Beruflich Dokumente
Kultur Dokumente
AUGUST 1, 2001
REGULATORY REQUIREMENT
REGULATORY REQUIREMENT
(THE STANDARDS)
On November 17, 1983, US EPA promulgated wastewater treatment standards for 2-pc
canmakers. The applicable standards for an existing facility (PSES) discharging to a Publicly
Effluent samples are to be taken a minimum of once each month or more frequently as
To verify compliance, effluent samples are to be taken a minimum of once each month, or
NOTE:
M = 1000
EXAMPLE:
a sample that is composited or formed by mixing together various smaller samples taken
at regular time intervals of half hour or one hour each during the full 24-hour period.)
Also, on grab sample is collected randomly during the 24-hour sampling period. The 24-
Hour Composite Sample is for the analysis of Cr, Cu, Zn, F, P and Mn. The Grab
2. The 24-Hour Composite Sample and the Grab Sample are then sent to a local
laboratory for analysis. Plastic and/or glass jars that have been thoroughly cleaned and
Method E.
3. The laboratory submits the results in terms of concentration (mg/l) of the pollutants in the
(mg/l)
Cr - 0.032
Cu - 0.200
Zn - 0.100
F - 12.000
P - 1.000
Mn - 0.050
O&G - 2.000
4. During the 24-hour sampling period Total Flow going through to the sanitary sewer is
also measured. Say it was found to be 132,100 gallons. Then: 132,100 gallons x 3.785
5. Also the Total Can Production during the 24-hour sampling period is obtained. Say it
6. Therefore, the Rate of Flow during the sampling period is 250 L/M cans (500,000
Liters/2000 M cans).
multiplying the concentration of the pollutants supplied by the laboratory by the Rate of
Flow.
8. Compare the MASS OF POLLUTANTS discharged (mg/M cans values) with the
9. For the example under consideration, all pollutants are within both standards except
FLUORIDE, which is within DAILY MAXIMUM standard but out of standard for
Fluoride was initiated: Lime addition was increased to reduce Fluoride concentration in
the wastestream.
It will be noted that both the Concentration of Pollutants in the Effluent and the Rate of
Pollutants in the Effluent is a function of the effectiveness of the Treatment System whereas
the rate of Flow is governed by the water usage at the washer. In order that the Standard is
met the Treatment System is to be operated efficiently and the flow through the washer has
DESCRIPTION OF WASTEWATER
TREATMENT SYSTEM
The wastewater treatment system is comprised of 5 sub-systems working in unison with each other.
The 5 sub-systems are:
Washer effluent from the washer tanks containing the cleaner and treatment chemicals (counter
flows from washer stages), the D.I. wastes, washer trench wastes and the waste from the
trenches around the treatment system enter Waste Chemical Holding Tank. Hydrated lime
powder stored in the lime silo is mixed in a mixing tank located under the lime silo to form a light
Lime Slurry. The Lime Slurry is pumped or flows by gravity from the mixing tank directly into
the Waste Chemical Holding Tank where a mixer mixes the Lime Slurry with the contents of the
tank. The primary purpose of addition of lime slurry into wastewater effluent is to remove fluoride
and miscellaneous metals. The secondary purpose is to control the condition of sludge developed
at the end of process treatment. The pH in the Waste Chemical Holding Tank can range from 9.5
to 9.8 or higher up to 10.5 if required, to a chemical reaction between the contents of the Waste
Chemical Holding Tank and the Lime Slurry. Lime neutralization and precipitation is also
commonly used for the treatment of wastewaters containing heavy metals. The reactions involve
the removal of metals as Metal Hydroxide precipitants. The contents of the Waste Chemical
Holding Tank carrying the lime slurry with it overflow into the pH Neutralization Tank Stage #1.
1. Lime Ca(OH)2
Precipitation agent for fluoride and heavy metals (Cr, Cu, Zn, Mn, etc.)
pH adjustment
pH adjustment
Precipitation agent for heavy metals (Cr, Cu, Zn, Mn)
Accentuates solid particle size in an effort to increase the efficiency of the Lamella
Clarifier solid removal system.
Fluoride Removal
1. H3PO4 3H + PO4-3
TREATMENT
REMOVAL
The contents of the Chemical Waste Holding Tank after mixing with lime slurry,
overflows or is pumped into the pH Neutralization Tank Stage #1. Cationic polymer
(coagulant) and/or Phosphoric Acid (H3PO4) are added to the pH Neutralization Tank:
Stage #1. Cationic polymer (coagulant) and/or H3PO4 act as a coagulant aid, assist in
the removal of oil and grease and further removal of the fluoride from the wastestream.
