DOHA WEST SEWAGE TREATMENT WORKS

EXTENSION No. 5
CIVIL PROJECT CP807
PROJECT CODE IA 14/15 C077G

CLIENT

ASHGHAL
PO Box 22188,
Doha, State of QATAR .

O&M JV CONTRACTOR's
DOHA WEST O&M – Degremont Marubeni JV
DOHA WEST Sewage Treatment Plant
PO BOX 24 038
DOHA QATAR
TEL +974 4476 5333
http://www.degremont.com

5 12-10-2017 Final version LBO SGO JPI

4 09-10-2017 Review the file LBO SGO JPI
3 23-07-2017 Add Extension 5 LBO SGO JPI
2 29-11-2015 Change logo, Add template MIL SPO DWR
1 16-05-2013 Review the file,Add extension 4 PLU CRO TCH
0 08-11-2011 First emission SPA RBU OMA
Rev Date Modification Issued by Checked Approved

BIOLOGICAL TREATMENT

COMPANY DOCUMENT NUMBER REV: D.STATUS

SUEZ MRB P-OM-001-003 5 FA
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OPERATOR MANUAL

BIOLOGICAL TREATMENT

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1. Introduction
The aim of this manual is to provide a standard reference to biological treatment equipment and their operation.
It will address the following subjects:

What are the targets of Biological Treatment?

Which physical and chemical principles are included in this treatment?

What is the configuration of this unit?

What are the main adjustments, instructions and maintenance activities to be implemented?

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1. INTRODUCTION .......................................................................................................... 3

2. GENERAL PRESENTATION ............................................................................................ 6

2.1. Objectives .............................................................................................................................. 6
2.2. Localization ............................................................................................................................ 7
2.3. P&ID’s Reference .................................................................................................................... 8
2.4. Risks ...................................................................................................................................... 9
2.4.1. Biological risks on Human Health ............................................................................................ 9
2.4.2. Effects of chemicals used on Human Health .......................................................................... 10

3. PHYSICAL AND BIO-CHEMICAL PRINCIPLES ................................................................. 11

3.1. Carbon Removal ................................................................................................................... 12
3.2. Nitrification and Denitrification ............................................................................................. 13
3.2.1. Nitrification ......................................................................................................................... 13
3.2.2. Denitrification ...................................................................................................................... 13
3.3. Phosphorous Removal ........................................................................................................... 14

4. TECHNICAL DESCRIPTION .......................................................................................... 15

4.1. Aeration tank Distribution ..................................................................................................... 16
4.2. Aeration Tanks ..................................................................................................................... 19
4.2.1. Biological Reactor Tanks ....................................................................................................... 20
4.2.2. Recirculation Pumps (for mixed liquor) ................................................................................. 21
4.2.3. Aeration by Hyper Classic Mixer/Aerator (INVENT) ................................................................ 22
4.2.4. Air Production for aeration ................................................................................................... 24
4.3. Deaeration of Activated Sludge ............................................................................................. 26
4.3.1. Degassing chambers ............................................................................................................. 27
4.3.2. Air production for deaeration ............................................................................................... 30
4.4. Conventional Secondary Settling............................................................................................ 32
4.4.1. Secondary Settling Tank ....................................................................................................... 32
4.4.2. Grease/floating matter/scum lobe Pump .............................................................................. 34
4.5. Activated Sludge Recirculation and extraction ........................................................................ 36
4.5.1. Recirculation pumping stations ............................................................................................. 37
4.5.2. Extraction pumping stations ................................................................................................. 39
4.6. Ferric Chloride Part two ........................................................................................................ 41
4.7. Shock Chlorination - Sodium Hypochlorite injection ................................................................ 43

5. ADJUSTMENTS ......................................................................................................... 45
5.1. Process Control Philosophy ................................................................................................... 46
5.1.1. Control of sludge flow .......................................................................................................... 46
5.1.2. Control of air flow ................................................................................................................ 46
5.2. Secondary treatment Line – S1 .............................................................................................. 47
5.2.1. Aeration Tank ...................................................................................................................... 47
5.2.2. Aeration tank mixed liquor recirculation (internal recirculation) ........................................... 52
5.2.3. Secondary Settling Tank ....................................................................................................... 54
5.2.4. Activated Sludge Recirculation ............................................................................................. 55
5.2.5. External recirculation pump control on 488A ........................................................................ 56
5.2.6. Extraction pump control ....................................................................................................... 58
5.3. Secondary treatment line – S2 ............................................................................................... 60
5.3.1. Aeration Tanks Distribution chamber – 471B ......................................................................... 60
5.3.2. Aeration Tanks ..................................................................................................................... 63
5.3.3. Air Production for Aeration 711B .......................................................................................... 72
5.3.4. Deaeration of Activated Sludge – 481B ................................................................................. 75
5.3.5. Secondary Settling Tanks ...................................................................................................... 77

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5.3.6. Activated Sludge Recirculation ............................................................................................. 82

5.4. Shock chlorination ................................................................................................................ 92

6. ROUTINE TASKS AND FIRST LEVEL MAINTENANCE....................................................... 95

6.1. Sub Station 930F ................................................................................................................... 95
6.2. Aeration Tanks ..................................................................................................................... 96
6.3. Deaeration of activated Sludge .............................................................................................100
6.4. Conventional Secondary Settling...........................................................................................102
6.5. Air Production for Aeration in Biological Tanks ......................................................................106
6.6. MCC Room ...........................................................................................................................108
6.7. Sodium Hypochlorite ............................................................................................................109
6.8. Ferric Chloride Injection Part two .........................................................................................109

7. OPERATION PROCEDURES ....................................................................................... 111

7.1. P-OM-012-821A Starting of Ferric Chloride Injection ..............................................................111
7.2. P-OM-012-821A Adjustment of ferric chloride .......................................................................113
7.3. P-OM-009-711 Control of air blowers ....................................................................................115
7.4. P-OM-008-481 Disposal of floating material in scum Pit .........................................................119
7.5. P-OM-007-480 Disposal of Scum in Clarifiers Scum Pit in manual ............................................121
7.6. P-OM-001-000 Resetting of one tripped equipment ...............................................................123
7.7. P-OM-020-470 First Level Maintenance of the sensor of Aeration Tank ...................................125
7.8. P-OM-023-470 Filamentous Bacteria Crisis ............................................................................126
7.9. P-OM-024-771 Resetting of air blowers valve due to a power failure ......................................129
7.10. P-OM-000-472 Emptying an Aeration Tanks X (= F/G/H) .........................................................130
7.11. P-OM-001-472 Filling an Aeration Tanks X (= F/G/H) ..............................................................132
7.12. P-OM-069-480 Stop of clarifier (X = F to H) ............................................................................134
7.13. P-OM-068-480 Restarting of clarifier (X = F to H) ...................................................................135

8. TROUBLESHOOTING AND REPAIR ............................................................................. 139

8.1. Important Remarks ..............................................................................................................139
8.2. Biological Tank ....................................................................................................................139
8.2.1. Disturbance of the aerobic condition .................................................................................. 139
8.2.2. Filamentous Bacteria .......................................................................................................... 142
8.2.3. Odour ................................................................................................................................ 143
8.2.4. Colour ................................................................................................................................ 144
8.2.5. Appearance ........................................................................................................................ 145
8.3. Clarifier ...............................................................................................................................146
8.3.1. Colour ................................................................................................................................ 146
8.3.2. Appearance ........................................................................................................................ 146

9. APPENDICES ........................................................................................................... 148

9.1. Details Supplier ...................................................................................................................148
9.2. Acronyms ............................................................................................................................151

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2. General Presentation
2.1. Objectives

 Biological treatment of waste water requires a wide range of micro-organisms, and, primarily, bacteria. These
micro-organisms convert the biodegradable organic (carbone) and inorganic (ammonia, phosphate) matterfound
in waste water into simple products, such as carbon dioxide and additional biomass.

