HomeMy WebLinkAboutOperation and Maintenance ManualTOWN OF SOUTHOLD
SUFFOLK COUNTY NEW YORK
SCAVENGER WASTE
TREATMENT FACILITY
OPERATION AND MAINTENANCE MANUAL
PREPARED FOR
HOLZMACHER, MCLENDON & MURRELL, P.C.
i 125 BAYLIS ROAD, MELVILLE, NEW YORK
0
BY
CLYDE PORTER, JR., CONSULTING ENGINEERS,
405 SUMMIT AVENUE, MT. VERNON, NEW YORK
DECEMBER 1985
TABLE OF CONTENTS
List of Tables
List of Figures
List of Abbreviations
Preface
Manual
Chapter 1 - Introduction
Chapter 2 - Permits and Standards
Chapter 3 - General Laboratory Controls
Chapter 4 - Reports and Records
Chapter 5 - Safety Precautions and Emergency Response Program
Chapter 6 - Plant Personnel
Chapter 7 - Preliminary Treatment Facilities
Chapter 8 - Equalization Tank Facilities
Chapter 9 - Chemical Coagulation and Flocculation Facilities
Chapter 10 - Primary Clarifiers
Chapter 11 - Secondary Treatment Facilities
Chapter 12 - Final Clarifiers
Chapter 13 - Sludge and Scum Treatment Facilities
Chapter 14 - Odor Control System
Chapter 15 - Electric Power and Lighting Systems
Chapter 16 - Heating and Ventilating Systems
Chapter 17 - Maintenance and Utilities
APPENDICES
A - Operator Qualifications
B - Scavenger Waste Disposal Ordinance
C - Reference Materials
D - Manufacturer's Literature (Under Separate Cover)
E - Shop Drawings (Under Separate Cover)
F - As Built Drawings (Under Separate Cover)
i
LIST OF ABBREVIATIONS
BOD
Biochemical Oxygen Demand
RBD
Rotating•Biological Discs
d.c.
direct current
deg F
degrees Fahrenheit
gpd
gallons per day
gph
gallons per hour
G.P.M.
Gallons per Minute
HOA
Hand -Off. -Automatic
HP
Horsepower
Hz
Hertz
KVA.
Kilowatt -Volt -Ampere
RW
Kilowatt(s)
lb
pound(s)
FeC13
Ferric Chloride
HCL
Hydrochloric Acid
M.G.D.
Million Gallons Per Day
mg/l
milligrams per liter
NYSDEC
New York State Department of
Environmental. Conservation
NPDES
National Pollutant Discharge
Elimination System
% Percent
ii
LIST OF ABBREVIATIONS
pH _
Hydrogen ion concentration
ppd
pounds per day
psi
pounds per square inch
psig
pounds per square inch gage
M.C.C.
Motor Control Center
spm
stokes per minute
SPDES
State Pollutant Discharge
Elimination System
SS
Suspended Solids
USEPA
United States Environmental
Protection Agency
INF.
Influent
EFF.
Effluent
PRESS. Pressure
scfm standard cubic feet per minute
D.O. Dissolved Oxygen
gal. gallons
iii
PREFACE
MANUAL FORMAT AND USER GUIDE
This Operation and Maintenance (0&M) Manual is a primary reference
book for the Town of Southold Scavenger Waste Treatment Facility. As
such, it is essential that those persons responsible for the operation
and maintenance of the treatment plant be thoroughly familiar with its
contents and format so that desired information can be found quickly.
Although it is a primary reference document, it is by no means the only
reference, nor is it totally self-contained or comprehensive.
References are provided in the Manual, directing the user's attention
to more detailed manufacturer's literature, technical reference,
textbooks and other sources of information which may or may not be
appended hereto.
A Table of Contents listing all chapters is presented in the
beginning of this Manual to permit easy identification and location of
the topics addressed herein. It is intended here to give some
explanation of the Manual's organization, as depicted in the Table of
Contents, and to discuss its intended use.
Chapter 1 serves only to acquaint the user with the general
background concerning the Manual's preparation, scope and use. It is
not, as are most of the remaining chapters of this Manual, meant to
convey information pertinent to the day-to-day operation of the plant.
This chapter contains information pertaining to the design and
performance criteria under which it is to operate. Chapter 2 includes
information concerning the discharge permit and the New York State
Water Quality Standards for the Long Island Sound.
Chapter 3 contains information regarding the testing schedule
delineating testing frequency, sample location and sample type,
description of sampling locations, and some general guidelines with
respect to procedures. Also included in this section are
interpretations of some significant laboratory testing results and
suggested operating procedures with respect to these results.
Descriptions of specific laboratory testing controls for individual
processes are contained in the chapters of this Manual for each process.
Chapter 4 contains information regarding the keeping of proper
records and guides for filling out the required reports.
Chapter 5 is an overview of the general problem regarding safe
working procedures and equipment in a treatment plant, as well as the
actions that have to be taken during an emergency situation. All plant
personnel are urged to familiarize themselves with this material.
P-1
Chapter 6 contains information regarding staffing needs for the
Southold.plant.
Chapter 7 through 13 include the description of the operation and
controls for treatment of the scavenger wastewater flow and the
operation and control of the sludge handling facilities. It is meant
to provide the plant operator with a clear picture of the treatment
plant, since major treatment processes in the treatment plant do not
operate independently, but are preceded by and/or followed by units
which contribute significantly to the overall treatment efficiency. A
schematic diagram is presented which physically traces the scavenger,
wastewater flow through the various components of the plant. In
addition, a list of major plant components with respective size or
capacity data is included. It is within these chapters that operating
personnel can find thorough descriptions of units and processes within
the plant, and can obtain guidance on operating and controlling these
units and processes. The purpose and basic theoretical concepts of
each process are discussed, as are the details of process operation and
control. In addition, common operating problems for the units and
processes are indicated and suggested solutions discussed. Several
blank pages for Notes and Addenda are inserted after each chapter so
that plant personnel may record additional information or significant
observations deemed appropriate for the purpose of the Manual.
Chapter 14 describes the operation and control of the odor control
system used for removing odors in the Grit Building and the vented gas
from the equalization tank.
Chapter 15 describes the electrical system and gives instructions
for its operation and maintenance.
Chapter 16 describes the heating and ventilating system and gives
instructions for its operation and maintenance.
Chapter 17 provides a complete equipment list for the Southold
plant, including the name, address and telephone number of
manufacturers, for service needs. Also included is general information
regarding maintenance of the facility utilities.
The Appendices contain the following information: Operator
Qualifications; Scavenger Waste Ordinance; Reference List and
Manufacturer's 0&M Material.
P-2
CHAPTER 1® INTRODUCTION
OPERATION AND MANAGERIAL RESPONSIBILITY
PURPOSE OF MANUAL
TYPE OF PLANT AND DESIGN CRITERIA
DESCRIPTION OF PLANT TYPE AND FLOW PATTERN
NOTES AND ADDENDA
LIST OF FIGURES
Figure
1-1 SCAVENGER WASTE FLOW SCHEMATIC
1- 1
PAGE NO.
1- 3
OPERATION AND MANAGERIAL RESPONSIBILITY
The operation and maintenance of the scavenger waste
treatment plant is under the direct charge of the Chief Plant
Operator. The Town of Southold has the overall managerial
responsibility for maintaining, staffing and operating the
scavenger waste plant.
PURPOSE OF MANUAL
The purpose of this manual is to
with the basis of design, to provide
equipment and facilities, and to make
operation and maintenance so that the
plant may function -in a satisfactory
TYPE OF PLANT AND DESIGN CRITERIA
familiarize plant personnel
a description of the
recommendations for
scavenger waste treatment
and economical manner.
The scavenger waste plant (see Figure 1®1) has been designed
to meet the current and future treatment needs of the Town of
Southold.
The flow stream for the plant consists of primary
clarification with chemical addition, carbonaceous BOD removal
and secondary clarification. Final effluent is metered and
discharged to the existing Village of Greenport treatment plant.
The sludge system consists of scum/sludge pumping, anaerobic
digestion and dewatering sludge drying beds.
DESCRIPTION OF PLANT TYPE AND FLOW PATTERN
The head end facilities consist of receiving ports, a
manually cleaned bar screen, an aerated grit chamber and an
equalization tank.
In order to minimize the waiting time for scavenger waste
haulers, and to discourage illegal dumping which might occur if
excessive waiting times were encountered, two (2) receiving ports
are provided for unloading of scavenger waste. Hoses are
provided for washdown of spills.
Significant quantities of grit, rags, sticks and other
deleterious materials are typically contained in scavenger waste.
A manually cleaned bar screen and an aerated grit chamber are
provided to protect downstream equipment from these materials.
Air flow to the grit chamber can be regulated to control the
efficiency of grit removal. Grit will be removed from the tank
via an inclined screw conveyor and discharged to a container for
removal to the landfill. The bar screens and grit removal
1- 2
7 + r
SCAVENGER
WASTE TRUCK
INFLUENT
PORTS
0
v
c-
0 0
O
Z
Cn
C
q
Z
0
rnZ
G7
Z
Irl
G�
BAR
SCREEN
GRIT CHAMBER
EXISTING SLUDGE
DRYING BEDS
I
1
FE CL 3
STORAGE TANK
EQUALIZATION TANK
PRIMARY
DIGESTER
scum
SLUDGE
WET WELL
FLASH
MIX TK.
LIME
EAD BOX
FLOCCLATION TANK
PRIMARY
CLARIFIERS
HCL
STORAGE
:) F-1 TAN
R OTATI N G
BIOLOGICAL
DISCS
— FLOW METER
TO OUTFALL.................
I I
EXISTING VILLAGE OF EFFLUENT
GREENPOINT PLANT WET WELL
SCAVENGER WASTE FLOW SCHEMATIC
HCL MIXING
TANK
FINAL
CLARIFIER
c�
c
m
equipment are housed inside a building to minimize odors at the
site. An odor control system is provided in this building.
The scavenger waste flows from the grit chamber to the
equali- zation tank. Air diffusers are provided for mixing of
the waste. The equalization tank is sized to provide storage for
peak flows, as well as to maintain a flow to the biological
system throughout the weekend when no wastes are received. The
equalization tank also serves to homogenize the scavenger waste,
which exhibits varying characteristics from truckload to
truckload. The equalization tank is covered and vented to the
odor control system within the Grit Building.
Scavenger waste is pumped from the equalization tank to a
flash mix tank where lime and ferric chloride are added.
Scavenger waste then flows to a flocculation tank. The waste
then flows to a primary clarifier. After primary clarification,
the waste flows by gravity to the rotating biological discs
(RBD's) .
The rotating biological discs are utilized for BOD removal
and nitrification. Prior to biological treatment the waste
stream is mixed with HCL for pH adjustment. A pH probe will
regulate the amount of HCL added to the liquid stream. From the
RBD units the flow goes to the final clarifier.
A single clarifier has been provided for final
sedimentation. Following final sedimentation, the flow is
metered and discharged to the existing Village of Greenport
treatment plant.
Scum and sludge collected in the primary and secondary
clarifiers flows by gravity to a scum/sludge tank. From this
tank scum/sludge is then pumped to a high rate anaerobic
digester. The digester is heated, mixed and provided with a
floating gas holder cover. Recovered methane gas is used to heat
the digester contents. Digested sludge is pumped to an existing
and expanded sludge drying beds. The final sludge cake is then
trucked to a landfill for disposal.
1- 4
CHAPTER 20 PERMITS AND STANDARDS
GENERAL
REPORTABLE SPILLS
REPORTING SYSTEM
STATE POLLUTANT DISCHARGE ELIMINATION SYSTEM
WATER QUALITY STANDARDS
NOTES AND ADDENDA
LIST OF TABLES
2-1 MUNICIPAL WASTE WATER SPILL REPORT
2-2 CLASSES AND STANDARDS FOR SALINE SURFACE
WATERS
2-3 CLASS "SA"
LIST OF FIGURES
PAGE NO.
2- 2
2- 2
2- 3
2- 7
2- 8
2-21
2- 6
2-20
2-20
2-1 SAMPLE LETTER FOR REPORTING SPILLS 2- 5
2- 1
GENERAL
The United States Environmental Protection Agency (USEPA)
has implemented and enforces a permit program under the
provisions of the Federal Water Pollution Control Act Amendments
of 1972 (Public Law 92®500, Section 402). In general, anyone
discharging pollutants from a point source into the waters of the
United States, including the oceans and the contiguous zone, must
obtain a discharge permit.
If there are any questions concerning any of the items of
the permit, contact the USEPA office at the address shown below:
Regional Administrator, Region II
Environmental Protection Agency
Office of Water & Compliance
26 Federal Plaza
New York, New York 10007
ATTENTION: Mr. George Meyer
Tele-. No.: (212) 264®2676
An agreement has been reached between the USEPA and NYSDEC
in which the State discharge permit (SPDES) is acceptable in lieu
of the NPDES permit. Therefore, information regarding the
discharge permit for the plant can also be obtained at the
following address:
New York State Department of
Environmental Conservation
Permit Administration Section
50 Wolf Road
Albany, New York 12233
ATTENTION: Mr. William L. Garvey
Tele. No.: (518) 457®5968
REPORTABLE SPILLS
Any discharge from a municipal wastewater system which is
not in compliance with the effluent limitations established for
that system is classified as a reportable spill.
For the purpose of the above definition, a wastewater system
includes, but is not limited to, a treatment plant, a pumping
station and sanitary sewers. A discharge includes, but is not
limited to, any spilling, leaking, pumping, pouring, emitting,
emptying, dumping, overflowing or bypassing.
The intent of the reportable spill definition given
previously is to provide maximum protection to the downstream
water users and to give the responsibility for the incident
severity analysis to the State Water Pollution Control Agency
(the New York State Department of Environmental Conservation).
2- 2
The importance of treatment system personnel at all levels
being informed of the reporting procedures for spills of raw or
inadequately treated wastewater cannot be overemphasized. Prompt
reporting ensures spill cleanup and monitoring assistance can be
dispatched to help minimize health hazards and environmental
damage. Penalties for being negligent in reporting these
conditions are generally severe and the damage done to public
relations can be disastrous to any treatment system.
REPORTING SYSTEM
The legal requirements for spills of raw or inadequately
treated municipal wastewater is these spills should be reported
promptly. As an aid to the personnel responsible for this
reporting, the telephone numbers of the State and County Water
Pollution Control Agency that can be called 24 hours a day, 7
days a week to report emergencies are listed as follows:
New York State Oils Spills Bureau
Albany, New York
EMERGENCY NO.: (518) 457-7362
Suffolk County Department of
Environmental Control
Enforcement Section
15 Horse Block Place
Farmingville, New York 11738
EMERGENCY NO.: (518) 451-4629
Any spills should also be reported to the following address:
New York State Department of
Environmental Conservation
Building 40
State University of New York
Stony Brook, New York 11790
ATTENTION: Mr. A. Yerman
Tele. No.: (516) 751-7900
When reporting a spill, the operator should give as much
information as possible about the spill.
To avoid confusion, the emergency response plan should
include all reports from the spill site to follow a specific
format. This format is as follows:
1. SITUATION - Should include location, what happened,
strength and volume of wastewater spilled, extent of emergency,
success of emergency response actions.
2- 3
2. ACTION - Summary of all actions taken by the
municipality, or by others.
3. PLANS - All planned actions by the municipality, or
others.
4. RECOMMENDATIONS - Any recommendations pertaining to the
emergency that the operator has.
5. STATUS-- Should indicate whether emergency condition has
ended or is continuing, give details of conditions existing.
6. The verbal report should be followed by written
correspondence documenting the verbal notification. This should --
include the facts listed 1 through 5 above and the date, time and
names of individuals reported to. A sample letter is shown as
Figure 2-1.
Table 2-1 is a sample form which can be used to record all
spills.
2- 4
FIGURE 2-1
SAMPLE LETTER FOR REPORTING SPILLS
S A M P L E
(DATE)
ADDRESS OF STATE OR COUNTY WATER POLLUTION CONTROL.AGENCY
CONTACTED
DEAR MR.
IN ACCORDANCE WITH OUR TELEHONE CONVERSATION ON (DATE AND
TIME)
REGARDING SPILLAGE OF INADEQUATELY TREATED WASTEWATER TO THE
LONG ISLAND SOUND; PLEASE FIND HEREIN THE VERBAL INFORMATION
CONVEYED TO YOU.
1. SITUATION
2. ACTION
3. PLAN
4. RECOMMENDATIONS
5. STATUS
Very truly yours,
2- 5
TABLE 2-1
MUNICIPAL WASTEWATER SPILL REPORT
NAME OF FACILITY:
LOCATION (RIVER BASIN):
(CITY) :
OWNER: TELEHONE:
(Area Code)
PERSON REPORTING SPILL:
DATE REPORTED: TIME REPORTED:
(DAY) (MONTH) (YEAR)
SPILL STARTED: (TIME):
( DAY) ( MONTH ( YEAR )
SPILL STOPPED: ,(TIME):
SPILL VOLUME: GALLONS IF SPILL STOPPED.
SPILL"RATE: M.G.D. IF SPILL CONTINUING.
IF SPILL CONTINUING, ESTIMATED DURATION HOURS.
ESTIMATED TREATMENT AS PERCENT OF NORMAL o
IS CHLORINATION BEING PROVIDED? -
YES NO
DESCRIBED CONDITIONS SURROUNDING SPILL (POWER FAILURES, EQUIP-
MENT BREAKDOWN, BROKEN LINE, ETC.
ACTION TAKEN TO STOP SPILL AND PREVENT REOCCURRENCE:
ASSISTANCE REQUIRED:
2- 6
i
{
STATE POLLUTION DISCHAGE
ELIMINATION SYSTEM
olvew York State Department of Environmental Conservatio
So wolf Road, Albany, New York
PublicMr. James I. Monsell
-
Greenport,Village of Greenport
236 Third Street
Dear Mr. Honsell:
November 25, 1981
M
Le: MODIFICATION OF POLLUTANT DISCHARGE
ELIMINATION
NY -0020079
Greenport
Greenport
This -is to inform you that pursuant to Environmental Conservation Law
(1!ECL11), Article 17, Title 8 (McKinney'&) and 6 NYCRR, Part 757, the New York State
Department of Environmental Conservation has made a determination to modify your
referenced Pollutant Discharge Elimination System Permit as indicated on the attached
'Tinal Effluent :_tion_ .:•-_ ._ der
permitof the • /force
The revised page indicates the deletion of the 85% r val require—nt for suspende-A
solids as anincrease in the suspended solids effluent limitation was granted an
cto20, 1981 bertherebymaking e removal
Unless otherwise specified, this modification will become effective
immediately unless you petition, pursuant to ECL Section 17®0907, that you be given
an opportunity to be heard -in connection with this determination and where applicable,
if no written objection is received by this office within 30 days after receipt of this
modification by the Regional Administrator of EPA. Any such petition for a hearing
shall contain specific evidence to support your contention that a hearing is necessary
and that you were sot previously given an opportunity to be heard.
Enclosures
Mr. Pulaski
Suffolk Co.
DEIS
,. . Stevens
,_
Spear-
Frank Russo,
E2M,-
Crouin
Very truly yours,
William L, Carvey, PX
Chlafs, Permit Adminletr4tIon Sect
Divi-sion. of Water I
NJ
125 Baylis Rd., Xelville,, New York 11747
Fiml EF: LUF.�ri QfITATIONS
periodaring the beginning October 20, 1981 and
ischarges from the permitted facility shall
TABLE I
Part I
Page 2 of 8
Facility I.D. No. NY0020079
MODIFIED: 10/20/81 - 11/25/81
lasting until June 1, 1982
and monitored by the permittee
Effluent Limitations (YA_-dm=
Limits except where
otherwise indicated)
(z)
Floe
30 day arithmetic mean
0.5 ot )??OD ( )CPD
(x)
BODS
30 day arithmetic mean
30 mg/1 and 125 lbs/day(1)
(x)
BODS
7 dap arithmetic mean
mg/"I and lbs/day
BOD
Do -U7
mg/l and lbs/da
( )
UODS(2)
y
mg/I and lbs/dal
(A)
Suspended Solids -_
_0 day arithmetic mean _.
D mgfl and 292 lbs/day
($)
Suspended Solids
7 day, arithmetic mean
mg/1 and 7_3r®lbs/da7
()
Suspended Solids
ng/1 and lbs/day
(x)
Effluent disinfection required: (x) all year
( ) Seasonal from
to
nnIjfQ='2
...-
...�i"ee1emC'e
r"�T..
.,.r. eW+ e®®
If chlorine is used
for disinfection, a chlorine residual of 0.5-2.0 mel
shall be maintained
in the chlorine contact chamber mh-enever disinfection
is required. If specified here, the chlorine
residual in the final discharge
shall not exceed
2.0 zgp..
(�
Total Colifore
, 7
700 100 MI
{)
Total Kjeldahl Kl troge_-
Da;'' y
/Mr as
()
onia
/mel as NE3
()
Dissolved Oxygen
ylini=
greate= than
(�
PE
Flange
6.0 to 9.0
(�
Settleable Solids
Daily
MI/1
( )
Phosphorus
Daily
mg/1 as P
( )
Total Nitrogen
Daily
mg/1 as N
:onitorine Reouiez-e=ents TABLE
?axaneter frecuen= SadeT7De
�) Total Flow, IZD tinuous
x) BOD , mg/1 m 6 hr cowosite
I
Sus ended Solids, mg/1 2 month 6_hr ea=site
) Fecal Coliform, Ivo./100 ml
x) Total Coliform, No./100 ml hb
Tonal Kjeldahl Nitrogen, mg/l as N
gonia, Wjl as NHI
Dissolved Oxygen,
X) PE Grab
X) Settleable Solids, ml/1 /div Grab
X) Residual Chlorine, mel 1/dav Qmb
Phosphorus, as P
x) Temperature,oC
Total Nitrogen, mg/l as N
Visual Observation
(1)and effluent values shall not exceed 15 of influent
(2)UOD (Ultimate Oxygen Demand) shall be computed and reported as
UOD ® 1i x ECD5 + 41 z TKF (Total Kjeldahl Nitrogen)®
Wapplicable only in the Interstate Sanitation District.
/1¢ow++1^ eenw64 n$ _U'_ 9— W441-9-4 vwa ♦i s,g1 OM Tn��, +, jj+ 1jvj�v .�_
Sa=ule Location
Inflvent Effluent
X X
X
+t -j P.- " -`-- 1-4,6
ivE:+1 YORK SPATE DEP
.I:RTMENT OF ENVIROINMELTAL CONSERVATION
STATE POLLUTANT DISCH.-kRGE ELIMI�ZATION SYSTEZI (S PDES )
DISCHARGE PERMIT
GENERAL CONDITIONS
(PART I I )
PAG E
General, Provisions............ 1
Prohibitions ................................................. 1-2
Exclusions..................................................... 2
Modification, Suspension, Revocation .......................... 2-3
Reporting Noncompliance ....................................... 3-4
Insoectiors........... ,................. I........................ 4
Transfer of Ownership......... 5
Pernit Ren=wal....:........................................... 5
Special Provisions, - Proposed or Expanded Facilities.......... 5-
Limitation of Disharges of Oil and Hazardous Substances
in Harmful Quantities....... .................................. 6
Monitoring Recording and Reporting ..................4.4....... 6-8
1. General ........ ...:......... 6
2. Monitoring,Locations ............................ .. 6
3. Recording of Monitoring Activities and Results...... 7
4.. Analytical Methods............. ...................... 7-8
5. Abplication for Alternate Test Procedures..........., 8
6. Confidential Information ............................. 8
Facility Operation and Quality Control ........................ 9-11
1. General......... ........................ 9-10
2. Prohibition of Bypass ............................... 10
3. S.oecial Condition - Facilities with Septic Tanks.... 10
4. Disposal of Collected Solids ........................ 10-11
Special Conditions - Publicly Owned Treatment Works............ 11
_elAsed
2-8
-1-
" - PART 11 - GENERAL CONDITIONS
GENERAL PROVISIONS
a. A determination has been made on the basis of a submitted
application, plans, or other available information, that compliance
with the specified permit provisions will reasonably assure compliance
with applicable water quality standards. Satisfaction of permit
provisions notwithstanding, if operation pursuant. to U!e permit
causes or contributes to a condition in contravention of State
water quality standards, or if the Department determines, on the
basis of notice provided by the permittee and any related investigation,
inspection or sampling, that a modification of the permit is necessary
to assure maintenance of water quality standards or compliance with
other provisions of ECL Article 17, or the Act., the Department may
require such a modification and may require abatement action to be
taken by the permittee�.and may also prohibitthe noticed act until
the permit has been modified.
b. All discharges authorized by this permit shall be consistent
with the terms and conditions of this permit; facility expansions,
production increases, or process modifications which result in new
or increased discharges of pollutants must -be reported by submission
of a new SPDES application -or, if such new or increased discharge
does not violate the effluent limitations specified in this permit,
by submission to the permit issuing authority of notice of such new
or increased discharges of pollutants. (in which case the permit may
modified to specify effluent limitations for any pollutants not
identified and limited herein); -the discharge of any pollutant not
identified and authorized or the discharge of any pollutant more
frequently than or at a level in excess of that identified and
authorized by this permit shall constitute a violation of the terms
and conditions of this permit.
C.. The provisions of this permit are severable, and if any
provision of this permit, or the application of any provision of
this permit to any circumstance, is held invalid, .the application of
such provision to other circumstances, and the remainder of this
permit, shall not be affected thereby.
PROHIBITIONS
a. The following discharges into the waters of the State are
hereby prohibited:
(1) The discharge of any radiological, chemical or biological
warfare agent or high-level radioactive waste, such as
terms are defined by the Act or pursuant thereto;
2-9
-2 -
Any discharge which the Secretary of the Army acting
through the Chief of Engineers finds would substantially
impair anchorage and navigation;
(3) Any discharge to which the Regional Administrator has
objected in writing pursuant to any right to object
provided the Administrator in Section 402(d) of the
Act; and
(4) Any discharge from a point source which is in conflict
with a plan or amendment thereto approved pursuant to
section 208(b) of the Act, or any other discharge not
permitted by this article, article 17 of the ECL, other
rules and regulations adopted or applicable pursuant
thereto, the Act, or the provisions of a SPDES permit.
EXCLUSIONS
a. The issuance of this permit by the Department and the receipt
thereof by the Applicant does not supersede, revoke or rescind an
order or modification thereof on consent or determination by the
Commissioner issued heretofore by the Department or any of the terms,
conditions or requirements- contained in such order or modification
thereof.
b. The issuance of this permit does not convey any property
rights in either real or personal property, or any exclusive privileges,
nor does it authorize any injury to private property or any invasion
of personal rights, nor any infringement of Federal, State or local
laws or regulations; nor does it obviate the necessity of obtaining
other assent required by law for the discharge authorized.
c. This permit does not authorize or approve the construction
of any onshore or offshore physical structures or facilities or the
undertaking of any work in any navigable waters.
MODIFICATION SUSPENSION REVOCATION
a. if the permittee fails or refuses to comply with an interim
or final requirement in a SPDES permit, such noncompliance shall
constitute a violation of the permit for which the Commissioner may
modify, suspend, or revoke the permit or take direct enforcement
j action pursuant to law. When, at any time during or prior to a
period for compliance, the permittee announces or otherwise lets it
be known, or the•Commissioner on reasonable cause determines, that
2-10
J
the permittee will not make the requisite efforts to achieve compliance
with" an interim or final requirement, the Commissioner may modify,
suspend or -revoke the permit or take direct enforcement action pursuant
to law, without waiting for expiration of the period for compliance
with such requirements. I
b. After notice and opportunity for a hearing, this
dprrmiti may
be
modified, suspended, or revoked in whole or -in p g
erm
for cause including, but not limited to, the following:
1. violation of any terns or conditions of this permit; or;
2. Obtaining this permit by misrepresentation or failure
to disclose fully all relevant facts, or false or inaccurate
statements or information in the application; or;
3. A change in any physical circumstances, requirements or
criteria applicable to discharges that requires either a
temporary or permanent reduction or elimination of the authorized
discharges, such as:
(i) standards for construction or operation of the discharging
facility,
(ii) the characteristics of the waters into which such discharge
is made,
(iii) the water quality criteria applicable to such. waters,
(iv) the classification of such waters, or
(v) effluent limitations or other requirements applicable
pursuant, to the Act or, S,tate Law.
if a toxic effluent standard or pro -
c. Notwithstanding (b) above,
hibition (including any schedule of compliance specified in Section
17-0813 of the Environmental Conservation Law or Section 307(x) of the
Act) is established for a toxic pollutant which is present in the dischar
authorized herein and such standard or prohibition is more stringent
than any limitation upon such pollutant in this permit, or if this permit
contains no limitations on such pollutants, this permit shall be revised
or modified in accordance with the toxic effluent standards or prohibitic
and the permittee shall be so notified. _
REPORTING NONCOMPLIANCE
a. If for any reason the permittee does not comply with or will be
unable ,to comply with any daily maximum effluent limitation
Specified in this pal -mit or should any unusual or extraordinary
discharge of wastes occur for the permitted --Facilities, the permittee
` shall immediately notify the Department of Environmental conservation
2-11
ME
Regional office by telephone and provide the following information
in writing within five days of such notification:
(1) Cause of noncompliance;
(2) A"description of the noncomplying discharge including its
impact upon the receiving waters;
(3) Anticipated time the condition of noncompliance is expected to
continue, or if such condition has been corrected, the duration of
the period of noncompliance;
(4') Steps taken by the permittee to reduce and eliminate the.
noncomplying discharge; and
(5) Steps to be taken by the permittee to prevent recurrence of
the condition of noncompliance.
b. Permittee shall take all reasonable steps to minimize any
advance impact to navigable waters resulting from noncompliance
with any effluent limitation specified in this permit, including
such accelerated or additional monitoring as necessary to determine
C. Except as provided herein under Prohibition of Bvoass of Treat-
ment Facilities, nothing in this permit shall be construed to
relieve the permittee from civil or criminal penalties for
noncompliance.
INSPECTIONS
The permittee shall allow, the Commissioner of the Depart*nent
of Environmental Conservation, the Regional. Administrator, and/or
their authorized representatives, upon the presentation of credentials:
a. To enter upon the permit -tee's premises where an effluent
source, is located or in which any records are required to be kept
under the terms and conditions of this permit, or State law;
b. To have access to and copy, at reasonable times, any records
required to be kept under the terms and conditions of this permit;
c. To inspect any monitoring equipment or practices being
maintained pursuant to this permit-; or
2-12
I
..d. -. To have access to and sample any discharge of pollutants to
waters or to publicly owned treatment works resulting directly oi:
indirectly from activities or operations of the owner or operator
of the premises in which the effluent source or outlet is located.
TFLANSFER OF OWNERSHIP
Any permittee who intends to transfer a S-PUES permit is required
to notify the Department in advance of the transfer. In the case o
a change of ownership only, notice to the Department is required
hip change accompanied by
prior to change; in the case of an owners
a change or proposed change in wastewater characteristics, a minimum
of -180 days prior notice to the Department is required.
The terms and -conditions of this permit are binding on the suc-
cessors or assigns in interest of the original permittee.
PERMIT RENEWAL
The permittee shall file for renewal of this permit no later
than 180 days prior to the expiration date by submitting any forms,
fees, or supplemental information which may be required by the Depart-
ment.
SPECIAL PROVISIONS - PROPOSED OR EXPANDED FACILITIES.
a. No construction of the waste disposal facilities shall commence
without written approval of the .Department or its --designated field
office.
b. The facilities shall be fully constructed and completed in
compliance with the engineering report,
plans and specifications as
approved, and any additional standards which are consistent with the
state =,aw and Code, as specified in writing (letter of approval) by
the Department or its designated field office.
c. The construction of the facilities shall be under the super-
vision of a person or firm qualified to practice professional engineer-
ing in the State of New York under the Education Law of the State of
New York, whenever engineering services are required by such law for
such purposes.
d. Before operation commences, where such facilities are under
the supervision of a professiona'_ engineer, he shall certify to the
Department and to the permittee that the constructed facilities have
been fully completed in accordance with the approved engineering report
plans and specifications, permit and letter of approval.
e. Acceptance and approval o. wastewater disposal facility plans
does not constitute approval of the facility's structural integrity.
New York State Department of Environmental Conservation reviews reports
plans and specifications for process capability' only.
2- 13
!
LIMITATION OF DISCHARGES OF OIL AND HAZARDOUS SUBSTANCES IN
HARMFUL QUANTITIES
The permittee shall not discharge oil into or upon navigable
waters or adjoining shorelines in quantities defined as harmful in
regulations published at 40 CFR 110, including any amendments or
revisions to such regulations effected subsequent to the date of
this permit. In addition, the,permittee shall not discharge
hazardous substances into or upon navigable waters or adjoining
shorelines in quantities defined as harmful in regulations promul-
gated by the Administrator pursuant to Section 311(b)(4) of the
Federal Water Pollution Control Act, as amended. Nothing in this
permit shall be deemed to preclude the institution of any legal
action nor relieve the permittee from any responsibilities, liabilities,
or penalties to'which the permittee is or may be subject under
Section 311 of the Federal Water Pollution Control Act, as amended, or
under any other Federal or State law or regulation.
MONITORING RECORDING AND REPORTING
1. General
a.. The permittee shall comply with all recording, reporting,
monitoring - and sampling requirements herein and such other additional
terms, provisions, requirements or conditions that'theDepartment
may deem to be reasonably necessary to achieve the -purposes of the
Environmental Conservation Law, Article 17-,. the Act, or rules and
regulations adopted pursuant thereto.
b. Samples and measurements taken to meet the monitoring require-
ments specified herein shall be representative of the volume and nature
of the monitored discharge. All composite samples should be "flow
proportioned" over the entire sampling period.
c. The permittee shall periodically calibrate. and perform main-
tenance procedures on all monitoring and analytical instrumentation
to insure accuracy of measurements.
2. Monitoring Locations
a. Permittee shall take samples and measurements to meet the
monitoring requirements at the locations specified.
b. Unless specified otherwise, samples of the effluent shall be
taken at the point of combined flow into the outfall sewer.
c. Unless specified otherwise, samples of the -influent wastewater
shall be taken at the point of plant inflow.
2-114
3. Recording of Monitoring Activities and Results
a. The permittee shall make and maintain records of all infor-
mation resulting from the monitoring activities required by this
permit.
b. The pp rnittee shall record for each measurement or sample
taken pursuant to the requirements of this permit the following
information: (1) The date, exact place, and time of sampling;'
(2) The -ates analyses were performed; (3) Who performed the
analyses; (4,) The analytical techniques or methods used; and,
(5) The results of al -1 required analyses.
C. If.the permittee monitors any pollutant more frequently than
is required by this permit, he shall include the results of such moni-
toring in the calculation and reporting of the values required in the
Discharge Monitoring Report form. Such increased frequency shall be
indicated on the Discharge Monitoring Report form.
d. The permittee shall retain for a minimum of three (3) years
all records of monitoring activities and results including all records
of calibration and maintenance of instrumentation and original strip
chart recordings from continuous monitoring instrumentation. This
period of retention shall be extended during the course of any unre-
solved_litigation or 'other proceedings regarding the discharge of
pollutants by the permittee or when requested by the Commissioner of
the Department of Environmental Conservation or the EPA Regional
Administrator.
4. Analytical Methods
Following promulgation of guidelines establishing test procedures
for the analysis of pollutants, published pursuant to Section 304(g)
of the Federal Water Pollution Control Act, as amended, all sampling
and analytical methods used -to meet the monitoring requirements
specified above shall conform to such guidelines. If the Section 304(g)
guidelines do not specify test procedures for any pollutants required
to be monitored by this permit and until such guidelines are promul-
gated, sampling and analytical methods used to meet the monitoring
requirements specified in this permit shall, unless otherwise specified
by the Commissioner, conform to the. latest edition of the following
references:
1. Standard Methods for the Examination of Water and Waste -
Waters, 14th Edition, 1976, American Public Health
Association, New Yb rk, New York 10019.
2. A. S. T. M. Standar?s, Part 31, Water; Atmospheric
Analysis, 1975, American Society for Testing and Materials,
Philadelphia, Pennsylvania 19103.
2-15
W -M
3. Methods for Chemical Analysis of Water and Wastes,
1974, Environmental Protection Agency Water Quality
Office, Analytical Quality Control Laboratory, NECK,
Cincinnati, Ohio 45268.
5. Aoplication for Alternate Test Procedures
The applicant shall submit his application to the Director of the
Bureau of Monitoring and Surveillance, Division of Pure Waters, N.Y.D.E.C.,
50 Wolf Road, Albany, New York 12233.
Unless and until printed application forms are madEt available, an
application for an alternate test procedure may be made by letter in
triplicate. Any application for an alternate test procedure shall:
(1) Provide the name and address of the responsible person or
firm making the. discharge .(if not the applicant) and the applicable
ID number of the existing or pending permit, issuing agency, and type
of permit for which the alternate test procedure is requested, and the
discharge serial number.
(2) Identify the pollutant or parameter for which approval of.an
alternate testing procedure is being requested.
(3) Provide justification for
those specified in Table I, FEDERAL
Tues. Oct. 16, 1973 • or, as amended.
using testing procedures other than
REGISTER, 28759, Vol. 38. No. 199,
(4) Provide a detailed description of the proposed alternate
test procedure, together with references to published studies of the
applicability of the alternate test procedure to the effluents in
question.
6. Confidential Information
Except for data determined to be confidential under Section
17-0805 of the Environmental -Conservation Law or Section 308 of the
Act, all such reports shall be available for public inspection at the
offices of the Department of Environmental Conservation and the Regional
Administrator of EPA Region II. Knowingly making any false statement
on any such report may result in the imposition of criminal penalties
as provided for in Section 71-1933 of the Environmental Conservation
Law or Section 309 of the Act.
2-16,
Om
FACILITY OPERATION AND QUALITY CONTROL
1. General
a. The facilities shall not receive or be committed to receive
wastes beyond their design capacity as to volume and character of
wastes treated, nor shall the facilities be changed or modified or
otherwise altered as to type., degree, or capacity of treatment
provided, disposal of treated effluent, or treatment and disposal of
separated scum, liquids, solids or combinations thereof resulting
from the treatment process without prior written approval of the
Department of Environmental Conservation or its designated field
office.
b. The permittee shall at all times maintain in good working
order and operate as efficiently as possible all treatment or control
facilities or systems installed or used by the permittee to achieve
compliance with the terms and conditions of this permit.'
C. Maintenance of treatment facilities that results in degrada-
tion of effluent quality shall be scheduled during non-critical water
quality periods and shall be carried out in a manner approved,by,the
New York State Department of Environmental Conservation.
d.. When required under Title 6 of the Official Compilation of
Codes, Rules and Regulations of the State of New York (6NYCRR650),
sufficient personnel meeting qualifications for operators of sewage
treatment works as required therein shall be employed to satisfactorily
operate and maintain the treatment facilities.
e. The permittee shall not discharge floating solids or
visible foam, unless specifically authorized by this permit.
f. Under no circumstances shall the permittee allow introduction
of the following wastes into the waste treatment system:
(1) Wastes which create a fire or explosion hazard in the
treatment works.
(2) Wastes which will cause corrosive structural damage to
treatment works, but in no case wastes with a pH lower
than 5.0, unless the works is designed to accomodate
such wastes.
2-17
-la -
(3) Solid or viscous substances in amounts which cause
obstructions to the flow in sewers or interference with
the proper operation of the treatment works.
(4) Wastewaters at a flow rate and/or pollutant discharge
rate which is excessive over relatively short time
periods so as to cause a loss of treatment efficiency.
2. ' Prohibition of Bypass o.f Treatment Facilities'
The diversion or bypass of any discharge from facilities utilized
by the permittee to maintain compliance with the terms and conditions
of this permit'is prohib it�ed, except (i) where unavoidable to prevent
loss of life or. -severe property damage, or (ii) where excessive storm
drainage or runoff would damage any facilities necessary for compliance
with the terms and conditions of this permit. The permittee shall
immediately notify the Department of Environmental Conservation Regional
-office of each such diversion or bypass in accordance with the procedures
specified herein for reporting noncompliance.. The permittee shall
within 30 days after such incident submit to the Department for approval
a plan to prevent recurrence of such incidents. -
3. Special Condition - Facilities With Septic Tanks
If a septic tank is installed as part of the treatment system,
it shall be inspected by the permittee oe his agent for scum and sludge
accumulation. at intervals not to exceed
accumulation will be removed before the
fourth (4) of the liquid depth so that
will leave in the septic tank effluent.
disposed of in an approved manner. _
one year's duration, and such
death of either exceeds one -
o setteable solids or scum
Such accumulation shall be
4. S LUDO' L DISPOSAL
Collected screenings, sludges, and other solids and precipi-
tates separated from the permittee's discharges authorized by this
permit and/or intake or supply water by the permittee shall be dis-
posed of in. such a manner as to prevent entry of such materials into
classified waters or their tributaries. Any live fish, shellfish, or
other animals collected or'trapped as a result of intake water screen-
ing
creen-ing or treatment may be returned"to their water body habitat. The.
permittee shall maintain records of disposal on all effluent screen-
ings, sludges and other solids associated with the discharge(s) herein.
described- The following data shall be compiled and reported to the
De_oartment or its designated field office upon request:
a. The sources of the materials to be disposed of; _
2-18
• - -11-
b. The approximate volumes and weights;
c. The method by which they were removed and transported;
d. Their final disposal locations.
SPECIAL CONDITIONS - PUBLICLY OWNED TREATMENT WORKS
1. Notice shall be given the Department of Environmental Conservation
of any new introduction of pollutants into such treatment works from
a source which would be a new, source as defined in section 306 of the
Act if such source was discharging pollutants; and, except as to such
categories and classes of sources specified by the Commissioner, any
new introduction of pollutants which exceed 10,000 gallons on any one
day into such treatment works from a source which would be subject to
Section 301 of the Act if such source was discharging pollutants; and
any substantial change in volume or character of pollutants being intro-
duced into such treatment works at the time of issuance of the permit.
Such notice shall include information on the quality and quantity of
effluent to be introduced into such treatment works; and an anticipated
impact of such change in the quantity or quality of effluent to be
-discharged from such publicly owned treatment works.
2.. The permittee shall require any industrial user of such. treatment
works. to comply'with the requirements of Section 204(b), 307, and
308 of the Act. Any industrial user subject to the requirements of
Section 307 of the Act shall be required by the permittee to prepare
and transmit to -the New York State Department of Environmental Conser-
vation periodic notice, (over intervals not to exceed 9 months) of
progress toward full compliance with Section 307 requirements. The
permittee, upon receipt of such reports shall transmit a copy promptly
to the Department.
3. The permittee shall require any industrial user of storm sewers
to comply with the requirement of Section 308 of the Act.
4. For discharges from publicly owned treatment works, appropriate
measures will be established by the permittee to insure compliance
by industrial users with any system of user charges and recovery of
construction costs. required under the provisions of the Act.
5. Persons discharging industrial waste -to a publicly owned treatment
works shall comply with toxic effluent standards and pretreatment
standards and with monitoring, reporting, recording, sampling and
entry requirements provided by the Act or the Environmental Conservatio:
Law, Article 17 or adopted pursuant to the Act or the Environmental
Conservation Law, Article 17.
2-19
TABLE 2-2
CLASSES AND STANDARDS FOR SALINE SURFACE WATERS*
The following items and specifications shall be the
standards applicable to all New York Saline Surface
Waters which are assigned the classification of SA,
SB, SC or SD, in addition to the specific standards
which are found in this Part under the heading of
each such classification.
Quality S-tanda.rds for Saline Surface Waters
Items Specifications
1. Garbage, cinders, ashes, None in any waters of the marine
oils, sludge or other district as defined by Environ -
refuse. mental Conservation Law (S 17-0105).
2. pH The normal range shall not be
extended by more than one-tenth
(0.1) pH unit -
3. Turbidity No increase except from natural
` sources that will cause a sub-
stantial visible contrast to natural
conditions. In cases of naturally
turbid waters, the contrast will be
due to increased turbidity.
4. Color None. from man-made sources that
will be detrimental t.o anticipated
best usage of waters.
5. Suspended, colloidal None from sewage, industrial wastes
or settleable solids. or other wastes which will cause
deposition or be deleterious for
any best usage determined for the
specific waters which are assigned
to each class.
6. Oil and floating No residue attributable'to sewage,
substances industrial wastes or other wastes,
nor visible oil film nor globules
of grease.
7. Thermal discharges (See Part 704 of this Title.)
*Source: NYSDEC,-Classifications and Standards Governing the
Quality and Purity of Waters of N.Y.S., Part 701.5, OffiLi'al
Compilation of Codes, Rules and Regulations.
2-20
CHAPTER 3; GENERAL LABORATORY CONTROL
PAGE NO.
PURPOSE 3- 2
COLLECTION OF SAMPLES 3- 2
ANALYSIS OF SAMPLES AND TESTING SCHEDULE 3- 3
SAMPLING LOCATIONS 3- 4
INDUSTRIAL WASTEWATER MONITORING 3- 7
INTERPRETATION OF LABORATORY RESULTS 3- 7
PROCESS CONTROL STRATEGIES 3-10
NOTES AND ADDENDA 3-15
LIST OF TABLES
3 - 1
RECOMMENDED SCHEDULE OF LABORATORY ANALYSES
3- 5
3 - 2
TROUBLESHOOTING INDUSTRIAL WASTE DISCHARGE
3- 8
3 - 3
PROCEDURE FOR RUNNING LABORATORY JAR TEST
3-13
LIST OF FIGURES
3 - 1 SAMPLING LOCATION DIAGRAM
3- 1
3- 6
PURPOSE
The proper conduct of laboratory analysis coupled with other
operating records is important for the following reasons:
1. To form a rational basis for the control of treatment
plant process.
2. To define the operational efficiency of the plant,
and aid in the predictions of problems that might develop.
3. To obtain a historical record of the conditions under
which the plant has been operated as an aid to the design of
plant expansion or modification, and as a budgetary aid.
4. To satisfy the report requirements of the applicable
Municipal, State or Federal agencies.
5. Data which may be utilized to enforce the Town's Scavenger
Waste Ordinance.
COLLECTION OF SAMPLES
Proper sampling techniques are as important as analytical
techniques. Care should be taken to ensure that a sample
obtained is representative. Sampling points should ideally be
located at points of turbulence.
There are two basic types of samples. The first "grab"
sample is a single sample taken at neither set time nor flow, it
represents an instantaneous condition. It is used primarily when
test samples cannot be mixed, such as when testing for residual
chlorine or pH. The second, a "composite" sample is defined as a
combination of individual samples taken at selected time
intervals, for some specified period. These samples are
proportional to the flow at the time of sampling. This type of
sampling provides an average representation of the wastewater
over a period of time, thus minimizing the effect of the
variability of the individual sample.
The following is a list of general guidelines for sampling
wastewater:
1. Samples should be taken at locations where the wastewater
is as completely mixed as possible.
2. Particles greater than 1/4 -inch in diameter should be
excluded when sampling.
3- 2
3. If samples are to be kept for an hour or more prior to
testing, they should be immersed in ice water or
refrigerated (approximately 42 deg. F) to retard bacterial
action, but not frozen.
4. Consideration should be given to the
relationship between the plant's daily flow variation and
detention time through the units so that influent and
effluent samples relate to the same waste.
5. All samples should be large enough to perform
the required tests. At least one liter should be furnished
for most tests.
6. Caution should be exercised in sampling below
weirs. The upstream pool may have solids lying below the
weir crest, and downstream sampling may introduce floating
oils or grease.
7. The most desirable location in sampling from
sewers and channels is from the middle third (depth wise).
Skimming the water surface will introduce oil and grease
into the sample, and dragging the bottom or sides will
introduce settled solids.
8. The most desirable location in sampling from
settling tanks, if samples cannot be collected from effluent
troughs, is just prior to the outlet weirs below any
floating layers.
9. Composite samples should be proportioned to the flow.
A suggested method would be mixing 200 ml of sample for each
M.G.D. of flow each hour.
ANALYSIS OF SAMPLES AND TESTING SCHEDULE
Operating personnel at the plant perform only routine
operational tests such as, settleable solids, temperature,
chlorine residual and pH. These tests will be performed in_
the laboratory of the existing Village of Greenport
Treatment Plant. The chief operator and all operators
should be capable of interpreting their significance. As a
guide to the various test procedures, it is recommended that
the operator refer to the following publications®
1. Standard Methods for the Examination of Water and
Wastewaters, Fifteen Edition, American Public Health
Association, Inc., 1980.
2. Laboratory Procedures for Wastewater Treatment Plant
Operators, New York State Department of Health, 1969.
3- 3
3. Simplified Laboratory Procedures for Wastewater
Examination, Publication No. 18, Water Pollution Control
Federation, Second Edition, 1976.
All other tests required for evaluation of plant operation
is performed by an outside State approved laboratory.
The required tests, location(s), the type of sample to be
collected and the frequency of testing are shown in Table 3-1
(also see Figure 3-1). The indicated frequencies should be
considered as minimum. In addition to the tests cited, each
sample should be given a cursory inspection and any apparent
abnormalities in color, odor and appearance should be noted.
SAMPLING LOCATIONS
The following is a descriptive listing of the points in the
plant where samples may be obtained. The numbers correspond to
the same numbers on Figure 3-1.
1. Influent Ports - samples of scavenger waste can be
obtained from the waste hauler vehicles prior to their
discharging into the influent ports. The collected sample bottle
will labeled, refrigerated and stored for a designated time
period. If an upset occurs at the facility, the contents of the
bottles will be analyzed as indicated in Table 3-1 to determine
the origin of the upset.
2. Grit Chamber Tank Effluent - samples may be
collected from the effluent end of the aerated grit tank.
3. Equalization Tank Effluent - samples may be
collected from the head box.
4. Flocculation Tank Effluent - samples may be obtained
from the flocculation tank outlet.
5. Primary Clarifier Effluent - samples may be obtained
from.the clarifier effluent channel preceeding the RBD units.
6 & 7. Final Clarifier Influent and Effluent - samples
may be obtained from the RBD effluent channel and the clarifier
effluent channel preceeding the effluent wet well.
8. RBD Units - Samples may be obtained from the RBD
tanks on a daily basis.
3- 4
a
LOCATION(S)
1
2
3 - 7
3 m 8
TABLE 3 - 1
RECOMMENDED SCHEDULE OF LABORATORY ANALYSES
TYPE OF
PARAMETER/ANALYSIS SAMPLE
Raw Scavenger/Suspended Solids Grab
Wast Total Solids Grab
Total Volatile Solids Grab
BOD5 Grab
Total Kjeldal Nitrogen Grab
Ammonia Grab
Heavy Metals Grab
Grit/Total Volatile Solids Grab
Wastewater/BODS 24 Hr.
Wastewater/Suspended Solids
5 & 6 Wastewater/Alkalinity
3,4,5,6 & 7 Wastewater/pH
2, 4, 5 & 6 Wastewater/Settleable Solids
3 & 7 Wastewater/Temperature
8 RBD Basin/Dissolved Oxygen (D.O.)
9 Digested Sludge/Total Volatile
Solids
pH
Alkalinity
3- 5
Composite
24 Hr.
Composite
Grab
Grab
G rab
Grab
Grab
Grab
Grab
Grab
Grab
FREQUENCY
As Required
As Required
As Required
As Required
As Required
As Required
As Required
Daily
Weekly
Weekly
Weekly
Twice/Day
Twice/Day
Twice/Day
Daily
Weekly
Weekly
Daily
Weekly
PRIMARY
'
DIGESTER
EXISTING SLUDGE
BEDS
_DRYING
® i Scull
ROTATING
-- BIOLOGICAL
I
L®®-v®®®J=
DISCS
B
SLUDGE
c-
WET WELL
9
Z
Ll
C
6
®®� FLOW METER
I
TO OUTFALL I
FINAL
I
CLARIFIER
m
EFFLUENT
m
_
EXISTING
XISTING VILLAGE OF
WET WELL
Z
GREENPOINT PLANT
w
.m
1
LING LOCATION
I M
9. Primary Digested Sludge - samples may be taken
from the sampling taps located in the digester building.
INDUSTRIAL WASTEWATER MONITORING
Many Municipal treatment plants provide satisfactory
treatment to a variety of industrial wastewaters, and there
are many reasons that such joint treatment is a desirable
solution to a community problem. Any arrangements of this
nature, however, should be approached with caution, as
industrial wastes are frequently cited as the cause of a
large number of operation and maintenance problems at
treatment plants and in sewer systems. It is beyond the
scope of this manual to characterize the many different
types of wastes or to detail the difficulties which their
presence may cause.
