TDB& C Training Manual

PETRUSTEYN
PACKAGE PLANT
(MMAMAFUBEDU)PLANT
Recycling Unit Operation

& Maintenance
MANUAL
Submitted by:
TDB&C AGENCY
PO Box 11889
Universitas 9321
0799913057@vodamail.co.za
RECYCLING UNIT OPERATION & MAINTENANCE MANUAL
TABLE OF CONTENTS
1. INTRODUCTION
2. GENERAL DESCRIPTION OF THE WORKS
3. INLET WORKS
3.1.1 Screens
3.1.2 Grit traps
4. ANAEROBIC DIGESTION SYSTEM

General Description of the Process
Operation of the Process
Sludge Removal
Sludge Drying Beds
Waste Sludge
Biological Filter Feed
5. BIOLOGICAL FILTRATION
Description of the Process
Operation of the Filter
Cleaning and maintenance
6. HUMUS TANK
Description
Operation and maintenance
7. Chlorine contact tank

Description
Operation and maintenance
Recycling pumps
2
8. Rapid Reactor
Description of Process
Design
Sludge draw off
Overflow sump
9. Upflow Filter Media Filtration

Description of Process
Operation
Maintenance
Chemical Dosing
Trouble shooting
10. Final Effluent

Chlorination
Dosing rate
Breakpoint chlorination
3
1. INTRODUCTION
The main function of a sewage treatment works is to treat water to such an extent
that it may be safely discharged to a public water body or reused as grey water
for the flushing of toilets.
At the same time the solid phase (screenings, grit, sludge and scum) should be
treated and disposed of in such a way that it does not give rise to offensive odours
or constitute a danger to public health.
Since a WWTW is the only barrier between polluted water and water exposed to
public health, the need for proper operation and maintenance of the works can
hardly be overstressed. Diligence in this respect is therefore of utmost importance.
This manual is intended to provide guidance to the operating personnel to operate

the works optimally from both an economical and public health point of view. In
conjunction with this manual, operating personnel should also consult the operat-
ing and maintenance manuals for the mechanical and electrical equipment. The
maintenance schedules provided therein should be carefully followed to ensure
the equipment last as prescribed.
4
2. GENERAL DESCRIPTION OF THE WORKS
The WWTW was constructed as an oxidation pond system and extended to a Bio-
logical Filtration Plant which can treat an estimate of 3ML/day at an average dry
weather flow. The treatment works offers the following facilities:
• Screening
• Grit-removal
• Anaerobic sludge digestion pond
• Sludge drying beds
• Biological filtration
• Recycling
• Humus tanks
• Humus removal
• Disinfection
• The new Rapid Reactor (RR) unit was commissioned during 2009 and
can treat 500 cubic meters average flow and 1ML/day recycled flow
(from Bio-filters). The process is an activated sludge process with air in-
duction by course bubbles. The treated effluent from the reactor pass-
es through an Upflow Filter Media system where flocculation, colour
removal and disinfection of the treated effluent from the RR.
• These units offer the following facilities:
• Small screen
• Dividing chamber
• Aeration reactor (basin)
• Clarification
• Sludge removal
• Clear water sump.
The Upflow Media Filtration system consisting of:
• Raw water feed pumps
• Chemical dosing pumps
• Disinfection
• Compressor
• Air actuating valves
• Automatic backwash system.
5
3. INLET WORKS
3.1 Inlet Unit

Although most raw water gravitates, some water is pumped to the works and
reaches the works at 500mm below ground level. The inlet works is covered by a
roof to enable the operation of the screen during bad weather
3.1.1 Sreens
Provision has been made for one Huber-Rotamat screen. The screen can be re-
moved from the inlet canal and a hand rake screen can be put into place during
maintenance or failure. The screen has openings of 6mm and water is provided
to wash the screenings. The screen has been designed to handle a PWWF of 5ML/
day. The screenings are conveyed with a 150mm auger and are deposited at a
height suitable for a wheelbarrow to collect the screenings. The screenings is dis-
posed of on site into trenches or at the landfill site.
3.1.2 Grit traps.

