QED AutoPump AP-3 User manual

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AutoPump Controllerless System
(for 3-inch wells or larger)
AP-3 AutoPump®
Document No. 602234 03
1565 Alvarado Street
San Leandro, California 94577-2640
[phone] — North America Only
[phone] — Tele.
[phone] — Fax
PO Box 3726
6095 Jackson Road
Ann Arbor, Michigan 48106-3726
[phone] — North America Only
[phone] — Tele.
[phone] — Fax
[e-mail] — E-mail
www.qedenv.com
Copyright QED Environmental Systems, April 2009
Environmental Systems

The equipment in this manual is protected under U.S. and foreign patents issued and pending:
U.S. Patents:
Selective Oil Skimmer (SOS) 4,497,370
Specic Gravity Skimmer (SPG) 4,663,037
AutoPump (AP) 5,004,405
Specic Gravity Skimmer (SPG) Product Sensing 5,474,685
Vacuum/Pressure Hydrocarbon Recovery System 4,761,225
SPG PSR technology 5,474,685
AP-2 5,641,272
Genie System 5,704,772
Canada Patent:
Specic Gravity Skimmer (SPG) 1,239,868
"AP" is a Registered Trademark of "QED Environmental Systems"
"AutoPump" is a Registered Trademark of "QED Environmental Systems"
"SOS" is a Registered Trademark of "QED Environmental Systems"
"Genie" is a Registered Trademark of "QED Environmental Systems"
"SPG" is a Registered Trademark of "QED Environmental Systems"
"AutoSkimmer" is a Registered Trademark of "QED Environmental Systems"
The QED Environmental Systems logo is a Registered Trademark of "QED Environmental
Systems"
QED Environmental Systems is a Registered Trademark of "QED Environmental Systems"

Page i
AP-3 Manual Table of Contents
Revision 3 - April, 2009
Table of Contents
Introduction_________________________________________________1
Safety .......................................................................................................1
ATEX Certication ...................................................................................1
How to Contact QED................................................................................4
Chapter 1: Safety ____________________________________________5
A Partial List of Safety Procedures ..........................................................5
Fire and Explosion Protection ..................................................................6
Personal Protection ...................................................................................6
Spill Protection .........................................................................................6
Chapter 2: Overview _________________________________________7
General Specications ..............................................................................7
This is How it Works ................................................................................8
Major AutoPump Features........................................................................8
Special Operating Conditions ................................................................... 10
Cold Weather .....................................................................................10
Actions To Take .................................................................................10
Flow induced freezing .......................................................................12
The well is under a vacuum...............................................................12
Abrasive particles in the well ............................................................12
Hard pipe air supply connection to the pump....................................12
Options and Accessories ...........................................................................13

QED Environmental Systems
AP-3 Manual
Page ii
Chapter 3: Equipment________________________________________14
Unpacking.................................................................................................14
Equipment List..........................................................................................14
Tools..........................................................................................................15
Parts List ...................................................................................................15
AP-3 AutoPumps ......................................................................................15
Bottom-Loading AP-3/BL ................................................................15
Top-Loading AP-3/TL ......................................................................15
Specications.....................................................................................18
Component Materials ........................................................................18
Performance and Air Use Curves ...................................................... 18
Leachate Screens ...............................................................................19
Optional “WYE” Fitting....................................................................20
Short Top Loading Cup .....................................................................21
Long Top Loading Cup......................................................................22
Single Stage Filter/Regulator....................................................................23
Hoses and Fittings.....................................................................................24
Hose and Tubing Color Code Table................................................... 24
Volumes Pumped Per Cycle......................................................................25
Pump Support System...............................................................................25
Chapter 4: Assembly & Installation_____________________________26
Cautions ....................................................................................................26
Compressed Air Supply ............................................................................27
Component Assembly...............................................................................27
Quick-Connects/Hose Barbs .............................................................27
AutoPump Assembly .........................................................................27
Dry Test.....................................................................................................33
Pump Support System and Hose Bundling Assembly..............................34
AutoPump Installation..............................................................................39