 The biological process is the heart of the water treatment but is equally important for the resulting sludge. It also
includes the clarification of water and sludge recirculation .

 The rule of the clarifiers is to achieve the settlement and separation of suspended solids of the mixed liquor flow
from the aeration tanks. The settled sludge is then recirculated at the inlet of the aeration tanks in order to
maintain the required amount of bacteria inside of the tank. Excess sludge (suspended solids coming from inlet
and created by biological activities and not used in recirculation) is extracted towards thickening/dewatering
unit.

 Water that has been separated of settling sludge is conveyed towards tertiary treatment (Balancing tank, Sand
Filters, Ultrafiltration & Disinfection).

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2.2. Localization

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2.3. P&ID’s Reference

CP807 DGT M DS 470 001 L Aeration Tanks Distribution

CP807 DGT M DS 470 002 Z Aeration Tank Zoom

CP807 DGT M DS 470 003 Z Aeration Tank A B

CP807 DGT M DS 470 004 Z Aeration Tank C D

CP807 DGT M DS 470 005 J Aeration Tank E

CP807 DGT M DS 470 006 F Aeration Tank Distribution 471B

CP807 DGT M DS 470 007 F Aeration Tank zoom

CP807 DGT M DS 470 008 F Aeration Tank F to H Outlet

CP807 DGT M DS 480 001 Z Deaeration of Activated Sludge

CP807 DGT M DS 480 002 Z Conventional Secondary Settling Zoom

CP807 DGT M DS 480 003 O Conventional Secondary Settling B-C

CP807 DGT M DS 480 004 Z Conventional Secondary Settling A-D

CP807 DGT M DS 480 005 Z Conventional Secondary Settling E-H

CP807 DGT M DS 480 006 Z Conventional Secondary Settling F-G

CP807 DGT M DS 480 007 O Activated Sludge Recirculation

CP807 DGT M DS 480 008 H Conventional Secondary Settling I-J

CP807 DGT M DS 480 009 H Activated Sludge Recirculation tank I-J

CP807 DGT M DS 480 011 E Deaeration of activated sludge 481B

CP807 DGT M DS 480 012 G Conventional Secondary Settling K-L

CP807 DGT M DS 480 013 G Conventional Secondary Settling N-M

CP807 DGT M DS 480 014 G Conventional Secondary Settling O-P

CP807 DGT M DS 480 015 G Activated Sludge Recirculation 488C

CP807 DGT M DS 711 001 Z Air Production for Aeration

CP807 DGT M DS 711 002 I Air Production for Aeration

CP807 DGT M DS 711 003 H Air Production for Aeration 711B

CP807 DGT M DS 800 002 Z Ferric Chloride Part One

CP807 DGT M DS 821 002 Z Ferric Chloride Part Two

Storage of sodium hypochlorite for post chlorination, CIP and shock
CP807 DGT M DS 851 001 F
chlorination
CP807 DGT M DS 851 003 G Sodium hypochlorite for shock chlorination

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2.4. Risks

2.4.1. Biological risks on Human Health

 Wastewater constitutes a vector for many bacteria likely to cause man diseases. In the water treatment plant,
the risk is important and there are many possibilities for co ntact with sludge or wastewater:
o All contacts with sludge or water whatever their state
o Breathing the bacteria in suspension in the air close to the aerators

Symptoms

 When the symptoms mentioned below are detected, the concerned person should be
immediately transported to the hospital:
o Digestive problem;
o Diarrhea;
o Gastro-enteritis;
o Viral Maladies.

Precaution

 Avoid any contact with sludge, water, Screening Risk of

microbiological
 Use gloves and clean overalls and adapted boots if necessary. contamination
 Respect elementary hygiene rules (wash the hands before eating, taking a shower after
work...).

 Check that you are vaccinated against the most current diseases.

First Aid Measures

 When contact with a risky product occurs: wash with soap immediately.
 After a fall in a tank: wash immediately yourself AND consult a doctor.
 If you have the symptoms in a chronic way, prevent your hierarchy, AND consult a doctor

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2.4.2. Effects of chemicals used on Human Health

 Appropriate chemical PPE must be worn during any intervention which can lead to contact with the chemical.
 Refer to SAFETY DATA SHEET for more information.

 Ferric chloride – FeCl 3

Use for: Dephosphatation

Characteristics: Amber and odourless liquid. Personal Protection:

Potential health Irritant to eyes and skin, corrosive.

effects:

Immediately flush with large quantiti es of cool water

First Aid Measures: continuously for at least 15 minutes.

 Sodium Hypochlorite - NaClO

Use for: Shock Chlorination in Recirculated Activated Sludge.

Personal Protection:

Characteristics: Yellowish-green liquid with a faint chlorine odor.

Potential health Burns to skin, eyes and alimentary canal. Harmful if

effects: swallowed .

Immediately flush with large quantities of cool water

First Aid Measures: continuously for at least 15 minutes.

SAVING RULES

Do not handle chemicals products without appropriate protection.

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3. Physical and Bio-Chemical Principles

The two secondary lines have the same design regarding the internal & external recirculations.

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3.1. Carbon Removal

 The main part of the pollution in raw water is made up of organic

carbon. This organic carbon is the food for the bacteria, which use it for
growth and energy. The carbon content is directly linked to bacteria
growth.

 The more carbonaceous pollution there is, the more bacteria n eeds oxygen
to assimilate the pollution.

 The oxygen demand increases depending on the pollution, so the

biological oxygen demand (BOD 5 ) is a good indicator to estimate the
quantity of carbonaceous pollution.

 After degradation, carbon is assimilated and tr ansformed into CO 2 which

goes to the atmosphere.
Carbon removal

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3.2. Nitrification and Denitrification

3.2.1. Nitrification
The nitrification

 Nitrification is a series of chemical reactions during which the nitrifying Aerobic

bacteria transform the ammonium ions into nitrate ions.
NH4+ NO2- NO3-
o First of all the micro-organisms transform ammonium into
nitrite (NO 2 - ).
o Then the micro-organisms transform nitrite into nitrate (NO 3 - ). O2 O2
 These reactions require a strong dissolved oxygen concentration in
water, as the following reaction shows:

(O 2 ) (O 2 )
NH 4 + → NO 2 - → NO 3 -

3.2.2. Denitrification
The denitrification
 Denitrification is a chemical reaction during which the denitrifying N2
bacteria transform nitrate into nitrogen gas.

 To breathe, the bacteria initially use dissolved oxygen. However, for NO3-
denitrification to occur, the bacteria must "breath" the combined O2 O2
oxygen present in nitrates.
Anoxie
 Thus, denitrification is done in the anoxic zone: to live the bacteria are
obliged to use the oxygen contained in the nitrates. This involves the
transformation of nitrate into nitrogen (harml ess gas).
Process of nitrification-
denitrification
NO 3 - → N2

Wastewater
NH 4+ NO2-
N org NO3-

Denitrification

NO3- N2

Nitrific ation

NH 4+ NO 3-

O2

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3.3. Phosphorous Removal

 The principle of biological phosphate removal consists in accumulating

phosphorus in bacteria.