Cationic polymer (coagulant) is a demulsifier that is added for the removal of petroleum
based oil and grease. It destroys the emulsifying properties of oil by neutralizing the
Neutralization Tank Stage #1. This is the most important step in the wastewater treatment
system.
the pH of the pH Neutralization Tank to the optimum pH around 8.0 8.2. The addition of
the acid and caustic is accomplished by the Beckman or equivalent pH Control System.
Returned sludge for the Lamella Clarifier can be added to Stage #1 to assist in sludge
formation prior to being pumped to the Lamella Clarifier. All contents in this tank are mixed
thoroughly to form a uniform chemistry. The effluent overflows from the pH Neutralization
Tank Stage #1 to Stage #2. This stage is also called the Lift station Stage #2.
Treatment chemicals are added to the effluent at various points in the system. The treatment
chemicals are added for adjusting pH, sludge conditioning or precipitation of the pollutants.
The chemicals used for pH adjustment are sulfuric acid and caustic. Sulfuric acid and caustic
normally purchased in regular tote tanks from which the chemicals are dispensed using
metering injection pumps which dispense either caustic or acid as required by the pH control
set point in this stage. The pH probe in the effluent stream senses the pH of the effluent
entering Stage #1 pH Neutralization Tank and sends a signal back to the pH Controller.
The Controller then sends a signal to the metering injection pumps which dispense sufficient
quantities of either sulfuric acid or caustic to adjust the pH to the desired set point. The
normal desired set point for this tank is 8.2. If the pH of the effluent stream is below the set
point, the probe will call for addition of caustic. If the pH of the effluent stream is above the
set point, the probe will call for sulfuric acid. The system is completely automatic except for
maintaining a supply of acid and caustic in the tote tanks, cleaning the pH probes once or
CAUTION
EXTREME CARE SHALL BE TAKEN IN PLACING THE SULFURIC ACID AND CAUSTIC
TOTE TANKS TO INSURE THAT THE PROPER CHEMICAL IS PUMPED THROUGH THE
AND DISCHARGE SIDES OF PUMPS. TO PRIME THE PUMPS, TURN THE BLACK
LOCATED ON THE DISCHARGE SIDE OF THE PUMPS. RUN WITH VALVE OPEN UNTIL
SOLID STREAM OF FLUID COMES OUT OF BYPASS TUBING. TURN THE SCREW
CAUTION
CAUTION
CAUTION
USE GLOVES, SAFTY GLASSES AND/OR SAFTEY SHIELD AND CHEMICAL RESISTANT
APRON WHEN HANDLING CAUSTIC, SULFURIC ACID AND ANY OTHER DANGEROUS
The treatment chemicals are directly discharged into the effluent stream by metering pumps
To vary the feed rate of the metering pumps, there are 2 controls available: one regulates the
speed of the pump (0-100% speed) and the other regulates the stroke of the piston (0-100%
stroke). The maximum rating of the metering pump used for this is 60 gpd or any other
capacity. If, however, the speed is set at 50% and the stroke is also set at 50% the pump will
the pump is the product of (% stroke) X (% speed) X (pump max rating) or in the above case
15 gpd.
The metering pumps are used to dispense Cationic Polymer (Coagulant) and/or Phosphoric
Acid to the pH Neutralization Tank Stage #1. To ensure proper chemical injection feed,
maintain a sufficient supply of cationic polymer (coagulant) and phosphoric acid in the tote
tanks or drums.