It is absolutely necessary that the Town maintains
control of the types of wastes admitted to the scavenger
waste plant. An ordinance regulating scavenger waste
disposal has been adopted, and it is recommended that the
Town stand prepared to enforce it if necessary. A copy of
the Scavenger Waste Disposal Ordinance is shown in Appendix
G.
It may also be desirable to equip the existing
Greenport Treatment Plant laboratory to perform non -routine
tests for constituents of the industrial waste, and thereby
maintain a continuing watch for adverse changes in the
nature of the treatment plant influent (see Table 3-2).
INTERPRETATION OF LABORATORY RESULTS
One of the purposes of laboratory testing in wastewater
treatment, and perhaps the most important one, is providing
a basis for process control. It is necessary that the plant
operator be able to interpret the laboratory results in
order to be able to apply them to the control of unit
processes.
The following are descriptions of some significant test
results which have a direct bearing on plant operation.
Biochemical Oxygen Demand: The BOD -5 is a widely
employed method of describing the organic or pollutional
strength of a wastewater. It is of prime importance in
design, in operational control and in defining plant
efficiency. Since the test requires five (5) days for
completion, it cannot be used for rapid control adjustments.
However, it does provide a record of loading conditions and
affords the most rational basis for making major operational
changes.
3- 7
TABLE 3 - 2
TROUBLESHOOTING INDUSTRIAL WASTE DISCHARGE
INDICATORS
1. Discoloration of influent.
2. Sterilization of biological treatment process.
3. Change in influent odor.
4. Unusual amounts of solids in influent.
MONITORING, ANALYSIS AND/OR INSPECTION
1. Constantly monitor influent for pH above 8.0 or below
6.0.
2. Check pH of sludge in the disgestion chamber.
3. Check influent temperature.
4. Run settleable solids test.
5. Run BOD test on contaminated effluent and compare
results with normal plant loading.
CORRECTIVE MEASURES
1. Isolate and dispose of all contaminate sludges.
2. Raise pH above 6.5 by adding lime to the digester tank
(see Chapter 14).
3. Institute program of source control (Scavenger Waste
Ordinance).
0=1
Suspended Solids: A Suspended Solids (SS) test will
measure quantitatively all the settleable solids. When
conducted on raw waste, the test is one of the two principal
parameters for defining wastewater strength.
When coupled with tests on the effluent, the SS test
becomes an important expression of the efficiency of the
treatment process. Chronically high effluent solids
indicate serious operating difficulties.
Chlorine Residual: Chlorine residual tests on the final
plant effluent are generally accepted as the means of
demonstrating that a satisfactory degree of disinfection is
being provided. In general, residuals of 1.0 mg/l are
acceptable., but the operator should be guided primarily by
the requirements of the State regulatory agency.
pH: The pH value, expressed in a numerical unit,
provides a measure of acid or alkaline conditions. Although
the following definition is oversimplified, a pH value of
7.0 is considered to be neutral. Increasing pH values
indicate a more alkaline condition, whereas decreasing pH
values represent greater acidity.
Although FeC13 has a wide optimum pH range of 4.0 to
11.0, abrupt changes in raw wastewater pH over an extended
period of time will make jar testing necessary for adjusting
the FeC13 feed concentration to ensure the desired removal
efficiency in the primary settling tanks. Note that the
equalization tanks at this facility should dampen the
effects of wide pH fluctuations.
Biological reactions, such as those occurring within
the RBD`s, proceed most efficiently at pH values near 7.0,
and serious process deterioration may be expected at values
outside a pH range of about 6.0 to 8.0. A pH probe has been
provided to measure and record the influent pH to the RBD
tanks. The pH readings must be monitored on a daily basis
to ensure that the HCl feed system is operating in the
desired range. Daily checks of primary settling tank
effluent pH is recommended so that the operator can more
readily spot an increasing or decreasing trend and can
adjust the limefeed rates accordingly.
Daily pH checks of the contents of the digestion tanks
are recommended so that the operator will notice any
variations from the 6.8 to 7.6 range required for stable
operation.
pH tests on the digested sludge may help the operator
to determine the appropriateness of the polymer dosage
required for sludge dewatering.
3- 9
Settleable Solids: The settleable solids test shows
qualitatively the volume of material which can be removed by
gravity settling during a specific interval. The settling
time is normally one hour on wastewater samples. Results
are expressed as ml/l, or occasionally as a percent by
volume.
When applied to raw wastewater the settleable solids
test gives an indication of wastewater strength and visually
shows the operator the type of solid material which should
be captured within the primary tanks. Although there are
better indicators, the test may also be used to express
treatment efficiency.
PROCESS CONTROL STRATEGIES
In some cases, the operator may need to make more
in-depth tests to tell how well the plant is working. Some
of these tests may be performed by an outside State approved
laboratory, if necessary. The following non -routine tests
should be performed as required®
1. Turbidity
2. Jar Test.
Turbidity: Turbidity refers to the interference of
light passage through water. Fine particles of suspended
matter hinder the passage of light by scattering and
absorbing the rays. Turbidity in the denitrification
filters is chiefly due to suspended solids in the filter
effluent.
Measurement of the turbidity of the wastewater entering
and leaving the denitrification filters will indicate the
degree of turbidity removal through the tanks.
Precautionary Procedures: When performing the turbidity
test, the following procedures should be followed in
conjunction with the procedures outlined in the most recent
edition of Standard Methods.
1. Hold the turbidimeter test vial near the top.
The test vial must be kept clean, both on the inside and the
outside.
2. Calibrate the turbidimeter using a standard in
the range of the turbidity expected.
3. Stir the sample before pouring. Pour the
sample slowly into the vial, being careful not to create or
trap air bubbles.
3-10
4. Be sure the outside of the test vial is dry
before inserting it into the turbidimeter.
5. After allowing any air bubbles to escape,
promptly read the results.
6. Replace any test vials that are scratched or
damaged.
Trend Analysis: Routine hourly observation of influent
wastewater samples entering the primary settling tanks can
be invaluable in maintaining control of the flocculation
process. If they are collected on the hour, and allowed to
.settle in liter glass containers, the clarity can be readily
observed. To be most helpful to the.operator maintaining
watch for process control use 24 liter sample containers.
Then by placing the collected settling samples in sequence,
corresponding to the time of collection, one for each hour,
a rapid comparison is continuously available so that changes
in coagulated water quality can more easily be detected. In
other words, a sample may be collected every hour on the
hour throughout the operating day. This sample is placed on
an observation shelf with the other samples collected before
it. At the end of the operating day samples should be
discarded and replaced with a new sample corresponding to
the same hour of the following day. If water clarity after
settling changes, the operator who is observant and
concerned, will notice the relative change and proceed to
search for the causes. For example, empty chemical hoppers,
stopped -up hoppers, machines that were accidentally not
turned on, mechanical or electrical failure of feed machines
or accidental wrong feed machine setting. This method of
floc detection and observation can provide not complete, but
very adequate continuous surveillance of the flocculation
process.
There is no formula for determining coagulant doses for
best clarification in the primary settling tanks.
Laboratory tests are valuable indicators of the probable
doses that will be required and should be used frequently;
but, in the final analysis, actual records of results at the
plant in question are the best guides.
Jar Test: The jar test is a laboratory procedure which
affords a rapid means to determine the effects of chemical
treatment on wastewater. It consists of a series of six
stirring paddles which can be rotated at a variable
controlled speed to mix contents of 1 - liter beakers. This
permits the simultaneous treatment and observation of six
samples under identical mixing conditions in order to
determine the optimum dosage of FeC13.
3-11
What constitutes the optimum dosage depends upon the
objectives of treatment. In the case of clarification, size
and density of the floc particles are important. Very often
a small, dense floc, about pinhead size, will settle more
rapidly and completely than a large, flaky floc, so that a
floc size is not in itself necessarily a good criterion to
use.
Some simple tests of the wastewater being treated,
before or after mixing and settling of the samples are a
valuable part of the procedure. Measurements of turbidity,
pH, BOD -5 and suspended solids are necessary to ascertain
optimum coagulant dose.
Standard strength solutions of coagulant (FeC13) may be
prepared by dissolving 1 grain (64.8 mg) of the chemical in
100 ml of distilled water. A milliliter of this solution in
the 1,000 ml of water being treated forms a dose of 10 mg/l.
A dose of 1 mg/l is equal to 8.34 lbs. of the chemical per
million gallons of water being treated. One (1) grain per
gallon amounts to 17.1 mg/1.
In making jar tests it is desirable to duplicate
insofar as possible actual full scale plant conditions. It
is common to start the mixer at say 40-80 RPM, add the
chemical and mix rapidly for about 30-60 seconds, then
reduce the paddle speed to 10-20 RPM and slow mix for an
additional 15-30 minutes. At the end of the slow mix
period, the paddles are then removed from the jars and the
floc is allowed to settle. The time for all of the floc to
settle to the bottom of the beakers is observed. The
recommended procedure for performing laboratory jar tests is
given in Table 3-3.
The dosage giving the best BOD -5 and suspended solids
removal is the optimum FeC13 dose.
Results given by this test are valuable as a guide in
finding what dosage is best on a plant scale. The dosage
shown as best by the jar test may not be the best one, in
actual plant practice, but it will usually be close to it,
and with some modifications gives good results.
3-12
TABLE 3 - 3
PROCUDURE FOR RUNNING LABORATORY JAR TESTS
(MULTIPLE STIRRER)
COAGULATION
1. Prepare a solution of the coagulant (FeC13) of such
strength that 1 ml contains 10 mg of coagulant.
2. Measure 1 to 2 liters of freshly drawn sample and pour
it into a beaker. A 2 -liter sample is preferred, but
1 -liter is usually sufficient to produce uniform results.
Never use less than a liter or quart sample. A guide for
numbering the jars and the dose per jar follows:
Dose per Liter
Jar Number
ml
mg/l
1
1
10
2
2
20
3
3
30
4
4
40
5
5
50
6
6
60
3. Lower paddle of the stirrers into the beakers, start
multiple stirrer and adjust speed to 80 RPM.
4. Add desired volumes of the coagulant (FeC13) starting
with the first jar on the left, in rapid succession from
fast delivery Mohr pipettes.
5. Continue stirring at 80 RPM for 30 seconds, after the
last chemical is added, for good mixing.
6. Reduce speed to 40 RPM for 7 minutes to permit floc to
form. Note speed of floc formation; that is, time required
for discrete particles of floc to form at the reduced speed.
Now continue stirring test for 3 minutes at 10 RPM for the
floc to grow. The suggested time intervals for the 40 RPM
and 10 RPM mixing may be changed. The samples should be
stirred for a length of time equivalent to the mixing period
used in the plant.
7. Remove paddle from test solution and allow floc to
settle for at least 15 to 30 minutes. Note size and
settling rate of the floc. If no floc forms, insufficient
coagulant (FeCL3) has been added. If a large flaky floc
forms, this indicates that the dose of coagulant used may be
reduced.
3-13
8m The floc is designated as poor, fair, fairly good, good,
very good, or excellent (large floc to pinhead floc).
9. Siphon off the supernatant into clean containers for
analysis.
3-14
CHAPTER 4: REPORTS AND RECORDS
LIST OF TABLES
Table
4 - 1
PAGE NO.
IMPORTANCE
4- 2
QUARTERLY REPORT TO USEPA AND NYSDEC
4- 2
REPORTS
4- 2
WASTEWATER TREATMENT PLANT OPERATION LOGS
4- 6
DAILY INSPECTION REPORT.'
4-13
ALARM LOG
4-13
EQUIPMENT RUNNING TIME LOG'S
4-17
LABORATORY
4-17
MAINTENANCE
4-17
OPERATING COSTS
4-17
SAFETY
4-19
NOTES AND ADDENDA
4-20
LIST OF TABLES
Table
4 - 1
DAILY OPERATING LOG
4- 3
4 - 2
DAILY INSPECTION REPORT
4- 5
4 - 3
WASTEWATER TREATMENT PLANT OPERATION LOG
(MONTHLY REPORT)
4- 7
4 - 4
SUMMARY OF TREATMENT PLANT OPERATING
4-10
CONDITION
4 - 5
SUMMARY OF OPERATING EXPENDITURES FOR THE
4-12
ANNUAL REPORT
4 - 6
ALARM LOG
4-14
4 - 7
EQUIPMENT RUNNING TIME LOG
4-18
4- 1.
IMPORTANCE
The importance of keeping accurate records cannot be over
stressed, as they provide the basis for making operational
decisions, troubleshooting problem areas, planning future plant
expansions or modifications, justifying or adjusting budgets, and
supplying evidence of performance in compliance with regulations
and objectives of water pollution control agencies.
In addition to operating records, any background information
relating to water pollution control, such as preliminary
engineering or planning reports, should be readily available at
the plant. Contract drawings modified to reflect "As Built"
conditions, shop drawings, manufacturers' operation and
maintenance catalogs, nameplate data and relevant cost
information should also be on hand.
QUARTERLY REPORT TO USEPA AND NYSDEC
A quarterly self-monitoring report must be submitted to the
USEPA and NYSDEC within 28 days after the end of the quarterly
reporting period. A completed copy of the discharge monitoring
report must be submitted to the following regulatory agencies:
NYSDEC - Albany, NYSDEC - Region #1 and the USEPA - Region #2.
An additional copy should be filed with the treatment plant
records. The data for this facility will be incorporated as part
of the Village of Greenport treatment plant quarterly
self-monitoring report. A copy of the SPDES permit is included
in Chapter 2.
REPORTS
Daily, monthly and annual reports should be kept, each
summarizing and commenting on the data in the reports covering
the preceding shorter periods, adding pertinent data thereto, and
making comparisons with previous performances during similar
periods.
The daily report should include a statement concerning the
weather, temperature, rainfall, wind and -the results of periodic
measurements of quantity and quality of scavenger waste and of
the influent to and effluent from the various treatment units, of
which chemical and physical analysis should be made. In addition
to such routine material the daily report should contain a record
of any unusual happenings about the plant, e.g., construction
work, floods, complaints, or visitors. A sample daily operating
log is contained in Table 4- 1 and a sample daily inspection
report in Table 4- 2.
4- 2
--I- A 4
DAILY OPERATING LAG
DATE
OPERATOR
DAILY OPERATING LOG
I. GENERAL DATA
A. Waste Flow: (a) Total Received gals.
(b) Mag. Flow Meter Reading.
Rate gpm.
Total gals.
(c) Number of Trucks
B. Odor Conditions:
C. Temperature of Raw Waste at Headbox OF.
D. Weather: (a) (b) Direction of Wind
(c) Rainfall or Snowfall in. (d) Outdoor Air
Temperature (i) Maximum 'F (ii) Minimum F.
(e) Time Recorded: M M
II. PROCESS OPERATION DATA
A. Coarse Bar Rack: (a) Cleaning Period hr.
(b) Quantity of Screenings lbs.
B. Grit Chamber: (a) Cleaning Period hr.
(b) Quantity of Grit lbs.
C. Primary Settling Tank: (a) Tank in Service
(b) Cleaning Period hr. (c) Quantity of Sludge Removed gal.
(d) Scum Removed cu. ft.
D. RBD Units: (a) Unit in service
E. Final Settling Tank: (a) Tank in service
(b) Cleaning Period hr. (c) Quantity of Sludge removed gal.
(d) Scum Removed cu. ft.
4- 3
TABLE 4 ® 1 (Cont"d)
DAILY OPERATING LOG
F. Totalizer Readings (GALS/24 Hrs)
G. Methane Gas Meters (CF/24 Hrs) H. Digester Operation
SERVICE IQ= TOTAL PRIMARY
THIS DAY +
PREV. DAY +
24 HR. +
I. Sludge Transfer Pumps
PUMP #1 PUMP # 2
RUNNING TIME
(HRS.)
EST.
GALS.
K. Sludge Recirculation Pumps
PUMP # 1 PUMP # 2
RUNNING TIME
(HRS.)
EST.
GALS.
L. Sludge/Scum Wet Well Pumps
PUMP # 1 PUMP # 2
RUNNING TIME
(HRS.)
EST.
GALS.
M. Remarks
TEMP. (OF)
pH
PRESS. (In.)
J. Fuel Oil Consumption (GAL/24 HRS)
TREAT. BLDG DIG. BLDG TOTAL
PREY. DAY + _
THIS DAY + _
24 HR. + _
4 ® 4
DATE
TABLE 4 - 2
DAILY INSPECTICN REPORT
OPERATOR
ACTION
ITEM
YES NO
REMARKS
1. Inspection of motors & machinery
2. Cleaning bar screen and disposing
of screenings
3. Operating the sludge collectors
or checking their operation
4. Reading all meters and recorders
5. Pumping sludge to the digester
6. Checking gas flow from digester
7. Checking sludge temperature and,
operation of heating system
8. Drawing supernatant liquor from
digester
9t. Cleaning grit removal equipment
or devices
10. Check operation of MD'units
and air diffuser nozzles
11. Hosing down and squeegeeing tank
walls
12. Removing scum from settling tanks
13. Collection of samples, performance
of laboratory tests and recording
of results
14. Adjust equipment operation as
indicated by tests
15. Maintenance of minor plant
equipment, oiling & greasing of
machinery -and ground work, etc.
16. Complete records and report for
the da
The monthly report summarizes the daily records and includes
such additional information as any special analyses made,
equipment repaired or renewed, and changes in personnel. A
sample monthly report is contained in Table 4- 3.
The annual report is an accounting by the plant operator to
the Town and to the public of the performance, economy and needs
of the plant as shown by the year's experience°
It is recommended that the plant operator be responsible for
the preparation of a formal annual report. The purpose of the
report, prepared at the end of either the calendar year or the
fiscal year, is to summarize the year's operation in terms of
loading conditions, treatment efficiency and operating costs.
Inclusion of a completed copy of Table 4- 4 (Summary of
Treatment Plant Operating Conditions) in the report would serve
to summarize important operating conditions and overall plant
performance. This table should be completed monthly by
summarizing the plant operation logs (Table 4- 3). The actual
conditions that prevailed during the year should be compared with
conditions for which the plant was designed.
A detailed summary of operating expenditures should also be
presented, and would include discussion of such items as
manpower, chemical usage, maintenance, utility costs and
miscellaneous supplies. A sample is provided in Table 4- 5.
The report should include explanation of any extraordinary
occurrences such as major operational problems, process upsets,
equipment failures or lost -time accidents. Any other situations
(i.e., citizens' complaints, directives from regulatory agencies)
which may have contributed to, or resulted in, a change in
operating procedures should also be discussed.
WASTEWATER TREATMENT PLANT OPERATION LOGS
Table 4- 3 has been developed and is recommended for use.
Space has been provided for 31 calendar days each month, although
it is not expected that all laboratory tests will be performed
every day of the month. The degree of uniformity of waste volume
and characteristics will determine, to a large extent, how much
more frequently laboratory analysis will be required above the
frequencies indicated in Table 3-1, Chapter 3.
The Wastewater Treatment Plant Operation Logs (Table 4- 3)
should be completed weekly (daily were required). Most of the
information required to complete these forms will be available
from the laboratory results. This form was designed to aid the
operator in observing the weekly results of each unit process and
to summarize and show the average conditions which prevailed
4- 6
WASTEWATER TREATMENT PLANT OPERATIONS LOG
PRIMARY CLARIFIERS
MONTH 19 OPERATOR
SETTLEABLE SOLIDS, m1/1 B 0 D, mg/1 SUSPENDED SOLIDS, mg/1
DAY
OF % % %
wrath 11Hrr; IM". r;r'r'. tMmuVr;u INF. r;r'r. mnivw tNr'. MIT'. MMUVE;u
I TOTAL
TABLE 4 — 3 (CONT'D)
WASTEWATER TREATMENT PLANT OPERATIONS LOG
SECONDARY CLARIFIER
MONTH 19 OPERATOR
SETTLEABLE SOLIDS, m1/1 B 0 D, mg/1 SUSPENDED SOLIDS, mg/1
DAY
OF % % $
WEEK IJRE1; INY. EtV. mnivrll LNb,. -zr'r'. xc muvbu INr'. Lr'r'. libmuvw
F- 1 1
TOTAL
A
WEE 4-3OW'D
WASBITM TFERNM PLW CPEPqnQ5 DOG
PLW EFFIi W Dllk
m im 19 CPLTA[R
S1P UME SMW, m1/1 B O D, rqA SUADEIM a m, NAL, Q H1r
QU HIM
FCM RM—
DAY FIIPL FRML tw UIP,L
CF RAF. EFF. % EFF. % DF. EFF. % EFF. % INF. EFF. % EFF. % 1W awl
a� • u •.� .!WfMEMOKa • zI I I I I MMTa • nb ••a• D—DIM A I•a • �• •.o • o
9 -FT,.- �
Che g mm of FeC13 - 11 pard-. of FUC13
Che ga11rn of HZ = 9.6 pm -ds of HZ
Adividedby[l,OM,OWx(area),],'EmmmmmmmmmmmI
Che g mm of FeC13 - 11 pard-. of FUC13
Che ga11rn of HZ = 9.6 pm -ds of HZ
TABLE 4® 5
SUMMARY OF OPERATING EXPENDITURES
FOR THE ANNUAL REPORT
OPERATING EXPENSES ($)
SALARIES (OPERATING PERSONNEL). ........................
SALARIES (PREVENTIVE MAINTENANCE) ........................
SALARIES (CORRECTIVE MAINTENANCE) ........................
SALARIES (CLERICAL STAFF) ................................
SALARIES (ADMINISTRATIVE STAFF) ..........................
CHEMICALS................................................
LABORATORY...............................................
TREATMENT ................................................
VEHICLE OPERATION ........................................
MISCELLANEOUS.....................................................
TOTAL EXPENSES ($) ................................................
BUDGET OR REVENUE ($) .............................................
REMARKS
4®12
during any month. It is expected that use of this form
will help the operator to collect data to determine and recognize
long-range trends and will make it easier for him to compare
loading and operating conditions with results produced in terms
of treatment efficiency.
It is suggested that a copy of the completed logs (Table 4-
3) be sent to the consulting engineers so they may observe the
general pattern of performance of individual units and provide
advice if it is requested.
Keeping accurate Operation Logs (Table 4- 3) for`the
process systems is an important part of plant operations. The
accuracy of the data entered on these sheets should be checked
before they are filed for reference information.
DAILY INSPECTION REPORT
An important tool for the plant operator is a daily plant
inspection in the morning. The Daily Inspection Report (Table
4- 2) should be completed by the operator during his morning plant
tour.
In addition to keeping the Daily Inspection Report it is
recommended that all gauges (pressures,, temperature, etc.) be
marked with red paint indicating the normal operating range. The
operator can then note at a glance whether the pump is operating
within or outside its normal range. If the gauge is outside its
normal range, the operator should investigate and correct the
cause.
It is recommended that self-adhesive temperature plates be
placed on all motors. As the temperature tape is exposed to
temperature exceeding the maximum rated temperature, it turns
irreversibly black and an overheating motor can be easily noted
by the operator. One such type of tape is TEMP -PLATE
manufactured by William Wahl Corporation, Santa Monica,
California.
ALARM LOG
Table 4- 6 is an Alarm Log sheet. An alarm should be
located adjacent to each instrument panel or console. Every time
an alarm occurs, it should be entered on this form. These should
be reviewed periodically and, if there is a recurring problem, a
change in operating procedure or corrective action should be
evaluated.
4-13
TABLE 4-6
ALARM LOG
DATE
ALARM POINT
TIME OF
MALFUNCTION
CAUSE
CORRECTIVE
AC'T'ION
OPERATOR
Note: Place one log near each panel.
EQUIPMENT RUNNING TIME LOGS
Table 4- 7 is an Equipment Running Time Log sheet.
Equipment Running Time Logs should be completed each shift by the
operator, as appropriate. These records should be made available
to the mechanic for his use in scheduling routine and preventive
equipment maintenance based on equipment running time.
LABORATORY
Sample forms suggested for use in the laboratory are presented
and discussed in Chapter 3, Laboratory Controls.
MAINTENANCE
Forms for maintenance sheduling, repair work orders, main-
tenance, lubrication and repair records, spare parts inventory
and related subjects are presented in Chapter 17.
OPERATING COSTS
It is recommended that plant personnel maintain complete
records of expenditures as they occur and summarize on a monthly
or quarterly basis those items contributing to the cost of plant
operation. Major categories of costs will be labor, utilities,
chemicals, maintenance and supplies.
Bills for utilities such as electrical power, heating fuel
and water should be reviewed and pertinent information such as
amounts used, unit costs, total costs and any miscellaneous
charges should be recorded.
Chemicals such as methanol, ferric chloride, hydrochloric
acid and lime are used in significant quantities at the plant.
The summary should include total usage, unit costs and total
costs.
Whenever maintenance or repairs must be performed by outside
craftsmen or by representatives of equipment manufacturers, the
details of each visit, including the nature of the problem, the
persons involved and costs for parts and labor, should be
recorded and filed. Costs incurred in the operation and
maintenance of vehicles used in connection with the plant may
also be summarized as a separate item. In addition, records
should be maintained showing the decription and cost of plant
supplies, as well as any additional miscellaneous expenditures.
In accounting for costs incurred in the operation of his
plant, the operator should, of course, be guided by procedures or
requirements established by that branch of the Town government
having jurisdiction in budgetary matters.
4-17
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SAFETY
A form for recording and reporting pertinent information
relative to accidents is shown in Chapter 5, Safety Precautions
and Emergency Response Program, and is suggested for use if the
insurance company does not provide a standard accident report
forme
4-19
CHAPTER 5: SAFETY PRECAUTIONS AND EMERGENCY
RESPONSE PROGRAM
GENERAL
PREVENTION OF INFECTION
PROTECTION AGAINST MECHANICAL AND PHYSICAL HAZARDS
PROTECTION AGAINST ELECTRICAL HAZARDS
PROTECTION AGAINST CHLORINE HAZARDS
PROTECTION AGAINST OTHER GAS AND EXPLOSIVE HAZARDS
PRECAUTIONS DURING CHEMICAL HANDLING
SLUDGE DIGESTION HAZARDS
FIRST AID EQUIPMENT
FIRE -FIGHTING EQUIPMENT
ACCIDENT REPORTS
SAFETY EQUIPMENT FOR THE PLANT
RECOMMENDED REFERENCE MATERIAL ON SAFETY
EMERGENCY RESPONSE PROGRAM
General
General Response Pattern to Emergencies
EMERGENCY TELEPHONE NUMBERS
EMERGENCY EQUIPMENT INVENTORY
TREATMENT SYSTEM RECORDS
COORDINATING INSTRUCTIONS FOR POLICE AND FIRE
DEPARTMENTS
Police Department Checklist
Fire Department Checklist
NOTES AND ADDENDA
5- 1
PAGE NO.
5- 3
5- 3
5- 4
5- 6
5- 6
5- 9
5-10
5-12
5-13
5-14
5-14
5-14
5-16
5-17
5-17
5-30
5-32
5-32
5-32
5-32
5-37
5-37
5-38
5- 2
LIST OF TABLES
PAGE NO.
Table
5 ® 1
COMMON DANGEROUS GASES ENCOUNTERED IN
SEWERS AND AT WASTEWATER TREATMENT PLANTS
5®11
5 ® 2
SUGGESTED ACCIDENT REPORT FORM
5-15
5 m 3
EMERGENCY PROCEDURES FOR FLOW METERING
5®18
SYSTEMS
5 m 4
EMERGENCY PROCEDURES FOR CONTROL
5®20
SYSTEMS
5 ® 5
EMERGENCY PROCEDURES FOR CHLORINATION
5®23
SYSTEM
5 m 6
EMERGENCY PROCEDURES FOR ELECTRICAL
5®26
SYSTEM
5 ® 7
LIST OF EMERGENCY TELEPHONE NUMBERS
5-33
5- 2
GENERAL
The operation of wastewater treatment plants can be a
dangerous occupation if proper safety procedures are not
followed. Physical injuries and body infections are continuous
threats. Explosions and asphyxiation from gases or oxygen
deficiency are constant hazards. The injury rate of wastewater
collection and treatment personnel is relatively high compared to
other industrial groupings.
Safety measures for operation and maintenance of wastewater
treatment plants are effective if hazards are known and if proper
safety precautions are followed. Personnel should be aware of
hazards, preventive measures and emergency procedures. Any
accidents or injuries which occur should be immediately
investigated and recorded. Safety meetings, formal or informal,
should be held on a regular basis, and safety equipment must be
maintained and tested routinely. It is desirable that all
employees become safety -conscious and develop a personal concern
in preventing accidents at their plant.
The telephone numbers of several physicians, the nearest
hospital, the police and fire stations, and one or more ambulance
service should be prominently posted at each plant telephone.
Telephone numbers of the chlorine equipment manufacturer and the
chlorine supplier should also be posted for ready reference in
the event of a chlorine emergency.
The hazards commonly associated with a wastewater treatment
plant may be classified into the following broad categories:
1. Bacterial and viral infection.
2. Mechanical and physical hazards.
3. Electrical hazards.
4. Chlorine hazards.
5. Other gas and explosive hazards.
PREVENTION OF INFECTION
Constant caution is necessary to prevent infection by the
bacterial and viruses present in wastewater. Workers are
continually exposed to such water -borne diseases as typhoid
fever, amoebic dysentery and infectious hepatitis. Tetanus and
skin diseases must also be guarded against. The local health
department should be requested to notify plant personnel when
cases of water -borne diseases are encountered.
5- 3
Some of the more basic, if not obvious, rules of safety are
as follows:
1. Personal cleanliness cannot be stressed too strongly.
Personnel must make a habit of frequently and thoroughly washing
with soap and hot water, especially before meals and before
leaving the plant.
2. Wastewater and sludge on hands contaminates doorknobs and
fixtures. Dirty clothing or careless washing of hands may spread
infection beyond the wastewater plant area.
3. Emergency first aid must be promptly given to all minor
cuts and injuries. A two (20) per cent tincture of iodine or
tincture of methiolate solution should be immediately applied to
any wound or cut. Major injuries must be treated by a physician
at once. As many of the personnel as possible should have Red
Cross first aid training.
4. Rubber gloves should be worn when handling sludge,
wastewater or similar materials. Special precautions should be
taken to prevent wastewater from coming in contact with open cuts
or other injuries. Fingers must be kept out of the nose, mouth
and eyes at all times.
5. Drinking water from any source other than regular drinking
fountains must be prohibited. Hands should be thoroughly washed
before using the drinking fountains.
6. Personnel should have typhoid and tetanus innoculations
followed by booster shots at the appropriate intervals.
7. There should be no smoking in sewers or in other areas
in the vicinity of wastewater or sludge. It is impossible to
avoid contamination of the ends of pipes, cigars or cigarettes.
PROTECTION AGAINST MECHANICAL AND PHYSICAL HAZARDS
1. Care must be taken when repairing or performing
maintenance on automatic or remote-controlled equipment to ensure
that power is shutoff so that equipment cannot be started. Power
should be shutoff at the system control center or lighting panel
as appropriate and the breaker marked with a red tag. The red
tag should read: "WORKMAN IS WORKING ON LINE° and be signed by
the workman.. The tag should be removed only by the person whose
name is on the tag.
2. Insofar as practical, lubrication or adjustments
should not be made on machinery in operation. If such services
must be performed on operating machinery, a second man must be
present and stationed at the control switch.
5- 4
3. Belt and shaft guards must be kept in place.
4. Floors and stairways must be kept clean, dry and free
of grease, oil and ice to prevent slipping.
5. Tools must be picked up and manhole covers or hatch
covers kept closed. If it is necessary for openings to be
uncovered, they must be protected with guards and warning
signals.
6. Cleaning fluids with flash points below 100 deg. F
should not be used.
7. Hard hats should be worn by personnel working in areas
where tools or other heavy items may be dropped from above.
8. One of the most common injuries results from the improper
lifting of objects. All personnel should become familiar with
correct lifting techniques. Portable hoists and power equipment
should be used wherever possible.
9. Life preservers with throw lines should be attached
to railings around open tanks.
10. Tools to be used in an empty tank should be lowered in
a pail on a rope and removed in the same way.
11. While washing floors, all personnel should wear rubber
boots with good, treaded soles and heels.
12. When an extension ladder is used to enter an empty tank,
the ladder should be lashed to a handrail.
13. Clothes must not be hung on electrical disconnect
handles, light switches or control panel knobs.
14. A safety belt with a short rope and safety snap should
be used by personnel when leaning out through the railings over
any tank.
15. Fire prevention is an important part of every safety
program. Flammable materials should be kept in approved safety
cans. Oily rags should be stored outdoors in a covered bin.
16. Permanent warning signs should be placed at all
hazardous locations and should be supplemented by temporary signs
during emergency operation.
17. Sharp projections or locations of low headroom
should be padded and identified by being either marked clearly or
painted with a contrasting color.
5® 5
18. Employees working in noisy areas for prolonged
periods should wear ear -protecting devices, e.g. ear muffs or
plugs.
PROTECTION AGAINST ELECTRICAL HAZARDS
1. Only electrical tools and lights having three wire
grounded extension cords should be used.
2. Major electrical maintenance and repairs should be
performed only by licensed, qualified electricians.
3. Operators should become familiar with the types of
electrical accidents, how to administer first aid and artificial
respiration, and how to rescue another person without endangering
themselves. Examples of electrical accidents are, electrical
shock and burns from electrical fires.
4. Rubber mats should be placed on the floors in front of
control panels when work is being done on this equipment.
5. When work is to be done on equipment controlled by
a switch located at some distance from the equipment, the switch
should be tagged with a red card to prevent others from closing
the circuit.
6. Consider all electrical circuits to be dangerous.
Contact with even low voltage wiring has caused workmen to fall
from ladders and scaffolds.
7. Treat dead circuits as though they were alive; an
accident can result from the negligent closure of the circuit by
another person.
PROTECTION AGAINST CHLORINE HAZARDS
Chlorine gas is an extremely active chemical which is very
toxic and corrosive in moist atmospheres. As a result, the
handling of chlorine must be performed in an intelligent and
cautious manner. The following suggested rules will help to
prevent accidents or, if an accident occurs, to minimize the
damage:
1. At least one employee should be fully informed
concerning the safe handling of chlorine and the repairing of
leaks, and should be responsible for proper handling of chlorine
cylinders, for maintenance of chlorination equipment, and for
inspection and care of the self-contained breathing apparatus.
All other employees should be instructed in the principles of
safe handling of chlorine and procedures to follow in case of an
emergency.
5- 6
2. Do not drop chlorine cylinders or allow them to
strike against each other, as damage may result to the fusible
plugs or other parts of the cylinder and allow chlorine gas to
escape.
3. Do not heat or store chlorine cylinders where the
temperature might exceed 125 deg. F (such as adjacent to steam
lines), as the fusible plug will soften or melt and allow the
chlorine within the container to discharge to the atmosphere.
4. Chlorine gas, as drawn from a cylinder, is dry and
non -corrosive to metals. In combination with moisture, however,
chlorine will attack all but the noble metals and a few other
materials. Liquid chlorine will attack both hard and soft
rubber. Chlorine in the atmosphere, even in small amounts, is
particularly damaging to metal objects and electrical equipment.
5. Connections between the manifold and chlorine
cylinders should be carefully inspected at regular intervals and
should be replaced promptly when defects are found.
6. The flexible connections between the chlorine
cylinders and the manifold should be replaced yearly.
Deterioration on the inside of these pipes can be extensive and
may not be readily noticed. Any small pinhold will increase in
size very rapidly.
7. Plastic -coated gloves should be worn by personnel
changing cylinders.
8. When the chlorine cylinder is being connected to
the headers, it is important to eliminate bending stresses at the
end of unions of the flexible tube connectors.
9. When piping on cylinders is connected, or when it
is necessary to break a connection and recouple it, a new lead or
fiber washer (gasket) must be used.
10. Never connect a full cylinder to a header with
other cylinders until the temperature of all cylinders are
approximately the same. Chlorine would tend to flow from the
warmer to the cooler cylinder and cause it to overfill. Bursting
pressures could be developed as the temperature of the cool,
overfilled cylinder increases.
11. Keep the valve -protection caps on cylinders except
when cylinders are in use.
12. Close the valve on a cylinder as soon as it is empty
and replace the protective caps.
5- 7
13. All lines used for chlorine must be perfectly dry;
all oil and grease must be thoroughly removed by means of
trichloroethylene rather than water.
14. After full chlorine cylinders have been installed,
all joints must be checked for leaks.
15. Do not start up a chlorinator or turn on a cylinder
unless a self-contained breathing apparatus is on hand in the
chlorine room area.
16. The slightest leaks of chlorine gas must be given
immediate attention. Leaks may be located by passing an un -
stoppered bottle of strong ammonia solution along pipelines and
fittings. If chlorine leaks are present, white fumes will appear
at the mouth of the bottle. (The ammonia solution should not be
allowed to enter any fittings).
17. Inaccessible locations may be conveniently leakchecked
by tying a cloth saturated with ammonia solution to the end of a
long pole.
18. An uncapped bottle of ammonia left on the floor
of a chlorine area permits the detection of a leak without
entering the room.
19. Chlorine valves should be opened only one turn so
that they may be closed quickly in case of emergency.
20. Self-contained breathing apparatus must be used if
personnel must enter the chlorine room to repair a leak. The
breathing apparatus should not be stored in an area likely to be
affected by chlorine leak.
21. Emergency repair Kit "A" for cylinders should be
provided. Drills should be held at frequent intervals to review
the use of the kit and the emergency procedures to be followed in
the event of a leak.
22. Local Fire and Police Departments should be
instructed in emergency procedures and should participate in the
drills at the plant.
23. When a leak is detected, the emergency procedures
should include the following:
(a) Designated employees should use the self-contained
breathing apparatus and investigate the source and severity
of the leak, locating the point of leakage with ammonia as
previously described.
OM
(b) Notify the Police and Fire Departments of the emergency.
(c) Notify the office or plant of the chlorine supplier
and request the assistance of emergency personnel.
(d) Never put water on a leak, as water will always make
the situation worse.
(e) If the leak is downstream of the valve on the
container, turn off that valve before repairing the leak.
24. One person should never work on a leak alone.
Someone should always observe him and be equipped to go to his
aid if necessary.
25. Never be ashamed to call for help in a chlorine
emergency.
PROTECTION AGAINST OTHER GAS AND EXPLOSIVE HAZARDS
Normal air contains about 21 per cent oxygen by volume. Any
atmosphere containing less than 13 per cent oxygen is dangerous
to human beings and is termed oxygen deficient. Such a situation
may occur in any confined space if another gas displays the
oxygen.
Noxious and toxic gases or vapors may also exist in enclosed
areas. The following are some of the more common hazardous
situations found in treatment plants.
1. Gas emitted by wastewater or sludge is explosive when
mixed with certain proportions of air, can be asphyxiating, and
is sometimes toxic. Methane is the main constituent of such gas
mixtures and accounts for 60 to 70 per cent of their volume. It
is odorless and colorless and cannot be detected without testing
equip- ment. Manholes, wet wells and other enclosed or poorly
ventilated spaces should not be entered for inspection or repairs
until their atmosphere has been tested for flammable gas
mixtures, for oxygen deficiency and for hydrogen sulfide. If any
doubt exists about the quality of air in a confined space,
positive ventilation or self-contained breathing apparatus
should be used. A second man should always be present in case of
trouble.
2. Hydrogen sulfide has an odor similar to rotten eggs
and can be easily detected by smell in small concentrations.
However, in strong concentrations, it causes impairment or
temporary loss of the sense of smell and may cause suffocation
before one realizes what is happening. Manholes, wet wells and
other poorly ventilated spaces should not be entered if a
hydrogen -sulfide reading obtained by a detector is in excess of
0.005 per cent.
5- 9
3. Gasoline and other flammable and volatile substances
find their way into the system from time to time. Such materials
pose a serious fire and/or explosion hazard in wet wells or
wherever there is an open surface of wastewater. Smoking or open
flames should be absolutely prohibited in such areas, and only
explosion -proof lights or flashlights should be permitted. Tools
should be of'the non -sparking type.
4. Materials releasing toxic gases may also enter the
system occasionally and could cause personnel hazards in the
previously mentioned areas. Personnel should be alert to such
danger and be sure that an area is purged of all foreign gases
before entering. If irritation of the eyes, nose or throat is
experienced, personnel should leave immediately.
5. The first workman to enter a confined area should wear a
safety belt and be witnessed by two men of ample strength to pull
him to safety if necessary. A good rule to observe around
treatment plants is never to go alone into a tank or other
hazardous location. Someone should be present who can observe
the worker's condition and who is equipped to give all necessary
assistance in case of emergency.
6. Smoking should be prohibited near hazardous areas
such as manholes, wet wells or the sludge digestion tanks.
7. Responsible personnel should be familiar with the care
and use of the self-contained breathing apparatus. This
equipment should be stored in a readily available location, but
one which is appropriately remote from potential sources of toxic
gases.
8. Painting in confined areas should be undertaken only
with proper ventilation.
Table 5- 1 summarizes the properties of, and the tests for,
the more common dangerous gases encountered in sewers and at
wastewater treatment plants.
PRECAUTIONS DURING CHEMICAL HANDLING
Reasonable care should be exercised in the.handling and
preparation of the hydrated lime, ferric chloride, methanol
liquid polymer and hydrochloric acid used in the various plant
processes.
Hydrated lime, supplied in the dry form, is a fine white
powder, and results in an alkaline slurry when mixed with water.
It is recommended that plastic safety goggles, gauntlet gloves
and dust masks be worn when lime is being unloaded, stored or
mixed, to avoid contact with the eyes and hands and to prevent
inhalation of dust particles.
5-10
TABLE S-1. COMMON DANGEROUS GASES" ENCOUNTERED IN SEWERS AND AT SEWAGE TREATMENT PLANTSM
_.ger ..o.� .. .eeca. mrgrn.e ,.aa
2. Gars with • sprcifrw gravity kr Nun 1.0 ere lghter than ala; those mors thea 1.0 ere bevkr thaw sk.
1 The fiat nrthodgiven is the pnfcrabk leanrg Proccclum
4. One percent IQusls 14000 ppm (parts per -M- -
Erpbaiue
sp-i k
(% h
w
County
tseuty
wluwe .L)
prep�ty
lbyc6olcg;d r)frda
Lff'
afar. safe
J<Lx. wfi
N~
Chrwivf
of por
cl wity(2)
(prsn7a- Mbr
-we parorwt is .ir
(pv¢nto�ea
are perces a.L
Kon eomwoa
Simp4R era f
eheapeat wfearpoewe,
"-i..k
Q.h.w
r:pwwe,
---r--
Lox � f)ppw
ofN
forwuia
(.i- 1)
U.." twit
by wlueve)
by. -4-4)
a r- . u ares
avrrhod Wefry(7)
% by
%
of
aolr.ve()
8y wbwe(e
Oxygen
03
1.11
Not flammable
Colorless. odorka%
Normal kir contains
Oxygen depletion
Oxygen deficiency-
(in �)
tastclra. nos
20.975.( 0,, Man
from poor v<ntila-
ivdrcatar. -
poi.onous gaa.•Sup•
tolerates down to
tion and ab.orplioa
-
porta eombustioeL
1256. Below 55 to
or chemical
7% likely to be
corwmption of
fatxL
a "bla 03.
Gasoline
C, lf,i
7.0 to
1.5 7.0
Cobrlm odor
Anesthetic effects
Luka atonge
1. Combuv ibk San
0.4%.
0.10
vapor
0.0
noticeable in 0.07%.
when inhaled_
tanks, durhvges
indicator-
0.7
C
CeH�e
Flammable.
2.4714 n d fatal.
from garagea, and
2. Oxygen defiuene7
•
i
Explosive-
1.1 k to'237i
commndal or home
indicator for
dangerous for even
dry -doming
concentrations
"
short exposerm
operation.
over 0.71..
Carbon
CO
0.97
12.5 74.2
Colorless. odorka
He bbin of
xur
Manufaced
CO smd
poul,
0.06 0.01
monoxide
nonirritatiq,
bkwd hu strong
fuel p.a
.
tasteless,
affinity for Ira
Flammable.
causing oxygen
E:pb:va
star.sticeL 035 to
0.2 % cau cs
t000crcourvcs in
70 aninutea
-
Hydrogen
H,
0.07
4.0 74.2
Colorkea, odorkst
Acts rncdudcaffy
Manufactured
Combustible gas
taatesy now
u
to deprive tie of
fuel p.
indicator.
'
po6korwu , Fla®
oxygen. Does not
ruble. Expb:vc.
support &ft_ A
propagates flans
simple asordeol
t
rapidly: very
i
dargeroaL
'
Methane
CH.
0.55
S.0 1S.0
Cobrlcm. tadeleak
S¢ hydrogen.
Nat -I pa, marsh
1. Combua6ble Sm
- -
odorkas, now
pa manufactured
indrcalor.
poisonous. Flans
'fuel pti ars gas
2. Oxygen deficiency
'mabk. Expl..i
indicator.
,
Hydrogen
H,S
1.19
4.7 66.0
Rotten egg odor in.
Death in few
�rninutca
fu
Prtrokfumes
1.
1. H S ampoules
0.02 to. 10.002
-tricksmall
•
conccntntions
at 625.
From b Issv^g`
2: $' by
0.07
but icnsc of smc&
Pira ly"xn:
�$c�er gas:
, s
so do
� a¢Lt solution.
MP,.dh impaired:
rcepoxtary center"
Odor not evident at
�.,
high concentration.
-
c lorles. F16
moble: Exp&"'a,
raiaonous:
t
Carbon
co,
1.Si
Not flammable
Colnrknfil odorless.
10% cannot be
Lacs from
oxygen deficiency
6.0 to . OS
"xide
Nonflammable. Not
endured for more
nubonsecous strata.
indicator.
6.0
K7LJy present it
than a few minute
Sewer g
g
I'
vow
rugvow amounts
A ev onuns of.
unless there is
r-Parano.. _.
■kead'y a deficie"7
of oxygc&
i
Phu.6cm
N,
0.97
Not flammabk
Colorless. Wteka6
Scat hyd4o5e<
trues from some
Oxygen delioersq.
odorless. Now
rods strata"
indicator.
'
•
flammabk. Now
Sewer t -
poisonous. Principal
eonacewnt of ala
(about 795).
Etharn
C2H6
1.05
7.1 15.0
Cokrkas, taateka.
See hydrogen.
Natural gas:
,Combustible W.
odorki,non.
I
�aid'ru'i.6
'
pworou. Fla -
enable. Eaplo in.
Chlanne
CI,
2S
Not flammable
Greenish yellow
Respwolory britant;
Laking pipe
Odor. strong
0.0006
0.0001
Not expb:ve
aa• a amber color
�pud
irritating to eyes
conne ction
uiunoni. on -.h
•
under
and mucous maw
Oterdouge-
off white
pneurwe. Highly
bran. 70 ppm
F"m
fumes.
wntatisg a
cause couthm
pp��netratug odor.
40"60 ppm dangerous
tighlyaxroinn
i.70msnuts. LOW
'
in presence ofp
Mey b be
1
nrouwtre.
lapl in It- lrcath.
_.ger ..o.� .. .eeca. mrgrn.e ,.aa
2. Gars with • sprcifrw gravity kr Nun 1.0 ere lghter than ala; those mors thea 1.0 ere bevkr thaw sk.
1 The fiat nrthodgiven is the pnfcrabk leanrg Proccclum
4. One percent IQusls 14000 ppm (parts per -M- -
Ferric chloride solutions are strong acids and will cause
chemical burns to eyes and clothing and will attack and stain
concrete and most metals. Plastic safety goggles, plastic or
rubber aprons and plastic -covered canvas gloves are recommended
for use while liquid ferric chloride is being mixed or handled.
While the chemical will not normally harm the skin, it is
recommended that any spills be washed off immediately.
Precautions should be taken to avoid contact of polymer with
the skin surface. It is recommended that plastic safety goggles,
gauntlet gloves, and dust masks be worn when chemicals are being
unloaded, stored or mixed, to avoid contact with the eyes and
hands.
Precautions should be taken to avoid contact with the skin
when hydrochloric acid is being handled. Plastic safety goggles,
plastic or rubber aprons and plastic -covered canvas gloves are
recommended to avoid contact with the eyes and hands. Any spills
should be washed down immediately with ample amounts of water.
SLUDGE DIGESTION HAZARDS
Because of the highly combustible and explosive nature of
the gases associated with sludge digestion, special precautions
are absolutely necessary. The design of sludge digestion tanks
and gas control equipment includes pressure relief valves, flame
traps and other precautionary devices to minimize the possibility
of an explosive mixture of gases. In addition, all electric
motors, switches and lighting fixtures are explosionproof and no
substitute to this construction type should be allowed for any
reason in the future.
For reasons of safety, the gas system controls should be
given a high priority on maintenance scheduling. All gas piping
and appurtenances should be checked periodically for gas leaks by
use of a combustible gas detector. Leak checkpoints should
include piping joints, gas valve stems, drip trap ports, pressure
relief devices and flame traps. If the combustible gas detector
is not available for any reason, a soap solution may be brushed
over possible leak areas under pressure, so that leaks will be
detected by bubbling.
The odor of sludge gas cannot be depended upon to indicate
leaks. Serious leaks can exist even though the gas odor is not
strong.
The following precautions should be completely understood by
all operating personnel:
1. No smoking or use of any open flame within the control
Building or on digestion tank roofs should be permitted.
5-12
2. Only nonsparking tools should be used in a sludge
digestion area.
3. If exhaust fans in the Control Building are not running,
they should be operated manually when personnel enter the
building.
4. No use of ungrounded electrical tools can be allowed in
the restricted area.
While combustion may occur at lower concentrations, the
greatest hazard results when a mixture of air and sludge gas
produces 5 to 15 percent methane by volume. In this range, the
mixture is very explosive. Similarly, special precautions must
be observed during dewatering of digestion tanks to prevent the
formation of explosive mixtures.
Prior to personnel entering a digestion tank for inspection,
repair or cleaning, the following precautions should be taken:
1. A qualified individual should test the interior of the
tank for presence of any toxic, explosive, or oxygen -deficient
condition.
2. A mechanical means of fresh air circulation must be
provided and must be in operation at all times while men are in
the tank.
3. All electrical disconnects on gas -mixing equipment must
be locked out or tagged.
4. All piping leading into the tank from tanks for sludge
or gas transfer should be blanked off as well as valved off.
5. At least two men should be stationed at the entrance to
observe the men inside the tank and to render any other
assistance that may be required of them.
6. Personnel must be trained in the use of breathing
apparatus, safety equipment and first aid procedures.
7. Self-contained breathing equipment, safety harnesses and
a method of sounding an alarm should be located at the entrance.
8. After any break in the work, the tank atmosphere should
be retested.
FIRST AID EQUIPMENT
First aid kits should be provided throughout the treatment
plant. The cabinets and kits should be kept well supplied, neat,
5-13
clean and in order. Replacement items should be obtained before
the supply in the kit is exhausted, to ensure their availability
when needed.
Personnel should be familiar with first aid procedures. In
case of serious injuries, a doctor should be called or the
injured person removed to a hospital by ambulance.
FIRE FIGHTING EQUIPMENT
Plant personnel should know the exact locations of all
extinguishers and should be thoroughly familiar with their use.
The extinguishers should be checked periodically for operability
and changed as recommended by the local Fire Department.
ACCIDENT REPORTS
Any injury, however slight, must be reported to the
supervisor by means of a standard form. This procedure gives
some legal protection to both employee and employer. A suggested
accident report form is shown as Table 5 - 2. However, if the
insurance company has standard forms for this purpose, they
should be utilized.
After an accident has occurred, an injury investigation
(formal or informal) should be undertaken to determine the cause
of the injury and to take steps to prevent a recurrence. If
plant personnel are allowed to play a role in determining the
cause of injury, overall safety -consciousness is likely to
increase. Copies of accident reports should be made available to
all employees for their review, in the hope that they will adjust
their work habits to avoid similar injuries.
SAFETY EQUIPMENT FOR THE PLANT
It is recommended that the plant be equipped with the
following safety equipment:
1. One cotton -web safety belt, complete with 50 feet of 3/4
inch -rope.
2. One combustible gas indicator with carrying straps, 5
foot sampling tube and probe tubing.
3. One oxygen -deficiency indicator, complete with sampling
tube and carrying case.
