OPERATING
&
MAINTENANCE
MANUAL
PLANT
: SEWAGE TREATMENT PLANT
TRICKLING FILTER PLAN
CLIENT
: XXX
CONTRACT : XXX
VWS REF.
: XXX
DATE
: OCTOBER 2010
REV
0
1
DATE
12/07/2010
11/10/2010
BY
AL
AL
COMMENTS
Preliminary
Draft copy issued internally for comments
RESTRICTIONS & COPY RIGHTS
•
The use of this document including all data, details and drawings is restricted to that of
XXX and the client’s trained operators.
•
Veolia Water Systems (Pty) Ltd disallows the reproduction of this document or its
contents to be divulged without written permission.
•
This manual must be clearly understood before plant installation, start-up and
operation can commence.
•
This document has been written with the intention to provide all the required
information to the operating staff, in order for competent operation and maintenance of
the plant.
•
This plant should be operated and serviced by trained persons only.
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TABLE OF CONTENTS
1
2
3
4
5
6
TECHNICAL DATA........................................................................................................... 5
1.1
BACKGROUND......................................................................................................... 5
1.2
SUMMARISED TECHNICAL DESCRIPTION ........................................................... 5
1.3
RAW AND FINAL WATER QUALITY AND FLOW .................................................... 6
TREATMENT PLANT ....................................................................................................... 7
2.1
TREATMENT PLANT OVERVIEW............................................................................ 7
2.2
EQUIPMENT DETAILS ............................................................................................. 7
2.2.1
Diversion sump .................................................................................................. 7
2.2.2
Control valve sump ............................................................................................ 8
2.2.3
Float valve sump with flow control...................................................................... 8
2.2.4
Collection sump.................................................................................................. 8
2.2.5
Screening facility - Inlet box with manual rake screen........................................ 8
2.2.6
Flow equalisation and anaerobic digestion – Septic tank modules .................... 9
2.2.7
Anoxic Zone – Recycle sump ............................................................................. 9
2.2.8
Trickling filter towers with collection basins ...................................................... 10
2.2.9
Secondary Clarifier ........................................................................................... 12
2.2.10 Disinfection – Chlorine contact channel ........................................................... 12
2.2.11 Final Water Discharge ...................................................................................... 13
2.2.12 Valves .............................................................................................................. 13
2.2.13 Instruments ...................................................................................................... 13
2.3
SOLID WASTE REMOVAL ..................................................................................... 13
2.4
OPERATING PARAMETERS & PROCEDURES .................................................... 14
2.4.1
Influent flow ...................................................................................................... 14
2.4.2
Chlorine Dosing (Treated effluent) ................................................................... 14
2.4.3
Plant Start-Up................................................................................................... 14
2.4.4
Normal Operation ............................................................................................. 14
2.4.5
Plant Shutdown ................................................................................................ 15
2.4.6
Maintenance..................................................................................................... 15
2.4.7
Septic Tank Inspection ..................................................................................... 16
CONTROL PHILOSOPHY.............................................................................................. 18
3.1
PLANT INLET FEED PUMPS ................................................................................. 18
3.2
TRICKLING FILTER FEED PUMPS........................................................................ 18
3.3
SECONDARY SETTLER DESLUDGE .................................................................... 18
3.4
DOSING CONTROL................................................................................................ 18
3.5
FINAL WATER DISCHARGE PUMPS .................................................................... 19
3.6
CONTROL PANEL MCC1000 ................................................................................. 19
3.7
ALARM CONDITIONS ............................................................................................ 20
3.8
HMI PARAMETER SETTING .................................................................................. 20
3.9
HMI PASSWORD .................................................................................................... 20
3.10 CONTROL PANEL MCC2000 ................................................................................. 21
ELECTRICAL CONTROL ............................................................................................... 22
RECOMMENDED SPARES ........................................................................................... 23
DRAWINGS, DIAGRAMS, TABLES, SCHEDULES & PROCEDURES.......................... 24
6.1
Pump Schedule ....................................................................................................... 24
6.2
Valve Schedule ....................................................................................................... 24
6.3
Instrument Schedule ............................................................................................... 24
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6.4
Plant General Layout Drawings ............................................................................... 24
6.5
Process & Instrument Diagrams .............................................................................. 24
6.6
Electrical Diagrams & Panel Drawings .................................................................... 24
6.7
Civil Drawings.......................................................................................................... 24
7 SUPPLIER DOCUMENTS.............................................................................................. 25
7.1
Chemicals – Data Sheets & MSDS ......................................................................... 25
7.2
Collection Sump – Grundfos pumping station ......................................................... 25
7.3
Instruments ............................................................................................................. 25
7.3.1
Flow measuring system – Endress + Hauser Promag ......................................... 25
7.3.2
Flow transmitter – Endress + Hauser Prosonic.................................................... 25
7.3.3
Level switches – Grundfos ................................................................................... 25
7.3.4
Level switches – ITT Flygt ................................................................................... 25
7.3.5
Pressure indicators – WIKA ................................................................................. 25
7.4
Lifting Equipment..................................................................................................... 25
7.5
Manhole covers – Coalition Trading polymer covers ............................................... 25
7.6
Media – Trickling filter packing ................................................................................ 25
7.7
Nozzles – Trickling filter .......................................................................................... 25
7.8
Pumps ..................................................................................................................... 25
7.8.1
Collection sump – Grundfos ................................................................................ 25
7.8.2
Dosing pumps – Grundfos Alldos ........................................................................ 25
7.8.3
Effluent sump – Sakuragawa ............................................................................... 25
7.8.4
Recycle sump – Grundfos ................................................................................... 25
7.9
Tanks – Chemical dosing ........................................................................................ 25
7.10 Valves ..................................................................................................................... 25
7.10.1 Valve actuators – Noah ....................................................................................... 25
7.10.2 Float valve – Vosa ............................................................................................... 25
7.10.3 Gate valves – Pleix-Quip ..................................................................................... 25
7.10.4 PVC valves .......................................................................................................... 25
8 COMMISSIONING & HANDOVER ................................................................................. 26
8.1
Installation & Commissioning Checklist ................................................................... 26
8.2
Installation Parameters............................................................................................ 26
8.3
Commissioning Parameters .................................................................................... 26
8.4
Normal Operating Parameters ................................................................................ 26
8.5
Operator Training Register ...................................................................................... 26
8.6
Commissioning Certificate ....................................................................................... 26
8.7
Handover Certificate................................................................................................ 26
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1 TECHNICAL DATA
1.1 BACKGROUND
VWS Envig is a total solutions water and wastewater treatment company, offering a full range of
activities from turnkey contracting for small and large projects, to specialised services and speciality
chemicals for the industrial and municipal markets. These activities are all undertaken from the
company's offices in South Africa, Botswana and Namibia.
