Inlet Works Operating Instructions Rev 01-BR - 2018!06!01

Document Number
Group Five
G5-113248-12.14-001
Revision Number
PROJECT MANAGEMENT SYSTEM
02
Page Number
OPERATING INSTRUCTIONS FOR INLET WORKS Page 1 of 87
Project Name Darvill Waste Water Treatment Works Upgrade

Project
2013/136 (113248)
Number
Project To Increase the Waste Water Treatment Capacity From 65
Intention 𝑀𝑙/𝑑𝑎𝑦 to 200 𝑀𝑙/𝑑𝑎𝑦
Appointment 01-08-2014
Key Project
Commencement 01-08-2014
Dates
Completion
Consulting
Hatch
Engineer
Main Contractor Group Five – Coastal
Contractors
Sub-Contractors DML (JV)/LWT/ELECTRON
Version
02
Number
Originated By (Group Reviewed By Approved By Approved By

Five) (Group Five) (Group Five) (Hatch)
Welshman Acklen Reddy Michael Mc Kenna
Name
Chizemo/Ben Radebe
Designation Junior Engineer/MEIP QA Engineer MEIP Manager
Engineer
Signature
Date 20/08/2018
 Copyright Group Five. All Rights Reserved - This documentation is considered the intellectual property of Group Five.
Unauthorised reproduction or distribution of this documentation or any portion of it may result in severe civil and criminal
penalties, and violators will be prosecuted to the maximum extent possible under law.
Document Number
Group Five
G5-113248-12.14-001
Revision Number
02
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Tables of Contents
Tables of Contents .................................................................................................................................. 2
LIST OF FIGURES ...................................................................................................................................... 6
LIST OF TABLES ........................................................................................................................................ 7
ABBREVIATIONS ...................................................................................................................................... 1
ERRATUM ................................................................................................................................................ 1
1. GENERAL METHOD AND PRINCIPLE OF OPERATION .......................................................................... 2
1.1 DESIGN BRIEF AND REQUIRED PURPOSE ...................................................................................... 2
1.2 OUTPUT AND FUNCTIONALITY...................................................................................................... 5
1.3 PRINCIPLE AND METHOD OF OPERATION – INLET WORKS .............................................................. 6
1.3.1 Remote auto operation.............................................................................................................. 6
1.3.2 Remote manual operation ......................................................................................................... 7
1.3.3 Local manual operation ............................................................................................................. 7
2. GENERAL PROCESS SAFETY INSTRUCTIONS ........................................................................................ 8
2.1 HAZARDOUS IDENTIFICATION RISK ASSESSMENT ........................................................................ 8
2.2 PPE REQUIREMENTS ..................................................................................................................... 9
2.3 IMMEDIATE ACTION PLAN ............................................................................................................ 9
2.3.1 ELECTRICAL EQUIPMENT IN MCC ROOMS ........................................................................... 10
2.4 EVACUATION PLAN ..................................................................................................................... 11
2.4.1 Evacuation Routes and Key Locations.................................................................................. 12
2.4.2 Emergency Evacuation ......................................................................................................... 13
2.4.3 EMERGENCY CONTACT NUMBERS ....................................................................................... 14
2.5 PRESSURE OR POTENTIAL ENERGY RELIEF .................................................................................. 17
2.6 HAZARDOUS MATERIAL INFORMATION ..................................................................................... 17
2.7 ALARMS, TRIPS AND INTERLOCKS ............................................................................................... 17
2.7.2 ALARM CATEGORIES ............................................................................................................ 17
2.7.3 ALARM ALLOCATIONS .......................................................................................................... 18
2.8 OTHER SAFETY RELATED INFORMATION .................................................................................... 19
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3 OPERATING INSTRUCTIONS ............................................................................................................... 20

3.1 ACTUATORS/AUTOMATED VALVES ............................................................................................ 20
3.1.2 REMOTE MANUAL OPERATION............................................................................................ 20
3.1.3 LOCAL MANUAL OPERATION ............................................................................................... 21
3.2 COARSE SCREENS ........................................................................................................................ 23
3.2.1 REMOTE-AUTO OPERATION OF COARSE SCREEN ................................................................ 24
3.2.4 NORMAL OPERATING PROCEDURE/READINGS ................................................................... 31
3.2.5 EMERGENCY SHUT-DOWN ................................................................................................... 31
3.2.6 ISOLATION ............................................................................................................................ 31
3.2.7 TROUBLE SHOOTING ............................................................................................................ 31
3.2.8 PERIODIC MAINTENANCE SCHEDULE................................................................................... 31
3.3 FINE/STEPPED SCREENS .............................................................................................................. 31
3.3.1 REMOTE- AUTO OPERATION ................................................................................................ 31
3.3.6 ISOLATION ............................................................................................................................ 38
3.4 SCREW WASH PRESS AND COUNTER PRESSURE SCREW ...................................................... 38
3.4.1 REMOTE-AUTO OPERATION................................................................................................. 40
3.4.5 ISOLATION ............................................................................................................................ 49
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3.5 FOGG CHANNEL .......................................................................................................................... 49
3.5.1 REMOTE- AUTO OPERATION OF FOGG CHANNEL ............................................................... 49
3.5.6 ISOLATION ............................................................................................................................ 59
3.5.8 SAMPLING, CALIBRATION AND MEASUREMENTS ............................................................... 59
3.6 FOG PUMP STATION ................................................................................................................... 59
3.6.5 ISOLATION ............................................................................................................................ 66
3.7 AIR BLOWERS .............................................................................................................................. 66
3.8 GRIT CLASSIFIERS ........................................................................................................................ 69
3.8.1 REMOTE AUTO-OPERATION................................................................................................. 69
3.9 DRAINAGE PUMPS ...................................................................................................................... 71
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3.9.1 REMOTE AUTO OPERATION ................................................................................................. 71

3.10 ACESS HATCHES ........................................................................................................................ 73
3.10.1 Unblocking the launders and coarse screen. ..................................................................... 74
3.11 HOIST CRANE............................................................................................................................. 75
3.11.1 Sequence Steps .................................................................................................................. 76
3.11.2 EMERGENCY SHUT-DOWN ................................................................................................. 76
3.11.3 ISOLATION .......................................................................................................................... 77
3.12 HVAC System Testing ................................................................................................................ 78
3.12.1 REMOTE AUTO OPERATION ............................................................................................... 79
3.12.2 NORMAL OPERATING PROCEDURE/READINGS ................................................................. 79
3.12.3 TROUBLE SHOOTING .......................................................................................................... 79
3.12.4 EMERGENCY SHUT-DOWN ................................................................................................. 79
APPENDIX A: EMERGENCY EVACUATION PLAN .................................................................................... 80
APPENDIX B: COARSE SCREEN FDS ....................................................................................................... 80
APPENDIX C: FINE SCREEN FDS ............................................................................................................. 80
APPENDIX D: SWP AND CPS FDS ........................................................................................................... 80
APPENDIX E: FOGG CHANNEL FDS ........................................................................................................ 80
APPENDIX F: FOG PUMP FDS ................................................................................................................ 80
APPENDIX G: AIR BLOWERS FDS ........................................................................................................... 80
APPENDIX H: GRIT CLASSIFIER FDS ....................................................................................................... 80
APPENDIX I: DRAINAGE PUMPS FDS .................................................................................................... 80
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LIST OF FIGURES
Figure 1: Emergency Response Structure ............................................................................................. 11
Figure 2: Emergency Evacuation Diagram ............................................................................................ 13
Figure 3: Actuator in remote mode ...................................................................................................... 20
Figure 4: Operating an actuator from the SCADA................................................................................. 21
Figure 5: Actuator in local mode ........................................................................................................... 22
Figure 6: Coarse and fine stepped screen Settings ............................................................................... 23
Figure 7: Coarse screen in PLC mode .................................................................................................... 25
Figure 8: Checking alarm status for the coarse screen ......................................................................... 26
Figure 9: Re-setting any pre-alarm conditions...................................................................................... 27
Figure 10: Initiating screen operation................................................................................................... 28
Figure 11: Coarse screen motor in LOCAL mode .................................................................................. 29
Figure 12: Operating the screen on the field ........................................................................................ 30
Figure 13: Fine stepped screen in PLC mode ........................................................................................ 32
Figure 14: checking the alarm status of the fine stepped screen ......................................................... 33
Figure 15: Re-setting present alarm conditions.................................................................................... 34
Figure 16: Initiating remote manual operation .................................................................................... 35
Figure 17: Fine stepped screen in Local mode...................................................................................... 36
Figure 18: Operating the fine stepped screens from the field ............................................................. 37
Figure 19: Washer Compactor Settings ................................................................................................ 39
Figure 20: SWP motor in PLC mode ...................................................................................................... 40
Figure 21: CPS motor in PLC mode....................................................................................................... 41
Figure 22: Checking the alarm status of SWP. ...................................................................................... 42
Figure 23: Checking the alarm status for CPS ....................................................................................... 43
Figure 24: Re-setting any present alarm conditions on SWP ............................................................... 44
Figure 25:Re-setting any present alarm conditions on CPS .................................................................. 44
Figure 26: Starting the Screw Wash Press ............................................................................................ 46
Figure 27: Starting the CPS.................................................................................................................... 47
Figure 28: SWP and CPS in Local Mode ................................................................................................ 47
Figure 29: Operating the SWP and CPS from the field.......................................................................... 48
Figure 30: FOG trolley, scraper and de-grit pump in PLC mode. .......................................................... 50
Figure 31: Checking the alarm status of trolley drive motor. ............................................................... 51
Figure 32: Checking the alarm status of the scraper ............................................................................ 52
Figure 33: Checking the alarm status for the grit pump ....................................................................... 53
Figure 34: Re-setting any present alarm conditions on the trolley drive motor .................................. 54
Figure 35: Re-setting the trolley scraper motor ................................................................................... 54
Figure 36: Re-setting the grit pump ...................................................................................................... 55
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Figure 37: Operating the trolley from the SCADA................................................................................. 56