AP-3 Manual Table of Contents
Revision 3 - April, 2009 Page iii
Chapter 5: Start Up and Operation _____________________________41
Start Up Checklist.....................................................................................41
Observation of System Operation.............................................................42
Downwell Testing of the AutoPump.........................................................42
AutoPump Shutdown while Submerged...................................................42
AutoPump Removal Technique (optional) ...............................................42
Chapter 6: Maintenance ______________________________________43
General Maintenance ................................................................................ 43
Maintenance Table....................................................................................44
Air Quality Check.....................................................................................44
Single Stage Filter/Regulator Maintenance.......................................44
AutoPump Service .................................................................................... 46
AutoPump Shutdown and Removal from Well .................................46
For Bottom-loading pumps................................................................46
For Top-loading pumps ......................................................................46
Removing Pump Casing .................................................................... 47
Cleaning Pump Interior .....................................................................49
Iron Build-up Cleaning Procedure.....................................................56
Installing Pump Casing .....................................................................57
Checking Volumes Pumped Per Cycle .....................................................58
Chapter 7: Troubleshooting & Repairs __________________________59
Troubleshooting ........................................................................................ 60
Returning Equipment for Service .............................................................63
Equipment Cleaning Requirements ..........................................................64
Hoses and Fittings .............................................................................64
AutoPumps ........................................................................................64

QED Environmental Systems
AP-3 Manual
Page iv
Appendix A: Performance Curves_______________________________65
Appendix B: Air Consumption Curves ___________________________79
Appendix C: AP-4 Conversions _________________________________93
Appendix D: Vacuum on Well __________________________________100
Terms, Conditions, and Warranty _______________________________105

AP-3 Manual Table of Contents
Revision 3 - April, 2009 Page v
Figures:
Figure 1 - ATEX Label Detail, Example and Explanation ................................ 2
Figure 2 - AP-3 ATEX Label Location and Appearance ................................... 3
Figure 3 - How it Works..................................................................................... 9
Figure 4 - Overview of the AutoPump System .................................................. 11
Figure 5 - Long and Short Bottom-Loading (AP-3/BL)................................... 16
Figure 6 - Long and Short Top-Loading (AP-3/TL) .......................................... 17
Figure 7 - Long and Short AP-3 Bottom Loading with Leachate Screen.......... 19
Figure 8 - Short AP-3 Top Loading with Optional Brass “WYE” Fitting ......... 20
Figure 9 - Short AP-3/TLC and Short AP-3/TL Comparison............................ 21
Figure 10 - Long AP-3/TLC and Long AP-3/TL Comparison ............................ 22
Figure 11 - Single Stage Filter/Regulator 60 with Quick-Connects ................... 23
Figure 12 - Locking Quick-Connects .................................................................. 28
Figure 13 - Two-Ear Clamp and Hose Barb Assembly Instructions.................... 29
Figure 14 - Worm Drive Clamp and Hose Barb Assembly Instructions.............. 30
Figure 15 - AP-3 Assembly: Well Cap with Holes .............................................. 31
Figure 16 - AP-3 Assembly: Well Cap with Hose Barbs..................................... 32
Figure 17 - Examples of Well Caps ..................................................................... 35
Figure 18 - Hose Bundling: Part 1 of 2................................................................ 37
Figure 19 - Hose Bundling: Part 2 of 2................................................................ 38
Figure 20 - Removing AP-3 Pump Casing .......................................................... 48
Figure 21 - Internal View of a Bottom-Loading and Top-Loading AP-3............. 50
Figure 22 - Exploded View of a Top-Loading Long AP-3................................... 51
Figure 23 - Exploded View of a Bottom-Loading (Long & Short)...................... 52

QED Environmental Systems
AP-3 Manual
Page vi
Figure 24 - Exploded View of AP-3 Lever Assembly.......................................... 53
Figure 25 - Exploded View of a Top Loading Short AP-3................................... 54
Figure 26 - Bottom Intake Check Valve Assembly.............................................. 55
Figure 27 - Long AP-3/BL Performance Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 67
Figure 28 - Long AP-3/BL Performance Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 68
Figure 29 - Long AP-3/BL Performance Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 69
Figure 30 - Long AP-3/TL Performance Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 70
Figure 31 - Long AP-3/TL Performance Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 71
Figure 32 - Long AP-3/TL Performance Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 72
Figure 33 - Short AP-3/BL Performance Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 73
Figure 34 - Short AP-3/BL Performance Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 74
Figure 35 - Short AP-3/BL Performance Curves::
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 75
Figure 36 - Short AP-3/TL Performance Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 76
Figure 37 - Short AP-3/TL Performance Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ........... 77
Figure 38 - Short AP-3/TL Performance Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 78
Figure 39 - Long AP-3/BL Air Consumption Curves::
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 81
Figure 40 - Long AP-3/BL Air Consumption Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ........... 82

