b) Complete DD Form 1970. c) Give reports/logs/forms to supervisor at the end of each shift. 2) Shut down pumps. If boost pumps are operated in manual or electric manual mode, monitor pressure at suction ports. Allow the first boost pump to operate until the suction pressure falls to 20 psi. At that time, manually decrease engine speed. When suction pressure reaches 10 psi, shut down pump. Isolate the pump assembly from the hose line by opening the butterfly valve on the bypass system and closing the butterfly valves on the suction and discharge hoses. Repeat procedure with each down line pump. ag. Dismantle the Tactical Water Distribution System (TWDS) hose line (F06). 1) Preparing TWDS for movement requires the following: a) Removing water from system. b) Shutting down and disassembling major components. c) Repacking major components. 2) Remove water at lead pumping station first, then move down the line to the last boost pumping station. After hose line water has

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been removed, empty storage tanks and begin to disassemble major components. 3) To begin emptying hose line, shut down lead pump. Close butterfly valves on suction and discharge ports of lead pump. Run boost pump stations in manual mode until suction pressure drops to 10 psi. Shut down boost pumping stations. CAUTION: Do not operate 600-GPM pumping assemblies below 10 psi. Damage to 600-GPM pumping assemblies may result if they are operated below 10 psi. 4) Close butterfly valves on suction and discharge ports of boost pumping stations. 5) Once all pumping stations have been shut down and isolated from hose line, use 125-GPM pumping assembly to drain storage tanks. Empty solution from reservoirs on hypochlorination units. Temporarily leave units in operation to flush parts with untreated water. After flushing for 10 minutes, disconnect hypochlorination units and continue to empty storage tanks. 6) Pumping stations can be disassembled when they are shut down. Distribution points can be partially disassembled while storage tanks are being drained, and completely disassembled when tanks are empty. Storage assemblies can be disassembled when tanks are collapsed. 7) Begin hose line shutdown at the first 500-foot length and move down the line. Move air compressor down two hose lengths. Evacuate trailing hose, then load hose length to minimize number of times air compressor is to be moved. When a hose line length has been evacuated, collapsed, and capped, it is ready for packing in a flaking box. Personnel repacking hose line segments can follow behind those evacuating and collapsing hose line. Suspension devices, road crossing guards, and the pressurereducing valve assembly that were placed along hose line route are removed when crews reach installation sites. 8) The pumping stations, storage assemblies, and distribution points can be repacked in any sequence. Pack the 10-mile hose line segment crate, containing kits required to repack the hose line, last. 9) Pack all components for the six pumping stations in one crate, except for trailer-mounted pump assemblies. Collect pumping station components and packing materials at a single site before repacking crate. Otherwise, all packing materials must be shuttled to each installation site for packing. 10) Pack all components for the two storage assemblies, except 20,000 gallon pillow tanks, together in one crate. Collect all components for both storage assemblies and all packing materials at a single site before repacking crate.

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11) Pack all components for two distribution points, except 125-GPM pumping assemblies, in one crate. Collect all components for both distribution points at a single site before repacking crate. 12) Pack all components for the 10-mile hose line segment, except for hose line and flaking boxes, in one crate. Collect all 10-mile hose line segment components at a single site before repacking crate. 13) Packing TWDS requires the following general steps: a) Remove lids from crates. As required, remove blocking, bracing, anchoring, packing materials, and fiberboard and plywood boxes stored in each crate. b) Return components to original containers. c) Pack fiberboard boxes in plywood boxes. d) Install blocking, bracing, and anchoring securing contents within each crate as required. e) Install plywood sheathing on top of each crate. Nail down plywood sheathing. f) Roll out polyethylene barrier and position over plywood sheathing on top of each crate.

