AM-PRO-WWT-WWT 3.1 Primary Treatment-SEC3 Issue 1.1

THAMES WATER Asset Management
Internal Company and Partners Asset Standards

Technical Lead: Bryan Bleeker Issue 1.1
AM-PRO-WWT-WWT 3.1 Primary Treatment-SEC3 Page 1 of 21
UNCONTROLLED WHEN PRINTED

Asset Management
Asset Standard
Section 3 of 5
Operating Standard

Wastewater Non-Infrastructure
WWT 3.1 Primary Treatment

Document Reference AM-PRO-WWT-WWT 3.1 Primary Treatment-SEC3
Version Issue 1.1
Data Owner Sarah Shipsey
Data Steward Kevin Kelleher
Technical Lead Bryan Bleeker
Document Author Tim Wheatley
Authorised by Asset Standards
Document Location AM Lotus Notes Best Practice Database on LNAPP01
Date of Issue December 2012
Reason for Issue Conversion and validation of old BOP into new Standard format
Next Review December 2014



Contents:-

3.0 Operating Standard..................................................................................................................... 3
3.1 Primary Treatment Performance Measures ............................................................................ 3
3.2 Operator Activities ................................................................................................................... 5
3.2.1 Process Checklist Circular Primary Settlement Tanks.................................................. 5
3.2.2 Process Checklist Horizontal Scraped Primary Settlement Tanks ............................... 6
3.2.3 Process Checklist Pyramidal Autodesludged Primary Settlement Tanks..................... 7
3.2.4 Process Checklist Pyramidal No Power Primary Settlement Tanks............................. 8
3.2.5 Process Checklist Horizontal Unscraped Primary Settlement Tanks ........................... 9
3.2.6 Process Checklist Lamella Primary Settlement Tanks ............................................... 10
3.2.7 Process Checklist Notes ................................................................................................ 11
3.3 Troubleshooting Guide.......................................................................................................... 12
3.3.1 Dos and Donts............................................................................................................... 14
Appendices .......................................................................................................................................... 15
3.4 Operation............................................................................................................................... 15
3.4.1 Primary Settlement Efficiency........................................................................................ 15
3.4.2 Impact on Secondary Treatment Processes.................................................................. 16
3.4.3 Primary Settlement Tank Optimisation........................................................................... 18
3.4.4 Contingency Planning.................................................................................................... 19
3.4.5 Plant Release / Taking out of and Bringing into service ................................................ 20



3.0 Operating Standard

3.1 Primary Treatment Performance Measures

Measure Why Frequency Method of
Collection
Screened
Crude
Sewage
Concentration of BOD to calculate organic load and TSS
to calculate suspended solids load.
This is taken downstream of site liquor returns.
Operational
Sampling
Program
Sampling /
Laboratory
Analysis
Site Return
Stream Flow
Site Return stream that may be required for process
calculations. This could be SAS from Activated sludge
works, humus sludge from biological filtration works,
backwash sludge from tertiary plants and liquor return
from sludge works.
Daily or
continuous
SCADA, Onsite
flow reading,
Daily log
Settled
Sewage
Concentration of BOD / NH
3
to calculate organic load
and TSS to calculate suspended solids load.
Works PE
<5000
5,000 - 25,000
25,000-100,000
100,000-250,000
250,000-1,000,000
>1,000,000

Quarterly
Quarterly
Monthly
Monthly
Weekly
Weekly

Sampling /
Laboratory
Analysis
Settled
Sewage
Flow
Settled Sewage Flow required for Process Calculations. Continuous SCADA, Onsite
flow reading,
Daily log
Sludge
Blanket
Level
To ensure Sludge Blanket levels are controlled so that
gross solids are not lost or discharged in the settled
sewage
Daily or
Continuous
SCADA, Fixed
or Portable
Blanket
Detectors.
Hydraulic
Retention
Time
The hydraulic retention time is the length of time that the
screened sewage actually spends in the primary
settlement tank(s). Typically it should be above 2 hours
but the ideal figure varies for different tank
configurations. A reduction in the retention period occurs
for example during periods of peak flow. Measure within
process design ensures robust plant performance and
compliance the withdrawal of fresh sludge.
Quarterly Process
Calculation
Sludge Flow Control of Primary Sludge withdrawal Rates (on large
works): The amount of solids withdrawn from the system
will determine the amount of solids settled in the tanks
and therefore the efficiency and performance of this
stage of treatment.
Daily or
Continuous
Automatic De-
sludge Pump
Control.
SCADA


Measure Why Frequency Method of
Collection
Percentage
dry solids of
the sludge
thickening
Plant
Concentration of suspended solids to calculate organic
load to calculate suspended solids load withdrawn from
the primary treatment stage.
Operational
Sampling
Program
Sampling /
Laboratory
Analysis