The grit is removed by settling into two grit canals. One grit canal is cleaned every
week by closing it off from the inflow. The supernatant is removed by drain valves
and the grit is removed by spade. The grit is left to dry for one day and is disposed
of in the same manner as the screenings.
6
4. Anaerobic Digestion Pond
The inflow enters the anaerobic pond where settling of organic matter occurs and
digestion of solids to release nutrients into the water. The inflow water is transported
in HDPE pipes to the bottom of the pond which is a concrete structure 900 m2 and
4m deep. Sludge digestion takes place in the bottom layer of the dam. Blocked
feed pipes can be unblocked by rodding it. Normal unheated digestion occurs for
at least 60-90 days.
Digested sludge from this pond is removed to the drying beds with two pipes from
the bottom of the tank. The sludge draw of vales enables sludge from the bottom
of the tank to be removed onto the concrete drying beds.
NB. SLUDGE DRAW OFF MUST BE DONE ONCE A MONTH FOR 20min.
NB. If sludge is not removed, the suspended matter will carry over with the water
and will cause blockages to the feed pipe of the biological filter as well as the filter
with huge financial implications and a total failure of the filter.
Floating scum and rags must be removed daily to prevent crust formation on the
surface and eventual contamination of the bio-filter feed water.
Waste sludge on the drying beds is left to dry and is removed by front end loader
and disposed as class 2 sludge to the landfill sites or for soil conditioning. Waste
sludge must never be deposited onto a drying bed together with partial dried
sludge. This will cause the drying time of the sludge to multiply, resulting in no drying
beds for sludge disposal.
7
5. Biological Filtration
A Bio-filter can best be described as a rock media where tons of microbial organ-
isms, also known as biomass live. The bio-filter media consist of rock and enables
water and air to pass from the top to the bottom of the filter. The rough ends of
the rock media enables micro –organisms to attach to the media and utilizes the
carboneous material and nitrogen compounds in the water as energy source and
for the synthesis of protein. Protein synthesis increases the biomass and will keep the
organisms on the bio-filter in equilibrium. Reduction in both carbon and nitrogen
concentration occurs through the filter. The effluent from the filter is normally dark-
ish brown in colour with suspended mass floating in the water. This mass is removed
from the effluent by the Humus tank.
From the anaerobic digestion pond, water is fed to the bio-filter through a pipeline.
This pipeline can sometimes gets blocked and need to be kept free of floating
debris and sand. The pipeline gravity feeds to the filter and the water is distributed
onto the media with for rotating distribution arms. Rotation is accomplished when
the water exist the distribution pipes and forms a pushing movement. Splash plates
underneath the openings of the distribution arms distribute the water evenly over
the media. The downward movement of the water transports oxygen through the
media.
The bio-filter is maintained by cleaning the distribution arms from rags and debris.
If blockages occurs to frequently (once a day), cleaning of the feed water must
receive attention. (Too much rags etc. is overflowing from the anaerobic pond).
The centre bearing of the filter needs to be greased at least once a month.
The surface of the bio-filter must be kept tidy at all times.
The effluent canal at the bottom of the filter must be swept once a month.
Two 110mm Gorman Rupp pumps recycle the filter effluent back to the feed line
of the filters coming from the anaerobic pond. These pumps must always be in an
operating condition and one pump will under normal conditions be in operation.
Recycling of the filter effluent improves the quality of the water and keeps the bio-
mass on the filter active. If the filter runs dry because of a lack in recycling, all bio-
mass will die and the filter will be swept from all living organisms. This means that the
filter needs to grow bacteria every day which will result in poor filter effluent quality.
8
6. Humus tank
The humus tank is a circular, coned shaped structure approximately 10-15m deep.
Effluent from the filters consists of suspended solids and this is removed in the humus
tank by sedimentation. The feed to the humus tank is in the middle into a cen-
tre pipe. The inlet is just below the water level. Sedimentation occurs in the cone
shape structure and heavy material slide along the sides of the cone to the bottom
of the tank. The humus sludge is removed from the tank by gravity to a sump from
where the sludge is pumped back to the inlet works for stabilization in the anaero-
bic pond. Two Gorman Rupp pumps return the suspended solids to the inlet works.
The humus tank must overflow at normal speed and care must be taken that it does
not overflow. This will contaminate the humus effluent. The humus return pumps
MUST at all times be operational and at least one pump must run continuously. If
not, the chlorine contact chambers will become full of sand, damaging the final
effluent pumps which pump effluent to the Rapid Reactor Unit. The operation of
the humus sludge pumps must be seen as high priority.
Clean the Humus tank sludge sump at least once every 2 months by vacuuming
the sediment with a vacuum tanker.
9
7. Chlorine Contact Tank
The Humus tank overflow flows into the chlorine contact channel where Sodium Hy-
pochloride is added to disinfect the effluent before discharging the effluent. Chlo-
rine is added by chemical dosing pump and is normally dosed at a concentration
of 5mg/l. The chlorine dosing tank stores 5000l of Hypo chloride and is situated next
to the pump house building. The chemical dosing pump can be set according the
dosing speed required by turning the buttons on the pump.
The dosing pump must be cleaned and flushed with water every 2 months to pre-
vent the liquid chlorine from crystallizing in the pipes.
NB. The above operation is for the normal running mode of the plant and is NOT
APPLICABLE when running in conjunction with the Rapid Reactor Recycling Unit.
Two submersible sewage pumps pump the final effluent from the Biological filter
system to the inlet of the Rapid Reactor for the “polishing” of the water before fil-
tered through the Upflow Filtration Unit.
The pumps have a capacity of 1000 cubic meters/day and can pump this at a
head of 10 meters.
The pumps are controlled by float switches and pump the effluent from the chlo-
rine contact tank to the inlet of the RR.
NB. The pumps needs to be removed once a month or when deemed necessary to
clean the impellors and to remove debris. The switchgear for the pumps is situated
in the pump house building and is marked for identification. (Remember to switch
of the pumps before cleaning)
The pumps are of the open impellor type, 3phase and 3kWh power consumption.
10
8. Rapid Reactor Unit (RR)
The RR consists of 12 reactor units in two rows of 6 each. The units are constructed
from HDPE and divide the tank into different compartments for each function.
The effluent from the network is screened at the entrance of the unit to ensure that
rags and plastic does not enter the tank. This is a secondary screen and is not de-
signed to remove screenings which should not be in the final effluent or should be
removed by the earlier processes of the plant.
The inflow divides into three parts and is fed into the tank with 3 x110mm PVC pipes.
Each pipe feeds 2 reactors.
11
Transfer port
Partition
Aeration diffuser
AERATION TANK
CLARIFIER
Air is introduced into the tank by 6 Rota vain blowers. (3kWh, 3phase) The air input
into the tank is 1.5m deep and oxygen of medium bubble size dissolves in the wa-
ter and is distributed by circulation. The air moves the water mass in a circle and
circulates the volume of the tank every 30 seconds. This brings the micro organisms
into contact with the air every 30 seconds. The concentration of oxygen in the tank
must be at least 2mg/l.
12
During the circulation process the centre of the circulating mass will move slower
than the outside and an anoxic zone in the middle will promotes denitrification.
Ammonia is converted to Nitrate and this is denitrified to nitrogen in the denitrifica-