VWS Envig specialises in the design, construction, commissioning and operation of water and
wastewater treatment plants and offers a full range of operational contracts including technical
assistance, complete outsourcing, and financing of projects.
VWS Envig is recognised worldwide for its water treatment expertise.
VWS Envig was contracted to design a sewage treatment plant for XXX in XXX to alleviate the pressure
on the overloaded oxidation ponds currently in use. VWS designed the plant in conjunction with Aqua
Services and Engineering our Namibian sister company. VWS constructed all steel work and provided
all process and mechanical equipment including the design guidelines of the civil structures for the
sewage treatment plant. VWS also constructed the steel work for the treated effluent sump including
supply of pumps and piping within the contract battery limits.
Guidelines were given to the civil engineer for design of the diversion sump, float valve sump and
effluent sump.
1.2 SUMMARISED TECHNICAL DESCRIPTION
The Sewage Treatment Plant was designed to cater for extensive daily fluctuations, as well as to allow
future extensions to the plant to double the capacity at a later stage by adding similar modules as exist
now.
Trickling filter technology was chosen because it constitutes simple but extremely versatile
technology, does not require skilled operators and produces a final effluent of high quality that
can be discharged back into the environment or re-used as irrigation water for gardening or to grow
selective crops.
Major treatment components in this plant include rough screening, anaerobic digestion in a septic tank,
carbon removal and nitrification in a trickling filter, sludge removal by means of a secondary clarifier,
and disinfection in a chlorine contact tank.
The final effluent is stored in a reservoir for recirculation to the process plant or irrigation purposes.
Warning: Untreated sludge should not be discharged directly into stream, rivers or
dams due to the possibility of presence of diseases, worms, etc.
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1.3 RAW AND FINAL WATER QUALITY AND FLOW
Plant capacity
Maximum no. of people
Flow rates:
Average dry weather flow (ADWF)
Peak hydraulic flow (PWWF)
Inflow water quality (average):
Chemical Oxygen Demand (COD)
Biological Oxygen Demand (BOD)
Ammonia Nitrogen NH4-N
XXX
XXX
m3/d (max)
PE
XXX
XXX
m3/h
m3/h
800
400
49
mg/l
mg/l
mg/l
Final (treated) water quality:
After treatment, the final effluent will have a quality equal or better than specified in the South African
Water Resources Management Act, 2004 (Act No 24 of 2004).
[Final effluent will comply with the General Standards as laid out in the Government Gazette Regulation
R553 of 5 April 1962, in Section 21(1) and 21(2) of the Water Act (Act No 54 of 1956).]
In line with common practice in South Africa, the plant has been designed to produce final effluent to
comply with the RSA General Standard for Discharge as published in Table 3.2 of Gazette No. 20526 of
8 October 1999 as shown below.
Substance/Parameter RSA Standard
Faecal Coliforms (per 100 ml)
Chemical Oxygen Demand (mg/l)
pH
Ammonia (ionised and un-ionised) as Nitrogen (mg/l)
Suspended Solids (mg/l)
BOD
1,000
75* after removal of algae
5.5 - 9.5
3
25
20
The parameters can not be guaranteed due to these being dependant on the effluent supply content.
Further treatment processes might have to be added dependant on the supply effluent analysis.
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2 TREATMENT PLANT
2.1 TREATMENT PLANT OVERVIEW
A complete treatment based on new generation trickling filter technology, was provided. The plant
includes all unit processes and treatment components required to accomplish rough screening before
entering the septic tank, primary treatment, carbon removal and nitrification, solids removal (secondary
settling) and disinfection (chlorination).
Raw sewage from the inlet pipe to the oxidation ponds is diverted from a sump above the trickling filter
plant. From the diversion sump it flows through a float valve sump which is equipped with a flow control
valve and float valve which will shut the flow to the trickling filter plant to prevent overflow during power
outages. From the float valve sump raw sewage flows into the final collection sump TK-1000 fitted with
duty/standby pumps pumping the raw sewage to the trickling filter sewage treatment plant where it
discharges into an inlet box CT-1100 before flow is diverted equally into the septic tank modules CT1200 & CT-1201. The following section describes the process and equipment that is provided. Please
also refer to the included process and instrumentation diagram.
An effluent treatment plant to serve a mining community with shift workers must cater for extreme
fluctuations in flow (and load) throughout the year. This requires great flexibility if a biological treatment
plant is employed. New generation trickling filter technology in conjunction with a septic tank to serve as
buffer tank was considered to be the most appropriate technology for this application. Trickling filters
employ fixed film technology, which can accommodate considerable fluctuations in flow and load
(biological), incorporate simple technology and require no process control.
The trickling filter design incorporates continuous recirculation through and wetting of the media, even
during times of low or no inflow. This ensures that the bioculture is kept alive during times of low or no
inflow.
The sludge settled in the secondary clarifier CT-1600 of the trickling filter system is recycled back to the
primary treatment tank (septic tank) CT-1200 & CT-1201 and the recycle stream is variable. Latter is
achieved by an adjustable timer, which is set to switch the sludge recycle flow on/off on a time basis.
Also, part of the mixed liquor (outflow from the trickling filter) is recycled.
For biological treatment the following unit processes are as follows:
•
Flow equalisation / smoothening and anaerobic digestion in septic tank (CT-1200 & CT1201);
•
Anoxic treatment with nitrate rich recycle in a recycle sump (CT-1300);
•
Aerobic/attached growth treatment for carbonaceous material removal and nitrification in
trickling filters (TF-1400 & TF-1401).