Figure 38: FOG trolley, scraper and grit pump in Local Mode. ............................................................. 57
Figure 39: Trolley field operating panel board. .................................................................................... 58
Figure 40: FOG pump in PLC mode. ...................................................................................................... 60
Figure 41: Checking the alarm status of the FOG pump. ...................................................................... 61
Figure 42: Re-setting present alarm conditions.................................................................................... 62
Figure 43: operating the FOG pump in Remote Manual ...................................................................... 63
Figure 44: FOG pump in Local mode. .................................................................................................... 64
Figure 45: Operating fog pump from the field...................................................................................... 65
Figure 46: Blower in PLC mode. ............................................................................................................ 67
Figure 47: Operating Blower from site. ................................................................................................ 69
Figure 48: Grit Classifier in PLC mode. .................................................................................................. 71
Figure 49: Drainage Pump in PLC mode................................................................................................ 72
Figure 50: Access Hatches on launder and coarse screens................................................................... 74
Figure 51: Operating switch for a Hoist Crane. ..................................................................................... 77
Figure 52: Isolation switches for 3 Inlet Works Hoists .......................................................................... 77
Figure 53: HVAC operating panel. ......................................................................................................... 78
LIST OF TABLES
Table 1: Abbreviations ............................................................................................................................ 1
Table 2: Table of Information to Finalise. ............................................................................................... 1
Table 3: Tab Access Levels ...................................................................................................................... 5
Table 4: Level Sensors Output and Functionality.................................................................................... 5
Table 5: Flow meters Output and Functionality ..................................................................................... 6
Table 6: DOs and Don'ts in Electrical Rooms ........................................................................................ 10
Table 7: Fire Services Contact Numbers ............................................................................................... 14
Table 8: Medical Services Contact Numbers......................................................................................... 14
Table 9: Police and Security Services Contact Numbers ....................................................................... 15
Table 10: Miscellaneous Services Contact Numbers ............................................................................ 15
Table 11: Umgeni Water Contact Numbbers ........................................................................................ 16
Table 12: Pressure or Potential Energy Relief ....................................................................................... 17
Table 13: Alarm Categories and Descriptions. ...................................................................................... 17
Table 14: Trips and Meaning................................................................................................................. 18
Table 15: Coarse Screen Normal Operating Readings. ......................................................................... 31
Table 16: Fine Stepped Screen Normal Operating Readings. ............................................................... 38
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ABBREVIATIONS
Table 1: Abbreviations
ABBREVIATION MEANING
MCC MOTOR CONTROL CENTRE
FOG FATS OIL AND GREASE
FOGG FATS OIL GRIT AND GREASE
PTC POSITIVE TEMPERATURE CO-EFFICIENT
PST PRIMARY SETTLING TANK
P&ID PIPING AND INSTRUMENTATION DIAGRAM
SWP SCREW WASH PRESS
CPS COUNTER PRESSURE SCREW
SP SET POINT
WPC WASH PER CYCLE
OEM ORIGINAL EQUIPMENT MANUFACTURER
ERRATUM
Table 2: Table of Information to Finalise.
Missing information Page no. Reason
Inlet flow #### MLD to #### MLD 9
Coarse screen size ## mm 9 Awaiting new control philosophy
Launder HP wash water system of #### KPa 10 & 81
FOG Level in Hopper ##%, 11,66 & 69
MCC Temp probe (D-03TT-###) 11 & 85
CPS power setpoint ## 46
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1. GENERAL METHOD AND PRINCIPLE OF OPERATION
1.1 DESIGN BRIEF AND REQUIRED PURPOSE

The flow into the works is controlled by two manually operated channel gates D-01-PGV-1011A and
D-01-PGV- 1011B. The new head of works is capable of handling 200MLD (under storm conditions) of
raw sewage. Downstream of the channel gates is a flow meter chamber, which houses a flow meter
D-01-FT-1006. The flow meter measures the instantaneous flow rate as well as the totalised inflow.
From this, one can calculate the average flow rate for any given period of time. From the Flow-meter
chamber, raw sewage flows into the inlet chamber, D-01-TK-1002, where it is split between two
channels. Excess flow spills over into a side channel, through a horizontal screen, D-01-SCN-1001 and
into the storm dam. The contents of the storm dam are pumped back to the head of works later when
the works has capacity to accommodate it. The storm dam is equipped with 3 pumps, 2 duty and 1
standby with a level transmitter. The storm dam influent returned to head of works is measured by
flow meter D-01-FT-1002 located on the return discharge line.
The default maximum flow through the plant is 120MLD. This value is however, adjustable from the
SCADA by the operator. The maximum flow is achieved by summing the values of Flow transmitters
D-01-FT-1003, D-01-FT-1004 and D-01-FT-1005. By modulating the position of penstock gate valves,
D-01-PGV-1001A and D-01-PGV-1001B, the operator will be able to control the flow between ####
MLD to #### MLD through the plant. Downstream of D-01-PGV 1001A/B are two hand-raked screens
D-01-SCN-1002A and D-01-SCN-1002B; these manually operated screens prevent objects greater ##
mm from causing blockages in the mechanical screens launders. The screenings will be raked and
collected in a launder and then dumped into a skip, thereafter is a stone trap which traps all small
stones and heavy objects which would have otherwise affected the operation of equipment further
down the process.
The flow then enters four mechanical screening channels, via four actuated penstock valves; D-01-
PGV-1002A, D-01-PGV-1002B, D-01-PGV-1002C and D-01-PGV-1002D. Each channel is equipped with
a mechanical coarse screen (D-01-SCN-1003A, D-01-SCN-1003B, D-01-SCN-1003C, D-01-SCN-1003D),
followed by a mechanical stepped fine stepped screen (D-01-SCN-1004A, D-01-SCN-1004B, D-01-SCN-
1004C, D-01-SCN-1004D). A channel is deemed in service if both of its coarse and fine stepped screens
are operational and actuated penstocks at the entry and exit of each screening channel are fully
opened. The channels work on a default maximum of 3 duty and 1 standby system. This means,
depending on the flow, the plant may have: (i) 1 duty, 3 standby; (ii) 2 duty, 2 standby; (iii) 3 duty, 1
standby channels. Number of channels in service increases in multiples of 40MLD.
1. 0-40MLD: 1 channel in operation.

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2. 40-80MLD: 2 channels in operation.

3. 80-120 MLD: 3 channels in operation.
ONLY UNDER HEAVY STORM CONDITIONS SHALL ALL FOUR SCREENING CHANNELS BE OPERATIONAL.
Duty channels rotate on a weekly basis, or by operator intervention. The standby channel fills in for
the unhealthy channel. There are two hand-raked bypass screens D-01-SCN-1002A and D-01-SCN-
1002B; these manually operated screens sandwich the mechanically operated coarse screens. In the
event that the screens become blocked or otherwise inoperable, the upstream water level will
increase and will overflow into a pair of concrete weirs (D-01-WR-1002A and D-01-WR-1002B) to two
by-pass channels. Ultrasonic level sensors monitor the levels in these channels. A high level alarm is
triggered at 80% and a high-high level alarm is triggered at 100%. This alarm is triggered on the SCADA
by “Inlet Works Flood Alarm, Rake Manual Screen”. A siren will go off, notifying the operator of the
need to clean the by-pass rakes.
Screenings are discharged from the coarse and fine stepped screens into a screenings collection
launder where High Pressure (HP) wash water system of #### KPa is in place to flush the screenings
into a screenings washer –compactor unit. The washer compactor is a dual unit which works on a duty
standby system; Diversion Chute D-01-CHT-1001, shall change over from Washer Compactor D-01-
SCRF-1001A & D-01-SCRF-1002A on a daily basis, to ensure equal operating hours, or if there is a fault
on the current duty motor set. Diversion Chute motor shall only change duty if washer compactor
screw conveyor are both in working order and ready to run.
The unit washes and compacts the screenings which are later dropped into a skip for disposal. The
drainage liquids from the Washer-Compactor system gravitate to the drainage sump and subsequently
pumped by pumps D-01-P-1007/8 to the Flow Inlet Chamber, D-01-TK-1002. During planned
maintenance the mechanical screens can be isolated manually by closing penstocks at the entry and
exit of the channels. From the fine stepped screens, the raw sewage flows into a common chamber,
D-01-CHN-1002 where it is distributed amongst four FAT OIL GRIT AND GREASE (FOGG) lanes. Because
of the fairly low velocity of the screened sewage in this chamber, Fats tend to settle and float. To
clear/clean these fats, there are two downward opening penstock gate valves D-01-PGV-1004E and
D-01-PGV-1004F which leads to the F.O.G launder. Opening these valves will result in the F.O.G that
would have settled in D-01-CHN-1002 to flow into the FOG launder. These penstocks valves can be
opened as and when the operator sees fit.
The screened sewage exits the screen channels and flows into the combined fat, oil, grease and grit
(FOGG) removal plant. Flow into the FOGG plant is controlled by four manually operated penstock
gate valves, D-01-PGV-1004A, D-01-PGV-1004B, D-01-PGV-1004C and D-01-PGV-1004D. The grit
settles to the bottom of the FOGG channels, D-01-TK-1005, D-01-TK-1006, D-01-TK-1007 and D-01-
TK-1008 and is pumped into the grit channel launders D-01-CHN-1003, D-01-CHN-1004, D-01-CHN-
1005 and D-01-CHN-1006 by submersible pumps D-01-P-1003, D-01-P-1004, D-01-P-1005 and D-01-
P-1006 which are coupled to travelling bridges D-01-TRL-1001, D-01-TRL-1002, D-01-TRL-1003 and D-
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01-TRL-1004. From the launders, the grit flows to a grit classifier, D-01-SCRF-1005 or D-01-SCRF-1012
(Duty/Standby) and is removed from site in skips. Two air blowers, D-01-PDB-1001A and D-01-PDB-
1001B (duty/standby) bubble air through each FOGG channel by means of diffusers. The air bubbles
assist in suspending the FOG which is then skimmed by the scrapers SCPR-1001, SCPR-1002, SCPR-
1003 and SCPR-1004 into the FOG launder. HP Wash Water of washes the FOG into the FOG pump
station. The FOG pump-station is equipped with two screw pumps D-01-SCRF-1003 and D-01-SCRF-
1004 which work on a duty/standby system. Two knife gate valves (KGV-1007A and KGV-1007B)
upstream of the FOG hoppers determine which pump is on duty and which one is on standby.
Downstream of the FOG pump is a set of bursting discs D-01-BDSK-1001 and D-01-BDSK-1002. When
the FOG level in the hopper is high ##%, the diaphragm valve (D-01-DV-1001 or D-01-DV-1002) shall
fully open and then the PLC shall start the pump. If the FOG delivery line is blocked, pressure increases
within the line. Pressure increase above 7 bar will cause the discs to rupture and divert flow to the
drainage sump. The bursting discs are used to protect the pumps from high system pressures. From
the FOG pump station, FOG is pumped to the oil separator for later disposal. For any over-spillage in
the pump station, the sump pump, D-01-P-1007A/B (duty/standby) pumps the spillage back to the
FOG launder.
From the FOGG channels, the sewage flows to the collection chamber CHN-1006 where the flow is
distributed between the 4 PSTs; PST1, PST2, PST3 and PST4. Stop logs on Weir D-01-WR-1003, D-01-
WR-1004 and D-01-WR-1005 shall be used for temporary isolation during maintenance and repair
works or for flow control to the PSTs. Downstream of the common chamber is a flow meter chamber
which houses 3 flow meters, D-01-FT-1003 for PST3, D-01-FT-1004 for PST 1&2 and D-01-FT-1005 for
PST4 . These flow meters record the amount of flow to each tank. The
The MCC room is equipped with a HVAC system consisting of a temperature probe (D-03TT-###) and
two forced ventilation fans (duty/standby). If the temperature rises above the high 40oC, the PLC shall
start the extraction fan until the temperature drops below the low 20oC.
STARTING UP AND SHUTTING DOWN OF THE BUSBAR SHOULD ONLY BE DONE BY QUALIFIED
PERSONNEL. UNDER NO CIRCUMSTANCES IS THE OPERATOR ALLOWED TO OPERATE THE BUSBAR
MAIN SWITCH!!
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1.2 OUTPUT AND FUNCTIONALITY