g) Install cross-sheathing boards on top of each crate. Nail down cross-sheathing boards. 14) After repacking, TWDS is ready for movement to another location. 15) 10-mile hose line disassembly and packing requirements. a) The displacement and evacuation kit and the packing kit will be required to pack hose line segments in flaking boxes. If a forklift is not available, the lifting sling will be required to load, unload, and stack flaking boxes. b) When flaking boxes are returned to packing site, stack them in groups of four. Pack each group in crate marked HOSE ASSEMBLY, 6-INCH, 500-FEET. (Number of groups packed in crates will depend on number of hose line segments used during TWDS operation.) Repack components that were removed for TWDS operation and/or disassembly. ah. Operate the 125-gallon per minute (GPM) pump (F07). 1) 40,000-gallon PWS/DS -- The 125-GPM pump is used to fill the tanks and distribute water to the loading stations. When filling the tank, water flows through inlet valves, then through the 4-inch hoses into the tanks. Close outlet valves during the filling operation. During distribution to the loading stations, close inlet valves and open outlet valves. The water flows from the tank through the pump and then to the hypochlorinator unit, after which distribution is complete to the loading or dispensing station.

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2) FAWPSS The FAWPSS is operated by a 125-GPM centrifugal pump. Six 500-gallon water storage and dispensing drums are attached and replace, two at a time. Quick-disconnect couplings connect the drums to the balance of the system. These drums provide water by the suction of the pump through hoses, valves, and connecting assemblies to four distribution nozzles where the water is manually discharged. The rationale for authorizing six drums is based on two drums being filled while two are being transported and two are being used with the system. 3) TWDS - The 125-GPM pump is also used for this system. 4) Centrifugal - Uses high speed rotating motion and forces water away from the center. 5) Self-contained - The pump and engine are coupled together as one unit. 6) Frame-mounted - For ease of handling. ai. Operate the Potable Water Storage and Distribution System (PWS/DS) (F08). 1) The water distribution system shows configurations for maximum storage and distribution capacities. To increase storage and distribution capacities beyond the capabilities of one system, additional water distribution systems may be connected to the existing system. To reduce storage capability, turn off valves to unwanted storage tanks. 2) The WDS40K system has two 125-GPM pumps and one 350-GPM pump. One 125-GPM pump fills one or two 20,000 gallon tanks by opening valves V1 through V6. The 350-GPM and remaining 125GPM discharges water from the two tanks on demand at the rate determined by the nozzles, discharge hoses or bag filler connections. If discharge demand is less than the capacity of one pump, the remaining pump can be shut down and the associated pump valves closed. The hypochlorination unit mixes a hypochloride solution with the water in the correct proportion to water flow. 3) The fill mode of operation fills the water storage tank and the discharge mode draws water from the water storage tank. The fill mode and discharge mode draws water from the water storage tank. The fill mode and discharge mode can occur at the same time. Each water distribution system has four elements that make up the system: water pumps, water storage tank(s), hypochlorination unit, and a water distribution system consisting of distribution stations. 4) Perform during-operations PMCS. a) Perform chlorine residual tests at 30-minute intervals to ensure that the proper residual is being maintained. Log chlorine residual test results on DA Form 1714-R or DA Form 1714-1-R.

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b) Prepare hypochlorite solution when the level in the reservoir drops within 2 or 3 inches of the bottom. c) Log all actions/deficiencies on DA Form 2404. d) Give form to supervisor at the end of each shift. aj. Operate the Forward Area Water Point Supply System (FAWPSS) (F09). 1) The FAWPSS is used to dispense potable drinking water to troop units in arid regions. 2) FAWPSS components are lightweight and air transportable. They can be delivered by LAPES, parachute airdrop, or sling load delivered by Army utility helicopter. The FAWPSS is also transportable by ocean cargo ship, rail car, standard military 5-ton cargo truck, or a semitrailer. 3) The drums weigh approximately 4,500 pounds full and 300 pounds empty and are shaped like the 250-gallon drum. 4) The FAWPSS is operated by a 125-GPM centrifugal pump. Six 500-gallon water storage and dispensing drums are attached and replaced, two at a time. Quick-disconnect couplings connect the drums to the balance of the system. These drums provide water by the suction of the pump through hoses, valves, and connecting assemblies to four distribution nozzles where the water is manually discharged. 5) Operation of the FAWPSS. a) Prime the pump and start the centrifugal pump engine. b) Check the entire system for leaks, beginning with the 2-inch elbow couplers on the water storage and dispensing drums. c) If you discover a leak, shut off the centrifugal pump engine. d) If the leak is at a quick-disconnect coupling assembly, open and remove the assembly. e) Inspect the hose assembly. f) Check the couplings.

g) If gaskets are damaged or missing, obtain these items from the overpack kit and replace. h) If couplings are damaged, replace the entire assembly with a spare assembly from the overpack kit. If foreign matter is present, thoroughly flush the hose. Refasten the assembly. i) Start the engine of the centrifugal pump, and repeat the above procedure until no leaks are seen.

