Revised November 2013
G:\Facilities Services (Miller)\Bldg Maint\Chilled Water Discharge (Utilities -do not delete)\June 2005 Draft Chilled water discharge
plan Utilities.doc
Operating Procedure - ISU Utilities
Central Chilled Water System Discharge Identification and Correction
To be updated by Steve Mayberry
Purpose
To identify and minimize discharges from the central chilled water system.
Primary Authority / Coordinator
The Power Plant Shift Supervisor(phone 294-4926) will be the primary authority
coordinating activities until a discharge (leak) is found and corrected. The Power Plant
control room will act as the message center to receive and provide information to the
personnel responding to locate the discharge. Searches to locate the point of discharge
shall be continued until new direction is given from the Power Plant Shift Supervisor. If
needed, the Power Plant Shift Supervisor may arrange a meeting in the Power Plant with
the Departmental Contacts (see table in this document).
Background
The chilled water system is chemically treated. Molybdate had been the corrosion
inhibitor maintained in the system at concentrations near 5 PPM (3 -PPM molybdenum).
Molybdenum concentration in the university sanitary outfall is limited to 0.250 PPM by
the University / City of Ames Domestic Water Pretreatment Agreement. Therefore,
chilled water discharges into the sanitary sewer system needs to be managed to prevent
violations and fines. The Utilities Department manages the Domestic Water Pretreatment
Agreement for the University. The current chemical treatment program no longer uses
molybdate as the corrosion inhibitor; this treatment program eliminates chemical loading
concerns with the Ames treatment facility.
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Approval of Discharges & Filling of the System Within Each Building
Unavoidable discharges of chilled water shall be coordinated with Mike Murray (2948751). Randy Larabee (520-1503) is the backup coordinator. Approval of intentional
chilled water discharges may be granted provided discharge times, flow rates, and
quantities are pre-planned. Actual discharge information shall also be provided to the
coordinator when the discharge is completed.
Approval of Filling of the System Within Each Building
An organization planning an activity, which will cause chilled water make-up to occur,
shall contact the Power Plant Shift Supervisor (phone 294-4926) to notify when the
activity is to start and finish. This reduces the chance of having the Power Plant staff
misinterpret the planned maintenance activity as a leak.
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System Maintenance
Chilled water piping and coils are to be inspected regularly for leaks as part of routine
maintenance schedules. Maintenance personnel shall correct any detected leaks at the
time of the inspection. Un-repairable leaks shall be reported to the Power Plant Shift
Supervisor who will maintain an on-going file of current issues. The file will include
approximate flow rates and the expected repair date. Once repaired, the Power Plant Shift
Supervisor shall be notified.
Training
All ISU employees associated with the chilled water system shall be familiar with the
contents of this procedure. Departments should review this document as needed to
maintain familiarization.
Chilled Water Make-up Monitoring
The chilled water make-up is monitored by a metering installation in the Power Plant.
Chilled water make-up to the system should occur only in the Power Plant. Otherwise,
erroneous measured make-up quantities will occur. Potential make-up from other sources
shall be identified and removed. If makeup rates occur outside of established parameters,
the appropriate action plan listed within this document shall be followed.
Action Plan When Unplanned Losses Are Recognized
The action plan is based upon the flow rate magnitude as listed in the sections below. The
Power Plant Operator (phone 294-4926) will provide email instructions / updates. The
Power Plant Operator will communicate directly to the Departmental Contacts across
campus as shown in the table below. Communication and coordination within the
department will be the responsibility of the Departmental Contact. Information provided
by the Power Plant Operator shall include

when the situation started

average flow rate (gpm)

expected action including the urgency (dependant on flow rate)