 The biological removal of phosphates requires alternating anaerobic and

aerobic sequences.

 The anaerobic phase:

Phosphate accumulating bacteria (poly-P bacteria) take up readily
biodegradable organic substrate under anaerobic conditions. The organic
matter storage occurs in a form of poly-B-hydroxyalcanoates (PHA).

The energy required for PHA storage by poly-P bacteria is obtained from
decomposition of intracellular polyphosphates.

 The aerobic phase:

In aerobic environment the poly-P bacteria use organic storage products for
generating energy which is utilized for bacterial growth and phosphate storage
in a form of intracellular polyphosphate.

The quantities reabsorbed exceed the amount released d uring the anaerobic
phase. Thus, the amount of phosphorus in an activated sludge process could
reach 4 to 10% g P/g MLVSS.

 Chemical precipitation of phosphorus

A slight chemical precipitation of phosphorus might be required to reach the concentrati on of 2 mg/L in effluent,
depending on the RBCOD (readily biodegradable COD) of influent.
With simultaneous precipitation, the precipitant (ferric chloride) is added to the mixed liquor at the outlet of the
aerobic zone.

Flocs are settled out in the clarifier. Another advantage is turbidity removal and better sludge settling characteristics
(SVI).

Iron salt is added to precipitate phosphorus:

Fe 3+ + PO 4 3- FePO 4

Solid salt produced is then trapped within activated sludge and extract ed with settled sludge.
Sludge production is slightly increased due to ferric salt addition and precipitation during dephosphatation reaction.
4 dosing pumps (stand by in store) are provided, each with injection line.

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4. Technical Description
 At the outlet of the pre-treatment (410), only Air Process and Ferric Chloride injection are common for the two
lines.

 Under Ext. 3 an. 1, a distribution chamber 471 was distributing effluent to 4 aeration tanks 472A to D associated
to 8 clarifiers and 1 aeration tank 472E associated to 2 clarifiers I&J.

 The Extension 5 has provided a new distributing chamber 471B splitting raw water to 3 new aeration tanks (472F
to H) and to the existing aeration tank 472E.
The distribution chamber 471 operates now with the 4 aeratio n tanks A,B,C & D (The 5 th pit E have been isolated)
and the distribution chamber 471B operates now with the 4 aeration tanks A,B,C & E.
From the 3 new aeration tanks F,G & H, effluent flows to a splitting and degassing chamber 481B to equally feed
6 secondary clarifiers (480K to M). Clarified water overflows to the balancing tank. Activated sludge flows to a
pumping station 488C. A part is recirculated into the anoxie zone of aeration tanks. The surplus of sludge and
scum removal is extracted toward a sludge balancing tank 610B to be thickened and dewatered on a new sludge
treatment line.
From the existing aeration tank E, effluent flows to its own splitting and degassing chamber to equally feed 2
secondary clarifiers (480I & J). Clarified water overflows to the balancing tank. Activated sludge flows to the
existing pumping station 488B to be pumped toward the recirculation channel of the new pumping station 488C.
There is no modification on the scum removal from clarifiers I&J. Scum is extracted toward the sludge balancing
tank 610A by the common line of sludge extraction.
The balancing pipe joining the aeration tanks A to D outlet and tank E outlet is not used anymore. This pipe has
been partially deleted and reused to connect tanks F to H outlet to the tank E outlet.
Hereunder is the Extension 5 configuration:

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4.1. Aeration tank Distribution

Repartition Chamber of aeration tanks (471)

 The repartition chamber is located upstream of the 4 aeration tanks A to D.

 The two ND1500 pipes from the Inlet Works ar e entering in a common chamber.
 There are five separated distribution boxes. Four pits are dedicated to individually feed each of the aeration
lines A, B C & D. The fifth one used to feed the aeration tank E during extension 4 is not used anymore and
isolated definitely with stop logs. (The feeding pipe to aeration line E has been removed during extension 5).

 The influent is equally distributed to each of the 4 pits by means of weirs.

 Another common chamber is fed with Return Activated Sludge from clarifiers via two ND1400 coming pipes from
sludge extraction/recirculation building (488 A).

 The return activated sludge is equally split to each of the 4 pits by means of weirs, at the opposite side of the
influent feeding.

 From each of the individual pit a ND1500 duct serve each of the aeration line.

Repartition Chamber

Distribution chamber 471 scheme

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Repartition Chamber of aeration tanks (471B)

 The water coming from pre-treatment is distributed to the 4 aeration tanks 472E to 472H through a distribution
chamber 471B after being mixed with the Return Activated Sludge.
o At full flow (280 00 m 3 /d) the 4 aeration tanks are in operation (4 in duty).
o The maximum flow admissible on each aeration tank is 1700 m 3 /h.

 This distribution chamber is fed with:

o Two ND1600 pipes from the Inlet Works;
o Two ND1400 pipes from the RAS Chamber 488C.

 The structure of this unit is composed of several chambers (scheme below):

o Pre-treated influent chamber;
o Return activated sludge chamber;
o Pre-treated influent / recirculated sludge mixing chamber to ensure homogeneity of pre-treated water
and recirculated activated sludge;
o Stilling chamber;
o 4 outlet pits to feed each aeration tank using motorized controlled valves. Each pit can be isolated with
a manual penstock at its inlet.

 Each pit (and so each aeration tank) can be isolated with manual pen stock (471EF/G/H_VH403_).
 The inlet flow to an aeration tank is managed by a motorized penstock ( 471EF/G/H_VZ403_) controlled by the
flowmeter measurement (471E/F/G/H_FIT301_).

 A mobile drainage pump (471__PO152 - located in the store) can be used to drain each compartment. (Pump
characteristics: 10 m 3 /h / 2,740 / 50 Hz).

 Each line is equipped with a flowmeter. Two flowmeter chambers located downstream the distribution chamber
house the flowmeters:
o Flowmeter chamber 051G housing the aeration tank E flowmete r;
o Flowmeter chamber 050H housing the aeration tanks F, G & H flowmeters.

 The flowmeter measures the sum of pre-treated water flow plus the recirculated activated sludge. Therefore,
the set point value used for control takes into account RAS flowmeter s and also pre-treated water flowmeters.

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 Equipment and instruments included in this section

Equipment / instrument TAG Number Equipment’s supplier
REPARTITION CHAMBER OF AERATION TANKS (471B)
Mixer 471__QG151_*** 1 INVENT
471__XZ451A/B
Pre-treated water feeding stop log frame 4
471__XZ452A/B
IREAL
471__XZ453A/B
Activated sludge recirculation stop log frame 4
471__XZ454A/B
Mobile motorized actuator (in store) 471H_MO401_ 1 EBRO ARMATUREN
Isolating manual penstocks 471E/F/G/H_VH402_* 4
KWT
Motorized controlled penstock to aeration tanks 471E/F/G/H_VZ403_** 4
Mixing chamber level measurement 471__LIT320_ 1 E+H
Mixing chamber very low level switch 471__LSLL321_ 1 BAMO
Mobile drainage pump (in store) 471__PO152 1 XYLEM
Sewage water to aeration tanks E/F/G & H
471E/F/G/H_FIT301_ 4 E+H
flowmeters measurement
Flowmeter chamber 051G very high level switch 471__LSHH301_ 1
BAMO
Flowmeter chamber 051H very high level switch 471__LSHH302_ 1
*Those penstocks are equipped with high & low limit switches.
**Those penstocks are equipped with high & low limit switches, position transmitter and high torque switch.
***This mixer is equipped with high temperature switch.