4. One safety breathing apparatus which is a self-contained
unit of the type approved by the U.S. Bureau of Mines for use
for a minimum of 30 minutes severe service in hazardous areas.
5-14
Accident
TABLE 5-2. SUGGESTED ACCIDENT REPORT FORM 'classification,
Date of report Person reporting
Name and title of injured
Occupation Age Sex
a.m. on duty or visitor
Date of injury time p.m. off
Place of injury
Name of doctor, if seen
Administrant of first aid, if any
Description of accident:
Type of injury: Fatal Permanent Temporary Nondisabling
What did injured person do to cause accident?
Was injured acting in regular line of duty?
What other persons were involved?
What did these persons do to contribute to the acci at?
Did defective equipment or unsafe• condition contrib = to accident?
How?
Other persons who witnessed accident
Corrective action taken:
What steps have been taken to prevent future accide s?
Recommendations
Cost of accident: $
Cost. of accident computation (to be filled in on 'ad-iistration
copy
Compensation $
Medical $
Public liability $
Property loss $
Time off job $
Other $
Total cost _ $
(to be filled in above
5. First aid cabinets complete with contents and 10 pound
carbon dioxide, hand -type fire extinguishers should be purchased
and located in each of the following areas:
(a) Scavenger Waste Receiving Station
(b) The Plant Administration Building
(c) The Sludge Digestion Tank Area
6. Life preservers with throw lines should be attached to
railings around open tanks.
7. Emergency repair Kit "A" for chlorine leaks.
RECOMMENDED REFERENCED MATERIAL ON SAFETY
Water Pollution Control Federation:
Publication No. 1
Publication No. 4
Publication No. 11
Publication No. 13
Publication No. 14
Packet
Safety in Wastewater Works
Chlorination of Wastewater and
Industrial Wastes
Operation of Wastewater
Treatment Plants
Wastewater Treatment Plant
Operation Training Course One
Wastewater Treatment Plant
Operator Training Course Two
How to Promote Safety in Water
Pollution Control Operation
State of New York, Health Education Service: `
Manual of Instruction for Sewage Treatment Plant
Operators
Chlorine Institute:
Chlorine Manual
Solvay Technical and Engineering Services:
Liquid Chlorine, Bulletin 7
Ontario Water Resources Commission:
Safety Regulations for Plant Operators
5-16
EMERGENCY RESPONSE PROGRAM
General
The USEPA Construction Grants Program requires that the
grantee provide an emergency operating and response program in
accordance with Section 35.935 of 40 code of Federal Regulations,
Part 35.
This Chapter of the manual contains emergency procedure
guides (See Tables 5- 3 through 5- 6) for a variety of possible
emergency conditions which could occur during the treatment of
wastewater and the production, handling and disposal of the
solids accumulated during the wastewater treatment process.
The procedures discussed in the emergency procedure guides
are part of a response plan for ensuring the effective continued
operation of the wastewater treatment system under emergency
conditions imposed by catastrophe, failure of process or
equipment, or unavoidable shutdown of components, and the guides
suggest methods for responding to various types of disasters.
Effective emergency planning requires considerable coordination
and fore -thought by the operating staff; therefore, these guides
are meant to idenify the major considerations in each type of
emergency. Detailed plans should be worked out by the operating
staff who can best assess their own capabilities for dealing with
emergencies and who have fuller knowledge of emergency resources
available in the area.
The USEPA has developed two manuals entitled, "Emergency
Operating Procedures for Municipal Wastewater Treatment
Facilities" and "Emergency Response Programs for Municipal
Wastewater Treatment Facilities, State -Local Aspects", both under
Contract No. 68-01-0341 to assist in the preparation of local
emergency plans. Another EPA report entitled, "Design Criteria
for Mechanical, Electrical and Fluid System and Component
Reliability", under Contract No. 68-01-0001, also contains
information related to emergency planning.
It is necessary for the operator to have an idea of what his
procedures should be in the event of an emergency. Emergency
conditions are of varying degrees of seriousness. In any event,
the operator should be concerned with:
1. Safety of personnel both within the plant and in the
surrounding area.
2. The safety equipment within the plant area.
3. Continuation of the plant functioning to assure proper
treatment of wastewater.
5-17
EMERGENCY SITUATION TYPE/LOCATION
1. Power Failure a. General Area
2. Act of God
3. Fire and/or
Explosion
TABLE 5 - 3
EMERGENCY PROCEDURES FOR FLOW METERING SYSTEMS
b. Treatment plant
a. Flood
b.. Hurricane
c. Earthquake
d. Windstorm
a. In plant
EQUIPMENT REACTION
No change in operation if
emergency generator functioning
properly. May experience slight
blip on charts.
Same as 1 a..
Equipment will function
normally until electrical
service is interrupted or
equipment is damaged.
Same as 2 a.
b. In instrument con- Same as 2 a-.
trol cubicle or
individual enclosure.
STAFF RESPONSIBILITY
None.
May have to readjust time arcs on
charts if generator fails to start
or cuts out before electrical
service is restored.
Assess condition of equipment
after emergency is over. Call
manufacturer's representative
to have equipment repaired,
recalibrated and returned to
service.
Call Fire Department and Medical
Services. Alert Supervisor. -
Continue as per 2 a.
Call Fire Department and Medical
Services. Alert Supervisor -
This will be an electrical fire,
if attempting to extinguish fire,
use CO2 or dry chemical only. Do
not use watet or liquid. Proceed
as specified in Z a.
EMERGENCY SITUATION TYPE/LOCATION
4. Equipment Failure a. Transmitters
b. Recorder
c. Totalizer
TABLE 5 - 3 (CONT'D)
EMERGENCY PROCEDURES FOR FLOW METERING SYSTEMS
EQUIPMENT REACTION
Indicating recorder - incorrect
reading or "Dead".
Same as 4 a..
Recorder functions normally.
Totalizer fails to count.
STAFF RESPONSIBILITY
Check power to transmitter; should
be 1.20 volts, 60 Hertz. Attach
mercury manometer to test head
connections, calculate flow from
calibration curves supplied with
flow tubes. If calibration equipment
not available, call manufacturer's
service representative. "
Verify correct operation of transmitter
as in 4 a. Check power supply•to
recorder; shoul& be 120 volts,
60 Hertz. If above, check okay. Call
manufacturer's service representative.
Call manufacturer's service represent-
ative.
-EMERGENCY SITUATION
1. Power Failure
2. Act of God
3. Fire and/.or
Explosion
TABLE 5 - 4
EMERGENCY PROCEDURES FOR CONTROL SYSTEMS
TYPE/LOCATION
EQUIPMENT REACTION
STAFF RESPONSIBILITY
a. General Area
Emergency generator should start
Essential equipment as listed in
automatically and return all
specifications should -be
essential. equipment to operational
physically checked to verify operation.
status.
b. Treatment plant
Same as 1 a.
Same as 1 a.
c. False alarm
None.,
Advise Supervisor -determine, and
if possible, correct the cause of
the false alarm.
a. Flood
b. Hurricane
1. Wet -well level and waste
In most c#"s, there should be
c. Earthquake
pump control system will
sufficient #dvance warning to
d. Windstorm
function normally as long
provide fora routine shutdown of
as instrument air and
the facility if such is warranted.
electricity is available
Following the emergency, assess
and equipment is not damaged.
condition of the.equipment. Where
equipment damage has been sudtained
2. Compressed air system will
or or suspected, and/or accuracy is
function normally as long as
questionable, call the manufacturer's
electricity is available and
service representative to have
equipment is not -damaged.
equipment repaired, recalibrated and
returned to service.
a. In plant
Generally speaking, the equipment
Advise Supervisor - call Fire
will function normally until air-
Department and Medical Service..
supply or electrical service is
Should an attempt be made to
interrupted or equipment is
extinguish a localized fire on
damaged.
instrument equipment, use a CO2 or
dry chemical extinguisher only - Do
not use water unless electrical
power has been disconnected..
a
EMERGENCY SITUATION
TABLE S - 4 (CONT'D)
EMERGENCY PROCEDURES FOR CONTROL SYSTEMS
TYPE/LOCATION EQUIPMENT REACTION
b. Air compressors Wet -well level will cease to
function when air pressure
drops below 2 psig. Wastewater
pumps will cease to operate on
automatic, but can be operated
on manual at the -plant. For the
pumping station redundant on/off
operation is initiated if the rest-
of
estof the system is not damaged.
c. Pump controls Wet -well level control will drop
off if signal line to pump control
cabinets has been damaged, thus,_
automatic speed control will
cease to function if wiring
damaged. Pumps may cease to
function depending on damage
to electrical equipment.
d. Instrument control
cubicle
4. Equipment Failure a. Wet -well level
transmitter
STAFF RESPONSIBILITY
After emergency is over, assess.
damage and call manufacturer's
representative.
.11
3 a. applies, also the following.
If damage has been confined to control
cabinets but pump motors are service-
able, -the local electrical utility
or a local electrical contractor may
be able to wire pump motors direct
through a switch and rheostat to
provide temporary manual control.
Wet -well level indication and Call manufacturer's service represent -
wastewater pumps on/off and speed ative.
control will fail.
Indicated wet -well level will not
follow actual level. Pump
operation may become erratic.
Level indication may go to'O or
100 -per cent.
Make sure bubble tubes are clear; if so
check air supply to tranmitter; must be
minimum of 18 psi. Place wastewater
pumps on manual and remove transmitter
from cubicle. Following manufacturer's
0&M Instructions, repair transmitter
if possible, if not, call service
representative. <
TABLE 5 - 4 (CONT'D)
EMERGENCY PROCEDURES FOR CONTROL SYSTEMS
EMERGENCY SITUATION TYPE/LOCATION EQUIPMENT REACTION
STAFF RESPONSIBILITY
b. Level controller Level indication will not be
Place wastewater pumps on manual
affected and pump on/off
control. Local attempt to repair
sequencing will not be affected.
controller is not recommended -
Pump speed control will be erratic
call manufacturer's service
or cease functioning.
representative.
c. Pressure switch Equipment operates out of sequence
Change pump sequence so that mal -
or fails to function, i.e., pump
functioning control is on standby.
fails to start or stop on level
Place all pumps on manual control
changes.
and replace defective switch
if new one is available.
Place pumps back on automatic after
d. Pump speed control Pump speed fails to respond to
repairs are completed.
level changes on automatic or
Change pump sequence so that mal -
manual.
functioning controls is•on standby --
position and deenergize
electrically. Call manufacturer's
r
service representative.
z
MWENCY SITUATION
Power Failure
Act of God
TABLE 5 - 5
.EMERGENCY PROCEDURES FOR CHLORINATION SYSTEM
TYPE/LOCATION EQUIPMENT REACTION
a. General Area Automatic startup of emergency
generator set. On power failure,
to operate:
blip on charts.
b. Treatment plant
c. False alarm
a. Flood
b." Hurricane
c. Earthquake
d. Windstorm
Same as 1 a.
None
Chlorine equipment will continue
.to function until failure of
either electrical service,
water supply or solution piping
damage, initiates automatic
shutdown.
STAFF RESPONSIBILITY
1. Check operation of .emergency
generator set.
2. Check operation of chlorina-
tion equipment.
3. If chlorination system fails
to operate, shut chlorine gas-""
valves on cylinders until'
cause of restart failure - has
been determined.
Same as La.
Advise supervisor and/or note
in operations log book, determine
and correct cause of false alarm..,
in plant.
In most cases, there should be
sufficient advance warning to
permit a routing shutdown'of the
system as outlined in the
preceding Tables. Chlorine gas
valves on cylinders should be
shutoff any time system is
shutdown either automatically or
manually, and remain closed until
the system is ready for startup.
TABLE 5 - 5 ( CONV D )
EMERGENCY PROCEDURES FOR CHLORINATION SYSTEM
EMERGENCY SITUATION
TYPE/LOCATION
EQUIPMENT REACTION
STAFF RESPONSIBILITY
3.- Fire -and/or
Explosion
a. In plant, but remote
Equipment will function normally
Assess situation, call Fire and
from chlorine area.
until either damage or
Medical Services, shutdown
interruption of utilities
chlorination system, shut chlorine
initiates automatic shutdown.
supply valves on cylinders,
disconnect cylinders from mani-
fold, install safety cap and remove
from building if possible.
b. Chlorine area
Same as 3 a.'
Assess situation, call Fire and
Medical Services, alerting both
to the possibility of chlorine
leakage. -Using approved chlorine
respirator, shutoff gas supply
valves on cylinders, if possible.
4. Freezing
a. Solution piping -
Equipment will automatically shut.
Assess situation, consider possi-
either blockage or
down chlorine feed as result of
bilities of selecting alternate
rupture,
vaccum loss.
chlorination point to achieve
required treatment, correct '
problem and return to service.
5. Ruptures and
a. Solution piping
Same as 4 a.
Same as 4 a.
Stoppages
TABLE 5 - 5 (CONT'D)
EMERGENCY PROCEDURES FOR CHLORINATION SYSTEM
EMERGENCY SITUATION TYPE/LOCATION
EQUIPMENT REACTION
STAFF RESPONSIBILITY
b. Chlorine gas supply
Equipment will continue to function
Avise supervisor, have other staff
piping or cylinders
as long as gas supply pressure
members or medical team standby.
is 30 psi or above. Leak will.be
Then, using approved respirator,
detected by: (1) leak detector;
enter area and using ammonia, locate
(2) odor; (3) visual (green haze
source of leak. If leak is in
in chlorine area); and (4)
piping, shutoff ga'ss supply.valve
increased rate of change on weigh
on cylinders, then repair or replace
scales.
defective pipe.
If leak involves cylinders (either
valve failure or cylinder rupture)
Close supply valve, disconnect
cylinder, install safety cap, remove
from'chlorine room and relocate
to an isolated -area where if will
do the least harm, rotate tank so that
gas escapes rather than liquid chlori)
and call supplier for emergency
assistance.
4. Equipment Failure a. Chlorinator
Loss of chlorine feed rate and/or
Make necessary valves changes and
components failure.
loss of vaccum indication.
place alternate chlorinator in
service. Advtse supervisor, call
manufacturer's service representative
or, if qualified, repair chlorinator.
EMERGENCY SITUATION
1. Power Failure
2. Act of God
TABLE 5 - 6
EMERGENCY PROCEDURES FOR ELECTRICAL SYSTEM
TYPE/LOCATION EQUIPMENT REACTION
a. General Area All electrical equipment in plant
will shutdown temporarily.
Essential loads will restart upon
automatic transfer to the standby
power source (engine -generator).
b. Treatment plant Same as 1 a.
c. Individual circuit Equipment on individual circuit
will shutdown - operation of
all other equipment will be
normal.
a. Flood Flooding will cause failure of
all electrical equipment involved,
with the possible exception of
that in watertight enclosures.
STAFF RESPONSIBILITY
Advise plant Supervisor.
After normal power has been restored
and essential loads have been
automatically retransferred to normal
power, restart loads which do not
restart automatically.
Same as 1 a.
Advise plant Supervisor.
Determine cause of power failure and
correct, following procedures outlined
in Electrical Systems Chapter.
I
Shutdown all electrical circuits to
areas in imminent danger of being
flooded to protect equipment and avoid
hazards to'personnel.
After flooding condition has passed,
all electrical equipment in the flooded
area should be cleaned, thoroughly dried
-out, and properly tested before being
energized. This work should be
performed by personnel who are
thoroughly experienced in repairing
and testing electrical equipment which
has been subjected to flood damage.
V
EMERGENCY SITUATION
3.- Fire and/or
Explosion
TABLE 5 - 6 (CONY D)
EMERGENCY PROCEDURES FOR ELECTRICAL SYSTEM
TYPE/LOCATION
EQUIPMENT REACTION
c. Hurricane
}
Most likely damage is to incoming
}
power lines, with consequent
d. Windstorm
}
loss of power.
(See Power Failure).
e. Earthquake
Probably no electrical damage
unless very severe.
Most likely damage in severe
earthquake would be electrical
overloads caused by mechanical
damage to rotating machinery,
and by short-circuits caused
by the failure and collapse of
structures.
a. In treatment plant Equipment will continue to
operate normally except for
portions of electrical system
which may have been damaged.
STAFF RESPONSIBILITY
See Power Failure, 1 and 2.
All electrical circuits should be de -
energized as quickly as possible by
opening the circuit breaker on the
standby engine -generator control panel.
This will help to minimize damage to
equipment, hazards to personnel
and the danger of fire.
After cessation.of earthquake, inspect
all electrical equipment, electrically
driven equipment, cables and ductwork
for physical damage before energizing
any electrical circuits.
Advise'plant Supervisor and Fire
Department.
Shutdown all electrical circuits to
the area involved in the fire or
explosion to minimize hazards to
personnel and spread of fire.
After the emergency has passed, all
electrical equipment and cables in,the
affected area should be inspected for
damage before restoring electrical power.'
EMERGENCY SITUATION TYPE/LOCATION
b. In electrical
equipment.
4. Equipment Failure a. Motors
b. Control devices
TABLE 5 - 6 (CONY D)
EMERGENCY PROCEDURES FOR ELECTRICAL SYSTEM
EQUIPMENT REACTION
Extensive damage to the
equipment will result unless
it is de -energized immediately.
Motor stops, overheats or
repeatedly trips circuit breaker.
Equipment stops, fails to start
or operates improperly.
STAFF RESPONSIBILITY
De -energize affected equipment at 'once.
Advise plant Supervisor and Fire
Department.
Shut down all electrical circuits to th
area in which the fire has_
as occurred, in
order to minimize hazards to personnel
and damage to other equipment.
Shut down equipment and notify plant
Supervisor.
Try to determine cause of failure as
outlined in -Electrical Power and
Lighting Systems, Chapter 15.
If unable to determine the cause of
failure, call an electrician.
Shut down equipment and notify plant
Supervisor.
Try to determine cause of malfunction,
as outlined in Electrical Power and
Lighting Systems, Chapter,15.
TABLE 5 - 6 (CONT'D)
EMERGENCY PROCEDURES,FOR ELECTRICAL SYSTEM
EMERGENCY SITUATION TYPE/LOCATION EQUIPMENT REACTION
c. Motor control center Same as 2., except caused by
equipment device in motor control center
(starter, relay, switch or
circuit breaker),.
_d. Wiring Wiring -overheats or short-
circuits (generally due
to severe overload or
physical damage).
STAFF RESPONSIBILITY
Same as 2. '
Shut down affected circuit
immediately, notify'plant Supervisor
and call an electrician.
Try to determine cause of overload or
location of. short-circuit.
If circuit supplies vital equipment,
have electrician disconnect both ends
of damaged cable and connect a temporar,
cable in its place while'lrepairs are
in progress.
General Response Pattern to Emergencies
There is a logical sequence of steps in responding to
emergencies which should be followed by the operator on duty.
This sequence includes identifying the emergency, investigating
the extent of the emergency, deciding on the proper initial
course of action, taking corrective action to rectify the
situation, and following up with a post -emergency investigation.
Identify Emergency: This step is obvious in most cases and
is essentially that of becoming aware that an emergency exists.
Equipment breakdowns, power failures, injuries and natural
disasters are usually rather dramatic and will capture the
operator's attention immediately upon occurrence. In other
cases, the operator may have prior warning of an impending
emergency through weather reports in the case of natural
disasters, and trends in equipment performance in the case of
breakdown, etc.
Some emergency situations exist long before the operator is
aware that an emergency exists. These cases usually produce
larger disasters which then become immediate and obvious.
Unattended equipment may have minor breakdowns which go
unnoticed; further operation may then lead to complete
destruction of the equipment with possible injury to the unwary
bystander.
Initial Investigation® Once the operator is aware that
an emergency situation exists or that a disaster is impending, an
immediate initial investigation should be made. This step is
undertaken to assess the severity of the situation and collect
enough information to make an initial action decision.
Assessment of the emergency should include identifying
obvious injured persons (if any), damage to buildings and
equipment, noting possible impending damage which could occur if
corrective action is not taken immediately, and itemizing
resources immediately required to correct the situation.
Initial Action: Once the extent of emergency is known,
the operator should make an immediate decision as to what initial
steps should be taken to correct the emergency situation. This
first action, in the case of large scale emergencies, usually
consists of notifying responsible authorities and/or calling for
the necessary assistance in order of priority.
After the necessary calls have been made, the operator
should begin action on his own to remedy matters but within
limitations. The operator should not unduly endanger himself or
others by attempting tasks for which the proper equipment is not
available or with which he is unfamiliar. Injury cases are the
5-30
best example. If the operator is not familiar with first aid
techniques, he should do little more for an injured person than
to keep him out of further danger. Moving a patient
unnecessarily or attempting first aid when not absolutely needed
may cause further, lasting injury to the patient.
In all cases, if in doubt, wait until qualified help arrives
before taking action.
Corrective Action: When help arrives, the operator should
immediately inform those called of the pertinent details of the
situation. If the type of emergency is beyond his own
capabilities, the operator should also immediately appoint the
proper person to supervise corrective action. While work is
underway, the operator should find time to notify persons not
called initially, but who have interests at stake in the
emergency.
Corrective action should be continued until the situation is
either under control or completely rectified. If correction will
take considerable time, the operator should consult with the
required parties to outline a long-term effort to complete the
task.
Follow -Through: After the situation is corrected, the
operator should make every effort to determine why the emergency
occurred, review the corrective action taken and then take
preventive action to minimize the chance of recurrence.
In the case of equipment failure, if negligence was not a
factor, then revising maintenance procedures would be the most
likely first preventive step. For natural disasters which cannot
be prevented from recurring, the procedures followed in dealing
with them can be reviewed to develop more effective action plans.
NOTE: IN ALL EMERGENCIES, THE STATE REGULATORY
AGENCY AND THE FEDERAL ENVIRONMENTAL PROTECTION
AGENCY REGIONAL OFFICIALS SHOULD BE NOTIFIED
AND A FOLLOW-UP REPORT MADE DETAILING WHAT
HAPPENED AND HOW THE SITUATION WAS CORRECTED.
ALSO, THE OPERATOR SHOULD ASK FOR AND EXPECT
ASSISTANCE FROM THESE AGENCIES WHEN THE
SITUATION WARRANTS. (THESE AGENCIES HAVE
BEEN ESTABLISHED NOT ONLY TO REGULATE PLANT
OPERATION, BUT ALSO TO ASSIST THE OPERATOR
IN MEETING THEIR OWN REQUIREMENTS).
Summary: This section has outlined a general pattern which
the operator should follow in responding to emergencies. In most
small emergencies, the operator will go through these steps
automatically; however, they should be kept in mind (and perhaps
5-31
posted near telephones) in order to effectively deal with major
disasters.
In summary, these steps are:
1. Identify emergency (be aware).
2. Investigate quickly (know what has happened).
3. Take initial action (notify).
4. Take corrective action (remedy, implement
action plans).
5. Follow-through (prevent future similar disasters).
EMERGENCY TELEPHONE NUMBERS
Table 5- 7 shows•a suggested list of emergency telephone
numbers which should be completed and posted in a conspicuous
place near each telephone at the plant.
This list should be checked for accuracy at least quarterly
and changes in names and/or telephone numbers should be noted on
posted listes. One person should be given the responsibility for
maintaining the accuracy of the lists.
EMERGENCY EQUIPMENT INVENTORY
An inventory should be made of equipment, materials and
chemicals available within the treatment system which can be used
in case of an emergency. Any additional emergency equipment and
supplies required should be purchased and stockpiled and/or
arrangements made to obtain these items through mutual aid
agreements or outside contracts.
TREATMENT SYSTEMS RECORDS
A system should be established for the protection of
essential records, maps and inventories. Full size copies of
maps and other details sheets should be made each year and kept
in a vault that is not subject to flooding. Copies of the
layouts of important pumping installations should also be kept
there. These items will then be available for immediate use and
can be reproduced as required.
COORDINATING INSTRUCTIONS FOR POLICE AND FIRE DEPARTMENTS
The treatment system's emergency response program should be
coordinated with the local Police and Fire Departments.
Coordinating instructions are outlined below and consideration
should be given to the items in the following checklists.
5-32
TABLE -S — 7
LIST OF EMERGENCY TELEPHONE NUMBERS
T E L E P H O N E
OFFICE HOME
1. PHYSICIANS/AMBULANCE
Dr.
Address
Dr.
Address
Ambulance
Address_
Ambulance
Address_
2. FIRE
Department
Department
3. POLICE
City Police
County Sheriff
County Deputy
State Police
Local Headquarters
4. POWER COMPANY
Name
Address
Name
Address
S. EMERGENCY POWER
UNITS (MOBILE)
Name
Address
Name
Address
f
S—
33
TABLE 5 - 7
LIST OF EMERGENCY TELEPHONE NUMBERS
T E L E P A 0 N E
OFFICE HOME
6. TELEPHONE COMPANY
Name Address
Name Address
7. ELECTRICIANS
Name Address
Name Address
8. PLUMBERS
Name Address
Name Address
9. HEAVY EQUIPMENT OPERATORS
Type Equipment
Name Available
Type Equipment
Name Available
10. EXTRA LABOR
Name Address
Name Address
11. CONSULTING ENGINEER
Holzmacher, McLendon & Murrell, P.C.
125 Baylis Road
Melville, New York 11747
ATTN: Mr® Gary Loesci� (516) 752-9060
5-34,
I
TABLE 5 7
LIST OF EMERGENCY TELEPHONE NUMBERS
12® EQUIPMENT REPRESENTATIVE/MANUFACTURERS
Comany/Name Address_
Comany/Name Address
Comany/Name Address
Comany/Name Address
Comany/Name Address
13. COUNTY OFFICIALS
Suffolk County Dept. of
Environmental Control
15 Horse Block Place
Farmingville, New York
14, COUNTY HEALTH DEPARTMENT
Offidial Address
Official Address
15. STATE REGULATORY AGENCY
New York State Dept® of
Environmental Conservation
Building 40
State University of New York
Stony Brook, New York 11790
16. AREA CIVIL DEFENSE
Official Address
Official Address
5-35
T E L E P H 0 N E
OFFICE HOME
451-4629
751-7900
TABS E 5 — 7
LIST OF EMERGENCY TELEPHONE NUMBERS
T E L E P H O N E
OFFICE HOME
17. FEDERAL ENVIRONMENTAL PROTECTION AGENCY, REGIONAL OFFICE
Official Address
Official Address
18. OTHER
Chlorine Equipment Mfg. Address
Chorine Supplier Address
Address
Address
Address
i
Address
Address
e
5-36
Police Department Checklist
1. Critique existing treatment system security
measures.
2. Make routine checks of treatment facility.
3. Be prepared to assist during emergencies within the
treatment system.
Fire Department Checklist
1. Routinely check fire -fighting equipment within the
facility and inspect facility for potential fire hazards.
2. Provide first aid instruction to treatment system
personnel.
3. Coordinate with treatment system personnel on safety
precautions to be used with chlorine gas.
5®37
CHAPTER 6: PERSONNEL
6- 1
PAGE NO.
GENERAL
6®
2
CERTIFICATION
6®
2
JOB DESCRIPTIONS
6®
3
Superintendent
6®
3
Operator
6®
4
Equipment Mechanic
6®
5
Attendant
6®
6
NOTES AND ADDENDA
6®
7
6- 1
GENERAL
This Chapter consists of a description of the personnel
requirements for the operation and maintenance of the Town of
Southold Scavenger Waste Treatment Facility.
The recommendations made herein should be considered
flexible with adjustments made for changes in conditions and in
the capabilities of the personnel available.
The job descriptions which follow are based on the
information given in Part 650 of the Public Health Law adopted by
the State of New York, and the recommendations are based on the
anticipation that outside skilled tradesmen, such as motor or
engine mechanics and instrumentation servicemen; will be engaged
to perform specialized maintenance -and repairs on the occasions
when plant personnel do not have the knowledge or the means to
conduct complicated repairs or tests.
Regardless of the care which goes into the design and con-
sideration of a treatment facility, the full capabilities of the
plant cannot be realized without qualified personnel in adequate
numbers to operate the processes. Up-to-date training for
operators and maintenance personnel is stressed as being of
critical importance in the proper functioning of the facility to
protect the plant equipment from damage or -deterioration and to
maintain the quality of the effluent.
Staffing will consist of a Superintendent/Chief Operator who
will be responsible for the operation and maintenance of the
facility. In addition, two (2) additional attendants will be
added to assist in the operation of the plant.
CERTIFICATION
The present certification program for pollution control
plant operators is mandatory in the State of New York and is
under the administration of the Department of Environmental
Conservation, Division of Water Resources. The details of the
certification program are presented in the Division of Water
Resourses Regulations, Chapter -10, Part 650, enclosed as Appendix
"A".
In summary, the regulations state that an operator must be
certified by a combination of experience, education level and
written examination. In addition, pollution control plants are
classified into grades by the Department of Environmental
Conservation, Division of Water Resources, in accordance with
flow and degree of complexity of the treatment process. The Town
of Southold Scavenger Waste Facility has been classified Grade B.
Each pollution control plant must be manned by at least one
certified operator of the assigned grade.
6- 2
It is strongly recommended that all operators be encouraged
to obtain the highest degree of certification possible for their
experience level, and to take full advantage of any operator
training courses which may be available. The Town of Southold
should also consider providing incentives to encourage personnel
to voluntarily obtain certification and/or additional schooling,
as their increased knowledge would be expected to result in a
higher level of performance, more competent operation of
facilities, and a more flexible staff, better able to meet and
solve problems.
Various methods of training are available. For example,
courses are sponsored by Local Enforcement Agencies in operation,
laboratory procedures, safety, etc. The Long Island,Section of:
Water Pollution Control Association also provides educational
meetings and field trips at which the operators can see how other
plants are operated.
JOB DESCRIPTIONS
General job descriptions for the recommended types of
positions follow. General qualifications, job descriptions and
suggested duties of the usual types of personnel commonly
employed for the operation and maintenance functions of
conventional waste treatment plants are listed and these
descriptions include, but are not limited to, the
responsibilities indicated. The suggested duties, qualifications
and experience explained in these.personnel.job descriptions
should be used as a guide only, as the need for manpower
requirements, based on individual capabilities, will vary with
the municipalities' ability to recruit suitable employees.
Superintendent
General Statement of Duties: Has responsible charge of the
operation and maintenance of the water pollution control
facilites; does related work as required. .
Distinguishing Features of the Class: This is an important
technical and supervisory position involving responsibility for
the proper operation and maintenance of the existing Southold
water pollution control plant and the scavenger waste treatment
plant. Work performed requires use of independent judgement in
the development of procedures and methods. Supervision is
exercised over all employees of the plants.
Example of Work: Supervises and administers the operation
and maintenance of the treatment plants; lays out procedures and
methods of operation; plans and lays out work of subordinates;
investigates complaints, of wastewater stoppage; requisitions
6- 3
parts and materials; prepares budget estimates; maintains records
and prepares reports; inspects plant regularly; evaluates
personnel; initiates or recommends new or improved practices;
recommends plant improvements and additions; controls
expenditures of budgeted funds; and maintains effective
communication and working relationship with employees, government
officials and general public.
Required Knowledge, Skills and Abilities: Thorough knowledge
of -the theory and practice of the operation and maintenance of a
public wastewater disposal system; good.knowledge of the
principles and practices of water pollution and wastewater
disposal; ability to plan and supervise the work of others;
understanding of managerial, administrative and accounting
practices -and .procedures involved in successful plant operation;
ability to deal successfully with public officials and others on
wastewater disposal problems; ability to understand and follow
oral and written directions; initiative; resourcefulness; good
judgement; and good physical condition.
Acceptable Experience and Training: One year of experience
in the operation, maintenance or construction of wastewater
treatment plants and graduation from a college or university of
recognized standing with a degree in public health, sanitary,
chemical or civil engineering, including acceptable courses in
sanitation; or five years of experience in the operation,
maintenance or construction of wastewater treatement plants and
completion of a course of instruction in wastewater treatment,
approved by the public health council as qualifying for a Grade
3B Operator's Certificate or any equivalent combination of
experience and training.
Special Requirements: Eligibility for a Grade 3B Wastewater
Treatment Plant Operator's Certificate issued by the State of New
York.
Operator
General Statement of Work: Performs routine mechanical work
in the operation of a water pollution control plant; does related
work as required.
Distinguishing Features of the Class: Duties are of a
routine mechanical nature involving responsibility for efficient
operation of plant and for assisting in the maintenance of
equipment at the plant. The work is performed under the
immediate supervision of a superior and requires strict adherence
to established procedures. Supervision may be exercised over the
work of water pollution control plant attendants.
6 4
Examples of Work: Starts and stops pumps, motors, air
blowers and other machinery and equipment; operates, maintains
and lubricates mechanical screens and mixers, the RBD units,
pumps and similar equipment; takes samples of water and makes
simple physical tests; makes minor repairs to machinery and
equipment; monitors meters, gauges and control pumps; keeps
records and makes reports of plant operations; observes
variations in operating conditions and makes appropriate
equipment adjustments.
Required Knowledge, Skills and Abilities: Some knowledge of
and skill in the operation of pumps, motors and -other mechanical
equipment; ability to make simple mechanical repairs, aptitude
for mechanical work; ability to understand and carry out oral and
written directions; industrious; dependability; alertness; and
good physical condition.
Acceptable Experience and Training: One year of satisfactory
experience in a water pollution control treatment plant; or three
months of satisfactory .experience in a water pollution control
treatment plant and completion of a course of instruction in
wastewater treatment approved by the public health council; or
any equivalent combination of experience and training.
Special Requirements: Eligibility for a Grade 3B Wastewater
Treatment Plant Operator's Certificate issued by the State of New
York.
Equipment Mechanic
General Statement.of Work: Works as a skilled mechanic in
the maintenance and repair of water pollution control plant
equipment; does related work as required.
Distinguished Features of the Class: This is skilled work
involving responsibility for efficient and workmanlike
performance of a variety of mechanical tasks requiring a good
knowledge of the electrical, mechanical and plumbing trades.
General instructions are received from the plant operator,
permitting wide leeway for planning the details of each
assignment. Immediate supervision may be occasionally exercised
over the work of attendants on un -skilled or semi -skilled work.
Examples of Work: Lines up and fits bearings on machine
shafts; greases and oils motors, machinery and pumps; maintains
and repairs motors, machinery, pumps, blowers, compressors,
conveyors, sludge collector drives, valves and gates, and similar
equipment; maintains and repairs plumbing and heating appliances;
and makes estimates and prepares requisitions for materials.
6- 5
Required Knowledge, Skills and Abilities: Good knowledge of
common. practices, tools, terminology and accident precautions of
the electrical, mechanical and plumbing trades; ability to work
from plans and specifications and to follow rough sketches and
oral instructions; good motor, hand and eye coordination; manual
dexterity; good physical condition; and ability to organize and
supervise work of others.
Acceptable Experience and Training: Five years of experience
in practical plumbing work and machine repairing and completion
of a standard grade school course; or any equivalent combination
of experience and training.
Attendant
General Statement of Work: Performs manual work at the water
pollution control plant; does related work as required.
Distinguishing Features of the Class: This is routine manual
work requiring no previous training or experience, but requiring
physical endurance and a willingness to perform various tasks.
The work is performed under immediate supervision.
Examples of Work: Starts and stops pumps, motors, air
blowers and other machinery and equipment, as directed; cleans,
flushes and maintains equipment, as directed; assists in
operation of the screens, mixers and pumps; removes snow;
performs a variety of custodial duties; cleans drains, ditches
and culverts; mows lawn and maintains landscaping; collects and
disposes of trash and garbage; washes and cleans vehicles; drives
truck used for sludge removal.; rough paints; lubricates machinery
and unloads materials.
Required Knowledge, Skills and Abilities: Willingness to
perform routine manual work; ability to lift heavy weights;
physical endurance; and good physical condition.
Acceptable Experience and Training: None required.
CHAPTER 7: PRELIMINARY TREATMENT FACILITIES
PAGE NO.
PURPOSE AND THEORY 7- 2
General
7-
2
Bar Screen
7-
2'
Aerated Grit Chamber
7-
2
UNIT DESIGN AND DESCRIPTION
7-
3
General
7-
3
Grit Removal.
7-
3
Air Blowers/Aeration Piping
7-
3
Odor Control Facilities
7-
7
OPERATION AND CONTROL
7-
7
General
7-
7
Normal Operation
7-
7
Start-up
7-
7
Routine Surveillance
7-
9
Sampling
7-
9
Housekeeping
7-
9
Troubleshooting
7-
9
NOTES AND ADDENDA 7-11
Table
7- 1
7- 2
Figure
7- 1
7- 2
7- 3
LIST OF TABLES
Units, Locations and Controls
Troubleshooting Guide for Aerated
Grit Chamber
LIST OF FIGURES
Influent Port Detail Plan and Section
Scavenger Waste Flow Schematic
Bar Rack and Aerated Grit Chamber
7- 1
7- 8
7-10
7- 4
7- 5
7- 6
PURPOSE AND THEORY
General
Preliminary treatment facilities include processes that
remove coarse materials from the wastewater stream. Removal of
such material eliminates interference with subsequent treatment
processes and minimizes damage to plant equipment. At the Town
of Southold Scavenger Waste Treatment Facility the preliminary
treatment units consist of a bar screen and a aerated grit
chamber.
Bar Screen
Trash such as cloth, rags, plastics, paper together with
some fecal matter and other large objects which may be present in
the scavenger waste stream can cause problems in the operation of
pumps, valves and other equipment at the plant. It is,
therefore, necessary to remove these objects prior to further
treatment of the waste stream. The removal of these objects
which are commonly known as screenings is achieved at the plant
by the bar screen. These objects are manually removed from the
waste stream and emptied into a screening can. When the can is
full it is emptied into a dump truck and the screening are
ultimately disposed of in a landfill.
Aerated Grit Chamber
The grit chamber removes grit,, consisting of sand, gravel,
cinders, or other heavy solid materials that have settling
velocities or specific gravities substantially greater than those
of the organic putrescible solids in wastewater. Grit also
includes eggshells, bone chips, seeds, coffee grounds, and large
organic particles, such as food wastes. Grit chambers protect
moving mechanical equipment from abrasion and accompanying
abnormal wear and reduce formation of heavy deposits in
pipelines, channels, conduits and anaerobic digesters.
Grit removal facilities are designed to slow the flow
through velocity to a point where the heavier grit settles out,
while the lighter organic solids are maintained in suspension.
In an aerated grit chamber, settling control is created
artificially by introducing air along the sides of the tank. The
air rising through the wastewater imparts a rolling motion to the
flow as it passes through the tank. The heavier grit particles
settle and the lighter organic particles stay in suspension.
This rolling motion also tends to wash the grit by removing
organics attached to the grit by scouring action.
7- 2
UNIT DESIGN AND DESCRIPTION
General
Scavenger waste enters the treatment facilities through one
or both influent ports, where it is directed via a 16 -inch pipe
to the screen. A plan and sectional view of a typical influent
port is shown on Figure 7- 1. Screening is the first scavenger
waste treatment step as shown on Figure 7- 2.
Manual Bar Rack
This unit is composed of 2 x 1/4 inch rectangular bars
fastened top and bottom to provide a clear spacing of 1 inch
between the bars at an angle of 45 degrees from the horizontal.
The bar rack extends 2 feet above the surface of the operating
floor.
Bar racks are manually raked as required. Debris is
collected in containers, removed and trucked to the landfill.
Grit Removal
Grit removal is the second step in the scavenger waste
treatment process. A sectional view of the bar screen and
aerated grit chamber is shown on Figure 7- 3.
Aerated Grit Chamber Design Data
Type of Diffusers
Orifices
Effective
depth, ft.
8.0
Effective
width, ft.
4.0
Effective
length, ft.
18.0
Detention
period
minutes
1.4
Recommended range of air
available scfm/ft. of length 5-8
Grit Removal Inclined Screw Conveyor
Grit Disposal To Town Landfill
The waste stream from the aerated grit chamber is discharged
over an effluent weir and into a 12 inch ductile iron pipe which
goes to the equalization tanks.
Air Blowers/Aeration Piping
Air is supplied to the grit chamber by a positive
displacement air blower with a capacity of 20 cfm at 4.1 psig.
The air blower is located in the grit room and is driven through
a V -belt drive connected to a constant torque, open, drip -proof 1
HP motor. The blower is equipped with an intake filter silencer,
a discharge silencer, flexible pipe connections, manometer and
pressure gauges, check valve, pressure relief valve, and
7- 3
FIGURE 7-1
•
SCAVENGER
WASTE -TRU C K
.. �
BAR
SCREEN
GRIT CHAMBER
INFLUENT
PORTS
FE 'CL 3
STORAGE TANK
FLOCCLATION TANK
EQUALIZATION TANK FLASH PRIMARY
MIX TK. ' CLARIFIER
HCL
STORAGE
LIME TANK
HEAD BOX HCL ' MIXING.
TANK
:)DIAA A DV
PROPOSED SLUDGE
BEDS_
_DRYING
i
SCUM ROTATING
BIOLOGICAL
n.
L-=-----�
DISCS
SLUDGE
WET WELL
in
C
r- - - -'
I
FLOW METER
TO OUTFALL I
®�
FINAL
CLARIFIER
EFFLUENT
G7
EXISTING VILLAGE OF
WET WELL
m
..Z
GREENPORT PLANT
m
SCAVENGER WASTE
FLOW SCHEMATIC
cn
r
-AIR l3E AD ER
1
GRIT--CHAMBER-
ROOM
RIT--CHAMSER-ROO.M _
_SCREW.-DRIV-_{JNIT_-,
AIR SLOWER
E.M SLY -
AIR SUPPLY LINE
GREASE- PIPE-
3A{= PLE PLATE
w/SCUM PORTS -
E: r F -L_ T-R000H
G)
SECTIONAL VIEW' c
rn
rc PJ CONSULTING ENGINEERS
temperature and pressure controls.
.Air is piped to the grit chamber through a 2 inch supply
manifold pipe providing air directly into the waste stream via
adjustable diffuser units.
When the aerated grit chamber blower is out of service for
maintenance and/or repairs,•Blower No. 1, located in the blower
room of the Treatment Building can be used as a,standby.
Odor Control Facilities
The odor control system for the -plant is also'housed in the
Grit Treatment Building. However; details regarding this system
will be presented'in Chapter 14, Odor Control System of this
manual,
OPERATION AND CONTROL
General
An important tool for plant operation is a daily plant
inspection. Generally, a tour of the plant as the first item on
the agenda each morning can be valuable in spotting potential
problems. It should be used -to -modify the regularly scheduled
operating and maintenance routines. Some items to,look for are
changed and excessive -equipment noise, and an abnormal appearance
of the effluent from the various unit operations.
Table 7-1 contains a list of units and location of controls
for various equipment with the Treatment Building.
NORMAL OPERATION
The inclined .grit screw conveyor is controlled by on/off
pushbuttons.
During the start-up period the grit channel should be probed
daily to determine the depth of grit accumulation. After
sufficient operating experience has been gained it will be,
possible to schedule grit removal without daily probing of the
grit channel.
START-UP,. Perform the following items before plant influent
is allowed to pass, into the mechanical bar screen/grit chamber
channel;
1. Check for debris such as rocks, sand, timber, waste
concrete or other foreign material. Short pieces of 2x4
boards and other form lumber can suddenly appear during
initial flow and this material can damage the air
diffuser assemblies.
7® 7
TABLE 7-1 - UNITS, LOCATIONS AND CONTROLS
LOCATION OF TYPE OF
UNIT (1) CONTROL (2) CONTROL REMARKS
Air Blower #1
MCC -A
Air Blower #3
MCC -A
Grit Screw
MCC -B
Flocculation°Tank-Mixer
MCC -B
Primary Clarifier
MCC -A
RBD #1
MCC -A
RBD #2
MCC -B
Sludge/Scum #1
MCC -A
Sludge/Scum #2
MCC -B
Effluent Pump # 1
MCC -A
Effluent Pump # 2
MCC -B
Equalization Tank #1
MCC -A
Submersible Pump
Odor Control Unit
MCC -A
Air Blower #2
MCC -B
Grit Blower
MCC -B
Flash Mixer
MCC -A
Secondary Clarifier
MCC -B
Equalization .Tank ,#2
MCC -B'
Submersible Pump,
Acid Mixer
MCC -A
Notes:, 1. All units have green
Clarifiers also have
2. MCC units located in
room.
3. CS - Control Switch
CS (3)
On/Off Control Switch
CS
On/Off Control Switch
CS
On/Off Control Switch
CS
On/Off Control Switch
CS
Start/Stop Pushbuttons
CS
Ori/Off Control Switch
CS
On/Off Control Switch
CS.
On-Off-Automtic
CS
On-Off-Automtic
CS
On-Off-Automtic
CS
On-Off-Automtic
CS
On -Off- Automatic`
CB
On/Off/Control
Switch
CS
On/Off Control
Switch
CS
On/Off Control
Switch
CB
On -/Off -Control
Switch
CS'
Start/Stop Pushbuttons
CS
On -Off- Automatic
CS On/Off Control Switch
indicating lights on MCC. Primary
red indicating lights.
the Treatment Building,- office
NW.
2. Start the air blower and have air passing through all
the diffusers as waste is admitted to the channel. This
will prevent the diffuser from being clogged by material in
the waste stream.
ROUTINE SURVEILLANCE. The following items should be checked
daily except as noted:
1. Check for any unusual objects or deposits in the bar
screen channel by using a rake. Stones, sticks and other
large -objects should be removed whenever- observed by
using a rake and shovel.,
2. Check for even turbulence throughout the grit chamber.
A relatively calm portion of the chamber may indicate a
clogged air diffuser.
3. Check the grit chamber bottom with a pole to detect grit
build-up.
SAMPLING. A grab sample should be taken from the effluent
end of the grit chamber once per week and analyzed for grit and
total volatile solids.
HOUSEKEEPING. Good housekeeping is essential in the area of
the bar screen and the grit chamber. Keep all walking surfaces -
free of grit, slimes, oils, greases or other material that will
make the surface slippery. This can be done by hosing down the
walkways, handrails and all other exposed parts of the structure
with water. Your housekeeping program should include the hosing
down of the influent channel walls above the water level to
prevent buildup of dried solids. If froth forms within the
aerated grit chamber and accumulates on structures and surfaces,
spray it down using water.
TROUBLESHOOTING. Table 7®2 contains guides for correcting
process malfunctions and a variety of common operating problems
which could occur during the treatment of waste stream and the
production, handling and disposal of the solids accumulated
during the treatment of the waste stream.
7® 9
TABLE 7-2
TROUBLESHOOTING GUIDE FOR AERATED GRIT CHAMBER
Indicators/ Probable Cause Check or Monitor Solutions
Observations
1. Corrosion of la. Inadequate. la. Ventilation la. Increase,
metal and ventilation. ventilation
concrete.
2m Removed grit 2a. Inadequate air 2a. Check air flow 2a. Increase air
is grey in flow rate. rate. flow rate.
color® smells 2b. Grit removal 2b. Use dye releases 2b. Increase velocity
and feels system velocity to check velocity. in grit chamber.
greasy. too low.
i 3. Surface 3a. Diffusers 3a. Diffusers. 3a. Clean diffusers.
CD turbulance in covered by rags
aerated grit or grit.
chamber is
reduced.
4. Low recovery 4a. Bottom scour. 4a. Velocity. 4a. Maintain velocity
rate of grit. 4b. Too much 4b. Aeration. near 1 ft/second.
aeration. 4c. Retention period. 4b. Reduce aeration.
4c. Not enough 4c. Increase retention
retention time. time.
CHAPTER 8: EQUALIZATION TANK FACILITIES
PAGE NO.
PURPOSE AND THEORY 8- 2
General 8- 2
UNIT DESIGN AND DESCRIPTION
8- 2
General
8- 2
Aeration System
8- 5
Effluent Pumping
8- 5
Head Box
8- 8
OPERATION AND CONTROL
8- 8
General
8- 8
Normal Operation
8- 8
Ultrasonic Transmitters
8-11
Pump Operation
8-11
Alternate Operation
8-11
Sampling
8-11
Troubleshooting
8-13
NOTES AND ADDENDA 8-16
LIST OF TABLES
Table
8- 1 Air Blowers and Valve Schedule 8- 7
8- 2 Control of Plant Flow Rate 8-12
8- 3 Troubleshooting Guide for
Submersible Pumps 8-14
LIST OF FIGURES
Figure
8-
1
Scavenger Waste Flow Schematic
8- 3
8-
2
Equalization Tanks -Sectional View
8- 4
8-
3
Air Blowers and Piping
8- 6
8-
4
Head Box Structure
8- 9
8-
5
Equalization Tanks -Plan View
8-10
8- 1
PURPOSE AND THEORY
General
Due to the nature and intermittent discharge of scavenger
waste fluctuation in quality and quantity occurs. Sustained
periods of extremely high organic loading to the RBD's may
temporarily cause an overload of the first stage of the RBD
system. Sustained overload conditions may result in some
reduction in BOD removal and may alter the settling
characteristics of the sloughed biological solids. The
equalization basin serves to balance these extreme quality and
quantity fluctuations. This results in a more homogeneous and
uniform hydraulic and organic loading to the downstream treatment
processes. At this facility in-line flow equalization is
provided. This method of equalization results in significant
dampening of the concentration and flow of the waste stream.
UNIT DESIGN AND DESCRIPTION
General
There are two rectangular, equalization tanks at the
facility. As shown on Figure 8-1, these equalization tanks
follow the aerated grit chamber. Effluent from the aerated grit
chamber enters these tanks via a 16 inch pipe.
EQUALIZATION TANK DESIGN DATA
Number of Tanks
Two
Detention Time @ Average
Flow, in minutes 41
Length in Feet/Tank 35.00
Width, in Feet/Tank 13.00
Water Depth, in Feet 8.10
Volume, in Cubic Feet/Tank 3,686
Volume, in Gallons/Tank 27,570
The major components of the equalization tank facilities are
as follows:
1. Aeration System
2. Effluent Pumping
Figure 8-2 shows a sectional view of the major components of
the equalization tanks.
SCAVENGER
WASTE TRUCK
INFLUENT
PORTS
BAR
SCREEN
GRIT CHAMBER
EXISTING SLUDGE
DRYING BEDS
FE CL3
STORAGE TANK FLOCCLATION TANK
EQUALIZATION TANK FLASH PRIMARY
MIX TK. CLARIFIER
HCL
STORAGE
LIME TANK
HEAD BOX HCL MIXING
TANK
PRIMARY
DIGESTER
SCUM / ROTATING
BIOLOGICAL
DISCS
SLUDGE
WET WELL
- - FLOW METER
TO OUTFALL
�- -- J EFFLUENT
EXISTING VILLAGE OF WET WELL
GREENPORT PLANT
SCAVENGER WASTE FLOW SCHEMATIC
FINAL
CLARIFIER
a
FLOORSTAND \,A//
IZ PIPE I -ROM GRIT HANDWHEEL
CHAMBER (Til?) -F IE3ERGLASS
ULTRASONIC GRATING_: TRANSMITTER (TYP.)
IR HEADER
Alt -
GUIDE Aw Q
RAIL (TYP
G - Pi pEDROP
1= Rom IPE (TYP)
HEAD BOX
(TYR) =AIR
-DIFFUSER
- - - (TYP_)
4' DISCHARGE LINE SUBMERSIBLE
TO HE-AIDBOX(TYP) PUMP (TYP_Fj -
12��KNkFE GATE
/Id'RE:RFORA7F-1D AlR
tN7AKE LINE (TYp)
VA LV E_
SECTIONAL VIES/
GPJ CONSULTING ENGINEERS
Aeration System
The aeration system is provided to mix the contents of the
tanks and to prevent deposition of solids in the tanks. Air is
supplied to the diffusers in the equalization tanks by two (2),
one standby, positive displacement air blowers. This blower and
corresponding controls are located in the Treatment Building.
The equalization tank blowers are driven through a V -belt drive
connected to a two (2) speed constant torque open drip proof 7
1/2 HP motor. The RBD blower has a 3 HP motor. The blowers are
equipped with an intake filter silencer, a discharge silencer,
flexible pipe connections, manometer and pressure gauges, check
valve, pressure relief valve and temperature and pressure
controls. Figure 8-3 shows a schematic of the blowers and air
piping. Table 8-1 contains the air blowers and valve schedule.
Each blower has the following SCFM of air and discharge pressure:
Blower No. Inlet Volume (SCFM) Discharge Pressure (PSIG)
1 100 3.0
2 205 4.0
3 205 4.0
There is a 4 -inch venturi flow meter on the air piping to
the RBD units rated for a maximum flow of 250 SCFM. On the air
piping to the equalization tanks there is a 6 -inch venturi flow
meter rated at a maximum capacity of 800 SCFM. Each venturi is
provided with a wall mounted SCFM flow indicator.