when feedback is needed

provide web link to this written procedure at
http://www.fpm.iastate.edu/utilities/chw_system_discharge/
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Helpful Tips to Assist in Locating a Leak
1) Process cooling loops sometimes have lines going to drains. These
locations are suspects and should be included in specific building
inspection checklists.
2) Locations where recent system modifications / construction have occurred
tend to increase the probability of a discharge.
3) Piping & coils exposed to extreme cold air conditions are suspect and
should be included in the specific building checklists. Examples include
air handlers with cooling coils that have outside air dampers. Accumulated
chilled water typically is present inside the air handler casing.
4) Gasketed joints in direct buried piping are subject to corrosion. The joints
are typically at hot tap valves. Removing the lids on direct buried valves
can sometimes show standing water that may be associated with an
underground leak.
A final update will be sent out to inform everyone that the situation has been corrected
along with information detailing what was found.
Departmental Contact Call List
Department
Primary Contact (phone)
Alternative Contact (phone)
Residence
Randy Monthei
(1) After hour Manager On-
Randy cell (290-5504)
Call pager
24 Hr Help Desk (294-3322)
(515) 239-2801
6:00am to 7:00pm M-F
6:00 am to 4:30 pm Sat-Sun
(2) Randy Monthei (8263425) cell (290-5504)
(3) Richard Garrey
Work phone 294-6836
Home 515-382-8733
Page 4 of 11
Ames Lab
Mark Grootveld
(1)Mike Valcav (294-7891)
Guard Desk 24/7 (294-3483)
(2) Mark Grootveld (2947895)
Soil Tilth
Jerry Hatfield (294-5723)
After hours
(1) xxxxx(xxx-xxxx)
(2) Ron Cochran (294-7515)
Memorial Union
Ken Umbaugh (294-1147)
(1) Mark Turner (4-1449)
Ken Umbaugh Cell (460-
Turner cell (450-0401)
6800)
(2) After Hours
Main Desk (294-1031) for
call-in list
Ron Home (597-2372)
(1)Kenny
Bollenbaugh(4608533)
(2) Don Hoffmann (733-
Service Center (294-5100)
4437)
FP&M General University
Ron Cochran
Building Maintenance
Ron cell (460-8531)
Hoffman cell (460-8534)
FP&M General University
Mike Murray (294-8751)
Mike Murray ( 296-1015)
Utilities Mechanical
Randy Larabee (520-1503)
Distribution
After Hour Call (294-5100)
FP&M General University
Mike McGraw (294-8333)
Jeff Witt (294-8286)
Utility Production
FP&M General University
Dean McCormick (294-0563) After Hours Service Center
Construction
(294-5100)
Administration
Ron Cochran (597-2372)
Page 5 of 11
Actions will be taken based up the makeup flow rate as shown in the
sections below.
O GPM Makeup (unintentional) Make-up average over the a day is essentially 0
GPM and this condition is sustained for two consecutive days. The condition would
suggest that unintentional / un-metered make-up is occurring.
A) Departmental Contact:
a. Initial Contact: Power Plant Operator (phone 294-4926) will email
departmental contacts to have each department inspect their buildings /
systems within next two business days.
b. Departmental Action: The departmental contact shall reply by email to
the Power Plant Operator indicating receipt of the email message as soon
they receive it and follow up with any questions that they may have. The
departmental contact will distribute the information with the appropriate
departmental staff members. The departmental contact shall maintain an
internal check-off list of building systems and tasks to complete.
c. Departmental Response: The completed task list shall be emailed back to
the Power Plant Operator within two days after being notified. The task
list should indicate what actions were taken and describe anything out of
the ordinary.
B) Set Up Meeting: If the unintended make-up is not located within 4 business days
of being observed, the Power Plant Operator (phone 294-4926) will arrange a
meeting with the Departmental contacts to discuss what additional actions can be
taken. During the meeting, potential resolution of the situation will be discussed.
Potential actions may include:
a. Shutting down individual buildings while monitoring the makeup
b. Shutting down sections of the distribution piping while monitoring the
makeup
c. Recalibrate / test makeup meter.
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0.2 -2 GPM Makeup
This is the expected make-up to the system under normal
operating conditions. No action is required.
2-10 GPM Makeup
Make-up average over the day is greater than 2 gpm and less than
10 GPM and the makeup is sustained for two consecutive days.
A) Departmental Contact:
a. Initial Contact: Power Plant Operator (phone 294-4926) will email
departmental contacts to have each department inspect their buildings /
systems within next two business days.
b. Departmental Action: The departmental contact shall reply by email to
the Power Plant Operator indicating receipt of the email message as soon
they receive it and follow up with any questions that they may have. The
departmental contact will distribute the information with the appropriate
departmental staff members. The departmental contact shall maintain an
internal check-off list of building systems and tasks to complete.
c. Departmental Response: The completed task list shall be emailed back to
the Power Plant Operator within two business days after being notified.
The task list should indicate what actions were taken and describe
anything out of the ordinary. Specifically, actions taken that result in an
increase or decrease in the system make-up should be clearly noted in
detail.
B) Utility Operations Actions
a. Main Plant
1. Check the evaporator vents and drains on chillers 1,2,3 & 4 for
any indication of leakage.
2. Check the primary pumps 1,2,3 & 4 and associated piping for any
indication of leakage.
3. Check the supply and return header piping for any indication of
leakage.
4. Check the filter, filter pump and associated piping for any
indication of leakage.
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5. Check the makeup controller and confirm set point 75 psi and
note controlled variable.
6. Check the 1 inch makeup valve and insure proper operation
b. North Campus Chiller Plant
1. Check all chilled water piping for any indication of leakage.
2. Check the evaporator vents and drains for any indication of
leakage.
3. Check the primary pump and associated piping for any
indication of leakage.