tion zone.
As the mixed liquor overflows from the first row of reactors into the second compart-
ment, the underflow from the second compartment is returned to the first compart-
ment by air lifting.
The second row of reactors performs the same function as the first section and the
overflow from these reactors settles in the clarifier section which receives the mixed
liquor from the second row of reactors.
In the third compartment chamber settling of the mixed liquor suspended (MLSS)
occurs. The settable solids settle to the bottom of the tank and returns to the sec-
ond reaction chamber by air lifting.
The concentration of the mixed liquor (MLSS) in the reaction chambers must not ex-
ceed 4500mg/l. This will hardly occur as the system will continuously transfer solids
in suspension to the Upflow Filtrataion Unit as mass is needed for flocculation.
13
The MLSS can be regulated by opening the sludge valve at the side of the tank.
The excess sludge will be removed from the aeration compartment (2 nd) and will
collect in the sludge draw off tank.
Sludge from the sludge draw off tank will overflow into the sludge disposal sump
and will be transferred into the unused oxidation pond by siphoning. In this pond
anaerobic digestion of the sludge will cause it to stabilize and to settle to the bot-
tom.
The air input into the plant can be controlled by timers. Two timers control the run-
time of the blowers. By setting the timers the amount of oxygen can be controlled
by switching off the blowers for certain periods of time. This is the normal operation
procedure when the plant is under its design capacity of 600 cubic meters per day.
The return flow rate from the chambers back to the previous ones is controlled by
reducing the airflow through the valves situated at the blowers. (This is set and can
be left as is).
Final effluent is collected in a launder and discharge into the clear water sump
from where it will undergo tertiary treatment through the Upflow Filtration Unit. Dis-
infection is performed in this sump, prior to filtration.
14
9. Upflow Filter Media Filtration
The system is a unique type filtration unit which enables flocculation and coagu-
lation of RR treated water by the addition of aluminum sulphate. The discharge
from the RR is pumped through the media consisting of lightweight HDPE pellets.
The water is dosed with alum and flocculation occurs as the water moves upwards
through the media, compressing the media against the top screen of the 6mx1.5m
column. Small particles are retained on the pellets as the water passes through the
filter, producing a clear effluent. Color is removed during the up flow.
The filtration unit is equipped with a PLC which controls the backwashing and scour-
ing of the media. This is normally set at a 6 hour interval.
Backwashing of the filter:

After the set time (6 hours) the PLC will switch of the supply feed to the filter. A com-
pressor opens the pneumatic valve at the bottom of the tank, draining all water
and sludge to the waste sludge sump. After flushing, the valve closes and the tank
is filled with water again. The air blower blows air through the media causing scrub-
15
bing of the pellets to remove all sludge attached. Again the contents are flushed.
The PLC opens the top valve and normal operation continuous. This process takes
approximately 30 min to complete.
Testing of the effluent:

To see if the water produced from the filter is clear, valves at the discharge are
installed to enable sampling of the water. By opening the valve on the discharge
16
line, the quality of the effluent can be monitored. By opening the valve on the feed
line, the inlet water and flow rate can be checked.
The system is designed to function fully automatically, but the operator must in-
spect the equipment and ensure that the filter goes through its complete cycle as
prescribed. (Every shift)
Any malfunctioning must be reported to the Supervisor which will contact the main-
tenance team of the Municipality.
10. Final Effluent
The most important issue for recycled water is the turbidity, color and disinfection
of the water.
The chemical quality of the water produced is not as important, as the water is only
used to provide basic sanitation.
The water must however be disinfected. The addition of chlorine (in this case Sodi-
um Hypo chloride) is essential to disinfect the water. It is suggested that a normal
swimming pool test kit is used to determine the free chlorine content in the water.
A medium pink color will indicate that free chlorine is available and indicates that
the water has been disinfected.
Chlorine can also be tested at the storage tanks to determine the available free
chlorine.
Sodium Hypo chloride can be purchased from a supplier in Bethlehem in 220kg

drums.
To increase the chlorine content, the dosing rate of the chlorine dosing pump can
be increased.
Breakpoint Chlorination (complete disinfection) is obtained if the water tested at

the storage tanks produced a slight pink color when tested with DPD tablets in the
test kit.
10.1 TOP UP WATER

The normal situation when using recycled wastewater for basic sanitation (toilet
flushing) is that more water enters the wastewater treatment plant than is needed
for toilet flushing. The reason for this is that waterborne sewage( from schools, clinics
and old serviced establishment) also enters the treatment plant and that water is
used as a top up. Taps, showers etc. It is seldom the case where the whole system
relies on the recycled water.
17
If however this might happen, alternative water from the oxidation ponds can be
used through the reactor, through the upflow filtration and then to the toilets.
Another alternative can be domestic water or borehole water, but this is the last
case scenario. This is be closely monitored and can be picked up on quality test
to be conducted by the plant operator every morning and also from the drop of
levels in the system.
10.2 WATER QUALITY STANDARDS
There is nothing that will change the concentration of heavy metals in the water
and it will stay the same as for the raw water source.
The Biological constituents in the water will comply with the General Standards with
the exception of the suspended solids which will be the same as for filtered domes-
tic water.
It must be stressed that the water is used for toilets only, and a chemical quality is
actually irrelevant, but the colour and odour plays a much larger role. For example,
the ammonia content in the water will increase the retention time of chlorine and
will increase its “carry” through the network.
18
The colour is removed through the upflow media filter with aluminum sulphate as
coagulant.
The odour is removed by the aerobic reaction in the reactor in the reduction of the
COD.
19
10.3 CONTROL MEASURES
Just as in any Domestic water supply system, the water will be treated with chlorine
and will be disinfected. The control will be to measure the free available chlorine
in the water on a daily basis. How does one control the drinking water quality that
people drink? (This is much less sensitive, as its for toilet flushing only)
10.4 BELOW STANDARD WATER
Below standard water must be diluted with water of a better quality until the re-
quired standard is reached, and will work the same way as supplemented water
to the supply.
20
GUIDELINES FOR THE UTILISATION AND DISPOSAL OF

WASTEWATER SLUDGE
(Department of Water and Sanitation (March 2006)
South African Sludge classification of waste activated sludge from the Rapid

Reactor activated sludge plant.
Mass of sludge produced for each application:
Single House 3.6kg/month
Single System 20kg/month
Double System 50kg/month

Quatro system 90kg/month
Octa System 180kg/month
300 Basic Sanitation houses 90kg/month
Classification of Rapid Reactor Sludge (B2a)
Microbiological Class: B
Stability Class: 2
Pollutant Class: a
Microbiological classification: Class B
Faecal coliforms <1 x 10 (CFU/ gdry)
Helminth ova < 1 (total viable ova/gdry)
Stability Classification: Class 2

Design to comply with the options below on a 75 percentile basis.

Option 1. Reduce the mass of volatile solids by a minimum of 38%.
Option 4. Meet a specific oxygen uptake rate for aerobically treated sludge.
Option 10. Incorporate sludge applied on surface of land within specific time
Periods after application.
Pollutant Classification: Class A
21
 Mental limits for Rapid Reactor (mg/kg)

 Arsenic (As) < 40
 Cadmium (Cd) < 40
 Chromium (Cr) < 1200
 Copper (Cu) < 1500
 Lead (Pb) < 300
 Mercury (Hg) < 15
 Nickel (Ni) < 42
 Nutrient Content of sludge on a dry weight basis.