rs Asset Standards

Internal Company and Partne

3.2 Operator Activities

3.2.1 Process Checklist Circular Primary Settlement Tanks
Any of the following checks that result in faulty operation needs to be logged and reported for maintenance / repair
Task Low PE
(10-1000)
Low-Med
(1000-5000)
Med PE
(5000-20,000)
High PE
(20,000-
350,000)
Manned
(350,000+)
PST - CIRCULAR - CHECK BRIDGE/SCRAPER OPERATION OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - CIRCULAR - CHECK SAFETY GUARDS OP/1W OP/1W OP/1W OP/1W OP/1W
PST - CIRCULAR - CHECK SCUM TRAP FOR NORMAL OPERATION AND CLEAN/HOSE OUT OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - CIRCULAR - CHECK DE-SLUDGE PUMP AND TIMER FOR NORMAL OPERATION OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - CIRCULAR - CHECK AND LOG SLUDGE LEVEL BY DIPPING TANKS OP/1W OP/1W/3D OP/1W/3D OP/1W/3D OP/1W/3D
PST - CIRCULAR - CHECK AND REMOVE ANY BUILD-UP OF SCUM OR RAG ON TANK
SURFACE, WEIRS OR LAUNDER CHANNELS
OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - CIRCULAR - CHECK SCUM BOARDS FOR BREAKS OR CARRY UNDER OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - CIRCULAR - CHECK SETTLED SEWAGE QUALITY (VISUAL CHECK ONLY) OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - CIRCULAR - CHECK STILLING CHAMBER FOR RAG, CLEAR AS NECESSARY OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - CIRCULAR - PERIODICALLY EMPTY AND CHECK INTEGRITY T1/48M T1/48M T1/48M T1/48M T1/48M
PST - CIRCULAR - DISTRIBUTION CHAMBER - CHECK ALL VALVES, PENSTOCKS AND
VARIABLE WEIR POSITIONS/OPERATION
OP/1W OP/1W OP/1W OP/1W OP/1W
PST - CIRCULAR - DISTRIBUTION CHAMBER - CHECK COPASACS AND CHANGE AS
NECESSARY
PST - CIRCULAR - DISTRIBUTION CHAMBER - CHECK FLOW SPLIT IS CORRECT OP/1W OP/1W OP/1W OP/1W OP/1W
PST - CIRCULAR - DISTRIBUTION CHAMBER - CHECK WEIRS AND CLEAN OP/1W OP/1W OP/1W OP/1W OP/1W
PST - CIRCULAR - DISTRIBUTION CHAMBER - REMOVE ANY SCUM AND DEBRIS,
INCLUDING GRIT

3.2.2

Process Checklist Horizontal Scraped Primary Settlement Tanks
Task Low PE
(10-1000)
Low-Med
(1000-5000)
Med PE
(5000-20,000)
High PE
(20,000-
350,000)
Manned
(350,000+)
PST - HORIZONTAL SCRAPED - CHECK BRIDGE/SCRAPER OPERATION OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - HORIZONTAL SCRAPED - CHECK SAFETY GUARDS OP/1W OP/1W OP/1W OP/1W OP/1W
PST - HORIZONTAL SCRAPED - CHECK SCUM TRAP FOR NORMAL OPERATION AND
CLEAN/HOSE OUT
PST - HORIZONTAL SCRAPED - CHECK DE-SLUDGE PUMP AND TIMER FOR NORMAL
OPERATION
PST - HORIZONTAL SCRAPED - CHECK AND LOG SLUDGE LEVEL BY DIPPING TANKS OP/1W OP/1W/3D OP/1W/3D OP/1W/3D OP/1W/3D
PST - HORIZONTAL SCRAPED - CHECK AND REMOVE ANY BUILD-UP OF SCUM OR RAG
ON TANK SURFACE, WEIRS OR LAUNDER CHANNELS
PST - HORIZONTAL SCRAPED - CHECK SCUM BOARDS FOR BREAKS OR CARRY UNDER OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - HORIZONTAL SCRAPED - CHECK SETTLED SEWAGE QUALITY (VISUAL CHECK
ONLY)
PST - HORIZONTAL SCRAPED - PERIODICALLY EMPTY AND CHECK INTEGRITY T1/48M T1/48M T1/48M T1/48M T1/48M
PST - HORIZONTAL SCRAPED - DISTRIBUTION CHAMBER - CHECK ALL VALVES,
PENSTOCKS AND VARIABLE WEIR POSITIONS/OPERATION
PST - HORIZONTAL SCRAPED - DISTRIBUTION CHAMBER - CHECK COPASACS AND
CHANGE AS NECESSARY
PST - HORIZONTAL SCRAPED - DISTRIBUTION CHAMBER - CHECK FLOW SPLIT IS
CORRECT
PST - HORIZONTAL SCRAPED - DISTRIBUTION CHAMBER - CHECK WEIRS AND CLEAN OP/1W OP/1W OP/1W OP/1W OP/1W
PST - HORIZONTAL SCRAPED - DISTRIBUTION CHAMBER - REMOVE ANY SCUM AND
DEBRIS, INCLUDING GRIT


3.2.3

Process Checklist Pyramidal Autodesludged Primary Settlement Tanks
Task Low PE
(10-1000)
Low-Med
(1000-5000)
Med PE
(5000-20,000)
High PE
(20,000-
350,000)
Manned
(350,000+)
PST - PYRAMIDAL AUTODESLUDGED - CHECK DE-SLUDGE PUMP AND TIMER FOR
NORMAL OPERATION
OP/1W OP/1W/3D OP/1W/5D N/A N/A
PST - PYRAMIDAL AUTODESLUDGED - CHECK AND LOG SLUDGE LEVEL BY DIPPING
TANKS
PST - PYRAMIDAL AUTODESLUDGED - CHECK AND REMOVE ANY BUILD-UP OF SCUM OR
RAG ON TANK SURFACE, WEIRS OR LAUNDER CHANNELS
PST - PYRAMIDAL AUTODESLUDGED - CHECK SCUM BOARDS FOR BREAKS OR CARRY
UNDER
PST - PYRAMIDAL AUTODESLUDGED - CHECK SETTLED SEWAGE QUALITY (VISUAL
CHECK ONLY)
PST - PYRAMIDAL AUTODESLUDGED - CHECK STILLING CHAMBER FOR RAG, CLEAR AS
NECESSARY
PST - PYRAMIDAL AUTODESLUDGED - MANUALLY DE-SLUDGE TO WATER OP/1W OP/1W OP/1W N/A N/A
PST - PYRAMIDAL AUTODESLUDGED - PERIODICALLY EMPTY AND CHECK INTEGRITY T1/48M T1/48M T1/48M N/A N/A
PST - PYRAMIDAL AUTODESLUDGED - DISTRIBUTION CHAMBER - CHECK ALL VALVES,
OP/1W OP/1W OP/1W N/A N/A
PST - PYRAMIDAL AUTODESLUDGED - DISTRIBUTION CHAMBER - CHECK COPASACS
AND CHANGE AS NECESSARY
PST - PYRAMIDAL AUTODESLUDGED - DISTRIBUTION CHAMBER - CHECK FLOW SPLIT IS
CORRECT
PST - PYRAMIDAL AUTODESLUDGED - DISTRIBUTION CHAMBER - CHECK WEIRS AND
CLEAN
PST - PYRAMIDAL AUTODESLUDGED - DISTRIBUTION CHAMBER - REMOVE ANY SCUM
AND DEBRIS, INCLUDING GRIT