Table 3: Tab Access Levels
PARAMETER TO BE CHANGED USER

Maximum and minimum set points Engineer and technician
The High and Low Process Set points Superintendent
Inlet Screens differential set points Senior Operator
Inlet Screens Time Set Superintendent
Blower Set point speed Engineer and technician
Wash press and Compactor Cycles Senior Operator
Wash press valve time set Engineer and technician
Screen Counts and Cycles Superintendent
Section Reset (Total Faults Reset) Senior Operator
Motor Reset Operator
Motor Start/Stop Operator
Table 4: Level Sensors Output and Functionality
TAG NUMBER MINIMUM S.P MAXIMUM S.P OUTPUT
D-01-LT-1003 300mm 1350mm Raw sewage level upstream of SCN-1003A

D-01-LT-1004 350mm 1350mm Raw sewage level downstream of SCN-1003A
D-01-LT-1005 350mm 1450mm Raw sewage level downstream of SCN-1004A
D-01-LT-1006 300mm 1350mm Raw sewage level upstream of SCN-1003B
D-01-LT-1007 350mm 1350mm Raw sewage level downstream of SCN-1003B
D-01-LT-1008 350mm 1450mm Raw sewage level downstream of SCN-1004B
D-01-LT-1009 300mm 1350mm Raw sewage level upstream of SCN-1003C
D-01-LT-1010 350mm 1350mm Raw sewage level downstream of SCN-1003C
D-01-LT-1011 350mm 1450mm Raw sewage level downstream of SCN-1004C
D-01-LT-1012 300mm 1350mm Raw sewage level upstream of SCN-1003D
D-01-LT-1013 350mm 1350mm Raw sewage level downstream of SCN-1003D
D-01-LT-1014 350mm 1450mm Raw sewage level downstream of SCN-1004D
D-01-LT-1015 50% 70% FOG level in HP-1001
D-01-LT-1016 50% 70% FOG level in HP-1002
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Table 5: Flow meters Output and Functionality
TAG NUMBER MINIMUM S.P MAXIMUM S.P OUTPUT

D-01-FT- 1006 0 140MLD Inlet flow
D-01-FT-1003 20MLD 80MLD Outlet flow to PST3
D-01-FT-1004 15MLD 85MLD Outlet flow to PST1&2
D-01-FT-1005 20MLD 55MLD Outlet flow to PST4
NB: BLOWER FREQUENCY IS SET AT A DEFAULT SET-POINT OF 25Hz per FOGG CHANNEL
1.3 PRINCIPLE AND METHOD OF OPERATION – INLET WORKS

The plant has three modes of operation:
1. Remote auto operation

2. Remote manual operation
3. Local manual operation
1.3.1 Remote auto operation

In this mode, PLC uses the process variables from the specific area as well as process variables
from other areas to automatically open or close valves and start or stop motors to operate the
plant within pre-determined settings and values. Selection of this mode enables automatic control
under PLC software actuation.
Equipment which can be operated in this mode are:

 Actuated Valves,
 Course Screens,
 Fine stepped screens,
 Screenings Handling (SWP & CPS),
 FOGG Plant Trollies,
 Grit Classifier,
 Blowers,
 Pumps &
 HVAC
THIS IS THE NORMAL MODE OF OPERATION.
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1.3.2 Remote manual operation

When operating in this mode, all system interlocks will be active. If manual operation of an area
needs specific system interlocks to be overridden, this can be done from the SCADA with correct
level password. Remote manual operation allows the operator to manually operate the plant
from the SCADA. The operator can open or close solenoid valves and start or stop motors.
This mode of operation is normally chosen for maintenance purposes, during communication,
network or control system failures. It is safer practice to attempt operating any set of equipment
in this mode before opting for Local manual mode.

 Blowers &
 Pumps
1.3.3 Local manual operation

This mode of operation overrides all system interlocks. For operating in this mode, the operator
is required to operate all equipment from site by selecting LOCAL with the LOCAL/PLC switch for
each piece of equipment.
This mode of operation is normally chosen for maintenance purposes, during communication,
network or control system failures.

 Course Screens,
 Blowers,
 Pumps,
 HVAC &
 Cranes
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2. GENERAL PROCESS SAFETY INSTRUCTIONS

2.1 HAZARDOUS IDENTIFICATION RISK ASSESSMENT
A INJURY SEVERITY B FREQUENCY of OCCURRENCE RATING
No Injury 0 Has not occurred in last two years RISK CLASSIFICATION RISK VALUE
Minor laceration, wound (first aid case) 2 Occurs very seldom LOW 0---6
More severe injury medical attention 4 Occurs occasionally MEDIUM 6---16
Serious injuries, broken bones, amputation etc 8 Occurs often HIGH 16---32
Loss of life / fatality 10 Could / has happened CRITICAL 32---40
C POTENTIAL DAMAGE / LOSS D ENVIRONMENT ACTION REQUIRED

Supervision, training, certification,
method/risk assessments, safe Good
No damage, minimal costs R10 – 100 0 No effect LOW
work procedures training, toolbox instruction.
talks.
Competent supervision, training
certification, method/risk
Change method,
Minor damage, small costs R100 – 1000 2 Minor effect MEDIUM assessments, safe work
mitigate
Spillage, noise, procedures training, toolbox
water, dust / talks.
vapours/ fauna and Competent supervision, training
flora certification, method/risk
Med damage, stoppage (On site repair) Serious effect Change method,
4 HIGH assessments, safe work
medium cost R1000 – 5000 (Short term) mitigate.
procedures training, toolbox
talks.
Close competent supervision,
training certification, method/risk Intolerable,
More serious damage / / loss / delay < R5000 - Very serious effect
8 CRITICAL assessments, safe work change method,
+ (Long Term)
procedures, PJO’s, work permits, transfer risk.
training, and toolbox talks.
Risk ratings
Task/Activity Hazards/ Associated risks Control measures
A B C D RR
Opening/Activating the Valves on the Plant Slips and falls when using cat-ladder that could Ensure that safety shoes are clean, free of mud or wet 4 2 4 2 32
lead to serious injuries to employees Ensure that safety harness are used where at climb is above
1.5mt and hook it as you climb up, both hands to be holding
firmly on the rails.
Working/walking in the plant Slips and falls on floors made slippery by sewage Ensure the surface/walk ways are clear of trips and falls, i.e. 2 2 2 2 16
pipes, extension cables, etc.
Ensure surface is dry; clean any spillage immediately and safety
foot wear is always on.
Working on the plant with overhead hoist Overhead loads from hoists Prior to hoisting ant material, ensure that communication is clear 4 2 4 2 32
People coming in contact with the load amongst your team that you intend hoisting material/load.
Loads falling into people Ensure no one will be on the way or under the hoisted material,
display signs or activate alarm/siren within the plant before
hoisting; the siren will serve a warning to unaware employees.
The meaning of the siren needs to be known by all plant
users/visitors prior to going to the plant. (Induction).
The plant area in strictly hard hat area, this is prevent injuries to
people should any objects hoisted are accidentally dropped or
falling.
Plant Operation Contact with moving machinery Ensure that you have enough knowledge or information of what’s 4 2 4 2 32
to be done.
Ensure that prior to manually opening any machinery to clear or
release any blockage the machinery has completely stopped
and on OFF position to prevent an automatic start that could
cause injuries.
When you done please be satisfied that you have close and all
moving components are tightly closed before restarting.
Wear appropriate PPE for the task.
Working in the Plant Diseases caused by infectious agents present in Ensure that when working in the plant you always wear your 4 2 4 2 32
the raw sewage PPE, mandatory PPE being Safety shoes, appropriate musk,
Diseases caused by toxins released by infectious appropriate hand gloves, hard hat and reflective clothing.
agents. Avoid eating or drinking in the area.
Dermatoses caused by exposure of the skin to Wash your hands and sanitise immediately upon leaving the plant.
waste waters Check with your SHE personnel for appropriate immunisation
when working at the plant.
Always wear long sleeves clothing, avoid any skin contact with
any chemicals or sludge splashes, should that happen please
leave the area and rinse your self thoroughly with clean water
and soap.
Notify your supervisor or SHE representative and get medical

help should you experience or notice any of the following…
Respiratory (asthma, chronic bronchitis, and chronic sinusitis),

(abdominal pain and bloating, nausea, vomiting, diarrhoea,
constipation), skin (skin rash, ulcer on the skin) or systemic
(headache, fever, chest pain or discomfort, muscle spasms
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2.2 PPE REQUIREMENTS

Standard site PPE should be worn at all times when working at the inlet works. The minimum PPE
requirements include:
1. Hard hat
2. Safety shoes/gumboots (steel toed).
3. Reflective Visible vest.
4. Overalls.
5. Gloves and dust masks (when cleaning at the inlet works).
6. Safety harness (when working on heights).
2.3 IMMEDIATE ACTION PLAN

LOCALISED FLOODING ON SITE
 Upon detecting excess surface water from any source, immediately notify the responsible
management member, who in turn will notify the Emergency Coordinator.
 If possible, take steps to prevent the flooding (e.g. isolate the source of the problem, and
start diversion activities).
 Where necessary, evacuate staff and other persons on site.
 In the event of a burst pipe or similar situation, technical staff to assist with resolving the
matter.
 Switch off any equipment which may be damaged by water.
 Where possible, take actions to divert water from critical installations/facilities.
 Once the problem has been resolved, arrange for cleanup of affected area and get technical
staff to arrange for cleaning and/or repair of all motors, fans and electrical switchgear
equipment.
 Ensure that the responsible engineer inspects all electrical equipment to certify that power
can be safely restored to the area.
POWER OUTAGE
Power outages may cause disruption to operations and potentially compromise the safety of
building occupants. The results of electrical failures will have the following effects on site:
 Standard lighting and air conditioning will be off.

 Computers/PLC will most likely be inoperative unless they are connected to a UPS.
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FOR UNPLANNED OUTAGE:
 Treat all circuits as LIVE.