Total N 3,2 – 4,5%
Total P 1,5 – 1,7%
Total K 0,2 – 0,3%
 ORGANIC Content 40 – 70%
 Benchmark Metal Values (mg/kg)
 Antimony (Sb) < 1,1
 Baron (B) < 23)
 Barium (Ba) < 108
 Beryllium (Be) < 0,8
 Cobalt <5
 Manganese (Mn) < 260
 Molybdenium <4
 Selenium (Se) <5
 Strontium 9Sr) < 84
 Thallium (TI) < 0,03
 Vanadium (V) < 85
 Sludge Application Rate.
 Maximum of 10 tons dry mass per hectare per year
 Prevention of Soil Erosion
20
 Sludge will be applied with no contribution to soil erosion

 Buffer Zone for Groundwater and Surface
 Depth of aquifer > 5m
 Distance from borehole >200m
OPTION 1. FERTILAZATION OF TREES (TYPE-C SLUDGE)

WAS: 0.4% solid concentrate
Application Rate:
 10 Kg dry mass/tree/year
1080Kg = 120 trees
 Excess water in sludge mixture sufficient to watering the trees @ 250l/tree/
month.
 Total volume = 30 000l WAS @0.4% solid/month.

OPTION 2. IRRIGATION OF INSTANT LAWN (type C sludge & EFFLUENT).
 35mm water /week (effluent and sludge)
 0.6 hector instant lawn = 30 000l effluent
 1 day sludge irrigation on lawn @ 1 x month. (Divide lawn in 4 parts)
 Apply after lawns have been removed. (Fill the furrows)
3. OTHER USAGES
 Wetland: From waste material from excavations for bird life improvement
and effluent polishing.
 NB: Ponds: For bird life improvement and effluent polishing.
21
1. CHARACTERISTICS OF SEWAGE, REASON FOR AND

OBJECTIVES OF TREATMENT
1.1 Characteristics
Sewage as it arrives at the treatment works contains a complex biological flo-

ra. There are many millions of harmless micro-organisms, many of which aid in
the subsequent purification. However, as sewage also includes man’s excreta,
often together with hospital wastes, abattoir wastes, and industrial effluent, it
is not surprising that there are also millions of potential dangerous pathogens.
Besides pathogens as those causing gastric fever, dysentery, typhoid fever and
tuberculosis, there are also viruses among others those of poliomyelitis, togeth-
er with eggs of certain intestinal worms, such as roundworms, hookworms and
tapeworms. Many of these pathogens do not survive long in sewage but others,
like the eggs mentioned, can remain viable for weeks or months. Sewage is
therefore capable of transmitting diseases and untreated sewage must at all
times be regarded as potentially dangerous.
22
The organic compounds in sewage have complex carbon based molecules

which can be oxidized. These reactions require specific amounts of oxygen.
Various tests have been developed to measure the oxygen demand (COD,
BOD, OA and total organic carbon. (Table 1.1)
23
Table 1.1 Characteristics of sewage of different strengths.
Criteria Weak Average Strong

Chemical oxygen demand (mg/l COD) 400 600 800
Permanganate value (OA mg/l) 40 60 80
Biological oxygen demand (BOD mg/l) 250 350 450
Ammonia Nitrogen (N mg/l) 30 40 50
Total Phosphorous (P mg/l) 10 13 16
Total suspended solids (mg/l) 250 350 400
Settable Solids (ml/l) 6 10 14
1.2 Reasons for Sewage Treatment
Untreated sewage can bear a serious threat to the environment. Large volumes
of untreated sewage water discharging into streams causes an imbalance to
the ecosystem. The oxygen demand in the water body will increase and the
dissolved oxygen concentration of the river will decrease to such a low level
that it cannot support any fish life. The water body will become loaded with sol-
ids and the release in nutrients into the water from the sewage will cause alien
vegetation to thrive. Algae blooms occur and the water become unsuitable for
domestic use. Eutrophication leads to unpleasant odour emission an unpleas-
ant looking water body.
From a health perspective, sewage is potentially dangerous to man as it con-

tains millions of dangerous pathogens. These pathogens can cause different
illnesses and it therefore necessitates the treatment of sewage, as well as the
proper disinfection thereof.
1.3 Objectives of Sewage Treatment
Sewage has to be treated for the following reasons to:

• Free it from disease causing organisms
• Stop smelling and makes it look pleasant for future use.
• Make it suitable for discharging into a public stream.
• Render it fit for reuse. This has become of major interest in South Africa.
• Comply with Legal requirements for discharging into public stream.
24
2. CHARACTERISTICS OF PETRUSTEYN WASTEWATER

TREATMENT PLANT
2.1 History
Due to the request of water borne system in mamafubedu the existing plant
could not handle the estimated volumes resulting in the final effluent from the
oxidation ponds being not compliant the legal requirements
The capacity of the domestic water supply, prevents the municipality to eradi-
cate the buckets system and to supply basic sanitation to the people.
It can be estimated that this treatment plant receives an inflow exceeding 1Ml/
day.
NEW SCENARIO:
A new 600 cubic meters per day package plant has been constructed during
2008 and treats this volume of sewage water by biological oxidation through
an activated sludge process. Following the treatment process, the effluent of
the package plant flows through an up flow filtration system where flocculants
are added to flocculate the suspended solids in the effluent, filters it and disin-
fects the water for the reuse in the toilets as grey water. These processes enable
the municipality to reuse the sewage water, reduce the organic and hydraulic
loads on the oxidation pond system and to supply basic sanitation to the inhab-
itants.
2.2 COMPONENTS OF THE WORKS
• 1 Inlet works
• 2 Huber screen
• 2 Grit channels
• 1 Venturi type flow channel
• 1 x 110mm distribution pipes
• 16 Bioreactors with medium bubble diffusers
• 6 Rotavane blowers
• 1 Air distribution pipe system
• 1 Control panel controlling the blowers
25
• 1 Clarification and settling compartment

• 1 Sludge draw off valves
• 1 Over flow weir (horizontal type)
• 1 Clear water sump with overflow pipe to oxidation pond
• 1 Feed pipe to the up flow filtration unit
• 2 Centrifugal pumps to the up flow filter
• 2 Chemical dosing pumps
• 1 Up flow filtration column with HDPE pebbles.
• 2 Pneumatic air valves
• 1 Air compressor
• 1 Chlorine disinfection and filtered water sump
• 2 High pressure delivery pumps to header tank
• 1 Up flow filtration unit control panel
• 1 Backwash pipeline to oxidation pond
• 2 Submersibles pumps
26
3. OPERATION AND MAINTENANCE OF THE PACKAGE

PLANT
INLET WORKS SECTION:
When the operator arrives at work, the following standard procedures are followed:
1. Arrives at work in his own clothes and shoes.