CAUTION
USE GLOVES, SAFETY GLASSES, FACE SHIELDS AND APRON WHEN HANDLING
CAUTION
AND DISCHARGE SIDES OF PUMPS. TO PRIME THE PUMPS, TURN THE BLACK
LOCATED ON THE DISCHARGE SIDE OF THE PUMPS. RUN WITH VALVE OPEN UNTIL
SOLID STREAM OF FLUID COMES OUT OF BYPASS TUBING. TURN THE SCREW
The anionic polymer is injected into the system via the flash mix tank. The polymer must be
added in a diluted form at a predetermined rate. The Polyblend Mixing System is utilized to
Please refer to Schematic A. Liquid polymer in solution or emulsion form is drawn from the
drum (1) by an adjustable metering pump (2). Depending on the output rating of the model,
At the same time, the inflow of water from a supply source (3) is regulated by a solenoid
valve (4) and the rate-adjusting valve/rotameter (5). In some models, a differential pressure
The polymer and water are injected near the bottom of the mixing chamber (6). The impeller
(7) blends polymer and water in high-energy, low-shear, completely back-mixed environment
to assure complete polymer activation. The blended and activated polymer then exits at the
top of the mixing chamber through the discharge port (8) and is piped to the flash mix tank of
The polyblend PB-50 or PB-100 series units have a current-to-frequency converter box
mounted and are connected internally to the electronics of the diaphragm metering pump
Signal Converter. To activate this box, the speed control knob is set to EXTERNAL and
the stroke control knob is set to any desired value (e.g. 60%) on the metering pump of the
polyblend unit. The unit can be operated manually when the mode selector witch is in the
INTERNAL position on SPM or SPH. To increase or decrease the injection rate in strokes
per minute/hour, simply turn the OUTPUT knob clockwise to increase the polymer solution
flocculation tank of a clarifier. If floc particles are too small and take a very long time to settle,
an insufficient amount of polymer is being added to the flash-mixing tank. This may mean the
polyblend-metering pump has lost its prime or that the polymer drum is empty. When the
motor/pump switch is in the ON position, the impeller inside the mixing chamber, which is
filled with water starts rotating. The pump should begin to make a clicking sound with a
blinking stroke indicator light upon injecting small amounts of polymer into the mixing
chamber. The water in the mixing chamber will rapidly turn milky or cloudy as the polymer
is injected. If the water in the mixing chamber is clear, the metering pump may have lost its
prime due to a large air bubble in the suction line or the polymer drum may be empty.
To prime a polyblend unit, the procedure described below should be followed: (Refer to
Schematic B.)
2. Locate and remove the PVC pipe plug in the clear plastic pump head. Wrap Teflon
tape over the threads of the labcock valve. Hand tighten the valve into place (open
valve).
3. Wrap Teflon tape over threads of the barbed fitting. Hand tighten the fitting into the
labcock valve.
5. Hold tip in the fitting while opening syringe (pull back on plunger).
6. Repeat procedure until polymer enters syringe and the suction tube completely filled with
polymer solution with no air pockets or bubbles. The pump is now primed.
8. Clean syringe and keep it near the unit for future use.
Hydrated lime in powder form is stored in the lime silo and is fed by an accurate feeder into a
lime slurry mixing tank. The accurate feeder is driven by an independent pH control system
programmed to dispense hydrated lime into a lime slurry mixing tank. The pH probe in the
effluent stream senses the pH of the effluent entering in to the Waste Chemical Holding
Tank and sends a signal back to the pH Controller. The Controller then sends a signal to the
accurate feeder which dispenses required quantities of hydrated lime until the desired set
point is reached. The accurate feeder speed will vary based on the effluent pH entering in to
this tank. Fresh water and/or treated water is added to the lime slurry mixing tank, which
mixes the powdered hydrated lime and fresh water to form a light lime slurry. Lime slurry is
then overflowed in to the Waste Chemical Holding Tank. The primary purpose of addition of
lime is to control the amount of Fluoride and miscellaneous metals in the wastestream and
The purpose of the physical treatment process is to separate the solids generated by the
chemical treatment process from the wastewater effluent prior to discharge. This process is
B. Sludge Dewatering
The effluent from the lift station Stage #2 first enters the flash mix tank attached to the
Lamella Clarifier. An anionic polymer is added to the flash mix tank to assist in the
overflows into the flocculation tank. In the flocculation tank, a secondary gate mixer provides
additional time for the reaction to take place. The flocculation tank discharges into the
clarifier where the solids are settled by gravity and separated from the effluent stream as it
flows out of the clarifier. A portion of the treated effluent from the clarifier is diverted to the
lime slurry mix tank in the lime silo and remaining treated effluent then discharges to the
sanitary sewer. The sludge from the Lamella Clarifier is drawn off from the bottom at a rate
of approximately 5 to 10 gpm and discharged to the Sludge Holding Tank, and/or back to
LAMELLA CLARIFIER
The solids that settle to the bottom of the Lamella Clarifier are drawn off by the air operated
Lamella sludge pump from the bottom of the Lamella Clarifier. The liquid sludge, at this
point, is mostly all water and is pumped to the sludge holding tank and/or to Stage #1 (i.e.,
pH Neutralization Tank). The treated water generated by the Used oil Treatment System is
pumped directly to the waste chemical holding tank where it becomes part of the process.