AP-3 Manual Table of Contents
Revision 3 - April, 2009 Page vii
Figure 41 - Long AP-3/BL Air Consumption Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNIT............... 83
Figure 42 - Long AP-3/TL Air Consumption Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 84
Figure 43 - Long AP-3/TL Air Consumption Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 85
Figure 44 - Long AP-3/TL Air Consumption Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 86
Figure 45 -Short AP-3/BL Air Consumption Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 87
Figure 46 - Short AP-3/BL Air Consumption Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 88
Figure 47 - Short AP-3/BL Air Consumption Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 89
Figure 48 - Short AP-3/TL Air Consumption Curves:
1-inch (25.4 mm) I.D. Discharge US and METRIC UNITS ............ 90
Figure 49 - Short AP-3/TL Air Consumption Curves:
3/4-inch (19 mm) I.D. Discharge US and METRIC UNITS ............ 91
Figure 50 - Short AP-3/TL Air Consumption Curves:
5/8-inch (16 mm) I.D. Discharge US and METRIC UNITS ............ 92
Figure 51 - Conversion from Top-Loading to Bottom Loading........................... 95
Figure 52 - Conversion from Bottom Loading to Top-Loading........................... 97
Figure 53 - Conversion from Short Bottom-Loading to Short Top Loading ....... 99
Figure 54 - AP-3/BL with Vacuum In the Well and Pump Exhaust
Outside the Well ................................................................................ 101
Figure 54 - AP-3/BL with Vacuum In the Well and Pump Exhaust
In the Well ......................................................................................... 102
Figure 56 - AP-3/TL with Vacuum In the Well and Pump Exhaust
Outside the Well ................................................................................ 103
Figure 57 - AP-3/TL with Vacuum In the Well and Pump Exhaust
In the Well ......................................................................................... 104

Page 1
AP-3 Manual
Revision 3 - April, 2009
Introduction
Welcome to QED Environmental Systems’ AutoPump® (AP-3) manual.
To ensure the best operator safety and system performance, it is strongly recommended that
the operators read this entire manual before using the system.
This manual reects our many years of experience and includes comments and suggestions
from our sales and service personnel and most importantly from our customers. The chapters,
their contents and sequence were designed with you, the user and installer, in mind. We wrote
this manual so it can be easily understood by users who may not be familiar with systems of
this type or are using a QED system for the rst time.
Safety
Safety has been a cornerstone of our design which has been proven out in building and
shipping systems throughout the world. Our high level of performance is achieved by using
quality components, building in redundancies or backup systems, and not compromising
our commitment to quality manufacturing. The net result is the highest quality and safest
pneumatic pump recovery system on the market. We feel so strongly about safety, based
on years of working with the hydrocarbon industry, that it is the rst section in all of our
manuals.
ATEX Certications
Equipment with an ATEX label similar to the example on Figure 1, page 2 is ATEX certied.
Equipment without the label is not ATEX certied.
Figures 1 and 2 explain the ATEX label, the label location and appearance.

QED Environmental Systems
AP-3 Manual
Page 2
Figure 1 - ATEX Label Detail, Example and Explanation

Page 3
AP-3 Manual
Revision 3 - April, 2009
602206 03
Pump Serial No.
BOTTOM LOADER
TOP LOADER
6.9 BAR [100 PSI]
MAXIMUM PRESSURE
[80 PSI]
5495890, 5358038
5.5 BAR
PAT. 5004405,
YEAR
QED, 94577-2640, USA
FM08ATEX0028
II 1 G c IIB
T6 Ta = 1°C to 65°C
1725
AP3
Figure 2 - ATEX Label Location and Apperance