Air is piped to each equalization tank through a 6 inch
supply header. The air then flows through coarse bubble
diffusers.. The upward motion of the air bubbles from the
diffuser tubes keeps the bottom of each tank swept clear of
settled solids and provides gentle mixing.
Effluent Pumping
At the effluent end of each equalization tank a submersible
pump is provided which discharges flow to the head box downstream
of the tanks.
EQUALIZATION TANK PUMPING
Number Two (One/Tank)
Type Submersible
Discharge Capacity 40 gpm at 11.5 ft. TDH
Motor
HP 0.75
Rating 460, 3 phase 60 HZ
RPM 1150
Odor is removed from the equalization tanks via a 10 inch
E=
FIGURE s --3
BLOWER NO.l
TO A E R AT E ED GRI -r
G HA M BER
c D I E
BLOWER NO,2
H M
G
[BLOWERS
L.00AT E D
IN TR F.AT
BLDG.
TO F-' Q u A.11_-2-- ATI OIC
TANK I 4TO R B®
TAN KS
AIR BLOWERS AND PIPING
r -
TABLE 8- 1
AIR BLOWERS AND VALVE SCHEDULE
NORMAL OPERATION: Blower No. 1 operating to feed RBD units.
Blower No. 2 or 3 operating to feed
equalization tanks (alternating
system) .
Blower located in grit chamber room operating
to feed grit chamber.
VALVE POSITION
B Open
D Open (alternate)
I Open (alternate)
G Closed
F Open
E Closed
------------------------------------------------------------------------
Alternate Operation:
Alternate #
1
2
3
4
5
Valve No.
_ B
Open
Open
Closed
Open
Open
D
Open
Open
Open
Closed
Open
I
Closed
Open
Open
Open
Closed
G
Closed
Open
Open
Closed
Closed
F
Closed
Closed
Closed
Open
Open
E
Open
Open
Closed
Closed
Closed
Alternate #1: Blower No.
Blower No.
Alternate #2: Blower No.
Blower No.
Blower No.
Alternate #3: Blower No.
Blower No.
1 used as standby blower for grit chamber unit.
No air flow to RBD units.
2 used to supply air to equalization
tanks.
1 used as standby blower for grit chamber unit.
2 used to supply air to RBD units.
3 used to supply air to equalization
tanks.
1 out of service.
2 used as standby blower for RBD units.
Alternate #4: Blower No. 2 out of service.
Alternate #5: Blower No. 3 out of service.
8- 7
PVC pipe installed in each tank. The odors from these tanks are
treated in the odor control facilities located in the Odor
Control room of the Treatment Building.
There are two ultrasonic transmitters provided (one per
tank) located at the south end of the equalization tanks.
Head Box
Effluent from the equalization tank flows through a 4 inch
force main to the head box structure. The head box is divided
into two chambers by a wall with a 6 -inch diameter sluice gate
and pipe. When the flash mix and/or flocculation tanks require
servicing, the sluice gate is opened, allowing the waste flow to
be recirculated to the equalization tanks. When the flash mix
and/or flocculation tanks are ready for service the sluice gate
is closed. The sluice gate should be operated for one complete
cycle, open -close -open at least once a month.
When the elevation of the flow in the head box reaches 18.67
feet it overflows the V -notch adjustable weir separating the head
box structure from the flash mix tank. Ferric chloride and lime
are feed into the flash mix tank. The waste stream then flows
through a 6 -inch pipe into the flocculation tank. From the
flocculation tank the waste stream flows by gravity to the
primary settling tank.
Elevation of weir height in the head box is adjustable,
thus the flow can be controlled by adjusting the weir height.
A sectional view of the head box structure is shown on
Figure 8- 4.
OPERATION AND CONTROL
GENERAL. The position of the valves associated with the
equalization tanks for both normal and alternate operation is
given in Figure 8-5.
NORMAL OPERATION. Normal pump operation is continuous, one
pump in operation at a time. Pumps should be alternated weekly.
Normal operation of the diffusers is continuous. The gate valve
between the two tanks is normally open to equalize tank levels,
and to allow use of one pump at a time to empty both tanks.
Submersible pumps will be controlled by floats.
ULTRASONIC TRANSMITTERS. The ultrasonic transmitters emit
a beam of ultrasonic sound. The sound waves rebound after
hitting the liquid level in the equalization tank. The
transmitter computes the distance between it and the liquid level
CHECKERED STEEL PLATE
W/CONT.IN000S HINGE(TYF.)
OVERFLOW
TO EQUALI M AT 1 O N
TANK
VALVE STAND W/
H-ANDW HEEL
e -
J,;
A®%.JUSTAlBL
WEIR PLATE
N OTC H ED WOR
SLUICE GATE
M�
fP-J CONSULTING ENGINEERS
-'O :HEAD EBOX
FROM a
--HEAD BOY,
6
PLUG ILIO_ -I
PLUG NO.2
PLUG NO.3
t4J E s b
CHAM GER
�a
�• � e �'' 'pro
R' •
IBL -IDG
FROM GRIT CHAMSERI
,(I' � l HEAD BOX
_.PLUG NO -7
PLUG NC), 5
igAsT
CHAMBER
L7ERNATE OPERATION
. m w .g
Lei ma,
EA 5T CHAMBER
TAKEN OUTOF SERV
1
OPEN
CLOSE®
OPEN
CLOSED
OPEN
s
CLOSED
OPEN
CLOSEID
OPEN
CLOSED
OPEN
_.PLUG NO -7
PLUG NC), 5
igAsT
CHAMBER
L7ERNATE OPERATION
EST CHAMBER
KEN OUT OF SERV.
EA 5T CHAMBER
TAKEN OUTOF SERV
OPEN
OPEN
CLOSE®
OPEN
CLOSED
OPEN
CL®SED
CLOSED
OPEN
CLOSEID
OPEN
CLOSED
OPEN
CLOSED
N•
VALVE:" -.T o
D! _ DIFFUSER.
Tt4E:N BE •
by measuring the total time of travel of the sound wave. The
_ transmitter converts this distance to a signal and sends it to
the panel located in the administration room of the Treatment
Building. A continuous readout of liquid level for each chamber
is provided at the panel. The overall range of the units is from
1 to 15 feet from the face of sensor.
PUMP OPERATION. The controls provided for the equalization
tank pumps consist of pump on and pump off float switches, an
elapse time meter for each pump and a high level alarm. These
controls are located on MCC located in the office room of the
Treatment Building. The high level alarm is located on an
instrumentation panel located in the administration room of the
Treatment,Building. The float switches are located in each tank.
The flow rate through the plant must be adjusted on a daily
basis, depending on the volume received the previous day and the
number of days per week in which the plant receives scavenger
waste (5 or 6 -day operation). In order to maintain flow through
the plant on days when the plant does not receive waste (Saturday
and Sunday, or Sunday), the operator must pump slightly less flow
through the plant than is received. This will result in a rising
equalization tank level during the week and a declining level on
the weekend. Table 8-2 is provided as a guide to the operator
for adjusting plant flow.
ALTERNATE OPERATION. Should it be necessary to take a tank
out of service to clean the diffusers, the operator should close
valve #4. After this is complete, the operator should operate
only the pump in the tank to be taken out of service until the
level is sufficiently reduced. If the flow to the tank in
service triggers the high level alarm, the operator should open
valve #4. This valve should remain open until the high level
alarm stops. When the alarm stops, the operator should close
this valve and continue to pump from the tank being removed from
service. In order to drain the tank below the pump off level,
the pump must be operated in the hand position and the level
visually checked to avoid running the pumps dry. When the tank is
empty, the pump should be shut off and the pump in the operating
tank should be placed in service. Note that for this situation,
the plug valve feeding the tank to be taken out of service will
be in the closed position (No. 3 or No. 6). The air supply
should remain on until the tank level is brought below the
diffuser piping, at which time the plug valve controlling the air
feed to the tank being taken out of service should be closed.
The submersible pumps can be removed for maintenance without
taking the tank out of service. A mobile hoist is provided for
raising the air diffusion units from the equalization tanks.
SAMPLING. Access to each equalization tank is obtained by
opening one of the roof scuttle located near the effluent end of
each tank. A 24 hour composite sample should be taken, one per
week, and analyzed for BOD5 and suspended solids. A
representative sample of the equalization tank contents can also
be obtained from the head box.
8-11
TABLE 8-2
CONTROL OF PLANT FLOW RATE
Previous Day's Approximate Pump Rate Required
Volume Received (Gallons)
(Gallons)* 5 -day Operation 6 -day Operation
5,000
3,5%1
' 4,286
10,000
7,143
I 8,571
15,000
+ 10,714
12,857
20,000
14,286
` 17,143
22,000
15,714
18,857
24,000
17,143
20,571
26,000
+ 18,571
22,286
28,000
20,000
24,000
30,000
` 21,429
+ 25,714
32,000
22,857
I 27,429
34,000
24,286
29,143
36,000
25,714
30,857
38,000
27,143
32,571
40,000
28,571
34,286
42,000
30,000
36,000
44,000
31,429
` 37,714
46,000
I 32,857
39,429
48,000
34,286
` 41,143
50,000
I 35,714
a 42,857
52,000
37,143
44,571
54,000
1 38,571
46.,286
56,000
+
40,000
58,000
41,429
+ 49,004
60,000
42,857
` 51,429
62,000
44,286
53,143
64,000
45,714
54,857
66,000 I
47,143
I 56,571
68,000
48,571
i 58,286
* Plant operator should read the totalizer reading, every
morning, on the flow indicator mounted in the administration room
of the Treatment Building.
8- 12
TROUBLESHOOTING
Table 8®3 contains guides for correcting process
malfunctions and a variety of common operating problems which
could occur during the treatment of waste stream and the
production, handling and disposal of the solids accumulated
during the treatment of the waste stream.
8® 13
00
i
TABLE 8-3
TROUBLESHOOTING GUIDE FOR SUBMERSIBLE PUMPS
Indicators/
Probable Cause
Check or Monitor
Solutions
Observations
Inspect pump for
2a.
Remove obstruction.
1. Pump not
running,
la. Replace defective
la. Defective control
la. Use a meter to
running
circuit.
check switching
part.
circuits.
'
lb. Defective motor.
lb. Motor operation.
lb. Replace motor.
2.
Pump not
2a.
Clogged pump or
2a.
Inspect pump for
2a.
Remove obstruction.
running,
closed valve.
obstruction.
circuit
'
breaker will
not reset.
3.
Pump is
3a.
Pump air -bound.
3a•.
Air bleed pipe.
3a.
Remove obstruction.
running, but
3b.
Clogged impeller.
3b.
Inspect for
3b.
Remove obstruction.
reduced
3c.
Wearing rings.
obstructions.
3c.
Replace worn rings.
discharge.
3c.
Check clearance.
4.
Clogged pump
4a.
Grease
4a.
Check grease
4a.
Frequent cleaning
or pump
accumulations.
accumulation on
of tank walls or
suction line.
walls of tanks.
removal of grease
by dewatering the
tank, and scraping
the bottom.
5.
Rising power
5a.
Clogged pump.
5a.
Total daily
5a.
Remove obstruction
consumption
5b.
Misaligned belt
pumpage and
in pump.
per gallon.
drives.
maximum and minimum
flow rates.
00
i
TABLE 8-3
TROUBLESHOOTING GUIDE FOR SUBMERSIBLE PUMPS
Indicators Probable Cause Check or Monitor Solutions
Observations
6. Improper 6a. Coating on liquid 6a. Probe. 6a. Clean probe.
liquid levels. high probes. 6b. Float detector. 6b. Remove obstruction,
6b. Hang-ups in float 6c. Bubbler. release float.
level detectors. 6c. Clean bubbler.
6c. Leaks in bladders.
6d. Fouling in bubbler
controls.
7. Excessive 7a. Sand accumulations
wear or in the wet well.
damage to
pumps. 7b. Grease accumulations
in the wet well.
7a. Inspect for
eroding action,
corrosion, and
solids build
up.
7b. Inspect tank
walls.
7a. Remove sand from
wet well.
7b. Clean walls.
CONT'D
CHAPTER 9: CHEMICAL COAGULATION
AND FLOCCULATION
THEORY AND PURPOSE
General
Delivery of Ferric Chloride
Delivery of Lime
UNIT DESIGN AND DESCRIPTION
Ferric Chloride System
Lime Feed System
Mechanical Flash Mixer
Mechanical Flocculation
OPERATION AND CONTROL
Ferric Chloride Solution Feed Pump
Flash Mixer/Flocculator
Normal Operation
Alternate Operation
Start-up
Routine Surveillance
Troubleshooting
Sampling
Housekeeping
NOTES AND ADDENDA
LIST OF TABLES
PAGE NO.
9- 2
9- 2
9- 3
9- 3
9- 3
9- 3
9- 4
9- 4
9- 7
9- 8
9- 8
9- 8
9- 8
9- 8
9- 8
9- 9
9- 9
9-10
9-10
9-12
Table
9- 1 Troubleshooting Guide for Chemical 9-11
Coagulation and Flocculation
LIST OF FIGURES
Figure
9- 1 Scavenger Waste Flow Schematic 9- 5
9- 2 Head Box, Flash Mix and Flocculator Tanks 9- 6
9- 1
THEORY AND PURPOSE
General
The addition of chemicals to the waste stream is an effective
method of removing suspended solids and BODS. The process of
"chemical clarification" includes coagulation and flocculation,
accomplished by a combination of physical and chemical processes.
These processes thoroughly mix the chemicals with the waste stream
and promote the aggregation of waste stream solids into particles
large enough to be separated by gravity settling.
The first step of the process involves the thorough mixing of
the waste stream with ferric chloride and lime. Flash or rapid
mixing of the chemicals and waste stream mixture completely
disperses the coagulants so that the maximum possible portion of
influent suspended and colloidal solids are absorbed and
destabilized.
For particles in the colloidal size range, natural stabilizing
forces dominate over natural aggregating forces and the natural
mechanism which tends to cause particle contact and agglomeration.
The stabilizing forces include electrostatic repulsion and physical
separations by absorbed water layers. The natural aggregating
forces include the van der Waals force and Brownian movement of the
particles.
Destabilization, the action of the chemical coagulant, may
involve any of several mechanism. Briefly, destabilization may be
accomplished by electrostatic charge reduction, thus reducing the
repulsive forces between the particles, along with enmeshment of
the particles in the gelatinous hydrolysis products formed by
reaction of the metal salt coagulant with hydroxyl ions in the
water.
Lime treatment takes place within a range of pH 9.0 to 11.5.
The second step in the chemical clarification process involves
flocculation or slow mixing to increase the natural rate of
contacts between particles. This makes it possible, within
reasonable detention periods, for destabilized colloidal solids to
coagulate into "flocs" - particles large enough for effective
separation by gravity settling.
A period of gentle agitation is directly proportional to the
velocity gradients established in the water being treated. The
stirring action derived from flocculating mechanisms is responsible
for establishing these gradients and, therefore, fundamental to the
process. The end result is promotion of the floc growth so that
finely divided suspended solids and colloidal particles can be
removed by the settling tanks.
DELIVERY OF FERRIC CHLORIDE. Ferric chloride will be
delivered to the plant in solution form (30 - 32% concentration) to
the ferric chloride storage tank installed in a below grade
concrete vault. The vault is located east of the sludge digestion
tank.
DELIVERY OF LIME. Hydrated lime is delivered to the plant
in 50 lb. bags. Lime feed is usually based on parts of hydrated
lime Ca(OH2) per parts of water. Initially, the lime slurry
prepared at this facility will be a 5% solution at 85% standard
strength. When prepared continuous mixing of the lime slurry in
the solution tank is required. The lime feed system is manually
controlled by use of an adjustment knob located on the lime feeder
control panel which is calibrated from 0 - 100% of feeder
capacity.
UNIT DESIGN AND DESCRIPTION
FERRIC CHLORIDE FEED SYSTEM. The components of this system
consist of the following:
1. Liquid ferric chloride storage tank - One
fiberglass ferric chloride tank with a capacity of
470 gallons. The tank is equipped with a 4 inch
fill line, side access manway and a vent line. There
is a 1 1/4 inch suction line with a 1 1/4 inch turn
off and relief valves which connect to the ferric chloride
feed pump. The tank is also equipped with a liquid level
gauge located in the Treatment Building.
2. Ferric chloride feed pump - The ferric chloride pump draws
the ferric chloride solution from the storage tank, and
pumps it, through a 3/4 inch feed line that discharges
into the flash mix tank.
FERRIC CHLORIDE FEED PUMP DESIGN DATA
Pump
Number
Type
Capacity Rating (Max.)
Feed Range - 2 four
capacity steps
Motor
Hp
Rating
1
Hydraulically activated Diaphragm
38.5 GPD @ 150 psig
20 : 1
D.C.
1/4
115V, 1 phase, 60 Hz
9- 3
LIME FEED SYSTEM. The lime feed system located in the lime
' room of the Treatment*Building feeds hydrated lime solution to the
flash mix tank. The lime feed equipment consists of a 100 gallon
solution tank and a lime meter pump with the associated piping.
The 100 gallon solution tank is equipped with a mechanical
mixer.The lime feed pump draws the lime solution from the solution
tank and discharges it through a 1 inch pipe to the downstream
flash mix tank.
The lime solution tank will be required to be filled with
approximately 100 pounds, per. day, of lime.
The rate of lime slurry feed pumped to the flash mix is
controlled by a manual adjustment of the lime feed pump.
LIME FEED PUMP DESIGN DATA
Pump
Number
Type
Capacity Rating (Max)
Feed Range - 2 four capacity steps
Motor
HP
Rating
1
Hydraulically activated Diaphragm
20 gph @ 400 psig
10 0 1
TEFC
1/4
115/270V,60 Hz, 1 phase
MECHANICAL FLASH MIXER. As shown on Figure 9- 1, flash
mixing and flocculation are the next treatment processes. The
waste stream enters the flash mix tank via a v -notch weir . The
waste stream is then chemically dosed with lime and ferric chloride
prior to being mixed. Within the flash mix tank intense mixing is
required in order to insure uniform chemical distribution of the
coagulants throughout the waste stream before floc begins to form.
The flow is mixed by submerged propellers. Figure 9- 2 shows a
sectional view of the mixing tank.
FLASH MIXING TANK BASIC DESIGN DATA
Number of Tanks One (1)
Length, in Feet 2.5
Width, in Feet 2.5
Water Depth, in Feet 3.0
Volume, in Cubic Feet 18.75
Propeller Diameter, in Inches 13.0
Type of Turbine Blade Axial
9- 4
SCAVENGER
WASTE TRUCK
BAR
SCREEN
GRIT CHAMBER
EXISTING SLUDGE
DRYING BEDS_,
FE CL3
STORAGE TANK FLOCCLATION TANK
EQUALIZATION TANK FLASH PRIMARY
MIX TK. CLARIFIER
HCL
STORAGE
LIME 77ANK
HEAD BOX HCL MIXING
TANK
PRIMARY
DIGESTER
SCUM ROTATING
BIOLOGICAL
DISCS
SLUDGE
WET WELL
FLOW METER
TO OUTFALL
L_ ---J EFFLUENT
EXISTING VILLAGE OF WET WELL
GREENPORT PLANT
SCAVENGER WASTE FLOW SCHEMATIC
�
I
ml
.1-1--l— I..,. ,". 1 _' 1. " I — , ".: ' 7' , , , " , 1� , .: cep — , "�tl q
WIp
:P-LOC--CULAT-OR MIXER
MOTO p
VALVF- STAND W1
-HANDWHEEL
FROM E_ FFLUENT.- M 1)(F- R
WET WE -LL FLOCCULATION
---MOTOR
TANK
-HF-AD BOX
I
F /:CD r-, IkA C- n I A I
ROM E:�UALIZATION
-------
TANK
FLASH MIX
I ANK TO PRIMARY SETTLING
- C. LSP
L AT E::
L
Nrp
CHE.CKERE:O�---,-S-T.--PL-A-T-E:.----w/
C-ONT.1-NUOU.S'-H,INGF---(TYP-)-
HEAD F30X
-WEIR 'PLATE
NOTCHED WEIR
!XD
FROM EQUALIZA
1: -7- AT 10 N
TAN K
-FLASH MIX TANK
TANK
PLAN SECTIONAL VIEW
HEAD BOX, FLASH MIX AND FLOCCULATION TANK
• -FCPJ CONSULTING ENGINEERS
Shaft Speed, in RPM 0 - 350
Motor
Horsepower 0.65
Rating 230/460 V, 60 HZ, 3 phase,
1800 RPM
MECHANICAL FLOCCULATION. The flow from,the flash mixer
enters the flocculation tank via a 6 inch wall sleeve opening. It
is within this tank that floc forms.
Flocculation is accomplished by revolving radial -flow turbine
impellers which gently agitate and maintain solids in suspension
throughout the flocculation unit, thus enhancing floc formation.
These turbine impellers impart a vortex flow pattern throughout
the tank.
Also see Figure 9-2'for a typical sectional view of the
turbine impeller in the flocculation tank.
FLOCCULATION TANK BASIC DESIGN DATA
Number of'Tanks
Length, in Feet
Width, in Feet
d
Water Depth, in Feet
Volume, in Cubic Feet
Turbine Impeller Agitator
Impeller Diameter, in Inches
Type of Turbine Impeller
Shaft Speed, in RPM
Motor
Horsepower
Rating
9- 7
One (1)
4 0
4.0
4.58
73.28
One (1)
24.0
Axial
153
1.5
230/460 V, 60 HZ, 3 phase,
1750 RPM.
After flocculation the flow enters -via a 6 inch opening to the
primary settling tank.
OPERATION AND CONTROL
FERRIC CHLORIDE SOLUTION FEED PUMP. Controls for the FeC13
feed pump consist of a SCR variable speed drive control unit
located in the Treatment Building. The SCR control unit contains a
rate -control knob, a meter reading out motor speed, stop -run
switch, power on-off switch and a switch to change from automatic
control to local -manual control. The meter reading out motor speed
is calibrated for 0.- 100% of pump speed.
FLASH MIXER/FLOCCULATOR. The controls consist of START/STOP
push buttons located on MCC in the administration room of the
Treatment Building and on the control panel near the unit.
NORMAL OPERATION. The flash mixer and flocculator variable
frequency controllers should be set at the desired speed settings
and the START pushbuttons should normally be pressed so that the
units operate continuously. Ferric chloride and lime feeding is
continuous. Initially, the ferric chloride and lime feed pumps
should be set to feed 2.4 GPD (32% solution) of FeC13 and 2.00 GPD
(5% solution) of lime. This is based on treating the design flow
of 23,000 gpd. However, these feed rates are subjectto change
based on -the actual flows and the scavenger waste suspended solids
concentration experienced at the facility. Laboratory analysis of
the waste stream is needed to determine the proper amount of feed.
The equalization tankseffluent should be analyzed once per week
for suspended solids concentration. Use the previous weeks
analysis to determine the feed rate for the current week, as well
as the facility flow rate. During normal operation the sluice gate
in the head box is closed.
ALTERNATE OPERATION. When the flash mixer and/or flocculator
require maintenance and repair, shut off each unit. Open thIe
sluice gate located in the head box to divert flow to the
equalization tanks. The flash mixer and/or flocculator tanks can
be dewatered by use of the plant portable submersible pump and
hosing, and inserting the discharge end of the hose into the
overflow chamber of the head box (Refer to Figure 9-2). Upon
completion of the dewatering the operator can inspect the mixer and
flocculator blades.
START-UP. Before starting a new flash mixer or flocculator unit,
or restarting one that -has been out of service for maintenance and
repairs, inspect the tank carefully as outlined below:
1. Check for debris such as rocks, sand, timber, waste
concrete, or other foreign material. Short pieces of
2 x 4 boards and other form lumber can suddenly appear
during initial flow, this material can damage a propeller
and turbine blade. s
Fes;
2. For instructions on startup for the flash mixer and
flocculator units consult the manufacturer's bulletins
which are included in Appendices D 9-1 and D 9-2. The
manufacturer's guides for the above equipment must be
rigidly followed.
If no problems develop initiate normal operation of the flash
mixer and flocculator units by letting flow into the tanks while
the units are in operation.
ROUTINE SURVEILLANCE. The flash mixer and flocculator units
should be given a daily routine inspection consisting of a visual
inspection and observation for oil leaks or unusual noises. If
either occur, unit should be shut down at once, the cause of
leakage or noise found and corrected.
The lime feed system should be checked routinely for plugging
of the discharge lines. The discharge piping from the lime feed
pump contains a pressure relief valve to protect the pump from
damage due to a line blockage. The relief valve overflow is piped
to the solution tank. All 90 degree bends in the slurry piping have
been provided with plugged tees or crosses to enable the operator
to clean the piping with high pressure water and/or rodding.
The discharge piping of the FeC13 pump is also equipped with a
relief valve, with the overflow being returned to the storage tank.
A clear section of piping is utilized to enable the operator to
detect an overflow condition. The operator should routinely check
the FEC13 vault for an overflow condition and for any leakage.
TROUBLESHOOTING. The following table contains guides for
correcting process malfunctions and a variety of common operating
problems which could occur during the treatment of waste stream and
the production, handling and disposal of the solids accumulated
during the treatment of the waste stream.
The purpose of Table 9-1 is to properly identify the problem
by defining the indicators. Once the problem has been identified,
certain analyses and/or inspections must be performed prior to
making a decision as to which corrective measures should be
utilized. In some cases, the data -gathering process can be simple
visual observation and in other cases it can involve sampling and
laboratory procedures. The resulting information should then be
systematically utilized to make a determination on which of the
corrective measures should be implemented.
The problems discussed in this table are those which could
occur frequently in practice and the suggested solutions have been,
for the most part, accepted procedures in the industry. There may
be times when the suggested corrective measures do not correct the
problem, or a problem may exist which does not fit into the common
category. In a case such as this, it is prudent to seek expert
advice on the subject prior to undertaking any coarse of action.
SAMPLING. Jar test should be performed on samples from the
equalization tank effluent as indicated in Chapter 3, Table 3-3.
HOUSEKEEPING. The greatest hazard involved in working on or
in the flash mixing and flocculation tanks is the danger of
slipping. Wash off with water under pressure accumulations of
solid particles, grease and other material from walkways, handrails
and all other exposed parts of the structures and equipment. Be
extremely cautious during freezing weather. A small amount of ice
can be very dangerous.
9- 10
s
TABLE 9 ® 1
TROUBLESHOOTING GUIDE FOR
CHEMICAL COAGULATION AND FLOCCULATION
PROBLEM
SYMPTOMS
ACTION
SOLUTION
Improperly
Cloudy appearance
Conduct laboratory
Correct coagulant
coagulated
waste of waste stream at
tests to determine
concentration if
stream
the outlet end of
optimum dose
required
the flocculation
tanks
Adjust speed of
Monitor the
flash mixer
turbidity of the
and/or
flocculation
flocculator units
tank effluent
per hour and
compare with the
results obtained
from satisfactory
floc formation
9® 11
CHAPTER 10: PRIMARY SETTLING TANKS
PAGE NO.
THEORY AND PURPOSE 10- 2
UNIT DESIGN AND DESCRIPTION
10- 2
Tanks
10- 2
Sludge Collector Mechanism
10- 5
Scum Collector Mechanism
10- 5
OPERATION AND CONTROL
10- 5
General
10- 5
Normal Operation
-10- 5
Alternate Operation
10- 5
Alarms
10- 7
Start Up
10- 7
Routine Surveillance
10- 8
Dewatering
10-10
Troubleshooting
10-10
Sampling
10-13
Housekeeping
10-13
NOTES AND ADDENDA 10-14
LIST OF TABLES
Table
10 - 1 Primary Settling Tank Record 10- 9
10 - 2 Troubleshooting Guide for the Primary 10-11
Settling Tanks
LIST OF FIGURES
Figure
10 - 1 Scavenger Waste Flow Schematic 10- 3
10 - 2 Plan and Sectional View of Primary Settling 10- 4
Tank
10 - 3 Primary Settling Tank Flow Schematic 10- 6
10- 1
THEORY AND PURPOSE
Sedimentation is the separation of suspended solids from a liquid
during relatively quiescent conditions.
Those solids having a higher specific gravity than the liquid will
tend to settle (gravitational settling) and those solids with a lower
specific gravity will tend to rise (floatation).
Within the primary settling tanks sedimentation is responsible for
removing the floc formed in the flocculation tank, and thus reducing
the suspended solids and organic loading to the rotating biological
discs.
The settled sludge is removed from the bottom of the tanks by a
sludge collector mechanism, and floating scum by scum removal troughs.
UNIT DESIGN AND DESCRIPTION
As shown on -Figure 10-1 sedimentation follows the flocculation
tank.
Flocculated wastewater enters each primary settling tank via a 6
inch pipe into the influent well of the settling tank.
The cylindrical influent well that surrounds the center column
(torque tube) in the tank improves the distribution of the flow by
forcing it downward several feet underneath the well rather than
allowing it to pass horizontally across the top of the tank, thus
preventing short-circuiting of the flow. After emerging from under the
well, the flow moves radially at a low velocity towards the V -notch
weir around the periphery of the tank. The weir is baffled to prevent
scum from being discharged with the effluent. From the weir, the
effluent enters the effluent trough around the outside of the tank and
is discharged to the hydrochloric mixing tank.
Sludge from these tanks is drawn -off via a 6 inch pipe by
telescoping valves located in a pit adjacent to the sludge/scum
tank.
There is one circular primary settling tanks at the facility, the
major components of which are as follows:
1. Tank
2. Sludge Collector Mechanism
3. Scum•Collector Mechanism
On Figure 10-2 is a plan and sectional view of the major
components of the primary settling tank.
10- 2
SCAVENGER
FE CL3
WASTE TRUCK
STORAGE TANK
FLOCCLATION TANK
EQUALIZATION TANK FLASH
PRIMARY
LBAR
EN
MIX TK.
CLARIFIER
GRIT CHAMBER
HCL,
- STORAGE
INFLUENT
LIME
TANK
PORTS
HEAD BOX
HCL MIXING
TANK
PRIMARY
DIGESTER
EXISTING
SLUDGE
DRYING
BEDS_
i
SCUM ROTATING
BIOLOGICAL
�
L-------�
DISCS
SLUDGE
WET WELL.
C7
O
Z
Cn
C
— —
FLOW METER
z
TO OUTFALL I I
FINAL
CLARIFIER
mi
Z
EFFLUENT
G7
EXISTING VILLAGE OFe
WET WELL
m
Z,
GREENPORT PLANT
m
SCAVENGER
WASTE FLOW SCHEMATIC
°
PRIMARY SETTLING TANK BASIC DESIGN DATA
Number of Units
Diameter, Feet
Side Water Depth, Feet
Detention Time:
At design flow of
M.G.D.
Overflow Rate:
At design flow of
M.G.D
Sludge Collector Mechanism
One (1)
12 Feet
8 Feet
8.2 hrs.
523 gals./sq. ft./day
This mechanism consists of a truss assemblage concentric with
the torque tube with two (2) radial trussed arms at 180 deg. F to
each other. There are flights with squeegees set at an angle attached
to each truss arm. As the truss revolves these flights push the
sludge towards the central sludge hopper. This entire mechanism -is
driven by a 1/2 HP, 230/460 V, 3 phase, 60 hertz, motor mounted on a
turn -table on top of the torque tube.
Scum Collector Mechanism
This mechanism moves radially, horizontally and vertically as it
automatically removes surface scum. The skimming device consists of a
scum deflector plate and a hinged blade connected to a skimmer boom.
As the boom rotates scum is deflected to the hinged blade which
collects and conveys the floating material into the scum trough. The
collected scum flows by gravity from the scum trough via a 6 inch pipe
to the scum wet well where it is stored until it is pumped out.
OPERATION AND CONTROL
General
The primary settling tank collector drives are controlled from a
panel near the motor. The control consists of a start,_ stop and reset
switch.
Normal Operation
Continuous operation of the sludge collector mechanism is
desirable in order to keep the sludge in constant motion toward the
sludge hopper and prevent sludge build-up on the tank bottom. This
would avoid the possibility of overloading the mechanism by starting it
with a load of sludge on the tank bottom.
Alternate Operation
When the settling tank is out of service for maintenance and repairs
press the STOP button on the control panel (see Figure 10.-3).
10- 5
PRIMARY SETTLING TANK FLOW SCHEMATIC
)EN
3ED
Alarms
The circular sludge collector has a torque indicator and overload
system. As the drive mechanism approaches an overload condition
increased torque causes the wormshaft of the gear to deflect a spring.
This deflection is indicated by a torque dial indicator mounted on the
walkway. Also included are two (2) micro switches (one N.O. and one
N.C.) .
Should the deflection equal or exceed the first pre-set limit
(1200 load condition) the internal switching mechanism will sound an
alarm. If this condition persists and exceeds the first limit and
advances to the second pre-set limit (1400 load condition) the internal
switching mechanism will de -energize the drive motor, stopping the
collector arms. Following this terminal overload, the overload
detector will reset automatically, but the electrical system must be
restarted manually by switching the selector switch for the terminal
overload system to the ON position.
A torque overload alarm condition should be investigated
immediately, and the trouble located and corrected. No attempt should
be made to keep the unit in operation while overloaded. Overloads are
most likely to result from too great a sludge accumulation or from some
foreign object in the tank. If overload is due to sludge accumulation,
incoming flow to the tank should be reduced or stopped, and the sludge
load should be lightened by pumping sludge. If a foreign object is the
cause of overload, the.obJect should be located and removed'if
possible: As a last resort, it may be necessary to dewater the tank to
locate and correct the difficulty. Following such a shutdown, the
collectors must be restarted..
DO NOT ATTEMPT TO KEEP COLLECTOR RUNNING
WHEN AN OVERLOAD IS INDICATED.
FIND THE TROUBLE AND CORRECT IT.
DO NOT START COLLECTOR WITH A LOAD
OF SLUDGE IN THE TANK..
Start Up
Before starting -up a new unit or one which has been out of service
for cleaning or repair, inspect the tank carefully as outlined in this
section.
Check the following items before the flocculation tank effluent
is allowed to pass into -the primary settling tank(s):
1. Check for debris such as rocks, sand, timber, waste
° concrete, or other foreign material. Short pieces of
2 x 4 boards and other form -lumber can suddenly appear
10- 7
during initial flow, this material can stall a sludge
collector mechanism.
2. Check collector drive mechanism for lubrication, drive
alignment and complete assembly.
3. Check squeeges blade on the collector flight for
proper distance from the floor of the tank.
4. Check hopper and sludge line for debris and obstructions.
If everything checks out properly, turn the mechanism on and
let it make several revolutions, checking that the squeegee does not
travel high and low, missing the bottom or scraping in some areas. The
scraping action should control the entire area from the outside wall
to the sludge hopper. Also be certain that the mechanism runs smoothly
without jerks or jumps.
Test the overload alarm to see if the mechanism will stop on
overload. With the unit running, time the period for the flights to
make one complete revolution around the tank and record the time for
later reference.
Check the amperage that the motor draws and record. Let the unit
operate for several hours and if no problems develop, it should be
alright (see Table 10-1) .
Routine Surveillance
The following items should be checked daily except as noted.
1. Be sure that the sludge collectors are operating smoothly.
2. Check for any unusual objects in the tank(s).
3. Check tank surface for rising or bulking sludge.
4. Check scum trough. Remove scum when necessary.
5. Check to see if any grease or rags are passing over or
are stuck on the effluent weirs. Effluent weirs must be
kept free of floating debris which may be blown into the
tank.
TABLE 10 - 1
PRIMARY SETTLING TANK RECORD
DATE COMMENT
E X A M P L E
10- 9
TIME - MIN. AMPERAGE
ONE REVOLUTION (AMPS)
6. Check overload indicator on tank bridge.
Dewatering
The primary settling tanks can be dewatered by following the
steps indicated below:
1. Isolate the tank by closing plug valve #1 (See Figure 10-3).
2. Remove the sludge from the bottom of the tank by adjusting
the telescoping valve.
3. Shut-off the sludge collector mechanism.
4. Lower the plant portable submersible pump and hosing into
the tank to be dewatered.
5. Remove the checkered plate on the head box and insert the
discharge end of the hose into the section of the head box
which will return flow to the equalization tanks (Refer to
Chapter 8, Figure 8®3).
6. Turn on the portable submersible pump. Hose down tank and
scum trough.
7. When the tank is about empty, turn off pump.
8. Remove the submersible pump and hosing from the tank and
the hosing from the head box.
9. Examine all equipment and tank surfaces below the water
line and repair, adjustor replace parts as needed. A
ladder will be required to perform this task.
10. Check all wear of the scum pick-up wiper blade. Replace
worn wiper blade.
11. To place the settling tank back into service follow the
steps indicated in the Start Up section of this chapter.
Troubleshooting
Table 10®2 contains guides for correcting process malfunctions
and a variety of common operating problems which could occur during the
treatment of the waste stream and the production, handling and disposal
of the solids accumulated during the waste stream treatment process.
10® 10
TABLE 10-2. TROUBLESHOOTING GUIDE FOR PRIMARY TREATMENT - PRIMARY SETTLING TANKS
-----------------------------------------------------------------------------------
Problem Action Solution
Poor sludge settling; sludge 1. Check telescoping valve 1. Adjust telescoping valve
flowing over weirs; sludge setting. setting to increase rate of
particles rising to surface sludge removal from settling
in settling tanks; effluent 2. Determine if the weir tanks.
clarity poor. overflow rate is equal
for the entire weir.
Erratic operation of
sludge collection
C) mechanism.
3. Dewater settling tanks
and check for damage on
sludge scraper mechanisms
especially at the peri-
phery of the tank.
1. Check all drives for
gear wear. Dewater
settling tanks and
check for damage on
sludge scraper
mechanisms.
2. Probe bottom for ex-
cessive accumulation
of sludge.
2. Level the weir. If uneven
weir overflow rate is
caused from wind; install
a windbreak,
3. Repair or replace all damaged
sludge scraper mechanisms.
1. Repair all worn or broken
sludge collector equip-
ment and drives.
2. If sludge accumulation
is a problem, increase
frequency of pumping sludge
from tanks.
TABLE 10-2. TROUBLESHOOTING GUIDE FOR PRIMARY TREATMENT - PRIMARY SETTLING TANKS (CON'D)
------------------------------------------------------------------------7--------------------
Problem Action Solution
---------------------------------------------------------------------------------------------
Visible grease particles 1. Check depth of the 1. Adjust the elevation of
being discharged. skimming blade in the the skimming blade for
water. Check the correct operation.
contact the skimming
blade makes with
the trough.
2. Check the depth of floating
scum and water in the pit.
r
Co
I
N
SAMPLING
+ Grab samples of primary effluent collected from the.effluent
channels twice a day should be analyzed for settlable solids and pH.
Twenty four-hour composite samples analyzed once a week for BOD5 and
suspended solids are collected at the sample place.
'HOUSEKEEPING
The greatest hazard involved in working'on or in a settling tank
is the danger of slipping. Wash off with water under pressure
accumulations of solids particles, grease, slime and other material
from walkways, handrails and all other exposed parts of the structures
and equipment. Be„extremely cautious during freezing weather. A
small amount of ice can be very dangerous. Your housekeeping program
should include the brushing or cleaning of effluent weirs and the
removal of any settled sludge from the launders.
10- 13
CHAPTER 11® SECONDARY TREATMENT FACILITIES
PURPOSE AND THEORY
Acid Neutralization
Secondary Treatment Process
UNIT DESIGN AND DESCRIPTION
pH Control System
Hydrochloric Acid Feed System
Hydrochloric Mixing Tank
Rotating Biological Discs
Aeration System
OPERATION AND CONTROL
pH Control System
Hydrochloric Feed Pump
Normal Operation
Alternate Operation
Start Up
Routine Surveillance
Sampling
Troubleshooting
NOTES AND ADDENDA
LIST OF TABLES
PAGE NO.
11-22
11- 1 RBD Load Cells 11-12
11- 2 Troubleshooting Guide for the RBD 11-13
Units
11- 3 Routine Maintenance Surveillance 11-20
s
LIST OF FIGURES
11-
1
pH Probe
11- 3
11-
2
Scavenger Waste Flow Schematic
11- 5
11-
3
Hydrochloric Acid Mixing Tank
11- 6
11-
4
RBD Units Cross Sectional View
11- 9
j
t
PURPOSE AND THEORY
Acid Neutralization
For this facility the use of lime in the flash mixing tank
increases the alkalinity and pH of the waste stream. Therefore,
to insure the proper environment for biological treatment to take
place the pH of the waste stream must be adjusted downward. To
lower the pH, hydrochloric acid is added to the waste stream.
The use of an acid to lower the pH is called acid neutralization.
Secondary Treatment Process
Rotating biological discs are used at this facility for
secondary treatment. The RBD process is a fixed film process
very similar to trickling filters.
The waste water passes over the discs in a thin film and
absorbs oxygen from the air. The microorganisms attached to the
disc remove organics and dissolved oxygen from the thin film.
The disc then rotates through the waste water picking up more
organics, completing the process. The absorbed BOD is oxidized
and synthesized by the bacteria, resulting in the oxidation
products of carbon dioxide and water, and the production of new
cells.
RBD performance is sensitive to the wastestream temperature
above- 90 deg. F or below 55 deg. F. Above 90 deg. F the
reduced solubility of oxygen in water will depress the dissolved
oxygen levels to a point where soluble BOD removals will be
adversely affected. When temperatures decrease below 55 deg. F
the treatment efficiency also decreases.
The shearing forces exerted on the biomass as the media is
rotated through the waste water cause excess biomass to be
stripped from the media into the waste water. These shearing
forces maintain a constant microorganism population on the media.
The mixing action of the rotating media keeps the stripped
biomass in suspension until the flow of the treated waste water
carries it downstream to the final settling tank for removal.
UNIT DESIGN AND DESCRIPTION
pH Control System
As mentioned in Chapter 9, lime treatment takes place within
a range of pH 9.0 to 11.5, therefore, pH adjustment will be
required before the wastestream enters the RBD units. To
accomplish the pH adjustment a submersible probe is located at
the influent channel of RBD #1 (see Figure 11®1). This probe is
used to monitor the pH level of the influent wastestream. This
11® 2
FIGURE 11-1
TO TRANSMITTER IN
1-REATMENT BLDG.
JUNCTION BOX
GRADE
vw.e).
--ELECTROOE
7-ASSEIVISLY
INFLUCNT CHA,-NNEL TO
-L
R15-0 TANK NO. I
pH PROBE DETAIL
[-CPJ CONSULTING ENGINEERS
probe sends a signal to the,pH control panel located in the
administration room in the Treatment Building. The pH control
panel consists of a pH receiver and indicator, pH controller, pH
recorder and electrical controls for the hydrochloric acid pump.
At high pH, the acid feeder speed controller increases the"rate
of flow to the hydrochloric acid mix tank located upstream -of the
RBD units and reduces the rate of flow at low pH.
HYDROCHLORIC ACID FEED SYSTEM
The acid neutralizing system for this plant utilizes
hydrochloric acid. Hydrochloric acid will be delivered to the
plant in solution form (30-32% concentration) to the hydrochloric
storage tank installed in a.below grade concrete vault. This
vault -is located northeast of the Administration/Treatment
Building.
1. Liquid hydrochloric acid
fiberglass hydrochloric
1,031 gallons. The tank
fill line, side access m
There is a 1 1/4 inch su
inch turn off and relief
storage tank - One
acid tank with a capacity of
is equipped with a 4 inch
anway and a vent line.
ction line with a 1 1/4
valve which connects to the
hydrochloric acid feed pump. The tank is also equipped
with a liquid level gauge, mounted in the administration
2. Hydrochloric acid feed pump - the hydrochloric acid pump
draws the hydrochloric acid solution from the storage tank
and discharges through a 3/4 inch,line into the
hydrochloric mix tank.
Pump
Number
Type,
Capacity Rating (Max.)
Control Range
Motor
HP
Rating
HYDROCHLORIC ACID FEED PUMP DESIGN DATA
1
Hydraulically activated Diaphram
3.83 gph @ 125 prig
0-100%
1 /'4
90 V, D.C., 1725 RPM, TENV
HYDROCHLORIC ACID MIXER._ As shown on Figure 11-2,
hydrochloric mixing is the next treatment process. The waste
stream enters the mixer tank a 6 inch line. The waste stream is
then chemically dosed with hydrochloric acid prior to being
mixed. Within this tank intense mixing is required -in order to
insure uniform chemical distribution of the acid throughout the
waste stream. The flow is mixed by submerged propellers. Figure
11-3 shows a sectional view of the mixing tank.
11- 4
SCAVENGER
WASTE TRUCK
INFLUENT
PORTS
n
L
n
O
Z
cn
C
_q
Z
G7
Z
G7
Z
rn
m
X
cn
BAR
SCREEN
GRIT CHAMBER
EXISTING SLUDGE
DRYING BEDS—
P
EQUALIZATION TANK
PRIMARY
DIGESTER
FE CL 3
STORAGE TANK
FLOCCLATION TANK
FLASH PRIMARY
MIX TK. CLARIFIER
HCL
STnRAr.F
SLUDGE
WET WELL
LIME
EAD BOX
ROTATING
BIOLOGICAL
DISCS
r-' FLOW METER
TO OUTFALL
EXISTING VILLAGE OF EFFLUENT
GREENPORT PLANT WET WELL
SCAVENGER WASTE FLOW SCHEMATIC
HCL MIXING
TANK
FINAL
CLARIFIER
FIGURE II -3
TO R OTAT l lel G
BIOLOGICAL SURFACE
UN ITS
WS.EL. 16.4
I
FROM
PRIMARY
CL%RIP(ER
HYDROCHLORIC ACID MIXING TANK
FCPJ CONSULTING ENGINEERS
HYDROCHLORIC ACID MIXING TANK BASIC DESIGN DATA
Number of Tanks
One (1)
Length, in Feet
2.5
Width, in Feet
2.5
Water Depth, in Feet
4.0
Volume, in Cubic Fee
25.0
Turbine Diameter, in Inches
13.6
Type of Turbine Blade,
Axial
Shaft Speed, in RPM
0 - 350
Motor Horsepower
0.65
ROTATING BIOLOGICAL DISCS
From Figure 11-2 the RBD units are the next treatment
process at the plant.
The RBD units at this facility consist of a series of
closely spaced polyethylene discs mounted on a horizontal shaft
and placed in concrete tanks. The shafts are supported above the
surface of the waste stream, allowing the lower portion of the
discs to extend into the waste stream. Approximately 40 percent
of the surface area is submerged. The RBD shaft rotates,
continuously submerging the biomass and exposing it to the
atmosphere. Rotation of the shaft is accomplished by mechanical
drives. Supplemental air supplied by coarse bubble diffusers
located on the bottom of the RBD tanks are used to assist in the
shearing of the biomass. Operation of the supplemental air is
intermittant.
The RBD system consists of two RBD tanks. The four (4) RBD
units in Tank No. 1 are arranged for parallel flow (single
stage). Effluent from the acid mix tank enters the RBD influent
channel via a 6 inch line. From this channel flow is distributed
equally to each RBD unit. The four (4) RBD units in Tank No. 2
are arranged for series flow (three stages by utilizing the
baffle system). Flow from RBD Tank No. 1 is discharged to the
center channel between RBD Tank No. 1 and No. 2. This flow
then enters the RBD units in Tank No. 2, further treated and
discharged to the RBD effluent box. From here it flows by
gravity via a 6 inch line to the secondary settling tank.
11- 7
As the waste stream passes from stage to stage, it undergoes
a progressively increasing degree of treatment.
An enclosure is provided for the RBD unit for odor control,
aesthetic requirements, and for protection against extreme
weather conditions. In the winter, an enclosure protects the
biological growth from freezing temperatures and prevents
excessive heat loss from the waste stream; during the summer it
controls algal growth on the media. The enclosure also prevents
ultraviolet degradation of the plastic media. Figure 11-4
indicates a cross sectional view of the RBD units.
RBD DESIGN DATA
RBD loading rate at 50 deg. F (gpd/sf)
RBD area (1) (sf/reactor)
Total area of media (sf)
Surface area per shaft (sf)
Number of shafts
Air supply (acfm/shaft)
Motor/Unit
Speed
Rating
Influent Parameters
0.099
600,000
200,000
100,000
2
70 - 350
7.5 HP
1200 RPM
230/460V, 3 phase, 60 HZ
Average Daily Flow (ADF) - (Totalized) - 19,700 gpd
Peak Flow (hourly) - 39,400 gpd
Minimum Flow Rate - 0 gpd
Sustained Period of No Flow (Max.) - 6 hours
Sustained Period of Maximum Flow - 4 hours
BOD -5 (soluble) - Avg. Diurnal concentration based on 24 hr.
composite sample - 2000 mg/l.
Temperature - 47 degrees F Minimum
Waste stream pH range 7.0 to 9.0
11® 8
90 degrees F Maximum
INFL. i
M I.K,TANK
liNt-t_--( , L -11\4t_
SECTIONAL VIEW
I
AERATION SYSTEM
As mentioned in Chapter 8, one (1) positive displacement air
blower located in the air blower room of the Treatment Building
supply air to the RBD units.
OPERATION AND CONTROL
pH Control System
The pH control system includes an adjustable sampling period
timer and an adjustable running period timer. The sampling
period timer controls the output signal from the proportional
plus reset controller. This timer is adjustable from 0-30
minutes and includes an automatic reset and a progress indicator
which shows the time remaining to the timed out position. The
running time timer controls the length of time for each
corrective action period. This timer is adjustable from 0-15
seconds and also has an automatic reset and a progress indicator.
Hydrochloric Feed Pump
Controls for the HCL feed pump consist of ON-OFF.,
AUTO -MANUAL switch and a single turn manual speed adjust
potentionmeter. These controls are on a panel mounted in the
administration room in the Treatment Building. The ON-OFF switch
turns the unit on and off. In the AUTO position the pump is
paced by a 4 to 20 ma signal from the pH receiver proportional to
a 4 to 12 pH range. In the MANUAL position the unit disregards
the signal from the pH receiver and can only be controlled
manually.
NORMAL OPERATION
The HCL mixer variable frequency controller should be set at
the desired speed setting. HCL feeding is intermittant depending
upon the desired pH value. Initially, the hyrochloric acid feed
pump -should be set to feed 3.5:GPD (30% solution) of HCL.
However, this feed rate is subject to change based on actual
plant operating experience.
The RBD process is inherently stable under conditions of
fluctuating hydraulic and organic.loads. There are no process
control functions to -perform such as -recycle of,sludge or
effluent for proper operation.
The RBD rotational speed has a significant effect on
treatment efficiency. As long as the RBD rotation is maintained,
the -process will operate satisfactorily. At this facility the
periphera-1 velocity is 16 fpm and the shaft speed is 1.5 rpm.
C
It wi11 take several days of operation before biomass
appears on the disc. After a week to 10 days a thin layer of
biomass will appear. At this time .some sloughing of the biomass
may take place. In 2 or 3 weeks of operation, the biomass will
be reestablished and the anticipated levels of BOD removal should
be achieved.
The operator should visually examine the appearance of the
biomass growth on each disc, on a daily basis. 'Biomass growth on
the discs will typically appear as a gray, shaggy mass when fully
developed. The growth will also typically be very irregular in
thickness. Once the biomass growth has been fully established,
any deviations in appearance from day to day should be
investigated.
There are load cells on the RBD units at this facility. The
operator should use the loadcell weight read-out device daily to
ascertain the approximate biomass thickness. See Table 11-1.
The operator should monitor dissolved oxygen (D.O.) levels
for each RBD basin on a daily basis. A minimum D.O. of 0.5 to
1.0 mg/l should typically be present.
Typical RBD problems which may occur and their solutions are
shown in Table 11-2.
ALTERNATE OPERATION
When the HCL mixer requires maintenance and repair, shut off
the unit and remove from the tank for servicing.
If one of the RBD tanks is taken out of service for
maintenance and repair, dewater the affected tanks to make sure
that the idle shafts are not submerged in a tank filled with
waste. Close the 6 inch plug valve to the RBD influent channel
and open the 6 inch plug valve to the RBD effluent box to by-pass
the kBD units and insert the removable stop gate for the RBD
effluent box. Use a portable submersible pump to dewater the
tank(s), with discharge to the head box overflow structure.