•
Solids removal in a secondary clarifier (CT-1600)
2.2 EQUIPMENT DETAILS
2.2.1 Diversion sump
Qty
Purpose
Ancillaries
C792_DEIA_AppendixE1_OMPlan.doc
: 1 in main sewage line feeding oxidation ponds
: To divert raw sewage from the main line to the new plant
: Proposed 1 off screen
Page 7 of 34
2.2.2 Control valve sump
Qty
Purpose
Ancillaries
: 1 in newly diverted sewage line feeding trickling plant
: To control inflow to new STP, shut off flow based on rising level in
time of power outages and reopen if level has dropped after
power reconnection
: 1 off 150NB gate valve for flow control
2.2.3 Float valve sump with flow control
Qty
Purpose
Ancillaries
: 1 in newly diverted sewage line feeding trickling plant
: To control inflow to new STP, shut off flow based on rising level in
time of power outages and reopen if level has dropped after
power reconnection
: 1 off 150NB equilibrium float valve
2.2.4 Collection sump
Prefabricated pump sump
Qty.
Tag No.
Make / M.O.C.
Selected pump duty point
Capacity
Ancillary items
Pumps in sump
Pump make and model
:1
: TK-1000
: Grundfos PUST 10.25.D.A.SS.DPSE 1000 X 2500
: 15 m3/hr at 17.5 mWG
: 1.8 m3
: The PUST tank comes pre-mounted with all necessary
accessories and valves as supplied by Grundfos.
: 2 off (duty/standby) PC1000 & PC1001
: Grundfos SLV 65.65.30.2.50D
2.2.5 Screening facility - Inlet box with manual rake screen
The inlet box is fitted with a bar screen (manual screen) and drip tray. Access for an operator with a
wheelbarrow is provided next to the inlet box. Once per day, the operator has to rake trapped
matter (screenings) with the rake onto the drip tray and leave this to dewater until the next day. The
(semi-dry) screenings from the previous day should be discarded at a suitable waste disposal site
or incinerated.
Qty.
VWS Tag No.
Make / M.O.C.
Capacity
Flow control
Screening
C792_DEIA_AppendixE1_OMPlan.doc
: 1 Split box with inlet to each of two septic tank compartments
: CT-1100
: Concrete structure
: 2.4 m3 each x 2 compartments
: Manually adjusted stainless steel penstocks PS-1100 & PS-1101
: MS-1100 & MS-1101 manually cleaned with rake and drip dry
system
Page 8 of 34
2.2.6 Flow equalisation and anaerobic digestion – Septic tank modules
After screening the effluent enters a twin module, three-compartment septic tanks (CT-1200 & CT1201). Solids and sludge settle out and are digested in the first compartment of this tank, while the
second and third compartment mainly contains grey water. Anaerobic conditions in this tank ensure
BOD removals of at least 35 % to 50 %.
Additionally, aerobic sludge from the secondary settler is recycled to the inlet box, to be further
digested in the septic tank. This reduces the overall sludge volume produced in the biological
system.
The design parameters of the septic tank are as follows:
Type
Capacity
Retention time
(based on ADWF)
: Three-compartment, horizontal flow
: 180 m³ x 2 modules = 360 m3
: 36 h
Occasionally, the sludge accumulated in the septic tank must be removed. The amount of sludge
accumulated in especially the first compartment of each train of the septic tank has to be assessed
at least every six months. This is further described in Section 2.4.7 of this manual.
When approx. 400 to 500 mm of sludge has accumulated on the bottom of the first compartment of
the septic tank, desludging is required. Only the sludge and scum in the first compartment needs to
be removed by pumping it out. To remove this sludge, the operator can use his own desludge
pump or he may use one of the trickling filter feed pumps which is on standby for this purpose.
The effluent from the septic tank is discharged into the recycle sump (CT-1300).
2.2.7 Anoxic Zone – Recycle sump
In the recycle sump (CT1300), oxygen deficient effluent from both septic tanks is mixed with
aerated, nitrate-rich effluent that is recycled from the sumps of the trickling filter (CT-1500 & CT1501). The recycle sump is sized to ensure anoxic conditions are maintained inside this tank, and
is fitted with three open impeller submersible pumps (2 on duty (one for each module), 1 common
standby, cyclic operation) as follows:
Tag Number
Make and Model
Type
Selected duty point
Motor
: PC1300 / PC1301 / PC1302
: Grundfos SLV 65.65.30.2.50D
: Submersible, open impeller
: 29 m³/h at 12 mWG
: 3.0 kW, 380-415 V
During times of no inflow to the plant, there will be no discharge from the septic tank into this sump.
The pumps will then continue recirculating water from the trickling filter basin through the recycle
sump back to the filter media, ensuring that the biomass on the media is kept wet (and alive). The
pumps are fitted with a run dry protection level switch (LS1300 LL). If the period of non-inflow to
the plant is very long, it can be expected that water will be lost through evaporation and the level in
this sump will drop. To then prevent the pump(s) from running dry, they will be switched off (trip) at
low low-level.
Should the plant receive inflow again, the level in the sump will rise and the level switch (LS1300 L)
will switch the pump(s) on automatically.
The recycle flow is reduced as the level in the pump sump rises due to closing of the electrically
actuated return valves (XV1501, XV1502, XV1503 & XV1504) by high level switch (LS1300 H) and
more effluent is discharged to the clarifier. This also ensures that no operator will be required to
switch the plant on or off.
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An access platform is provided for manual valve operation and for maintenance purposes on the
pumps, valves and level switches within the recycle sump.
Pumps in sump
See detailed pump section / pump schedule
2.2.8 Trickling filter towers with collection basins
The trickling filter system (TF1400 & TF1401) consists of a bed of highly permeable medium, which
serves as a platform for micro-organisms to attach to and grow on, to form a biological film. The
wastewater is sprayed over and percolates through the media. Organic material in the wastewater
is absorbed by micro-organisms growing as a biological film on the media. In the outer portion of
the film, aerobic organisms degrade organic material, whereas anaerobic organisms exist deeper
into the biological film, i.e. near the surface of the media.