2. Changes into the correct work clothes and shoes.
3. Puts on gloves and boots.
4. Collects the correct tools and equipment.
5. Does NOT EAT OR DRINK near inlet works
6. Wash hands with soap and water before eating.
7. Eat and drink in designated places.
8. Takes a shower or washes before going home.
9. Changes back into his own clothes and shoes before going home.
10. Washes the dirty clothes.
11. Sign off his shift to the next operator.
• AUTOMATIC OPERATED INLET SCREEN
27
Screening of the raw water is part of the preliminary treatment phase and
is applied to remove non-biodegradable floating objects. The purpose is to
protect the mechanical equipment in downstream process units, as well as
to reduce blockages in pipes, channels and sumps. In addition, floating ma-
terial can encourage the development of odours and fly breeding.
 The operator:
o Collects the material at the top to the platform to dry.
o Collects the screenings in a wheelbarrow.
o Dumps the screenings at the collecting site.
o Clean the area surrounding the screen.

o Checks for unusual obstructions
o Must not let screening material build up in the inlet chamber.
o Material build up will causes blockages upstream in manholes.Ac-

cumulation causes odours, health problems. Causes pipe blockag-
es, scum formation.
o Check the inflow to the inlet works.
o Checks the colour of the inflow.
o NB. Shut off the inflow during power failures or when the distribution
reservoir is full.
• GRIT CHANNELS
28
The grit removal takes place downstream of the inlet works and forms part of
the preliminary treatment phase. It is applied to remove the inorganic mate-
rial, or detritus, from the suspended organic material in the raw waste water.
The purpose is to protect mechanical equipment located in downstream
process units, particularly pumps, from excessive wear and tear. Inorganic
material that is allowed to pass through the preliminary treatment phase will
also unnecessarily occupy process volume.
 The operator :
o Removes diverts the inflow from the channel to be cleaned by in-
stalling sluice gates, allowing the waste water to pass through the
clean channel.
o Take care not to open the valve too quickly, as grit will be washed
out.
o Drains and cleans alternative channels on a regular basis (once a
week).
o Removes settled grit from the drained channel.
o Places the grit on the area adjacent to the channel to allow the
grit to dry.
o Must not brush the settled grit along the channel into the down-
stream units.
o Removes the grit from the channels and dispose of it at the collect-
ing site.
o Upkeep the area around the grit channels.
• FLOW MEASUREMENT
Regular measuring of the flow is required to determine the hydraulic and
organic loadings imposed on the works. In addition, regular flow recordings
can provide warnings on blockages or pump failure in sewer reticulation.
 The operator:
o Takes flow meter readings every day at the same time.
o Gives the readings to the supervisor for inclusion in the works oper-
ating book.
o Maintains the correct work procedures and correct readings must
be recorded
o Checks on the flow recorder for turbulences in the reading.
o Reports washed out grit to the supervisor.
o Checks the power supply.
o Clean and maintain the flow meter and surroundings.
29
4. BIOLOGICAL REACTOR UNIT 1 AND 2
This is the receiving compartment for raw sewage water to enter the biological
reactor. The raw sewage enters this compartment and gets into contact with ox-
ygen an the mixed liquor. Oxygen is introduced into this compartment and forms
aerobic and anoxic zones. Micro-organisms utilize the carbon sources in the water
for energy and for metabolism. The oxygen deprived raw sewage receives oxygen
which is needed by the micro-organisms in the reactor to convert it from anaero-
bic to aerobic conditions. Over aeration will inhibit the metabolizing process and
will prevent biomass from developing. It is essential that the oxygen concentration
in this compartment is kept to between 1-2mg/l oxygen. The centre portion of the
circulating mass becomes anoxic (low oxygen concentration) and denitrification
will occur resulting in the removal of nitrogen through the uptake of nitrate oxygen,
releasing nitrogen gas into the air. The mixed liquor overflows into the next biolog-
ical reactor, and return activated sludge returns to unit 1 from the second unit by
air lifting.
30
 The operator:
o Checks that air blows evenly from all 16 units.(daily)
o Removes floating material from the tank.(twice a week)
o Do a settling test to determine the volume of mixed liquor in the
31
reactor. (weekly basis) Take sample in 2l plastic bottle and leave