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4.2. Aeration Tanks

 Equipment and instruments included in this section

Equipment’s
Equipment / instrument TAG Number
supplier
PREANAEROBIC ZONE
Mixers 472[A-H]_QG103*** 8 INVENT
Temperature measurement 472[A-H]_TT302_ 8 HACH
ANAEROBIC ZONE
Mixers 472[A-H]_QG103A/B*** 16 INVENT
ANOXIC ZONE
Mixers 472[A-H]_QG102*** 8 INVENT
AERATION ZONE
Aerator-mixers 472[A-H]_AA101 A to H*** 64 INVENT
Aeration tank - air flow rate measurement 711[A-H]_FIT307_ 8 ABB
Aeration tank air injection control valves 711[A-H]_VZ403_** 8
Aeration tank air injection isolating motorized EBRO ARMATUREN
711[A-H]_VM405_* 8
valves
Aeration tank - dissolved oxygen measurement 472[A-H]_AIT304_ 8
Aeration tank - redox measurement 472[F-H]_AIT301_ 3
Aeration tank - dissolved oxygen measurement 472[A-H]_AIT310_ 8
HACH
Aeration tank - suspended solids measurement 472[A-H]_AIT306_ 8
Aeration tank - dissolved oxygen measurement
472[A-H]_TIT304_ 8
probe temperature measurement
RECIRCULATION PUMP (FOR MIXED LIQUOR)
Mixed liquor recirculation canister pumps 472[A-H]_PO104A/B 16 GRUNDFOS
Flow rate measurement of mixed liquor
472[A-H]_FX303_ 8 TECHNIFLOW
recirculation - Parshall flume
AERATION TANKS OUTLET
472__V_406A/B
Aeration tanks A to D outlet stop log frame 4 /
472__V_407A/B
Aeration tank E outlet stop log frame 472E_V_406_ 2 /
472__XZ401A/B
Aeration tanks F to H outlet stop log frame 4 IREAL
472__XZ402A/B
*Those valves are equipped with high & low limit switches.
**Those valves are equipped with high & low limit switches and position transmitter.
***Those mixers is equipped with high temperature switch.

 Biological reactor tanks characteristics

Number of biological trains 8
Total biological volume 152,000 m 3
One Biological reactor tank characteristics
Biological Train volume 19,000 m 3
Water depth 8m
Volume of pre-anaerobic zone 500 m 3
Volume of anaerobic zone 3,500 m 3
Volume of anoxic zone 4,000 m 3
Volume of aerated zone 11,000 m 3

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4.2.1. Biological Reactor Tanks

Biological Reactor Tanks – Secondary Line S1

 There are 4 biological reactor tanks (472 A/B/C/D).

 The 4 aeration tanks can be operated separately or jointly which offers most flexibility.
 Each tank can be isolated as above described by weirs.
 The configuration considers 4 aeration tanks associated to 8 secondary settlers:
 From the 4 biological reactors 472 A/B/C/D, effluent flows to a repartition chamber and degassing chamber (481)
to equally feed 8 secondary clarifiers (480 A to H).

 The design takes into consideration either the stop of an aeration tank or a clarifier for maintenance purposes or
for inspections of civil works:
o Normal operation: 4 aeration tanks and 8 clarifiers. The total flow is split between the 4 aeration tanks (472
A/B/C/D) and then the flow from those aeration tank is split between the 8 existing clarifiers (480 A to H).
o One aeration tank is stopped: 3 aeration tanks and 8 clarifiers. The total flow is split between the 3 aeration
tanks (472 A/B/C or D) and then is split between the 8 clarifiers (480 A to J).

Biological Reactor Tanks – Secondary line S2

 There are 4 biological treatment tanks (472 E/F/G/H).

 Each tank can be isolated as above described with isolating penstock.
 From the biological reactor 472E, effluent flows to the 472E degassing and repartition chamber to equally feed 2
secondary clarifiers (480 I & J).

 From the biological reactors 472 F/G/H, effluent is mixed in a common canal and send to a degassing - distribution
structure which split water between 6 secondary clarifiers (480 K to P).

 The design takes into consideration either the stop of an aeration tank or a clarifier for maintenance purposes or
for inspections of civil works:
o Normal operation: 4 aeration tanks and 8 clarifiers. The total flow is split between the 4 aeration tanks (472
E/F/G/H) and then:
 The flow from aeration tank E is split between the 2 clarifiers (480 I&J);
 The flow from aeration tanks F/G/H is split between the 6 clarifiers (480 K to P).

o The aeration tank E is stopped: 3 aeration tanks and 8 clarifiers. The total flow is split between the 3 aeration
tanks (472 F/G/H) and then is split between the 8 clarifiers (480 K to P and 480 I&J) by opening of the outlet
aeration tanks F/G/H and E connection pipe;

o One aeration tank F/G or H is stopped: 3 aeration tanks and 8 clarifiers. The total flow is split between the
3 aeration tanks (472 E and F and/or G and/or H):
 The flow from aeration tank E is split between the 2 clarifiers (480 I&J);
 The flow from aeration tanks F and/or G and/or H is split between the 6 clarifiers (480 K to P).

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4.2.2. Recirculation Pumps (for mixed liquor)

 Each of the aeration lanes is equipped with two canister pumps (one in operation, one as stand by) at the outlet
of aeration tank, to raise liquors to a gravity channel feeding back at the inlet of anoxic zone.

 The recovery channel is equipped with a parshall flume at the end.

 Recirculation pumps characteristics:

TAG NUMBER: 472[A-H]_PO104A/B
The 16 pumps are equipped with a variable frequency drive, high moisture
and high temperature switches.
- Unit flow rate: 5.625 m 3 /h / 422 rpm / 50 Hz

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4.2.3. Aeration by Hyper Classic Mixer/Aerator (INVENT)

 The Hyperclassic Mixer/aerator is a unique mixing and aeration system which provides excellent homogenisation
and at the same time is capable of dissolving oxygen with high efficiency.

 The required air is supplied underneath the mixer/aerator via separate sparger system which is moun ted below
the mixer-body. The shear ribs located on the rim of the mixer -body ensure dispersion of the air in fine bubbles
which are distributed in the tank by the flow.

 The schematic below shows how the Hyperclassic Mixer/aerator system works in a typical aeration tank.

Hyperboloid – Mixer / Aerator with a top mounted drive

The Hyperclassic Mixer/aerator consists of a non -clogging

Hyperboloid-body with integrated transport ribs and stainless
steel shear ribs, a shaft and a motor with a mounting base as well
as the air sparger with pipe connector and the bottom bearing.