The new generation trickling filter is provided with a bed of approximately 80 m³ per module (inside
dimension of each module 2.975 m x 4.4 m x 6 m high) plastic (UV protected PVC) packing
medium as shown in Figure 1 & 2.
Figure 1. Trickling Filter Media (Packing)
Figure 2. Packing after glueing into blocks
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Water (effluent) from the trickling filter feed sump (recycle sump CT-1300) is distributed (not
necessarily evenly) and sprayed over the top surface of the media using a simple system of open,
non-clogging nozzles positioned on a 100mm OD uPVC header. The water then percolates through
the media. The orifice sizes of the nozzles have been set to Ø 18mm.
The uPVC header is equipped with flushing valves on the ends of each leg. After checking /
cleaning the nozzles once a week, these valves need to be opened to clear any sludge that
accumulated in the pipes.
The reason for an aerobic and anaerobic layer being established is an increase in the thickness of
the microbial layer, causing the diffused oxygen to be consumed before it can penetrate the full
depth of the microbial layer. Therefore, oxygen only reaches the outer layer of micro organisms
resulting in aerobic conditions, whereas deeper into the biological film no oxygen is available
resulting in anaerobic conditions. Figure 3 demonstrates this principle.
Figure 3. Biological activity on trickling filter media
Water that has passed through the trickling filter is collected in the trickling filter basins (CT 1500 &
CT-1501) and then flows to a static settler.
Biological solids that have become detached from the packing media must be removed before the
effluent is disinfected and can be finally discharged. Removal of the biomass is achieved in a
conventional, secondary settling tank.
The design parameters of the trickling filter are as follows:
Tag Number
Type
Design Flow (ADWF)
Design Load
: TF-1400 & TF-1401
: Modern, plastic media packing (UV stabilised PVC)
: 240 m³/d
: 192 kg/d COD + 11.7 kg/d NH4-N
A simple system of non-clogging, open nozzles will be used to distribute the water from the recycle
sump over the top of the media. The wastewater is sprayed over and percolates through the
media. Organic material in the wastewater is absorbed by the micro-organisms growing as a
biological film on the media and ammonia nitrogen is converted to nitrites and nitrates.
The water, after percolating through the media, is collected in the trickling filter basin (CT-1500 &
CT-1501), where part of the nitrate-rich water is recycled back into the recycle sump and part
overflows into the secondary clarifier (CT-1600).
The trickling filter basins are each fitted with 45° V-Notch weirs to control the level in the system.
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2.2.9 Secondary Clarifier
Treated effluent from the trickling filter is discharged into the settling tank (CT-1600), where the
suspended solids settle out and clear water is drawn off via a draw-off pipe at the top of the
clarifier.
The sludge is collected in the bottom cone of the clarifier and pressed through a 63mm discharge
pipe by means of hydrostatic pressure. The sludge is allowed to periodically drain back into the
feed pipe of the inlet screen by opening a sludge discharge valve (XV1601). The sludge recycling
frequency can be changed by modifying the opening and closing duration of this actuator. These
levels are however set by the process engineer during commissioning and should not be changed
by the operator.
Biological solids that have become detached from the packing media have to be removed before
the effluent is disinfected and can be finally discharged. The hydraulics of the plant will ensure that
water from the trickling filter basin will only overflow into the secondary settling tank if there is inflow
into the plant.
The clarifier design parameters are as follows:
Tag Number
Type
Surface Area
Draw off system
Stilling well
: CT-1600
: Square tapering sides – casted concrete structure
: 3.5 m x 3.5 m = 12.25 m2
: 90mm OD uPVC pipe system with inverted draw off holes
: Stainless steel structure & internals
Design Flows (Hydraulic):
ADWF
PWWF
: 240 m³/d
: 15 m³/h
The clarifier is be fitted with a centre mixing/stilling well, clarified water draw off piping, and sludge
removal pipe.
2.2.10 Disinfection – Chlorine contact channel
Clarified water from the settling tank is discharged into the chlorine contact tank (CT-1700). This
tank is sized for an effective contact time in excess of the required 20 min at PF. The contact
channel is fitted with fibre cement boards channelling the effluent in such a way that it makes six
direction changes before discharge to ensure effective mixing of chlorine and effluent.
The effluent is disinfected utilising calcium hypochlorite / sodium hypochlorite in the form of
dissolved granules or liquid. Dosing pump PD1800 is injecting chlorine at 2-4 ppm through an
injection valve located at the inlet of the contact channel.
The chlorine contact tank is fitted with a 45° V-Notch weir at the outlet. This is being utilised to
measure the flow at any specific time through the plant by a Endress + Hauser Prosonic flow
transmitter. The level reading is transmitted to the controller and converted to flow rate indicated on
the in field display unit.
Dosing Ancillaries:
Chemical dosing tank – Sodium Hypochlorite (HYDREX 8023) / Calcium Hypochlorite
Qty.
:1
Tag No.
: TK-1800
Make / M.O.C.
: Sinvac TE0070 - Polyethylene
Dimensions
: Ø 385 x 615 mm
Capacity
: 70 Litre
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Dosing pump (Chlorine)
Qty
Tag No
Make
Model
Duty
Power
:1
: PD1800
: Grundfos Alldos
: DMI 208-1.0-10
: 0.22 lph @ 10 bar
: 0.011 kW @ 220-240 VAC, 50 Hz, 1~
2.2.11 Final Water Discharge
Disinfected water from the chlorine contact channel (CT-1700) discharges into the final water
reservoir / effluent sump (CT-1900) by gravitational flow from where it is be pumped away to the
evaporation pond or diverted to the tailings dam through an 80NB pipe line.
The effluent sump civil structure as per Sirston consultants drawing numbers 3035-S01 Rev E,
3035-S13 Rev A, 3035-S14 Rev A & 3035-S15 Rev A is fitted with an access platform leading to a
duty / standby pump set with the following detail:
Qty.
Tag No.
Make / M.O.C.
Selected pump duty point
Ancillary items
: 2 (duty/standby)
: PC1900 / PC1901
: Sakuragawa U-2153AW
3
: 30 m /hr at 65 mWG
: Endress + Hauser Promag flow meter on outlet.