for 30 minutes. Determine the settled sludge volume. Must not
exceeds 350 ml/l in 30 min.(one third of the bottle)
o If the blowers are set on timer, checks to see if it switches of at set
intervals (only if timers are set)
o Checks the colour of the mixed liquor
o Observe the odours release from the reactor
o Clean and maintain the area around the tank
5. CLARIFICATION/SETTLING UNIT
The clarifier is linked to the reactor units by means of an overflow weir stretching the
complete width of the process tank. Return settled sludge (RAS) is transported back
to the reactor compartments by air lift, which eliminates the pumping of the settled
sludge. Mixed liquor overflows over the 8 reactor weirs and is discharged into the
clarifier at a depth of 1.5m below the water level. RAS returns to the reactor units
from the bottom of the clarifier. The clarifier is rectangular and stretches over the
entire length of the basin. Sludge produced in the reactors settles to the bottom
while the supernatant (clear effluent) overflows over the horizontal overflow weir at
the side of the clarifier and into the clear water tank. (up flow rate is less than 1m/
hour). Approximate 0.44m/h at ADWF
30
 The operator:
o Checks to see if settling occurs
o Checks the supernatant at the overflow weir for solid carry over
o Checks for abnormal movement in the clarifier
o Checks for sludge build up in clarifier.
o Draw the surplus sludge using sludge draw off valves (15min/day
every 2nd day, or as seemed necessary.
o Draw off sludge using sludge valves in the sludge valve chamber
o Inspects the thickness of the sludge at each draw off valve.
o Removes floating material from the clarifier.
o Spray the scum on top of clarifier with water.
o Collects removed debris and dispose of with screenings
31
6. SETTLED WATER TANK (FILTRATION FEED/OVERFLOW)
The over flow from the clarifier falls into the settled water tank from where it supplies
the up flow filtration unit with water. The settled water tank acts as storage and flow
equalizing tank supplying a constant feed to the filtration unit. Water to the filtration
unit is from the bottom of this tank via a 110mm PVC pipe. During low consumption
periods and when the reservoir is full, water will overflow through a 150mm overflow
pipe and discharge into the sludge sump from where it gravitates to the oxidation
ponds. Suspended solids in this tank will be removed through the filtration unit.
 The operator:
o Removes floating material from the tank
o Check the clearness of the water.
o Inspects for odours arising due to uncompleted oxidation.
o Ensure that the overflow is open and all restrictions are removed
o Check the liquid level (float) to see if it is still functioning.
7. UP FLOW FILTRATION UNIT
The filtration unit receives water from the settled water tank through a 110mm PVC
pipe. Two centrifugal pumps (duty and standby) pumps water through the filter
column from the bottom to the top discharging at the top into a 150mm PVC pipe
which discharges into the final storage and disinfection tank. The water abstracted
from the settled water tank is dosed with liquid alum for flocculation, phosphate
and colour removal. Dosing is done by chemical dosing pump and the flocculant
32
is stored into a 200l plastic drum. (The product is purchased from the same supplier
as for the domestic water treatment plant). Dosing is set by the supplier (default)
but can also be set by the operator after consultation with the supplier.
Liquid chlorine is also dosed with a dosing pump and the purchasing is the same as
for the flocculant. Chlorine is dosed at approximate 6-10 mg/l (36l/day). In effect,
a 200 l drum will last for 5days. NB. Keep stock in hand.
IMPORTANT: A complete operation and maintenance manual for the filtration unit
is supplied as separate document. PLEASE CONSULT THIS MANUAL!!
Flushing, backwashing and rinsing of the filter are controlled by PLC and any mal-
functioning can be communicated with the supplier.
Backwash water discharges into the sludge draw off valve chamber from where it
gravitates to the oxidation ponds.
The operational process is as follows:
• Water is pumped through the filter by 2 centrifugal pumps (duty and stand-
by)
• Flocculant is dosed by a dosing pump into the water
• Flocculation occurs in the filter and the suspended matter is removed.

• The clear discharge is disinfected with chlorine (dosed) and flows into the
final effluent storage tank.
• When the filter is clogged, the flow stops and the filter are flushed.
• Air from the compressor is forced through the filter to scrub off all sludge at-
tached to the pebbles. (Air scouring)
• After scouring, the filter is rinsed with water.

• The air valves sets to their operational position and normal operation contin-
ues.
 The operator:
o Check the discharge into the final effluent tank to ensure that
pumps are not blocked. If blocked, switch off system and clean
the pumps.
o Checks to see if flushing, scouring and rinsing occurs.
o Check for leaks
o Check the compressor.
33
o Measure the motor temperatures by touching

o Clean the pump room
o Check the dosing pumps and clean when blocked
o Check the chemical stock.
o Listen for abnormal noises
8. FINAL EFFLUENT STORAGE AND DISINFECTION TANK
The final storage tank is the last tank in the process where the water can be moni-
tored, both physical and bacteriological. Form this tank water is pumped into the
storage reservoir which will supply the toilets with water. The disinfection compart-
ment ensures the needed retention time for the chlorine to disinfect the water.
 The operator:
o Removes all floating material from the surface of the tank.
o Check the water quality. (visual)
o Checks the level of the tank to ensure that the inflow and outflow
balances
o Check the liquid level control
o Clean and maintain the area around the tank.
9. PANNEL BOARDS AND BLOWER ROOMS
The blower room houses 6 of 5.5kWh Rotavane Blowers. The blowers blows air into
the reactor units to produce an oxygen concentration of between 1 and 2 mg/l.
The blowers can be set to operate together or individually as the need arises. The
blowers can also be set to run on a timer schedule to give flexibility to the aeration
process. Electrical control boards are necessary to ensure that the correct power
supply is supplied to each mechanical item and to rotect equipment from dam-
age by lightning. Electrical control panels provide information on the operation of
mechanical equipment.
34
 The operator:
o Checks for strange sounds from the blowers
o Check the temperature of the motors by touching them.
o BEWARE NOT TO TOUCH THE AIR VANE AREA: VERY HOT
o Clean the sieves at the intake pipe (weekly)
o Clean the floors to prevent dust from entering the blowers.
o Check that all valves are in the open position
o KEEP THE ROOM TIDY AND DUST FREE
o Clean blowers and pumps at filter pump house.
o Visually inspect for high temp on PVC pipes
o Turn some blowers off if to much heat is generated.
o Clean all panel boards
35
o WHEAR PROTECTIVE EQUIPMENT (ear plugs)

o Calls the supervisor when there is a flashing orange light on the
board. (tripped)
o The operator notes all pumps and blowers running and standing.
o Switches blowers on and off when necessary.
o Notes when blowers are overheating.
o Make sure there is flow at the suction of the blower.
o Check for blockages and obstructions.
o Report all leaks.
o Cleans level control instruments.
o Don’t leave foodstuff lying around.
36
OPERATORS MANUAL
Submitted
by: TDB&C
AGENCY PO
Box 11889
Universitas 9321
0799913057@vodamail.co.za
UP-FLOW FLOATING MEDIA CLARIFICATION

The plant consists of an up-flow floating media filtration tower with a
manual set valve at the inlet and four air actuated valves controlling
the automatic operating cycles required for water clarification.
Clear water overflow
Top baffle plate equipped with

1.5mm slotted nozzles.
Floating media (Polyethylene

beads RD 0.90 – 0.94)
Bottom baffle plate equipped with

1.5mm slotted nozzles.
Manual set valve.
Inlet valve.
Rinse valve.
Flush valve.
Air blower valve.