 Ensure equipment, machinery or apparatus are stabilized or safe.
 Check all equipment on emergency power to ensure that it is running properly. DO NOT
CONNECT ITEMS NOT INTENDED TO BE ON EMERGENCY POWER DURING A DISRUPTION
PERIOD!!
 Where possible, continue working using emergency power (indicated by red plug points).
 When the power is restored, restart/restore equipment one by one. This may prevent an
overload on the system.
 Ensure that equipment is returned to safe operation mode.
 Inform your superior should you experience any problems related to the start-up.
2.3.1 ELECTRICAL EQUIPMENT IN MCC ROOMS

Table 6: DOs and Don'ts in Electrical Rooms
DO’s DON’T
1 Keep the MCC room clean. Don't touch open electrical wires.
2 Keep visitors out of the MCC room. Don't try to adjust control devices.
3 Keep a logbook and let maintenance Don't switch OFF the main switch or other circuit
personnel fill in their particulars, dates breakers unnecessarily. This causes abnormal wear
and the work undertaken. and tear and can lead to back-up battery failure.
4 Read the voltmeters and ammeters Don’t keep on starting motors which keep on tripping.
frequently. Report the problem immediately.
5 Report any abnormal occurrence or Don’t keep on resetting equipment, which keep on
motor noise immediately to the tripping. Report the problem immediately.
supervisor on duty.
6 Be present in or around the pump Don't work on any pump-set before switching off the
station when pumps are in operation. starter main switch and pressing the lock-stop button
on the motor.
7 Access to the MCC room should be Don’t touch rotating shafts or machine Parts.
controlled.
8 Keep electrical equipment and motors Don't leave operating equipment unattended.
dry.
9 Don't let untrained personnel operate pumping
equipment.
10 Don’t run pumps dry.
11 Don’t unnecessarily switch pumps and blowers on and
off.
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2.4 EVACUATION PLAN
The operation and maintenance evacuation plan has been developed by Umgeni Water (UM), refer
to the “Emergency Response Plan & Procedures Template: Darvill Wastewater Works”. The
structure for the emergency response (ER) is depicted below in figure 1Error! Reference source not f
ound., the structure illustrates the manner in which the incident is reported and escalated at the site
level to the Umgeni Water Head Office. Each role player responsibility is defined in terms of dealing
with the emergency situation at hand.
Figure 1: Emergency Response Structure
In the event of an incident, the individual that discovers it will report it to the responsible
management member, namely the supervisor/ manager/ systems manager/ work superintendent,
depending on the working environment. The responsible management member will then analyse
the situation and activate the emergency procedure, or notify the emergency coordinator (EC) to
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make a decision. In cases that warrant so the ER team and plan will be activated and the relevant
response will be taken, the local emergency services will be utilised as required.
The EC is then to inform and give details of the incident to the UW BCM coordinator. Depending on
the severity of the incident the BCM coordinator will inform the crisis management team (CMT)
leader and decisions will be made to activate the CMT and procedure.
2.4.1 Evacuation Routes and Key Locations

The evacuation routes and key locations are as follows:
1. Command Centre: The control room acts as a command centre in the event of an emergency.
However, if the control room cannot be used the main gate guard house will be used as the
command centre.
2. Forward Control Point: The forward return point is to be used by the fire department on site
and will be located at the command centre. The primary purpose of the forward control point
is to act as a location where the ER team can convey information to the Fire department and
other emergency services.
3. Emergency Assembly Points: a minimum of two (2) assembly points are located within each
work station, i.e. a primary point, located on site, and a secondary point for large scale
evacuations, located at a suitable distance away from buildings or working areas,
alternatively, the secondary point could be located off site. The following locations act as an
emergency assembly points, refer to Error! Reference source not found. below:
a. Assembly Point A: From the alum dosing area, through to the aerators, proceeding to
the main buildings passing through to the workshops and go left.
b. Assembly Point B: From the alum dosing area, through to the aerators, proceeding to
the main buildings passing through to the workshops and go right to the canteen.
c. Assembly point C: From the chlorine area, through to the main pump station, proceed
to the head of works, and go right to the inlet.
From the Digester area, through to the PST and go straight to the inlet.
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Figure 2: Emergency Evacuation Diagram
2.4.2 Emergency Evacuation

There are three evacuation plans based on the mobility of the personnel namely: general personnel,
mobility impaired personnel and hearing or visually impaired personnel. For other more specific
emergency procedures refer to the UW “Emergency Response Plan & Procedures Template: Darvill
Wastewater Works” document, in Appendix A.
2.4.2.1 General Evacuation Procedure for all personnel

Upon hearing the alarm or following notification by the ER team to evacuate the building / premises,
DO NOT PANIC!
Step 1. Stop all activities.

Step 2. Time permitting:
 Secure vital / confidential documents and valuable items
 In the event of a fire, close windows and doors, switch off air-conditioning
 In the event of a bomb scare, open doors and windows, but close blinds/curtains
 If using machinery and/or electrical equipment – isolate or switch off
Note: If you are in an operations environment – do not shut down the plant
Step 3. Evacuate the premises via demarcated escape routes, proceed to your assembly points (refer
to Section 0). Please remember, depending on the type and extent of the event, your EC may
ask that you proceed to the secondary assembly point to avoid danger.
Step 4. Where applicable, take your visitors with you and assist disabled persons in the area.
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Step 5. If you are unsure, or require any assistance, your area’s EC / fire marshal / fire warden will be
able to assist you.
Step 6. Do not run, walk in an orderly manner and assist others where needed.
Step 7. Keep away from any "Disaster" area.
Step 8. At the assembly point
 Gather with other individuals from your department / division for roll call
 The EC will take roll call to identify any missing persons
 Remain at the assembly point, do not re-enter the building until further instructions are given
by senior management
2.4.2.2 Personnel with Mobility Impairments

In the event of an emergency evacuation situation, other staff members will assist any persons with
mobility impairment. If no one is available to assist, remain where you are or move to a nearby area
of refuge if this is required for your safety. Await assistance from the EC or other ER team members.
2.4.2.3 Personnel with Hearing or Visual Impairments

In the event of an emergency evacuation situation, persons with communication disabilities such as
hearing or visual impairment may not be aware of any emergency situation and the need to carry
out ER procedures. It is the responsibility of surrounding staff members to assist such persons and
ensure that they are able to safely evacuate the building /premises.
2.4.3 EMERGENCY CONTACT NUMBERS

Table 7: Fire Services Contact Numbers
Name Contact Number Extra Details
FIRE DEPARTMENT (033) 845 5911
Ricky Pillay 082 804 4411
Table 8: Medical Services Contact Numbers
MEDI CLINIC – HOWICK PRIVATE

033 - 3302456
HOSPITAL
GREY’S 033 - 8973000
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MEDI CLINIC - PMB 033 - 8453700
ST ANNE’S - PMB 033 – 8975000
ESCOURT 036 - 3427000
PROVINCIAL AMBULANCE 10177
ER 24 084 124
Table 9: Police and Security Services Contact Numbers
Enforce Security Services 033 – 342 1347
Loop Street - SAP 033 - 8452400
Alexander Road - SAP 033 – 8457700
Hilton - SAP 033 – 8456521
Flying Squad 10111
Table 10: Miscellaneous Services Contact Numbers
Eskom 0860 037 566
NCP ( Chlorine Emergency) 011-9762115 or 011-9213333
Nomvuyo Zulu – Disaster

Management Msunduzi 072 525 1228
Municipality
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Mike Amod - Disaster

Management Msunduzi 079 874 4637
Municipality
Ethekwini Municipality 031 - 3610000
Table 11: Umgeni Water Contact Numbbers
Cyril Gamede 033 341 1041 / 082 771 1840 Overarching BCP Team Leader
Thandeka Zulu 033 – 719 7300 / 083 383 2135 Deputy Overarching BCP Team Leader
Ingrid Cawood 033 341 1244 / 083 292 5060 BCM Coordinator
Dan Naidoo 031 719 7300 / 083 272 4436 Deputy BCM Coordinator
Steve Gillham 033 341 1164 / 083 453 0240 GM: Engineering & Scientific Services
Msizi Cele 033 3411308 / 060 5773 246 GM: Operations
Thami Hlongwa 033 341 1507 / 082 818 8300 GM: Finance
Mokete Mayongo 033 3411011 / 060 521 7475 GM: Corporate Services
Thulasizwe Shangase 033 341 1012 / 083 459 8550 GM: Human Resource
Nonhlanhla Gumbi 033 341 1006 / 083 244 2310 GM: Supply Chain Management
Sipho Zulu 033 341 1135 /082 437 3329 GM: Property Services
Bradley Sampson 033 346 1583 / 083 642 7733 GM: ICT
Sunil Maharaj 083 274 3013 96290) Regional Manager
Eric Nene 083 345 6708 (6265) Area Manager
Ntsiki Baai 083 289 1450 (6372) Asset Manager
Mulalo Murigwathoho 078 801 1181( 6965) Systems Manager
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Goodman Ngcemu 084 444 3815 (6897) Superintendent DARVILL WWW
2.5 PRESSURE OR POTENTIAL ENERGY RELIEF
Table 12: Pressure or Potential Energy Relief
Equipment Possible cause Action Plan

Blowers High pressure build up Pressure Relief Valve on blower
FOG pumps Blockage in pipe work causing high Bursting discs divert flow to drainage
pressure build up. sump
Counter pressure Too much screenings in the washer Torque limit switch on Screw Wash
screw compactor causing the motors to draw Press motors, causing the power
more power. drawn by the motors not to exceed a
pre-set value.
2.6 HAZARDOUS MATERIAL INFORMATION

Raw sewage contains micro-organisms such as bacteria, virus etc. that can be harmful. Safety
precautions need to be under taken when handling settled sewage in SSPS.
2.7 ALARMS, TRIPS AND INTERLOCKS
2.7.2 ALARM CATEGORIES

Table 13: Alarm Categories and Descriptions.
CATEGORY DESCRIPTION
LEVEL 0 Where there is a change in operation status of equipment and
(NOTIFICATION) instrumentation on the plant during normal operating mode. The
alarm is generated as a line statement on the ALARM SCREEN in BLUE
print.
LEVEL 1 An alarm condition that warns the Senior Operator of impending
(FAILURE) negative impact on process performance, plant integrity, personnel
safety or environmental safety. The alarm is generated as a line
statement on the ALARM SCREEN in RED print. The text will change to
BLUE print if the ALARM CONDITION is rectified before the Senior
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Operator acknowledges the alarm. The Senior Operator must

acknowledge the alarm.
LEVEL 2 An alarm condition that warns the Senior Operator of severe negative
(CRITICAL FAILURE) impact on process performance, plant integrity, personnel safety or
environmental safety. This alarm is generated as a yellow POP-UP
SCREEN that must be acknowledged by the Senior Operator.
2.7.3 ALARM ALLOCATIONS

Table 14: Trips and Meaning
TRIP MEANING
E300 TRIP This will generally refer to a motor over load
PTC TRIP PTC stands for “Positive Temperature Co-efficient”, this refers to the
thermistor protection supplied in each motor. It provides protection
against the motor from overheating.
CABLE BREAK FAILURE This is only on the course screens. This is in reference to the stainless
steel cables used to lift/lower the rake. If the cable remains “slack”, for a
time period while running, we enter into a cable break scenario.
COMMUNICATION FAILURE The PLC constantly communicates with the E300 motor controller in
each starter. If communication to the unit is interrupted, we trigger a
fault as we are then unable to control the starter as we should.
MOTOR OVER-LOAD TRIP This when the motor trips out if the power drawn by the motor exceeds
a certain limit.
EARTH LEAKAGE This indicates a ground fault.
COMMUNICATION LOSS Same as Communication Failure
TORQUE TRIP Trip same as motor overload Trip
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2.8 OTHER SAFETY RELATED INFORMATION