Refer to schedules and supplier’s documentation provided
2.2.12 Valves
Refer to valve schedule
2.2.13 Instruments
Refer to instrument schedule
2.3 SOLID WASTE REMOVAL
Sludge stabilisation and digestion takes place in the septic tank. This tank is bi-annually inspected. If the
sludge at the bottom of the first compartment of the septic tank has accumulated to a height of ca 400 to
500 mm the sludge has to be removed by pumping it into the adjacent sludge drying beds. A separate
sludge pump can be used for this, or alternatively one of the trickling filter feed pumps can be used to
manually remove this sludge from the tank.
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2.4 OPERATING PARAMETERS & PROCEDURES
2.4.1 Influent flow
Flow rate
Peak design flow
Supply pressure
: ADWF 240 m3
: 15 m3/hr
: Gravity flow from oxidation pond diversion sump then pumped by
collection sump pumps at 15 m3/hr at approximately 1.8 bar into
trickling filter sewage plant.
2.4.2 Chlorine Dosing (Treated effluent)
Guidelines:
Chemical
Tank make up (dilution)
Total make up
Tank capacity
Dosage
Dosing pump stroke setting
: Sodium Hypochlorite 12% (HYDREX 8023)
: 15 Litre sodium hypo + 50 Litre purified water
: 65 Litre
: 70 Litre
: 2 mg/l free chlorine
: 69% - Refer to Dosing pump selection sheet
Caution:
Inhaling chlorine fumes may cause serious lung damage. Avoid direct skin contact with
liquid chlorine solution. Use of correct PPE is recommended.
2.4.3 Plant Start-Up
Initial start-up
The anaerobic micro-organisms (in the septic tank) take about 5 months to mature / fully develop
the aerobic micro-organisms take about 8 to 12 weeks. If there is an anaerobic pond close by, it
will accelerate the process drastically by filling some of the sludge into the septic tank - 3 m3 to 5 m3
will do a lot to accelerate the process!
The above is also true for any other biological sewage treatment process, even pond systems.
The treated effluent will not be to standard upon initial start-up due to deficiency of microorganisms,
because the microbial cultures need time to establish, the clarifier outflow should also still look a bit
murky, because it will not have the bioflocs yet - that will only form once a proper biomass is
established and latter is slouched off by the water trickling through.
The following steps need to be followed to start the plant after a shutdown:
•
•
•
•
•
•
•
•
Check all pipework is in good condition;
Check that all valves (isolating and non-return valves) are functional;
Ensure all manual isolating valves are fully open;
Ensure the chlorine dosing tank contains the correct amount and concentration of chemical;
Switch on the electricity and all electrical equipment;
Check nozzles on top of trickling filter. Water must spray out of each nozzle and the
complete surface area must be covered (not necessarily evenly).
Select all valves & pumps to AUTO.
Press F1 to accept all alarm messages.
2.4.4 Normal Operation
No adjustments or special operational procedures other than routine operation and maintenance,
as described under Section 2.4.6, are required.
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2.4.5 Plant Shutdown
The following steps need to be followed to stop the plant:
•
•
•
•
•
•
•
Select all valves to SHUT, wait for the SHUT lamps to illuminate.
Select all pumps to OFF.
Desludge all tanks where aerobic sludge can accumulate (clarifier and recycle sump);
Switch off all power at the control board;
Keep water in all structures at all times.
Groundwater may lift empty structures!
Remove and clean all mechanical equipment;
For long shutdowns, take out all submersible pumps, clean with potable water and store in a
suitable store room.
2.4.6 Maintenance
This plant requires very little maintenance. However, the following routine maintenance is
necessary:
Daily
•
•
•
•
•
Remove all objects accumulated on the bar screen of the inlet box. Use a rake to remove
these and discard into waste bin;
Check that the chlorine dosing tank still contains sufficient chemical – replace when almost
empty;
Check free chlorine concentration of the final effluent at the outlet of the chlorine contact
tank. It should be at least in the range of 0,5 to 1,0 mg/l. Adjust if not within this range;
Check all indicating lights on the electrical panel. If any pump/motor has tripped, a red light
as well as the general alarm (strobe) light will come on;
Check pump operation.
Weekly
•
•
When operating in low-flow mode, check nozzles of trickling filter weekly and clean if
necessary. If a nozzle does not spray water, it is clogged. Manually clean nozzle with a piece
of wire. Use extreme care and put on safety gloves when working with effluent;
Remove collected grit and sand in inlet box and behind the inlet screen. Open screen to gain
access to grit and sand collected behind it.
Monthly
•
•
•
Dispose of contents in waste bin to a suitable landfill site. Cover with at least 800 mm soil. Or
incinerate if possible;
Check nozzles of trickling filter. If a nozzle does not spray water, it is clogged. Manually
clean nozzle with a piece of wire. Use extreme care and put on safety gloves when working
with effluent;
Check functionality of all manual valves by opening and closing each valve – replace if
necessary.
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Bi-Annually
•
Check sludge and scum accumulation in septic tank (see method below – Section 2.4.7).
Empty sludge into sludge drying bed and allow to thoroughly dry.
Annually
•
•
•
•
Clean settling tank pipework;
Inspect and maintain feed pumps as per manufacturer’s manual;
Check sludge and scum accumulation in septic tank (see method below – Section 2.4.7).
Empty sludge into sludge drying bed and allow to thoroughly dry;
Check all pipework and valves for leaks. Paint, repair or replace if necessary.
2.4.7 Septic Tank Inspection
The scum and sludge accumulations in a septic tank should be measured every six months to a
once a year. A useful tool for measuring the thickness of the scum is a rod graduated in
centimetres to which a disc or square flap is attached as shown in Figure 4. If this rod is pushed
through the scum mat, moved sideways to a place where the scum is undisturbed, and then pulled
up gently, the bottom of the scum layer can easily be felt. In the same way the bottom of the outlet
device can be located. The top of the sludge layer can be determined by slowly lowering this tool
into the tank. The increase in resistance encountered when the sludge layer is reached can
usually be felt quite easily, especially after a little experience.