Air-operated sludge delivery pumps transfer the liquid sludge from the Sludge Holding Tank
for dewatering the sludge in the Filter Press. The liquid sludge passes through the
polypropylene filter media in the Filter Press allowing the water to pass through while
retaining the solids to form a filter cake. When the Filter Press is full (i.e., when the sludge
delivery pump stops pumping), compressed air is forced at 30 35 P.S.I. through the filter to
increase the dryness of the cake. This process is called BLOWING DOWN of filer press
medias. Compressed air for drying the cake is turned off, the press is opened and the filter
press residue is dropped into a dumpster for disposal at a landfill. The filtered water (filtrate)
is returned to the Waste Chemical Holding Tank for further treatment. (See following page
for schematic.)
from the liquid; therefore, the filter cloth must remain porous to provide high filtration rate.
During the normal operation, the filter cloth may gradually become plugged with minute
particles, such as those from metal hydroxide sludge. The particles enter the cloth and
become lodged in the depth of the weave, which leads to decreased filtering action. These
particles must be removed periodically to maintain high filtration rates and drier cakes.
Filter cloth washing is required when one of the following factors indicate plugging has
occurred:
The most commonly used method with metal hydroxide sludge particles is the Acid Wash
System. The acid wash system is designed to pump a solution of 30% muriatic acid through
the filter press and return to a storage tank. The acid wash system consists of an air
operated acid pump, a 300-gallon acid wash holding tank and all associated piping. To
conduct an acid wash of a filter press you must remove the press from operation and remove
all solids. When press is clean close valve (to drain) open valve (from acid wash holding
tank) and open valve (return line from filter press to acid wash holding tank). Run acid
through press for a minimum of 30 minutes and a maximum of 60 minutes. Upon completion
of wash allow press to drain by gravity and use only air blow down (max 15 psi) to remove
the final traces of the acid. To place press back into service reverse procedure outlined
above.
2. Next, turn the SELECTOR switch to the OPEN position. The hydraulic cylinder will
3. When the press is completely open, turn the air supply to the OFF position.
You are now ready to clean the plates. Position the collection dumpsters under the filter
press to be cleaned.
Separate the plates. When the plates are separated, the filter cake will fall to your collection
drums or dumpsters. Refer to the diagram at the top of the next page for proper cleaning
techniques.
! NOTE: Make sure the gasket sealing surfaces are free of filter cake.
When the plates are thoroughly clean, you can close the J-Press and repeat the filtration
If your air supply is properly connected to the press, the line pressure will register on the
LINE AIR PRESSURE GAUGE as shown below on the standard control panel. Refer to
YOUR J-PRESS SPECIFICATIONS for the required air pressure for your press.
2. Now turn the SELECTOR switch to the CLOSE position. The hydraulic cylinder will
extend and move the follower, along with the plate stack, toward the head end of the
press.
3. Once the hydraulic cylinder is fully extended, turn on the HYDRAULIC PUMP switch.
You will hear the air-oil pump cycling and see the HYDRAULIC PRESSURE rise. The
pumps cycling rate will slow as it reaches the preset closing pressure. Finally, the pump
will stall.
Tank.
The used oil from the used oil holding tank is transferred to the Used oil Treatment Tank for batch
processing where an estimated 2,800 gallons of used oil can be treated at a time.
The batch processing of the used oil treatment system involves the addition of oil breaking cationic
After treatment with the oil breaking cationic polymer and caustic addition, the used oil is mixed for a
period of time after which the mixer is turned off and the contents of the tank are allowed to stand idle
During this idle period, all the oily particles from oil-in-water emulsions, which are separated during
demulsifier (oil breaking polymer) addition, will float to the top of the tank leaving water at the bottom
portion of the tank. This Used oil Treatment Tank is equipped with an optical sensor with adjustable
sensitivity to detect top layer of demulsified oil from the treated water.
The bottom portion of treated water is discharged into the Waste Chemical Holding Tank via trench
where it becomes part of the continuous process wastewater for final treatment. As soon as the top
layer of demulsified oil comes in contact with the optical sensor, the valve shuts off so that the
demulsified used oil does not discharge into the Waste Chemical Holding Tank.
The top portion of the demulsified used oil is discharged to the Treated Used oil Holding Tank from
which a tanker truck hauls away the treated used oil for final disposal.
The used oil treatment is a physical-chemical separation of oil from water. The physical-chemical
Operating Instructions
Used oil Treatment
(Oil De-watering Only)
Step 2 When level in used oil treatment tank reaches working level (6 below
overflow pipe), turn on tank mixer.
Step 5 Upon completion of adding polymer, continue tank mixing for one hour.
Step 6 After 1 hour of mixing, sample tank to ensure that oil particulization has
taken place.
Step 7 Discontinue mix. Allow treatment tank to stand idle for at least one hour
so the oil/water separation can occur.
Step 8 Discharge the water portion from the oil/water separation by opening the
inch drain line at the bottom of the used oil treatment tank.