3.2.4

Process Checklist Pyramidal No Power Primary Settlement Tanks
Task Low PE
(10-1000)
Low-Med
(1000-5000)
Med PE
(5000-20,000)
High PE
(20,000-
350,000)
Manned
(350,000+)
PST - PYRAMIDAL NO POWER - CHECK AND LOG SLUDGE LEVEL BY DIPPING TANKS OP/1W OP/1W/3D OP/1W/3D N/A N/A
PST - PYRAMIDAL NO POWER - CHECK AND REMOVE ANY BUILD-UP OF SCUM OR RAG ON
TANK SURFACE, WEIRS OR LAUNDER CHANNELS
PST - PYRAMIDAL NO POWER - CHECK SCUM BOARDS FOR BREAKS OR CARRY UNDER OP/1W OP/1W/3D OP/1W/5D N/A N/A
PST - PYRAMIDAL NO POWER - CHECK SETTLED SEWAGE QUALITY (VISUAL CHECK ONLY) OP/1W OP/1W/3D OP/1W/5D N/A N/A
PST - PYRAMIDAL NO POWER - CHECK STILLING CHAMBER FOR RAG, CLEAR AS
NECESSARY
PST - PYRAMIDAL NO POWER - DESLUDGE ACCORDING TO AGREED PROCEDURES. ON
MOST PLANTS WHERE TWO TANKS EXIST, ALTERNATE THE TANKS; RETAINING ONE IN
USE WHILE THE OTHER IS DESLUDGED MANUALLY.FOR MULTIPLE TANKS THE
DESLUDGING OPERATION WILL BE STAGGERED.
PST - PYRAMIDAL NO POWER - MANUALLY DE-SLUDGE TO WATER OP/1W OP/1W OP/1W N/A N/A
PST - PYRAMIDAL NO POWER - RECORD OPERATION AND VOLUME OF SLUDGE REMOVED
IN LOG
PST - PYRAMIDAL NO POWER - PERIODICALLY EMPTY AND CHECK INTEGRITY T1/48M T1/48M T1/48M N/A N/A
PST - PYRAMIDAL NO POWER - DISTRIBUTION CHAMBER - CHECK ALL VALVES,
PST - PYRAMIDAL NO POWER - DISTRIBUTION CHAMBER - CHECK COPASACS AND
CHANGE AS NECESSARY
PST - PYRAMIDAL NO POWER - DISTRIBUTION CHAMBER - CHECK FLOW SPLIT IS
CORRECT
PST - PYRAMIDAL NO POWER - DISTRIBUTION CHAMBER - CHECK WEIRS AND CLEAN OP/1W OP/1W OP/1W N/A N/A
PST - PYRAMIDAL NO POWER - DISTRIBUTION CHAMBER - REMOVE ANY SCUM AND
DEBRIS, INCLUDING GRIT

3.2.5

Process Checklist Horizontal Unscraped Primary Settlement Tanks
Task Low PE
(10-
1000)
Low-Med
(1000-
5000)
Med PE
(5000-
20,000)
High PE
(20,000-
350,000)
Manned
(350,000+)
PST - HORIZONTAL UNSCRAPED - CHECK AND LOG SLUDGE LEVEL BY DIPPING TANKS OP/1W OP/1W/3D OP/1W/3D N/A N/A
PST - HORIZONTAL UNSCRAPED - CHECK AND REMOVE ANY BUILD-UP OF SCUM OR RAG ON TANK
PST - HORIZONTAL UNSCRAPED - CHECK SETTLED SEWAGE QUALITY (VISUAL CHECK ONLY) OP/1W OP/1W/3D OP/1W/5D N/A N/A
PST - HORIZONTAL UNSCRAPED - PERIODICALLY EMPTY AND CHECK INTEGRITY T1/48M T1/48M T1/48M N/A N/A
PST - HORIZONTAL UNSCRAPED - ON SMALL SITES WITH ONE TANK AND NO SLUDGE HOLDING
FACILITY: - CHECK CONDITION OF TANK.
OP/3M OP/3M OP/3M N/A N/A
PST - HORIZONTAL UNSCRAPED - SITES WITH TWO OR MORE TANKS: - CAUTIOUSLY EMPTY TANK. OP/3M OP/3M OP/3M N/A N/A
PST - HORIZONTAL UNSCRAPED - SITES WITH TWO OR MORE TANKS: - CHECK CONDITION OF TANK. OP/3M OP/3M OP/3M N/A N/A
PST - HORIZONTAL UNSCRAPED - SITES WITH TWO OR MORE TANKS: - DE-SLUDGE ONE TANK UNTIL
WATER IS DETECTED.
OP/3M OP/3M OP/3M N/A N/A
PST - HORIZONTAL UNSCRAPED - SITES WITH TWO OR MORE TANKS: - RETURN IT ON-LINE. OP/3M OP/3M OP/3M N/A N/A
PST - HORIZONTAL UNSCRAPED - SITES WITH TWO OR MORE TANKS: - START ON THE NEXT TANK. OP/3M OP/3M OP/3M N/A N/A
PST - HORIZONTAL UNSCRAPED - RECORD OPERATION AND VOLUME OF SLUDGE REMOVED IN LOG OP/1W OP/1W OP/1W N/A N/A
PST - HORIZONTAL UNSCRAPED - DISTRIBUTION CHAMBER - CHECK ALL VALVES, PENSTOCKS AND
PST - HORIZONTAL UNSCRAPED - DISTRIBUTION CHAMBER - CHECK COPASACS AND CHANGE AS
NECESSARY
PST - HORIZONTAL UNSCRAPED - DISTRIBUTION CHAMBER - CHECK FLOW SPLIT IS CORRECT OP/1W OP/1W OP/1W OP/1W OP/1W
PST - HORIZONTAL UNSCRAPED - DISTRIBUTION CHAMBER - CHECK WEIRS AND CLEAN OP/1W OP/1W OP/1W OP/1W OP/1W
PST - HORIZONTAL UNSCRAPED - DISTRIBUTION CHAMBER - REMOVE ANY SCUM AND DEBRIS,
INCLUDING GRIT

