APENDIX A: THE POLYFAST SYSTEM

APENDIX A: THE POLYFAST SYSTEM

LWR’s PolyFAST unit is specifically designed to automatically prepare a 0.5% concentration of grō17 polymer, ensuring smooth system operation with minimal supervision or operator intervention. It is essential to calibrate the unit during the initial start-up, and regular calibration checks should be conducted on a monthly basis thereafter or if the unit sits idle and full of dry polymer for more than a week.

Comprising two 5500 Liter tanks, tank mixers, a polymer powder handling system, dry polymer feeder, polymer wetting cone, eductor, and electrical control system, the PolyFAST unit is equipped to provide approximately 45 minutes of aging time after the polymer is adequately prepared. These two tanks serve the dual purpose of batching/maturing the polymer solution and storing the application polymer solution, alternating their roles to ensure a continuous supply of properly made polymer solution to the system.

Operating the PolyFAST unit is a straightforward process, as it is fully automated through the PLC (Programmable Logic Controller). The operator's responsibility primarily involves ensuring that the polymer hopper contains a sufficient quantity of polymer to ensure uninterrupted operation.

With proper care to prevent moisture contamination, the PolyFAST unit requires minimal maintenance. Please refer to the maintenance schedule provided for detailed maintenance requirements and guidelines.

CALIBRATION PROCEDURE

  1. Remove the wetting cone from underneath the dry polymer feed auger.
    1. If full of water, ensure no dry polymer is in the surrounding area or on the ground.
    2. Disconnect the tri-clover fitting from from the cone's water feed hose. Do not lose the gasket.
    3. Disconnect the tri-clover fitting from the base of the wetting cone. Do not lose the gasket.
    4. With the cone off, inspect for polymer build up inside the cone and the eductor.
  2. Prepare an appropriately sized container to collect the dry grō17 powder. A 2 or 5 (US) gallon pail is recommended. Measure and record the weight of the empty container in the table below.
  3. Using a cloth, carboard, or other covering, loosely cover the open piping where the cone was to prevent polymer from falling into the piping.
    1. If any polymer does fall into into the line, manually remove as soon as possible to prevent a blockage from forming.
  4. Position the container under the dry polymer feed auger.
  5. Access the polyFAST feed screen on the HMI (Human Machine Interface).
  6. Set the polyFAST feed auger to AUTO.
  7. Locate and press the CALIBRATION button located in the top left corner of the polyFAST feed screen.
  8. In the TEST FEED TIME box, enter a suitable feed time for the calibration. (The recommended starting value is 30 seconds). Adjust this value based on the size of the container placed under the auger. Note: A longer test feed time yields a more accurate calibration.

  1. Initiate the calibration process by pressing the START CALIBRATION button. The dry polymer feed auger will operate for the duration set in step 6.
  2. Once the timer reaches completion, the auger will stop. Press STOP CALIBRATION once auger has completely stopped.
  3. Measure the weight of the pail containing the dry grō17 and record the value in the table below.
  4. Calculate the net weight by subtracting the weight of the empty pail from the measurement obtained in step 9.
  5. Empty the container back into the dry polymer hopper.
  6. Repeat steps 7-11 three times and calculate the average of the three readings.
  7. Remove covering and replace wetting cone.
  8. Enter the average weight value in the MEAS. WEIGHT box. Please note that the measurement should be in grams.
    1. If the scale used displays the value in kilograms (kg), multiply the shown value by 1000. For example, if the scale reads 1.85 kg, the value in grams would be 1850 g.
    2. If the scale displays the value in ounces (oz), multiply the shown value by 28.35. for example, if the scale reads 65 oz, the value in grams would 1843 g.
  9. Verify that the FEED RATE and CALC. FEED TIME displayed on the screen are accurate.
    1. Ensure that the polyFAST unit will finish feeding within 1 -2 minutes of the polymer tank filling. If calculated feed time is much shorter or longer than anticipated, Follow auger cleaning instructions and recalibrate.
Ensure that the container used for calibration is clean and free from any residual polymer or debris before each measurement.

Calibration Table

Test #

Weight of Empty Container (g)

Feed time (S)

Weight of full container (g)

Weight of dry polymer                 (Full cont. – empt. Cont.) (g)

1

 

2

 

 

3

 

 

 

 

Average weight of polymer from above three tests.

 

 

NORMAL OPERATION

  1. Access the polyFAST screens on the HMI (Human Machine Interface).
  2. Set PB-142, MOV-1402, MOV-1404, and SV-001 to auto mode.
  3. Ensure that there is an adequate water supply to the polyFAST inlet and that the booster pump (if applicable) is functioning properly.
  4. Set MOV-1401 and MOV-1403 to auto mode. MOV-1401 and SV-001 should open, initiating the filling of Poly Tank 1.
  5. Once the level in Tank 1 reaches 10 inches, the mixer for that tank will start operating.
  6. When the level in Tank 1 reaches 15 inches, the auger will start and run for the calculated time determined during the calibration procedure mentioned above.
  7. Once the timer completes, the dry polymer auger will stop.
  8. The tank will continue filling until it reaches full capacity. At this point, MOV-1401 and SV-001 will close, and the mixer will continue running for 45 minutes to ensure thorough mixing of the polymer.
  9. After Tank 1 is filled, the system will automatically switch to Tank 2 and repeating the same procedure, opening MOV-1403 instead of MOV-1401.
  10. Once the mix timer for Tank 1 completes (45 minutes), MOV-1402 (tank 1 drain valve to the polymer pumps) will automatically open.
  11. During normal operation, MOV-1402 will close, and MOV-1404 will open simultaneously once Tank 1 is empty (assuming the mix timer for Tank 2 has completed), and the system will start filling Tank 1 again.