PLANT DISCRIPTION
Filter/Clarification Cycle
During the filtration cycle raw water dosed with the required chem-
icals enters the tower from the bottom flowing through the floating
media that traps coagulated particles. The clarified water then over-
flows into clear water drainage pipe.
Inlet valve open
Air/scour valve closed
Dosing pumps on
Flush valve closed
Rinse valve closed

Scour Cycle
During the scour cycle the raw water feed, and chemical dosing
pumps are off. The inlet, rinse and flush valves are closed. The Com-
pressor is on and the blower valve is open.
Air is blown in through the bottom the filter through the media loosen-
ing trapped particles accumulated during filter cycle.
Raw water feed is off.
Dosing pumps are off.
Inlet valve Closed.
Flush and rinse valves closed.
Blower valve open.

Flush Cycle
During the flush cycle the raw water feed, and chemical dosing
pumps are off. The inlet, rinse and blower valves are closed. The flush
valve opens and all the water and loosened particles/sludge are
drained from the tower.
Raw water feed is off.
Dosing pumps are off.
Inlet valve Closed.
Flush valve Open.
Rinse valve closed.
Blower valve closed.

Rinse Cycle
During the rinse cycle the raw water feed and chemical dosing
pumps are on. The inlet valve and rinse valves are open. The flush and
blower valves are closed.
Water passes through the tower and rinse water passes through to the
rinse valve.
Raw water feed is on.
Dosing pumps are on.
Inlet valve Open.
Flush valve Closed.
Rinse valve Open.
Blower valve closed.

Manual operation
All the control panels are equipped with a manual cycle button.
Should a flush cycle be required outside of the timer cycle
Button: To initiate the flush cycle simply press the button

once.
The plant will flush for the full cycle as set
The plant will automatically return to normal cycle.
Chemical requirements.
Make sure that tested and approved chemicals are used for coagula-
tion and biological control.
The plant warrantee is void when non approved chemicals are used.
The chemical dosage is dependent on the raw water quality and

chemical supplier.
Plant Equipment Maintenance

Electrical Control panel The electrical control panel must be
kept clean and dry at all times.
NB The power should always be
off when opening or working on
the panel
Chemical dosing pumps The chemical dosing pumps should be
kept clean and dry at all times.
Always use protective equipment when

Make sure that all dosing and suction
Working on the chemical dosing pumps lines are connected correctly.
Water should be pumped through

the pump to clear it from any form of
chemical precipitation and crystalliza-
tion.
SCOUR CYCLE The compressor oil should be checked
once per week and topped up with oil
The compressor is sized to give suffi- if required
cient air for the 2minute scour cycle
Only engine/gear oil should be used to

top up.
Compressor Oil level should be checked once per

week
The compressor is an important part of
the system which supplies air for the
scour cycle and operates the air ac-
Oil should be toped up with SAE20W40
tuated valves. If the compressor is not
functioning there will be no FLUSHING
Water should be drained from the air

receiver tank once per week.
If voltage dips occur the electrical

will trip and the reset button must be
pushed.
FCE 220volt CHEMICAL DOSING PUMP
1
2
1- ON OFF SWITCH – PRESS LIGHTLY TO SWITCH ON AND OFF

2- VOLUME ADJUSTMENT KNOB-100% WILL EQUAL THE MAXIMUM THE PUMP IS RATED
AT 0 TO 5LTS/HR OR 0 TO 10LTS/HR
EACH GRADING EQUALS PLUS MINUS 10% OF RATED VOLUME
3- OUTLET VALVE OF THE DOSING-HEAD. POPPET BALL SHOULD BE CLEANED
PERIODICALLY (PATICULARLY IF CALCUIM HYPOCHLORIDE IS DOSED). ENSURE THAT
THE BALL AND “O”RING SEAT ARE PROPERLY REPLACED. THE DIRECTION ARROW MUST
FACE THE CORRECT DIRECTION.
4- BLEED OFF VALVE FOR PRIMING THE DOSING PUMP IN THE EVENT OF AN AIRLOCK.
 PRESS BUTTON #1 LIGHTLY TO SWITCH OFF DOSING PUMP
TURN THUMB SCREW ANTI-CLOCKWISE-DO NOT FORCE

PRESS BUTTOM #1 LIGHTLY TO SWITCH ON PUMP

TURN VOLUME ADJUSTMENT #2 TO 100% TO ALLOW CHEMICAL TO FLOW FROM THE
 NIPPLE #5. BE SURE TO PLACE A CONTAINER BELOW NIPPLE #5
CLOSE OFF BLEED OFF VALVE AND RESET VOLUME ADJUSTMENT #2 TO DESIRED
 SETTING.
5- BLEED-OFF NIPPLE
6- SUCTION VALVE SCREWS INTO THE BOTTOM 9 OF THE DOSING HEAD #7
7- DOSING HEAD-BOLT ONTO THE BODY OF THE DOSING PUMP WITH 4 SCREWS
1
7
6
2
Compressor
Pressure switch and emergency switch (in off/out on). The pressure switch is
factory set and should not be tampered with
Pressure Gauge
Electric Motor and #6 overload protection reset button for the motor
Air hoses
Oil level indicator, should be halfway in the site-glass
Electric Motor overload, if the motor trip-press the button in to reset
Air intake and air cleaners
Condensation drain valve, open for 2 to 3 seconds once per week
Oil filler cap. If the oil level in the site glass be low #5. Top up with motor engine
oil
10
COMPRESSOR TROUBLE SHOOTING AND MAINTENANCE

• Compressor will not run
a. Is there power?
b. Is the pressure # 1 in or out?
c. Has the overload/cut-out button # 6 out, if so reset by pushing in
d. What is the pressure on the pressure gauge? Remember the pressure
switch will automatically shut off the compressor if the pressure is at the
factory set point.
• Check the oil level
a. Check the oil level in site-glass # 5 at least once per week

b. If the oil level is below the centre line, top-up with motor car engine oil # 9
• Drain off condensate/water

a. When the compressor runs it will accumulate moisture in the holding tank.
This should be drained off once per week.
b. To drain the condensate open valve #8 at the bottom of the storage tank
c. Check air lines for leaks every day, as any leak will cause the compressor
to run excessively
NB.
REMEMBER THE COMPRESSOR IS THE MOST IMPORTANT PART OF THE
SYSTEM
IT OPENS AND CLOSES THE AIR ACTUATED VALVES AND IS USED TO
SCOUR THE MEDIA
Trouble Shooting FCE Chemical Dosing Pump.