3.2.6

Process Checklist Lamella Primary Settlement Tanks
Task Low PE
(10-1000)
Low-Med
(1000-5000)
Med PE
(5000-20,000)
High PE
(20,000-
350,000)
Manned
(350,000+)
PST - LAMELLA - CHECK BRIDGE/SCRAPER OPERATION OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - LAMELLA - CHECK SAFETY GUARDS OP/1W OP/1W OP/1W OP/1W OP/1W
PST - LAMELLA - CHECK SCUM TRAP FOR NORMAL OPERATION AND CLEAN/HOSE OUT OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - LAMELLA - CHECK DE-SLUDGE PUMP AND TIMER FOR NORMAL OPERATION OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - LAMELLA - CHECK AND LOG SLUDGE LEVEL BY DIPPING TANKS OP/1W OP/1W/3D OP/1W/3D OP/1W/3D OP/1W/3D
PST - LAMELLA - CHECK AND REMOVE ANY BUILD-UP OF SCUM OR RAG ON TANK
PST - LAMELLA - CHECK SCUM BOARDS FOR BREAKS OR CARRY UNDER OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - LAMELLA - CHECK SETTLED SEWAGE QUALITY (VISUAL CHECK ONLY) OP/1W OP/1W/3D OP/1W/5D OP/1W/5D OP/1W/7D
PST - LAMELLA - PERIODICALLY EMPTY AND CHECK INTEGRITY T1/48M T1/48M T1/48M T1/48M T1/48M
PST - LAMELLA - DISTRIBUTION CHAMBER - CHECK ALL VALVES, PENSTOCKS AND
PST - LAMELLA - DISTRIBUTION CHAMBER - CHECK COPASACS AND CHANGE AS
NECESSARY
PST - LAMELLA - DISTRIBUTION CHAMBER - CHECK FLOW SPLIT IS CORRECT OP/1W OP/1W OP/1W OP/1W OP/1W
PST - LAMELLA - DISTRIBUTION CHAMBER - CHECK WEIRS AND CLEAN OP/1W OP/1W OP/1W OP/1W OP/1W
PST - LAMELLA - DISTRIBUTION CHAMBER - REMOVE ANY SCUM AND DEBRIS,
INCLUDING GRIT


3.2.7 Process Checklist Notes

What to check Action / What to check for on deviation
Sludge blanket level Check to compare level against the target level for optimum performance. Dip
the PSTs at the same time of day and at the same location for accurate
readings. The selected location(s) must be assessed for health and Safety
and be clearly marked.
Check that no more than half a metre of sludge is held within a tank.
Screened Sewage
Quality
Check colour of the sewage. Greyish/green colour shows fresh sewage. Dark
grey or black indicates the sewage may be septic.
The colour of incoming sewage may be affected by trade effluent.
The colour of incoming sewage may also be affected by works returns i.e.
sludge liquors which can turn the sewage black, or from septic / cess tanker
discharges, or SPS wet well level control.
Operate with the
correct de-sludge
regime
This determines that the de-sludge timers are set correctly. Where this is not
possible the last de-sludge time must be recorded.
In cases of manual de-sludging the correct de-sludge valve needs to be used.
Some control systems will inhibit de-sludging from a high level Sludge Holding
Tank or Sludge Blending Tank. For multiple lamella or conventional PSTs the
de-sludging times will normally be staggered. De-sludging times to be as
detailed in the Site Operational Manual. If changes are required they must be
logged in the Log Book at the Site Information Point.
Tank
Bridge/Scraper
operation.
Check for smooth rotation / travel with no jerky movements.
Check for excessive noise from drive wheels, motors or gear boxes.
Check the integrity of the concrete surface of the PST walls.
Periodically check condition of PST scraper blades by emptying tank.