QED Environmental Systems
AP-3 Manual
Page 4
How to Contact QED
If for any reason you are unable to nd what you need in this manual please feel free to
contact the QED Service Department at any time. We encourage you to use following
communication methods to reach us at any time:
Service Department
QED Environmental Systems
www.qedenv.com
San Leandro Service Center
1565 Alvarado Street
San Leandro, California 94577-2640
[phone] — North America Only
[phone] — Tele.
[phone] — Fax
Ann Arbor Service Center
PO Box 3726
6095 Jackson Road
Ann Arbor, Michigan 48106-3726
[phone] — North America Only
[phone] — Tele.
[phone] — Fax
[e-mail] — E-mail
QED can be reached 24 hours a day
We welcome your comments and encourage your feedback regarding anything in this
manual and the equipment you have on-site.
Thank you again for specifying QED remediation equipment.

Page 5
AP-3 Manual
Revision 3 - April, 2009
Chapter 1: Safety
Safety has been a prime consideration when designing the AutoPump System. Safety
guidelines are provided in this manual, and the AutoPump System safety features are listed
below. Please do not attempt to circumvent the safety features of this system.
We have also listed some possible hazards involved when applying this system to site
remediation. Nothing will protect you as much as understanding the system, the site at which
it is being used, and the careful handling of all the equipment and uids. If you have any
questions, please contact the QED Service Department for guidance.
As you read through this manual, you will encounter three kinds of warnings. The following
examples indicate how they appear and lists their respective purposes.
Note: Highlights information of interest.
Caution: Highlights ways to avoid damaging equipment.
WARNING: Highlights personal safety issues.
A Partial List of Safety Procedures
WARNING:
The air compressor and any other electrical equipment used with this
pneumatic system must be positioned outside of any area considered
hazardous because of possible combustible materials.
These safety procedures should be followed at all times when operating QED equipment on or
off site, and should be considered as warnings:
• Wear safety goggles when working with the AutoPump System to protect eyes from any
splashing or pressure release.
• Wear chemically resistant rubber gloves, boots, and coveralls when handling the AutoPump
and uid discharge hose to avoid skin contact with the uid being recovered.

QED Environmental Systems
AP-3 Manual
Page 6
• Point all hoses away from personnel and equipment when connecting or disconnecting.
• Always ensure that the uid discharge hose is connected before the air hose to prevent
accidental discharge.
The AutoPump System minimizes the potential for accidents with the following safeguards:
Fire and Explosion Protection
Almost all of QED underground uid extraction systems are pneumatic. This offers many
inherent re and explosion protection features:
• Compressed air lines eliminates electrical wiring in hazardous areas.
• Aluminum or berglass enclosures prevent sparking.
• Standard systems use brass ttings to help eliminate sparking hazard.
Personal Protection
On-site, service and maintenance personnel can safely use QED equipment. Safety-
in-use is the primary design feature in all systems. Following are some samples:
• All standard high pressure air hoses have automatic shut o quick-connects on the
supply side which prevents injury due to hose whip or air blown particles.
• Metal regulators and lter bowls are rated at 150 psi. The metal air lter bowl
is made of aluminum, providing greater pressure and chemical resistance than
plastic bowls and it is less prone to damage if dropped.
Spill Protection
On-site spills cannot always be prevented. QED equipment is designed to take into
consideration such unpredictable occurrences that may happen despite strict adherence to
standardized safety practices.
• The standard air and uid hoses are rated at over 800 psi burst pressure to prevent
accidental hose breakage.
• Down well quick-connects have locking features to prevent accidental disconnections.

Page 7
AP-3 Manual
Revision 3 - April, 2009
Chapter 2: Overview
The AutoPump® lls and empties automatically, and is very easy to install, use, and maintain.
The AutoPump is a pneumatic uid extraction pump that pumps in pulses. It handles any
liquid which ows freely into the pump and is compatible with the component materials and
with the connecting hoses.
The AutoPump is very versatile and available in a range of lengths and uid inlet
arrangements to meet particular site specications.
Equipment will vary by application and site specications. (See Chapter 3)
General Specications
Bottom Loading 2.8-inch I.D. and larger 7.2-cm I.D. and larger
Top Loading with
Standard Fluid Inlet
Fitting 3.75-inch I.D. and larger 9.53-cm I.D. and larger
Top Loading with
Optional Brass Inlet
Fitting 3.0-inch I.D. and larger 7.6-cm I.D. and larger
Top Loading Cup 3.2-inch I.D. and larger 8.1-cm I.D. and larger
Long 5-100 psi 0.4-7.1 Kg/cm2
Short 5-80 psi 0.4-5.7 Kg/cm2
Long BL 0 to 7.3 gallons per minute (GPM) 0 to 27.6 liters per minute (LPM)
Long TL 0 to 5.4 gallons per minute (GPM) 0 to 21.2 liters per minute (LPM)
Short BL 0 to 6.0 gallons per minute (GPM) 0 to 22.7 liters per minute (LPM)
Short TL 0 to 4.8 gallons per minute (GPM) 0 to 18.1 liters per minute (LPM)
Minimum
Internal
Well
Diameter
Pressure Range
Flow Range