Whenever the distance between the scum layer and the outlet device is 150 mm or less, the tank
should be cleaned.
A second (better) method of determining the extent of sludge accumulation is to push a rod
wrapped in white towelling, down to the bottom of the tank and rotating it a few times. On
withdrawal, the towelling will be blackened to the depth of the sludge. For this method the scum
should be broken away from the surface, in order to ensure free withdrawal of the towelling.
When the distance between the top of the sludge layer and the bottom of the outlet device is less
than 150 mm, the tank should be cleaned.
Before sludge and scum can be effectively removed by pumping, they must be intimately mixed
with the liquid by stirring with a wooden rod or the tool described above if it is made sufficiently
sturdy. Alternatively, the pump used for desludging can be inserted into the sludge and switched
on to turn around the sludge without connecting it up to the flexible hose. This mixture will form a
less viscous mass, which will flow more easily than undisturbed sludge or scum.
When septic tanks are cleaned, they should not be washed or disinfected. In order for the
digesting process to continue when the tank is put into use again, a small quantity of sludge must
be retained to serve as a starter.
VWS recommends using a separate submersible pump to empty the septic tank sludge as it
is not practical on large plants to remove the recycle sump standby pump for this purpose.
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Figure 4. Measuring Sludge and Scum in the Septic Tank
When handling sludge, operators should wear overalls and boots at all times and
direct contact with the sludge should be avoided to prevent infection with worms or
diseases.
For safety reasons, any person that is required to open or inspect the septic tank,
that person is required to wear a life jacket prior to and during opening of any
hatch. It is recommended to install a rope ladder on the inside of each chamber to
assist in case of accidental falling into the tank.
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3 CONTROL PHILOSOPHY
3.1 PLANT INLET FEED PUMPS
Two pumps PC1000/1001 (duty/standby) are situated in the collection sump. These pumps are
controlled automatically by level switches.
Effluent level falling below switch LS1000LL stops the duty pump, effluent level rising above switch
LS1000L starts the duty pump. This is a normal condition and does not alarm.
Pump duty is swapped each pump start. If the duty pump trips or fails to start then the standby
automatically takes over duty.
Effluent level rising above switch LS1000H will issue an alarm.
3.2 TRICKLING FILTER FEED PUMPS
Three submersible pumps (2 duty/1 standby) transfer the effluent from the septic tank to the top of the
trickling filters. Sufficient sump level is maintained to allow these pumps to run continuously.
Sump level falling below switch LS1300LL stops the duty pumps, effluent level rising above switch
LS1300L starts the duty pumps. An alarm is issued at low level.
Pump duty is swapped every eight hours. If a duty pump trips or fails to start then the standby
automatically takes over duty.
Sump level falling below switch LS1300L opens the recycle valves to maintain the minimum sump level.
Sump level rising above switch LS1300H shuts the recycle valves to allow normal treatment to continue.
Sump level rising above switch LS1300HH will issue an alarm.
3.3 SECONDARY SETTLER DESLUDGE
The secondary settler is fitted with a draw-off pipe to remove accumulated sludge from the bottom of the
settler and transfer it to the septic tank. The flow in this pipe is regulated periodically by means of an
electric actuator valve.
Note that this valve maintains its current position at power failure. If power is lost while the valve is open
then it must be manually shut by the operator.
During normal operation this valve should be set to open for a few minutes every hour. The shut period
(minutes) and open period (seconds) are set on the hmi screen on the mcc control panel.
3.4 DOSING CONTROL
The dosing pump is permanently powered on. Dosing rate is controlled by using the pulse (frequency)
output from flow transmitter FIT1701 as the stroke input of the dosing pump.
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3.5 FINAL WATER DISCHARGE PUMPS
Two pumps PC1900/1901 (duty/standby) are situated in the treated effluent sump. These pumps are
controlled automatically by level switches.
Treated effluent level falling below switch LS1900LL stops the duty pump, effluent level rising above
switch LS1900L starts the duty pump. This is a normal condition and does not alarm.
Pump duty is swapped each pump start. If the duty pump trips or fails to start then the standby
automatically takes over duty.
Treated effluent level rising above switch LS1900H will issue an alarm.
3.6 CONTROL PANEL MCC1000
Automated operation of the pumps and dosing is by PLC in control panel MCC1000. Operator
interaction is via the hmi, selector switches and lamps mounted on the mcc. The plant is designed to run
continuously, all pumps and valves should be selected to auto.
EMERGENCY STOP:
Pressing this button stops all equipment immediately. Twist the button to release.
400VAC/230VAC HEALTHY:
The mcc control panel has a voltage window comparator which will shutdown all controls if any phase
deviates by more than 5%. There is a start up delay of about ten minutes after power up, wait for the
healthy lamp before the plant will start.
PUMPS:
OFF – The pump will not run.
AUTO – The pump will run as required by the plc.
TEST – The pump will run regardless of conditions or interlocks. This should only be used for
maintenance purposes and never to operate the plant.
While selected to OFF or TEST position, a trip/fault alarm is active and HEALTHY lamp is off.
VALVES:
AUTO – The valve will open as required by the plc.
SHUT – The valve is forced shut, plc is ignored.
OPEN – The valve is forced open, plc is ignored.
An OPEN or SHUT lamp lights up when the valve has reached the respective position. This can take a
few seconds while the actuator is moving.
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3.7 ALARM CONDITIONS
Every new alarm activates the audible strobe beacon mounted at the mcc room. Press the CANCEL
button below the hmi screen to silence the beacon.
On the hmi scroll up/down using the arrow buttons to display all active messages, alarm messages are
display before status messages.
Alarm messages are latched, the message is only removed from display after the fault condition has
been corrected AND function button F1 is pressed to accept the alarm. Interlocks remain in force until
the relevant message has been cleared.
ALARM MESSAGES:
TK1000 level high
Effluent sump level is high.
CT1300 low stopped
Trickle filter sump level is low, transfer pumps stopped.
CT1300 level high
Trickle filter sump level is high.
PC#### trip/fault
Pump mcc tripped or field isolator activated.
PC#### run fail
Pump has failed to run after plc start issued.