Dimensional view on a Hyperboloid Mixer/Aerator with top mounted

drive

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 Hyper Classic Mixer/Aerator characteristics

Their characteristics are differents in each biological zone of th e aeration tank:

Aeration tank Zones Preanaerobic zone Anaerobic zone Anoxic zone Aerated zone
TAG NUMBER 472[A-H]_QG103 472[A-H]_QG103A/B 472[A-H]_QG102 472[A-H]_AA101A to H
Number of Mixer /
1 2 1 8
Aerator per tank
Diameter 2,500 mm
Mixer pumping capaciy 16,056 m 3 /h 26,712 m 3 /h 29,412 m 3 /h 33,375 m 3 /h
Speed 16 rpm 28 rpm 32 rpm 40 rpm

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4.2.4. Air Production for aeration

 An air blower building 711 houses 5 blowers, together with a MCC room. 5 individual chambers houses each of the
blowers.

 From extension 5, a new air blower building 711B houses 3 air blowers, together with a MCC room. 3 individual
chambers houses each of the blowers.

 The two air blower buildings 711 & 711B are linked together:
o Any blower from building 711 can operate for tanks A,B,C,D & E;
o Any blower from building 711B can operate for tanks F,G & H;
o A set of valves is installed in order to attribute the blower E either the Blower building 711 (aeration tanks
A to E) either the Blower building 711B (aeration tanks F to G).

 An automatic flow regulation system is provided for each line in order to match with the oxygen req uirements of
each aeration tank.

 Basically, as the dissolved oxygen concentration varies, the air regulating valve of each tank adjusts its position
automatically based on a calculation chart. The pressure drop created by the position of the valve will then
regulate the pressure at the outlet of the blowers.

 The flow meter will measure the flow and will compare it to the expected flow due to the valve position, which
will be again adjusted to fit the air requirement.

 The corresponding MCC control rooms are adjacent to the blower’s buildings.

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Air production for aeration tanks A to E

TAG NUMBER: 711__KE101A/B/C/D/E

 4 blowers are in duty (A, B, C and D) and 1 as stand-by (E). In normal conditions, only two blowers are in operation.
Blowers 711__KE101A/B/C and D air blowers are on soft starter and blower 711__KE101E is on variable speed
drive.
- Unit flow: 19,500 Nm 3 /h

Air production for aeration tanks F to H

TAG NUMBER: 711B__KE101F/G/H

 Blowers characteristics:
3 blowers are in duty (F, G and H) and 1 as stand-by
(E). 711B__KE101F/G and H are on soft starter.
- Unit flow: 19,500 Nm3/h

Note: Blower 711__KE101E is on variable speed drive but it is operate as soft starter.The management and
regulation of the blowers is only based on pressure (to provide a constant pressure in the network at 840 mbar). The
flow is controlled by the regulation valve 711E_VM403 according to the air flow to maintain a Dissolved Oxygen at
the set point chosen.

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4.3. Deaeration of Activated Sludge

 The air contained in mixed liquor sludge has to be removed upstream of the final SST to avoid any sludge floating
problems in these works. Therefore, degassing is performed in the di stribution structure for the clarifiers.

 The aim of degassing is to:

o Remove the micro-bubbles trapped in the flocs,
o Remove the gases produced by denitrification,
o Remove the gases (mostly nitrogen) that are in supersaturation with regard to the atmosphere,
o Reflocculate the sludge if necessary.

 Consequently, the principle of the degassing tank involves two steps:

o Production / release of bubbles in supersaturation in the activated sludge and floc: this step requires the
use of energy (air mixing, etc.);
o Removal of the bubbles from the activated sludge.

 Therefore, the degassing tank design is based on two -stage process: one mixed zone for degassing and one calm
zone before clarifier feeding.

 The distribution structure is designed with 8 degassing zones able to feed up to 8 SST.
 For the degassing efficiency, the water depth is higher than the clarifier water depth and the energy necessary for
the mixing / degassing comes from:
o The water fall of the repartition weirs;
o Air injection (large bubble) to complete the w ater fall energy and bring a spiral flow movement to evacuate
the possible settled sludge.

 Each zone includes an agitation system (coarse bubble type) linked with a dedicated blown air production.
 In the calm zone (bubble removal zone) the agitation syste m that can be activated by the operator if necessary in
order to limit all deposits in this zone and the mixing of floating matter that may be created/stored in this zone.
As air injection is only occasional, there is no dedicated air production. The air p roduction planned for the mixed
zone is used. That means while there is air injection in the calm zone, there is temporarily no air injection in the
degassing zone.

 Scum collecting pits (4) are provided to collect the possible scum on the quiet zone, and a rotary lobe pump is used
to discharge the scum to the surplus activated sludge delivery.

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4.3.1. Degassing chambers

Degassing chamber 481 for clarifiers 480 A to H

 This structure
o Receiving the flow of mixed liquors coming from the aeration tanks 472 A/B/C/D;
o Is used to split the flow to each clarifiers 480 A/B/C/D/E/F/G/H.

 A set of stop logs are provided to isolate up to 4 clarifiers depending on the flow conditions.

Degassing chamber to clarifiers A to H

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Degassing chamber 472E for clarifiers I & J

 This structure
o Receiving the flow of mixed liquors coming from the aeration tanks 472 E;
o Is equipped with an air injection for degassing the water before being split to the two clarifiers I&J.

 The following installation was used during Extension 4 – It is not used anymore from Extension 5.

 Two configurations are possible depending on the number of aeration tanks and clarifiers in service thanks to two
sizes of stop logs equipped with weirs:
o if all aeration tanks and clarifiers I&J are in service OR if one aeration tank is out of service and both
clarifiers I&J are in service: stop logs with full weirs to be installed on both the opening and on both RAS and
sewage sides:

concrete
Full stoplogs with
weir

o if 4 aeration tanks (including aeration tank E) and one clarifier I or J is out of service: one stop log with full
weir and one stop log with partial weir to be installed on both RAS and sewage sides (stop log with partial
weir to be installed on East side). This is to limit the flow going through the remaining clarifier.

Stop log with partial

concrete opening

Full stoplogs with

weir

Degassing & Distributing chamber to clarifiers I & J

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Degassing chamber 481B for clarifiers 480 K to P

 This structure
o Receiving the flow of mixed liquors coming from the aeration tanks 472F/G/H;
o Is used to split the flow to each clarifiers 480 K/L/M/N/O/P.

Degassing chamber Localisation Degassing chamber to clarifiers K, L, M, N, O, P

 Grease/floating matter/scum from deaeration of activated sludge tank (degassing chamber 481B) are produced
and collected from each compartment in 4 pits. Manual penstocks (481B_VH40x_ - with x = 1, 4, 6, 7, 8 & 9)
can isolate each pit. All pits are interconnected each other. From one pit, a rotary lobe pump ( 481B_PO101_)
is used to discharge the scum to the surplus activated sludge delivery depending of the leve l in the pit
(481B_LSH301_).

 Scum removal pump characteristics:

TAG NUMBER: 481B_PO101_
The pump is equipped with a motor reducer.
- Unit flow rate: 30 m 3 /h / 324 rpm

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4.3.2. Air production for deaeration

 Each Degassing chamber 481A, 472E & 481B has his own air production system.

Degassing chambers 481A

 Air production system characteristics:

TAG NUMBER: 481A_KI201A/B
481B_KI201A/B
The air production system is composed of 2 air blowers. (One on duty, one on stand -by).