Bridge rotation on circular PSTs may be prone to stopping due to the concrete
top of the tank breaking up and causing a hole that the wheel gets stuck in.
On rectangular PSTs with scraper bridges there is the need to ensure that the
bridge has moved throughout the day, as it may appear that bridge is not
moving.
On Lamella Settlement Tanks with scraper systems there is the need to
ensure that the scraper mechanism has moved throughout the day, as it may
appear that it is not moving.
In icy conditions consider using salt or sand on walls to prevent drive wheel
slipping.
Scum trap blockage Check the traps for normal operation. This avoids excessive build up on tank
surface. Remove scum manually where possible.
In some cases the scum trap(s) may be blocked and kept blocked on purpose
to avoid excess water going to Sludge Holding Tanks (SHTs).
Tank structural
integrity
Check frequency of tank emptying for inspection.

Scum board
integrity
Check scum boards for cracks or breaks.
Check for scum breakthrough and carryover into settled sewage channel.
Cockpit Data
Collection
Sludge level, de-sludge timer operation, power and flow readings should be
logged and captured on the Site Cockpit / Dashboard.


3.3 Troubleshooting Guide
WWT 3.1 Troubleshooting Guide - Primary Settlement Tanks
Symptom Possible Cause Action Risk / Consequence
Excessive
gassing
and/or
rising
sludge

Sewage
colour and
odour

Inadequate sludge removal.
De-sludge pump inhibited from
downstream processes
Strong influent.
Tank overloaded.
Scraper not working or damaged.
Blocked desludge line
Scraper operation and de-sludging
out of sequence.
Poor flow distribution to tanks.
Sludge has floated with excess
gassing
Sludge build up on walls
(Pyramidal Tanks)
Timer clock faulty / incorrect
settings / no settings
Seasonal increase in sludge
Manually de-sludge
Review Process Control
Chart and action lines
Review dip frequency.
Review de-sludging
regime.
Review flow distribution.
Check control
philosophy.
Check flow split
Check scraper
Consider cleaning /
emptying tank
Poor sludge
condition.
Higher load to
secondary
treatment.
Poor Picket Fence
Thickener / Sludge
Holding Tank
performance.
Possible Effluent
failure
High
sludge
blanket
which may
be a result
of
blockages
on sludge
line
Sludge too thick.
Reduced de-sludge pumping rate.
Blockages on sludge line
De-sludge pump inhibited by
downstream processes
Valve damaged / jammed
Build-up of rag or grit.
Impact of storm washout.
Seasonal Issues producing extra
sludge
Rag
If possible de-sludge by
hand.
Review action lines on
Process Control Chart.
Review de-sludge pump
timers.
Check flow split
Review grit removal
frequency / Inspect grit
removal system.
Flush lines
Repair Valve
Review SAS rate.
Check screens
Storage of sludge in
PST with increased
sludge blanket.
PST Performance
Impact on Picket
Fence Thickener/
Sludge Holding
Tank performance.
Impact on
Secondary
treatment
Possible Effluent
failure

Excessive
solids
carryover
Inadequate sludge removal.
Strong influent.
Tank overloaded.
Scraper operation and de-sludging
out of sequence.
Valve damaged / jammed.
Poor flow distribution.
Incorrect SAS rate
Sludge build up on walls
(Pyramidal Tanks)
Stilling chamber and scum board
condition
Timer clock faulty / incorrect
settings / no settings
Check de-sludge pump
timer.
Check valve operation
Review de-sludging
regime
Check flow split
If applicable, is SAS
return rate correct (for
co-settling)
Check stilling chamber
and scum boards.
Higher load to
secondary
treatment.
Increased aeration
costs
Filter ponding.
High / increased
SAS production.
Possible Effluent
failure
Scraper
not
operating
Fault
Drive wheel slipping on wall.
Alarm Fault
Check for build-up of
sludge in tank.
Repair fault.
Salt/sand wall if due to
ice.
Build-up of sludge in
tank.
Impact on all
downstream
processes.


Alarm Call Out Troubleshooting Guide
WWT 3.1 Alarm Troubleshooting Guide - Primary Settlement Tanks
Symptom Possible Cause Action Risk / Consequence
PST Scraper
Fail Alarm

No De-
sludge in 24
hours Alarm

Alarm fault
Power Failure
Gear box Failure
Drive Wheel
Failure / slipping
Obstruction on
tank wall
Ice on surface of
wall
Scraper not
working or
damaged.
Faulty limit
switches

Restore power
Arrange for Defective
Maintenance
Check sludge blanket levels
Salt/sand wall if due to ice
Review de-sludging regime.
Review flow distribution.
Check control philosophy
Check flow split
Check scraper
Consider cleaning / emptying
tank
Poor sludge condition.
Higher load to secondary
treatment.
Possible Effluent failure
Inadequate sludge removal
Scraper operation and de-
sludging out of sequence
Excessive gassing and/or
rising sludge
Sewage colour and odour
PST De-
sludge Pump
Fail Alarm

No De-
sludge in 24
hours Alarm

De-sludge pump
failure
De-sludge pump
inhibited from
downstream
processes
Build up of rag or
grit
Sludge too thick.