Note:
If the system will be inactive for more than 24 hours, it is recommended to drain the polymer tanks. To do so, set MOV-140, MOV-141, and MOV-144 out of auto mode, then either run the system until the tanks are empty or manually drain them.


polyFAST Auger Cleaning

If water is able to enter the auger chamber or the system is idle for prolonged periods in high humidity, blockages can form around the auger. If this occurs, even polymer dispersal may be interrupted or polymer may not flow at all. The following provides instruction on how to clean the auger chamber.

  1. Disconnect the FDR-001 VFD from power.
  2. If needed for additional working room, remove wetting cone from piping following Step 1 and 3 in “Calibration Procedure” in this section.
    1. Ensure floor and working area around polyFAST unit is dry to prevent a slipping hazard from forming due to spilt polymer.
  3. Close the knife valve on the polymer hopper.
  4. Place a container below the connection of the auger cover and the hopper to catch any spilt material.
  5. Remove the nuts holding the auger cover to the hopper body.
  6. Remove any stuck polymer from the auger.
  7. Using a shop vacuum, remove as much loose material as possible.
  8. Visually inspect for large chunks or potential blockages.
  9. Using a pick or pry bar, break up solid polymer pieces and remove with a vacuum.
  10. Dispose of solids in compliance with local regulations.
  11. Replace auger cover and tighten nuts.
  12. Open the knife valve on the polymer hopper.
  13. Restore power to auger VFD.
  14. Perform polyFAST calibration and verify all blockages removed.


PolyFast Preventative Maintenance Schedule

Equipment

D

W

M

Q

SA

A

BA

Notes

Inlet Water Ball Pneumatic Valve

 

 

 

 

 

GI

 

When system is not in operation, close isolation valves to the wetting cone cycle the ball valve to ensure that it is operating freely.

Inlet Water Pressure Gauge

 

GI

 

 

 

 

 

Ensure needle is showing a pressure; not maxed out and not reading 0.

Wetting Cone

GI

 

 

C

 

 

 

Inspect the wetting cone, checking to see the water level is correct, and there is no buildup of polymer.

Eductor

GI

 

 

C

 

 

 

Inspect the wetting cone, if water is backing up in the cone, the Eductor may need to be cleaned.


Equipment

D

W

M

Q

SA

A

BA

Notes

Hopper Powder Level Switch

 

 

GI

 

 

C

 

Check to ensure that the rotating level switch is engaged when Powder is in the hopper and spinning freely when there is no powder.

Powder Feeder Gear Reducer

 

 

 

 

 

GI

 

Listen to the gear box for excessive noise. Replace if grinding noise is heard.

Powder Feeder Gear Reducer

 

 

 

 

 

X

 

Replace gearbox oil.

PolyActivate Frame

 

 

 

GI

 

 

 

Inspect the frame every quarter, checking the welds and looking for any undue stress or loading.

Check Valve

 

 

 

C

 

 

 

Quarterly remove and clean the check valve, keeping the ball free to open and close.

Pressure Transmitter (Mix Tank & Stock Tank)

 

 

GI

 

 

C

 

Check the HMI to ensure that the readings are accurate. Annually, clean the diaphragm on the pressure transmitter.

“GI” – General Inspection – Review the integrity of the item – Replace if any defects are visual

“C” – Cleaning – Remove the component and wash with warm water

“R” – Replacement – Recommended life cycle of the component. Remove and replace the component

“D” – Daily

“W” – Weekly

“M” – Monthly

“Q” – Quarterly

“SA” – Semi Annually

“A” – Annually

“BA” – Bi-annually


polyFAST TROUBLESHOOTING
​

SYMPTOM

CAUSE

ACTION

Water coming out of polyFAST wetting cone, no water going into polymer tank

Restriction in line

Disassemble check valve and ensure it is clean and in good working order

Remove eductor piping from the polyFAST unit and check thouroghly for polymer blockages.

Closed valves

Check all manual valves past wetting cone and ensure they  are open

Verify polymer tank fill MOVs open and close in both AUTO and HAND.

If problem persists, contact LWR

Water coming out of polyFAST wetting cone, water going into polymer tank

Restriction in line

Disassemble check valve and ensure it is clean and in good working order

Remove eductor piping from the polyFAST unit and check thouroghly for polymer blockages.

Open flow control globe valve further to boost flow and line pressure to system specification

Ensure SV-01 is fully actuating. Remove and clean if necessary

Ensure polymer tank fill MOVs are fully opening by viewing the position indicator on the housing. If not fully opening or closing, contact LWR.

Boost pump not providing adequate flow/pressure

Check motor rotation.  If motor is running backwards reverse any two motor leads to change direction.

If problem persists, disassemble pump to determine failure.

If problem persists, contact LWR

No polymer coming from auger, level switch indicates full

Valve closed

Verify gate valve is open and allowing polymer from the hopper to enter the auger chamber

Motor Overload Tripped

Check overload relay for flag indication.  Press overload 'RESET' button.  Check overload setting and match to motor FLA, if set above motor FLA.  Check Auger for maintenance.

Level switch stuck and hopper is empty

Verify hopper level switch is rotating freely. Remove and clean.

Polymer has hardened

Follow auger cleaning instructions and remove all solidified polymer.

If problem persists, contact LWR

Polymer concentration is not correct

Incorrect polyFAST calibration

Follow polyFAST calibration procedure.

Polymer has hardened

Clumps coming out of the auger renders calibration data inaccurate and causes polymer to not fully hydrate. If clumping is occurring, remove polymer from hopper and use new polymer

If problem persists, contact LWR

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