Whether you are the owner, operator, or maintenance personnel for the installed equipment, safety
is your responsibility. You are responsible for operating and maintaining this equipment in compliance
with these instructions and for using intuitive judgment. It is extremely important that the operator
reads, understands, and follows the relevant safety procedures and regulations carefully before
handling the machines.
The following special messages warn of potential hazards or to call attention to information that clarifies or
simplifies a procedure.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING/ATTENTION
WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE addresses practices not related to physical injury including certain environmental hazards, potential damage or
loss of data.
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3 OPERATING INSTRUCTIONS
3.1 ACTUATORS/AUTOMATED VALVES

Automated valves can be operated in the aforementioned modes of operation. For actuator general
maintenance and fault finding, refer to Operation and Maintenance Manual, Inlet Works, Volume
2.1, file 2/3, Section 7.5
3.1.2 REMOTE MANUAL OPERATION
3.1.2.1 Purpose
To operate the actuated valves in Remote manual.
3.1.2.2 Pre-start up checks

1. From the field, the operator must ensure the actuator is in Remote Control Mode.
Light indicating a
close position
Knob switched to
remote control
mode
Figure 3: Actuator in remote mode
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3.1.1.3 Sequence Steps

1. From the SCADA, the operator checks the alarm status of the valve by
clicking on the specific valve on the SCADA.
2. Reset any present alarm conditions.
3. The Operator initiates valve operation.
Manual selected
“indicated by a
red light”
Figure 4: Operating an actuator from the SCADA
4. When the valve is opening or closing (neither open nor closed limits have
been reached), a blue colour will be displayed on the actuator icon from the
SCADA.
5. When the open limit in the actuator is triggered, the actuator will open and
a signal will be sent to the SCADA and a green colour will be shown on the
SCADA icon.
6. When the close limit is triggered, the actuator will be closed and a red
COLOUR WILL BE SHOWN ON THE SCADA.
3.1.3 LOCAL MANUAL OPERATION
3.1.3.1 Purpose
To Operate the Actuated valve in Local Manual Operation.
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Light indicating
an open position
Knob switched to
local control
mode
Figure 5: Actuator in local mode

1. From the field, the operator must ensure that the actuator is in Local Mode
and healthy.
2. Press the dedicated button for the required operation (open/close).
3. When the valve is opening or closing (neither open nor closed limits have
been reached), a blinking orange colour will be displayed (when the valve is
closing) and a blinking green colour will be displayed (when the valve is
opening) on the actuator.
4. When the open limit in the actuator is triggered, the actuator will open and
a green colour will be shown on the actuator.
5. When the close limit is triggered, the actuator will be closed and a red
colour will be shown on the actuator.
NB: THERE IS NO POSITION FEEDBACK INDICATING WHAT PERCENTAGE THE VALVE HAS MOVED.
ONCE THE OPEN LIMIT AND CLOSED LIMIT ARE RELEASED, THE VALVE WILL TURN BLUE
INDICATING TRAVEL.
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3.2 COARSE SCREENS

The Head of works has 4 coarse screens which operate on the same principle. Under normal working
conditions, the screens work on level differential across the screen and time intervals, first priority
being given to level differential. For motor maintenance and fault finding, refer to Inlet Works
Operations and Maintenance Manual, volume 2.1, File 1/3, section 6.9.
SCREEN SETTINGS
The inlet screen settings are adjustable, these are the set points located in red. These set
points are password protected. The green figures are the elapsed time or count (see figure
below).
Figure 6: Coarse and fine stepped screen Settings
 Step count required: number of steps the fine stepped screen needs to complete a
cycle.
 Cycle required: number of cycles required before the wash compactor starts.
 Fine stepped screen SP: the differential level.
 Coarse screen SP: the differential level.
 The coarse screen and fine stepped screen cycle SP: the time that will initiate the
screens cycle if the level has not been reached in the time.
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3.2.1 REMOTE-AUTO OPERATION OF COARSE SCREEN
3.2.4.1 Purpose
To operate the coarse screen in remote-auto mode from the SCADA.
3.2.4.2 Pre-start-up operation checks

1. Check to see that all rear covers, top plates and bus-bar covers are installed
and closed.
2. Close all front doors of the MCC on all starter panels and instrument panels,
as well as the main door of the main switch as this door is interlocked with
the main switch and it is not possible to switch the main power on with this
door open or slightly opened.
3. Ensure all manual or isolation valves relevant for operation are
opened/closed.
4. Check to see that personnel are not working on motors or pumps before start-
up.
5. Do not operate faulty pumps, motors or open shaft pump sets. Have them
repaired.

1. Check if duty/standby screens are switched into PLC mode.
2. Check the alarm status of the duty/standby motors by clicking on the motor.
3. The operator must ensure that the main panel door isolator is switched on.
4. The Operator must ensure coarse screen motor is switched into PLC mode.
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PLC mode selected

from the panel board
Figure 7: Coarse screen in PLC mode
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5. Check the alarm status of the duty/ standby motors by clicking on the motor.
Click orange dot
Alarm status
Figure 8: Checking alarm status for the coarse screen
6. Reset any present alarm conditions by first pressing the reset button on the
panel door and then follow procedure as shown in figure 9 below.
7. PLC monitors differential levels across the screen.
8. When differential level exceeds set point (difference of 300mm across the
screen), PLC will initiate screen cycle.
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9. PLC confirms duty Screw Wash Press and Counter Pressure Screw are healthy
(if the duty Screw Wash Press and Counter Pressure Screw are not healthy,
PLC will not open the wash water solenoid vales).
10. PLC opens the common launder solenoid valve.
11. PLC opens screen specific launder solenoid valve.
12. After every cycle, PLC checks the differential level, if below set point, the
screen stops until the next level initiation, otherwise another cycle is initiated.
(1) Click
pump icon
(2) Press
“Reset Alarm”
Figure 9: Re-setting any pre-alarm conditions
13. If the differential water level is not reached after 5 minutes, the PLC starts the
screen according to steps 6-8.

Remote manual operation of the coarse screens ONLY AFFECTS THE SELECTED EQUIPMENT. The rest
of the equipment will be automatically operated.
3.2.5.1 Purpose
To operate the screen in remote manual mode from the SCADA.
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2. The operator must ensure coarse screen motor is switched into PLC mode
(see figure 7 above).
3. Check to see that personnel are not working on motors or pumps before start-
up.

1. Check the alarm status of the duty/ standby motors by clicking on the motor
panel door and then follow procedure as shown in figure 9 above.
4. The operator initiates screen operation as and when required.
(2)Select ”Man” (3) Select the required operation

(1) Click motor
Figure 10: Initiating screen operation
5. PLC confirms duty Screw Wash Press and Counter Pressure Screw are healthy
(if the duty Screw Wash Press and Counter Pressure Screw are not healthy,
PLC will not open the wash water solenoid valves)
6. PLC opens the common launder solenoid valve.
7. PLC opens the specific launder solenoid valve.
8. After every cycle, PLC checks the differential level (300mm across the screen),
if below set point, the screen stops until the next level initiation, otherwise
another cycle is initiated.
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Although manual operation overrides all system interlocks, it is safe practice and recommended for
the operator to reset all interlocks before running the screens manually. This will ensure safe
operation of the screens. Local manual mode is designed for testing and commissioning only. Running
in this mode is risky and can lead to equipment damage if not operated correctly.
3.2.6.1 Purpose
To operate the coarse screens in Local manual mode from the field.

2. The Operator must ensure coarse screen motor is switched into LOCAL mode.
Local mode
selected
Figure 11: Coarse screen motor in LOCAL mode
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1. Check the alarm status of the duty/ standby motors by clicking on the orange
dot next to the motor (see figure 8 above).
3. The operator must confirm duty Screw Wash Press and Counter Pressure
Screw are healthy from the field.
4. The operator starts the screen. (The operator has to continuously press the
button until the rake reaches its bottom limit).
5. PLC will open the HP wash water solenoid valves.
6. The operator stops the screen. (The rake operates of normally open switch and
stops immediately when the operator let go of the start button.
7. PLC will close the solenoid valve after each cycle.
To move
rake up
To move rake
down
To stop rake
immediately and
prevent it from
being moved.
Figure 12: Operating the screen on the field
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3.2.4 NORMAL OPERATING PROCEDURE/READINGS
Table 15: Coarse Screen Normal Operating Readings.
Channel No. 1 Channel No. 2 Channel No. 3 Channel No. 4

Screen Set point (SP) 220 sec 220 sec 220 sec 220 sec
Time Cycle Set point (SP) 60 sec 60 sec 60 sec 60 sec
3.2.5 EMERGENCY SHUT-DOWN

During an emergency, an operator should press the emergency switch for the specific screen that they
intend to stop and then close the relevant inlet and outlet flow channels (every screen have a red
emergency button on its operating switch, see example on figure 12 above).
3.2.6 ISOLATION
Coarse Screens can be isolated in remote auto and local mode by closing corresponding inlet pen
stork gate vales (D-01-PGV-100A/B/C/D) and outlet pen stork gate valves (D-01-PGV-1003A/B/C/D)
on the same flow channels.
3.2.7 TROUBLE SHOOTING

Refer to OEM operating manual, 2 cables vertical screen (LT-1320-MU-D)
Page 11 off 16 table 2.1 - Trouble shooting guide
3.2.8 PERIODIC MAINTENANCE SCHEDULE

Refer to OEM operating manual, 2 cables vertical screen (LT-1320-MU-D)
Page 12 off 16 table 2.2 – maintenance and lubrication instructions
3.3 FINE/STEPPED SCREENS

The fine stepped screens work on the same principle as the coarse screens. Under normal working
conditions, the screens work on level differential and /or time intervals, first priority being given to
differential level. For fault finding and general maintenance of the fine stepped screen, refer to Inlet
Works Operations and Maintenance Manual, Volume 2.1, file 1 of 3, section 4.3.
3.3.1 REMOTE- AUTO OPERATION
3.3.1.1 Purpose
To operate the screens on remote-auto mode from the SCADA.
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3.3.1.2 Pre-Start-Up Operation Checks

2. The operator must ensure fine stepped screen motor is switched into PLC
mode.
PLC mode selected

from the panel board
Figure 13: Fine stepped screen in PLC mode
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3.3.1.3 Sequence steps:

dot on the top right corner of the motor.
(1) Click orange dot
(2) Active alarm status
Figure 14: checking the alarm status of the fine stepped screen
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panel door and then follow procedure as shown in figure 15.
(1) Click motor

(2) Press “Reset
Alarm”
Figure 15: Re-setting present alarm conditions

4. When differential level exceeds set point (difference of 300mm), PLC will
initiate screen cycle and it runs for 1 step.
5. PLC confirms duty Screw Wash Press and Counter Pressure Screw are healthy.
6. PLC opens the launder solenoid valve.
screen stops until the next level initiation, otherwise another cycle is initiated.
8. If the differential water level is not reached after a certain time interval, the
PLC starts the screen according to steps 6-8.
3.3.2.1 Purpose
To operate the fine stepped screens in remote manual from the SCADA.