Step 9 Adjust the drain valve to maintain a flow rate of 2 5 gpm into the
treatment system.
Step 10 Close the inch discharge line when water draining is completed. Care
must be taken not to allow the oil portion from the oil/water separation
from entering the WWT system. This is normally controlled by the optical
sensor with the adjustable sensitivity installed at the bottom of the tank.
Material Needed
Procedure
2. Turn on mixers.
3. From the top of the used oil tank, pull a representative sample. Decant 500 ml of
6. Using the 5-ml syringe, add cationic polymer into the used oil sample at 0.5-ml
intervals.
7. After each addition, visually check for a discernable break in the used oil. The
break is characterized by a solution color change from gray to black. At this pint,
8. Discontinue mix.
9. By using the attached chart, determine the amount of gallons of cationic polymer
0.25 1.4
0.50 2.8
0.75 4.1
1.00 5.5
1.25 6.9
1.50 8.3
1.75 9.6
2.00 11.0
2.25 12.4
2.50 13.8
2.75 15.1
3.00 16.5
3.25 17.9
3.50 19.3
3.75 20.6
4.00 22.0
4.25 23.4
4.50 24.8
4.75 26.1
5.00 27.5
Please Note:
If a successful oil/water separation is not achieved with 5 milliliters or less, the used oil batch
contains too much oil for a polymer treatment and should be pumped directly into the final
PH Adjustment Chart
Please Note:
To ensure correct operation of the treatment system, certain quality control checks must be
conducted. All quality control observations shall be recorded on the plants computer
terminal. The following should be a representation of the screen for entering the wastewater
treatment system observations in the computer each shift, however the computer screen
The frequency of observation per shift, required for each category of data entry, is stated in
the itemized instructions. However, only the most representative observation per shift is to
be entered on the screen for each category. The itemized instructions follow:
1. Clarity of Discharge
The effluent from the clarifier shall be checked as to clarity (i.e., free of suspended solids,
color, etc.). Observations should be recorded in the plant's computer. The frequency of
Samples are to be collected from the Waste Chemical Holding Tank. At the time the
samples for analysis are collected, the reading on the pH Control System Display should
be noted. The samples are to be analyzed on the laboratory pH meter. The results
obtained on the laboratory meter should be compared against the readings noted on the
one brandone vision 46
pH Control System Display. The frequency of the check is twice per shift with results to
Samples are to be collected from the pH Neutralization Tank Stage #1 for analysis. At
the time the samples for analysis are collected, the reading on the pH Control System
Display should be noted. The samples are to be analyzed on the laboratory pH meter.
The results obtained on the laboratory meter should be compared against the readings
noted on the pH Control System Display. The frequency of the check is twice per shift
Samples are to be collected from the flume. The samples are to be analyzed on the
The pH Controller set point is to be noted on the panel and recorded in the plants
5. Fluoride Measurement
6. Sludge Settleability
Collect a sample twice per shift from the flocculation tank of the Lamella Clarifier and
check the settling rate of the sludge. To check the settling rate of the sludge, the following
A. Sample of liquid from flocculation tank shall be collected into a 1,000 ml graduated
cylinder.
Based on the above check, the polymer shall be either increased or decreased.
The instantaneous flow rate shall be read from the process discharge flow meter at the
8. Coagulant Injection
Collect a sample of coagulant twice per shift from the discharge point of coagulant
metering injection pump into a 25 ml graduated cylinder for one (1) minute. Results to be
Collect a sample of phosphoric acid twice per shift from the discharge point of phosphoric
acid metering injection pump into a 25 ml graduated cylinder for one (1) minute. Results
Stroke per minute from the polyblend display shall be checked and recorded twice per
The level of the caustic in the Tote tank shall be checked as required. Replace tote tank
immediately when this tank becomes empty. The frequency of this check is twice per shift
tank immediately when this tank becomes empty. The frequency of this check is twice per
Collect a sample of powdered lime from the lime feeder into a 1000-ml plastic pre-
weighted beaker for one (1) minute. Obtain the net weight of the powdered lime placing
the pre-weighted beaker (taking the empty beaker weight into account to zero the scale)
onto weighing scale. Convert the net weight powdered lime obtained in ounces into
pounds (divide by 16, I lb = 16 ounces) and multiply the pound numbers by 60 to obtain
pounds of dry powdered lime feed. Results to be recorded twice per shift in pounds per
720A METER
pH DETERMINATION
1. Push 2nd button and then channel button to get to #2 channel for pH probe.
5. Enter number of buffers used, 3 then push yes. (use buffers: 4.0 and 7.0 and 10.0)
6. Immerse pH probe in 4.0 buffer. When meter displays ready enter 4.0 and push yes.
7. Meter will advance to buffer 2. Rinse the probe with D.I. water and immerse into the 7.0
buffer.