C) Mechanical Distribution System Actions:
a. Sewer Sampling: Utility Mechanical Distribution staff will take a grab
sample from the sanitary sewer manhole SA11D10 (City # 739) located at
the intersection of Beach Avenue and Lincolnway within one business
days after being notified. The sample(s) shall be retained for testing to
identify molybdate levels should the sustained make-up present a sewer
effluent violation potential based upon discussions with the City of Ames
Water Pollution Staff (see external notification section).
b. Surface Check: The Mechanical Distribution staff will also survey the
ground surface over buried distribution piping to locate water that may be
coming out the ground.
c. Valve Box Check: After the initial surface review, each valve box shall be
check within two business days after being notified to see if water is
accumulating in the box. Accumulated water shall be tested in the Power
Plant water lab to verify if molybdate is present which would tend to
indicated a chilled water leak.
D) Set Up Meeting: If the leak is not located within 4 business days of being
observed, the Power Plant Operator will arrange a meeting with the Departmental
contacts to discuss what additional actions can be taken. During the meeting,
potential resolution of the situation will be discussed. Potential actions may
include:
a. Shutting down individual buildings while monitoring the makeup
Page 8 of 11
b. Shutting down sections of the distribution piping while monitoring the
makeup
c. Monitoring the storm and sanitary sewer effluent to measure molybdenum
concentrations in trunk lines across campus that potentially could focus the
search to specific locations on campus.
d. Recalibrate / test makeup meter.
In Excess of 10 GPM Makeup
Make-up average over a four hour period is greater
than 10 GPM. Each department shall maintain their staff on-site looking for the leak
unless the Power Plant Operator provides different instructions.
A) Departmental Contact:
a. Initial Contact: Power Plant Operator (phone 294-4926) will call the
departmental contacts to have each department inspect their buildings /
systems after the four hour period. After hour call in lists will be utilized
by the Power Plant Operator if needed to personally contact each
departmental contact. The Power Plant Operator will also send out an
email to document relevant information.
b. Departmental Action: The departmental contact will distribute the
information with the appropriate departmental staff members. The
departmental contact shall maintain an internal check-off list of building
systems and tasks to complete.
c. Departmental Response: The departmental contacts shall email the task
list back to the Power Plant Operator within 4 hours after being notified
and follow-up with an email. The task list should indicate what actions
were taken and describe anything out of the ordinary. Specifically, actions
taken that result in an increase or decrease in the system makeup should be
clearly noted in detail.
B) Utility Operations Actions
a. Main Plant
Page 9 of 11
i. Check the evaporator vents and drains on chillers 1,2,3 & 4 for any
indication of leakage.
ii. Check the primary pumps 1,2,3 & 4 and associated piping for any
indication of leakage.
iii. Check the supply and return header piping for any indication of
leakage.
iv. Check the filter, filter pump and associated piping for any
indication of leakage.
v. Check the makeup controller and confirm set point 75 psi and note
controlled variable.
vi. Check the 1 inch makeup valve and insure proper operation
b. North Campus Chiller Plant
i. Check all chilled water piping for any indication of leakage.
ii. Check the evaporator vents and drains for any indication of
leakage.
iii. Check the primary pump and associated piping for any indication
of leakage.
C) Distribution System Actions:
a. Sewer Sampling: Utility Mechanical Distribution staff will take a grab
sample from the sanitary sewer manhole SA11D10 (City # 739) located at
the intersection of Beach Avenue and Lincolnway within 4 hours after
being notified. The sample(s) shall be retained for testing to identify
molybdate levels should the sustained make-up present a sewer effluent
violation potential based upon discussions with the City of Ames Water
Pollution Staff (see external notification section).
b. Surface Check: The Mechanical Distribution staff will also survey the
ground surface over buried distribution piping within 4 hours after being
notified and follow-up with an email to locate water that may be coming
out the ground.
c. Valve Box Check: After the initial surface review, each valve box shall be
checked within 4 hours after being notified to see if water is accumulating
in the box. Accumulated water shall be tested in the Power Plant water lab
to verify if molybdate is present which would tend to indicated a chilled
water leak.
Page 10 of 11
d. Confirming Task Completion: Upon completion of the sewer sampling,
surface check, and valve box check; an email shall be sent to the Power
Plant Operator.
D) Set Up Meeting: If the leak is not located within 4 hours, the Power Plant
Operator (phone 294-4926) will arrange a meeting with the Departmental contacts
to discuss what additional actions can be taken. This meeting would be set up
even if this search is occurring outside the normal working hours. During the
meeting, potential resolution of the situation will be discussed. Potential actions
may include:
a. Shutting down individual buildings while monitoring the makeup
b. Shutting down sections of the distribution piping while monitoring the
makeup
c. Monitoring the storm and sanitary sewer effluent to measure molybdenum
concentrations in trunk lines across campus that potentially could focus the
search to specific locations on campus.
d. Recalibrate / test makeup meter.
E) External Notification: If the discharge exceeds 10 gpm for 15 hours, External
Notification procedures will be followed. Mike Murray (alternate – Randy
Larabee) will be responsible for notifying the City of Ames Water Pollution
Control Facility of planned and accidental chilled water discharges. If directed by
the City of Ames Water Pollution Control Facility, a continuous wastewater
sampler may be needed at sanitary sewer manhole SA11D10 (City # 739) located
at the intersection of Beach Avenue and Lincolnway.
Page 11 of 11