2. The Operator must ensure fine stepped screen motor is switched into PLC
mode (see figure 13 above).
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dot (see figure 14 above).
2. Reset any present alarm conditions first pressing the reset button on the panel
door and then follow procedure as shown in figure 15 above.
3. PLC monitors differential level across the screen.
4. The Operator initiates screen operation (see figure 16 below).
5. PLC confirms duty Screw Wash Press and Counter Pressure Screw are healthy.
6. PLC opens the launder solenoid valve.
screen stops until the next level initiation, otherwise another cycle is initiated
(3) Select
(2) Press “Reset required option
(1) Click motor Alarm”
Figure 16: Initiating remote manual operation
3.3.2.4 Shut-down
1. The operator stops the screen by selecting stop on PLC.
2. PLC closes the solenoid valve after each cycle.
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3.3.3.1 Purpose
To operate the fine stepped screens in Local Manual Mode from the field.

2. The Operator must ensure coarse screen motor is switched into LOCAL mode.
Local mode
selected
Figure 17: Fine stepped screen in Local mode.

dot (see figure 14 above).
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3. The operator must confirm duty Screw Wash Press and Counter Pressure
Screw are healthy from the field.
4. The operator starts the screen.
5. PLC will open the HP wash water solenoid valves.
Press here to
start screen
Press here to
stop screen
Press here to
stop screen
immediately and
prevent it from
being started.
Figure 18: Operating the fine stepped screens from the field
6. The screen runs for the required number of steps.
3.3.3.4 Shut-down
1. The operator stops the screen by pressing the stop button on the control
switch.
2. PLC closes the solenoid valve after each cycle.
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Table 16: Fine Stepped Screen Normal Operating Readings.
Channel No. 1 Channel No. 2 Channel No. 3 Channel No. 4

Step Count Required 10 10 10 10
Cycles Required 1 1 1 1
Screen Set point (SP) 250 sec 250 sec 250 sec 250 sec
Time Cycle Set point (SP) 600 sec 600 sec 600 sec 600 sec

During an emergency, an operator should press the emergency switch for the specific screen that they
intend to stop and then close the relevant inlet and outlet flow channels (every screen have a red
emergency button on its operating switch, see example on figure 18 above).
3.3.6 ISOLATION
Fine Stepped Screens can be isolated in remote auto and local mode by closing corresponding inlet
pen stork gate vales (D-01-PGV-100A/B/C/D) and outlet pen stork gate valves (D-01-PGV-
1003A/B/C/D) on the same flow channels.

Refer to RS 29-100-3 Operating and Maintenance manual section 14 – Trouble shooting.

Refer to RS 29-100-3 Operating and Maintenance manual section 12 – Maintenance.
3.4 SCREW WASH PRESS AND COUNTER PRESSURE SCREW
Screw Wash Press (SWP)
These machines are operated on a duty standby system. A run cycle on SWP is generated by a number
of screen cycles counted, across all the screens. This count is made up of coarse screens cycles and
fine stepped screen cycles. To ensure equal operating hours, both SWPs should be changed on a daily
basis. For fault finding and general maintenance of the Screw Wash Press, refer to Inlet Works
Operations and Maintenance Manual, Volume 2, file 1 of 3, section 5.3.
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Counter Pressure Screw (CPS)
Power drawn by the SWP is monitored by power meters in the SWP panels. When the power drawn
exceeds the high limit of ##, indicating a clogged/blocked SWP, a start signal is then given to the
corresponding CPS to start. The CPS runs for a pre-set period and then waits for the next command.
For fault finding and general maintenance of the Counter Pressure Screw, refer to Inlet Works
Operations and Maintenance Manual, Volume 2; file 1 of 3, section 5.5.
WASH COMPACTOR SETTINGS
Figure 19: Washer Compactor Settings
 Screen operations to start SWP: the number of fine stepped screens

operations to start screen wash press
 Wash Press Cycles: Wash Press starts to acknowledge a cycle.
 SWP operations to start CPS: the number of cycles of the SWP to
activate the compact press.
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3.4.1 REMOTE-AUTO OPERATION
3.4.1.1 Purpose
To start the SWP and CPS in remote auto from the control building.

2. The operator must ensure SWP and CPS motors are switched into PLC mode.
PLC mode
selected
Figure 20: SWP motor in PLC mode
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PLC mode
selected
Figure 21: CPS motor in PLC mode
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Click orange dot
Active alarms
Figure 22: Checking the alarm status of SWP.
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Click orange dot
Active alarms
Figure 23: Checking the alarm status for CPS
dot next to the motor.
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panel door and then follow procedure as shown in figures 24 & 25.
(1) Click motor
(2) Select
“Reset
alarm”
Figure 24: Re-setting any present alarm conditions on SWP
(1) Click motor
(2) Select
“Reset
alarm”
Figure 25:Re-setting any present alarm conditions on CPS
3. PLC confirms the counter pressure screw is healthy.

4. PLC starts the SWP when number of screen operations equals the set point.
5. PLC runs the SWP for a pre-set time period of 5 sec and the stop the SWP.
6. PLC opens wash solenoid valve for a pre-set time period of 5 sec and then
closes wash solenoid.
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7. Steps 6 and 7 are repeated for a pre-set number of cycles.

8. PLC opens flush solenoid valve and then closes the valve after 15 sec.
9. PLC then waits for next command.
10. When power drawn by SWP exceeds limit, PLC initiates start command to CPS
or when number of SWP operations exceeds the set number of operations.
11. PLC runs CPS for a set time period of 5min.

3.4.2.1 Purpose
To start the SWP and CPS in remote manual from the SCADA.

2. The Operator must ensure SWP and CPS motors are switched into PLC mode
(see figure 20 & 21).

2. Reset any present alarm conditions (see figure 24 & 25).
3. PLC confirms the counter pressure screw is healthy.
4. The Operator starts the SWP
(1) Click motor
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(2) Select
“Man”
(3) Select the required operation

Figure 26: Starting the Screw Wash Press
3. PLC runs the SWP for a pre-set time period of 5 sec.

4. PLC will open wash solenoid valve for a pre-set time period of 5 sec and then
close wash solenoid.
5. Steps 6 and 7 are repeated for a pre-set number of cycles.
6. PLC opens flush solenoid valve and then closes the valve after a given time
period 15 sec.
7. PLC then waits for next command.
8. PLC monitors the power drawn by the SWP.
9. The Operator must start the Counter Pressure Screw from the SCADA.
(1) Click motor
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(2) Select
“Man”
(3) Select the

required
operation
Figure 27: Starting the CPS
10. PLC runs CPS for a set time period of 5 min.
3.4.3.1 Purpose
To start/operate the SWP and CPS from the field, in Local Mode.

2. The operator must ensure the SWP and CPS motors are switched into Local
mode (see figure 28 below).
Local mode
Selected
Figure 28: SWP and CPS in Local Mode
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3.4.3.3 Sequence steps
1. Check SWP operation required as determined by screen cycle operation

count.
2. Check the alarm status of the duty/ standby motors by clicking on the motors
3. Reset any present alarm conditions (see figure 24 & 25).
4. Confirm duty CPS is healthy.
Press here to
start
Press here to
stop
Press here to
stop
equipment
immediately
and prevent it
from being
started.
Figure 29: Operating the SWP and CPS from the field
5. Operator must start the CPS
3.4.3.4 Shut-down
1. Operator must stop the SWP by pressing the red stop button on figure 29
above.
2. Operator must stop the CPS by pressing the red stop button on figure 29
above.
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During an emergency, an operator should press the emergency switch for the specific equipment they
intend to stop and then inflow into the equipment.
3.4.5 ISOLATION
SWP & CPS equipment’s are isolated by changing from one operating unit (SWP+CPS) to the other
and can be isolated in remote auto mode or local manual mode.
Remote Auto mode

1. Select the word “Launder” between the 2 units on PLC.
2. Select manual on the small window which pops up.
3. Press start button to switch to the unit you intend to put in operation on the launder switch.
Local Manual mode

1. Select local from the control panel.
2. Press start button on the launder switch to switch to the unit you intend to put in
operation.

Refer to RS 29-100-3 Operating and Maintenance manual section 14 – Trouble shooting.

Refer to RS 29-100-3 Operating and Maintenance manual section 12 – Maintenance.
3.5 FOGG CHANNEL

The FOGG plant has 4 trolleys which work on the same principle. The trolleys are started in reverse of which
triggers the grit pumps to run, when the trolley reaches the reverse limit, the pump stops and the scrapper
is lowered. The trolley then moves forward until it reaches is forward limit on which it stops and raises the
scrapper. For fault finding and general maintenance of the grit removal system, bar the grit classifiers,
refer to Inlet Works Operations and Maintenance Manual, Volume 2, file 1 of 3, sections 6.7 and 6.8.
3.5.1 REMOTE- AUTO OPERATION OF FOGG CHANNEL
3.5.1.1 Purpose
To start the FOGG channel in Remote Auto from the SCADA.

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2. The Operator must ensure FOGG Channel scrapper, Trolley and De-grit
pump are switched into PLC mode.
PLC mode
selected
PLC mode
selected
Figure 30: FOG trolley, scraper and de-grit pump in PLC mode.
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(1) Click
orange
dot
Active alarms
Figure 31: Checking the alarm status of trolley drive motor.
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(1) Click
orange
dot
Active Alarms
Scraper Lift
Figure 32: Checking the alarm status of the scraper
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(1) Click
orange
dot
No
Active
Alarms
Figure 33: Checking the alarm status for the grit pump
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(1) Click
motor
(2) Press
“Reset
Alarm”
Figure 34: Re-setting any present alarm conditions on the trolley drive motor
(1) Click
motor
Scraper
(2) Press
“Reset
Alarm”
Figure 35: Re-setting the trolley scraper motor
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(1) Click (2) Press

moto “Reset
r Alarm”
Figure 36: Re-setting the grit pump
3. PLC confirms number of channels in service.

4. PLC lowers scraper to bottom scrapper position.
5. PLC starts FOGG Channel Trolley Drive in forward direction of travel.
6. PLC stops trolley Drive motor when forward travel limit of is reached
(determined by a relevant limit switch).
7. PLC starts next in service channel trolley (steps 5-6).
8. PLC raises scraper to top scraper top position of initial trolley.
9. PLC starts the trolley Drive motor in the reverse travel direction of initial
trolley.
10. PLC starts De-grit pump of initial trolley.
11. PLC stops the trolley drive motor and De-grit pump of initial trolley when the
reverse travel limit is reached.
3.5.2.1 Purpose
To start the FOGG Channels in Remote Manual from the control building

2. The operator must ensure FOGG Channel scrapper, Trolley and De-grit pump
are switched into PLC mode (see figure 30)
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dot next to the motor (see figure 31, 32 & 33).
2. Reset any present alarm conditions (see figure 34, 35 & 36).
3. PLC confirms number of channels in service
4. The operator starts FOGG Channel Trolley Drive in forward direction of travel
from the SCADA.
(1) Select “Man” (2) Select

the
required
operation
Figure 37: Operating the trolley from the SCADA
5. PLC lowers scraper to bottom scrapper position.