XV#### fault
Electric actuated valve has failed to open/shut.
3.8 HMI PARAMETER SETTING
Sludge purge sequence times are set at the hmi. To display these settings use the down/up arrow
button to move to the desired setting, positioned on the top display line of the hmi. Press ENTER to
update the value field, use the up/down arrow to increase/decrease the value and press ENTER to
accept. Press ESC to exit all field value updates, the cursor moves to the left of the display and
up/down arrow buttons scroll up/down the display again.
• SLUDGE SHUT ### min - Set the wait time between sludge purge cycles in minutes.
• SLUDGE OPEN ### sec - Set the sludge valve open period per cycle in seconds.
NOTE: The wait timer is accumulated on running hours.
3.9 HMI PASSWORD
The HMI has no password restriction.
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3.10 CONTROL PANEL MCC2000
Automated operation of the final water discharge pumps is by PLC in control panel MCC2000. Operator
interaction is via the selector switches and lamps mounted on the mcc. The pumps are designed to run
according to level control, both pumps should be selected to auto.
PUMPS:
OFF – The pump will not run.
AUTO – The pump will run as required by the plc.
TEST – The pump will run regardless of conditions or interlocks. This should only be used for
maintenance purposes and never to operate the plant.
While selected to OFF or TEST position, a trip alarm is active and HEALTHY lamp is off.
LAMPS:
SUMP LEVEL LOW – The duty pump will not run. This is a normal condition.
SUMP LEVEL HIGH – Final water sump level is too high, this is an alarm condition.
DRIVE TRIPPED – MCC tripped or field isolator activated, this is an alarm condition.
ALARM CANCEL:
Press the button to silence the audible alarm.
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4 ELECTRICAL CONTROL
Refer to EC&I document C10-1436-06-11 for panel schematics.
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5 RECOMMENDED SPARES
The following spare holding is recommended to minimise long period shutdown in the event of failure:
All spares can be obtained from VWS Envig. Please refer to Engineering Schedules for detail on items.
Item
Qty
Description
1
1 ea
Submersible pump Grundfos SLV65.65.30.2.50D
2
1 ea
Submersible pump Sakuragawa U-2153AW
3
1 ea
Dosing pump – Alldos DMI 208 1,0-10 and service kit + installation set DN4 suitable for Cl 2
4
2 ea
Level switch – ITT Flygt ENM-10 (13 m)
5
2 ea
Pressure indicator – Wika, 63 mm, 0-1000 kPa, glycerine, back entry ¼” BSPT
6
1 ea
Endress + Hauser Prosonic Flow transmitter Prosonic S FDU90
7
1 ea
Endress + Hauser Promag 10W80 with local display
8
1 ea
PVC non return valve DN65
9
1 ea
PVC ball valve DN65
10
1 ea
Pleix-Quip butterfly valve 80NB
11
2 ea
Noah Electrical valve actuator SA-005
12
6 ea
Trickling filter distribution nozzles orifice sized down to diameter 18mm
Electrical Spares – Refer to Electrical Bill of Quantities on drawings Section 6
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6 DRAWINGS, DIAGRAMS, TABLES, SCHEDULES &
PROCEDURES
6.1
Pump Schedule
6.2
Valve Schedule
6.3
Instrument Schedule
6.4
Plant General Layout Drawings
6.5
Process & Instrument Diagrams
6.6
Electrical Diagrams & Panel Drawings
6.7
Civil Drawings
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7 SUPPLIER DOCUMENTS
7.1
7.2
7.3
Chemicals – Data Sheets & MSDS
Collection Sump – Grundfos pumping station
Instruments
7.3.1 Flow measuring system – Endress + Hauser Promag
7.3.2 Flow transmitter – Endress + Hauser Prosonic
7.3.3 Level switches – Grundfos
7.3.4 Level switches – ITT Flygt
7.3.5 Pressure indicators – WIKA
7.4 Lifting Equipment
7.5 Manhole covers – Coalition Trading polymer covers
7.6 Media – Trickling filter packing
7.7 Nozzles – Trickling filter
7.8 Pumps
7.8.1 Collection sump – Grundfos
7.8.2 Dosing pumps – Grundfos Alldos
7.8.3 Effluent sump – Sakuragawa
7.8.4 Recycle sump – Grundfos
7.9 Tanks – Chemical dosing
7.10 Valves
7.10.1 Valve actuators – Noah
7.10.2 Float valve – Vosa
7.10.3 Gate valves – Pleix-Quip
7.10.4 PVC valves
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8 COMMISSIONING & HANDOVER
The following checklists are to be completed by VWS and one copy issued to Client or Client’s
representative (receipt signed for)
8.1
Installation & Commissioning Checklist
8.2
Installation Parameters
8.3
Commissioning Parameters
8.4
Normal Operating Parameters
8.5
Operator Training Register
8.6
Commissioning Certificate
8.7
Handover Certificate
Reference documents:
General Layout
Process & Instrumentation Diagrams
Electrical Panel Diagrams
Operating & Maintenance Manual
C792_DEIA_AppendixE1_OMPlan.doc
C10-1436-00-01
C10-1436-01-01 & C10-1436-01-02
C10-1436-06-11
C10-1436 O&M
Page 26 of 34
Section 8.1
Doc. No. : C101436 INSTALLATION & COMMISSIONING CHECKLIST
Sheet: 1 / 1
Date :
No.
Description
Comments
Done
1
All equipment mounted securely
Yes
2
All mechanical & process connections done
and checked
Yes
3
All electrical and control instrumentation
connections done and checked
Yes
4
Chemical dosing tank positioned and dosing
line connected and tested
Yes
5
All installation measurements taken and
recorded
Yes
6
All panel tests performed
Yes
7
All spares and chemical supply handed to
client
Yes
For VWS Envig:
______________ ________________
Name
Title
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___________________
Signature
Section 8.2
Doc. No. : C101436 INSTALLATION PARAMETERS
Sheet: 1 / 1
Date :
No.