9. Meter will advance to buffer 3. Rinse the probe with D.I. water and immerse into the
10.0 buffer.
10. When meter displays ready enter 10.0 and push yes.
12. Remove probe, rinse with D.I. water and immerse probe into sample. Push measure
13. After calibration immerse probe in each buffer and record reading of each. Rinse probe
NOTE: Follow the Operation and Maintenance manual for more detailed instructions.
APPENDIX A
PROCEDURE
1. Use channel #1. Push 2nd button and then channel button until channel #1 is
displayed.
10. Immerse probe in 10 ppm standard. (blue) When ready is displayed enter 10.0 and
push yes.
25 mls of waste water from clarifier discharge and 25 mls of Tisab. Mix well.
13. Rinse probe with D.I water and immerse in sample. Push measure button. Read
0 to 15 In compliance
16 to 20 Borderline
Above 21 Out of compliance
NOTE: To reset meter if you make a mistake just unplug the meter.
APPENDIX B
The effectiveness of the treatment system is dependent upon the correct dosage of
chemicals being added to the treatment system. The chemical concentrations must remain
the same regardless of the rate of effluent flow through the system.
Given this premise, the dosage of chemicals into the effluent stream shall be adjusted
dependent upon the flow. The method of adjusting the dosage is to adjust the chemical
metering pumps or to add or decrease the amount of lime added to the system through the
accurate feeder.
To assist in the operation, attached to this chapter are two graphs showing the relationships
between pump settings, lime dosage and flow. These graphs are developed for your plant at
To change chemical dosage using Graphs A and B the following steps must be followed
STEP 1: Collect sample from Stage 2 of can washer and check for F using standard
STEP 3: Using appropriate chart select flow closest to flow through the flume select
The cationic polymer should be regulated by visual observation, i.e., keep increasing
discharge rate till effluent from lamella is clear. However, remember any change in dosages
settings at which the concentration of the treatment chemicals will result in the most efficient
operation of the treatment chemicals will result in the most efficient operation of the treatment
system for the removal of the pollutants in the effluent stream. In the event the flow
characteristics change due to process modifications, the settings will have to be changed as
well.
GRAPH A
GRAPH B
LIME ADDITION
TABLE 3
TREATMENT CHEMICAL ADDITION OPERATING PARAMETERS SETTINGS
one brandone vision 55
The following are the operational settings for the Treatment Chemical Addition Systems,
which will produce the most consistent results:
pH Control System
1. Buffer Low
2. Buffer High
3. Slope calibration
4. Slope recall
5. Set pH value
6. Output 0/4 MA
7. Simulate pH
8. Temperature
9. ALM. Pt 1
10. ALM. Pt 2
14. Gain
15. Reset
A. Cationic Polymer
1. Speed %
2. Stroke %
3. ML/MIN
2. Stroke %
3. ML/MIN
1. Speed %
2. Stroke %
3. Rotometer
GPH
4. SELECTOR
MODE SWITCH
EXT/INT
SPM/SPH
5. STROKES PER
MINUTE/HOUR
TROUBLESHOOTING PROCEDURE
No Flow through System. Can lines down. No flow All chemical feeds should be
from washer. turned off for semi-automatic
system. Remember to turn
them on when washer
comes back on line.
High liquid level in Stage #2. Lift pumps not operating. Verify that pumps are turned
ON. If not, turn them on. If
ON, but not operating,
contact plant maintenance
for corrective action.
High liquid level in Stage #2. Ball and/or check valves at Put the spare lift pump in
(cont.) discharge line clogged with service and arrange for
sludge buildup. maintenance to remove and
clean valves.
Low pH Stage #1. No caustic in caustic storage Pump caustic into storage
(i.e., pH<6.0) tank. tank.
High pH Stage #1. No sulfuric acid in sulfuric Pump sulfuric acid into
(i.e., pH>10.0) acid storage tank. storage tank.
Excessive caustic usage. Metering pump for sulfuric Using a repair kit, rebuild the
acid is siphoning due to pump. Refer to pump
pump diaphragm failure. manual for correct rebuilding
procedure.
Excessive usage of sulfuric Metering pump for caustic is Using a repair kit, rebuild the
acid. siphoning due to pump pump. Refer to pump
diaphragm failure. manual for correct rebuilding
procedure.
High sludge level in Lamella. Failure of sludge transfer. Switch to Standby pump.
