OPERATING & MAINTENANCE MANUAL

PLANT : SEWAGE TREATMENT PLANT TRICKLING FILTER PLAN CLIENT : XXX

CONTRACT : XXX VWS REF. DATE : XXX : 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 clients 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 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

4 5 6

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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 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 XXX XXX XXX XXX 800 400 49 m3/d (max) PE m3/h m3/h mg/l mg/l mg/l

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 : 1 in main sewage line feeding oxidation ponds : To divert raw sewage from the main line to the new plant : Proposed 1 off screen

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2.2.2 Control valve sump

Qty Purpose : 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

Ancillaries

2.2.3 Float valve sump with flow control

Qty Purpose : 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

Ancillaries

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 : 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

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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 m 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 m/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 m 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 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 m/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 Design Flows (Hydraulic): ADWF PWWF : 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

: 240 m/d : 15 m/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 : 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 suppliers 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 manufacturers 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
1 2 3 4 5 6 7 8 9 10 11 12

Qty
1 ea 1 ea 1 ea 2 ea 2 ea 1 ea 1 ea 1 ea 1 ea 1 ea 2 ea 6 ea

Description
Submersible pump Grundfos SLV65.65.30.2.50D Submersible pump Sakuragawa U-2153AW Dosing pump Alldos DMI 208 1,0-10 and service kit + installation set DN4 suitable for Cl 2 Level switch ITT Flygt ENM-10 (13 m) Pressure indicator Wika, 63 mm, 0-1000 kPa, glycerine, back entry BSPT Endress + Hauser Prosonic Flow transmitter Prosonic S FDU90 Endress + Hauser Promag 10W80 with local display PVC non return valve DN65 PVC ball valve DN65 Pleix-Quip butterfly valve 80NB Noah Electrical valve actuator SA-005 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 6.2 6.3 6.4 6.5 6.6 6.7 Pump Schedule Valve Schedule Instrument Schedule Plant General Layout Drawings Process & Instrument Diagrams Electrical Diagrams & Panel Drawings Civil Drawings

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7 SUPPLIER DOCUMENTS
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 7.1 7.2 7.3

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8 COMMISSIONING & HANDOVER

The following checklists are to be completed by VWS and one copy issued to Client or Clients representative (receipt signed for)

8.1 8.2 8.3 8.4 8.5 8.6 8.7

Installation & Commissioning Checklist Installation Parameters Commissioning Parameters Normal Operating Parameters Operator Training Register Commissioning Certificate Handover Certificate
Reference documents:
General Layout Process & Instrumentation Diagrams Electrical Panel Diagrams Operating & Maintenance Manual C10-1436-00-01 C10-1436-01-01 & C10-1436-01-02 C10-1436-06-11 C10-1436 O&M

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Section 8.1 Doc. No. : C101436 INSTALLATION & COMMISSIONING CHECKLIST Sheet: 1 / 1 Date :
No. 1 2 3 4 5 6 7 Description All equipment mounted securely All mechanical & process connections done and checked All electrical and control instrumentation connections done and checked Chemical dosing tank positioned and dosing line connected and tested All installation measurements taken and recorded All panel tests performed All spares and chemical supply handed to client Comments Done Yes Yes Yes Yes Yes Yes Yes

For VWS Envig:

______________ ________________ Name Title

___________________ Signature

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Section 8.2 Doc. No. : C101436 INSTALLATION PARAMETERS Sheet: 1 / 1 Date :

No. 1 1.1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 4 4.1 4.2 5 5.1 5.2 5.3 6 6.1 6.2 6.3 Description Float valve sump Float shut off height Collection sump LS1000LL height LS1000L height LS1000H height Recycle sump LS1300LL height LS1300L height LS1300H height LS1300HH height Trickling filter TF1400 V-Notch crest to floor TF1401 V-Notch crest to floor Chlorine contact tank CT1700 V-Notch crest to floor CT1700 V-Notch crest to FIT1700 membrane FIT1700 probe to V-Notch plate Effluent sump LS1900LL height LS1900L height LS1900H height 600 mm from floor 1150 mm from floor 3330 mm from floor 1633 mm 477 mm 1000 mm 510 mm 510 mm 450 mm from floor 1180 mm from floor 1650 mm from floor 2560 mm from floor 450 mm from floor 1000 mm from floor 1880 mm from floor 580 mm from floor Value Comment

For VWS Envig:

______________ ________________ Name Title

___________________ Signature

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Section 8.3 Doc. No. : C101436 COMMISSIONING PARAMETERS Sheet: 1 / 1 Date :

No. 1 1.1 1.2 2 2.1 2.2 3 3.1 3.2 4 4.1 5 5.1 6 6.1 Description Trickling filter Spray Nozzle orifice diameter Nozzle spray diameter Chlorine dosing Chlorine make-up dilution PD1800 pump setting Chlorine Contact Tank CaCl 2 concentration Max flow rate during commissioning Effluent sump Max flow rate to evaporation pond during cold commissioning Recycle sump Pump pressure Collection sump Pump pressure 0.6 bar 1 bar 56 m3/h @ 2 bar 2.5 mg/l 15.69 m3/h 0.5 kg HTH per 10 l water 80 % 18 mm 1450 mm Value Comment

For VWS Envig:

______________ ________________ Name Title

___________________ Signature

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Section 8.4 Doc. No. : C101436 NORMAL OPERATING PARAMETERS Sheet: 1 / 1 Date :
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Description Collection sump PC1000/1001 Recycle sump PC1300/1301/1302 Dosing pump setting Effluent sump PC1900/1901 Design 4.2 l/s @ 15 mWG 7.8 l/s @ 17 mWG 69 % 30 m3/hr @ 65 mWG Actual flow rate not recorded pressure 6 m WG flow rate not recorded pressure 10 m WG 80 % 56 m3/hr @ 20 mWG Unit

For VWS Envig:

______________ ________________ Name Title

___________________ Signature

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Section 8.5 Doc. No. : C101436 OPERATOR TRAINING REGISTER Sheet: 1 / 1 Date :
No. 1 2 3 4 5 6 7 8 9 10 Name Signed copy attached Title Signature

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

___________________ Signature

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8.6 COMMISSIONING CERTIFICATE CLIENT DESCRIPTION : : XXX WASTE WATER TREATMENT PLANT XXX m3/DAY TRICKLING FILTER STP XXX XXX

CONTRACT NO : VWS REF. No. :

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

Received By Client

__________________ Signature

________________________ Full name

__________________ Date

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HANDOVER
For handover the following requirements must be satisfied:
1 2 Installation & Commissioning Checklist C101436 must be complete. Any outstanding snag-list items must be clearly described on Checklist, including the action plan and time period as agreed by VWS and Client. Commissioning Operating Parameters C101436 must be complete. Operating and maintenance training must be complete and register C101436 signed by all attendees. Two copies of Updated Operating & Maintenance documents issued. Commissioning Certificate is issued.

3 4

5 6

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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

For Client

__________________ Signature

________________________ Full name

__________________ Date

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