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The Shutdown Process
Utah's Great Salt Lake West Desert Pumping Project was
shut down June 30, 1989,
after operating successfully for more than two years. A long-term, or
"mothball," shutdown procedure for the Pumping Plant proposed by
Dresser-Rand was accepted by the state. After meeting with representatives of
equipment suppliers, i.e. DresserRand Engine-Process Compressor Division,
Cummins Northwest, Ingersoll-Rand Pump Group, etc., the Dresser-Rand Services
Division implemented the preservation steps. Extensive preservation methods
requires monthly inspections by qualified individuals and periodic internal
inspections of preserved equipment.
The shutdown process took about eight weeks and cost approximately $200,000,
which was within the project's budget. The process included securing the Pumping
Plant; dismantling, preserving and storing tools, systems and control devices;
and inspection and maintenance of the project site.
The following are some of the shutdown procedures for some of the major
components at the Pumping Plant site.
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Pumping Plant Shutdown
- Engines and Pumps - Because the Pumping Plant was to remain in place as
insurance against future flooding around the Great Salt Lake, disassembly or
removal of the three large engines and pumps were not options.
- Control Panel - The circuitries of the Dynalco scanners, Moore SLD
controllers, and Allen-Bradley PLC-4 were removed and stored in the plant. Open
ports of the pneumatic safety shutdown and end devices were plugged, and the
pneumatic circuitry of the engine and control panel are maintained under a
slight positive pressure charge of nitrogen gas. The panel was covered with
plastic to prevent dust contamination and volatile corrosion inhibitor (VCI)
paper was placed inside the engine-mounted wiring junction box.
- Frame and Running Gear- The crankcase, valve train and accessory drive
components of the engines were protected through a combination of procedures.
During the last 30 to 60 minutes of each engine's operation,
a three-phase rust inhibitor was added to the engine oil. After
engines cooled, valve covers, crankcase doors and other access covers were
removed and a solvent-based rust inhibitor was sprayed on all engine internal
components. VC1 capsules were placed in various locations inside each engine to
augment the rust inhibitor protection. Fuel gas injection valves were removed
and solvent-based inhibitor was sprayed into power cylinders, then replaced
against original gaskets. Protective oil was poured into push rod tubes, and
hydraulic lifters were removed, dipped in protective oil, bagged and tagged for
location, and placed in the rocker arm area of the cylinder heads. The valve
stem lubricator reservoir, pumps and tubing were filled with protective oil. In
addition, electric motors for the valve stem lubricator and auxiliary oil pump
were wrapped and covered with plastic to prevent dust contamination. Crankcase
breather piping was also sealed with plastic.
- Lube Oil Piping- The engine oil/rust inhibitor mix was left in the engine
oil sump and piping. A reconfigured pneumatic auxiliary oil pump is periodically
operated with the small air compressor to recirculate the engine oil/inhibitor
mix through the gear reducer.
- Drive Line and Brad-Foote Gear Reducer - Exposed, unpainted portions of
the quill shaft were coated with protectorant, and quill shaft bearings
(pedestal bearings) were drained and refilled with protective oil. During the
last 30 to 60 minutes of the unit's operation, a three-phase rust inhibitor was
added to the gear oil to be carried to all moving parts. Internal components
were sprayed with solvent-based rust inhibitor. The gear oil/rust inhibitor
mixture is to be circulated periodically. A RASKEL pneumatic pump is used for
this task. The brine side of the heat exchanger was washed with fresh water and
allowed to dry.
- Ingersoll-Rand Pumps - The grease distributing tubes of the Farval grease
system were disconnected from the measuring valves and capped, as were the inlet
ports on the valve blocks. The main grease supply lines were also disconnected
at the unit's reversing valve. In addition, the electric motor was wrapped in
paper and plastic, the reversing valve and grease pump were purged of grease and
sealed, and the pump drive gearbox was filled with protective oil. The grease
reservoir and bulk grease transfer pump were cleaned and sealed, the bulk grease pump
motor lubricator was filled with protective oil, and the microprocessor circuitry was
removed and stored in a controlled environment. VC1 paper was placed inside the circuit
boxes.
- Brine Cooling Water System - The brine pump motors were removed and
stored. Brine pump rotating elements and casings were removed, flushed with
fresh water, and stored inside the engine room. Piping also was flushed.
- Fuel Gas Supply Pipeline - The natural gas fuel supply remains connected
to the engine room. Natural gas is used to power a small generator in the
Pumping Plant. Isolated fuel headers on the three engines are under positive
nitrogen gas pressure.
- Air Compressors and Piping - Motors on the air compressors were wrapped
in paper and plastic, and the entire piping circuit, including air receivers,
was isolated from the air compressors. Rust inhibitor was added to the air
compressors' crankcase oil. Air intake filters were removed and inlets were
sealed, and cylinders and valve decks were sprayed with preservative. The piping
circuit for instrument air received similar treatment.
- Siphon Break Valves - Rubber on the butterfly valve was cleaned and
coated with preservative. The actuator assembly was removed and stored in the
engine room. A VCI plug was fitted to each end of the pneumatic cylinder, and
protective oil was added to the linkage box. Handwheel threads were wrapped with
paper and plastic. The siphon break was sealed with reinforced plastic.
- Cummins Gas Engines - VCI paper was placed inside the housings for the
monitor panel and timing shift unit. Protection for the crankcase, valve train
and accessory drive units of the frame and running gear required a combination
of procedures. During the last 30 to 60 minutes that each engine operated,
three-phase rust inhibitor was added to the engine oil. Valve covers and access
covers were then removed and the engine's internal components were sprayed with
solvent-based rust inhibitor. Crankcase breather piping was sealed at the
engine. An actuator was removed and stored. Turbochargers, however, were left on the
engines. The Altronic III ignition units, ignition coils and high and low tension wiring were
removed and stored in a controlled environment. Exhaust piping outlets and air
filter inlets were sealed with reinforced plastic and various other elements
were sealed. The entire cooling system has been maintained under positive
nitrogen pressure.
- Pumping Plant Building - The pump/motor for the building's potable water
system was removed from the underground storage tank and stored in the service
building. The storage tank was drained, tank openings were sealed, pipes were
disconnected, and the tank was filled with nitrogen gas. The indoor pressurized
water tank and Pennwalt hypochlorinator was disconnected from the piping system
and filled with nitrogen gas. All water pipes were drained and blown out with
compressed air. The wastewater system was sealed and the septic tank was pumped.
Roof vents for the wastewater system remain open. Other elements of the building
that were sealed include the HVAC system, safety and emergency lighting systems,
control room electrical enclosures and doors, windows, and ventilating grilles.
Tools and other equipment were either boxed for storage in the building or
removed to other storage areas.
The Pumping Plant is inspected monthly by staff of the Division of Water
Resources and periodic evaluations are made on the condition of engines, pumps
and other equipment at the Pumping Plant site.
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Reactivating the Pumping Plant
In the event the West Desert Pumping Project is reactivated, the startup
process could take between 8-12 weeks to accomplish. In addition to reversing
the shutdown procedure, many pieces of equipment would need to be partially or
completely dismantled and inspected. A percentage of this equipment would likely
require replacement because some of the control electronics may be outdated; it
would be more efficient to replace it with current technology.
Reactivating the Pumping Plant would require startup services to be contracted
with Dresser-Rand
or another qualified mechanical services company. Estimated cost of reactivating
the Pumping Plant is $250,000 to $300,000. The Pumping Plant would not be
reactivated unless it were operated for one or more years. The State Legislature
would also need to appropriate a yearly operating budget of approximately $2
million.
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