Arrange repair of failed
pump.
Sludge cake not dry. Insufficient air blow-down. Increase air blow-down cycle
until dry cake is achieved.
Excessive solids carry-over High oil and grease. Correct solids settling
Lamella. problem.
Calcium carbonate buildup Excessive lime slurry. If feasible, reduce feed rate
(hard scale). of lime slurry to waste
chemical holding tank.
Filtrate from filter press is Torn filter cloth. Replace torn filter cloth(s).
dirty (cloudy).
Filter cloth is not in groove. Check to see if cloths are in
grooves.
YES YES
NO NO
VERIFY SYSTEM pHS CHECK THE VERIFY SYSTEM pHS
ARE CORRECT FUNCTION OF pH ARE CORRECT
CONTROLLER;
ACID/CAUSTIC FEED
OPERATIONAL, pH
PROBES
YES CALIBRATIONS, YES
REPLACE
BROKEN/WORN OUT
PROBES ETC.
NO NO
INCREASE CONTACT SHIFT INCREASE
COAGULANT FEED SUPERVISOR. FLOCCULENT AT
RATE TO IMPROVE INTERVALS OF 5%
CLARITY. OUTPUT FEED RATE
TO IMPROVE CLARITY.
Proper sample containers, with preservatives, to perform the necessary routine analysis
at your facility. The CHAIN OF CUSTODY RECORD for your facility, included with each
kit, indicates the permit requirements. Please review this for accuracy. If you know of
discrepancies, please contact Diana Mockler at TEST AMERICA Laboratories
immediately. If you require extra analysis and are unsure of sample container needs,
please contact TEST AMERICA Laboratories.
One TEST AMERICA Laboratories Chain of Custody Record. Chain of custody forms
will eventually all be preprinted, meaning that all you need to do is fill in the sample
date/time/etc. and sign the form. Again, if you see discrepancies, please contact TEST
AMERICA Laboratories. If you are requesting additional analysis, please complete a
separate Chain of Custody record for the additional parameters.
Complete the self-monitoring report page. If the monitoring report page is not complete,
sampling must be repeated. This monitoring report, in addition to all required paperwork,
must be placed in the plastic bag inside the sample kit return cooler.
Pack glass containers in a matter to ensure that they will not break in shipping. Bubble wrap
will be included with each cooler shipped after September 30, 1996. TEST AMERICA
Laboratories recommends that you utilize this bubble wrap by wrapping each individual glass
container at least twice with the bubble wrap.
Finally, each cooler must be packed in ice, not only ice packs. Place ice in large Zip Lock
Bags, clearly labeled ICE PACK. Two bags per cooler should be utilized if space permits.
The cooling demands change, obviously with the weather, so common sense and feedback
from the receiving lab will control the final amount of ice required. As previously mentioned,
sample temperature upon receipt at the laboratory should be 4C + 2C.
SAMPLING PROCEDURE:
1. Read the Wastewater Pretreatment Self-Monitoring Report form and be prepared to
complete this report.
2. Be certain the composite sample container, located in the plant sampler, is clean. The
bottle should be thoroughly cleaned at the end of each sampling period.
3. Enter the information on the Wastewater Pretreatment Self-Monitoring Report form
required for the start of the sampling (time sampling started, flow meter reading, etc.).
4. Commence sampling.
5. Twenty-four (24) hours later, turn the sampler to the OFF position.
6. It is recommended that disposable gloves be worn at all time when handling samples and
sample containers.
7. Mix the composite sample thoroughly.
8. Open each bottle in the kit identified as a COMPOSITE sample. Be certain to stand up
wind since the sample bottles contain preservatives, which can create fumes and cause
skin irritation. Do not spill the preservatives.
9. Again, mix the composite sample thoroughly and quickly fill each bottle identified as a
COMPOSITE sample.
10. Replace caps quickly after filling the containers.
11. Grab samples for Fats, Oil, and Grease (FOG) should be collected directly in the glass
bottle or bottles. BE SURE TO WEAR LATEX/RUBBER GLOVES WHEN COLLECTING
THE FOG SAMPLE. The bottles should be placed into the stream and filled completely,
allowing as little rinsing effect as possible in the bottle. The FOG bottles should not be
filled using another container unless it is necessary (i.e., you cannot get the glass bottle
into the stream to allow it to fill completely). If you have a problem with this, please
contact TEST AMERICA Laboratories at 219-464-2389. They will be happy to discuss a
procedure with you. TEST AMERICA Laboratories provides sample containers with
preservative already in place. If you are concerned that it may not be feasible to obtain a
sample and keep the acid in the bottle, check the pH following collection. The pH must be
below 2.0. If you cannot achieve this, please contact TEST AMERICA Laboratories.