Depending on the length of time the RBD°s are to be out of
service, the following procedures should be followed:
Short Period Shut -Down (2 to 8 Hours): If the shut -down
period exceeds two hours, the RBD shaft must be rotated manually
1/3 of a turn every hour. This must be done to avoid an
unbalanced condition,,and subsequent damage to the gear reducer
when the unit is restarted.
Long Period Shut -Down (Over Eight (8) Hours: If the RBD
process is shut -down for an extended period of time (8 or more
TABLE 11- 1
RBD LOAD CELLS
Load Cells Weight Read-out Estimated Biofilm Thickness
(lbs.) (inches)
15400 0.050
17200 0.055
18700 0.060
20200 0.065
21700 0.070
* 23600 0.075
25000 0.080
26700 0.085
28100 0.090
29600` 0.095
31100 0.100
32900 0.105
34000 0.110
* Operator should initiate corrective action as outlined in
Alternate Operation section of this chapter.
TABLE 11 - 2
'TROUBLESHOOTING GUIDE FOR THE RBD UNITS
PROBLEM
Influent wastes contain toxic
or inhibitory substances that
kill biomass.
0
.Severe and unusual
variations in influent. pH
to the process. Generally,
pH in the range of 6.0 to
8.5 will not cause any
sloughing problems to
occur. However,"if
unusual variations,
consisting of periods of
low (below 5) .or high pH
(above 10.5) occur, loss
of biomass may result.
Odor - Objectionable odors
do not normally occur when
the RBD process is
treating typical domestic
wastewater. However, when
SOLUTION -
Determine the substance that is
causing toxicity and its concentra-
tion, discharge frequency and
duration. Elimination of the toxic
substance is the best solution,
although this may not be possible.
In the event that the toxic sub-
stance cannot be eliminated,
loading peaks should be dampened
and a uniform concentration of
the toxic or inhibitory substance
created to permit an acclimatised
culture to adapt.
The equalization of the inhibitory
substance may be best accomplished
at the source. If this is not -
possible, it must be accomplished at
the treatment plant. When the
corrections are made at.the treatmen
plant, dampening may be accomplished
either by aerated equalization or
possbily altering contractor stage
configuration.
Neutralization is required to
ensure that.influent pH to the
system is maintained within the
range of 6.0 to 8.5 at all times
during the .day. Performance, will
;be optimized by maintaining pH
within these limits with as flat a
profile as possible.
Provide or increase the rate of
supplemental aeration.
Incrtase the ventilation.
11= 13 'w.
CONT'D
TABLE 11 - 2
TROUBLESHOOTING GUIDE FOR THE RBD UNITS
PROBLEM
a high strength wastewater
is processed, odors may
occur in the first stages
if insufficient oxygen is
available to satisfy the
demand exerted by the
higher strength wastes.
Under these conditions,
the biomass becomes
anaerobic. Similarly, if
the enclosure around the
RBD process prevents
adequate ventilation, the
biomass may become
anaerobic, even with
domestic wastewater.
Odors can also develop due
to solids depositing at
the bottom of the RBD
basin.
Loss of Biomass Growth - Under
normal operation, there should
not be a massive loss of biomass
from the RBD media, although
small patches of biogrowth
will be°continuously dropping
off, as -noted • in the process
description. A massive loss
.of biomass -.,can occur if a toxic
chemical ha'ss"•been discharged
,into the, -system, as described
above. However, a massive -
loss of the biomass can also
occur if the RBD.is subjected
to continuing blasts of
cold.air.. For instance, cold
air blowing across an RBD unit
from a door,or vent left open
on a very cold, windy day
can kill'the.'biomass within hours.
SOLUTION
Determine depth of sludge deposits.
Remove sludge deposits. Determine
and.correct the cause.` Use of
supplemental air can assist in
minimizing sludge deposits.
Eliminate source of toxic substance,
as previously described.
i 1- 14,X
a
SOLUTION
Determine depth of sludge deposits.
Remove sludge deposits. Determine
and.correct the cause.` Use of
supplemental air can assist in
minimizing sludge deposits.
Eliminate source of toxic substance,
as previously described.
i 1- 14,X
CONY D
TABLE 11 - 2
TROUBLESHOOTING GUIDE -FOR THE FCBD UNITS
P,
PROBLEM
Excessive Biomass Growth -
The."load cells must be
monitored on a daily basin
to ensure -that biomass
growth does not exceed the,
carrying capacity of the
',RBD shaft. If excessive
growth is determined,
corrective measures must
be implemented.
Development of White Biomass -
It is not uncommon to develop
organisms on the contactor
media that appear white in
color. There is no immediate
concern if the white organisms
(probably thiotrix or beggiatoa)
appear in limited areas on the
media. If this form of biomass
appears to dominate the surface,
however, reduced process
performance levels may be
expected. The probable causes
of these organisms are as
follows:
- Influent septic wastewater
and/or high hydrogen sulfide
concentrations. Septic
wastewater and industrial
discharges with high H2S
concentrations may cause
predomination of a white
filamentous growth on the
contactor media. .
11
SOLUTION
See Table.11-2 for allowable loads
and collective -procedures.
This situation may be solved by
preaeration of the influent
waste or by the addition of
chemicals to increase the
concentration of oxidized
materials. -The exact amount of
preaeration required will
depend on the- original ratio of
oxidized and reduced material
in the waste, and the pH. If
chemicals such as hydrogen peroxide
or sodium nitrate are used, the
dosage is determined by a process
of trial: and error.
7
CONT'D
TABLE 11 - 2
TROUBLESHOOTING GUIDE FOR THE RBD UNITS
PROBLEM
SOLUTION
- Overloaded first stage
of
Use of the supplemental air
the reactor system. When
should alleviate this situation,
severe organic overloads occur
if it is not severely overloaded.
on the first stage of the
process,
Severe overloading will require
it is possibleto develop
the
the operator to provide a larger
white filamentous biomass
on
amount of surface area on the
the first stage.
first stage. This may be
accomplished by adjusting .the
baffles between stages one
and two to increase the fraction
of total surface area on the
first stage,
Low Dissolved Oxygen Level in
RBD Basin Wastewater. Low D.O.
levels may be caused by an
overloaded first stage, sludge
deposits at the bottom of the
basin, and elevated wastewater
temperatures.
Determine the cause of the low D.O.
levels. Corrective procedures for
overloaded first stages and sludge
deposits were previously described.
Use of supplemental aeration.may
assist during extreme high
temperatures.
J
hours), an unbalancing of the. discs, caused by the drying out of
the top half of the discs, will induce unusual load conditions on
the equipment when put back into service.
Prior to placing the RBD units back into service, the'
following procedures est be carried out to prevent damage to
gear reducers:
1. Drain tank.
2. Wash down all discs while rotating shaft.
3. Grease bearings while rotating shaft.
4. Repeat Step #3 above once every 2 weeks if excessive
moisture is present.
5. Close plug valve to RBD effluent b'ox. Remove stop gate from
RBD effluent box. Open plug valve to RBD influent channel.
The maximum recommended operating film thickness for the RBD
units is 0.075 inches. Therefore, when the operator observes a
read-out of approximately 35,000 lbs. he should initiate the
following actions asa guide. Actual plant operating experience
will indicate how long RBD air supply system should be used:
l.. Start the supplemental air supply system to the RBD
units. After the air supply system has been on for 45 to 60
minutes. Use the load cell device to ascertain the weight. If
the reading is less than 35,000 lbs. continue to use the
supplemental air supply system for an additional 30 to 45
minutes.
2. If the reading is still 35,000 lbs., increase the amount
of supplemental air to the RBD units. Two to three hours after
the air supply adjustment, take another load cell reading. If
the read-out is less than 35,000 lbs. continue as indicated in
(1) above.
3. If the read-out remains at 35,000 lbs. remove the
baffles to increase the first stage surface area and turn off the
supplemental air supply system. Use load cell device in the
morning of the nextloperating day. Re-insert baffle when load
cell reading is less than 35,000 lbs.
During loss of power or mechanical failure, and the RBD
units are not rotating the operator MUST refer to the O&M manual
in Appendix D-11-2 for specific recommendations.
START UP
Before starting a new HCL mixer or restarting one that has
been out of service for maintenance and repairs, inspect the tank
carefully as outlined below:
1. Check for debris such as rocks, sand, timber, waste
concrete, or other foreign material. Short pieces of
2 x 4 boards and other form lumber can suddenly appear
during initial flow, this material can damage a propeller
and turbine blade.
2. For instructions on start up for the HCL mixer consult
the manufacturer's bulletins which are included in
Appendix D-11-1. The manufacturer's guides for the above
equipment must be rigidly followed.
If no problems develop, normal operation of the HCL mixer
may begin by letting flow into the tank while the unit is in
operation.
The following procedures should be followed prior to, and
during, start-up of the RBD system:
Final Check of RBD Equipment prior to Start-up
1. System Tank and Piping: Check RBD tankage and piping
(influent and effluent.) to assure they are free of foreign
materia..
2. RBD Assembly: Perform visual check of radial structure
and plastic media.
3. Main Shaft Bearings: Check that pillow blocks have been
filled with the recommended grease.
4. Shaft Mounted Reducer: Visually check bubble gauge to
assure reducer is at the proper attitude. Visually check
oil level in -the oi-1 sight gauge. Check belt tension on
motor/sheave V -belts. Install required belt guard.
5. Bushing Bolts: Check torque on reducer -taper lock bushing
bolts. Torque should be 75 foot-pounds.
6. Baseplate and Pillow Block Bolts: Check'that all nuts and
bolts have been securely tightened.
7. Electrical: Verify electrical connection to insure that
rotation,of main shaft assembly is in accordance with
engineering. drawings. "J
Initial Start-up Procedures (Empty Tank)
Start-up" (15 -minute run)
A. Turn on electric power.
B. Listen for unusual noises.
C. Visual check of V -belts.
D. Check temperature of bearing housing.
E. Check clearance between tank wall and media.
F. Shutdown.
Continuous Operation
After the initial start-up has been approved and the system
is filled with wastewater, the system should be kept running
until shutdown for standard maintenance is required. During a
maintenance shutdown, repairs should.be made as quickly as
possible.
NOTE: Operate the system under working conditions for a short.period.
Check and re -tighten all mounting bolts and nuts.
Repeat procedure until no adjustment can be made.
ROUTINE SURVEILLANCE
Table 11-3 contains a guide for routine maintenance
surveillance of the RBD units.
SAMPLING
Since there are no process control functions to be'performed
for the RBD units, only minimal analysis is required to -monitor.
performance. Samples taken from,the RBD tanks and the final
settling tank effluent will .monitor the overall I performance of
the RBD units.' Samples should be taken from the RBD tanks on a
daily basis and analyzed for D.O.
TROUBLESHOOTING
The following table contains guides for -correcting process
malfunctions and a;variety of common operating problems which
could occur during the treatment of waste stream and the
production, handling and disposal of the solids:accumulated
during the treatment of the waste stream.
"J
11- 19'
TABLE 11-3
ROUTINE MAINTENANCE SURVEILLANCE
------------------------------------------------------------------------------
------------------------------------------------------------------------------
I n t e r v a l
Semi
Procedure Weekly Monthly Quarterly Annually Annual
------------------------------------------------------------------------------
Check RBD shaft bearings. Feel to I I I I I
see if they are running hot. Listen I I { I
for unusual noises. This includes I { { { {
any pillow block on output of speed
reducer. X ,
Feel motors to see if they are run-
ning hotter than design temperature.
Check area around the drive train
and shaft bearings for oil spills.
Check oil levels in speed reducer
and chain drive system.
Lubricate contactor shaft bearings.
Consult manufacturer's instructions.
Check chain drives for alignment
and tightness.
Check belt drives (if any) for
alignment and tightness.
Coat machined ends of RBD shaft
with grease in case these ends do
not have permanent coating®
Adjust RBD shaft bearings. This
includes any pillow block on the
reducer output.
Change lubricant for chain drive
system. Change oil in speed
reducer. Clean magnetic drain
plug, if any.
Replace the grease in the seals'
(if any) in the speed reducer.
Consult manufacturer's instructions.
X
{
{
x
I
I
x
I
{
{ X
{
{
{ X
I
1
I
{
I x
I
I
{
{ g•
Grease bearings in the electric
motor (if applicable). Consult' {
manufacturer's instructions.
----------------- --------------------------------------------
11- ------------------------------------------"
11- 20�
The purpose of this table is to properly identify the
problem by defining the indicators. once the problem has been
identified, certain analyses and/or inspections must be performed
prior to making a decision as to which corrective measures should
be utilized. In some cases, the data -gathering process can be
simple visual observation and in other cases it can involve
sampling and laboratory procedures. The resulting information
should then be systematically utilized to make a determination on
which of the corrective measures should be implemented.
The problems discussed in Table 11-2 are those which could
occur frequently in.practice and the suggested solutions have
been, for the most part, accepted procedures in the industry.
There may be times when the suggested corrective measures do not
correct the problem, or problem'may exist which does not fit into
the common category. In a case such as this, it is prudent to
seek expert advice on the subject prior to undertaking any coarse
of action.
J
NOTES AND ADDENDA
E
J
i
CHAPTER 12:- FINAL SETTLING TANK
PAGE NO.
THEORY AND PURPOSE 12® 2
UNIT DESIGN AND DESCRIPTION
12® 2
Sludge Collector Mechanism
12- 5
Scum Collector Mechanism
12- 5
Effluent Wet Well
12- 5
Effluent Flow Metering
12- 5
OPERATION AND CONTROL
12- 8
General
12- 8
Normal Operation
12- 8
Alternate Operation
12- 8
Alarms
12- 8
Start-up
12-10
Routine Surveillance
12-11
Dewatering
12-11
Troubleshooting
12-13
Sampling
12-13
Housekeeping
12-13
NOTES AND ADDENDA 12-16
Table
12 - 1
12 - 2
Figure
12 1
12 - 2
12 - 3
12 - 4
12 - 5
LIST OF TABLES
Final Settling Tank Record 12-12
Troubleshooting Guide for the Settling 12-14
LIST OF FIGURES
Scavenger Waste Flow Schematic
Final Settling Tank
Effluent Wet Well
Flow Metering Device
Final Settling Tank Flow Schematic
12- 1
12- 3
12- 4
12- 6
12- 7
12- 9
THEORY AND PURPOSE
The final settling tank provides a quiescent condition for
the settling of the suspended solids from the rotating biological
discs. These solids are irregular in size and tend to form a
floc which settles rapidly. The resulting humus sludge,is
removed from the bottom of the settling tank by use of the
telescoping valve located in the sludge/scum wet well. In
addition, scum which floats on the water surface is collected and
removed from the tank to the scum well.
UNIT DESIGN AND DESCRIPTION
Effluent from the rotating biological discs enters the final
settling tankvia a 6 inch pipe into the influent well to the
settling tank. The cylindrical influent well that surrounds the
,center column (torque tube) in the tank improves the distribution
of the -flow by forcing it downward several feet underneath the
well rather than allowing it to pass horizontally across the top
of the tank, thus preventing short-circuiting of the flow. After
emerging from under the well, the flow movesradially at a low
velocity towards the V -notch weir around the periphery of the
tank. The weir is baffled to prevent scum from being discharged
with the effluent.. From the weir, the flow enters the effluent
trough around the outside of the tank and is discharged to the
process wet well as shown in Figure 12 —1.
Sludge from this tank is drawn -off via a 6 inch pipe by a
telescoping valve located in a pit adjacent to the sludge/scum
tank.
The major components of the final settling system are:
1. The tank.
2. Sludge Collector Mechanism.
3 Scum Collector Mechanism.
Figure 12 - 2 is a schematic plan and cross-section view
of the circular final settling tank.
FINAL SETTLING TANK BASIC DESIGN DATA
Number of Units One (1)
Diameter, Feet 10 ft.
Side Water Depth, Feet 8 ft.
Detention Time:
At design flow of
M.G.D. 5.7 Hrs.
12- 2
i
SCAVENGER
WASTE TRUCK
BAR
SCREEN
GRIT CHAMBER
EXISTING SLUDGE
®RYING BE®3®_
B
FE CL3
STORAGE TANK FLOCCLATION TANK
EQUALIZATION TALK FLASH PRIMARY
MIX TK. CLARIFIER
HCL
LIME STORAGE
TANK
HEAD BOX HCL MIXING
TANK
PRIMARY
DIGESTER
ROTATING
SCUM _ BIOLOGICAL
DISCS
SLUDGE
DIWET WELL
r — —, FLOW METER
TO OUTFALL I
J EFFLUENT
EXISTING VILLAGE OF WET WELL
GREENPORT PLANT
SCAVENGER WASTE FLOW SCHEMATIC
FINAL
CLARIFIER
i
a
i
i
SCUM TO WET WELL.�'
PLAN
FrAl V41. 11
'00or
momb 4m
ROT9TION
SLUDGE LINE
SECTION,
FINAL SETTLING -TANK
Overflow Rate:
At design flow of
M.G.D.
Sludge Collector Mechanism
251 gals./sq. ft./day
This mechanism consists of -a truss assemblage concentric
with the torque tube with two (2) radial trussed arms at 180
degrees to each other. There are flights with squeegees set at
an,angle attached to each truss arm. As the truss revolves these
flights push the sludge towards the central sludge hopper. This
entire mechanism is driven by a 1/2 HP, 230/460V 3 phase, 60
hertz, motor mounted on a turn -table on top of the torque tube.
Scum Collector Mechanism
This mechanism moves radially, horizontally and vertically
as it automatically removes surface scum. The skimming device
consists of a scum deflector plate and a hinged blade connected
to a skimmer boom. As the boom rotates scum is deflected to the
hinged blade which collects and conveys the floating material
into the scum trough. The collected scum flows by gravity from
the scum trough via a 6 inch pipe to the scum pit where it is
stored until it is pumped out.
Effluent Wet Well
Effluent from the final settling tank flows by gravity via a
6 inch line to the process wet well. From the wet well the waste
stream is pumped to the flow meter and to the existing Village of
Greenport plant for further treatment. Figure 12-3 shows a
sectional and plan view of the effluent wet well.
EFFLUENT WET WELL DESIGN DATA
Number of pumps Two
Type Submersible
Discharge Capacity 60 GPM @ TDH 17'
Speed 1725 RPM
Motor 0.9 HP
Rating 460 V, 3 phase, 60 HZ
Effluent Flow Metering
A flow metering device is located in a metering pit
following the effluent wet well. The rate of flow of the
scavenger waste stream is measured by a 3 -inch magnetic flow
meter tube (see Figure 12-4).
12- 5
f
VALVE BOX
TO F-XkST.
IMHOFF TANK -
FIGURE 12-3
SUBMERSIBLE E:FFL.
PUMP (TYP.)
VENT
UvEt--C't- L-UVV St --<um / w -
D,IGESTCR SLOG, -FROM SE:CC)NOA.IqY
-!Z-)E:T-7LING. TANK
EFFLUENT WET WELL PLAN VIEW
CPJ'
CONSULTING ENGINEERS
MANHOLE: COVER AND
FRAME
VALVE: BOX (TYR)
PLUG VALVE: (TYR)
41 X 411 TF—E: (TYP)
TO GREENPORT STP
IMHOFF TAN
FLG. CPLD. ADAPTER:,a'.,
W/ MAGNETIC
TUBE METER
FLOW METER PIT
—FLOW METER PUMP AND
TRAWMETER
—ELEC. LINE:
-SIGN.,64— TO TREAT.
FROM EFFL.WET
W ELL
—HYDPA,,Ut-IC FLUID LINES
HANDHOLD (TYP-)
The magnetic flow meter tube measures the volumetric -flow
rate through the tube by means of a 316 stainless steel
electrode.
The components of the flow -measuring system are the magnetic
flow electrode, a transmitter and a totalizer. Effluent flow
tube meter, measurement provides the following information:
1. A record of the hydraulic load on the various units in
the plant.
2. A means of computing the organic load to the plant.
3. Data for the preparation of composite samples.
The output signal is transmitted to the totalizer, mounted
inia panel on the wall of the Treatment Building, indicates the
rate of flow calibrated linearly from 0 to 75 GPM. The totalizer
provides a continuous total of the -quantity of wastewater passing
through the tube.
The operator should read the totalizer at the same time each
day and compute and record the total flow to the plant for the
previous day.
OPERATION AND CONTROL
General
The final settling tank collector drives are controlled
from a panel near the motor. The control consists of a start,
stop and reset switch.
Normal Operation
Continuous operation of the sludge collector mechanism is
desirable in order to keep the sludge in constant motion toward
the sludge hopper and prevent sludge build-up on the tank bottom.
This would avoid the possibility of overloading the mechanism by
starting it with a load of sludge on the tank.bottom.
Alternate Operation
When the settling tank is out of service for maintenance and
repairs press the OFF button on the control panel. Also.see
Figure 12-5.
Alarms
The circular sludge collector has a torque indicator and
overload system. As the drive mechanism approaches an overload
12- 8
TO SLUDGE:/SCUtA
WE'r VVELL-i
NORMAL OPE:R
-CLOSE:O
-OPEN
-NO14MAL OPERATION -OPEN
ALTERNATE: OPE:RATION-
CLOSCO
ink 4:41E
A
condition increased torque causes, the wormshaft of the gear to
~ deflect a spring. This deflection is indicated by a torque dial
indicator mounted on the walkway. Also included are two (2)
micro switches (one N.O. and one N.C.).
Should the deflection equal or exceed the first pre-set
limit (1200 load condition) the internal switching mechanism will
sound an alarm. If this condition persists and exceeds the first
limit and advances to the second pre-set limit (140% load
condition) the internal switching mechanism will de -energize the
drive motor, stopping the collector arms. Following this
terminal overload, the overload detector will reset
automatically, but the electrical system.must be restarted
manually by switching the selector switch for the terminal
overload system to the ON position.
A torque overload alarm condition should be investigated
immediately, and the trouble located and corrected. No attempt
should be made to keep the unit in operation while overloaded.
Overloads are most likely to result from too great a sludge.
.accumulation or from some foreign object in the tank. If
overload is due to sludge accumulation, incoming flow to the tank
should be reduced or stopped, and the sludge load should be
lightened by pumping sludge. If a foreign object is the cause of
overload, the object should be located and removed if possible.
Asea last resort, it may be necessary to dewater the tank to
locate and correct the difficulty. Following such a shutdown,
the collectors must be .restarted.
DO NOT ATTEMPT TO KEEP COLLECTOR RUNNING
WHEN AN OVERLOAD IS_INDICATED.
FIND THE TROUBLE AND CORRECT IT.
DO NOT START COLLECTOR WITH A LOAD OF
SLUDGE IN THE -TANK.
Startup
Before starting -up a new unit or one which bas been out of
service for cleaning or repair, inspect the tank carefully as
outlined in this section.
Check the following,items before the Rotating Biological Disk
effluent is allowed to pass into the secondary settling tank(s):
1. Check for debris such -as rocks, sand, timber, waste
concr.ete,'or other foreign material. Short pieces of
2 x 4 boards and other form -lumber can suddenly appear
during initial flow, this material can stall a sludge
collector mechanism.
12- 10
2. Check collector drive mechanism for lubrication, drive
alignment and complete assembly.
3. Check squeegee blades on the collector flight for
proper distance from the floor of the tank.
4. Check hopper and sludge line for debris and obstructions.
If everything checks out properly, turn the mechanism on and
let,it make several revolutions, checking that'the squeegee does
not travel high and low, missing the bottom or scraping in some
areas. The scraping action should control the entire area from
the outside wall to the sludge hopper. Also be certain that the
mechanism runs smoothly without jerks or jumps.
Test the overload alarm to see if the mechanism will stop on
overload. With the unit running, time the period for the flights
to make a complet revolution around the tank and record the time
for later reference.
Check the amperage that the motor draws and record. Let the
unit operate for several hours, and if no problem develops, it
should be alright (see Table 12®1).
Routine Surveillance
Y
The following items should be checked daily except as noted.
1. Be sure that the sludge collectors are operating smoothly.
2. Check for any unusual objects in the tank(s).
3. Check tank surface for rising or bulking sludge.
4. Check scum trough. Remove scum when necessary.
5. Check to see if any grease or rags are passing over or
are stuck on the effluent weirs. Effluent weirs must be
kept free of floating debris which may be blown into the
tank.
6. Check overload indicator on tank bridge.
Dewatering
The final settling tank can be dewatered by initiating
alternate operation and following the steps indicated below:
1. Shut off the sludge collector mechanism.
2. Remove sludge using telescoping valve.
DATE
TABLE 12- 1
FINAL SETTLING TANK RECORD
TIME - MIN. AMPERAGE
COMMENT ONE REVOLUTION (AMPS)
12- 12
3. Lower the plant portable submersible pump and hosing
into the final settling tank:
4. Open the roof scuttle on the equalization tank and insert
discharge end of the hose into the equalization tank
(Refer to Chapter 8, Figure 8-4)-.
5. Turn on the portable submersible pump. Hose down tank and
scum trough.
6. When the tank is about empty turn off pump.
7. Remove the submersible pump and hosing from the final
settling tank and the hosing from the roof scuttle.
8. Examine -all equipment and tank surfaces below the water
line and repair., adjust or replace parts as needed. A
ladder will be required to perform this task.
9. Check for wear of the scum pick-up wiper blade. Replace
worn wiper blade.
10. To place the settling tank back into service follow the
steps indicated in the Start Up section of this Chapter
and return to normal operation.
Troubleshooting
Table 1-2-2 contains guides for correcting process
malfunctions and a variety of common operating problems which
could occur during the treatment of the waste stream and the
production, handling and disposal of the solids accumulated
during the waste stream treatment process.
SAMPLING
Twenty four hour composite samples of RBD effluent collected
from the RBD effluent channel once,a week should be analyzed for
BODS and suspended solids. The pH should be monitored twice
daily from this location also.
HOUSEKEEPING
The greatest hazard involved in working on or in a settling
tank is the danger of slipping. Wash off with water under
pressure accumulations of solids particles, grease, slime and
other material from walkways, handrails and all other exposed
parts of the structures and equipment. Be extremely cautious
during freezing weather. A small amount of ice can be very
dangerous. Your housekeeping program should include the brushing
or cleaning of effluent weirs and the removal of any settled
sludge from the launders.
12- 13
TABLE 12-2. TROUBLESHOOTING GUIDE FOR SECONDARY TREATMENT - FINAL SETTLING TANKS
-----------------------------------------------------------------------------------
Problem Action Solution
Poor sludge settling; sludge 1. Check telescoping valve 1. Adjust telescoping valve
flowing over weirs; sludge setting. setting to increase rate of
particles rising to surface sludge removal from settling
in settling tanks; effluent 2. Determine if the weir tanks.
clarity poor. overflow rate is equal
Septic sludge
Erratic operation of
sludge collection
mechanism.
for the entire weir. 2. Level the weir. If uneven
weir overflow rate is
3. Dewater settling tanks caused from wind; install
and check for damage on a windbreak.
sludge scraper mechanisms
especially at the peri 3. Repair or replace all damaged
phery of the tank. sludge scraper mechanisms.
1. Check sludge withdrawal 1. Restore to suitable
rate. condition.
2. Check if collection
mechanism is off® obstructed
or not running continuously.
1. Check all drives for
gear wear. Dewater
settling tanks and
check for damage on
sludge scraper
mechanisms.
2. Second bottom for ex-
cessive accumulation
of sludge.
1. Repair all worn or broken
sludge collector equip-
ment and drives.
2. If sludge accumulation
is a problem® increase
frequency of pumping sludge
from tanks.
CONT®D
TABLE 12-2, TROUBLESHOOTING GUIDE FOR SECONDARY TREATMENT - FINAL SETTLING TANKS
-------------------------------------------------
Problem Action Solution
Visible grease particles 1. Check depth of the 1. Adjust the elevation of
being discharged. skimming blade in the the skimming blade for
water. Check the correct operation.
contact the skimming
blade makes with
the trough.
2. Check the depth of floating
scum and water in the pit.
N
Un
CHAPTER 13: SLUDGE AND SCUM TREATMENT FACILITIES
PAGE NO.
PURPOSE AND THEORY 13- 3
Sludge/Scum Handling Facilities 13- 3
Anaerobic Sludge Digestion 13- 3
Sludge Dewatering 13- 3
UNIT DESIGN AND DESCRIPTION
13- 4
Sludge/Scum Handling Facilities
13- 4
Anaerobic Sludge Digestion
13- 4
Gas Mixing System
13-11
Sludge Heating Unit
13-13
Gas Extraction
13-16
Sludge Transfer Pumps
13-16
Sewage Gas System
13-16
Sludge Dewatering
13-23
OPERATION AND CONTROL 13-25
Scum Removal 13-25
Normal Operation 13-25
Alternate Operations 13-26
Routine Surveillance and Housekeeping 13-27
Anaerobic Sludge Digestion
13-27
Normal Operation
13-27
Alternate Operation
13-27
Start Up
13-31
Routine Surveillance
13-36
Daily Procedures for Operation
13-39
Sampling
13-40
Instrumentation and Alarms
13-40
Housekeeping
13-41
Troubleshooting
13-41
Sewage Gas System Operation 13-41
Normal Operation 13-45
Alternate Operation 13-45
Gas Utilization 13-46
Safety 13-47
System Maintenance 13-48
Sludge Dewatering 13-49
Operation and Control 1,3-49
Procedure for Withdrawing Sludge 13-49
Filling Beds 13-50
Cleaning the Beds 13-50
Dried Sludge Characteristics 13-50
Schedules 13-50
Sludge Removal 13-51
13- 1
NOTES AND ADDENDA
LIST OF TABLES
Table
PAGE NO.
13-52
13m
1
Sludge
Recirculation Pumps Valve Schedule
13-18
13®
2
Sludge
Transfer Pumps Valve Schedule
13-20
13-
3
Units,
Location and Controls
13-37
13-
4
Sludge
Digestion Troubleshooting Guide
13-42
LIST OF FIGURES
Figure
13-
1
Scavenger Waste Flow Schematic
13® 5
13-
2
Sludge/Scum Wet Well
13- 6
13-
3
Reactions In a Digester
13- 8
13-
4
Sludge Digester
13-12
1.3-
5
Heat Exchanger Unit
13-15
13®
6
Sludge Recirculation Pumps
13-17
13®
7
Sludge Transfer Pumps
13-19
13-
8
Sewage Gas Piping
13-24
13®
9
Volatile Solids (VS) Reduction Chart
13-30
13- 2
PURPOSE AND THEORY
Scum Handling Facilities
Scum is that part of the waste stream that floats to the
surface because its specific gravity is lighter than water., This
includes soap, hair, oil and grease. If it is not removed from
the waste stream, scum will cause clogging of pipes and pumps and
will coat the RBD°s media. It can be a highly visible eye -sore
in the receiving waters and a constant source of odors. Scum is
removed from the primary and final settling tanks by skimming it
from the surface and gravity flow to the scum wet well.
Anaerobic Sludge Digestion
The purpose of digestion is to attain both of the objectives
of sludge treatment, a reduction in volume and the decomposition
of highly putrescible organic matter to relatively stable or
inert organic and inorganic compounds. Anaerobic digestion of
sludge is a complex biochemical process employing several groups
of anaerobic and facultative anaerobic organisms. In general,
the process can be considered to consist of two steps. In the
first step, facultative organisms called "acid formers" degrade
the complex organics of raw sludge to volatile organic acids. In
the second step, these volatile acids are fermented to methane
and carbon dioxide by a group of anaerobes called "methane
bacteria". In contrast to raw sludge, which is offensive in
appearance, odorous, and laden with pathogenic organisms, the
residue after digestion (digested sludge) is relatively
inoffensive and is basically innocuous. Thus, anaerobic
digestion achieves ultimate disposal by gasifying a portion of
the sludge and by preparing the remainder for ultimate disposal
by other methods. In addition, the end products have recycle
potential. A principal gaseous end product is methane, which is
often used as a fuel in wastewater treatment plants. Sludge
digestion takes place at almost any range of temperature likely
to be encountered, but the time taken to complete digestion
varies greatly with the temperature.
Sludge Dewatering.
Sludge drying beds are used for dewatering digested sludges
at this facility. Digested sludge is discharged onto a drying
bed and allowed to dewater and dry under natural conditions.
After digested sludge is applied to the drying beds, dissolved
gases are released and rise to the surface. The solids remain on
the drying bed media and the filtrate drains through the media.
The filtrate flows to the under drain system and to the
supernatant wet well. It is then pumped to the equalization tank
for further treatment. Drying beds drain very slowly in the
beginning, however, after 3 days the rate increases. After
13- 3
maximum drainage is reached, the dewatering rate gradually slows
down and evaporation continues. When the moisture content is low
enough the sludge can be removed. The drying out period can take
from 1 to 4 weeks.
Dry sludge is removed from the beds with a bobcat and taken
to a landfill for final disposal.
Figure 13-1 shows a flow schematic of the sludge handling
facilities.
UNIT DESIGN AND DESCRIPTION
Sludge/Scum Handling Facilities
A scum blade in each settling tank is used to direct the
floating scum to the scum trough in the settling tank. Scum from
the two primary and the final settling tanks flows by gravity via
a 6 inch pipe to the sludge/scum wet well. The sludge/scum wet
well structure consists of a below grade combined wet well and
pump room. See Figure 13-2. Access to the pump room and wet
well is obtained by removing the checkered plate covers on top of
the structure. The wet well has a capacity of 480 gallons which
when full can be pumped out in approximately three minutes by the
scum pump and is discharged via a 4 inch line to the primary
digester tank. The sludge/scum wet well has three (3) float
switches for pump control, pump on, pump off and high level
alarm.
SLUDGE/SCUM PUMP WET WELL DESIGN DATA
Number of Pumps
Type
Maximum Solids Pumped
Discharge Capacity
Maximum Allowable Speed
Suction and Discharge Connections
Suction
Motor
Float Switches
Anaerobic Sludge Digestion
Two
Positive Displacement
(Progressive Cavity)
150 gpm @ 27 ft.
450 RPM
6 -inch
Normally flooded
5 HP
Pump On level -
Pump Off level -
High level alarm
TDH
EL. 10.7
EL. 8.2
- EL. 11.8
Thickened sludge is pumped from the sludge wet well to the
13- 4
SCAVENGER
WASTE TRUCK
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PRIMARY
DIGESTER
SLUDGE
FE. CL 3
STORAGE TANK FLOCCLATION TANK
FLASH PRIMARY
MIX TK. CLARIFIER
HCL
STORAGE
LIME TAN
HEAD BOX HCL MIXING
TANK
TO OUTFALL FLOW METER
-J EFFLUENT
EXISTING- VILL.AGE OF WET WELL
GREENPORT PLANT
SCAVENGER WASTE FLOW SCHEMATIC
4
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SLUDGE
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FLASH PRIMARY
MIX TK. CLARIFIER
HCL
STORAGE
LIME TAN
HEAD BOX HCL MIXING
TANK
TO OUTFALL FLOW METER
-J EFFLUENT
EXISTING- VILL.AGE OF WET WELL
GREENPORT PLANT
SCAVENGER WASTE FLOW SCHEMATIC
4
FINAL
F I E -T,
lid
SLUDGE PIPE FROM
SECONDARY SETTLING TANK -
SCUM PIPE SECOND
SET"TLI N G TANK
SCUM PIPE FROM �RIMARY
SE-rTLIN G TK
SLUDGE PUMP (TYP)
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=PIPE TO AN
. IOIGESTER
SLUDGE PIPE FROM -CHECKERED PLATE TYP
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SLUDGE /SCUM WET WELL PLAN -VIEW
FIGURE 13-2
VALVE STAND W/
SECTIONAL, VIEW
digester for further treatment. See Figure 13-1. The Scavenger
Waste Facility treatsthe primary and secondary sludge in a
sludge digester tank where bacteria decomposes the organic solids
in the absence of dissolved oxygen.
The purposes of sludge digestion area
1. A 20 to 30 percent reduction of total, dry solids.
2. The conversion of highly putrescible organic matter
to relatively stable compounds.
3. The production of methane gas to be used in heating.
The anaerobic digestion process utilizes anaerobic
(living in the absence of oxygen) and facultative (living either
with or without oxygen) organisms for stabilization of the
organic matter in sludge. Digestion takes place in enclosed
tanks.
There are three stages of sludge digestion:
1. Acid fermentation
2. Acid regression
3. Intensive digestion
Figure 13-3 shows the typical.reactions which take place in
the digester.
During each stage the volatile acids and pH go through
dramatic changes.
In the acid fermentation stage of digestion, "acid forming"
microorganisms attack the soluble solids such as sugar and
produce organic acids at a concentration of upwards of several
thousands mg/L, causing the pH to drop to 5.1 or lower; carbon
dioxide, carbonates, and hydrogen sulfide are also produced by
the "acid forming" micro-organisms.
The second stage is acid regression, where the organic acids
and nitrogenous compounds are liquified by microorganisms to
which an acid environment is favorable. The pH climbs from 5.1
back to 6.8. Small quantities of carbon dioxide and methane are
produced in this stage.
099�A
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MMA2�00T*Q
REACTIONSFIGURE 13-3 DIGESTEA
Intensive digestion, stabilization, and gasification marks
the third state of digestion. The proteins and amino acids are
attacked by "methane forming" microorganisms. The pH becomes
stabilized in the range of 6.8 to 7.4 and the volatile acid
content is down to about 500 mg/L. At this point the solids can
be disposed of without causing a nuisance. During this last
stage of digestion a large amount of methane gas is produced
which can be burned off or utilized.
In a well -operated digester, all three stages are carried
out at the same time, with the acids produced in the first stage
being partially neutralized by the ammonia produced in a
.following stage until they can only be further degraded. The pH
of the third stage should predominate and keep the digester in a
neutral range. Once good alkaline digestion is established, the
acid stages are not apparent unless the normal digestion process
becomes upset by overloading, addition of poisonous chemicals,
large temperature swings or poor mixing.
The whole process can be considered to be an "assembly line"
process where the products of one stage are utilized and then
passed onto the next group of organisms. For this reason, any
action which hurts one group of organisms will have an adverse
effect on the entire process.
A well digested sludge should be black in color, have a
tarry odor, and contain solids in which the volatile fraction is
only 40 to 60 percent. The gas volume produced should be in the
range of 12 to 17 cubic feet of gas per pound of volatile matter
destroyed, or about 7 to 9 cubic feet per pound of volatile
matter added.
Most of the volatile solids reduction and gas production
takes place in the primary digester. To achieve this end, proper
conditions of temperature and complete mixing are provided.
Temperature is an important factor in determining the time
period required for complete digestion. At 95 deg F, digestion
takes about 25 days, but the time required doubles if the
temperature drops to around 60 deg F. The unit must be maintained
consistently within a narrow range of a few degrees to prevent
damage to the methane -producing organisms. It is recommended
that the temperature in the primary digester tank be maintained
between 95 and 98 deg F.
The food supply is another important factor in providing
maximum use of the digestion capacity. The total volume of raw
sludge pumped and the pumping rate are both important. If too
much sludge is added to the digester at one time, the first stage
(acid production) predominates and the environment becomes
unfavorable for the other organisms. This condition is termed
13- 9
"overloading". The organisms in the digester are most efficient
when food is furnished to them in small volumes at frequent
intervals. Fresh sludge, as concentrated as possible, should be
pumped to the digester at least twice a day.
Seeding (adding digested sludge from some other source) is
the best way to start up a new digester or restart an existing
"sick" digester. The seed sludge contains the organisms of the
second and third stage and allows the digester to begin
functioning in the shortest possible time. An adequate amount of
digested sludge must be maintained in the digestion tank as seed.
Mixing the contents of the digester is beneficial in many
ways. The mixing helps to maintain a constant temperature
throughout the digester, provide contact between the food and the
organisms, and reduce scum formation. The rate of digestion is
thereby increased, and the time required for complete digestion
is reduced.
The pH of a well operated digester may be expected to remain
in the range of 6.8 to 7.4. Any marked difference from these pH
values means that the digestion process is out of balance, and
corrective action must be taken before the process ceases to
function.
The ratio of volatile acids to alkalinity offers a sensitive
control for the operation of the digester. If the ratio is less
than 0.3, the digester is in good balance. A ratio of 0.4 shows
that the digester is under stress, and if the ratio reaches 0.8,
the process is in serious trouble. Other indicators which have
been used are the rate of volatile acid increase and the ratio of
carbon dioxide to methane in the digester gas. Although each
plant has a varying normal value, volatile acid concentrations
greater than 1,000 mg/L are usually detrimental to the digestion
process.
There are many reasons for failure of digesters. The major
reasons are poor mixing, overloading, and temperature
fluctuation. Other causes of failure are low pH, low alkalinity,
high volatile acids, toxic industrial wastes, toxic metals, and
addition of too much lime.
Precautions. Because of the highly combustible and
explosive nature of the gases associated with sludge digestion,
special precautions are absolutely necessary.
1. No smoking or use of any open flame within the
primary sludge digester building or on digester
roofs should be permitted.
2. Only nonsparking tools should be used in a sludge
digestion area.
13-10
3. If exhaust fans in the primary sludge digester
building are not running, they should be operated
manually when personnel enter the building.
4. Use of ungrounded electrical tools cannot be allowed
in the restricted area.
While combustion may take place at lower concentrations, the
greatest hazard occurs when air and sludge gas combine to produce
a 5 to 15 percent methane mixture by volume. In this range, the
mixture is -explosive. Special precautions must be observed
during dewatering of the digester tank to prevent the formation
of an explosive mixture.
DIGESTER DESIGN DATA
Number of Tanks One
Diameter, ft. 25.0
Sidewall Water depth, ft. 18.0
Volume, gallons 66,000
Cover Floating
Figure 13-4 contains a cross sectional view of the sludge
digestion tank.
Gas Mixing System
The primary digester tank is equipped with a gas mixing
system located on the top of the floating cover. This system
recycles the gases that have accumulated in the gas dome and
redistributes them at various points in the bottom of the
digestion tank providing a mixing of tank contents. Mixing
accelerates the digestion process. The high rate digestion must
continue once started. Digestion upset is probable when the gas
mixing is discontinued.
The gas mixing system consists of a compressor, motor and
safety controls, including a high pressure relief with flame
arrester, a low pressure regulator to maintain positive service
pressure, pressure indicating gauges, and motor operated valves
with interconnecting piping mounted in a ventilated housing. A
combination starter and circuit breaker with a start/stop
pushbutton is mounted on the outside of the compressor housing.
All of the electrical equipment is either explosion proof or
is installed in explosion proof enclosures.
The assembly housing is close to the gas dome to require
only short lines for the suction, control and by-pass relief
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lines. This central location reduces to a minimum the length of
distribution lines to each discharge well.
All of the discharge piping between the compressor housing
and the gas discharge wells is located in the cover within the
attic space between the ceiling plate and roofing. All the
discharge wells are designed to allow the installation and
removal of the-vertical gas discharge pipe without disconnecting
any of the distribution piping and without the release of gas
from the digester. The plain-end discharge and size of the pipe
eliminates clogging.
Pressure controls include a pressure-relief valve, a
pressure regulator, and low-pressure safety switch. The
pressure-relief valve is actuated by pressure in the compressor
discharge line and will open at a predetermined maximum pressure
to bypass back to the cover gas dome through the return line.
The pressure regulator will act to prevent an excessive drop in
pressure in the cover gas dome•and gas utilization system
occasioned when starting the compressor or when in operation. It
will be actuated by a pressure-control line directly connected
into the cover gas dome and will open at a .predetermined minimum
pressure to bypass back to the cover gas dome through the return
line. The low-pressure safety switch with manual reset will shut
down the compressor motor in the event the suction line pressure
at the compressor approaches 1 inch w.c. gas pressure.
Two dial type pressure indicating_ gages are flush-mounted on
the assembly housing. One gage is connected to the compressor
discharge and reads from 0 prig to 20 prig. The other gage is
connected to the pressure control line to the pressure regulator
and will indicate the pressure in the cover gas dome. It reads
from 20 inch vacuum to 20 inch pressure w.c.
A temperature control switch is provided and mounted in the
compressor discharge line and will stop the compressor motor when
the temperature in the line exceeds a predetermined point.
_Sludge Heating Unit
The heating unit -is a hot water boiler and heat exchanger.
The hot water boiler will burn digester gas•or oil.- The
automatic mode of operation will result in utilization of
digester gas whenever it is available.
Sludge to be heated passes through tubes in the heat
exchanger surrounded by hot water circulated from the boiler.
The unit has a sludge heating capacity of 140 BTU per hour and a
boiler capacity of 335 BTU per hour. ,
The digester has a tank temperature indicator mounted on an
13-13
instrument panel in the Primary Digester Building. The gages are
calibrated from 0-150 deg.. F.
The digester is insulated to maintain proper temperature in
the digesters. The temperature within the primary sludge
digester should vary no more than.l degree a day.
A deviation of more than a few degrees could upset the whole
dige'stive system. Therefore, the temperature in the primary tank
must be checked twice a day. The sludge recirculation pumps are
used to draw sludge from the digestion tanks and circulate it
through the heat exchanger and back to the digester.
Automatic control of the digester temperature, within plus
or minus 1/2 degree F., is by means of,a thermostat located at
the inlet to,the sludge tubes of the unit. The water circulation
pump for sludge heating and burner equipment is automatically
controlled,by the temperature of the sludge passing the
thermostat. A repeating cycle time switch is provided for
periodic starting of the digester recirculation pump, with
controls arranged such that the recirculation pump will continue
to operate until the digester heating requirements are satisfied,
or shall stop after a short cycle in case heat is not required by
the digester.
Sludge indicating thermometers with a range from 0 degress
to 150 degrees F. are placed in the sludge inlet and outlet of
the heat exchanger. Each thermometer -is provided with a mounting
socket to enable the removal of the thermometer without draining
the sludge tubes.
The digester contents may also be heated by'manually
controlling the recirculation pumps. Manual control of the
digester temperature is accomplished by use of the Manual/On/Off
switch mounted on the control panel.
When one of the recirculation pumps is started the hot water
circulation will also start automatically and provide hot water
at the proper temperature to the heat -exchanger. When the
digester is at the desired temperature the hot water circulator
should be manually stopped. When the water temperature in the
heat exchanger drops to approximately 130 deg. F. the
recirculation pump can be stopped. This sequence should be
followed to ensure that the sludge remaining in the tubes of the
heat exchanger is not baked by excessive water temperature.
Figure 13-5 shows a sectional view of the sludge heat exchanger
unit.
13-14
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SLUDGE RECIRCULATION PUMPS DESIGN DATA
Number of Units
Type
Discharge Capacity,
Maximum Speed
Motor
HP
Rating
Two (one standby)
Horizontal, Torque Flow
Max.' 200 gpm @ TDH 18'
770 RPM
Variable Speed Drive
5
230/460 V, 60 HZ, 3 phase,
1750 RPM
Figure.13=6 shows a sectional view of the sludge recirculation
pumps and Table 13-1 contains the valve schedule for these pumps.
Gas Extraction
Gas is extracted from the primary digester through the gas
dome. When the gas is not being used it will be stored under the
floating gasholder cover.
The gas is extracted from the primary digester via gas
piping within the gas dome in the gasholder cover. Gas is
extracted from the primary digester when the hot water boiler is
in operation. When gas storage capacity is full, excess gas is
burned in the waste gas burner. For a detailed description and
operating procedures see the sewage gas system section in this
Chapter.
Sludge Transfer Pumps
The sludge transfer pump in the Primary Digester Building is
used to draw digested sludge from the digester tank and pump it
to the existing sludge drying beds. Figure 13-7 shows a plan
view of the sludge transfer pumps and Table 13-2 contains the
valve schedule for these pumps.
SLUDGE TRANSFER PUMPS DESIGN DATA
Number of Units
Type
Discharge Capacity
Maximum Speed
Motor
HP
Rating
Sewage Gas System
Two (one standby)
Positive Displacement,
Progressive Cavity
150 gpm @ TDH 27'
410 RPM
Variable Speed Drive
5
230/460 V, 3 phase, 60 HZ
In the digestion of sewage sludges, gas is produced at a
rate of 12 to 17 cubic feet per pound of volatile matter
13-16'
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TO DIGESTER F -EEC)
SLUDGE PIPE
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MOUNTE:
.(WALL
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TA- N -K -
WET \#Vr—LL..-Il
SLUDGE RECIRCULATION PUMPS
PJ CONSULTING ENGINEERS,:
TABLE 13®1
SLUDGE RECIRCULATION PUMP VALVE
SCHEDULE
PUMP # 1 TO DIGESTER FEED"
VALVE NO.
A
OPEN
B
OPEN
C
CLOSED
D
CLOSED
PUMP # 2 TO DIGESTER FEED
VALVE NO.
A
CLOSED
B
CLOSED
C'
OPEN
D
OPEN
Note: Valve sequencing based upon weekly alternating each sludge
recirculation pump.
13®18
VALVE NO.,*Z
GL-uc)GE: -r-RANSF-ER
p --(Ty.,p -
r— I le. A �
S,LQ,I),,G,E, TRANSFER PUMPS
FROM SLUDGE DRAWOF-F'
-.4-DIGESTER TAW
jCPJ CONSULTING ENGINEERSI
TABLE 13-2
SLUDGE TRANSFER PUMP VALVE SCHEDULE
PUMP A TO SLUDGE DRYING BEDS
Valve No.
1 OPEN
2 OPEN
3 CLOSED
4 CLOSED
PUMP B TO SLUDGE DRYING BEDS
Valve No.
1 CLOSED
2 CLOSED
3 OPEN
4 OPEN
13-20
destroyed. This is roughly equivalent to 1.0 cubic
feet/capita/day. Gas production is variable depending on the
volatile concentration and more importantly, the biological
activity in the digester. The biological activity is based upon
many factors including the rate and amount of sludge withdrawal
and sludge addition, temperature variations, and recirculation of
tank contents. The best gas production will normally occur when
uniform operating conditions are maintained. This means that the
temperature should be kept constant, sludge additions should be
made in many small quantities rather than one large load and that
there is a continual mixing of the tank contents.
A good steady production of digester gas and the proper
utilization of this gas will result in minimizing the purchase
and use of oil, which will cut the operating costs.
Digester gas normally consists of about two thirds methane
and about one third carbon dioxide with other gases such as
hydrogen sulfide, nitrogen, oxygen, hydrogen and carbon monoxide
present in small quantities.
Digester gas has a heating value of between 600 to 700
BTU/cu. ft. under normal conditions.
WARNING:
A GAS MIXTURE RATIO OF 5.7% TO 13.5% DIGESTER GAS TO AIR IS
EXPLOSIVE (LOW AND UPPER LIMITS).
WARNING:
DIGESTER GAS CAN BE EXTREMELY DANGEROUS IN TWO WAYS. WHEN MIXED
WITH OXYGEN IT CAN FORM EXPLOSIVE MIXTURES AND IT ALSO CAN CAUSE
ASPHYXIATION OR OXYGEN STARVATION. SMOKING, OPEN FLAMES OR
SPARKS MUST NOT BE TOLERATED AROUND THE DIGESTERS OR SLUDGE
PUMPING FACILITIES.
Flame Traps
The flame trap element is made up of an aluminum spider and
cage casting in which are two coiled strips of aluminum. One of
these strips is specially crimped; the other is flat. These two
strips are tightly wound simultaneously on the spider, forming a
honeycombed series of ducts and channels. The gas from the
digester readily passes up through the ducts and through the
outlet to the service connection. The ducts formed by the
aluminum strips are of such a depth and cross section that a
flame cannot pass through them, but gas is able to pass with
little head loss. A spring actuated thermal valve will
automatically close if sufficient heat is developed to melt the
thermal release, shutting off the gas supply. A feeler pin is
also provided to check the condition of the thermal unit.
13-21
Flame traps should be serviced every three months by valving
off the gas and pulling out the cartridge. A build-up of scale,
salts from condensate and residue on the element could restrict
the gas flow.
Sewage Gas Meters
Two gas recorders and meters measure and record the volume
of digester gas produced and the amount used by the boiler. Both
gas flow meters measure the differential pressure across an
orifice plate located at these two places.
Sediment Accumulators
The sediment accumulators serve to keep the gas lines free
from scale and other solid impurities and also service to remove
condensate normally encountered in sludge gas lines. These units
have a capacity of five gallons for accumulated sediment which
may be emptied by removing a drain plug located at the bottom of
the unit. They also have a capacity for five gallons of
accumulated condensate. Each unit is equipped with a drip trap
to remove the condensate.
Drip Traps - Condensate Traps
Digester gas is quite wet and in traveling from the heated
tank to a cooler temperature the water condenses. The water must
be trapped at low points in the system and removed, or it will
impede gas flow and cause damage to equipment and interfere with
gas utilization.