Description
Value
1
Float valve sump
1.1
Float shut off height
2
Collection sump
2.1
LS1000LL height
450 mm from floor
2.2
LS1000L height
1000 mm from floor
2.3
LS1000H height
1880 mm from floor
3
Recycle sump
3.1
LS1300LL height
450 mm from floor
3.2
LS1300L height
1180 mm from floor
3.3
LS1300H height
1650 mm from floor
3.4
LS1300HH height
2560 mm from floor
4
Trickling filter
4.1
TF1400 V-Notch crest to floor
510 mm
4.2
TF1401 V-Notch crest to floor
510 mm
5
Chlorine contact tank
5.1
CT1700 V-Notch crest to floor
1633 mm
5.2
CT1700 V-Notch crest to FIT1700
membrane
477 mm
5.3
FIT1700 probe to V-Notch plate
1000 mm
6
Effluent sump
6.1
LS1900LL height
600 mm from floor
6.2
LS1900L height
1150 mm from floor
6.3
LS1900H height
3330 mm from floor
For VWS Envig:
580 mm from floor
______________ ________________
Name
Title
C792_DEIA_AppendixE1_OMPlan.doc
Comment
Page 28 of 34
___________________
Signature
Section 8.3
Doc. No. : C101436 COMMISSIONING PARAMETERS
Sheet: 1 / 1
Date :
No.
Description
Value
Comment
1
Trickling filter
1.1
Spray Nozzle orifice diameter
18 mm
1.2
Nozzle spray diameter
1450 mm
2
Chlorine dosing
2.1
Chlorine make-up dilution
0.5 kg HTH per 10 l water
2.2
PD1800 pump setting
80 %
3
Chlorine Contact Tank
3.1
CaCl 2 concentration
2.5 mg/l
3.2
Max flow rate during commissioning
15.69 m3/h
4
Effluent sump
4.1
Max flow rate to evaporation pond
during cold commissioning
5
Recycle sump
5.1
Pump pressure
6
Collection sump
6.1
Pump pressure
For VWS Envig:
56 m3/h @ 2 bar
1 bar
0.6 bar
______________ ________________
Name
Title
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___________________
Signature
Section 8.4
Doc. No. : C101436 NORMAL OPERATING PARAMETERS
Sheet: 1 / 1
Date :
No.
Description
Design
Actual
flow rate not recorded
pressure 6 m WG
flow rate not recorded
pressure 10 m WG
1
Collection sump PC1000/1001
4.2 l/s @ 15 mWG
2
Recycle sump PC1300/1301/1302
7.8 l/s @ 17 mWG
3
Dosing pump setting
69 %
80 %
4
Effluent sump PC1900/1901
30 m3/hr @ 65 mWG
56 m3/hr @ 20 mWG
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
For VWS Envig:
______________ ________________
Name
Title
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___________________
Signature
Unit
Section 8.5
Doc. No. : C101436 OPERATOR TRAINING REGISTER
Sheet: 1 / 1
Date :
No.
Name
1
Title
Signature
Signed copy attached
2
3
4
5
6
7
8
9
10
Training has been given to the above persons in respect of:
•
•
•
Operation of plant
Mixing and safe handling of chemicals
Cleaning Procedure & general maintenance of plant
For VWS
______________ ________________
Name
Title
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___________________
Signature
8.6 COMMISSIONING CERTIFICATE
CLIENT
DESCRIPTION
:
:
CONTRACT NO :
VWS REF. No. :
XXX
WASTE WATER TREATMENT PLANT
XXX m3/DAY TRICKLING FILTER STP
XXX
XXX
This certificate is the final Commissioning Certificate and precedes the final Contract Handover Notification and
Acceptance.
The attached sheets cover the mechanical/electrical equipment acceptance and may include certain items
awaiting finalisation for reasons noted.
All operating parameters have been set and tested; performance and sampling reports are attached where
possible with available testing instrumentation.
All relevant staff members have been trained, the training register is attached.
The following documents are issued with this certificate:
C101436 O&M
C101436
C101436
C101436
Updated Operating & Maintenance Document (Final copy to be couriered)
Installation & Commissioning Checklist
Operating Parameters
Operators Training Register
Please sign one copy and return to the VWS Commissioning Technician to acknowledge receipt of this
certificate and all accompanying documents as listed above.
Issued By (for VWS)
__________________
Signature
________________________
Full name
__________________
Date
________________________
Full name
__________________
Date
Received By Client
__________________
Signature
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HANDOVER
For handover the following requirements must be satisfied:
1
Installation & Commissioning Checklist C101436 must be complete.
2
Any outstanding snag-list items must be clearly described on Checklist, including the action
plan and time period as agreed by VWS and Client.
3
Commissioning Operating Parameters C101436 must be complete.
4
Operating and maintenance training must be complete and register C101436 signed by all
attendees.
5
Two copies of Updated Operating & Maintenance documents issued.
6
Commissioning Certificate is issued.
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8.7 CONTRACT HANDOVER ACCEPTANCE CERTIFICATE
CLIENT
DESCRIPTION
:
:
CONTRACT NO :
VWS REF. No. :
Attention
:
XXX
WASTE WATER TREATMENT PLANT
XXX m3/DAY TRICKLING FILTER STP
XXX
ES10-1436
Project Manager
XXX
Dear Sir/s,
We have pleasure in confirming that the above upgraded equipment has been checked and tested by our
commissioning engineer. We will look upon the date of _____/_____/ 20_____ as the hand over date.
This letter serves to confirm that the contract is complete and we are confident that all items and equipment are
functioning properly, and in accordance with our specification. This handover may be signed subject to minor
outstanding items to be corrected within a time period as agreed between yourself and Veolia Water Systems. All
outstanding items are to be clearly identified in writing as well as the agreed course of correction / resolution and
time period.
Please sign both copies of this certificate and return one copy to the Veolia Water Systems commissioning
engineer. If you are not completely satisfied, please advise Veolia Water Systems, in writing within 7 days. If, within
30 days, no correspondence or signed copy is received, Veolia Water Systems will assume acceptance and the
guarantee period will start from the handover date.
Assuring you of our best attention at all times.
For Veolia Water Systems
__________________
Signature
________________________
Full name
__________________
Date
________________________
Full name
__________________
Date
For Client
__________________
Signature
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