12. Place sample containers in coolers.
13. Take another grab sample from the flume and measure the pH of the grab. Enter the
value of pH on the Self-Monitoring report form.
14. Complete the Wastewater Pretreatment Self-Monitoring Report and make one (1) copy
for your records.
15. Place the original Wastewater Pretreatment Self-Monitoring Report in the plastic
envelope provided and place it in the mailing pack.
16. Clean your composite sample container thoroughly between sample events. Be sure to
place it where it will not be used for any other purpose until the next sampling.
17. Wash hands.
18. Pack coolers in ice, taking necessary precautions with the glass bottles. All paperwork
should be placed in a large zip-lock bag. Return address labels will be in each cooler.
19. Seal the cooler using shipping or duct tape and ship to the designated TEST AMERICA
Laboratories facility via next day air service (Federal Express, UPS, or equivalent).
CUSTODY
The initial startup of the wastewater pre-treatment system requires that the following
Step 1: Check all valves and piping to ensure that flow from all components is
directed to proper location (i.e., lift pump to inlet of the lamella, lamella
sludge transfer pumps to sludge holding tank, filter press feed pumps to
filter press, used oil delivery pumps to used oil tank, used oil sludge
Step 2: Fill all oilers for air operated diagram pumps and set pump regulators at
Step 3: Calibrate the metering injection pumps, the polyblend units, and the
Step 4: Adjust set point on Beckman or equivalent pH control unit to 8.0 allow
Step 5: Energize the Swaby lift pumps, thereby starting the process effluent
Step 7: Start lamella sludge transfer pump. The lamella transfer pump pumps
sludge from lamella to the sludge holding tank regulator. The pump
Step 8: Start chemical injection metering feed pump at setting to give 50 ppm in
stage #1 Check dosage chart prepared in Step 3 for proper setting. The
Step 10: When the sludge holding tank is full and overflowing to the trench, start
filter feed pumps to the filter press (start-up instructions for filter press, as
per manual).
Step 11: Start up flow monitoring system by turning power on to the flow monitor.
Fine-tuning of the wastewater treatment system requires that all components operate
as a single unit, which will generate a treated effluent of a quality, which will meet the
provided:
pump should be set at 75% rated capacity. After system has reached equilibrium
B. To fine-tune the lime slurry feed rate, determine the quantity of fluoride
concentration limit on a monthly average basis required for the discharge into
procedure outline in Chapter 3. Start optimizing the lime feed rate until the fluoride
wastewater permit. Leave the lime feeder running about 10%-15% higher than the
optimum value.
To adjust the lime slurry feed; you increase or decrease the amount of lime
delivered to the lime slurry tank through the accurate feeder, which is
C. Fine-tuning of the polymer dosage requires that the settling rate of the floc in the
flocculation tank of the lamella be determined. The optimum settling rate is 300
ml/min. in the flocculation tank. To determine the settling rate, follow procedures
adjusting the polymer feed to the Polyblend unit; the feed is adjusted by varying
the speed and stroke of the LMI pump associated with the unit.
Adjustments to the feed rate shall be made until the desired settling rate is
determined (i.e., 300 ml/min. once the desired settling rate is determined).
D. pH: To determine optimum pH, samples are to be collected and analyzed by the
lab with the results reviewed and optimum pH for treatment selected.
E. Sludge Draw-off Rate: The sludge draw-off rate from the lamella is related to the
state at which the sludge is formed. The optimum sludge draw-off rate is a rate
attached to this manual which will show settings, operating parameters, sludge settling
rate, etc. If a problem develops, the system should be returned to original settings and
The procedure which is to be followed to shut down and restart the wastewater treatment
system, is as follows:
Step 2: Shut manual valves just prior to acid and caustic Fox Boro valves.
Step 3: When filter press is full, empty solids from the press and do not put back
into service (this needs to be done only if plant will be down more than
48 hours).
Step 4: Turn off all air pumps, i.e., Lamella sludge transfer pumps, filter press
As will be noted from above Steps, we have not turned off the lift pumps, mixers and pH
Control System. These three are left on as a safety precaution in case the washer develops
any problem. When you get ready to start-up the wastewater treatment system just reverse
steps 1 through 7.
PREVENTIVE MAINTENANCE
PREVENTATIVE MAINTENANCE
To insure continuous and trouble free operation of the wastewater treatment system the
10. Lime silofilter bags. 1/nine months Replace all filter bags: 4
1/year required.