The drip or condensate traps are manually operated with a
mechanically interlocked inlet and outlet connection so that both
cannot be open at the same time.
Pilot Line Flame Cell
The flame cell installed on the pilot line to the waste gas
burner consists of a cover casting with a flame element composed
of an aluminum foil flame -resistant unit designed to prevent the
passage of flame. The flame cell is capable of passing the gas
required for the pilot lights.
Waste Gas Burner
The waste gas burner is used to burn the excess gas from the
digestion system and is on the roof of the primary digester
13-22
building. The burner consists of a pilot
and ignition chamber and a pipe pedestal,
support the burner. The burner also has
gas nozzle and shutoff valve. The burner
adjustable air inlet shutter.
flame ring, a mixing
about six feet high.to
a stainless steel pilot
is equipped with an
The waste gas,burner has a continuous pilot flame, so that
any excess gas will pass through the gas regulator and be burned.
The pilot flame should be checked daily to be sure that it has
not been blown out by wind. If the pilot is out, gas will.be
vented to the atmosphere creating an odorous and potentially
explosive condition.
The pilot is accessible for inspection and lighting from the
outside.
The waste gas burner also has an electric ignitor. The
ignitor consists of an electrode trough and control box. The
ignitor can be operated automatically or manually. With the
selector switch on "auto", sparking of the electrodes occurs by
means of the adjustable timer cams at intervals of three to
thirty-seconds per minute. With the selector switch on "hand",
continuous sparking of the electrodes will occur. The ignitor
should be operated in the automatic mode.
Figure 13-8 contains a schematic of the sewage gas piping
system.
Sludge Dewatering
Digested sludge from the digester is pumped to the sludge
drying beds for dewatering. This combination of open and covered
beds provides maximum usage of the drying facilities. For
example, open beds evaporate cake moisture faster than the
covered beds under favorable weather conditions, while the
covered beds enable a greater number of sludge drawings per year
because of the protection from the snow and rain.
The sludge drying bed media consists of 8 inches of coarse
sand, 4 inches of pea gravel, 15 inchesmaximum of washed gravel
and 9 -inches maximum of clean compacted fill. Underdrain piping
is imbedded in the drying bed media. For the covered beds, a PVC
liner separates the above media from the existing clay soil on
the site.
The filtrate from the covered beds flows through the
underdrain pipe by gravity to an existing filtrate manhole, the
filtrate from the opened beds flows, also, by gravity to the
existing filtrate manhole.
13'-23
WASTE GAS BURNER
- i
FROM FLEXIBLE
PIPING CONNECTION
SEWAGE GAS PIPING
DRIP TRAP
(TO SUMP)
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Fr
1 4
UNIT DESIGN AND DESCRIPTION
SLUDGE BED NO. 1
Type: Covered
Size: 2 bays @ 23.0' x 48.0' each
Area: 2208 S.F.
Volume: 1,479 C.F.
Surface: Clean Coarse Sand
Drain: Perforated PVC underdrain
SLUDGE BED NO. 2
Type: Uncovered
Size: 4 bays @ 24.25' x 59.25' each
Area: 5747.25 S.F.
Volume: 3,851 C.F.
Surface: Clean Coarse Sand
Drain: Perforated PVC underdrain
OPERATION AND CONTROL
Sludge/Scum Removal
The scum in the primary and final settling tanks is
collected by a skimmer attached to the sludge collector
mechanisms.
Sludge in the primary and final settling tanks is collected
in the sludge hopper at the bottom.of each tank and flows by
gravity to the sludge/scum wet well.
Normal Operation
Sludge/scum removal from the primary and final tanks is a
daily operation. Sluge1scum should be pumped from the wet well
to the digester periodically depending upon the amount of
sludge/scum, odor and the weather. During the winter the
sludge/scum should be pumped at least once a day to prevent
13-25
freezing. During the summer every other day should be adequate,
if odor is -not a problem. When pumping sludge/scum to the
digester, the digester sludge recirculation system should be
operating to mix hot digester sludge with the scum in the pipea
The mixing of the sludge/scum with the heated sludge results,
in a rise in temperature of the scum. This rise in temperature
helps to:
1. Prevent a scum blanket from forming in the digester.
2. Prevent the scum from balling and clogging the pipes.
3. Reduce the chance of sudden shock overload of the
digester.
The sludge/scum is pumped from the wet well into a 4 inch
line to the digester.
Before pumping sludge/scum to the digester, heated sludge
from the digester should be recirculated through the heat
exchanger line if necessary and back to the primary digester.
There are float switches located in the sludge/scum wet well
which activate the ON/OFF operation of the scum pump.
Alternate Operations
Removing Sludge/Scum from Wet Well
Under normal condition, the sludge/scum pump will be activated
by the float switches, which areas follows:
High Level Alarm ®- 11.80
Pump On Level 10.70
Pump Off Level -- 8.20
The level in the sludge/scum well should be checked daily to
ensure that -the float switches are operating properly. The scum
may -tend to coat the float switches, which should be hosed off
periodically as required. If required, the scum box at the
clarifiers should be hosed down to assist the, removal of scum.
1. -Check that all valves are in their proper position. See
Figures 13-5 and 13-6 and Table 1'3-1,to pump to the primary
digester.
2. Recirculate sludge from the digester. Once per day lift
open the checkered steel plate over the sludge/scum wet well.
Observe the scum level in the wet well. If required hose down
scum pit to ease scum flow.
13-26
3. Start sludge/scum pump.
4. Continue pumping for about four minutes then stop the
pump. The pit should not be pumped dry because this can air bind
the pump.
5. The pit can be hosed down -to clean it. The excess water
is also pumped to the digester.
6. Let circulation pump run for a -few minutes longer to
clear pipes of scum, then turn heat exchanger off.
T. Reset valves to normal positions (see Figures 13-5, 13-6
and Table 13-1).
Routine Surveillance and Housekeeping
1. The sludge/scum pump should be visually checked for oil
leaks before starting -and immediately after for unusual noises.
If either occur, the unit should be shut down at once and the
cause found and -corrected®
2. 'Change oil at six month --intervals for reduction gear
motor.
3. Keep -scum trough and surrounding area clean. The scum
can be cleaned -with a brush and hot water.
4. Check that the scum layer is removed'properly from both.
the primary and final settling tanks.
Anaerobic Sludge Digestion
Normal Operation
An anaerobic sludge digester is operating properly when the
rate of acid formation and methane fermentation are approximately
equal: Otherwise the reaction would be out of balance. The most
common-condition'of inbalance occurs when the methane fermenters,
which are sensitive anaerobes, fail to -keep pace with the acid
forming microorganisms and the,digester becomes acid.
Effective mixing -of incoming sludge with the contents of the
digester is necessary to provide all working -organisms with their
essential food supply -and to maintain a uniform temperature
throughout the digester. Mixing is accomplished by recirculating
gas, given off at the surface, through diffusers near the bottom
of the digester.
The digester may be operated in one of three temperature
zones or ranges, each of which has, its own particular type of
13-27
bacteria. The Scavenger Waste digester operates in the middle
range encouraging growth of organisms called the mesophilic
bacteria. The temperature range tolerated by this bacteria is
between 68-113 deg. F, more commonly between 95 and 98 deg. F.
Digestion at this temperature may take from 5 to 50 days, but
normally from 25 to 30 days.
The temperature of the digesting sludge should be recorded
so that both short -and -long-term fluctuations and trends may be
observed and recorded. Digester temperature should never change
more than 1 deg. F per day. The same temperature should be
maintained at all levels of the primary digester.
The pH in the -digester should be kept between 6.8 and 7.4
with the ideal pH at 7.0. At a pH of 7.0 the microorganisms are
the most effective in digesting the sludge. If the pH falls
below 6.8 those microorganisms of the second stage of digestion
will prevail. They will produce gas high in carbon dioxide, foul
smells and scum. If the pH should go above 7.4 those organisms
producing methane gas will start to become inactive.
At the pH level of 8.0 very little digestion will take place
and, at a pH of 9.0 digestion will cease.
As mentioned earlier in this manual, lime (and-FeC13) is -used
in the chemical coagulation and flocculation process. The.
addition of lime increases the pH and alkalinity of the waste. -
Lime treatment takes place between a pH of 9.0 to 11.5. Acid
neutralization is used ahead of the RBD units to lower the pH. If
the pH levels in the primary digester are consistantly high, the
operator should try one of the following:
1. Reduce the amount of lime used.
2. Increase the amount of acid used. (This will not be
as effective as. step 1, since the acid addition only
impacts the secondary clarifier sludge).
3. A combination of both of the above.
The volatile acids content of digesting sludge is quite
possibly the best indicator of digester condition. Proper
operating levels will vary depending on raw sludge feed
characteristics, the loading and detention time provided in
design, the degree of digestion allowable in the facility, and
the method of -testing. Generally, the volatile acids
concentrations should be kept below 500 mg/L. The volatile
acid/alkalinity ratio also has been used as a control index.
When the ratio exceeds 0.8, pH depression and inhibition of
methane production -occurs, the process is failing. Increases
above 0.3 to 0.4 indicate upset and the necessity for corrective
action.
13-28
Digester Efficiency. Volatile solids of the raw .sludge is a
basic measure of the organic load on a digester. When this data
is combined with the volatile solids content of the digested
sludge, the efficiency of the digester, expressed as percent
reduction of volatile acids, can be obtained. Figure 13- 9
presents a graphical method. The following equation also can be
used:
Percent Reduction Volatiles - Volatiles
Volatile Solids =: In Out
--------------------------
Volatiles - (Volatiles x Volatiles )
In ( In Out).
It usually is considered that -a minimum of about 45 percent
reduction of volatile solids is required. Figure 13- 9 and the
above equation assume the non-volatile solids in the raw sludge
remain unchanged during digestion. This is not precisely true,
but the relation is calculated easily and affords an excellent
control procedure for following the progress of digestion.
Normally digested sludge is pumped to the sludge drying beds.
by use of the sludge transfer pumps.
Alternate Operation
When the digester has to be taken out of service, its
contents can be removed as indicated below:
Figure 13-7 and Table 13-2 show the valving associated with
draining the digester.
This operation would only be done if it is necessary to
empty a digester for cleaning or repair.
Alternately the digested sludge flows into the overflow
sample line and through the 6 inch transfer line to the effluent
wet well. This occurs when sludge is pumped to and displaces the
digested sludge into the overflow sampling pipe.
Before draining the digester the steps to be followed are:
L. Stop feeding sludge./scum to the digester.
2. Shut off gas mixer.
3. After gas production has decreased to less than 10a of
normal production, the digester should be isolated from
the gas system and vented to the atmosphere. Venting
should be -by the positive opening -of the pressure relief
valve, properly and securely cocked open.
13-29
Start Up
The following steps should -be followed before placing a
digester in operation.
1.
Close all
gas lines to the digestion tank to be
started
up.
2.
Check all
sludge, water and gas lines for leaks.
Any
repairs needed
are made much more easily before
sludge
is added.
3.
Fill the
tank and all sludge lines with waste or
water
and check
for leaks.
4.
Start the
heating system and operate long enough
to be
sure it is
operating properly.,
5.
Check all
seals to see that they are in working
order.
Two start up procedures are given: one for starting a
digester with seed, the other for starting using lime addition.
The preferred procedure is to use seed for faster starting. Only
use the second procedure if seed is not available.
tank.
Starting a Digester With Seed from an existing digester
1. These procedures are recommended either for starting a
new digester or for restarting a "sour" one. However,
if an existing "sour" digester is to be restarted, it is
recommended that the contents be removed completely.
2. Fill the digester with fresh raw scavenger waste from
the sludge wet well. Water may also be used.
3. Heat the scavenger waste or water to 95 deg. F and
maintain temperature with + 3 deg. F throughout the
starting process.
4. The seeding culture from a nearby sewage treatment plant
will hasten the start up.
The quantity of -seed needed to start a digester tank is
equal to about 15 percent of the total volume of the tank. This
is 9900 gallons for the digester at this plant.
5. The amount of new raw sludge to be added per day is made
on two assumptions:
13-31
Assumption No. 1 - The digester at the nearby sewage
treatment plant is working properly and can supply the
necessary amount of seed to the primary digester at the
scavenger waste treatment facility.:
Proper working conditions include:
1. pH between 6.8 and 7.2.
2. Volatile acid is less than -1000 mg/L..
3. Alkalinity is 2-10 times the volatile acids.
4. Volatile acid/alka-linity relationship is b'etween'0.1
and 0.5.
Assumption No. 2 - The daily volatile solids loading of
new and raw sludge to the digester will not overload -the
digester.- A safe loading to start with is between 0.03
and 0.10 pounds of new volatile solids to be added per
day per pounds of volatile solids under digestion.
Using this method, the calculated amount.of raw sludge/scum
able to be fed into the primary digester. i -s 132 gallons per
day.
A better approach is to determine how much of a strain the
working'digester can take, use the remaining,volume of raw sludge
as the initial load to the -starting digester and then calculate
the volume of seed sludge needed for that initial load..
To calculate the amount of seed needed it is necessary to
first know the gallons of sludge/scum produced by the primary and
final settling tanks.
Example:
Assume 4!� solids for the combined primary and final sludge
and 45% volatile,solids
Volatile
material = (volume of sludge, gpd) x (solids, %)
pumped x (volatile, %) x (8.33 lbs/gal)
(lbs/day) =
4,500(.04) (.45) (8.33)
675 lbs/day
Note® The values used in the exemplary equations on these
pages are estimates only and should be revised to
13-32
reflect actual conditions experienced. The values
such as quantity of sludge/scum should be measured,
and the solids and volatile solids content can be
determined using laboratory procedures..
To find the pounds of seed necessary choose a ratio of
pounds per day raw sludge to pounds seed sludge between the range
of .03 to -.10. A commonly used ratio is .05 and will be used
here..
0.05 675 lbs/day
-----------------
1 seed sludge- ( lbs . )
Seed sludge (lbs.) _-13,500 lbs,:
Find the gallons of seed sludge needed
(seed sludge, lbs.)
Seed sludge (gal.) ---------------------------
(9 lbs. /gal. ) (solids o) (volatile %)
13,500 lbs.
--------------
9 (.10)(.30)
50,00.0 gallons.
Therefore, the amount -of seed sludge needed to seed.•'the,
primary digester is 50,000 gallons. Depending on the amount -of
seed needed it.may take from 3 to 9' days to supply the primary
digester..
6. Recirculate primary digester contents,daily.
The recirculation -speeds the digestive process by mixing_ the
new raw sludge with the seed..
Once the digester is producing gas, the gas mixing -unit
should -be turned on. This -will mix digester contents better.
7. The initial feed rate can be.increased once.the primary-
digester.has reached the operating criteria as outlined
in step 5. The most important condition is the -volatile
acid/alkalinity relationship. When this is between 0.1
and 0.5 the primary digester is in a well balanced
operating condition. The daily feed rate can then be
increased 50 to 100 percent per day until the total daily
sludge.production is pumped to the digester.
The volatile acid/alkalinity relationship should be
determined daily after the new thickened sludge has been seeded
13-33
and mixed. During the start-up period thickened sludge should
always be mixed with recirculated sludge from the digester.
If the volatile acid/alkalinity ratio starts to go above
0.5, corrective measures must be taken to prevent the digester
from going "sour". Corrective measures include:
1. Reducing the daily feed rate.
2. Adding.more seed from another digester.
3. Maintain temperature at 90 deg. F.
4. Improve mixing by:
a. gas mixing
b. recirculation
5. Adding lime in controlled amounts.
8. Digestion will be established between 30 to 40 -days.
Using Lime to Start a Digester.
The recovery of a sour digester or the start of a new one -
can be accelerated by neutralizing the organic,acids with lime or
by transferring alkalinity in the digested sludge from -the
secondary digester.. Neutralization increases the pH to a.level
suitable for growth of. -the methane fermenters and provides
buffering to help maintain the required volatile acids/alkalinity
relationship and -pH.
When neutralizing a digester, the quantity of lime must be
carefully calculated. Too little will be ineffective, and too
much is both toxic to the digester and wasteful. An accurate
method in calculating the proper -dosage is to add sufficient lime
to neutralize 100 percent of the volatile acids in the digester
liquor.
The following example illustrates the lime additions
necessary for different volatile acid concentrations.
Example: Volatile acids in the primary digester = 1,400 mg/L.
Find an equivalent amount of lime Ca(OH') to neutralize
it. 2
(Volatile acids expressed as acetic acid).
Reaction: Acetic Acid + Calcium hydroxide = Calcium acetate +
water
13-34
2C H 0 + Ca(OH) = Ca (C H 0 ) + 2H 0
2 4 2 2 2 3 2 2 2
Molecular
Weights 120 74
Ratio of molecular weights =
158 36
Lime 74
_ --- = 0.62..
Acetic Acid 120
Lime Required = 0.62 (Volatile Acids Concentration X
Tank Vol. x Conversion Factor)
0.62 (1400 mg/L. X 0.0659 M.G. X
8.34 lbs./gal.)
= 477 lbs. lime required
Gallons of Chemlime Required
Using Chemline with Ca(OH) of 35% solids
2
Lime solution has 35 percent solids content of which 95
percent is Ca(OH)
2
477 lbs... lime
Chemlime (gals.) _ --------------
(0.35),(0.95)(8.34 lbs./gal.)
These procedures can be used to start a new digester or to
restart a sour one. It usually is not considered necessary to
empty the sour sludge for this process in restarting a unit.
1. For a new digester, fill the tank with scavenger
waste and bring the temperature up to about 95 deg.
F. Maintain this temperature +/- 3 deg. F until
digestion is established. For a sour digester,
follow the same procedure until digestion is again
established.
2. When thickened sludge is added, also add hydrated
lime. The raw sludge feed would probably be less
than the design load at first, but full loads are
usually possible within 30 to 40 days. This method
also has.been used with full sludge loads from the
start.
3. When a mass of "sour" sludge already exists in a
restarting situation, lime should be added to bring
13-35
the pH up to 6.8 to 7.0 prior to addition of more
thickened sludge.
4. During the -daily feeding of raw sludge, use just
enough lime to maintain the pH at 6.8 to 7.0. It
is important that mixing be complete so that false
low pH readings will not result in excess lime
addition. Lime should be added in slurry form.
The lime can be added at the sludge or scum wet.well and
pumped to the digester and mixed with the digestion tank contents
in the combined sludge and scum line using the recirculation
PUMP.
5. Recirculate the sludge mass daily. The entire tank
contents should be overturned from bottom to top.
6. Keep a constant check on the pH at as many points in
the tank as is possible so that it is reasonably
certain that the 6.8 to 7.0 range is maintained
throughout the sludge mass.
7. Digestion usually is established within 30 to 40
days. However, if too much lime was used, many
upsets can occur over a period of several months.
Starting a Digester Without Seed.
The same procedure as outlined in the section on starting a
digester with seed is to be used except there are no seed
additions. The difference between starting'a digester without
seed is the time involved. The digester without seed will take
from 60-100 days to start.
Table 13-3 contains a list of units and location of controls
for various equipment with the Primary Digester Building.
Routine Surveillance
Items listed below are provided to help the operator keep
the digestion tank in a healthy condition.
Daily
A. Thickened Sludge Pump
1. Record thickened sludge volume pumped in past 24
hours, taken from counter.
2. Check pumps for proper operation (check motor, pump,
packing, suction, and discharge pressures while pump
is operating) .
13-36
TABLE
13-3 UNITS,
LOCATIONS.AND
CONTROLS
LOCATION
TYPE OF
UNIT
OF CONTROL
CONTROL
REMARKS
Sludge Recirculation
MCC -DA
HOA
Hand -Off -Automatic
Pump # 1
Digested Sludge
MCC -DA
CS'
On/Off Control Switch
Pump # 1
Digested Sludge
MCC -DB
CS
On/Off Control Switch
Pump # 2
Sludge Recirculation
MCC -DB
HOA
Hand -Off -Automatic
Pump #2
Gas Recirculation
MCC -DB
FSO
Fast -Slow -Off
Compressor
13-37
3. Check--sludge line valve positions..
B. Recirculated Digester Sludge
1. Check temperature of recirculated sludge.
2. Check boiler and heat exchanger temperatures and
pressures.
3. Check boiler and-heat exchanger operation.
4. Check recirculated sludge pump operation (check
motor, pump,,packing, suction-and discharge
pressures while pump is.operating)
C. Digesters
1. Drain gas line condensate traps and sedimentation
trap.
2. Record floating cover position.
3. Read gas meters..
4. Check operation of mixing equipment.
5. Check temperatures.
Weekly
A. Sludge and Gas System Valves
Exercise all sludge and gas system valves by opening and
closing.
B. Lubricate Equipment
Monthly
A. Scum Blanket
Check digester for scum blanket build-up.
B. Digester Structure
Examine digester structure for cracks and possible gas
leaks.
C. Gas Piping System
Inspect gas piping system for leaks.
13-38
D. Clean gas recirculation system flame arrester.
Quarterly
A. Gas Safety Device
Clean and check digester gas safety devices.
Semiannually
A. Clean and refill gas manometers-.
B. Flush and refill digester dome water seals.
Three to Eight Years
A. Clean and Repair Digester
Dewater digester and clean out, repair and paint as
required.
Daily Procedures for Operation
Feeding
Thickened sludge is fed to the digesters twice a day. The
thickened sludge should be pumped for two hours in the morning
and two hours at the end of the day.
Digester Mixing
The gas mixing system has controls on the mixers to program
a predetermined discharge period through each of the discharge
wells in sequence. Sequencing is controlled by relay actuated by
a pulse timer, with adjustable time cycle, which will reset at
the expiration of the time period to the next well in sequence.
A permanent nameplate with operation instructions is mounted
on the housing.
Recirculation
The two recirculation pumps in the sludge digester building
are manually operated by a HAND -OFF -AUTO switch and two ON-OFF
switches located on the sludge heat exchanger control panel. The
OFF -ON, switches control which pump will be ON and which will be
STANDBY. Only one of these switches should be ON at a time and
they should be alternated weekly to equalize pump wear. Once the
ON pump has been selected the HAND -OFF -AUTO switch will control
the daily operation of the pumps. In the.HAND position the
selected pump will run until it is manually shut-off. To use the
13-39
AUTO position, the. -timer located inside the control cabinet-, must
be set for the desired running time. The pump will then
automatically shut off after the number of hours set on the timer
have elapsed.
Sampling
The pH should be determined daily and the volatile acids and.
alkalinity weekly. The pH should be between 6.8 and 7.2. The
volatile acids, should be.below 600 mg/L and the volatile acid/
alkalinity relationship should be between 0.1 and 0.5. The
sample slop sink located next to the primary digester in the
primary digester building has sampling taps.for the primary
digester at three elevations for obtaining samples at different
levels in the tank.
The levels are:
Elevation 18.50
Elevation 2.0.50
Elevation 22.50
When collecting digester sludge samples the sludge should be
allowed to flow to clean the line out to make sure that you are
getting a proper sample and not some sludge that has been left.in
the line.
Alarms
Instrumentation and Alarms: On an instrument panel located
in the Digester building are two indicators,_ the liquid level and
cover position indicators. The dial type liquid level indicator
consists of a circular dial 12 inches in diameter with a scale
calibrated in increments of feet and inches. The function of the
liquid level indicator is to show the level of sludge in the
digester tank at all times.
The cover position indicator also has a circular dial 12
inches in diameter with a scale calibrated in increments of feet
and inches for the full travel of the Gas Holder Cover Dial. The
cover position indicator is provided with a low level alarm
consisting of a horn and red. warning lights which automatically
sound -and light when the gas holder. is lowered to within 6 inches
of the landing brackets. A high level alarm with a horn and a
green warning light will automatically sound and light when the
gas holder is raised to the overflow level.
A pushbutton is provided on the instrumentation panel for
silencing the horn. However, the warning light will remain lit
until the cover position moves out of the alarm position.
13-40
Housekeeping
Good housekeeping can and has prevented many accidents.
Have a place for your tools and equipment. When they
are not being used, see that they are kept in their proper place.
Clean up all spills of oil, grease, scavenger waste,
sludge, etc. Keep walkways and work areas clean.
Provide proper containers for wastes, oily rags, papers,_
etc. Empty these frequently.
A clean plant will reduce the possiblity of physical
injuries and infections.
Troubleshooting
Table 13-4 contains guides for correcting process
malfunctions and a variety of common operating problems which
could occur during the treatment of the waste stream and -the
production, handling and disposal of the solids accumulated
during the waste treatment process.
Sewage Gas System Operation
The gas produced in the digester will be used to the maximum
extent possible in the boiler. If this unit is not running, the
gas will be stored under the floating digester cover. After the.
maximum storage level is reached, excess gas will be burned in
the waste gas burner on top of the digestion control building.
The gas system is controlled by pressure control valves in
the system. The pressure and vaccum relief valve on top of
primary digester will be activated if the pressure in the
digester rises to 11 inches w.c. or drops to 2 inches w.c.
Another pressure relief valve, before the flame trap on the waste
gas burner piping opens when the pressure in the system reaches
12.5 inches w.c.
The floating'cover has a range of 3 feet from minimum gas
storage. As the cover moves through its range, the gas -pressure
in the tank will remain -fairly constant at its normal working
pressure of 9.5 inch w.c. When the cover is at maximum storage,
any additional gas production will start to pick the concrete
ballast ring out of the liquid. This will result in an immediate
pressure increase to 10.5 inch w.c. that opens the valve to the
waste gas burner preventing the water seal of the cover from
being broken.
If the pressure relief valve on the waste burner line fails
to operate the pressure will continue to rise and the pressure
13-41
(1) Problem
Indicators
Monitoring,
Analysis
and/or
Inspections
Corrective
Measures
(2) Problem
Indicators
Monitoring,
Corrective
Measures
TABLE 13-4
SLUDGE DIGESTION TROUBLESHOOTING GUIDE
- Foam in Digester
- Foam discharged from upper level
supernatant lines
(a) Determine total and volatile
solids of sludge being pumped to
digester and volume pumped.
- (b) Determine pH of digester contents.
(c) Check digester temperature daily.
(d) Monitor withdrawal rate of sludge
from digester.
(e) Check digester mixing program and
effectiveness of mixing equipment.
(a) Maintain digester pH between 6.8
and 7.4 and volatile acid/alkalinity
ratio below 0.2 by adding lime.
(b) Reduce or discontinue pumping raw
sludge to digester.
(c) Maintain digester temperature at
95 deg. F.
(d) Attempt to thoroughly mix digester
by increasing gas recirculation
and pumping tank contents.
(e) Break up scum layers.
(f) Add digester sludge from secondary
digester.
- Low Reduction of Volatile Solids in
Digester
- Volatile reduction calculates to less
than 50%.
- (a) Determine total solids of digested
sludge and/or raw sludge being
pumped to digester.
(b) Monitor solids loading, to digester
daily.
(c) Monitor solids withdrawal from digester.
(d) Determine volatile acid/alkalinity
ratio and pH of digested sludge.
(e) Monitor digester gas production.
(a) If total or volatile solids daily
loading to digester exceeds design
loading, reduce the amount of sludge
pumped to the digester daily.
13-42
(3) Problem
Indicators
Monitoring,
Analysis
and/or
Inspection
Corrective
Measures
(4) Problem
Indicators
Monitoring,
Analysis
and/or
Inspection
Corrective
Measures
CONT°D
TABLE 13-4
SLUDGE DIGESTION TROUBLESHOOTING GUIDE
(b) Keep digester tempertature at 95 deg. F
(c) Raw sludge pumped to digester should
contain more than 50% volatile solids.
(d) Recirculate and mix digester contents.
(e) Prolong periods of withdrawing digested
sludge until volatile reduction is abov
50%.
(f) Lower volatile acid/alkalinity ratio
and raise pH above 6.5 by adding lime
to digester.
Scum Blanket in Tank
- (a) Decrease in digester gas production.
(a) Core blanket through digester
sampling wells to determine thickness.
(b) Check digester temperature.
(c) Check daily digester gas production.
(d) Determine gallons of scum pumped
to digester daily.
(a) Run digester gas mixing system
continuously while increasing
digester temperature up to 100 deg.
F or 105 deg. F with the incremental
increases.not to exceed 1 deg. F per
day.
- Increase in Volatile Acid/Alkalinity
Ratio in Digester.
- (a) Drop in digester gas production.
(a) Determine volatile acid, alkalinity
and pH of digested sludge at least
twice daily.
(b) Check digester temperature.
(c) Check pH of raw sludge pumped to
digester.
(d) Check mixing in digester.
(a) If digester pH is below 6.5, add
lime to digester.
(b) If volatile acid/alkalinity ratio
is greater than 4.0, decrease or
discontinue feeding digester
and add lime.
13-43
CONT'D
TABLE 13-4
SLUDGE DIGESTION TROUBLESHOOTING GUIDE
(c) Do not feed digester raw sludges
with pHs lower than 6.8-
(d) Maintain digester temperatures
at 92 deg. F to 95 deg. F.
(e) If possible, transfer sludge with
low volatile acid/alkalinity ratio
content from another digester to
affected digester.
(f) Keep contents of digester well mixed.
(g) Decrease sludge withdrawal rates
from digester.
13-44
relief valve on top of the cover will open at 11 inch w.c. and
release the gas to the air. The gas that is vented is highly
combustible and special care must he taken not to ignite this
gas.
If the digester gas being utilized by the boiler is greater
than the amount being produced by the digesters, the cover will
fall as the stored gas is utilized. If the cover falls to 8
inches above the landing ledge; a valve opens and only oil is fed
to the boiler. If the cover continues to drop to 4 inches above
the landing ledge a low level alarm will sound on the Instrument
Control Panel in the Primary Digester Building. If the cover
seats on the corbels and the pressure continues�to drop to 2
inches w.c., the vacuum relief valve will open -and allow air to.
enter the digesters.
Normal Operation
Gas flows through a sediment accumulator with a drip trap
mounted on the digester and the gas passes through a gas meter
with a plug valve on both sides. Gas is burned in either the
boiler or the waste gas burner.
The gas will go to the boiler if it is operating. If the
boiler is not being used and the gas pressure reaches 10.5 inches
w.c., gas will flow to the waste gas burner. The gas flowing to
the waste gas burner,goes through a plug valve, pressure relief
valve, and a flame trap with drip trap at the low point before it
reaches the burning unit.
As the gas flows to the boiler
drip trap, plug valve, gas meter, a
a drip trap at the low point.
Alternate Operation
it will go through another
strainer and flame trap with
The gas system is equipped with bypass lines to enable the
operator to take most of the equipment out of service for a short
time without inhibiting the gas flow system.
When taking any gas unit out of operation, the greatest care
must be taken not to have any sparks or flames` in the area.
There may be some highly combustible gas left in the unit. The
bypass, valves are to be opened first before isolating a unit to
prevent increasing pressure within the system and opening
pressure relief valves.
13-45
Gas Utilization
Normal Operation
The gas compressor located in the Sewage Gas Piping room of
the Primary Digester Building automatically draws digester gas
from the digester cover. The digester gas is then filtered and
metered. Excess gas is diverted to the waste gas burner. The
required volume of digester gas is metered again and discharged
to the heat exchange unit where it is used as a fuel to heat the
water. It is anticipated that enough digester gas will be
produced at the plant to meet the hot water heating requirements.
If not, alternate operation procedures should be initiated.
Alternate Operation
Stable operation requires daily heating of the digesting
sludge if 95 deg. F is to be maintained. Heating time will vary
with outside temperature.
Recirculated sludge is to be mixed with thickened sludge,
and scum during pumping of the sludge or scum to the digester.
Heating of recirculated sludge is dependent on the sludge
temperature which also varies. with outside temperature. With the
gas holder cover at maximum elevation, about two hours of heater
burning time is available and it takes about four hours to
refill. Therefore, heating sludge should be on a cycle of the
first two hours in the morning and an off period with restarting
the sludge heating in accordance with the following schedule.
The boiler uses digester gas and/or fuel oil depending on
the availability of digester gas. For maximum use of the
digester gas, the heating of sludge should be performed as a
guide on the following basis when the sludge heating requirement
is less than eight hours per day.
Heating Time
Boiler
On
Boiler
Off
7
hours
8
AM
to
10
AM
11
AM
to
4
PM
10
AM
to
11 AM
6
hours
8
AM
to
10
AM
Noon
to.
4
PM
10
AM
to
Noon
5
hours
8
AM
to
10
AM
1
PM
to
4
PM
10
AM
to
1 PM
4
hours
8-
AM
to
10
AM
2
AM
to
4
PM
10
AM
to
2 AM
3
hours
8
AM
to
10
AM
3
AM
to
4
PM
10
AM
to
3 AM
These charts and tables are an estimate and the operator
should keep careful observation of the digester thermometer when
heating sludge.
It is recommended that the operator keep accurate records of
digester gas usage and heating times and modify the schedule
above accordingly.
13-46
Safety Ch
Because of the highly combustible and explosive nature of
the gases associated with sludge digestion, special precautions
are absolutely necessary. The design of sludge digestion tanks
and gas control equipment includes pressure relief valves, flame
traps and other precautionary devices to minimize the possibility
of an explosive mixture of gases. In addition all electric
motors, switches and lighting fixtures are explosion proof and no
substitute for this construction type should be -allowed for any
reason in the future.
For reasons of safety, the gas system controls should be
given a high priority on-maintanance scheduling.. All gas piping
and appurtenances should be checked periodically for gas leaks by
use of'a combustible gas indicator and probe tube. Leak check
points should include piping joints, gas valve stems, drip trap
ports, pressure relief devices and flame traps. If the
combustible gas meter is not available for any reason, a soap
solution may be brushed over possible leak areas under pressure,
so that leaks will be detected by bubbling.
Theodor of sludge gas cannot be depended upon to indicate
leaks. Serious leaks can exist even though the gas odor is not
strong.
The following precautions should be completely understood by
all operating,personnel:
1.. No smoking or use of any open flame within Primary
Digestion Building or on digestion tank roofs should be
permitted.
2. Only nonsparking tools should be used in the sludge
digestion area.
3. If exhaust fans in the Primary Digestion Building are
not running, they should be operated manually when personnel
enter the building.
4. No use of ungrounded electrical tools can be allowed in
restricted area.
While combustion may occur at lower concentrations, the
greatest hazard results when a mixture of air and sludge gas
produces 5 to 15 percent methane by volume. In this range, the
mixture is very explosive. Therefore, sludge withdrawal from the
primary digester should be carried out only when new sludge or
scum is being added, to avoid creating a vacuum which will cause
air to be drawn into a digester through the vacuum relief valve.
Similaryly, special precautions must be observed during
dewatering of a digester to prevent the formation of explosive
mixtures.
13-47
Prior to personnel entering a digester for inspection,
repair or cleaning, the following precautions should be taken:
1. A qualified individual should test the interior of the
tank for the presence of any toxic, explosive or oxygen deficient
condition.
2. A mechanical means of fresh air circulation must be
provided and must be in operation at all times that men are in
the tank.
3. All electrical disconnects on gas mixing equipment must
be locked out and tagged.
4. All piping leading into the tank from other tanks for
sludge or gas transfer should be blanked off as well as valved
off.
5. At least two men should be•stationed at the entrance to
observe the men inside the tank and to render any other
assistance that may be required of them.
6. Personnel must be trained in the use of breathing
apparatus, safety equipment and first aid procedures.
7. Self contained breathing equipment, safety harnesses,
and a method of sounding an alarm should be located at the
entrance.
8. After any break in the work, the tank atmosphere should
be retested.
System Maintenance
Digester gas, as it exists from the tank, can contain grease
aerosols. These aerosols will tend to accumulate on the inside
of the digester gas system piping. If allowed to accumulate,
reduced gas flow or blockage of the line can result. Therefore,
in addition to the normal maintenance precedures as described in
Chapter 18, cleaning of the interior of the gas system piping may
at times be required. Cleaning of the gas piping can be
accomplished by first isolating that section of the piping to be
cleaned. It should be remembered that a suitable safe bypass for
the gas must be provided during the cleaning operation. When the
piping has been isolated, hose down to thoroughly rinse out any
grease accumulations. After cleaning, the isolated section is
reconnected to the gas system and all connections are checked for
leaks.
13-48
SLUDGE DEWATERING
Normal Operation
During normal operations the digested sludge is pumped from
the digester to the sludge beds. This is accomplished by opening
the sludge withdrawal line and the valve to the appropriate
sludge drying bed.
During the winter months, at the completion of each sludge
withdrawal cycle, the 8 -inch line to the bed should be flushed
with water under pressure to dilute the sludge remaining in the
line. Enough liquid should be drained to insure that the
vertical discharge piping at the beds is empty and not subject to
freezing.
At the entrance of each sludge bed there is a distribution
box which directs the sludge to either bay of the sludge bed
where it will flow across the bed seeking its own level. The
sludge will dry most efficiently if it is spread to a depth not
greater than ten inches.
After the sludge has been placed on the bed, some water will
seep out and flow to the sand drain and into the 8 -inch PVC
perforated drain pipe. This water flows back to the filtrate
manhole of the existing Village of Greenport treatment plant.
The major portions of the drying, however, will occur through
evaporation.
Under good weather conditions the dewatering process will
take one to two weeks, but wet or damp weather can extend the
time to four or five weeks.
PROCEDURE FOR WITHDRAWING SLUDGE. The amount of sludge that
can be withdrawn from the primary digester to the drying beds
will depend upon the amount of gas in storage and whether the
digester gas is being used by the heat exchanger at the time of
sludge withdrawal.
Before withdrawing sludge, the gas holder cover position and
the liquid level indicator should be checked at the control panel
in the Primary Digester Building. The cover should be at least
at E1. 25.33° before sludge is withdrawn from the primary
digester. This will prevent the cover from resting on the
corbel.
The best time to withdraw sludge from the primary digester
to the beds is in the morning because the gas storage should be
at full capacity. The digester gas to the heat exchanger should
be shut off at night before withdrawing sludge, as a
precautionary measure, to ensure full capacity gas storage.
13®49
FILLING BEDS. During periods of foul weather, as in the
winter or during rainy weather, Sludge Drying Beds No. 1 should
be utilized as much as possible because it is covered and will
have a quicker dewatering period than the uncovered bed.
During periods of good weather, as in the summer, the sludge
will dewater faster in the uncovered bed than in the other beds.
This is because more water will evaporate due to the sun and
winds if the bed is uncovered.
Depending upon the weather conditions, the operator should
try to utilize the appropriate beds.
CLEANING, THE BEDS. Access to each bay of the sludge drying
beds is through a 6 feet wide by 8 feet high over head door and
ramp. The sludge is mechanically picked up by a small front end
loader and loaded on a truck for final disposal.
The sand above the drain pipe should be raked clean each
time sludge is removed. The top inch of sand should also be
removed to prevent -clogging of the sand by the sludge.
When approximately 4 -inches of sand has.been removed it
should then be replaced with clean sand.
DRIED SLUDGE CHARACTERISTICS. A well dewatered sludge has a
cracked spongy appearance when squeezed. It's moisture content
should be no more than 60-70 percent.
SCHEDULES. The amount of sludge withdrawn from the primary
digester and the time at which it.is withdrawn depends upon the
following factors:
1. The weather and its effect on the sludge drying time.
2. The position of the gas holder cover.
3. The availability of the drying bed.
The gas holder cover should have enough available vertical
movement to allow the sludge to be withdrawn without causing
the -cover to hit the corbel. This requires that the water level
in the primary digester be at the normal water level of El.
25.33'. All withdrawal of sludge should be stopped when the
level reaches E1. 18.331.
The 1.96 feet of sludge from the primary digester is equal
to about 7200 gallons. This would fill one bay of one of the
open beds to a depth of 8 -inches. At this depth the sludge will
dewater quite readily. Additional sludge should never be put on
drying sludge.
13-50
FINAL DISPOSAL. After being cleaned off the beds and loaded
on the truck the dewatered sludge is disposed of at the Town
landfill site.
13®51
CHAPTER 14: ODOR CONTROL SYSTEM
PAGE NO.
PURPOSE 14® 2
DESCRIPTION 14® 2
Wet Scrubbing 14® 2
UNIT DESIGN 14® 3
CONTROLS 14® 5.
NOTES AND ADDENDA 14® 6
LIST OF FIGURES
14 ® 1 Odor Scrubber System Schematic 14® 4
14® 1
PURPOSE
The principal source of odors for this treatment facility
emanate from the grit building and the equalization tanks. In
order to abate this problem, an odor scrubber has been provided
in the Odor Control room of the treatment building.
This scrubber permits contact between a scrubbing liquor and
a gas stream containing gaseous contaminates (odors), resulting
in the transfer (absorption) of the contaminant from the gaseous
to a liquid phase.
DESCRIPTION
Wet Scrubbing
Wet scrubbing is a process whereby soluble components in a
gas mixture pass over and dissolve in a liquid. The process
requires that the gas stream contact a very large surface of
liquid so that the soluble component is efficiently absorbed. In
the odor control applications considered herein, the malodorous
gases are the soluble components, the exhaust air stream is the
gas mixture and the liquid is one of several possible aqueous
solutions. For this facility the chemical scrubbing system
utilizes a packed tower with sodium hypochlorite (NaOC1).
The packed tower is a vertical cylindrical shell fitted with
air entry and exhaust ports, filled with packing material and
provided with an internal spray header and mist eliminator.
These packed tower scrubbers are generally of countercurrent
design. The air stream enters from below the packing and flows
upward while the solution is sprayed onto the top of the packing
and flows downward. It is within the packing that•the necessary
intimate contact of air and solution is achieved. Sodium
hypochlorite is reported as being able to achieve the following
removals of oxidizable odorous gases when other gas
concentrations in the treated air are minimal:
Hydrogen sulfide 980
Ammonia 98%
Sulfur dioxide 95%
Mercaptans 90%
Other oxidizable compounds 70% to 90%
The oxidation reactions between the hypochlorite and
absorbed hydrogen sulfide produces sulfates, sulfur and salt
(sodium chloride). When hydrogen sulfide concentrations are low
relative to the available hypochlorite in the scrubbing solution,
the sulfate reaction predominates. During heavy odor loads more
sulfur is produced in the process.
14- 2
This odor control system provides on-site regeneration of
the hypochlorite solutionm The regeneration equipment consists
of electrolytic cells and a DC rectifier. About 0.5 pounds of
brine and 2.5 kwh of power are needed to produce 1.0 pound of
hypochlorite. Hypochlorite solution is relatively safe and
easily handled even though it is corrosive.
The basic components of the odor control system are as
follows®
1. Electrolytic Module
2. Scrubber Tower and Tanks
3, Pumps
4. Exhaust Fans
5. Rectifier/Control Panel/Motor Control Center
Figure 14-1 shows a schematic of the odor control system.
UNIT DESIGN
The system is designed to destroy odors in a 1,000 cfm gas
stream containing oxidizable compounds having an average
continuous oxidation demand equivalent to 20 ppm hyrogen sulfide
(H2S) and is capable of generating a maximum of 29 lbs. of sodium
hypochlorite (NaOCl) per day, equivalent to 0.78 lb. equivalents
of oxidant per day.
ODOR CONTROL SYSTEM'DESIGN DATA
Electrolytic Module
Capacity
Rectifier
Operating Range
Rating
Scrubber Tower
Capacity
Size
Brine Tank
Capacity
Size
14- 3
500 amps.
0 to 500 amps.
0 to 12 volts
460V, 3 phase, 60 Hz
1,000 cfm
2'-6" dia. x 8'-2" high
58 gallons
2'-0" dia® x 2'-10" high
POTABLE WATER
SUPPLY
ELECTROLYTIC
HYPOCHLORITE
REGENERATOR
POWER
SUPPLY 11ZRECTIFIER
i 0 a 0 i I
mm
FAN
MALODOROUS
�— AIR
INLET
RECYCLE
PUMP
CPJ CONSULTING ENGINEERS
ui
c
m
m
G
Brine Tank Mixer
Rating -
Circulating Pump
Type
Capacity
Motor
Rating
Chemical Metering Pump
Type
Rating
Exhaust Fans
Motor
Rating
CONTROLS
115V, 1 phase, 60 Hz
Centrifugal
25 gpm @ TDH 30 ft.
TEFC 1 HP
460V, 3 phase, 60 Hz
.Adjustable
115V, 1 phase, 50/60 Hz
Explosion Proof
460V, 3 phase, 60 Hz
The odor control unit contains STOP -START pushbuttons, a
reset button, DC ammeter and voltmeter, with indicating lights
for current on or overload cut out for the recycle pumps, caustic
solution addition pump and the exhaust fan.
The unit is also equipped with an automatic level control to
automatically maintain an optimum solution level in the scrubber
tower basin.
A flow and temperature sensor located in the electrolytic
cell discharge line automatically turns off the main rectifier
power to the electrolytic cells when solution flows through the
cells is insufficient or the temperature is too high.
The exhaust fan motor starter automatically turns off the
odor control system in the event of exhaust fan malfunction.
The chemical metering pump is automatically ON-OFF operated
to control the fluctuating pH.
14- 5
CHAPTER 15: ELECTRIC POWER AND LIGHTING SYSTEMS
GENERAL
POWER SOURCE
SYSTEMS CONTROL
ALARMS
ELECTRIC MOTORS
EMERGENCY PROCEDURES
EMERGENCY ENGINE®GENERATOR SET
NOTES AND ADDENDA
LIST OF TABLES
PAGE NO.
15® 2
15® 2
15® 2
15- 2
15® 4
15- 8
15® 8
15®17
PAGE NO.
Table
15® 1 Emergency Procedures 15® 9
15- 2 General Troubleshooting Guide for Electric 15®13
Motors
GENERAL
This chapter of the manual describes the electrical system and
gives instructions for its operation and maintenance. This
system is also shown on the record drawings for Contract No.
4 -Electrical, which includes single line drawings, plans and
details for power and lighting. Additional information is also
available in the contract specifictions and approved shop
drawings attached -as Appendix E.
POWER SOURCE
• Primary power is supplied to the facility by a Village of
Greenport 400 AMP underground feeder from the Village service
pole to metering enclosure located outside of the Treatment.
Buildings. From here the secondary underground services are
distributed to the MCC's and other electrical receptacles
throughout the facility.
SYSTEMS CONTROL
ALARMS
The following alarm systems are provided at this facility:
UNIT
Odor Control Unit
Effluent Pumps
Sludge/Scum Pumps
Equilization Pumps
Primary Clarifier Overload
Secondary Clarifier Overload
ALARM CONDITION
Malfunction -
High Level
High Level
High Level
Over Torque.
Over Torque
These alarm conditions are connected to the annunciator panel
located in the Treatment Building.
Additional alarm conditions at the plant are discussed in
the following sections of Chapter 13, Sludge and Scum Treatment
Facilities; Anaerobic Sludge Digestion and Sludge Dewatering.
Preventive Maintenance
WARNING: NO MAINTENANCE WORK SHOULD BE,PERFORMED
WITHIN THE ENCLOSURE OF ANY ELECTRICAL EQUIPMENT BY
ANY PERSON WHO IS NOT A QUALIFIED ELECTRICIAN, EXCEPT
AS CLEARLY SPECIFIED.
Personnel who perform any maintenance procedures should
record the fact in the appropriate plant records, with signature,
date and comments as to actions taken, the reason for those
actions and the results obtained.
15- 2
At least every six months, each electrical panelboard should
be opened, visually inspected and cleaned. It is recommended
that this work be done by an electrician. The circuit breaker'or
switch of -the unit to be cleaned should be padlocked in the OFF
or OPEN position for safety during the cleaning -process.
WARNING: TAKE CARE NOT TO TOUCH ANY UNINSULATED
CONNECTIONS INSIDE THE COMPARTMENT. LETHAL VOLTAGES
MAY STILL BE PRESENT IF THE CONTROL CIRCUIT IS
ELECTRICALLY INTERLOCKED WITH A UNIT WHICH IS STILL
ENERGIZED.
Inspect for dust or dirt within the unit and remove with a
vacuum cleaner.
WARNING: THE,NOZZLE OF THE VACUUM CLEANER
MUST BE OF A NON -CONDUCTING MATERIAL ONLY.
After cleaning, inspect for evidence of overheating at
connections and contacts,. shown by discoloration, and at the
coils and wiring, shown by a burned appearance and a
characteristic unpleasant odor. Check for any other deficiencies
so they may be corrected by a qualified electrician.
At least once each year, each panelboard should be
deenergized, cleaned out and given an electrical inspection by a
qualified electrician.
To de -energize a particular panelboard or MCC, the following
procedure is 'recommended:
1. Open the main circuit breaker for the desired panel -
board (see Contract No. 4 -Electrical, record drawing,
Control and Line Diagrams), padlock the circuit
breaker on the OPEN position.
2. Cleaning and inspection as performed by the qualified
electrician should include buswork, insulators, bus and
terminal compartments, and each unit compartment. Remove
all dirt and dust by wiping, brushing and vacuum cleaning.
3. Tighten all connections, both.electrical and mechanical,
especially those of the buswork and wiring. Check all switches,
starter and relay contacts and all electrical wiring, paying
particular attention to any evidence of'overheading,
misalignment, poor contact or other faults. Contacts or
wiring found to be in poor condition should be repaird or
replaced.
4. Before cleaning, and again after all cleaning, inspection
and repairs have been completed, measure the insulation -
15- 3
resistance of the buswork and record the results in the plant
maintenance record. Follow the manufacturer's instructions.
5. At least once each year, unless otherwise specified in the
manufacturer's instructions, lubricate each motor. Check
the plant maintenance records to find the last lubrication
period. Follow the manufacturer's recommendations as to
frequency and amount of lubrication and use the specified
grade and quantity of lubrication.
6. To restore normal power reverse the procedure described
in 1 above.
ELECTRIC MOTORS
Semi-annually, all electic.motors should be examined for
excessive accumulation of dirt, excessive heating and proper
lubrication.
If a motor is suspected of running overheated, the
temperature should be measured by means of a thermometer. Should
the temperature prove to be excessive, a check should be made to
ensure that the bearings are adequately lubricated in accordance
with the manufacturer's instructions. If excessive dirt is
present on or in the motor, it should.be cleaned out as
previously noted.
Lubrication of bearings should be checked. Follow
manufacturer's instructions as to the time between lubrications,.
type of lubricant, and,procedure to be followed. DO NOT
OVER -LUBRICATE. Excess oil will seep into windings,. and excess
grease will cause overheating. When checking the oil level in
large bearings, stop -the motor. Replace dirty oil or grease. On
wick -oiled bearings, change the wicking at least once a year.
At intervals of approximately one year, each electic motor'
driving important equipment should be cleaned, lubricated and
checked for overheating, insulation resistance and phase current
balance.
Where,manufacturer's maintenance instructions are available.,
the procedures outlined therein should be followed. The
following general procedures may be used for guidance where -
specific manufacturer's instructions are not available.
The circuit°to the motor should be de -energized by opening
its circuit breaker in the MCC or panelboard from which it is
supplied. Padlock the circuit breaker in the OPEN position and
tag it.
15- 4
Bearing lubrication of motors should be accomplished in
accordance with manufactur:er's instructions when they are
available.. Otherwise the following general procedures should be
followed applicable®
Sleeve Bearings
Oil -ring Type Drain reservoir, refill to
indicated level with type and grade
of oil recommended by manufacturer
(generally a good grade of engine
oil, SAE #20). Check to be sure
that oil -ring is free.
Wood -packing Type Add oil slowly until packing is
thoroughly saturated. When oil
begins to flow out of the overflow
hole near the bottom, the bearing
is full. Use oil ,recommended by
manufacturer (generally a.good
grade of engine oil,, SAE #10) .
Ball Bearings
S
Grease -lubricated Type If the motor -end bells have grease
plugs or grease fittings, grease
may be added by the use of a low
pressure grease gun. Grease should
be added sparingly in accordance
with the manufacturer's
instructions (generally, a good
grade of grease made especially for
ball bearing electric motors is
used). If the motor has a grease
sump with a -plug near the bottom,
the plug should be removed before
any grease is added. Add only a
small quantity of grease - do not
overlubricate.
Sealed -cartridge Type-- If no grease plugs or fittings are
provided on the outside of the end
bells, the bearings are of the
sealed -cartridge type. In general,
bearings of this type are packed
with enough grease to last for
three years. Follow manufacturer's
instructions regarding greasing of
15- 5
End Bell and Bearing -
Removal
such bearings. In general, every
three years the -end bells of the
motor should be removed, the snap
rings and removable seals removed
from the outer ends of the
bearings. If the grease inspected
has a bad odor, the bearings should
be removed and cleaned with a
suitable non-flammable, non-toxic
solvent. Repack with a good grade
of grease made especially for all
bearing electric motors. Do not
pack tight. Only about half of the
grease space should,be used.