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j)

Test each of the four distribution nozzles.

k) Check the strainer inside the nozzle. l) Start the centrifugal pump engine, and repeat the procedures described until all distribution nozzles operate at full flow.

m) Assign two workers to fill the FAWPSS which contains 500gallon drums. There are two methods of filling the 500-gallon collapsible drums. n) One method is filling the drums directly from the PWS/DS. The other method is to use the 125-GPM pump that comes with the FAWPSS. o) The position and the tasks of the crew vary with each of these methods. p) If the drums are to be delivered by helicopter to the supported unit, you will need a vehicle to remove the filled drums to the loading point. q) Complete DA Form 1714-R for daily water issues. Give completed form to immediate supervisor at the end of the shift. ak. Operate the Semi-Trailer Mounted Fabric Tank (SMFT) and 5K tanker (F10). 1) Assembly. a) Uncrate the SMFT. When the tank is received in the crate, unload it as near to its point of installation as possible. (1) Remove the rails from the crate top and remove top from crate. (2) Using a lifting device (such as a forklift), grasp the lift straps of the sling and gently lift the tank out of its crate and transport it to its designated point of installation. b) The 5,000 SMFT tank is to be installed on the flatbed of a M872 semitrailer only. The 3,000 tank can be installed on the flatbed of a M872, M871, or M127 semitrailer. (1) Clear the trailer bed of splinters, protruding nails, and other foreign objects that could puncture or chafe the tank. (2) Locate the anchor points and install. Recheck the area for sharp objects. If the surface is rough or jagged, it will be necessary to place plywood or a tarpaulin down for the tank to rest upon. (3) Lay the tie-down straps crosswise to the length of the semitrailer bed at a slight angle. Make sure the belts are centered accurately between the eye bolts. Let a portion of

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the belts lie over the side of the trailer. Care should be taken to ensure that each strap is not twisted and is lying flat. The trailer is now prepared for tank unfolding. (4) Position the tank so that it will unroll toward the front of the semitrailer, and center the tank on the bed so that it will not hang over the sides and will not rub against the truck when the tank is filled. (5) Remove the lift straps, and unroll the tank. (6) Inspect the tank for damage. NOTE: Do not walk unnecessarily on the tank and walk on it only with soft-soled shoes. c) Fill the SMFT. (1) Check to see that the tank is properly installed. The trailer should be level to prevent the tank from rolling. (2) Tighten all bolts in fitting, using a 70-foot pounds torque ( 5 foot pounds) on the 1/2-inch-diameter bolts in the end clamps. (3) Attach the pressure gage to the filler/discharge valve and open the pressure gage valve. NOTE: Before using the tank for the first time or after prolonged storage, flush the tank with a disinfectant/potable water solution. (4) Expel all air from the tank so that the tank lies flat on the bed and then close the pressure gage valve. (5) Purge the air filler hose by opening the valve on the hose near the pump until water comes out and then close the valve. (6) The free ends of the hold-down belts should now be brought over the top of the tank and down the other side through the ratchet take-up mechanism attached to the truck bed. Slide ends of belt 2 feet through slot in ratchet assembly. Fold end back on belt and hold manually until one turn has been taken on roll-up spool. (7) Attach the hose to the tank fill-discharge valve. (8) Open the valve at the water supply. (9) Open the filler/discharge valve on the tank. (10) No pressure will show on the pressure gage until the tank is approximately 2 feet high. Periodically close the tank filler and discharge valve to obtain a precise tank pressure reading. Open the valve after the reading has been taken and resume filling.