If possible de-sludge by
hand.
Repair / reset pump
Maintenance
Review dip frequency
Check flow split
Review grit removal
frequency
Inspect grit / rag removal
system
Flush lines
Storage of sludge in PST
with increased sludge
blanket
Reduced de-sludge
pumping rate
High sludge blanket which
may be a result of
blockages on sludge line
Impact on Picket Fence
Thickener / Sludge Holding
Tank performance
Impact on Secondary
treatment
PST De-
sludge Valve
Fail Alarm
Valve damaged /
jammed
Build-up of rag or
grit.
Check valve operation
Repair Valve
Maintenance
Reduced de-sludge
pumping rate
Impact on Secondary
treatment
PST De-
sludge
Inhibit

No De-
sludge in 24
hours Alarm
De-sludge pump
inhibited from
downstream
processes not
working, i.e.
SHT full, Lime
Plant not
working
Review dip frequency
Determine how long
downstream plant will be out
of action
Review desludge pump timer
Tanker out sludge off site if
downstream plant remains
unavailable
Storage of sludge in PST
with increased sludge
blanket
Excessive gassing and/or
rising sludge
Impact on Secondary
treatment
PST
Distribution
Chamber
High
Impact of storm
wash-out
Poor flow
distribution
Check for downstream
blockages
Check flow split

Poor PST performance
PST flooded


3.3.1 Dos and Donts

Dos Donts
Regularly check de-sludge lines & plant
operability in line with SOM.
Leave de-sludge lines or scum removal systems
blocked
Control sludge blanket levels to within target
values
Allow sludge blanket levels & hence sludge
stocks to build unchecked
Sample the settled sewage quality of each
Primary Settlement Tank if problems arise to see
if it is one or multiple tanks, which are causing
the issues
Presume once optimisation / commissioning is
complete that everything will be great it needs
regular checks & adjustments
Ask for additional support if problems persist &
inform your Line Manager
Ignore issues hoping they will resolve
themselves.



Appendices
3.4 Operation
The operation of Primary Settlement Tanks must be in accordance with the design. Effective
operation will ensure a reduced and optimal biological loading onto the secondary treatment
processes and will reduce the whole life cost of assets.
For sites with SCADA (Supervisory Control And Data Acquisition) the key areas for primary
settlement tank operation are controlled and monitored. These areas of control are bridge rotation /
motion and de-sludge pump / valve operation.
The most important activity for Primary Settlement Tank (PST) operation, sludge management and
optimisation is the use of manual sludge dips with a sludge blanket detector and altering the de-
sludging (duration, frequency or flow rate) whilst also monitoring the Mixed Liquor Suspended Solids
(MLSS) in the case of Activated Sludge Plants.
This will also provide an early indication of blockages, scraper failure or de-sludge pump issues.
Taking proactive measures will minimise risk of sludge blanket inversion, i.e. the sludge blanket rising
to the surface of the tank. Every time an Operator visits site the Primary Settlement Tank (PST)
sludge blanket dips must be carried out, recorded and trended. There must also be an action line for
when the sludge blanket level rises too far on the run chart and Cockpit / Dashboard.

3.4.1 Primary Settlement Efficiency
For Activated Sludge Plants, if there is an increased air demand and the Mixed Liquor Suspended
Solids (MLSS) have not increased, check the Primary Settlement Tank (PST) sludge blanket levels
first.
Using Primary Settlement Tank (PST) sludge blanket level monitoring, the aim is to maintain good
Biochemical Oxygen Demand (BOD) and suspended solids removal and thus minimise the loading to
aeration plants, prevent high Mixed Liquor Suspended Solids (MLSS) or loading to biological filters
downstream.
Good operation of the Primary Settlement Tank and thus reduced loading will minimise aeration
power costs and Surplus Activated Sludge production on aeration plants and thus improve sludge
thickening and Final Effluent quality. Good operation will also help to maintain robust nitrification on
biological filter plants.
The difference in monitoring Primary Settlement Tank (PST) blanket levels and adjusting the de-
sludging accordingly is the key to controlling the load to the secondary biological treatment process.
For Activated Sludge Plants reducing the loading to the aeration plant consequently reduces the
amount of aeration required, hence reducing the aerator running costs.
In the event of the secondary treatment processes struggling, the sludge blankets must be checked to
ensure that the Primary Settlement Tank performance is as good as it could be.
High sludge blankets will also result in the production of dissolved hydrogen sulphide. This will be
stripped out when the settled sewage flows over the outlet weirs and into the collection channel, this
turbulence in the presence of air will strip the hydrogen sulphide out of the water, giving rise to odour
and corrosion problems.
Allowing sludge blanket levels to rise will detrimentally affect the Primary Settlement Tank
performance and ultimately affect downstream processes and Final Effluent compliance.
High sludge blankets will lead to increased aeration costs and SAS production on activated
sludge plants and may jeopardise final effluent compliance on trickling filter plants and
activated sludge plants



3.4.2 Impact on Secondary Treatment Processes
The wastewater secondary treatment process is essentially a biological process in which aerobic
microorganisms consume the organic contaminants in the incoming wastewater. Organic carbon in
the waste stream is the food on which these organisms live; hence the amount of food or Biochemical
Oxygen Demand (BOD) & solids within the settled sewage coming from the Primary Settlement tanks
directly affects the biomass within the biological process.
The amount of solids within sewage is usually related to the amount of Biochemical Oxygen Demand
(BOD), with Biochemical Oxygen Demand (BOD) being the food source for the microorganisms,
which we rely upon to treat the sewage.

The following table details the potential impacts on secondary treatment processes as result of poor
PST performance.