ALLWAYS WEAR EYE PROTECTION AND CLOVES BEFORE WORKING ON
THE CHEMICAL PUMPS.
1. Pump does not dose chemicals (CHECK CHEMICAL LEVEL IN DAY
TANK)
a. Press On Off #1 switch to see if there is power to the pump
b. Check pilot light below on off switch (Pulsing)
c. Adjust volume of the pulse #2, adjust to 100% and return to
normal setting
2. Pump pulses but does not pump chemicals
a. Switch off pump by pressing on/off switch #1
b. Adjust Volume setting #2 to 100%
c. Open Bleed off valve #4 anti-clockwise (hold a receptacle) be-
low nipple #5
d. Press the On/Off switch to restart the pump. Allow plus minus 4 to
5 minutes for the chemical to flow from the nipple #4.
e. Close off bleed valve #4 and reset volume dial #2 to desired set-
ting
3. Pump does not prime
The suction valve #6 and the delivery valve #3 could be fouled
with residue from chemical tank.
a. Switch off pump by pressing On/Off switch #1
b. Remove suction hose from valve #6 – Unscrew valve #6 – re-
move the ball and “O” ring and rinse with clean water
c. Replace suction valve #6 – replace suction onto suction valve #6
d. Repeat the process with delivery valve #3.
e. Remove the foot valve from the chemical tank and rinse out with
clean water.
4. Chemical pump will not switch on
a. Call agent
Guarantee/s
UFMC Plant
The Up-flow Floating Media Clarification plant filters are guaranteed
for a period of five years against faulty workmanship and defective
materials.
Electrical equipment
All electrical equipment is covered by the manufacturers guarantee,
normally for a period of 12 (twelve) months, subject to the conditions
as stipulated by the supplier.
Mechanical Equipment supplied.
All valves and mechanical equipment supplied are covered by the
manufacturer’s guarantee (twelve months), subject to the conditions
as stipulated by the supplier.
Water Quality
The final water quality is subject to the correct chemical dosage and
the use of the correct chemicals.
Trouble Shooting-Check list

• Plant will not flush automatically
1. Power on/time has elapsed on PC as set for flush cycle
2. Compressor has enough air to open and close air actuated valves
3. If all the above are OK press the Manual Cycle Button
• Final water is not clean

1. Chemical dosing pump for coagulant is primed and pumping the correct
amount according to the incoming/raw water quality
2. All chemical feed lines to the plant are clear and chemicals are reaching
the injection point
3. Switch the Rinse Valve on the control panel to ON allowing the final water
to run to drain. Adjust dosage of coagulant until effluent is clean. 8 to 10
minutes must be allowed for the effluent to show change, repeat if re-
quired. Reset Rinse Valve to Auto

4. If all the above are in order/have been checked and
the water is still not to standard press the Manual Cycle
button and allow the plant to go through the complete
Flush Cycle
• Compressor will not start

Refer to compressor handbook/manual
• Dosing pumps
Refer to dosing pump manual
• Air actuated valves not functioning

Refer to compressor handbook

TDB& C Training Manual

Uploaded by

Copyright:

Available Formats

TDB& C Training Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TDB& C Training Manual

Uploaded by

Copyright:

Available Formats

PETRUSTEYN

Recycling Unit Operation

2. GENERAL DESCRIPTION OF THE WORKS

4. ANAEROBIC DIGESTION SYSTEM

7. Chlorine contact tank

9. Upflow Filter Media Filtration

10. Final Effluent

This manual is intended to provide guidance to the operating personnel to operate

2. GENERAL DESCRIPTION OF THE WORKS

3.1 Inlet Unit

3.1.2 Grit traps.

4. Anaerobic Digestion Pond

7. Chlorine Contact Tank

8. Rapid Reactor Unit (RR)

Ammonia is converted to Nitrate and this is denitrified to nitrogen in the denitrifica-

9. Upflow Filter Media Filtration

Backwashing of the filter:

Testing of the effluent:

10. Final Effluent

Sodium Hypo chloride can be purchased from a supplier in Bethlehem in 220kg

Breakpoint Chlorination (complete disinfection) is obtained if the water tested at

10.1 TOP UP WATER

10.2 WATER QUALITY STANDARDS

10.3 CONTROL MEASURES

10.4 BELOW STANDARD WATER

GUIDELINES FOR THE UTILISATION AND DISPOSAL OF

(Department of Water and Sanitation (March 2006)

Double System 50kg/month

Classification of Rapid Reactor Sludge (B2a)

Stability Classification: Class 2

 Mental limits for Rapid Reactor (mg/kg)

 Nutrient Content of sludge on a dry weight basis.

 Sludge will be applied with no contribution to soil erosion

OPTION 1. FERTILAZATION OF TREES (TYPE-C SLUDGE)

 Total volume = 30 000l WAS @0.4% solid/month.

 NB: Ponds: For bird life improvement and effluent polishing.

1. CHARACTERISTICS OF SEWAGE, REASON FOR AND

Sewage as it arrives at the treatment works contains a complex biological flo-

The organic compounds in sewage have complex carbon based molecules

Table 1.1 Characteristics of sewage of different strengths.

Criteria Weak Average Strong

1.2 Reasons for Sewage Treatment

From a health perspective, sewage is potentially dangerous to man as it con-

1.3 Objectives of Sewage Treatment

Sewage has to be treated for the following reasons to:

2. CHARACTERISTICS OF PETRUSTEYN WASTEWATER

2.2 COMPONENTS OF THE WORKS

• 1 Clarification and settling compartment

3. OPERATION AND MAINTENANCE OF THE PACKAGE

INLET WORKS SECTION:

1. Arrives at work in his own clothes and shoes.

• AUTOMATIC OPERATED INLET SCREEN

o Collects the material at the top to the platform to dry.

o Collects the screenings in a wheelbarrow.

o Dumps the screenings at the collecting site.

o Clean the area surrounding the screen.

o Must not let screening material build up in the inlet chamber.

o Material build up will causes blockages upstream in manholes.Ac-

o Check the inflow to the inlet works.