6. PLC stops trolley Drive motor when forward travel limit is reached.
7. PLC starts next in service channel trolley (steps 6 and 7).
8. PLC raises scraper to top scraper position of initial trolley.
9. PLC starts the trolley Drive motor in the reverse travel direction of initial
trolley.
10. PLC starts De-grit pump of initial trolley.
11. PLC stops the trolley drive motor and De-grit pump of initial trolley when the
reverse travel limit is reached.
3.5.3.1 Purpose
To start the FOGG Channels from the field, in Local Mode.
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2. The Operator must ensure FOGG Channel scrapper, Trolley and De-grit
pump are switched into Local mode.
Local mode
selected
Figure 38: FOG trolley, scraper and grit pump in Local Mode.
dot next to the motor (see figure 31, 32 & 33)
4. Reset any present alarm conditions (see figure 34, 35 & 36).
5. PLC will confirm number of channels in service.
6. The operator lowers scraper to bottom scrapper position.
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Press here Press

Presshere
here Press
Presshere
here
Press
Presshere
here Press Press
to move to
tomove
move to
tomove
move
to
tomove
move here to here to
trolley trolley
trolley scrapper
scrapper
trolley
trolley stop the start the
forward backward
backward upwards
upwards
downward
downward grit pump grit pump
Press here to stop

the trolley unit in
case of emergency
Figure 39: Trolley field operating panel board.
7. The operator starts FOGG Channel Trolley Drive in forward direction of

travel.
8. The operator stops trolley Drive motor when forward travel limit is reached.
9. The operator starts next in service channel trolley (steps 1-6).
10. The operator raises scraper to top scraper position of initial trolley.
11. The operator starts the trolley Drive motor in the reverse travel direction of
initial trolley.
12. The operator starts De-grit pump of initial trolley.
13. The operator stops the trolley drive motor and De-grit pump of initial trolley
when the reverse travel limit is reached.
3.5.3.4 Shut-down
1. To shut down the FOGG system an operator shall switch off the main panel
door isolator.
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Under Normal operation, the trolleys run alternately, with two trolleys running in opposite
directions at any given time. The grit settles to the bottom of the channels and is removed by a
submersible pump which is connected to a travelling bridge.

During an emergency, an operator should press the emergency switch located at the bottom of the
operating panel board.
3.5.6 ISOLATION
The FOGG system shall be isolated per lane by manual closing the corresponding set of inlet PGV
(1004A/B/C/D) and outlet PGV (1005A/B/C/D). The relevant limit switch ZS (1001/2/3/4) and ZS
(1009/10/11/12) for inlet and outlet pen stock gate valves respectively shall not allow the isolated
FOG trolley to be in operation if valves are in close position.

For Trolleys, Refer to MOTOX gearbox operating instructions section 7, for Grit pumps Refer to
Grundfos SLV Installation and operating instructions section 11 and for scrapper Refer to MOTOX
gearbox operating instructions section 7)
3.5.8 SAMPLING, CALIBRATION AND MEASUREMENTS

Sampling the FOGG system will achieve determining the percentage amount of Total Suspended Solids
(TSS) coming into Inlet Works compared to the ones leaving the Inlet Works. The sample shall be taken
from the inlet tank (TK1002) and compared with the sample taken from the Collection Chamber (CHN
1006). Processing the sample shall be done in the lab.
3.6 FOG PUMP STATION

The inlet works has two FOG pumps which work on duty/standby mode. These pumps use the same
operating principle. Upstream of the FOG hoppers are two actuated knife gate valves, which when
opened, determine the duty pump. The pump duty rotation shall be based on operating time
(default 12 hours) which period shall be operator adjustable on an appropriate Operator access
level. Downstream of these pumps is a by-pass line which leads to the drainage sump. This line is
fitted with bursting discs, which in turn, have a bursting indicator. The indicator is connected to the
PLC and will raise an alarm when the bursting disc bursts. Bursting of this disc indicates that the main
line leading to the oil separator is blocked and needs to be cleaned. . When the FOG level in the
hopper is high ##%, the diaphragm valve (D-01-DV-1001 or D-01-DV-1002) shall fully open and then
the PLC shall start the pump. If the FOG delivery line is blocked, pressure increases within the line.
Pressure increase above 7 bar will cause the discs to rupture and divert flow to the drainage sump.
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This will also result in very little FOG being pumped to the oil separator as most of it will be pumped
to the drainage sump, and back to the head of works, hence FOG will be circulating around the inlet
works. For fault finding and general maintenance of the FOG pumps, refer to Inlet Works
Operations and Maintenance Manual, Volume 2, file 2 of 3, section 7.2.

3.6.1.1 Purpose
To start the FOG pumps on Remote-Auto Operation from the SCADA.

2. The operator must ensure the FOG pump is switched into PLC mode.
PLC mode selected
Figure 40: FOG pump in PLC mode.
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(1) Click orange dot
PLC mode selected
Figure 41: Checking the alarm status of the FOG pump.
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2. Reset any present alarm conditions first pressing the reset button on the
panel door and then follow procedure as shown in figure 39.
3. Operator ensures that the suction valves to the hoppers are open.
4. The PLC continuously checks the level of water in the hoppers using LT-
1015/1016.
5. The PLC confirms that the pump discharge valve is opened.
6. The PLC starts the FOG pump when the water in the hopper reaches its
maximum set level of ##%.
7. The PLC stops the FOG pump when the water level in the hopper reaches its
minimum set level of ##%
(2) Select
(1) Click
“Reset
motor
Alarm”
Figure 42: Re-setting present alarm conditions
3.6.2.1 Purpose
To start the FOG pumps in remote manual operation from the SCADA.

2. The operator must ensure the FOG pump is switched into PLC mode (see
figure 37 above).
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1. Check the alarm status of the duty/standby motors by clicking on the motor
3. The operator starts the FOG pump from the SCADA.
(2) Select
(1) Select
required
“Man”
operation
Figure 43: operating the FOG pump in Remote Manual
4. The Operator then selects Auto to revert back to REMOTE-AUTO mode.
3.6.3.4 Shut-down
The FOG pump shall be stopped on SCADA by selecting a stop button from
the operating screen (see figure 40 above)
3.6.3.1 Purpose
To start the FOG pump in Local Manual from the field.

2. The operator must ensure the FOG pump is switched into Local mode.
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Local
mode
selected
Figure 44: FOG pump in Local mode.
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3. From the field, operator confirms that the hopper inlet valve and pump
discharge valve are open.
4. The Operator starts the FOG motor by selecting the start button from the
field.
Press here to
start blower
Press here to
stop blower
Press here to
stop blower
immediately and
prevent it from
being started.
Figure 45: Operating fog pump from the field
5. The Operator stops the FOG motor by selecting the stop button from the
field when the hopper is empty.
3.6.3.4 Shut-down
The FOG pump is shut down by pressing the stop button on the operating panel on site (see figure
45 above).
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During an emergency, an operator should press the emergency button located at the bottom of the
operating panel board.
3.6.5 ISOLATION
FOG pumps can be isolated in remote auto mode and local manual mode.
Remote Auto mode

4. Click the motor you intend to isolate on PLC.
5. Select manual on the small window which pops up.
6. Select stop button to stop a pump from running.
7. Close the relevant suction actuated valve D-01-PGV-1003 or D-01-PGV-1004
Local Manual mode

3. Select local from the control panel.
4. Press stop button on the control switch on site to stop the motor (see figure 45 above).
5. On the relevant actuated on site, turn the knob to local.
6. Manually close the valve of the inlet to the pump you intend to isolate.

Refer to the Netzsch operating and maintenance instructions section 8 (Trouble shooting and
remedying table)

Refer to the Netzsch operating and maintenance instructions section 7.2 & 7.3 (Lubrication)
3.7 AIR BLOWERS

The inlet works consists of two air blowers which supply air to the FOG channels. They operate on a
duty/ standby mode. Coarse bubble diffused air creates a rolling motion in the FOGG chamber
keeping the solids in suspension. BEFORE STARTING THE BLOWER, CONFIRM THAT ALL VALVES ARE
OPEN. STARTING THE BLOWER WITH CLOSED VALVES WILL RESULT IN EQUIPMENT DAMAGE. THE
MAXIMUM ABSOLUTE BLOWER PRESSURE IS 1.241 bars.
3.7.1.1 Purpose
To operate the air blowers in remote-auto mode from the SCADA.
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2. The operator must ensure air blowers are switched into PLC mode.

1. From the SCADA, operator checks the Alarm status of the duty/standby
blowers by clicking on the blower.
PLC
mode
selected
Figure 46: Blower in PLC mode.
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2. Operator resets any present alarm conditions.

3. PLC confirms number of channels in service, and select speed reference.
4. PLC runs the blower at a pre-set frequency; this speed is adjustable from
the panel PLC via the respective VSD knob.
5. Air blower continues to run as long as at least 1 FOGG channel is in service
3.7.2.1 Purpose
To start the air blowers in Remote Manual from the control building.

2. The operator must ensure air blowers are switched into PLC mode.

1. Operator checks the alarm status of the duty/standby motors by clicking on
the motor.
2. Operator resets any present alarm conditions
3. Operator confirms number of channels in service, and select a speed
reference.
4. Operator starts duty air blower.
5. Air blower continues to run as long as at least 1 FOGG channel is in service.
3.7.3.1 Purpose
To start the air blowers from the field, in Local Mode.

2. The operator must ensure air blowers are switched into Local mode.

1. The operator must ensure at least one FOGG channel is in service
2. Operator adjusts speed according to number of channels in service
3. Operator starts/stops air blower as required.
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Press here to
start blower
Press here to
stop blower
Press here to
stop blower
immediately
and prevent it
from being
started.
Figure 47: Operating Blower from site.
3.8 GRIT CLASSIFIERS

The grit classifiers are operated in a duty standby mode. It is the Operator’s responsibility to manually
change from one grit classifier to the other, if the need arises. The grit pumped from the FOGG lanes
settles at the bottom of the grit classifier. A screw conveyor conveys the grit to a skip for later disposal.
The “grit free” sewage flows back to the common chamber downstream of the fine stepped screens
via a grit return line which runs inside FOGG lane 3. Downstream of the pipe are two actuated valves,
KGV-1008 and KGV-1009, which direct the sewage to either of the two sections of the common
chamber. These valves should be left in an “always open” position, unless such a time when the
operator sees the need to close either valve. For grit classifier motor maintenance and fault finding,
refer to, Inlet Works Operation and Maintenance Manual, Volume 2, File1/3, section 6.7
3.8.1 REMOTE AUTO-OPERATION
3.8.1.1 Purpose
To start the grit classifiers in Remote Auto from the control building.
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2. The operator must ensure Grit Classifiers, are switched into PLC mode.

the motor.
3. Confirm FOG channel De-grit pump 1, 2, 3 or 4 is running.
4. PLC confirms duty grit classifier by confirming chute position.
5. PLC starts Duty Grit Classifier.
6. Grit Classifier continues to run until de-grit pump is not running.
7. Grit Classifier run-off time is initiated; Grit Classifier is stopped when timer
expires.
3.8.2.1 Purpose
To start the grit classifiers in Remote Manual from the control building

2. The operator must ensure Grit Classifiers, are switched into PLC mode.

the motor.
3. Operator confirms FOG Channel de-grit pump 1, 2, 3 or 4 is running.
4. Operator confirms duty grit classifier by confirming chute position.
5. Operator starts Duty grit classifier.
6. Once all de-grit pumps are stopped, Operator stops grit classifier.
3.8.3.1 Purpose
To start the grit classifiers in Local Manual Operation from the field
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2. The operator must ensure Grit Classifiers, are switched into Local mode.
Local mode
selected
3. The operator must ensure at least one De-grit pump is running.
4. Operator starts/stops Grit Classifiers as required.
Figure 48: Grit Classifier in PLC mode.
3.9 DRAINAGE PUMPS

The Drainage pumps operate on a duty-standby mode. For fault finding and general maintenance of
the Drainage pumps, refer to Inlet Works Operations and Maintenance Manual, Volume 2, file 2 of
3, section 9.2.
3.9.1 REMOTE AUTO OPERATION
3.9.1.1 Purpose
To operate the drainage pumps in remote auto mode
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2. The operator must ensure pumps, are switched into PLC mode.
PLC mode
selected
Figure 49: Drainage Pump in PLC mode.