Symptom Consequence
Poor quality settled sewage
with high suspended solids.
For Activated Sludge works the solids within the sewage add directly
to the Mixed Liquor Suspended Solids (MLSS) within the aeration
plant. If the Mixed Liquor Suspended Solids (MLSS) are higher than
target levels then we start to have trouble getting enough air into the
aeration plant, consequentially the ammonia within the final effluent
starts to rise.
Increase in Mixed Liquor
Suspended Solids (MLSS)
due to poor quality settled
sewage with high
suspended solids.
If the Mixed Liquor Suspended Solids (MLSS) rise even further,
depending upon the specific plant, then we have problems removing
enough Surplus Activated Sludge (SAS) from the Final Settlement
Tanks (FSTs), which can lead to increased solids within the final
effluent as well, resulting from poor settleability & even sludge blanket
loss.
Excessively F:M levels The relationship between the Biochemical Oxygen Demand (BOD)
loading from the Primary Settlement Tanks and the amount of
biomass or Mixed Liquor Suspended Solids (MLSS) within aeration
plant is quantified as the food to mass ratio (F:M).
Excessively low F: M levels will reduce the food available to the
organisms to metabolise, which will result in reduced growth which in
extreme cases can lead to the mortality rate exceeding the
reproductive rate, resulting in a loss of treatment. However, in most
cases, there is a high F: M consequential from the over loading of
solids from the Primary Settlement Tank (PST).
This is resultant from either / or both the primary sludge blankets being
too high resulting in solids being carried over, or insufficient solids
removal or settlement from high flows which also results in solids
being carried over. Furthermore, if the removal of primary (RAW)
sludge is too low, i.e. insufficient desludging, then the sludge within
the Primary Settlement Tanks can age & go septic.



Symptom Consequence
Septic sludge in Primary
Settlement Tank
If sludge is left in the primary tank for too long it will begin to undergo
anaerobic digestion. The first stage of this is that some of the BOD in the
settled solids becomes solublised and therefore adds to the Biochemical
Oxygen Demand concentration in the settled sewage. The next phase of
this process is gas production. The gas produced will be trapped in the
sludge and will cause it to float to the surface. This rising sludge that
carries over into the Activated Sludge Plant will have the further
detrimental effect of some toxic inhibition of the Mixed Liquor Suspended
Solids (MLSS) biomass resultant from the septicity.
High or low F:M ratio Further problems with either high or low F: M ratio is the increased
potential to cause a filamentous bloom, which can further detrimentally
affect the treatment process.
Increased Primary
Sludge production as a
result of chemical dosing
for Phosphorus removal
In some cases where sites are required to remove phosphorus the
Primary Settlement Tanks are chemical dosed, usually with Ferric
Chloride, into the Primary Settlement Tank distribution chamber or inlet
channel. In these cases it is found that increased primary sludge is
produced as more solids in the sewage are removed as a consequence
and settle as raw sludge.
Desludge rates need to be set up to remove this extra raw sludge. It is
also important to manage downstream sludge handling processes
effectively so that desludge pumps are not inhibited and sludge does not
build up in the Primary Settlement Tanks.
Weaker settled sewage
as a result of chemical
dosing for phosphorus
removal
As a result of chemical dosing into Primary Settlement Tanks for
Phosphorus removal the result is generally a weaker settled sewage with
reduced organic load.
This can have an impact on downstream secondary biological processes.
Activated Sludge Plants can operate with lower Mixed Liquor Suspended
Solids (MLSS) or less aeration lanes in operation. The reduced load
passed onto percolating Filters will produce better quality effluents but
can also lead to increased to weed and moss growth on the filter surface.

Odour
Emissions of odour from our sites are more likely to occur when we are working on Primary
Settlement Tanks. On these tanks and on some sites this is more of an issue and must be mentioned
in the works Site Operating Manual in more detail.

Effective operation of Primary Settlement Tanks will minimise odour issues, however if the site does
have issues with odour then refer to the Asset Management Odour Strategy.

Odour can be minimised when a tank is out of service for repairs / maintenance by covering the
sludge on the tank floor with water.


Issue 1.1
Page 18 of 21
3.4.3 Primary Settlement Tank Optimisation
Adjusting de-sludging: It is important to remember that all changes must be made gradually; some
sludge blanket being present will aid settlement within the Primary Settlement Tank (PST), too large a
blanket will cause carry over. A medium / optimum depth target range must be established.
Where downstream Sludge Thickening processes are in operation, the aim ideally is to have no
sludge blanket in the Primary Settlement Tanks with Raw Sludge Dry Solids of about 1.0 to 1.5%
being produced. It is better to pump water or thin sludge to Sludge Thickeners than to have sludge
ageing on the Primary Settlement Tank floors. Some sludge blanket is possibly required if thick
sludge from the Primary Settlement Tanks is required to be produced or if site is an Activated Sludge
plant running in Biological Nutrient Removal (BNR).
For sites that use Sludge Cages in the Sludge Holding Tanks, as the dewatering is so effective the
Primary Settlement Tanks can be run to water with no sludge blanket. Care needs to taken with
approach as decanted liquors being returned to the inlet from the Sludge Holding Tanks (s) are much
stronger than sewage and where possible be returned continually and managed to avoid shock
loading and effluent failure.
Ensure that there are no blockages or maintenance issues that will detrimentally effect / inhibit raw
sludge removal. Monitor the sludge blanket depth with a sludge blanket meter, record and trend all
readings on a run chart or performance pack/cockpit, for each Primary Settlement Tank.
Check that there are no bottlenecks in the raw sludge-dewatering stream, if applicable. If the sludge
blanket levels start to rise, increase the de-sludging slightly and monitor, if they continue to rise adjust
accordingly. When the sludge blanket levels start to reach the lower end of their target range, reduce
the de-sludging in a stepped manner.
On small sites its recommended to manually operate the de-sludge pumps to ensure they are
working effectively and the Primary Settlement Tank has no sludge in it and runs to water. Also on
small rural sites its recommended that the Primary Settlement Tank(s) are emptied and cleaned out
periodically.