One degassing air blower is continuously running for the degassing process of the inlet water within the
distribution structure.
- Starter type: 481A_KI201A/B: Direct
- Nominal flow rate: 504 Nm 3 /h / 3,142 rpm / 50 Hz

Degassing chamber 472E

 Air production system characteristics:

TAG NUMBER: 472E_KI201A
Degassing chamber 472E has one air blower which is
continuously running for the degassing process of the outlet
water of the aeration tank E.
- Starter type: Direct
- Nominal flow rate: 326 Nm 3 /h / 2,860 rpm / 50 Hz

Degassing chambers 481B

 Air production system characteristics:

TAG NUMBER: 481B_KI201A/B
The air production system is composed of 2 air blowers.
(One on duty, one on stand-by).

One degassing air blower is continuously running for the

degassing process of the inlet water within the distribution
structure.
- Starter type: 481B_KI201A/B: Soft starter
- Nominal flow rate: 504 Nm 3 /h / 3,142 rpm / 50 Hz

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 Equipment and instruments included in this section

Equipment’s
Equipment / instrument TAG Number
supplier
Inlet sewage water from aeration tank stop log 481B_XZ423_ & 481B_XZ424_
4 IREAL
frame 481B_XZ425_ & 481B_XZ426_
Scum removal pump 481B_PO101_ 1 BORGER
Scum removal pump discharge pressure switch 481B_PISHL304_ 1 BAUMER
Pit High level switch 481B_LSH301_ 1 BAMO
AIR PRODUCTION
Strainer 481B_XH201A/B 2
Silencer 481B_XQ201A/B 2
Blower for mixing 481B_CS101A/B 2 AERZEN
Enclosure fan 481B_CV102A/B 2
Air blower air inlet filter pressure indicator 481B_PDI301A/B 2
2-Way Globe Valve 481B_VH410 1 INTERAPP
Discharge air flow measurement 481B_FI301_ 1 BAMO
Silencer for discharge air 481B_XQ203_ 1 ECIB
COMPARTMENT TO CLARIFIER K
Perforated pipe degassing 481B_AA201E & 481B_AA202E 2 /
Isolating Stop log frame to clarifiers 481B_XZ413_ & 481B_XZ414_ 2 IREAL
Scum pit manual isolating penstock 481B_VH401_* 1 KWT
COMPARTMENT TO CLARIFIER L
Perforated pipe degassing 481B_AA201F & 481B_AA202F 2 /
Isolating Stop log frame to clarifiers 481B_XZ411_ & 481B_XZ412_ 2 IREAL
Scum pit manual isolating penstock 481B_VH404_* 1 KWT
COMPARTMENT TO CLARIFIER M
Perforated pipe degassing 481B_AA201D & 481B_AA202D 2 /
Isolating Stop log frame to clarifiers 481B_XZ405_ & 481B_XZ406_ 2 IREAL
Scum pit manual isolating penstock 481B_VH409_* 1 KWT
COMPARTMENT TO CLARIFIER N
Perforated pipe degassing 481B_AA201A & 481B_AA202A 2 /
Isolating Stop log frame to clarifiers 481B_XZ421_ & 481B_XZ422_ 2 IREAL
Scum pit manual isolating penstock 481B_VH408_* 1 KWT
COMPARTMENT TO CLARIFIER O
Perforated pipe degassing 481B_AA201B & 481B_AA202B 2 /
Isolating Stop log frame to clarifiers 481B_XZ419_ & 481B_XZ420_ 2 IREAL
Scum pit manual isolating penstock 481B_VH407_* 1 KWT
COMPARTMENT TO CLARIFIER P
Perforated pipe degassing 481B_AA201C & 481B_AA202C 2 /
Isolating Stop log frame to clarifiers 481B_XZ417_ & 481B_XZ418_ 2 IREAL
Scum pit manual isolating penstock 481B_VH406_* 1 KWT
*Those penstocks are equipped with high limit switch.

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4.4. Conventional Secondary Settling

4.4.1. Secondary Settling Tank

 The clarifiers operate in relation with the aeration tanks in the activated sludge process providing final settlement
(see here below Secondary clarifiers).

 The clarifiers allow separating water and suspended solids from the mixed liquor. Suspended solid s settle at the
bottom of the clarifiers and make biological sludge. A part of this sludge is recirculated to the aeration tanks
distribution, and the other part is extracted to the sludge treatment.

 The sludge flow is almost continuous and can ensure the minimum retention time of the activated sludge within the
tanks.

 A clarifier is made up of:

o A concrete circular tank including central feeding tube, the clarified water is collected along the peripheral
concrete launders equipped with collecting weir.
o A surface scrapping which drives floating scum to a collection pit. Two collecting pits of adjacent clarifiers
are interconnected, one of them being equipped with a rotary lobe pump in order to transfer sum to the
sludge treatment.
o A mobile sludge draw off system is provided as follows;
o A peripheral radial bridge;
o Airlift tube which transfers directly the sludge within the chamber with low speed to reduce turbulence effect.

Clarifier

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Secondary Clarifiers “RACSUC” type (480 A to H)

Secondary Clarifiers “RACSUC” type (480 I to P)

 Equipment and instruments included in this section

Equipment’s
Equipment / instrument TAG Number
supplier
Secondary settling tanks outlet chamber 482B – 482B_XZ451_ & 482B_XZ452_
4 IREAL
Stop log frame 482B_XZ453_ & 482B_XZ454_
Motorized controlled penstock for sludge
482K/L/M/N/O/P_VM401_* 6 KWT
recirculation
Sludge recirculation pit level measurement 482K/L/M/N/O/P_LIT301_ 6
E+H
Sludge blanket high level switch 482K/L/M/N/O/P_LSH302_ 6
Scum removal pump 482L/M/P_PO104_ 3 BORGER
Scum removal pump pressure switch 482L/M/P_PISHL301_ 3 BAUMER
AIR PRODUCTION
Scraper bridge on wicket gate limit switch 482K/L/M/N/O/P_ZS101A 6
Scraper bridge on fixed access limit switch 482K/L/M/N/O/P_ZS101B 6
Scraper bridge 482K/L/M/N/O/P_QP101_* 6
Airlift Blower air suction filter 482K/L/M/N/O/P_XH201_ 6
Blower for sludge suction airlift 482K/L/M/N/O/P_CS103_ 6 COSME
Air lift manual control valve 482K/L/M/N/O/P _VH407_ 6
Air blower discharge silencer 482K/L/M/N/O/P _XQ201_ 6
Pump for floating matters sprayer suction filter 482K/L/M/N/O/P_XH203_ 6
Pump for floating matters sprayer 482K/L/M/N/O/P_PO102_ 6
* Those scraper bridges are equipped with high torque switch.
**Those penstocks are equipped with high & low limit sw itch & position transmitter.

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4.4.2. Grease/floating matter/scum lobe Pump

 These pumps are used to pump grease/floating matter/scum from deaeration of activated sludge tank (degassing
chamber) and conventional secondary settling tanks to sludge balancing tank .

 The parallel, 2-shaft design is common to all Rotary Lobe Pumps.

 The external synchronizing gear rotates the shafts in opposite directions.
 The displacement rotors are fitted on the shafts within the pump casing.
 The clearances between the rotors and casing are minimized to completely isolate the
suction and pressure areas of the pump.

 The rotation of the rotors creates a series of chambers within the pump casing. Product
fills the chambers on the suction side and is rotated circumferentially to the pre ssure
side.