1. The operator checks the alarm status of the duty/standby motors by
clicking on the motor.
2. Operator resets any Present alarm conditions by first pressing the reset
button on the panel door and then reset on the SCADA.
3. PLC confirms Sump Level LT-1027 is of sufficient level.
4. PLC starts Duty drainage pump.
5. Drainage pump continues to run, until a low level of 20% is reached.
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3.9.2.1 Purpose
To operate the drainage pumps in remote manual mode.

2. The operator must ensure Drainage Pumps, are switched into PLC mode.

the motor.
2. Operator resets any present alarm conditions by first pressing the reset
button on the panel door and then reset on the SCADA.
3. Operator confirms Sump Level LT-1027 is of sufficient level.
4. Operator starts Drainage Pump.
5. Drainage pump continues to run until a low level of 20%, is reached.
6. Operator stops duty pump.
3.9.3.1 Purpose
To operate the drainage pumps in Local manual mode.

1. The operator must ensure Drainage Pumps, are switched into Local mode.

1. The operator must ensure Level is above low, low set point.
2. Operator start/stops Drainage pumps as required.
3.10 ACESS HATCHES

To help with the cleaning of the launders after blockage, access hatches have been installed on both
the launders and the coarse screens. Below is the picture showing the location of the access hatch
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on the launder. Relevant protective personal equipment must be warn to perform this task to avoid
direct contact with the sewage.
Access hatch
opened for
unblocking
/cleaning
Figure 50: Access Hatches on launder and coarse screens.
3.10.1 Unblocking the launders and coarse screen.

1. Operator to carefully open the access hatch anticipating an over flow
through the hatch.
2. Operator should use high pressure water of ### KPa through the relevant
hatch provided in order to unblock or clean the equipment.
3. Operator to close the access hatch once finished cleaning or unblocking the
equipment.
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Note! There is no need to switch off the machine in order to clean or unblock it because the blocking
dirt should be processed in order to unblock the system unless the operator deems it necessary to
do so.
Warning! When unclogging the above mentioned equipment, the operator should not spray water
onto the operation switch or electric cables in the surrounding areas.
3.11 HOIST CRANE
The Inlet Works is fitted with 3 overhead hoist crane which should be used for maintenance of
relevant equipment fitted over. The first overhead hoist (on the Far East side when facing north) is
fitted above the coarse screens and is certified to carry a maximum load of 2500 Kg and is used to
install, remove or replace the coarse screens or the coarse screens motors.
The second overhead hoist is fitted over the fine stepped screens for their maintenance and is
certified to carry a maximum load of 1200 Kg.
The third overhead hoist is fitted over the hopper and the FOGG pumps to maintain them and is
certified to carry a maximum load of 495 Kg.
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Crane 3:
SWL 495 Kg
Crane 2:
SWL 1200 Kg
Crane 1: SWL
2500 Kg
Hoist Crane
Hoist Switch
Figure 51: Inlet Works Hoist Cranes
3.11.1 Sequence Steps

1. Switch on a relevant isolation switch to operate the hoist crane (see figure
2. Using a control switch, align the hoist with the equipment you intend to lift.
3. Ensure that there are no obstructions where the load (lifted equipment) is
intended to be transported.
4. Attach the load to the hoist using certified load tested rigging equipment.
5. Press the up arrow on the control switch to lift, down arrow to lower, left
and right arrows to move the hoist on the rail back and forth (see figure 51).
NB! Equipment lifting/rigging should not be done over people.

During an emergency, an operator should press the emergency button on the switch to stop the
hoist from moving and prevent it from being operated (see figure 51 below).
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Emergency button
Press here to lift
Press here to lower
Press here to move

crane forward
Press here to move

crane backward
Figure 51: Operating switch for a Hoist Crane.
3.11.3 ISOLATION
To isolate the hoist crane for maintenance, an operator should switch off the relevant isolation
switch from the panel on site (see figure 52 below.
Operate switch to
isolate the Crane 2
Operate switch to
isolate the Crane 1
Operate switch to
isolate the crane 3
Figure 52: Isolation switches for 3 Inlet Works Hoists
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3.12 HVAC System Testing
The Inlet Works MCC 10 room is equipped with a HVAC system consisting of a temperature probe
(D-03TT-XXX) and 2 fans (duty/standby) which supply the MCC room with forced ventilation
operating only on remote auto mode.
Press here to
stop fan
immediately
and prevent it
from being
started.
Figure 53: HVAC operating panel.
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3.12.1 REMOTE AUTO OPERATION
3.12.1.1 Pre-Start Checklist

1. Check filters on supply unit to see if they are clean.
2. Ensure the inlet louvre is not obstructed.
3.12.1.2 Starting and Stopping

1. If the temperature rises above the high 40oC, the PLC shall start 1 fan to filter and
force ventilation into the Dry Well until the temperature drops below 40oC. The
HVAC will be tested in remote manual mode to override the temperature settings.

1. Only one supply air fan should run when the system is on.
2. The Differential Pressure (DP Switch) should be working and below 250 Pa.
3. The duty/ standby fans should automatically alternate on a flip flop timer. This can be
viewed at PLC 11 Control Room and time settings can be overwritten for test purposes
if required.
4. Check for unusual vibrations or noise from the running fan.
5. The below items faults can be visually seen on the control and power panel and
should also be flagged by the PLC system. Check both control panel and PLC for
faults while fan is running.
 Fan running – should be on only on the running fan
 Fan fault – should be off.
 Dirty Filter – should be off.
 System Ok – should be on.
 High Temp Alarm – should be off.
 Dirty Filter Alarm – should be off.

If the filters need to be cleaned, this would be clear if the cooling is affected due to lack of airflow, or
by an alarm from the PLC, the system does not have to be switched off before the filters are
removed. The filters can then be rinsed under a tap and reinstalled damp.
NB! Ensure that the system in electrically isolated before working on the equipment.

During an emergency, an operator should press the emergency button located at top of the operating
panel board (see figure 53 above).
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Revision Number
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APPENDIX A: EMERGENCY EVACUATION PLAN
APPENDIX B: COARSE SCREEN FDS

APPENDIX C: FINE SCREEN FDS
APPENDIX D: SWP AND CPS FDS
APPENDIX E: FOGG CHANNEL FDS
APPENDIX F: FOG PUMP FDS
APPENDIX G: AIR BLOWERS FDS
APPENDIX H: GRIT CLASSIFIER FDS
APPENDIX I: DRAINAGE PUMPS FDS

Inlet Works Operating Instructions Rev 01-BR - 2018!06!01

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Project Name Darvill Waste Water Treatment Works Upgrade

Originated By (Group Reviewed By Approved By Approved By

3 OPERATING INSTRUCTIONS ............................................................................................................... 20

3.4.6 TROUBLE SHOOTING ............................................................................................................ 49

3.9.1 REMOTE AUTO OPERATION ................................................................................................. 71

Figure 37: Operating the trolley from the SCADA................................................................................. 56

Missing information Page no. Reason

Inlet flow #### MLD to #### MLD 9

Coarse screen size ## mm 9 Awaiting new control philosophy

Launder HP wash water system of #### KPa 10 & 81

FOG Level in Hopper ##%, 11,66 & 69

MCC Temp probe (D-03TT-###) 11 & 85

CPS power setpoint ## 46

1. GENERAL METHOD AND PRINCIPLE OF OPERATION

1.1 DESIGN BRIEF AND REQUIRED PURPOSE

1. 0-40MLD: 1 channel in operation.

2. 40-80MLD: 2 channels in operation.

1.2 OUTPUT AND FUNCTIONALITY

PARAMETER TO BE CHANGED USER

Table 4: Level Sensors Output and Functionality

TAG NUMBER MINIMUM S.P MAXIMUM S.P OUTPUT

D-01-LT-1003 300mm 1350mm Raw sewage level upstream of SCN-1003A

Table 5: Flow meters Output and Functionality

TAG NUMBER MINIMUM S.P MAXIMUM S.P OUTPUT

1.3 PRINCIPLE AND METHOD OF OPERATION – INLET WORKS

1. Remote auto operation

1.3.1 Remote auto operation

Equipment which can be operated in this mode are:

THIS IS THE NORMAL MODE OF OPERATION.

1.3.2 Remote manual operation

Equipment which can be operated in this mode are:

1.3.3 Local manual operation

Equipment which can be operated in this mode are:

2. GENERAL PROCESS SAFETY INSTRUCTIONS

More severe injury medical attention 4 Occurs occasionally MEDIUM 6---16

Loss of life / fatality 10 Could / has happened CRITICAL 32---40

C POTENTIAL DAMAGE / LOSS D ENVIRONMENT ACTION REQUIRED

Notify your supervisor or SHE representative and get medical

Respiratory (asthma, chronic bronchitis, and chronic sinusitis),

2.2 PPE REQUIREMENTS

2.3 IMMEDIATE ACTION PLAN

 Standard lighting and air conditioning will be off.

FOR UNPLANNED OUTAGE:

 Treat all circuits as LIVE.

2.3.1 ELECTRICAL EQUIPMENT IN MCC ROOMS

2.4 EVACUATION PLAN

Figure 1: Emergency Response Structure

2.4.1 Evacuation Routes and Key Locations

Figure 2: Emergency Evacuation Diagram

2.4.2 Emergency Evacuation

2.4.2.1 General Evacuation Procedure for all personnel

Step 1. Stop all activities.

2.4.2.2 Personnel with Mobility Impairments

2.4.2.3 Personnel with Hearing or Visual Impairments

2.4.3 EMERGENCY CONTACT NUMBERS

Name Contact Number Extra Details

FIRE DEPARTMENT (033) 845 5911

Ricky Pillay 082 804 4411

Table 8: Medical Services Contact Numbers

Name Contact Number Extra Details

MEDI CLINIC – HOWICK PRIVATE

GREY’S 033 - 8973000