Technical Lead: Bryan Bleeker
AM-PRO-WWT-WWT 3.1 Primary Treatment-SEC3



Some of the Costs associated with poor Primary Settlement Tank performance
(downstream aeration and SAS polymer costs)
Impact of Primary Settlement Tank operation on OPEX
(200K pe, power 0.08/Kwh)
0
10
20
30
40
50
60
70
15 20 25 30 35 40 45 50
BOD r emoval acr oss PSTs %
O
P
E
X

K
/
a
0
2
4
6
8
10
12
S
A
S

m
a
k
e

t
/
d
Increased aeration costs K/a Increased OPEX (exc sludge) K/d SAS make t/d

3.4.4 Contingency Planning
If the Primary Settlement Tank (PST) sludge blanket levels get too high and are in danger of weiring
over or going septic, the sludge blanket levels can be brought down quickly by over pumping into a
disused tank if available or removal by tanker off site. For Activated Sludge Plants additional aeration
can also be utilised in anticipation of this additional load.

For sites with percolating filters is it essential that sludge is not allowed to be discharged on to the
filters. If there is a danger that raw sludge will spill over from the Primary Settlement Tank (PST) on to
the percolating filters arrange for the sludge to be removed and taken by tanker off site before the
sludge spills onto the filters.

Where sludge has built up to excessive levels recirculation flows can be increased to thin the Settled
Sewage down until the sludge can be removed from the Primary Settlement Tank (PST).

DO NOT ALLOW SLUDGE TO GO ONTO PERCOLATING FILTERS



3.4.5 Plant Release / Taking out of and Bringing into service

Taking out of service - Planned
When Primary Settlement Tank(s) are being taken out of service the Plant Release procedure needs
to be followed together with site process risk assessment and plant availability. If a Primary
Settlement Tank cannot be taken out of service due to process risk then this needs to be highlighted
in the Risk Register for potential investment / capital delivery purposes.

The frequency for removing Primary Settlement Tanks from service must be set at a level that
ensures the performance of the tank is maintained and inspection of the scraper can be made prior to
any damage occurring. As a guide, this should be initially set at four years.

Draining of Primary Settlement Tanks for inspection is normally carried out in summer months or
during periods of low inlet flow to the works when plenty of time needs to be allowed for draining.
Primary Settlement Tanks can also be taken out of service in the summer months to improve settled
sewage quality due to septicity and reduced flows. This should be linked to any Odour Management
Plans.

The rapid return of sewage when draining Primary Settlement Tanks may overload the other Primary
Settlement Tanks in service and flush out sludge. The alternative is to pump off the top water to a
balancing or other tank for slow return to main flow. In small works where there is only one Primary
Settlement Tank the top water can be taken off by a tanker.

Increase the de-sludging run time and / or frequency on the other Primary Settlement Tanks, as the
higher loading on these tanks will result in an increase in sludge production.

Taking out of service - Unplanned
The Primary Settlement Tank may well have a lot of sludge in it that will need removing. This must be
removed in a controlled way either to the Sludge Holding Tank, directly into the sludge stream or if
unavoidable to the inlet works. The following points must be taken into account when taking a Primary
Settlement Tank out of service to maintain site operation, maintenance and compliance.

Always protect effluent quality.
Review operation of upstream processes, i.e. screens which may be causing problems
Control the Primary Settlement Tank pump down to protect the treatment process.
Be aware of Primary Settlement Tank flotation risk.
Plan flow diversion needs i.e. Tanker, pumping station etc.
Isolation of Primary Settlement Tank inflow.
When Primary Settlement Tank(s) are taken out of service ensure flow split and de-sludging is
redistributed among the other Primary Settlement Tanks.
De-sludge to water prior to emptying the Primary Settlement Tank.
Sludge Holding Tank capacity.
Primary Settlement Tank cleaning.
Health & Safety
Inspections required
Monitor downstream processes
Alarms that could lead to needless Call Outs, i.e. not temporarily disabled during outage.
Odour


Bringing into service
Check Primary Settlement Tank (PST) alarms before leaving site. Check that all Primary Settlement
Tanks have equal flow distribution to ensure optimal operation. Tanks should be brought back into
service slowly or there is a risk of solids carry over.

More than one tank on site
Fill Primary Settlement Tank by passing a proportion of the incoming flow through it. It is important
that the other Primary Settlement Tanks still receive flow.
One tank only on site
Fill with Humus Tank effluent / final effluent before restoring flow to the Primary Settlement Tank.

General
It is advisable that an inspection of the Primary Settlement Tank and its de-sludging system is carried
out within a few days of being put back in service.

Lessons Learnt
In the case example of Esher STW, due to a capital project, there was a requirement to carry out
works shutdowns during dry weather; this resulted in having to return strong (undiluted) sewage from
the storm tanks.

When this was being done, there was no account made for the increase in solids loading into the
Primary Settlement Tanks, hence no increase in de-sludging times were made. This resulted in
solids being carried over into the aeration plant. Initially this meant that the back-up aerators had to
run extra hours to maintain Dissolved Oxygen (DO) levels and ammonia treatment.

However, after a short period of time, this resulted in the Mixed Liquor Suspended Solids (MLSS)
increasing from 2,500mg/l (as target) to 8,000mg/l. This resulted in a breach in consent of ammonia
& solids within the final effluent.

There was also the further impact of requiring additional sludge to be removed from site, incurring
additional tanker cost, not to mention the extra power consumed by both the aerators & the sludge
thickening plant.

This scenario could also occur as a result of heavy rainfall after prolonged dry periods whereby the
network may be cleaned / flushed out resulting in additional solids being washed to the Sewage
Treatment Works. It is important to note that these solids maybe old and septic causing loading and
settlement difficulties within the Primary Settlement Tanks (PSTs).
Regular monitoring of sludge dips and pump timer adjustments can identify and combat this changing
situation.

---- End of section 3 ----

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