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(11) After pressure reading has been taken, open the 4-inch filler/discharge valve on the tank and resume filling to 2 to 3 psig. (12) Open the relief valve on the top of the tank until water flows from the valve. (13) The belts may now be tightened with the portable ratchet wrench. Tighten belts to the maximum possible with one hand on the ratchet handle. The second hand should be used to steady the ratchet assembly. Ensure that the ratchet handle has dropped securely into the locking mechanism. When all ratchet assemblies have been tightened uniformly, the pressure in the tank will be increased approximately 1/2 psi. NOTE: If the tank is not properly located on the floor of the trailer with reference to the sides, the tank may be rolled by releasing the ratchet on one side of the tank and then taking up the slack by tightening the opposite ratchet. (14) After filling the tank to correct pressure (4 to 6 psi), shut off filling line valve first, then shut off tank filler/discharge valve. Disconnect filling line. Some loss of water between the valves will be experienced at this point. Material is under pressure between the valves -- low pressure if the filling line valve is shut off first as directed above, and high pressure if the tank valve is shut off first. NOTE: The closed system of filling a tank allows the pressure to build up very rapidly as the tank reaches full capacity. It is recommended that tank containers be filled to final minimum pressure of 4 psi and a maximum of 6 psi. (15) The tank is now properly secured for transportation. Regular periodic check for tight belts is recommended. They should be tightened at least every two hours. Transport tank only when completely full or empty. 2) Emptying of the SMFT. a) Empty by gravity. (1) Empty by means of gravity by raising one end of the trailer, attaching discharge hose to the fill and discharge valve, and opening valve. The discharge hose should be at the lowest level of the tank. Use grade elevation or portable ramps under the appropriate trailer wheels. (2) Connect one end of the 20-feet by 4-feet -diameter hose to the tank filler/discharge valve. (3) Connect the other end of the hose to the line or container requiring the potable water. (4) Close the tank pressure gage valve.

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(5) Open the filler/discharge valve on the tank to start the dispensing of water. (6) After the operation is complete, close the filler/discharge valve at the end of the tank. b) Empty by pump. (1) Attach suction hose from pump to the filler/discharge valve. (2) Open the filler/discharge valve on the tank. (3) Open the filler/discharge valve on suction line and start pump. Slow rate is not important at this time. (4) Pump water from tank until tank is empty. NOTE: Conduct a check on learning and summarize the learning activity.

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SECTION IV.

SUMMARY Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:18 Time of Instruction: 0 hrs 5 mins Media: Group-paced Instruction

Review / Summarize Lesson

NOTE: Show VGT 07. The following key points were discussed within the lesson unit: a. Water Analysis Subjects b. General Water Purification Equipment Subjects c. Operation Of The 600-GPH ROWPU d. Operation Of The 3,000-GPH ROWPU e. Operation Of The 150,000-GPH ROWPU f. TWDS And Distribution Subjects

Check on Learning

Determine if the students have learned the material presented by soliciting student questions and explanations. Ask the students questions and correct misunderstandings. 1. What are five different kinds of water quality analysis tests performed by the Water Treatment Specialist? (pH, chlorine residual, color, temperature, turbidity, TDS, lewisite, nerve agent, cyanide and mustard, and radiological tests.) 2. What are three different designated interval checks for PMCS? (Before-operation, during-operation, after-operation, periodic operator/crew, fault, and deficiency.) 3. What kind of generator is required to operate the 600-GPH ROWPU? (30-kW generator.) 4. What are the three different kinds of shut down for the 3,000-GPH ROWPU? (Shut down to standby, shut down to temporary secured status, and shut down to long term secured status.) 5. What are four system maintenance elements for the 150,000-GPD ROWPU? (Multimedia filter backwash, reverse osmosis membrane cleaning, cartridge filter elements replacement, and reverse osmosis membrane element replacement.) 6. What are the three different modes of operation for the 600-GPM pump? (Manual mode, electric manual mode, and electric automatic mode.)

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SECTION V.

STUDENT EVALUATION NOTE: Describe how the student must demonstrate accomplishment of the TLO standard. Refer student to the Student Evaluation Plan.

Testing Requirements

The student must achieve a score of 70% on the End of Course Exam. The written examination will be administered following a block of instruction and is located in the Instructor Test Package. Refer to the Course Management Plan/Program of Instruction (CMP/POI) for guidance on administering the test. NOTE: Rapid, immediate feedback is essential to effective learning. Schedule and provide feedback on the evaluation and any information to help answer students' questions about the test. Provide remedial training as needed.

Feedback Requirement

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