 This produces a uniform flow from the suction to the discharge side with no need of
valves.

 The stress to the fluid is negligible as the product is transported almost free of shear and
with little pulsation and acceleration.

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Grease/floating matter/scum lobe Pumps from SST 482 A to H

TAG NUMBER: 482__PO106, 482__PO107, 482__PO108, 482__PO109 , 492_PO108

 Grease/floating matter/scum are conveyed toward thickening unit (GBT, 600).

Scum removal pump

Grease/floating matter/scum lobe Pumps from SST 482 I to P

 These pumps are used to pump grease/floating matter/scum from conventional secondary settling tanks
(482L/M/P_PO104_) to sludge balancing tank 610B.
The SST K scum pit is interconnected with the SST L scum pit where a pump (482L _PO104_) evacuate the scum.
The SST N scum pit is interconnected with the SST M scum pit where a pump (482M_PO104_) evacuate the scum.
The SST O scum pit is interconnected with the SST P scum pit where a pump (482P_PO104_) evacuate the scum.

Clarifier L scum removal pump

Degassing chambers Localisation

 Scum removal pump characteristics:

The pump is equipped with a motor reducer.
- Unit flow rate: 30 m 3 /h / 324 rpm

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4.5. Activated Sludge Recirculation and extraction

 The submersible pump motor causes to spin the impeller which

creates a vortex similar to that found in a toilet bowl when it is
flushed or a tornado. Since the impeller is not in the flow path of
the volute, the pump is ideal for handling liquids that contain
long stringy solids, large diameter solids, slurries or a
combination of all of these without plugging up.

Schematic of a vortex type pump

Schematic of clarifier and the recirculation sludge line

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4.5.1. Recirculation pumping stations

Recirculation pumping station 488A

TAG NUMBER: 488A_PO101A/B/C/D/E

 There are 5 submersible pumps for sludge recirculation 488A in the sludge pumping station : 4 pumps are in operation
and one pump is in standby.

 Sludge is raised from the common chamber, then flows by gravity to the aeration splitting c hamber via 2 x ND 1400
pipes. Each pipe is equipped with a magnetic flow meter.

 Each of the pumps is inverter controlled and the flow is adjusted by the operator according to the Process Engineer’s
requirement.

Recirculation pumping station 488B

TAG NUMBER: 488B_PO101A/B

 There are 2 submersible pumps for sludge recirculation in the 488B sludge pumping station : 1 duty + 1 standby. They
recirculate the sludge from clarifiers 480 I&J.

 Sludge is lifted to the recirculation pumping station 488C through a ND800 pipe where it is mixed with recirculated
sludge from clarifiers K to P.

 Each of the pumps is inverter controlled and the flow is adjusted by the operator according to the Process Engineer’s
requirement.

RAS pumping station 488C + 488B returns

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Recirculation pumping station 488C

TAG NUMBER: 488C_PO101A/B/C/D/E

 There are 5 submersible pumps for sludge recirculation in the 488C sludge pumping station : 4 pumps in operation
and 1 is in standby.

 Two pipes feed the RAS pumping station:

o One ND1400 pipe from clarifiers M, N, O & P;
o One ND900 pipe from clarifiers K & L;

 Sludge is raised from the common chamber to a canal where a ND 800 pipe discharge the activated sludge from RAS
pumping station 488B. Then the activated sludge flows by gravity to the aeration s plitting chamber via 2 x ND 1400
pipes. Each pipe is equipped with a magnetic flow meter located in the flowmeter chamber 051I.

 Submersibles pumps characteristics:

The 5 pumps are equipped with a variable
frequency drive, high moisture and high
temperature switches.
- Unit flow rate: 2,880 m 3 /h / 585 rpm / 50 Hz

 Equipment and instruments included in this section

Equipment / instrument TAG Number Equipment’s supplier
Inlet pumping station stop log frame 488C_XZ401A/B/C/D/E 5 IREAL
Recirculation pump 488C_PO101A/B/C/D/E 5 SULZER
488C_XZ403A/B
Outlet pumping station stop log frame 4 IREAL
488C_XZ404A/B
488C_LIT301_
Recirculation tanks level measurement 2 E+H
488C_LIT303_
488C_LSLL302_
Recirculation tanks very low level 2
488C_LSLL303_ BAMO
Recirculation tank high level switch 488C_LSH302_ 1
Recirculation flow measurement 488C_FIT302A/B 2 E+H
Flowmeter pit very high level switch 488C_LSHH306_ 1 BAMO

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4.5.2. Extraction pumping stations

Extraction pumping station 488A

TAG NUMBER: 488A_PO102A/B/C

 There are 3 submersible pumps for sludge extraction within (488A) sludge pumping station: 2 pumps are in operation
and 1 pump is in stand-by.

 Their capacity is sized to cover the extraction of the excess sludge.

 Sludge is raised to a pit and then flow to the stor age of the liquid sludge. In the same pit, grease floating matter
scum from the clarifiers and from the deaeration tanks arrives as well to follow the same way than the sludge.

 Each of the pumps is inverter controlled and the flow is adjusted by the operat or according to the Process Engineer’s
requirement.

 The pump might also operate on a time/sequence basis.

 Excess sludge from secondary settlement tank is extracted toward a gravity belt thickener (See operator manual OM-
010-600-z GBT) in order to be thickened.

Extraction pumping station 488C

TAG NUMBER: 488C_PO102A/B/C

 There are 3 submersible pumps for sludge extraction within (488C) sludge pumping station: 2 pumps are in operation
and 1 pump is in stand-by.

 Their capacity is largely sized to cover the ex traction of the excess sludge.
 Surplus sludge is pump through a main ND 400 pipe to a storage of liquid sludge called Sludge Balancing Tank 610B
to be thicken toward Gravity Belt Thickeners (See operator manual - OM-010-600-z GBT). A flowmeter
(488C_FIT301_) measures the sludge extraction to the balancing tank 610B.

 On this main ND400 pipe, three ND150 pipes are connected to send grease/floating material/scum from:
- Degassing chamber 481B;
- Clarifiers K & L;
- Clarifiers M, N, O & P.

 Submersibles pumps characteristics:

The 3 pumps are equipped with a variable frequency drive, high
moisture and high temperature switches.
- Unit flow rate: 330 m 3 /h / 1480 rpm / 50 Hz

 Equipment and instruments included in this section :

Equipment / instrument TAG Number Equipment’s supplier
SAS pump 488C_PO102A/B/C 3 SULZER
SAS flow measurement 488C_FIT301_ 1 E+H
SAS tank very low level 488C_LSLL305_ 1 BAMO

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 The extraction is done regarding the level of the Sludge Balancing Tank 610B. Depending this level, the extract flow
is manage by:
o The level threshold of the sludge balancing tank;
o Number of pump to run.

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4.6. Ferric Chloride Part two 1

Formula…………………………………...………………………………………………………..……..…………………..……………………………..…………..FeCl 3
Liquid Commercial form…………………………….….....……………………………………………… ………………….Liquid – 42% as pure product
Commercial Solution……………………………………………………………………….….....……………………………………………….….....…...…594 g/l

Dosing Pump (for Ferric Chloride Injection, 821A)

TAG NUMBER: 821A_PO103A to E

 Ferric chloride can be added to the mixed liquor at the outlet of the aerobic zone in order to precipitate
phosphorous.