Tightly packed bearings -will
overheat. I'f, upon examination, the
grease in the bearings is not
discolored and has no unpleasant
odor, the bearing may be put back
in service without cleaning and
regreasing.
If removal of motor end bells and
bearings for inspection or cleaning
and regreas-ing is'necessary, it
should be done very carefully to,
avoid damage to motor parts and
bearings. If possible, motors
should be disconnected from their
driven equipment and taken to the
shop for such servicing.
Couplings, gears, pulleys, etc.,
should be removed from the motor
shaft by means of pullers.
Excessive hammering or wedging is
likely to damage other parts in
addition to that being removed.
Clean each part as soon as it is
removed, store -,in a clean place,
and cover to protect from dirt.
End bells should be tapped or -
wedged uniformly around their
circumference to avoid damaging
their edges. Bearings should be
removed by means of a puller,which
exerts a uniform pull all around so
as not to distort the bearing or
damage the motor shaft. Reassemble
carefully, using the minimum amount
15- 6
of force. When replacing the
motor, carefully check alignment of
couplings. Be sure that motor is
solidly bolted in place, properly
lubricated and properly connected.
Be sure that fan or other cooling
devices are functioning properly.
Be sure that motor frame is
properly grounded.
On wound -rotor motors, the slip rings should be cleaned and
slip rings and brushes inspected for abnormal or irregular wear.
Should -any roughness or grooving of the slip rings be observed,
steps should be taken immediately to smooth and polish the slip
ring surfaces and replace the brushes.
On sleeve -bearing motors, a check should be made of the air
gap between the rotor and the stator. Four measurements should
be made, approximately 90 degrees apart, and the results recored.
Periodic comparison of air gap measurements will permit early
detection of bearing wear.
After cleaning and lubrication, the motor should be restored
to service and allowed to run for a sufficient time to reach
normal operating temperatures. During this period, it should be
carefully observed to ensure that it is operating normally,
without excessive noise or vibration and with proper circulation
of cooling air. When the motor -has been run for a sufficient
period to ensure its having reached normal operating
temperatures, its temperature should be measured and recorded.
Temperature measurements should be made in accordance with
the manufacturer's instructions, and temperature should not
exceed that indicated on the motor nameplate.
When the motor temperature has stabilized and is within
normal limits, the circuit to the motor should be de -energized by
opening its circuit breaker on the panelboard from which it is
supplied, locking the circuit breaker in the OPEN position, and
tagging it. The insulation resistance of the motor should then
be measured and recorded.
E
In case of a.wound-rotor motor., the rotor leads should be
disconnected and the insulation resistance of -both stator and
rotor should be measured separately.
Insulation resistance is ordinarily measured by means of a
megger. Care should be exercised to be sure that the megger
voltage does not exceed the rating of the motor. Measurements
are made from the stator leads (connected together), or the rotor
leads of a wound -rotor motor (connected together), to the
15- 7
grounded motor frame. For 480 volt -or lower voltage motors,.>the
insulation resistance readings should not be less than on megohm.
Insulation resistance readings of each motor should be taken
and recorded at yearly intervals. A comparison of current and
past readings should be made each time a motor is checked. A
significant and progressive. lowering of insulation resistance
over a period of time indicates deterioration of the motor
insulation or an accumulation of dirt in the windings, and warns
of impending trouble (Note® It is important that motors be hot
when insulation resistance measurements are taken).
After completion -of insulation resistance measurements, the
motor should be reconnected, and the connections properly
insulated (the motor connections should be temporarily left
accessible so that the motor leads will be available for checking
phase currents). After work has been completed and carefully
checked, the motor should be energized and run at normal load.
Current in each phase wire to the stator should then be measured
by means of a suitable clamp -on., or tong, type ammeter, and the
readings recorded. If any significant unbalance in phase
currents is discovered, a wattmeter should be installed in the,
circuit and a check made of -the power being used by the motor.
In the event of a significant and progressive lowering of,
insulation resistance, a serious unbalance of phase currents, or
an excessive power consumption,.it is recommended that the
services of a qualified motor repair organization be obtained to
determine the cause and repair the motor.
EMERGENCY PROCEDURES
For procedures to adopt in the event of emergency equipment
and/or power failures, see Table 15-1 - Emergency Procedures.
Table 15-2 is included as a general guide for
troubleshooting electric motors.
EMERGENCY ENGINE - GENERATOR SET
Manual Line Transfer Switch
There is an existing emergency engine -generator set at the -
Village of,Greenport wastewater treatment plant. Provisions have
been made to provide standby power to the Town of Southold
scavenger waste treatment facility via a connection to the
Village emergency engine -generator set. However, the existing
emergency engine -generator set does not have the capacity to
handle all of the electrical loads from the Southold facility.
15- 8
EMERGENCY
SITUATION TYPE/LOCATION
Power Failure 1. Treatment Plant
2. Individual Circuit
TABLE 15-1
EMERGENCY PROCEDURES
EQUIPMENT RESPONSE
All electrical equipment in plant
will shutdown temporarily,
appropriate loads will restart
upon transfer to standby power.
Equipment on affected circuit will
be shutdown - all other equipment
operation will be normal.
STAFF RESPONSIBILITY
Advise plant supervisor and power
company.
Determine cause of power failure
and correct, following procedures
outlined in Table 15-2 Corrective
Procedures.
Act of God 1. Flood Flooding will cause failure of all Shutdown all electrical circuits
electrical equipment involved to areas in imminent danger of
unless in watertight enclosures. being flooded, to protect equipment
and avoid hazard to personnel.
After flooding condition has passed,
all electrical equipment in the
flooded area should be cleaned,
thoroughly dried out, and properly
tested before being energized.
This work should be performed by
personnel thoroughly experienced
in repairing and testing electrical
equipment which has been subjected
to flood damage.
EMERGENCY
SITUATION
Fire and/or
Explosion
TYPE/LOCATION
2. Hurricane)
Windstorm)
3. Earthquake
1. Treatment Plant
TABLE 15-1
EMERGENCY PROCEDURES
EQUIPMENT RESPONSE
Most likely damage is to incoming
power lines, with consequent loss
of power.
Probably no electrical damage
unless very severe. Most likely
damage in severe earthquake would
be electrical overloads caused by
mechanical damage to rotating
machinery, and by'short circuits
caused by failures and collapse
of structures.
Equipment will continue to operate
normally except for portions of
electrical system which may be
damaged.
STAFF RESPONSIBILITY
See Power Failure, 1 and 2.
All electrical circuits in plant
should be de -energized as quickly
as possible by opening the main
circuit breaker control panel.
Advise plant supervisor and Fire
Department.
Shutdown all electrical circuits
to the area involved in the fire
and/or explosion in order to
minimize hazards to personnel and
the spread of fire.
After emergency has passed, all
electrical equipment in the
affected area should.be inspected
for damage before restoring
electrical power,
EMERGENCY
SITUATION TYPE/LOCATION
2. In Electrical
Equipment
Equipment Failure 1. Motors
TABLE 15-1
EMERGENCY PROCEDURES
EQUIPMENT RESPONSE
Extensive damage to equipment will
result unless it is de -energized
immediately.
Motor stops, overheats or
repeatly trips circuit breaker.
STAFF RESPONSIBILITY
De -energize affected equipment at
once.
Advise plant supervisor and Fire
Department,
Shutdown all electrical circuits
to the area in which the fire has
occurred, in order to minimize
hazards to personnel and damage
to other equipment.
Shutdown equipment, notify plant
supervisor. Call an electrician.
2. Control Devices Equipment stops, fails to start, Try to determine cause of failure
or operates improperly. as outlined in Table 15-2
Corrective Procedures.
Shutdown equipment and notify
plant supervisor.
Try to determine cause of
malfunction as outlined in Table
15-2 Corrective Procedures.
EMERGENCY
SITUATION
TABLE 15-1
EMERGENCY PROCEDURES
TYPE/LOCATION EQUIPMENT RESPONSE STAFF RESPONSIBILITY
3. Panelboard Equipment Same as 2, except caused by If unable to determine cause of
device in panelboard (starter, failure, call an electrician
relay switch or circuit breaker).
4. Wiring Wiring overheats or short circuits Same as 2.
(generally due to physical damage).
Shutdown affected circuit
immediately, notify plant
supervisor. Call an electrician.
Try to determine cause of overload
or location of short circuit.
If circuit supplies vital equipment,
have electrician disconnect both
ends of damaged cable and connect a
temporary cable in its place while
repairs are in progress.
TABLE 15-2
GENERAL TROUBLESHOOTING GUIDE FOR ELECTRICAL MOTORS
TROUBLE
Motors will not start and/or run
Motor will not start
Motor starters contact chatter
Contacts weld or freeze
POSSIBLE CAUSE
1. No supply line voltage.
2. No voltage at motor terminal.
3. Motor starter does not work.
1. Defective motor.
2. Single phasing on 3-phase
circuit.
3. Capacitor open or shorted
(single phase motors).
4. Centrifugal switch stuck
(single phase motors).
Broken shading coil, low voltage,
poor connection, dirty pole faces.
REMEDY
Check line circuit breaker or fuses.
Check motors starter operation, overload
relays and load connections.
Reset overload relay. Check starter coi
Check pilot -control circuit.
Replace.
Correct voltage condition.
Replace capacitor.
Clean and loosen switch.
1. High in -rush current. Check for grounds, shorts or excessive m
load current.
2. Insufficient contact pressure. Replace springs.
3. Low voltage. Check for dip in voltage during activati
TABLE 15-2
GENERAL TROUBLESHOOTING GUIDE FOR ELECTRICAL MOTORS
TROUBLE
Contacts do not close when
coil voltage is applied
Frequent tripping or overload
relays
Starter contacts do not drop out
POSSIBLE CAUSE
4. Foreign material or buildup
on contacts.
1. Open coil.
2. Shorted coil.
3. Undervoltage.
4. Dirt or rust on pole faces.
REMEDY
Clean contacts (do not file).
Replace coil.
Replace coil.
Correct system voltage.
Clean pole faces.
1. Loose connection on load wires. Clean and tighten.
2. High ambient of motor starter. Use larger heater.
3. Sustained overload. Check for grounds, shorts or excessive m
currents.
4. Insufficient supply voltage. Correct voltage conditions.
1._ Worn or rusted parts causing Replace parts.
binding.
2. Coil voltage not removed. Check control circuits.
Pushbuttons and selector switches 1. Faulty wiring. Repair or replace.
do not energize or de -energize
circuit 2. Foreign matter in operating Remove and clean.
parts.
TROUBLE
TABLE 15-2
GENERAL TROUBLESHOOTING GUIDE FOR ELECTRICAL MOTORS
POSSIBLE CAUSE
3. Contacts dirty.
4. Contacts welded.
5. Spring return units bind.
REMEDY
Clean - use commercial solvent.
Check for shorts and grounds. Replace
contacts.
Clean and lubricate.
During operations under standby power only the following critical
electrical loads should be connected to the engine -generator:
Air Blowers
Equalization Pumps
Effluent Pumps
RBD Units
As a general guide for initiating standby power operations
at the Southold facility follow the steps listed below:
10. All load breakers are turned off.
2m Once the engine -generator is operating turn on the
manual line transfer switch.
3. Individually load on critical electrical Toads indicated
above®
4e Depending on available capacity remaining, the operator
may add non-critical electrical loads up to ninety
percent of the engine -generator capacity.
15® 16
CHAPTER 16: HEATING AND VENTILATION SYSTEMS
PAGE NO®
ELECTRIC HEATING SYSTEMS 16- 2
Electric Baseboard Heater
16-
2
Maintenance
16-
2
Electric Unit Heater
16-
2
Maintenance
16-
2
Convection Heaters
16-
3
Maintenance
16-
3
VENTILATING SYSTEM
16-
5
Startup Check List
16-
5
Maintenance
16-
7'
NOTES AND ADDENDA 16-10
LIST OF TABLES
16®
1
Electric Heaters
16- 4
16-
2
Exhaust Fans
16- 6
16-
3
Miscellaneous Air Handling Devices
16- 9
16- 1
ELECTRIC.HEATING SYSTEM
Electric Baseboard Heater
Each baseboard heater is self-contained. It.consists of a
heating element housed in a steel casing.
Heat transfer is accomplished by a cast -aluminum heating
grid. The aluminum heating element is cast inside the heavy
finned aluminum grid,. This mass of aluminum acts as a heat bank,
which holds the.heat generated by the element -imbedded in it-;
discharging it slowly into the room air when the unit shuts down.
Mounted directly to the cast -aluminum heating`grid is a
thermal limit switch which provides protection against excessive
grid temperature. If for any reason normal air flow is
interrupted, the thermal limit switch safety device automatically
interrupts power,to the heater. When the condition causing air
blockage is corrected, the switch automatically resets and
restores current.
Maintenance
Regular inspection is the most important factor in
continuous economical,,troubl:e-free operation. Usually
inspection every four -months should be sufficient. On
inspection, check for dirty heating elements and loose electrical
connections.
The heating element should be cleaned' as often as -,required
to maintain maximum efficiency, at least once a year. The
heating capacity can be -seriously impaired by dirt.
The casing can be cleaned during inspection and rusted or
corroded spots removed. After this is done, retouch with paint.
Electric Unit Heater
Each unit heater is basically self-contained and is provided
with a thermal limit switch that protects against excessive
temperature on.the unit's grid. If for any reason normal air
flow is interruped, the switch automatically interrupts power
service to the heater. The unit is also equipped with louvers
which are individually adjustable so heated air can,be directed
as desired. Each unit heater is controlled by the setting on the
wall mounted thermostat which is provided with a thermometer.
Maintenance
Regular inspection is the most important factor in
continuous. economical, trouble-free operation. Usually,
inspection every four months should be sufficient. On
inspection, check for dirty heating elements, loose electrical
connections and excessive vibration, and clean the fan and the
outside of the motor.
16- 2
The heating element should be cleaned as often as required
to maintain maximum efficiency and at least once a year. The
heating capacity can be. seriously impaired by dirt.
To remove dirt, brush the fins on the side where the air
enters the unit and then turn on the fan. A bag may be placed
over the face of the unit to catch this dirt. Brush along the
fins -to avoid bending, because this could reduce unit capacity.
Removal of oil and dirt accumulations on the leading edge of .fin.s
can be done by using a mild alkali solution -or detergent to cut
oil or grease. Rinse thoroughly to remove any trace of this
solution. For very thorough cleaning, dismount the unit. Care
should be taken to rinse well afterward.
The fan should be cleaned at periodic intervals. Much
trouble can be caused by a dirty fan, such as getting out of
balance, noise and excessive vibration that may damage the
bearings and overload the motor. A check should be made to be
sure that the fan is in the proper position, the setscrews tight,
and that the fan blades have a uniform setting.
The casing can be cleaned during inspection and rusted or
corroded spots removed. -After this is done, retouch with paint.
Convection Heaters
The convection heaters are of the cabinet type and operate
on the principle of forced air application. They are provided
with a thermal limit switch which protects the heating element if
the air flow across the element stops or is blocked, by
interrupting current to it, or in the event of excessive
temperature on the -heating element, by de -energizing the element.
After shutdown the.thermal limit switch automatically resets.
The motor is also provided with a built-in automatic reset
thermal overload protection device..
Each heater'is controller by a wall mounted thermostat.
There is no temperature control knob, temperature adjustments can
be made only when the thermostat cover is removed and by using an
ordinary screwdriver.
Maintenance
Only a minimum amount of maintenance is required for these
.heaters, when required proceed as indicated in -the manufacturer's
bulletin (see Appendix D 16®1).
The electric heaters are located throughout the plant as
listed in Table 16®1.
16® 3
UNIT # LOCATION
H- 1 Aerated Grit
Chamber
H® 2 & Aerated Grit
H- 3 Chamber
H® 4 &
H® 5, Blower Room
Hm 6 Lime Room
Hm 7 Storage Room
H® 8 Bath Room
H® 9 Gas Equipment
Room
H®10 Digester Room
TABLE 16 ® 1
ELECTRIC HEATERS
CAPACITY VOLTAGE
(KW)
(V)
BTU/HR
TYPE
I, Group
D
480 17,075
Wall Mount
Forced
Wall
Mount
Forced
10.0
480
34,130
Air
Unit
Heater
Wall
Mount
Forced
5.0
480
17,075
Air
Unit
Heater
Wall
Mount
Forced
5.01
480
17,075
Air
Unit
Heater
5.0
480
17,075
Wall
Mount
Forced
Air
Unit
Heater
1.25
120
4,269
Automatic
Wall Heater
1.25
120
4,269
Automatic
Wall Heater
5 . Q_
H®.11 Sludge/Scum Well 3.0
480 19,,209
Explosion
Proof., Class
I, Group
D
480 17,075
Wall Mount
Forced
Air Unit
1
Heater
2.40 10,245
Wall Mount
Forced
Air Unit
Heater
NOTE: Units H®7, H®8 & H®11 are single phase, all other units are
3 phase.
16® 4
VENTILATING SYSTEM
The ventilation system for the treatment plant consists of
the following components:
1. Roof mounted exhaust fans.
2. Wall mounted exhaust fans.
3. Dampers:
a. Volume Control
b. Automatic
c. Fire
4. Louvers
5. Roof outside air intake and exhaust blowers
The exhaust fans draw air out of the service area, thus
keeping the area well ventilated.
The roof mounted exhaust fan consists of a centrifugal fan,
direct drive, dome covered, wired to a disconnect switch. These
fans are equipped with a bird -screen, a gravity louver damper and
a speed control switch.
The wall mounted exhaust fan is of the centrifugal type with
an adjustable shutter and a speed control switch. The exhaust
fans are located throughout the plant as listed in Table 16-2.
Startup Check List
Before putting any fan into operation the following check
list should be completed:
1. Lock out primary and secondary power source.
2. Make sure installation is in accord with manufacturer's
instructions.
3. Check and tighten all hold down (securing) bolts.
4. Spin wheel to see if rotation is free and does not bind
or rub.
5. Inspect wheel to see if it is the proper rotation
for the fan design.
16- 5
r
TABLE 16 - 2
EXHAUST FANS
* Explosion Proof Motor - 115 Volts - Single Speed
16- 6
RPM MOTOR HP
1250
1/10
CAPACITY
UNIT NO.
LOCATION
CFM AT .12518 S.P.
E-1
Aerated Grit
565
E-2
Blower Room
1707
E-3
Blower Room
565
E-4
Bath Room
214
E-5
Storage Room
214
E-6
Lime Room
214
E-7
Gas Equipment
Room
414
E-8
Digester Room
214
* Explosion Proof Motor - 115 Volts - Single Speed
16- 6
RPM MOTOR HP
1250
1/10
925
1/3
1250
1/10
1250
1/25
1250
1/25
1250
1/25
1725
1/4*
1250
1/25
6: Check all set screws and tighten if necessary.
7. Properly secure all safety guards.
8. Switch on electrica supply and allow fan to
reach full speed.
9. Check carefully for:
A':- Correct wheel rotation®
B. Excessive vibration.
C: Unusual noise.
If any problem is -indicated SWITCH.OFF IMMEDIATELY. Lock out
the; -electrical supply, check carefully- for the.= cause of the
trouble and correct as necessary..
Even if the fan appears to be operating satisfactorily,
shutdown after a brief period and recheck items 3 through 7 as
the initial startup may have relieved the tightness of bolts and
set screwsm
The fan'may now b.e,put into operation but, during -the first
eight hours of running, it should be periodically observed and,
checked for excessive vibration and noise. At this time checks
should be also be made of motor input current and motor and
bearing temperatures to insure that they do'not exceed
manufacturer's recommendations.
After eight hours of satisfactory operation, the fan should
be shutdown and the power locked out to check the following items
and adjust if necessary:
1. All set -screws and hold-down bolts.
2. Drive coupling alignment.
Maintenance
The wall exhaust fans are basically maintenance free and -
have motors with permanently lubricated ball bearings.
The .roof exhaust fans require a minimum amount o-f-
maintenance-. On a -routine basis, the operator should perform the
following®
1. Check that fans turn freely and that passages are not
obstructed.
2. Check for excessive vibration. Do not allow a fan to run
if it vibrates or makes scraping or rattling noises.
3. Keep fan blades and damper clean and remove accumulated
16® 7
4
dirt.
4. Check bird -screens and clean when necessary.
WARNING: DO NOT ATTEMPT ANY MAINTENANCE ON
A FAN UNLESS THE ELECTRICAL SUPPLY HAS BEEN
COMPLETELY DISCONNECTED.
The following suggestions may be helpful in locating the
sources of trouble in ventilating fan operations:
1. The failure of a fan to start could be caused by a
power failure, a bent shaft, a clogged housing of a
fan wheel which has shifted on the shaft and jammed
against the housing.
2. Excessive vibraition may be caused by unbalance in
the fan or motor, loose anchor bolts, bent fan blades
or dirt accumulations on the blades or housing. Also,
set -screws or keys holding the fan wheel to the shaft
may have loosened.
Table 16®3 contains a list of miscellaneous air handling
devices located throughout the plant.
8
UNIT NO. LOCATION
TABLE 16 ® 3
MISCELLANEOUS AIR HANDLING DEVICES
INCREMENTAL CONDITIONER SCHEDULE
CAPACITY (B T U/ HR)
COOLING HEATING
ICml Administration 13,800
Room
SUPPLY ROOF FAN SCHEDULE
CAPACITY
CFM @ 1/8" S.P.
S®1 Dig -ester Room 1,395000
16- 9
16,400
RPM
1,140000
MOTOR HP
1/4
CHAPTER 17: MAINTENANCE AND UTILITIES
GENERAL MAINTENANCE PROCEDURES
General
Scheduling
Equipment Data
Tools
Miscellaneous Supplies
Service Contracts
Warranty Provisions
Maintenance Records
Pipe Identification and Color Coding
Maintenance and Lubrication Table
General Process Startup Procedures
Process Tanks and Wells
Miscellaneous Equipment, Metalwork and Piping
Housekeeping
MECHANICAL EQUIPMENT MAINTENANCE
Pumping -Equipment
General
Horizontal Centrifugal Pumps
Submersible Pumps
Hydraulic Diaphragm (Chemical) Pumps
Progressive Cavity Pumps
Pump Packing
Mechanical Seals
Valves and Gates
Ball Valves
Plug Valves
Gate Valves
Buried Gate Valves
Butterfly Valves
Diaphragm Valves
Air and Vacuum Relief Valves
Solenoid Valves
Check Valves
Sluice and Slide Gates
17-
PAGE NO.
17- 3
17- 3
17- 5
17- 5
17- 6
17- 6
17- 6
17- 7
17-10
17-10
17-10
17-12
17-13
17-13
17-14
17-14
17-15
17-15
17-17
17-18
17-19
17-19
17-2-0
17-20
17-20
17-21
17-21
17-21
17-22
17-22
17-22
17-22
PAGE NO.
Drives
17-23
Chain Drives
17-23
V -Belts
17-24
Couplings
17-24
Circular Tank Sludge Collectors
17-25
Air Diffusers
17-27
Rotary Positive Displacement Blowers
17-27
Mixers
17-28
Sludge Digestion System
17-29
Compressors
1.7-31
Hoisting Equipment
17-32
Air Filters and Regulators
17-32
Flow Indicators
17-33
UTILITIES
WATER
1.7-33
REDUCED PRESSURE BACKFLOW PREVENTERS
17-33
Description
17-33
Operation
17-33
Maintenance
17-36
ELECTRICAL
17-36
TELEPHONE
17-36
FUEL OIL
17-36
NOTES AND ADDENDA
17-37
LIST OF. TABLES
17- 1 Maintenance and Lubricat'on
Requirements 17- 4
17- 2 Maintenance Record Form fi
17- 8
17- 3 Pipe Identification and Color
Coding
Schedule
17-11
LIST OF FIGURES
17- 1 Backflow Preventer Devic
17-34
17-
2
GENERAL" AND MAINTENANCE PROCEDURES
General
A well planned and executed maint nance program is absolutely
necessary if the treatment facility is to operate efficiently.
Attention to maintenance is particularly important in preventing
the accelerated corrosion and wear tharesults from the severe
conditions imposed by waste water acid'ty, gases and.dampne.ss.
The first requirement in keeping aintenance,to a minimum is
to have reliable and,properly installei equipment. The combined
efforts of the Engineer and the Contra for have met this
requirement.
The second requirement is to have
personnel. The people who will actual
of inspection, lubrication and minor r
acquainted with the equipment,,i.ts pur
operation. Major overhauls of certain
specialized equipment such as the Inst
generator facilities, may require the
representative.
The third requirement is the est
commitment to, a strong maintenance p
prepared to aid plant personnel in me
specific purposes of the chapter are
scheduling required,equipment mainten
suggest general good housekeeping pra
of -keeping detailed service -records.
Maintenance can be divided into
preventive maintenance and corrective
maintenance is the continuous process
painting, adjusting, lubricating and
important role of lubrication in prev
overstressed. In contrast, correctiv
repair or replacement of equipment (o
longer capable of performing their in
qualified maintenance
y perform the routine tasks
pairs should be thoroughly
ose and its proper
items, and.repairs to
umentation and emergency
ervices of the factory
lishment of, and firm
gram. This chapter has been
ing that requirement. The
provide assistance in
ce and lubrication, to
ices, and to suggest means
e general classification of
rocedures. Preventive
f inspecting, cleaning,.
placing small parts. The
tive maintenance cannot be
procedures refers to the
major parts) which are no
nded function.
Applying preventive maintenance -methods extensively and
conscientiously will minimize the amount of time and money spent on
corrective procedures and will result in more efficient treatment
operations.
SCHEDULING
The recommendations described in manufacturer®s literature
(furnished with the equipment) should be the primary source of
maintenance and lubrication information and MUST be followed in
detail. In addition, Table 17-1 is suggested for use as an aid to
scheduling the work. The table is a format onto which information
17® 3
TABLE 17-1. MAINTENANCE AND LUBRICATION REQUIREMENTS
Equipment:
Frequency i
Maintenance '
Lubrication i
Lubrication
Type
Daily {
{
{
Weekly
S A M P L E
Monthly
{
I
{
Quarterly
{
{
{
Semiannually{
{
{
Annually
i
{
When necessar
YI
I
-
I
{
{
17® 4
extracted from various equipment manufacturer's manuals can be
entered. It is intended as a supplement to, rather than a
substitute for, the manuals. Therefore, maintenance.personnel
should refer to the manuals for all specific details.
Table 17-1 should be completed by the Equipment Mechanic and
Plant Operator. This will aid them in becoming completely familiar
with the individual equipment operation and maintenance. .
Table 17-1 should be completed for all.equipment at the
facility. Tasks to be performed have been divided into the
categories of lubrication and maintenance.
It should be noted that sample Table 17-1 indicates when and
what to lubricate, but does not describe the type, grade or
quantity of required lubricant, all of which are important. The
various manufacturer's instruction booklets may recommend products
of several different oil companies. Therefore, it is suggested
that arrangements be made with one oil company to have its
representative review the lubrication requirements of all items of
plant equipment and prepare a listing of equivalent products made
by his company. a separate grease gun or oil can (properly labeled)
should be used for each type of grade of lubricant to avoid the
possibility of improper lubrication.
Suggestions for maintenance of equipment and structures are
discussed in greater detail in the remainder of this chapter.
Also, since it is often not possible or even desirable to separate
maintenance procedures from operating procedures, the operator
should refer to the other applicable chapters and sections of this
manual for additional comments on maintenance..
EQUIPMENT DATA
The following information should be kept for each piece of
equipment:
1. Identification and location
2. Nameplate nomenclature
3. Manufacturer and service representative
4.' References to applicable manufacturer's instruction
manuals and shop drawings.
TOOLS
No facility can be effectively maintained without the proper
types and .sizes of tools and other maintenance equipment, and these
tools and equipment must be kept in working order and .stored in a
proper place. An initial supply of tools and miscellaneous
equipment was provided under the construction contract.
17- 5
_ It is recommended that tools be locked in storage when not in
use, with access restricted by key, if necessary. It is further
suggested that a tool inventory be prepared and that all tools be
checked in and out of storage. Such a system would indicate where
a tool is being used and by whom, and would provide an incentive to
personnel to return tools to their designated places, clean and in
good working order.
MISCELLANEOUS`SUPPLIES
It is recommended that a list of necessary -expendable supply
items.be developed, including such materials as fuses, light bulbs,
flashlight batteries, waxes, cleansers, and paper products. The -
list should indicate size and type, minimum amounts to be kept in
stock and the most economical quantities. Such information,
together with periodic inventories of stock on hand, will provide
necessary reordering data, will help to avoid annoying shortages,
and will be of assistance in preparing future budgets.
SERVICE CONTRACTS
Many equipment manufacturers are willing to provide for the
servicing of their equipment on a contract basis. however,
reliance on manufacturers to perform routine inspection,
adjustment, lubrication, and minor repairs can become very costly.
As a general. rule, plant personnel should, insofar as possible,
develop their maximum maintenance capabilities in order to perform -
all but the most complex tasks..
It is recommended that consideration be given to a.service
agreement with the supplier of the instrumentation, denitrification
filter equipment and emergency generator because of the complicated
and highly specialized nature of'these items. The contract should
provide for periodic visits for inspection, cleaning and
calibration, with adjustments and repairs as necessary, .and for the
submittal of a formal.report after each visit. Annual visits are
suggested initially, until more experience with the reliability of
the systems is obtained. It is further recommended that the
contract include demand service which provides for the response of
a serviceman on one or two days' notice.
WARRANTY PROVISIONS
The contract under which the treatment facility was
constructed includes a one-year guarantee period, starting from the
date of completion and acceptance of work as stated in the final
estimate. During this one-year period, the contractor is required
to repair,. correct or replace without charge all work, equipment or
material that fails to be in strict accordance with the terms and
provisions of the contract. If,the contractor fails to provide
this service, the owner may have corrections made with monies
withheld for the purpose.
17- 6
In order that all problems,.of such -nature may be brought to a
satisfactory resolution, established procedures must be strictly
followed.
The fact that such a guarantee exists should not be used as an
excuse for improper operation, lubrication or maintenance of
equipment items. Lack of strict adherence to manufacturer's
recommendations for operation and maintenance may result in a
dispute as to responsibility for: equipment failures, and may void
any guarantee®
Alteration of supplied equipment by the owner, without the
knowledge and consent -of the contractor and the equipment supplier,
should be avoided, as it may result in a refusal by these parties
to accept-responsibility,for subsequent problems. Equipment not in
regular service during the guarantee period must be maintained as
recommended, and should undergo periodic operation and special
lubrication to prevent such typical problems as rusting and seizure
of rotating and permanent -setting of drive belts.
MAINTENANCE RECORDS
In the previous sections, special information and suggestions
for implementing a maintenance program have been discussed.
Another important and integral part of the program is to obtain,
record, and preserve accurate and,.detailed information on each
piece of equipment on both preventive maintenance and the
corrective procedures adopted to remedy equipment malfunctions.
A suggested format has been prepared for the recording of this
material and is shown in reduced size as Table,17-2® The record
form in full size measures 18 x 11-1/2 inches, is doublesided, and
is made of cover stock for durability. The form is designed to be
folded in half for filing so that it may serve as a convenient file
folder in which additional, pertinent information relative to that
piece of equipment (i.e., correspondence and repair bills) can be
kept.
The form is comprised of five main parts:
1. Nomenclature. The equipment data may be duplicated
here in order to have a complete reference of_
detail
2-.. Spare Parts. The type and number of spare parts
originally supplied may be recorded,in this section.
Space is:also provided for keeping the inventory up
17- 7
otuu—V sxYvrNT14r uAtNTr.NANCF NeeetltD TORM tSiDE 31
REPAIR RECORD (SIDE -2)
DATE DE.iCRIPTION OP REPAIR
PARTS REPAIRED OR REPLACED (DSY BY WHOM ltAN11OL'RS COST REMARKS
L COST-
PARTSTOTAC I LABOR TOTAL
DESCRIPTION OP REPAIR:
►%ITS IMPAIRED OR KLPLACID C/1ST bT ONIIM MA\Illll'RS CDiT REMARKS
T I I 1
- PARTSTtgAL-'LA&JR 7u1 AL - tMlO \TPIE:
IuTALItKi
e
MIMENCtATM 0111. 11
epulruFxT
INVENTORY NO: CAMP MTI:
,
REPERf.N�= _
_.._....gym. SAIlSA SERVICE:
..eaeDATE POT INTO SERVICE: DATE REPLACED: L&%f.TH OF SERVICE:
RPM TYPE
Pd.AMEPLATE DATA– PIODEL SERIAI. NO. SIZE _
_SERIAL NA. FRAME TYPE CODE LETTCR
MOTOR DATA— YODEL -
vntet AMPS RPM RUTZ _ -_ PHASE 'RATING NEMA DESIGN
INSL'LAT10! CLASS SERV'IEE FA(70R
SPARE PARTS
to date by entry of the date and number remaining each
time any part is used or restocked.
3. Preventive Maintenance Record. Space is provided in
the upper portion of this section to enter the recommended
type and frequency of maintenance for each piece of
equipment, utilizing the manufacturer's -instructions
together with the information developed in Table 17-1.
The lower portion of this section should be used:.to
record when and by whom -monthly, quarterly,- semiannually,
etc. preventive maintenance was performed.
4. Repair Record. Information regarding repairs or remedial -
maintenance work should be registered in this space.
5. Comments. Additional space is left for use at the plant
superintendent's discretion to enter his remarks or
additional information regarding the equipment.
It is intended that these card folders will serve as the basis
for a permanent record of information for each equipment item. To
help prolong the life of the folders, it is suggested that the
entries on the form be made by the plant superintendent or his
designee, rather than the many persons who may have actually
performed the maintenance or repairs. When available space on a
portion of the form has been completely used (such as the lower
part of side three), standard size sheets of the same format may be
prepared and inserted into the card folder.
PIPE IDENTIFICATION AND COLOR CODING
Table 17-3, Pipe Identification and Color Coding Schedule, was
used at this facility.
MAINTENANCE AND LUBRICATION TABLE
Table 17-1 has been provided for developing a preventive
routine maintenance program to be used in conjunction with the
MAINTENANCE RECORD FORM and the manufacturer's operation and
maintenance manuals.
Table 17-1 should be completed by the Equipment Mechanic and
Plant Operator by summarizing the manufacturer's operation and
maintenance manual data onto the table. The data for some typical
equipment has been entered as an example of the method to be
employed. The reverse side of the-card-dan serve as the routine
maintenance and lubrication record.
GENERAL.PROCESS STARTUP PROCEDURES
This section contains general process startup considerations
which are applicable to most unit processes. Careful and
systematic process startup procedures will help to prevent damage
to equipment and minimize safety hazards to operating personnel.
17- 10
TABLE
17-3
PIPE IDENTIFICATION
AND
COLOR CODING SCHEDULE
ANSI &
ASTM
SERVICE
COLOR
DESIG.
MARKINGS
Sludge
Brown
2006
SL
Potable Water
® Cold
Blue
2044
C.W.
v Hot
Blue
2044
H.W.
Sewage
Gray
2050
S
Compressed Air
Green
2036
A
Chemical m
Ferric
Chloride
Orange
2016
F.C.
®
Hydrochlo-
ric Acid
Yellow
2025
H.A.
®
Lime
Ca (OH)2
Orange
2016
LI
r
1. Clean all debris from tankage, pipelines and from the
vicinity of equipment. Assure that all packing material
and shipping tiedowns are removed per manufacturer's
instructions.
2. Check all protective coatings for damage and repair as
necessary.
3. Provide initial lubrication. Be sure all oil reservoirs are
properly filled. Remove any temporary protective coatings
which were supplied for shipping protection.
4. Operate all valves, shafts and other mechanical components
prior to filling will process liquid where possible. Adjust
drives, belt tension, alignment and other items at this time.
5. Adjust weirs and troughs to approximate position.
6. Check electrical components for operational status. Check out
control circuits as possible on a "dry -run" basis prior to
operation of drive.
7. Check all motors for correct voltage connections at the
terminal box.
8. Check all motors for proper direction of rotation.
9. Pressurize piping with water to check for leaks where possible.
10. Check out and calibrate instrumentation, controls and safety
devices.
11. Check that the necessary chemicals are on hand for initial
operation.
12. When tankage is filled, the weirs can be adjusted to final
level.
13. Start up all support facilities such as service water, air
supply, hot water and similar facilities.
14. Make sure safety equipment is available.
PROCESS TANKS AND WELLS
The equalization, settling, RBD and sludge thickener tanks
should be drained and washed down ANNUALLY unless conditions
require greater frequency. Tank draining should be staggered
during the year so as to minimize process effects.
Wet wells, scum wells, division or mixing boxes, and other
channels (some of which cannot be shut down and drained completely)
17® 12
should be cleaned of sludge or other accummulations. Items to be
cleaned should include but not be limited to weir plates, slide or
sluice gates, scum skimmers and collectors, and sludge collection
mechanisms. All areas showing rust, loss of paint or defective
paint coating should be cleaned to bare metal, preferably by
sandblasting, and touched up immediately with a epoxy base coating,
followed by one complete coat of good quality epoxy base coating.
Any areas in the metalwork above water level which show
evidence of rusting or paint failure should be thoroughly cleaned,
touched up with metal primer, and painted. In any case, all such
metalwork, except aluminum railings, should be given a complete
coat of paint at three-year intervals.
While a tank is drained, a careful check should be made for
missing parts, and adjustments should be made where necessary, to
prolong the life of the equipment.
Concrete surfaces and exposed piping above the water level
should be flushed weekly to avoid crusting or caking of unsightly
sludge deposits. Defective concrete surfaces should be thoroughly
cleaned and patched as required.
MISCELLANEOUS EQUIPMENT, METALWORK AND PIPING
Miscellaneous items of equipment, iron and steel work, and
piping and appurtenances should be frequently inspected for rust
spots or paint failure. As soon as defects are detected, they
should be thoroughly cleaned and touched up. All such items should
be completely repainted at least every three years.
Cleanout openings are provided in the sludge piping to allow the
pipes to be rodded if they become plugged. The primary sludge lines
should be flushed after each use.
Manhole steps should be inspected for soundness at least yearly.
HOUSEKEEPING
The general care of buildings and grounds is an area of
preventive maintenance which is often given a position of secondary
importance, but good housekeeping practices can go a long way
towards promoting public confidence and support by way of
preventing unnecessary odors and giving the treatment plant a clean
and pleasing appearance. Care and cleanliness are also helpful in
developing an employee's pride in his work while contributing
toward his overall safety.
Flushing or otherwise cleaning process structures should be
done frequently in order to prevent unsightly growths and deposits
and to minimize potential odor sources.
Floors and windows inside the buildings should be cleaned when
necessary and terrazzo floors sealed with a good quality protective
finish. Painted floors should be recoated as necessitated by wear
17- 13
or paint failure. Bare concrete floors should be kept clean and
free of grease, oil or other accumulations. Window and door glass
should be kept clean. Wall tiles should be kept clean, with
particular attention given to those in the toilet room. The shower
stall should be cleaned with an antibacterial cleaner at regular
intervals.
Outside the buildings, roof gutters and drains should be
cleaned semiannually to remove debris -such as.leaves and stones.
The -sidewalks and walkways should be kept clean and free from snow,
ice or other hazardous obstructions. Any deterioration should be
patched up as soon as practicable.
Landscaping maintenance is likely to occupy any spare time.
Lawns must be mowed as necessary, and weeding the planting beds
will be a periodic chore. During the growing months, the shrubbery
should be trimmed about once a month.
MECHANICAL EQUIPMENT MAINTENANCE
PUMPING EQUIPMENT
General
Pumps are used to raise a liquid to a higher level, to
increase its flow and pressure, and to provide the necessary motion
to convey it to another point. The treatment plant utilizes both
kinetic and positive -displacement pumps. All the centrifugal pumps
are the kinetic type, and the reciprocating pumps (diaphragm) are
the positive displacement type. The pumps are supplied in a wide
variety of designs to serve the many different plant needs. The
manufacturer's instruction book furnished with each pump should be
read carefully.
All pumps should be inspected at least daily to visually -
observe their performance and to check for unusual operating
conditions, such as the following:
1. Unusual noises
2. Excessive vibrations
3. High operating temperatures
4. Abnormal suction or discharge pressures
5. Improper flow readings
6. Excessive or insufficient leakage from packing glands
7. Leakage of lubricants.
Impellers and other wearing surfaces should be checked
annually for abnormal wearing and improper clearances. Diaphragms
and checks should be examined periodically and replaced when worn.
Oil levels in the pump housings on chemical feed or transfer pumps
are critical and must be checked often to ensure proper operation.
Horizontal Centrifugal Pumps
17- 14
These pumps are designed basically for a specific operation,
} and with proper'lubrication and maintenance will give long
trouble free service.
Grease -lubricated bearings are provided with grease fittings
and some models are provided with relief fittings or plugs. When
greasing, USE A HANDGUN ONLY and fill until the old grease is
forced out the opposite opening. Generally, grease every three
months or as necessary.
On oil -lubricated bearings, be sure to keep the oil reservoir
filled to the proper level. Do not overfill.
For water -sealed packings, a clean water supply is furnished
to the stuffing box.
For grease -sealed packings, a grease fitting is tapped into
the stuffing box. The stuffing box packing is subject to wear and
should be given regular inspection. If inspection indicates normal
operation with no excessive heating or leakage, it should be left
alone. If excessive leakage does occur and cannot be reduced by
tightening of the stuffing box gland, the gland should be repacked.
For correct packing sizes, consult manufacturer's operational
manual.
Submersible.Pumps
Submersible pumps are provided with motors designed to operate
continuously at rated load with a temperature rise not to exceed 55
deg. C when completely submerged in liquids with an ambient of 40
deg. C or less. Do not run the motors in air. Motors should not
be overloaded due to their enclosure.
Hydraulic Diaphragm (Chemical) Pumps
.On diaphragm pumps, replace the diaphragm and 0 -ring check
valve seals annually unless experience indicates more frequent
need.
1. Replacing Diaphragm.
a. Shut off pump and close the valves in suction and
discharge lines.
b. Remove angle bracket engaging measuring cylinder studs.
C. Drain pump housing of hydraulic oil. Remove both
check valve clamp studs. Slide the check valves from
between the elbows and the cylinder. Remove the nuts
from the cylinder -mounting studs. Remove one stud and
rotate the cylinder to clear the pipe connections. Lower
the measuring cylinder assembly and remove. If the
assembly resists removal, manually rotate the motor
coupling to raise the plunger and provide clearance.
17- 15
] d. Remove the end cap and push the diaphragm support from
the center of the diaphragm. Clamp the cylinder in a
vice and remove the diaphragm from the cylinder by doubling
in the lower flange and pushing the diaphragm through
the bore with a blunt -ended rod.
CAUTION: TO AVOID DAMAGING THE DIAPHRAGM, DO
NOT USE A SHARP -ENDED TOOL WHEN REMOVING OR
INSTALLING A DIAPHRAGM.
e. Wash all parts thoroughly before reassembling.
f. To install a new diaphragm,.repeat step d. in reverse,
then rotate diaphragm so that the high point of the•
air venting shoulder is adjacent to the flow passage in
the cylinder.
g. Insert the diaphragm support tube, reinstall the end
cap assembly cylinder to the pump housing in reverse
procedure to that in step c.
2. Ball -Type Check Valves. Examine valve balls and seats, and
replace 0 -rings at the same time that diaphragm is replaced.
a. To disassemble check valves, push on ball guide with
blunt rod. Examine ball and.seat. If ball has any
indentation., replace it. There must not be any irreg-
ularities on ball seating surface. NOTE: Seats are
reversible. To provide a new seating surface turn the
seat cover, unless it has been damaged by flow erosion
and/or corrosion.
b. Install new O -rings and reassemble.
C. Insert check valves between cylinder "ear" and suction/
discharge elbows. ARROWS ON CHECK VALVE BODIES MUST
POINT UPWARD.
d. Center valve bodies on base. Reassemble and tighten
both clamp studs.
e. If no additional service operations are to be performed
on pump, be sure to refill housing with oil to proper
level before startup.
3. Poppet -Type Check Valves. Examine valve parts, and replace
0 -rings at the same time that diaphragm is replaced.
a. To disassemble check valves, carefully push on poppet -
DO NOT DISTORT. Examine body and seating surface for
wear and/or corrosion. Check spring condition. Replace
worn or corroded parts.
b. Install new,0-rings and reassemble.
17- 16
C. Insert check valves between cylinder "ear" and suction/
discharge elbows. ARROWS ON CHECK VALVE BODIES MUST
POINT UPWARD.
d. Center valve bodies on base. Reassemble and tighten
both clamp studs.
e. If no additional service operations are to be performed
on pump, be sure to refill housing with oil to proper
level before startup.
4. Lubrication. Drain and replace SPEED REDUCER OIL after
first 240 hours of operation. For ambient temperatures
above 50 deg. F, use SAE No. 90 gear oil. Thereafter, change a
oil only occasionally - every two or three months for
continuous operation; every six months for eight hours
per day operation. FILL ONLY TO OIL LEVEL, NEVER HIGHER.
PROGRESSIVE CAVITY PUMPS
1.' Pump Bearings
S
DO NOT give these bearings routine lubrication because far
more bearings are ruined due to over -attention and improper
attention than otherwise.
DO NOT lubricate with any grease except an approved bearings
grease.
It is recommended, under normal use, that.no lubrication be
added for the first 12 months of operation.
At the end of this time, the bearing -shaft assembly should
be removed and washed with clean benzine.
All old grease should be removed from the bearing housing
and only enough new grease applied to bearing races so as
to fill them flush.
Add a few drops of oil.to bearing seals before remounting
assembly.
It takes several days of running for grease -lubricated ball
bearings in a new pump or relubricated pump to level off
to final running temperature. Prior to reaching this
condition, the bearings might run hot to the extent that it
is not comfortable to hold the hand on the housing.
2. Packing Maintenance Procedures (General)
a. Adjustment of packing gland should be.kept sufficiently
snug so as to prevent leakage but not so tight that the
stuffing box feels -hot to the touch. Gland bolts must
be kept evenly adjusted.
17- 17
b. Nearly all Moyno pumps are supplied with a lantern ring
in the mid-section of the packing and a grease fitting
communicating with it. Careful lubrication of the packing
with a grease insoluble in the liquid pumped will pay
dividends. Greasing often, but with limited quantities,
is best practice.
c.. Scored shafts are packing destroyers. If shaft is
scored as mush as 1/64 inch deep, it: -should be removed
and polished before renewing packing. Shafts can be
sent back to factory for grinding and resurfacing at a
nominal charge. Shafting grooved 1/32 inches or deeper
cannot always be reclaimed.
d. Packing replacements can best be made with formed rings
and these should be inserted with their joints staggered.
Do not use a one piece spiral wrap of packing. Care
must be exercised in slipping rings over the shaft -
part them as below to avoid deforming.
e. Forming of new packing in the stuffing box should be
done by pulling gland bolts down evenly and firmly. Bolts
should then be backed off gradually as stuffing box warms
up. Several "touch-up" adjustments with the new packing
can be expected before final running condition is attained.
Pump Packing
In repacking a pump, the packing glands should also be removed
to provide access to the packing. old packing should be removed
and a careful examination made of the shaft and/or sleeve. Badly
worn or pitted shafts or sleeves will result in short packing life,
and they should be repaired or replaced. Packing rings should be
carefully angle cut to the proper length and placed in the stuffing
box with staggered joints. Check that the lantern ring is located
in the proper location. After the stuffing box has been properly
packed, replace the gland and lightly tighten gland bolts. The
pump should be started and the packing gland drawn down snug, yet
loose enough to permit a liberal drip from the stuffing box.
New packing should be carefully broken in, to ensure long and
satisfactory life. As the packing "wears -in" from operation, the
glands should gradually be pulled down. Excessive tightening of
the gland may cause the packing to overheat resulting in damage to
packing and shaft sleeve.
Usual causes of packing failure and excessive leakage from
the stuffing box are as follows:
1. Packing has not been installed properly.
2'. Packing used is not suitable for the temperature and
pressure involved or may be subject to attack by the
liquid being handled.
17- 18
3. Inner rings of packing are not properly seated and outer
rings of packing are carrying all -the load.
4. Dirt and foreign particles in the stuffing box are
causing rapid scoring of the shaft sleeve.
Mechanical Seals
Mechanical seals are precision products with highly polished
and lapped -seating surfaces.
Mechanical seals have two sealing surfaces and are installed
inside the stuffing box, but the working mechanism is not exposed
to the fluid being handled. For proper lubrication and cooling of
these seals, the stuffing box must be filled with liquid at all
times. The pressure must be slightly higher than the pressure in
the casing of the pump. If the box pressure is not greater, the
pressure within the casing will force open the inner seal area and
allow the fluid to enter the seal area and ruin the seal.
Precautions to be used with mechanical seals are as follows:
1. The seal should be operated until there is fluid in the
seal box to ensure liquid in the seal. Loosen the vent
plug and retighten it only after fluid has started flowing
from the opening. Running the,seal with an air bound box
is the same as running it without fluid.
2. Make sure the pressure line is securely in place and free
of obstructions. Some seals will leak slightly when first
run but this leakage should cease within a short time.
Routine maintenance of mechanical seals should include the
following:
1. Blow out the filter on the water seal every week.
2. About every three or four months, disassemble and clean
the filter.
VALVES AND GATES
All valves, regardless of type and function, should be
operated throughout their entire range at least every three to six
months to ensure that they have not become frozen or -jammed in
position and can achieve full shutoff in any circumstances. The
timing of valve operation should be coordinated with tank
dewatering and other unit processes to minimize disturbance of
plant operation.
Because of the wide variety of valve types and service
applications, valve inspection, lubrication and -repacking can not
be precisely scheduled, except on an individual basis and as
operating experience dictates.. As a -general rule, valves in•sludge
17- 19
or gas lines should be isolated, drained and inspected for wear of
seats, balls and plugs, respectively, at six month intervals.
Valves located in process tanks should be thoroughly inspected for
wear, corrosion or hindered travel whenever tanks are dewatered.
Valves should be lubricated whenever they are dismantled for
servicing.
Ball Valves
Ball valves are nonlubricated and are self-cleaning, self-
adjusting floating ball that compensates for wear. Seat rings are
set deep into metal grooves to protect them from pressure
distortion, mechanical damage or the erosive effects of low flow
through the valve.
Valves are wrench or motor operated. These valves are
virtually maintenance free.
Plug Valves
Plug valves are the eccentric type. Valves of 8 inches or
larger are worm -gear or spur -gear operated; valves smaller than 8
inches are wrench operated except where, due to operational space
or distance from floor, are worm -gear or spur -gear operated with
wheel and chain.
Check the valve packing MONTHLY for leaks; tighten the gland
as needed.
To repack when leakage becomes excessive, relieve pressure on
valve, remove gland and old packing and repack with proper packing.
When unit is dismantled for servicing, lubricate the plug -journal
and plug -stem hex, with a good grade of light grease. Apply a light
grease on worm, gear sector and bearings in actuator. On oil -filled
units, fill with correct oil.
When plug replacement becomes necessary, be sure to follow
instructions in manufacturer's operational manual.
Gate Valves
Gate valves larger than 3 inches in size are iron -body, bronze
mounted, solid -wedge type. Most valves have packed stuffing boxes,
although some valves may have 0 -ring stuffing boxes.
The design of valves are such that repacking may be
accomplished with minimum leakage while in service.
1. Replace valve packing ANNUALLY. Gate valves can be repacked
without removing them from service. Before repacking, open
valve wide. This prevents excessive leakage when the packing
or the entire stuffing box is removed by drawing stem collar
tightly against bonnet on a nonrising stem valve, and tightly
against bonnet bushing on rising stem valve.
17- 20-
a. Stuffing Box. Remove all old packing from stuffing box
with a packing hook or a rattail file with bent end.
Clean valve stem of all adhering particles and polish
it with fine emery cloth. After polishing, remove the
fine grit with a clean cloth to which a few drops of oil
have been added.
b. Insert Packing. Insert new split -ring packing in stuffing
box and tamp it into place with packing gland. Stagger
ring splits. After stuffing box is filled, place a few
drops of oil on stem, assemble gland and tighten it
down on packing.