QED Environmental Systems
AP-3 Manual
Page 8
This is How it Works
The AutoPump is a submersible compressed air-driven pump which lls and empties
automatically. It also controls the uid level in a well automatically. The pump lls (see
Figure 1) when uids enter either the top or bottom check valve. Air in the pump chamber
exits through the exhaust valve as the uid lls the pump. The oat inside the pump is carried
upwards by the uid rising inside the casing until it pushes against a stop on the control rod,
forcing the valve mechanism to switch to the discharge mode.
The switching of the valve causes the exhaust valve to close and the air inlet valve to open.
This causes the pump to empty (see Figure 3) by allowing compressed air to enter the pump.
This pressure on the uid closes the inlet check valve and forces the uid up the discharge
tube and out of the pump through the outlet check valve. As the uid level falls in the
pump, the oat moves downwards until it pushes against the lower stop on the control rod,
forcing the valve mechanism to switch to the ll mode. The outlet check valve closes and
prevents discharged uids from re-entering the pump. The lling and discharging of the pump
continues automatically.
Note: The gures shown here are simplied schematics.
Major AutoPump Features
• The AutoPump System is small and lightweight and can be easily moved from site to site,
allowing quick response to changing conditions.
• The hoses are color coded and all the ttings are different so only the proper connections
can be made.
• Rugged construction ensures long system life, even under harsh conditions.
• The entire system is pneumatically powered with no electrical components, thus avoiding
sparks in control power and sensing devices.
• Durable stainless steel air valves that can pass liquids as viscous as 90 weight gear oil
without fouling. The air valves can handle reverse ow and submersion for long periods
of time. Unlike pumps with bubblers or bleed lines, there are no problems with start up,
clogging, and failure under these difcult conditions when using the AP-3. This results in
less downtime and lower training, maintenance, and repair costs.

Page 9
AP-3 Manual
Revision 3 - April, 2009
Figure 3 - How it Works
601345
Chapter 2: Overview

QED Environmental Systems
AP-3 Manual
Page 10
• Unlike systems that rely on bleeding air sensors or timers which pressurize and
depressurize the air hoses for each stroke, the air hose for the AP-3 remains pressurized to
the pumps at all times. Air compressor power consumption, compressor lter maintenance,
and thus operating costs are substantially reduced.
• The AP-3 can be congured to ll from the top or the bottom.
Figure 4 on the next page illustrates an overview of an AutoPump System.
The AP-3 System provides everything required for pumping uid from a well. QED can also
supply the air compressor, if desired.
The system is designed to perform for years and comes with a two year warranty.
Note:
An automatic drain on the compressor is highly recommended since it
dramatically decreases air lter maintenance. QED can supply an automatic
drain.
Caution:
Alteration of the System: Do not change or modify the equipment without
the expressed written approval of QED.
Special Operating Conditions
Conditions may require adjustment or adaptations to the equipment. Below is a list of some of
these conditions, their possible effects, and solutions.
Since every site is different, please contact your QED representative for detailed assistance
if needed.
Cold Weather
Moisture in the pneumatic lines can freeze causing problems with the system. Such
freezing could result in regulators not reducing the air pressure, valves sticking, and
hoses clogging.
Actions To Take
• Use water traps and automatic compressor tank drains. These are available at
industrial distributing companies (e.g., W.W. Graingers®).

Page 11
AP-3 Manual
Revision 3 - April, 2009
Figure 4 - Overview of the AutoPump System
Chapter 2: Overview