2. Lubricate gate valves ANNUALLY, as recommended by manufacturer.
Lubricate thoroughly any gearing in large gate valves. Wash
open gears with solvent and lubricate with grease.
3. Clean threads on rising -stem gate valves and lubricate with
grease, SEMIANNUALLY.
Buried Gate Valves
If a buried valve works hard, lubricate it by pouring oil down
through a pipe which is bent at the end to permit oiling the
packing follower below the valve nut.
Butterfly Valves
Butterfly valve bodies are cast iron and the shaft is
stainless steel. The valve disc and shaft connection is by means
of tapered pins secured by lock washers and nuts. Valves have a
pointer and scale which indicate position of the valve disc. Gear
operators are totally enclosed and lubricated with adjustable stops
for open and closed position.
1. Valves are supplied with nylon bearings which should never
be greased or oiled and which require no attention.
2. The only component of the valve which -is field replaceable
is the valve shaft packing. Refer to manufacturer's literature
or procedures.
3. The manual valve operators are shipped with grease in the
unit. The housing is completely filled with,grease and the
unit is lubricated for life.
4. Motors furnished with valve controls are lubricated for life.
Diaphragm Valves
1. Since valve diaphragm prevents fluid in line from entering
bonnet and washing lubricant from working parts, one shot
of lubricant should -be applied SEMIANNUALLY.
2.. Where valves are exposed to corrosive atmospheres or
17- 21
outside conditions, contacting surfaces of the handwheel
and bonnet shell .should also be lubricated.
3. Refer to manufacturer's literature for procedures to replace
diaphragms.
Air and Vacuum Relief Valves
1. These valves are automatic in operation and require little
or no maintenance.
2. Valves should be visually inspected to check for leakage.
A malfunction of the valve can be identified by the seepage
of water through the exhaust port.
3. If a malfunction occurs, follow manufacturer's instructions
to repair the valve.
Solenoid Valves
1. Turn off electrical power and line pressure to valve before
making repairs. It is not necessary to remove valve from
pipeline for repairs.
2. A periodic cleaning of all solenoid valves is desirable. The
time between cleanings will vary depending on the media and
service conditions. In general, if the voltage to the coil is
correct, sluggish valve operation or excessive leakage will
indicate that cleaning is required.
3. See.manufacturer's literature for procedures for coil
replacement and valve disassembly and- reassembly.
Check Valves
On swing check valves equipped with rubber seats or discs,
dismantle the valve and observe the condition of the facing. If
the metal seat ring is scarred, dress it with a fine file and fine
emery paper wrapped around a flat tool. Check pin wear on balanced
disc -check valves as disc must be accurately positioned on its seat
to prevent leakage.
Sluice and Slide Gates
Sluice gates are designed and constructed to operate
satisfactorily under the specified operating conditions. Care
should be taken in the operation of these gates to assure that the
specified operating conditions are not exceeded. If, in the
operation of a gate, an obstruction is met, either in the opening
or closing direction, the obstruction should be removed before
continuing the operation of the gate. The gates and particularly
the bronze seating surfaces, should be protected as much as
possible from debris which may be carried in the flow. When the
gate.is fully open or fully closed, excess force should not be
placed on the gate or gate stem by the operator in an effort,to
17- 22
move the gate further.
1. Sluice gates should require no maintenance other than
lubrication of the operating mechanism -and of the stem. It
is recommended that the stems be lubricated MONTHLY with a
light film of high-grade lubricant.
2. Manually operated floorstands are supplied with high pressure
grease fittings in the operating case and spur -gear case.
It is recommended that the hoists be lubricated with a high-
grade pressure grease that is impervious to,water. Service
intervals for lubrication should be no longer than SEMIANNUALLY.
3. For valves- seating against pressure, ANNUALLY check the bottom
and side wedges until in closed position, each wedge applies
nearly uniform pressure against gate. Adjust as necessary.
DRIVES
Chain Drives
Accurate alignment, proper chain tension, good lubrication and
frequent inspection are required to obtain maximum chain -and
sprocked wear. When installing chain, make sure it is free from
dirt and grit before -it is installed. Fit chain around both
sprockets bringing free ends together on one sprocket. Insert
connecting pin and secure in place.
The correctamount of slack is essential to the proper
operation of chain. Unlike belts, chains require no initial
tension and should not:be tightened around the sprockets. Properly
adjusted chain drives should permit slight flecture by hand in the
slack strand.
The primary purpose of chain lubrication is to provide a clean
film of oil at all load carrying points where relative motion
occurs. To maintain high efficiency and give long trouble free
service, roller chain drives must have oil delivered to the chain
in an appropriate manner to -assure that oil reaches all joints.
1. Chain drives may be designated for slow, medium or high
speeds.
a. Slow -Speed Drives. Because slow -speed drives are usually
enclosed, adequate lubrication is difficult.. Heavy oil
applied to the outside of the chain seldom reaches the
working parts; in addition, the oil catches dirt and grit
and becomes abrasive.
b. Medium -and High -Speed Drives. Medium -speed drives should
be continuously lubricated with a device similar to a
sightfeed oiler. High-speed drives should be completely
enclosed in an oil -tight case and the oil maintained at
proper level.
17- 23
Periodically check belt tension and retighten hub setscrews.
1. General. Maintaining a proper tension and alignment of belt
drives ensures long life of belts and sheaves. Incorrect
alignment causes poor operation and excessive belt wear.
Inadequate tension reduces the belt grip, causes high belt
loads, snapping and unusual wear.
a. Cleaning Belts. Keep belts and sheaves clean and free
of oil, which causes belts to deteriorate. To remove
oil, take belts off sheaves and wipe belts and sheaves
with a rag moistened in a non -oil base solvent. Carbon
tetrachloride is NOT recommended because exposure to its
fumes has many toxic effects on humans. It also is
absorbed into the skin on contact and is cumulative.
b. Installing Belts. Before installing belts, replace
worn or damaged sheaves, thenslack off on adjustments.
Do not try to force belts into position. Never use a
screwdriver or similar lever to get belts onto sheaves.
After belts are installed, adjust tension; recheck tension
after eight hours of operation.
c. Replacing Belts. Replace belts as,soon as they become
frayed, worn or cracked. NEVER REPLACE ONE V -BELT ON A
MULTIPLE DRIVE. Replace the complete set with a set of
matched belts, which can be obtained from any supplier.
All belts in a matched set are machine checked to ensure
equal size and tension.
d. Storing Spare Belts. Store spare belts in a cool dark
place. Tag all belts in storage to identify them with
the equipment on which they can be used.
V -Belts
A properly ajusted V -belt has a slight bow in the slack side
when running; when idle, it has an alive springiness when thumped
with the hand. An improperly tightened belt feels dead when
thumped.
a. Check tension MONTHLY. If tightening belt to proper
tension does not correct slipping, check for overload,
oil on belts, or other possible causes. Rubber wearings
near the drive are a sign of improper tension,incorrect
alignment, or damaged sheaves.
Couplings
1. General. Unless couplings between the driving and driven
elements of a pump or any other piece of equipment are kept
in proper alignment, breaking and excessive wear results in
either or both the driven machinery and the driver. Burned -
out bearings, sprung or broken shaft and excessively worn or
ruined gears are some of the damages caused by misalignment.
17- 24
To prevent outages and the expense of installing replacement
parts, check the alignment of all equipment before damage
occur.
a. Improper original installation of the equipment may not
necessarily be the cause of the trouble. Settling of
foundations, heavy floor loadings, warping of bases,
excessive bearing wear, and many other factors cause
misalignment. A rigid base is not alway security against
misalignment. The base may have been mounted off level
which could cause it to warp.
b. Flexible couplings permit easy assembly of equipment,
but they must be aligned as exactly as flanged couplings
if maintenance and repair are to be kept to a minimum.
Rubber -bushed types cannot function properly if the bolts
cannot move in their bushings.
2. Check coupling alignment SEMIANNUALLY. Excessive bearing and
motor temperatures caused by overload, noticeable vibration,
or unusual noises may all be warnings of misalignment. Realign
when necessary, using a straight edge and thickness gage or
wedge. To ensure satisfactory operation, level up to within
0.005 inch as follows:
a. Remove coupling pins.
b. Rigidly tighten driven equipment; slightly tighten
bolts holding drive.
C. To correct horizontal and vertical misalignment, shift
or shim drive to bring coupling halves into position so no
light can be seen under a straight edge laid across them.
Place straight edge in four positions, holding a light
back of straight edge to -help ensure accuracy.
d. Check for angular misalignment with a thickness or
feeler gage inserted at four places to make certain space
between coupling halves is equal.
e. If proper alignment has been secured, coupling pins can
be put in place easily -using only finger pressure. Never
hammer pins into place.
f. If equipment is still out of alignment, repeat the
procedure.
3. Lubricate flexible couplings SEMIANNUALLY.
CIRCULAR TANK SLUDGE COLLECTORS
The circular units consist of a turntable base, mounted on a
center column. Annular ball bearings support the internal gear and
underwater mechanism. The balls ride on hardened steel strips set
in grooves in the turntable base and internal gear. The pinion (or
17- 25
pinions) that mesh with the internal gear are driven by a worm gear
reduction unit (or units) which is mounted on top of the turntable
base, and is connected by chain and sprocket to a motor or gear
motor. Anti -friction bearings support the worm, worm -gear and
pinion.
Systematic inspection and lubrication will lengthen the life
of these units.
1. All oil baths should be inspected WEEKLY. Periodically remove
the drain plugs under worm housing (upper and lower reservoir)
and remove small quantity of oil to remove any water or foreign
matter. The oil fill plugs have vent holes; be sure.that
this hole is not closed by paint and that it is open at all
times.
2. Lubrication of the gears depends on the pumping action of
the meshing teeth. This is a maintenance -free feature and
requires no attention provided the proper oil level is
maintained. Check the oil level WEEKLY to make sure that
oil is maintained at the proper level.
3. The proper interval for changing oil will depend upon
condition of oil. However, for typical or average service,
SEMIANNUALLY can be considered often enough. Draining the
center mechanism is accomplished by removing a plug at the
following locations:
a. Under the worm
b. Under the upper reservoir bearing (when provided)
c. At the lower reservoir drain line
d. On large units, an additional lower reservoir drain
line is provided.
4. Because a high viscosity oil must be used, some time will
be required for the oil to settle. Fill to the number of
gallons specified in operational manual. If overload
device is provided, more oil may be needed. Never check oil
when unit is running.
5. The lower pinion bearings are provided with grease fittings,
grease SEMIANNUALLY. EVERY TWO YEARS, the cover plate
beneath each bearing should be removed and, without disturbing
the retainer plate, remove as much old grease as possible,
repack with grease and replace cover.
6. Dual -pinion units are provided with grease fittings in the
couplings at each end of an intermediate shaft. These should
be lubricated QUARTERLY. To do this, the unit must be stopped
and coupling and chain guards removed.
7. Roller chain, if in semi -enclosed guards, swab or brush
17- 26
with oil. If in oiltight guard, fill through opening
until lowest point of chain dips into oil.
8. Lifting or dragging of the arms can cause damage to mechanism.
Keep mechanism adjusted. Consult operational manual for
adjustment procedures.
9. Examine gears, oil seals and bearings ANNUALLY.
AIR DIFFUSERS
Air diffuser assemblies should be inspected each time the
tanks are cleaned.
ROTARY POSITIVE DISPLACEMENT BLOWERS
Grease -Lubricated Bearings
Bearings should be lubricated QUARTERLY when units are in
continuous use. When greasing bearings, remove plug at top of
bearing housing, also remove drain plugs in bearing housing cap
(both top and bottom). Insert grease in top opening. Dirty grease
will be forced out through drain hole in bottom of cap. Continue
adding grease until new appears at the drain hole. Start unit and
allow it to run with both top and bottom drain holes open until
grease stops dripping,then replace plugs.
Oil -Lubricated Bearings
Oil should be checked WEEKLY when units are in continuous
service. Check oilers on units, they may be preset and need no
adjustment. After servicing unit(s), always be sure the vent hose
between oiler base and the top of the machine bearing housing has
been connected. Oil should be changed every six months, unless the
units are operating under severe conditions.
It is good maintenance practice to remove old grease from
bearings housing and flush bearing housings SEMIANNUALLY. Do not
fill bearing housing more than half full.
Alignment
Proper alignment of drive and driven unit at operating
conditions is the single most important factor in providing
trouble-free operation.
All corrections of direct -drive units should be made with the
unit at operating temperature. Ambient (room) temperature
alignment does not allow for the units' thermal growth. Neglect of
this will result in misalignment, excessive vibration and shortened
bearing life. Worn.or defective bearings should be replaced
promptly to avoid damage to the unit. Spare bearings should be
readily available. When screen or filters are used, it is
imperative they be kept clean. When replacing bearings, it is
17- 27
necessary to only remove bearing housings. Disconnection of intake
or discharge piping not necessary. Bearings should not be forced
into the housings. It should slide into the shaft and into housing
with only a hand push. Never start the unit with both the inlet
and outlet open.
Proper direction of rotation is indicated by an arrow on unit.
If rotation is wrong, allow machine to reach full speed before
stopping.
Units should not normally be operated with both the inlet and
outlet connections wide open. This condition allows maximum flow,
and in some cases could seriously overload motor.
Under full load conditions, the unit should rotate at the full
load speed indicated on motor nameplate.
Check shutoff valves in line to ensure they are in the "open"
position.
An excessively hot motor indicates one or more of the
following conditions: overload, low voltage, high ambient
temperature or restricted ventilation.
MIXERS
1. Check oil level WEEKLY.
2. The operating temperature of the unit is the temperature
of the oil in the case. The maximum temperature should
not exceed 180 deg. F (200 deg. F for worm -gear units).
3. Instructions for "Grease Lubrication" and "Shut Down Periods"
should be followed as specified in manufacturer's literature.
4. For units with pressure lubrication systems, the above
information and instructions apply with the addition of the
following:
a. Whenever the unit is started, the oil pressure should
be check. When unit temperature is 160 deg. F, the
oil pressure should be approximately 15-30 psi. When
starting a cold unit, the pressure will be higher. If
no pressure is indicated, shut down until the condition
is corrected.
b. oil filters, when supplied with pressure -lubricated
units, should be cleaned periodically.
6. It is recommended to change oil SEMIANNUALLY.
7. Every precaution should be taken to prevent any foreign
matter from entering the gear case. Dust, dirt, moisture
and chemical fumes form sludge which is the biggest enemy
of proper and adequate lubrication.
17- 28
8. Bearings should be lubricated SEMIANNUALLY.
9. For units located outdoors; proper grade oils must be
used for winter and summer operation:
Winter oil - Shell Omala No. 66
Or
Mobil Gear No. 3
Summer oil - Consult Manufacturer's Operation and
Maintenance Manual.
SLUDGE DIGESTION SYSTEM
Digester maintenance should have high priority because of the
corrosive nature of the gases emitted during sludge -digestion.
Sludge gas, when mixed with air in certain proportions, presents an
exceedingly dangerous explosion hazard. It may also be toxic, and
a number of fatalities have resulted at waste treatment plants. It
is essential that the equipment be properly maintained to avoid
failures which might result in gas leaks or malfunctioning of the
fixed or floating cover, with the hazard of collapse if a vacuum
results.
Vacuum -pressure relief valves are designed to prevent
structural collapse should a vacuum develop within a tank or if gas
pressure exceeds preset limits.
Adjustments to the pressure -relief device are made by adding
or removing weights above the diaphragm.. The sheepskin leather
diaphragm should be treated with neat"s-foot oil and the drain hole
kept open to prolong its life. The aluminum surfaces of the relief
valve should be kept clean of slime. Check the vacuum -relief
reservoir frequently and maintain its liquid level. The flame cell
in the vacuum -pressure relief valve assembly should be inspected
frequently to maintain the passages to permit free gas flow. Slimy
material may be removed from the flame cell by water, steam or
compressed air. In winter months, frost must be removed, as
necessary, to keep the vacuum unit.open.
The gas recirculation systems are designed to mix sludge in
the primary digesters. Each time the control panel's explosion -
proof cover is opened, it must be resealed with grease. A silicone
spray should be applied annually to all metal parts of electrical
components. The compressor's lubricator should be set to dispense
oil to the compressor at a rate of 16 to 20 drops per minute
through each feeder. These units use a three -line oiler with
individual pumps for each feeder line, one oiler line to the rotor
and the other two to the main bearings at each end of the
compressor's shaft. The sight feed unit must be kept full of
liquid, normally glycerin, water or a combination of both. The
reservoir gageglass and the sight feed glass should be kept clean.
The ball check valves in the lubricator pump must be kept clean and
only clean oil be used. A commercial engine cleaner should be used
17- 29
MONTHLY to flush the lubricator reservoir, followed by oil of same
type used in the lubrication. The reservoir should be -kept full of
oil. Maintain all connections, oil leads and mounting hardware,
seeing that they are kept tight and free of vibrations. The drive
motor for the compressor and lubricator should be regreased YEARLY,
flushing all the old grease out and renewing it with fresh clean
grease. Alignment of flexible couplings should be checked YEARLY.
The compressor manufacturer's recommendations for rotor and blade
clearance and replacement must be followed.
Globe high-pressure relief and low-pressure regulator valves
will require occasional maintenance, such as repacking, replacing
valve seats, rings or stems, etc. Under no circumstances should
any form of maintenance be performed on this type of equipment
without first isolating the valve and relieving any internal
pressure from the valve body. Any maintenance performed should be
done with strict adherence to the manufacturer's recommendations
and procedures.
Gas safety equipment must be maintained to prevent gas leaks
and failure of protective devices. The flame trap and cell
elements must be checked frequently and kept clean to ensure
drainage and reduce clogging. If there is any indication of a
flashback within the piping system, or if it is known that severe
heat has been applied near a flame cell or trap, those units should
be investigated immediately and elements replaced if necessary.
The waste gas burner requires only a periodic check to ensure that
the pilot orifice and vertical holes throughout the ignition ring
are open. Condensate should be removed from drip traps and
accumulators daily or as often as necessary to prevent condensate
from interfering with the free flow of gas in the system. In
addition, the accumulator collects a considerable amount of
slime -producing matter that is present in sludge gas lines. This
sediment can be removed by the drain plug near the bottom of the
container. Diaphragms in the low-pressure check valves and gas
pressure gages must be kept soft and pliable, which can be done by
treating them with neat's-foot oil.
The digester heater and heat exchanger is a combination hot
water boiler and shell and tube heat exchanger, built as an
integral compact unit. It provides the necessary heat source for
heating the new digester control building and the new primary
digestion tank.
Since the boiler is automatic and under the limit control, the
main concern of the operating personnel should be systematic
inspection and servicing.
It is suggested that, about EVERY 5 to 10 YEARS, the level in
the digestion tanks be drawn down and the system purged to allow
complete inspection of the interior. Accumulations of inert solids
(primary sand) should be removed from the tanks. Access manholes
have been provided at near ground level and on the covers of the
digestion tanks. It is recommended that sealing gaskets be
replaced on the manholes or hatches opened and that a grease seal
17- 30
be applied to both sides of the gasket prior to sealing; this will
ensure a gastight closure and make it easier to remove the next
time the manhole is opened. Rollers on the floating cover
digesters should be relubricated every two or three months.
Whenever digestion tanks are dewatered, all interior steelwork
(pipes, support and ceiling plate, etc.) should be checked
thoroughly for paint failure or corrosion, repainting or replacing
as required. Exterior steelwork or metal, not directly exposed to
digester liquid, should be inspected annually and repainted when
there is evidence of rusting or corrosion. Water accumulation in
the sump well of the floating cover digesters should be drawn off
as frequently as necessary to prevent any standing water.
The operator is referred to the chapter .on safety precautions
and the manufacturer's bulletins and instructions for additional
details.
COMPRESSORS
A good grade of compressor oil will not form gummy or carbon
deposits at cylinder and head temperatures - assuring efficient
compressor valve operation. Consult factory or your oil company
for recommended type of lubricant. Some automobile oils are
suitable for intermittent use but not for heavy duty operation.
The compressor oil capacity is shown on the oil tag attached to the
pump. Keep oil level to the line on the visual oil gage at all
times. Some compressors are not equipped with visual oil gages.
For these models, keep oil level between marks on the bayonet gage
or as indicted on the base filter opening.
Drain oil from crankcase at least QUARTERLY and refill with
fresh oil. If in daily use, change oil MONTHLY.
Check belt tension and pulley alignment using a straight edge.
The motor may have shifted or have been loosened by vibration or
rough handling. Abnormal belt wear indicates poor alignment.
Belts should be kept tight enough to prevent slipping on the motor
pulley (heating of motor pulley indicates slippage).
Slots in the platform or motor rails make it easy to slide the
motor back and forth to adjust belt tension.
Failure to compress air is frequently due to a clogged filter
which prevents free intake of air. Inspect the filter element
daily and clean if necessary.
If the filter element is a wire mesh type, remove when dirty,
wash in kerosene or other solvent and dry. Then dip in new oil,
drain and replace. Felt pad -type elements may be cleaned in the
same manner but should not be oiled.
Never operate the compressor without the intake filter since
dirt -can be drawn into the compressor preventing proper valve
action and possibly scoring cylinder and piston walls.
17- 31
Atmospheric moisture is condensed and deposited in the tank.
Open tank drain valve at least WEEKLY and blow out moisture.
A check valve is used on automatic switch controlled for
centrifugal unloader compressor to seal off the storage tank from
the pumping unit and make it possible to relieve pressure from the
aftercooler so the motor can start against no pressure load. When
the compressor stops running, trapped air rushes out through the
automatic switch relief valve piping or the centrifugal unloader
outlet for a few seconds until the aftercooler has been drained.
If air continues to escape from that opening while compressor
is idle, a leaky check valve is indicated. This condition can
prevent the electric motor from starting or cause it to accelerate
slowly when current is turned on, thereby-damaging the starting
mechanism and windings. It is, therefore, of utmost importance
that the check valve be kept in good condition.
HOISTING EQUIPMENT
All hoist cables should be inspected MONTHLY and swabbed as
necessary to prevent rusting. Lack of lubrication may be expected
to result in rapid wear of the strands as the cables travel over
the sheaves and drum. The lubricant should be capable of
penetrating to the inner core and should be sufficiently adhesive
to prevent dripping.
Care should be exercised during operation to see that the
hoist cables do not jump the grooves in the drum, as the cables can
weaken and reduce service life.
AIR FILTERS AND REGULATORS
Filters
1. To maintain maximum filtering efficiency and to avoid excessive
pressure drop, the filter must be kept clean. Bowl drainage
is automatic; however, manual draining can also be done by
turning drain cock clockwise. A visible coating of dirt or
condensate on the filter element surface, or an excessive
pressure drop, is an indication that cleaning is necessary.
2. To clean, it is not necessary to remove filter from the line
disassembly is simple and does not require tools. Clean all
parts with methanol alcohol and blow out filter body before
reassembly. Wash filter element in alcohol and blow out from
the inside. Clean bowl with household soap ONLY; NEVER use
carbon tetrachloride, trichlorethylene, thinner, acetone or
similar solvents.
Regulators
1. It the air supply is kept clean, the regulator should provide
long periods of uninterrupted service. Erratic regulator
operation or loss of regulation is most always due to dirt
17- 32
FIGURE 17-1
rrn
0
o °
o ° 8
0 0 0 C
0
q 0 0 0 0
o G
o a
0
p E -
F
0
BACKFLOW PREVENTER DEVICE
IMCONSULTING ENGINEERS
on the disk area and cleaning is in order.
2. Remove bottom plug, spring, strainer
with denatured alcohol, wipe off seat
compressed air. Reassemble parts as
regulator - before tightening bottom
is in center hole in body.
FLOW INDICATORS
and disk. Clean parts
and blow out body with
a unit and screw into
plug, make sure disk
1. The only maintenance required is the occasional cleaning of
the tube and float. The meter should be cleaned frequently,
enough to preserve the accuracy and float visibility.
2. The meter tube and the float are precision manufactured parts.
Never subject the meter tube to unnecessary shock or strain.
When removing the tube, be careful not to drop the meter float.
Handle the float with care as a nick or scratch will destroy
the meter's accuracy.
3. Refer to the manufacturer's literature for procedures for
tube and float removal, installation and disassembly.
UTILITIES
Water
Water is supplied to the treatment facility via a 2 -inch main
at a pressure of about 65 psi. There is one water meter and one
reduced pressure backflow preventer at this facility, located in
the Administration Building. A description and function of the
reduced pressure backflow preventer follows:
REDUCED PRESSURE BACKFLOW PREVENTER
Description
The reduced pressure principle backflow preventer (Figure
17-1) operates on the principle that water will not flow from a
zone of lower pressure to one of higher pressure. It provides
protection against backflow caused by both backpressure and
backsiphonage.
The device consists of two spring-loaded check valves (A and
B) and a spring-loaded, diaphragm -actuated differential
pressure -relief valve (C) located in the zone between the check
valves.
Operation
Normal Operation. The first check valve (A) causes all water
passing through it to be automatically reduced in pressure by
approximately 8 psi.
17- 33
The second check valve (B) is lightly spring forms the "double
check" feature of the device. It acts to prevent unnecessary
drainage of the domestic system in case a backflow condition
occurs.
The relief valve (C) is spring-loaded to remain open and
diaphragm actuated to close by means of differential pressure.
To illustrate the operation, assume water, having a supply
pressure of 60 psi, is flowing in a normal direction through the
device. If all valves beyond area (F) are closed, creating a
static condition, the water pressure in area (D) will be 60 psi and
water pressure between the check valves (E) will be 52 psi.
The inlet pressure of 60 psi is transmitted through a cored
passageway to the underside of the diaphragm of the relief valve
(C). This valve is spring-loaded to remain in an open position
until the differential pressure amounts to approximately 4 psi
across the relief valve.
During normal operation, therefore, the 8 psi differential
pressure produced by the first check valve (A) exceeds the
spring -loading of the relief valve (C) and causes the relief valve
(C) to remain closed.
Backflow: There are two (2) conditions that tend to produce
backflow:
1. Backsiphonage - where the pressure in the drinking water
system becomes less than atmospheric due to a vacuum or partial
vacuum in that system.
2. Backpressure - where the pressure in the nonpotable system
exceeds that in the drinking water system.
Backsiphonage: As the supply pressure drops in area (D), it
also drops in the area below the diaphragm of the relief valve (C).
When the pressure differential across the diaphragm decreases to
approximately 4 psi, the relief valve (C) will start to open. This
happens because the spring above the diaphragm of the relief valve
(C), which is trying to force the valve open, is designed to
compress with a differential pressure of 8 psi. When that
differential is decreased to 4 psi, the spring will extend and
cause the relief valve (C) to start to open.
This spring-loaded relief valve is designed to eliminate
intermittent discharges and "spitting" with normal minor
fluctuations in the line pressure.
As the supply pressure continues to drop, the relief valve (C)
automatically continues to drop, the relief valve (C) automatically
continues to drain and regardless of the pressure on the supply
side, approximately 4 psi less pressure will be maintained between
the check valves (Zone E). This will cause continual drainage
which will be readily visible at the drain outlet.
17- 35
Maintenance
General. Reduced pressure backflow preventer should be
inspected WEEKLY for signs of discharge from the relief valve, in
order to obtain a "visual inspection" of need for maintenance. See
Appendix D18 for detailed maintenance instructions.
ELECTRICAL
Information on the electrical service to the plant is
discussed in Chapter 16.
TELEPHONE
The Treatment Building at this facility is provided with a tie
line to the Village of Greenpoint treatment plant which has a
telephone connection to police and fire departments.
There are audible alarms mounted on the outside wall of the
Village of Greenport plant, Control and Pump Building.
FUEL OIL
The fuel oil system at the plant consists of a fuel oil tank
which supplies fuel oil to the heater/heat exchanger. The tank is
located below grade between the ferric chloride storage vault and
the flow meter pit -and is of the horizontal cylindrical type, with
tapping aligned axially at the top of the tank for fill, vent,
dipstick, suction and return piping.
This tank is provided with a 4`° fill and vent lime.
Periodically check and record the fuel oil level in the storage
tank with a dipstick to insure that an adequate amount of oil is,
available at all times.
17® 36
C
C
CHAPTER X DIVISION OF WA^.'ER RESOURCES § 650.7
PART 650
QUALIQ+'ICATIONS OF OPERATORS OF PUBLIC SELVAGE
TREATMENT PLANTS
(Statutory authority: Public Health law, 1 225)
E Sec.
630.1 Desnitions 650.10 Grade 311-13
860.2 Qualtflcations required 650.11 Grade III -B
650.3 Grades established 650.12 Grade n -C
650.4 Type of plant and required grade of 650.13 Grade rrl-c
operator and assistant operator 650.14 Submission of evidence of
650.8 Preliminary qualifications qualifications
650.6 Grade I -A 650.15 Authority to alter requirements or
650.7 Grade IIA to require examinations
650.8 Grade'ffi-A 860.16 Statue of previously approved
650.9 Grade I -B operators
Historical Note
Part (if 660.1-860.18) added, filed April
28, 1972 eff. May-, --r?2.
Soafion 6".1 Definitions. As used hs.this Part the following words and terms
shall have the indicated meanings:
(a) Operator shall mean an individual who is employed or appointed by any
county, city, village, town, district, or by any State department, agency or authority,
or by any sewer company, corporation, person or group of persons, or by any
industry or institution, and who is designated by the appointing officials as the
person in responsible charge of the complete and actual operation of any sewage
treatment plant. It is not intended to include. city managers, superintendents of
public works or municipal or -other officials uness .their duties include the actual
operation. of a sewage treatment plant.
(b) As*tant operator shall mean an individual who is employed or appointed
by any county. city. village, town, district, or'by any State department, agency
or authority, or by any sewer company, corporation, person or group of persons,
or by any industry or institution, and who is designated by the appointing officials
as the person who, under the direction of an approved operator, is responsible for
the actual operation of a sewage treatment plant.
(o) Sewage tr+eat"ietst plant shall mean any plant or facilityowned or main-
tained by any county, city, village, town, district, or by any State department,
agency, or authority, or by any sewer company, corporation, person or group of
persona, or by any Industry_ or institution, which subjects sewage to a process for
removing or altering the objectionable constituents of sewage for. the purpose -of
making it less offensive. or dangerous. It - is .Intended to include a plant treating a
combination of domestic sewage and industrial wastes, but not a plant which treats
industrial wastes amllistvoly.,,Plauts consisting of the foffiowing treatment. schemes
We cWhided frpm the requirement of having`.a certified operator:
(1) Septic tanks followed by subsurface leaching facilities with eventual
dlacharge to the ground waters, regardless of design capacity.
(2) Septic tanks followed by open.or covered intermittent sand Biters, with
a designated- capacity of less than 50,000 gallons. per day.
(d) Actiosated ~ pry abaIl'mean a biological sewage treatment process
In. wbich a mixture of sewage and activated sludge is . agitated and aerated. It is
Intended to inctnde the modified forms of this process and also the aacalled pack-
age plants which make use of such modifications.
(a) M*IV(cas oxidation process shall mean a process by which-micrroorgwdems
881 CAT 480-72
g 650.2 TITL)0 Q VN'ViRONMi1NTAL .C,ON8EIRVAT1ON
ih the search for food break down complex organic materials if►•.o simple. more
Mable substances. It is intended to include treatment units such as trickling SI -
tors, land Sher, oxidation or stabilization ponds and any device performing the
ssrne funcUon. Such units are secondary treatment units.
Hlatorical Note
Hao. added, filed April 29, 1972 eft. May
1, 1472.
650.2 Qu&Ufic&uo`g rogldred. (a) A sewage treatment plant must be under
the responsible supervlslon of an appropriately approved operator at all times.
No person shall be employed or appointed hereafter as operator or assistant oper-
ator unless he shall possess at Ule time of employment or appointment the qualifl-
cauons herein prescribed for such position.
(b) Ttdz fart shall not apply to appointments made from civil service lists
established prior to October 1, 1937, nor to an Individual actually employed on Sep-
tember 30, 1937 as such an operator, nor to an Individual actually employed on
December $1, 1946 as an uperator of a sewage treatment plant serving the general
public and owned or operated by a sewer company, corporation, person or group of
persons, nor to an individual whose oualitications have beim approved in accordance
with prior Sanitary Code regulauona
111storioal Note
Sea added, tiled AVLII 2si, 1972 o8. Way
650.3 Owes oetablished. There are hereby established qualilicatiorw for
operators in grades I -A, 11-A, I -B, II -B, III -B, II -C sad III•C and for assistant
operators In grades 11-A, III -A, III -B and III -C.
Iiiatorloal Note
Hae. added, Sled April 28, 1973 off. May
1, I=
650.4 Type of plant and tvyuired grade of operator and assistant opoautor.
Tile following indicates the nrinimum grade of operator anis assistalit operator
rrquirod to bo in rosponsible charge of the actual operation of a sewage treatment
plant and a summary of the required qualifications of the personnel:
832 CN 4-30-72
T°t of
PL,at Treatment
A
Activated sludge
process (including
I
e. Luo tIl :tions)
Designated
8oalth Dept
Chemical precipl-
uired
Grade
tation or sludge
Required
Basic
.vacuum filtration
Required Type and Duration of
Experience
or sludge inciner-
ation or sludge
Training
oxidation or sepa-
Op—
Op
rate sludge diges-
Per Day
tion or biological
B
oxidation process
Greater than L5
I -A650.6
N
e
0
PUnt
by
I
Designated
8oalth Dept
FN.
Ailnicnum
uired
Grade
gfy--
Required
Basic
Required
Special
Required Type and Duration of
Experience
million GalionNo.
Education
Training
Operating
Op—
Op
Arai Oper.
Per Day
Course
Greater than L5
I -A650.6
—
Appropriate
One year oparsting experience at a
° use option
Approved
Plant with facilities egttiv3leat to
below
C-iurse
Type A plant. with ability to make
necessary tests.
n'A
650.7
M9hfchool
or high
or hi
Appropriate
�Type
Sly. months operating experience at
-
Approved
a plant with fs.cilitles equivalent to
31-A
equivalency
equivalency
Course
A plant, with ability to mak®
diploma
neceasary testa.
65C.8
Z"gb echool
cr high
echool
Appr:, rlateata
Approved
Three rvontha ope-&ting experience
l' last w th :ncElt'ica equlealent
than 0•III-A
�—j
III -A
equivalency
Courseto
Type A plant ith ability to
make necessary tests.
diploma
—650.9
Sc•e. option
Appropriate
One year operating experience at a
plant with facilities equivalent to
I -B
below
Approved
Course
Type B plant, with ability to make
Greater than 1
_
—
necessary tests.
II -B
650.10
High school
or high
school
Appropriate
Approved
fila tn- 'ire operating experience at
a plant with facilities equivalent to
__—
II -B
equivalency
Course
'type B plant, with ability to make
2.6-10.0
diploma
necessary testa.
]II'B650.11
High school
or high
Appropriate
Approved
Three months operating experience
at a plant with facilities equivalent
0.02—leas thea
school
Course
to Type B plant, with ability to
2.5
>�-B
IIS -B
equivalency
diploma
make necessary tests.
Oq.
TYp6
plant
off
Traetment
Plant -
ttaapa Capacity
�eaTth t�D�e�p�'
Jd.Rlion 1=ns
Pa D87
24aim� a e
pea•
No-
Regnircd
Beate
Mduca.tion
8
TM. ming
Course
g8gvlred D� and Duration of
Opp71M Mxperlewa
Aper. i Aast Oper.
B
Those esnd Alton i
with design ca-
pacltles of less
than 80,000 gpd
or those planta
employing the
activated sludge
process and/or
0.01—leas than
0.02
No grade required
until 12/30/70
After 1/1/11
III -B III -B
I
High school
or high
school
equivalency
diploma
Appropriate
A)aproved
Course
Three months operating experience
at a plant with facWtieo equivalent
Type BBplan with ability to
s
650.11
rt.ablllzation ponds
are excluded from
Les. than 0.01
No Grade
this category
Required
C
Settling tank
(plain or septic
or Imhof!) or
stabilization or
oxidation pond
Greater then 5.0
II -C
650.12
High reboot
or high
school
equivalency
diploma
Appropriate
Approved
Course
Four months operating experienee
t n plant with facilltir� equivalent
to Type C plant, with Obluty to
make necessary tests.
III -C
III -C
650.13
HiGh school
or high
school
equivalency
(diploma
Appropriate
Approved
Course
T-0months operating experience
at a plant with facilities equivalent
m Type C pleat, wills ability to
mah, ,we,, test..
°
0.05--5.0
III -C
Leve than n.08
- -------Required
No Grade
._.---------
�---------
I
— --- —
,Qualifying options for Grade I -A and I -B:
a. Bachelor of Science degree from a duly accredited university or school or
b. A. New York State Professional rngincer's license or
e. An Associate in Applied Science degree from a duly accredited univerelty or school In a currlculum approved by the New York State
Department of hnvironmental Conservation phis 21,1. years of approved experience or
d. An Associate In Applied Science degree fro,• :• duly accredited nniver.sIty or school plus 5 years of approved eaperlence or
e. A high school diploma or ec,uivalczw-y eerthicatt .1.nd 10 yr: ry appi oved experlen,-n.
Those IndlvOuals seeking apprnvnl of qu;sliflEutiurm under c, d, of a above, may be required to pass writen and/or oral examination..
U
U
V
CHAPTER X DIVISION OF WATER RESOURCES § 650.9
Mstoricai Note
Sec. added, filed April 28, 1972 Off. May
1, 1972.
650.5 Preliminary qualifications. An operator or assistant operator shall be
physically capable of performing his duties; shall be able to speak, read and write
the English language; and shall produce evidence acceptable to the appointing
authority as to his character and ability to maintain and operate properly all
equipment entrusted to his care.
Alatorleal Note
Sec. added, flied April 28, 1972 eff. May
1, 1972.
650.6 Qualifications, grad1-4. The qualifications for grade I -A operators
shall be education, training and practical experience consisting of: graduation from
a university or school recognized by the University of the State of New York with
a bachelor of science degree; satisfactory completion of an appropriate course of
instruction approved by the State Department of Environmental Conservation; not
less than one year of satisfactory experience in the actual operation of a sewage
treatment plant with facilities for the activated sludge process or Any similar proc-
ess; and the ability to conduct the routine laboratory and field tests required for
the control of the operation of a sewage treatment plant with such facilities. Sub-
stitution of approved experience or education may be made as detailed in the foot-
note to the table in section 650.4.
Historical Nato
See. added, filed April 28, 1972 eff. May
1, 1972.
650.7 Qualifications, Krade H -A. The qualifications for grade H -A operators
and assistant operators shall be education, training and practical experience con-
sisting of: graduation from high school or possession of a New York State high
school equivalency diploma; completion of an appropriate course of instruction
approved by the State Department of Environmental Conservation; not less than
six months of satisfactory experience in the actual operation of a sewage treatment
plant with facilities for the activated sludge process or any similar process; and the
ability to conduct the routine laboratory and field tests required for the control of
the operation of a sewage treatment plant with such facilities.
Historical Note
Sea added, filed April 28, 1972 eff. May
650.8 Qualifications, grade IIIA. The qualifications for grade IIIA oper-
ators and assistant operators shall be education, training and practical experience
consisting of: graduation from high school or possession of a New York State high
school equivalency diploma:. completion of ah appropriate course of instruction
approved by the State Department of Environmental Conservation; and not less
than three months of satisfactory experience in the actual operation of a sewage
treatment plant with facilities for the activated sludge process or any similar
process; and the ability to conduct the routine laboratory and field tests required
for the control of the operation of a sewage treatment plant with such facilities.
Historical Note
Sec. added, filed April 28, 197E eff. Mwy
1, 1972.
650.9 Qualifications, grade E -B. The quaUfieations for grade I -B operator
shall be education, training and practical experience consisting of: graduation from
335 CN 4-80-72
C-
-
C
CHAPTER X DIVISION OF WATER RESOURCES § 650.9
Mstoricai Note
Sec. added, filed April 28, 1972 Off. May
1, 1972.
650.5 Preliminary qualifications. An operator or assistant operator shall be
physically capable of performing his duties; shall be able to speak, read and write
the English language; and shall produce evidence acceptable to the appointing
authority as to his character and ability to maintain and operate properly all
equipment entrusted to his care.
Alatorleal Note
Sec. added, flied April 28, 1972 eff. May
1, 1972.
650.6 Qualifications, grad1-4. The qualifications for grade I -A operators
shall be education, training and practical experience consisting of: graduation from
a university or school recognized by the University of the State of New York with
a bachelor of science degree; satisfactory completion of an appropriate course of
instruction approved by the State Department of Environmental Conservation; not
less than one year of satisfactory experience in the actual operation of a sewage
treatment plant with facilities for the activated sludge process or Any similar proc-
ess; and the ability to conduct the routine laboratory and field tests required for
the control of the operation of a sewage treatment plant with such facilities. Sub-
stitution of approved experience or education may be made as detailed in the foot-
note to the table in section 650.4.
Historical Nato
See. added, filed April 28, 1972 eff. May
1, 1972.
650.7 Qualifications, Krade H -A. The qualifications for grade H -A operators
and assistant operators shall be education, training and practical experience con-
sisting of: graduation from high school or possession of a New York State high
school equivalency diploma; completion of an appropriate course of instruction
approved by the State Department of Environmental Conservation; not less than
six months of satisfactory experience in the actual operation of a sewage treatment
plant with facilities for the activated sludge process or any similar process; and the
ability to conduct the routine laboratory and field tests required for the control of
the operation of a sewage treatment plant with such facilities.
Historical Note
Sea added, filed April 28, 1972 eff. May
650.8 Qualifications, grade IIIA. The qualifications for grade IIIA oper-
ators and assistant operators shall be education, training and practical experience
consisting of: graduation from high school or possession of a New York State high
school equivalency diploma:. completion of ah appropriate course of instruction
approved by the State Department of Environmental Conservation; and not less
than three months of satisfactory experience in the actual operation of a sewage
treatment plant with facilities for the activated sludge process or any similar
process; and the ability to conduct the routine laboratory and field tests required
for the control of the operation of a sewage treatment plant with such facilities.
Historical Note
Sec. added, filed April 28, 197E eff. Mwy
1, 1972.
650.9 Qualifications, grade E -B. The quaUfieations for grade I -B operator
shall be education, training and practical experience consisting of: graduation from
335 CN 4-80-72
§-650.10 .TITLE 8 ENMONMENTAV CONSERVATION
a university or school recognized b_v the Urdversity of the State of New York with
a bachelor of science degree; satisfactory completion of an appropriate course of
instruction approved by the State Department of Environmental Conservation; not
less than one year of satisfactory experience in the actual operation of a sewage
treatment plant with facilities for chemical precipitation, sludge vacuum filtration,
sludge incineration, separate sludge digestion, or any biological oxidation process
other than the activated sludge and the stabilization or oxidation pond processes;
and the ability to conduct the routine .laboratory and field tests required for the
control of the operation of a sewage treatment plant with such facilities. Substitu-
tion of approved experience or education may be made as detailed in the footnote to
the table In section 850.4.
Historical Note
Sec. added, filed April 28, 1972 eff. May
1, 1972.
650.10 Qualifications, grade H -B. The qualifications for grade II -B operators
and assistant operators shall be education, training and practical experience con-
sisting of: graduation from high school or possession of a New York State high
school equivalency diploma; satisfactory .completion of an appropriate course of
Instruction approved by the State Department of Environmental Conservation; not
less than six months of satisfactory experience in the actual operation of a sewage
-treatment 'plant with facilities for chemical precipitation, sludge vacuum filtration,
sludge incineration, separate sludge digestion, or any biological oxidation process
other than the activated sludge and the stabilization or oxidation pond processes-, and'
the ability to conduct the routine laboratory and field tests required for the control
of the operation of a sewage treatment -plant with such facilities.
Historical Note
Bec. added, filed April 28, 1972 eff. May
1, 1972.
M The for III -B oper-
650:11 Qualifications, grade -B. qualifications grade.
ators and assistant operators shall be education, trairing and practical experience
consisttng-of: graduation from high school or the possession of a New York State
high school equivalency diploma; satisfactory completion of an,appropriate course of
instruction approved by the State Department of Environmental Conservation; not
less than three months of satisfactory experience in the actual operation of a sewage
treatment plant with facilities for chemical precipitation, sludge vacuum filtration,
sludge incineration, separate sludge digestion, or any biological oxidation process
other than the activated sludge and the stabilization or oxidation pond processes;
and the ability to conduct the routine laboratory and field tests required for the
control of the operation of a sewage treatment plant with such facilities.
BBtoriaal Note
�•
Sec: added, Sled , April 28_1972 eff. May
.450:1 Z Qusllflatbtts, 6rAft XI -Q, The ,qualifications for grade':11-0- operators
-shall be education, training and practical experience consisting,of: graduation from
high school or possesalon:of it New•York.State high school equivalency diploma,
satisfactory completion of an appropriate_ course of instruction. approved by the
State.. Department of -Environmental Conservation; not less than four months of
satisfactory experience- 4n the actual operation of a sewage treatment plant with
facilities for plain settling. -or the use of $A161hoff•tank, or these of a.stabilization
or oxidation pond; or the use of any similar facility; and the ability to conduct the
routine laboratory and field tests .required for the control of the operation of a new-
(`
age treatment plant with such facilities,
mamma Notts
Bee. added, Sled April 28,. 1872 eff. May
1, 1l1T3R. '
336 CN 4-30-72
e
t'
CSAPTEIR X DIVIBION OF WATER RESOURCES
i.
• $50.13 Qualifications, grade M -C. The qualifications for grade ffi-C operators
e and &blatant operators shall be eduration, training and practical experience con-
alsting of: graduation from high school or possession of a Now York State high
school equivalency diploma; satisfactory completion of an appropriate course of
instruction approved by the State Department of Environmental Conservation; not
less than two months of satisfactory experience in the actual operation of a sewage
treatment plant with facilities for plain settling, or the use of an Imho$ tank, or the
( use of a stabilization or oxidation pond, or the use of any similar facility; and the
ability to conduct the routine laboratory and field tests required for the control of
the operation of a sewage treatment plant with such facilities.
H -r` Sturical Nobe
B6c. added, filed April 28, 1872 eff. May
1, 1[r1Z.
630.14 Subtnlsalon of evidence of qual fleation s. Any person may submit his
qualifications for consideration to the State Department of Environmental Conserva-
tion and have them approved in a spec ,ific grade if such qualifications meet the
requirements for such grade as herein stated. _
itt:ztorical Note
1 Sea. added, flled April tri, 18T1 eft. May
3, 18iZ
650.15 Authority to titter mjuiremenhs or to require eaaminatiorm (a) In
the cake of a specifically designated sewage treatment plant, the State department
of Environmental Conservation mi.y require, on the basis of the designed plant,
capacity, type of treatment plant and the classification of the receiving waters, the
operator and assistant operator responsible for the actual operation of a sewage
treatment plant to have qualiflca6ions in either a higher or lower grade than those
therein required for a specific treatnent plant.
(b) The State Department of Krivironmental Conservation may require any person
whose qudlificutiuns ere submitted for consideral,.;n w take written, oral or practical
examinations and may approve such quali(ication� in a specific grade on the basis of
the results of sut h examinations.
111etorical Nota
t Sec. added, mita April 28, 1872 efr. May
1, 1SiT2
650.16 Status of previously approved operators. Individuals who have had
their qualifications approved in any grade prior- to April 1, 1963 shall be considered
t to be giWified to operate or to operate under supervision the type of treatment plant
for which his qualifications were approved under the previous Sanitary Code require-
ments.
r II+,cterical Nolte
Sea added, Sled April 28, 187% eff. May
1. MX
Ll
887 CM 9-30-72
REFERENCE MATERIALS.
Organized and easily accessible reference materials provide
operating and supervising personnel with ready access to facts, figures
and backup knowledge concerning the waste treatment facility. A listing
of some basic renference materials follows:
1. Water Pollution Control Federal Publications
Number 1 Safety and Wastewatr:r Works
Number 6 Units of Expressions for Wastes and
Waste Treatment
Number 11 Operation of Wastewater Plants
Number 17 Paint and Protective Coatings for
Wastewater Treatment Facilities
Number 18 'Simplified Laboratory Procedures for
Wastewater Examination
2. Standards Methods for the Examination of Water and Wastwater,
Current Edition, APHA, AWWA, WPCF
3. Glossary of Terms, WPCF, APRA, ASCE, and A14WA
4. Manual of Instruction for Sewage Treatment Plant Operators,
New York State Department of Environmental Conservation
S. Operation of Wastewater Treatment*Plant, EPA # 5TT1-WP-16-03,
prepared by Sacramento State College, Department of Civil
Engineering (Two volumes)
6. Wastewater Engineering: Collection,. Treatment and Disposal,
Metcalf & Eddy, Inc., McGraw Hill
7. Chemistry for Sanitary Engineers, Sawyer, C.H. and McCarty,
P.L., McGraw Hill
USEPA Manuals
1. Maintenance Management Systems for Municipal Wastewater Facilities,
EPA, 430/9-74-004
2. Emergency Planning for Municipal Wastewater Treatment Plant
Facilities, EPA 430-9-74-013
3. Start up of Municipal Wastewater Treatment Plants .Contract No.
68-01-0341
4. Safety in the Design, Operation and Maintenance of Wastewater
Treatment Works
APPENDIX D
MANUFACTURER'S LITERATURE
The manufacturer's maintenance manuals are listed by
Chapter, according to their location in the waste treatment
stream. The exceptions are the electrical equipment in Chapter
15 and the mechanical equipment in Chapter 16. A listing of
manufacturer's for this facility follows:
1. D- 7- 1 Grit Collector/Grit Screw Conveyor/Dewatering Screw
2. D- 7- 2 Positive Displacement Blowers
3. D- 8- 1 Coarse Bubble Diffusers
4. D- 8- 2 Peabody Barnes Submersible Sewage Pumps Installation
and Operation Manual/Equalization Tank
5. D- 8- 3 Fidelity Environmental Equipment Co., Inc.
Installation and Maintenance of Sluice Gate
6. D- 9- 1 Lime Feed system/Acrison, Inc. Instruction Manual for
Model 500 Polymair
7. D- 9- 2 Ferric Chloride Diaphragm Pump
8. D- 9- 3 Mechanical Flash Mixer
9. D- 9- 4 Mechanical Flocculator
10. D-10- 1 Sludge/Scum Collector Mechanism
11. D-11- 1 Hydrochloric Diaphrapm Pump
12. D-11- 2 Mechanical Flash Mixer
13. D-11- 3 Lyco Service Manual RBS Water Treatment
System
14. D-12- 1 Sludge/Scum Collector Mechanism
15. D-12- 2 Peabody Barnes Submersible Sewage Pumps Installation
and Operation Manual/Effluent Wet Well
16. D-13- 1 Peabody Barnes Submersible Sewage Pumps Installation
and Operation Manual Scum/Sludge Pumps
17. D-13- 2 Fidelity Environmental Equipment Co., Inc.
Installation and Maintenance of Telescopic Valve
18. D-13- 3 Ralph B. Carter Company/Installation, Operating,
Maintenance Instructions -Spiral Guide Gasholder
19. D-13- 4 Ralph B. Carter Company/Installation, Operating,
Maintenance Instructions -Digester Accessories
20. D-13- 5 Ralph B. Carter Company/Installation, Operating,
Maintenance Instructions -Sludge Heater H335C41-L
21. D-13- 6 Ralph B. Carter Company/Installation, Operating,
Maintenance Instructions-Pearth Gas Recirculation
Equipment
22. D-13- 7 Westinghouse Instruction Book 1.B.105-001- Ring
Balance Meter
23. D-13- 8 Prime -Mover Skid Steer Loaders LS-70/LS-75 Series
24. D-13- 9 Nemo Pump Operating Instructions/Sludge Transfer
Pumps
25. D-13-10 Wemco Torque -Flow Pump Installation, Maintenance
and Operation Instructions/Sludge Recirculation Pumps
26. D-14- 1 Pepcon Odormaster I - Model 1,000 CFM Operation and
Maintenance Manual
APPENDIX E
SHOP DRAWINGS
Supplementing the manufacturer's literature are the approved shop
drawings for the equipment, installed at this facility. These include
sketches, catalog cuts and electrical diagrams issued by the
manufacturer. A listing of the show drawings for this facility
follows:
-3
-Tlj,2
AS BUILT DRAWINGS
These drawings include a set of contract drawings reflecting the
actual installation of equipment, piping and structures at this
facility. These drawings are indexed on the cover sheet and kept in a
plan file in the Administration Building.
1
i