 This injection is used only in the case or phosphorous concentration is above 2 mg/ L at the outlet of the plant.

Four diaphragm dosing pumps have been provided:

 A diaphragm pump is a positive displacement pump that

uses a combination of the reciprocating action of a
rubber, thermoplastic or teflon diaphragm and suitable
non-return check valves to pump a fluid. Sometimes this
type of pump is also called a membrane pump

 When the volume of a chamber of either type of pump is

increased (the diaphragm moving up), the pressure
decreases, and fluid is drawn into the chamber. When the
chamber pressure later increases from decreased volume
(the diaphragm moving down), the fluid previou sly drawn
in is forced out. Finally, the diaphragm moving up once
again draws fluid into the chamber, completing the cycle.

 The stroke of the pump is changeable only manually on the

pump by the mean of the wheel on the gearbox.
Caution! Only move the wheel while the pump is running.

1 Ferric Chlorine Part one is dedicated to the Inlet Treatment.

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 The installation is composed of 5 pumps. Each pump is used for one or two aeration tanks:
o Pump A for aeration tanks A and F;
o Pump B for aeration tanks B and G;
o Pump C for aeration tanks C and H;
o Pump D for aeration tank D;
o Pump E for aeration tanks E.

 For each aeration tank F, G or H, a magnetic flowmeter (821A_FIT304F/G/H) and a control valve
(821A_VZ480F/G/H) are installed downstream of the ferric chloride pump to control the amount of ferric
chloride injected into each new aeration tank.

To secondary line S1
To secondary line S2

 Equipment and instruments included in this section

Equipment’s
Equipment / instrument TAG Number
supplier
Ferric chloride injection control motorized
821A_VZ480F/G/H* 3 GF
valve for Inlet and Aeration tank F to H
Ferric chloride part 2 - To aeration tank F to
821A_FIT304F/G/H 3 E+H
H flow measurement
*Those valves are equipped with high and low limit switches and position transmitter.

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4.7. Shock Chlorination - Sodium Hypochlorite injection

Formula…………..…………………………………………………………………………………………………….……………………………...………...…(NaOCl)
Commercial form.………………………………………………………………………………………….………………Liquid – 48° /12-15% Cl solution
Concentration of the solution…..…………………………………….…………………………………………………….152 g/l as active chlorine*
*calculation done for 110/l when assuming the local climatic condition which may affect chlorometric degree .

General description

 At Doha West, Sodium Hypochlorite NaClO is used for:

o Chlorination and Post-chlorination: Disinfection of treated water in the CCT 589 (Line T1) and 524 (Line
T2) inlet and outlet;
o Shock chlorination: two NaClO injection lines: one on the Balancing Tank 581 cells or one to the RAS
pumping stations outlet 488A & C;
o Smartrack 539 Short CIP (SCIP) and Long CIP (LCIP).

 The two shock chlorinations are done for different purposes:

o The injection in recirculated activated sludge pumping station 488C is foreseen for filamentous bacteria
control;
o The injection in the balancing tank 581 is foreseen for algae control;

 The Sodium Hypochlorite storage and dosing system is installed in the chemicals room for UF Smartrack 539
plant.

Shock chlorination

 Shock chlorination is used in case of filamentous bacteria development in the aeration tanks. The chlorine will
destroy the algae avoiding to disturb the secondary & tertiary treatment. It is an exceptional event.

 The two shock chlorination injection points - Balancing tank 581 and RAS pumping stations 488A & C - cannot be
both supplied simultaneously.

 Storage Tanks
Tanks Number Volume
Storage tanks (851__RF201A/B/C/D/E/F) 6* 66,0 m 3 (net)
*Storage tanks common for shock chlorination, post -chlorination, CIP

 Dosing pump characteristics:

TAG NUMBER: 851__PO120
One sodium hypochlorite pump is installed and supply
either the balancing tank, either the RAS pumping
station. The pump is equipped with VFD and high
temperature switch.

The dosing line is equipped with high pressure switch

and flowmeter.
- Flow rate range: 0 to 927 l/h
- Maximum operating pressure: 3.5 bar

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 Equipment and instruments included in this section:

Equipment / instrument TAG Number Equipment’s supplier
Sodium hypochlorite unloading
NaClO unloading pump 851__PO101_ 1 CEPIC
NaClO transfer automatic shut-off valve 851__VA540_ 1
GF
Solenoid valve for transfer automatic shut-off valve 851__VY540_ 1
Unloading Visual alarm 851__ZZ305_ 1
BIN GHALIB
Unloading Sound alarm 851__ZZ306_ 1
In Line Strainer Filter 539__XH252_ 1 EMERSON
Drinking water to safety shower - Low pressure
924__PSL351_ 1 BAUMER
switch
Sodium hypochlorite storage
Storage tanks 851__RF201A to F 6 CPE
Storage tank Level measurement 851__LIT301A to F 6 E+H
Storage tank very high level switch 851__LSHH201A to F 6
Storage tank very low level switch 851__LSLL201A to F 6 BAMO
Retention tank very high level switch 851__LSHH301_ 1
Drinking water to safety shower - Low pressure
924__PSL352_ 1 BAUMER
switch
Sodium Hypochlorite dosing
Dosing Pump 851__PO120 1
Dosing pump - High pressure switch 851__PSH322 1 MILTON ROY
Protection enclosure very high level switch 851__LSHH323_ 1
Flowmeter 851__FIT321 1 E+H

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5. Adjustments
 This part includes 2 main parts as described below:
o SCADA View Presentation
o SCADA Using and Adjustments

 Main parameters adjustments to ensure a good quality pa rameters monitoring using of biological treatment unit by
SCADA.

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5.1. Process Control Philosophy

5.1.1. Control of sludge flow

With:
Aeration tanks A to D Aeration tanks E to H
406A_FIT301
Inlet flow 471[E-H]_FIT301
406B _FIT301
Mixing liquor recirculation pumps 472[A-D]_PO104A/B 472[E-H]_PO104A/B
488B_PO101A/B
Activated sludge recirculation pumps 488A__PO101A/B/C/D
488C_PO101A/B/C/D/E
Activated sludge extraction pumps 488A__PO102A/B/C 488C_PO102A/B/C

5.1.2. Control of air flow

With:
Aeration tanks A to D Aeration tanks E to H
472[A-D]_AIT304 472[E-H]_AIT304
DO concentration
472[A-D]_AIT310 472[E-H]_AIT310

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5.2. Secondary treatment Line – S1

5.2.1. Aeration Tank

5.2.1.1. Aeration Tank Overview

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5.2.1.2. SCADA view presentation

Regulating air valve Air flow
 Similar SCADA view for Aeration tank A/B/C/D

Thermometer

Recirculated
sludge flow Suspended
solids
Dissolved apparatus
oxygen meter Feeding air
valve
Invent Mixer

Recirculation pumps

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5.2.1.3. Regulated air valve control

Regulated air valve is controlled by the pop-up:

Automatic Modes

Manual: the value of opening of the main air valve can be chosen manually.

Auto 1: Operation according to the hour and of the A ir Flow injected.

The starting and the Flow of Air are determined by a table of 24 values, its values corresponding per hour (expressed
in HH:MM) of starting and the Air Flow to be injected.

This mode has to be used only under the responsibility of the process Engineer.

Auto 2: Operation according to the Dissolved Oxygen Concentration on DO sensor 472x_AIT304 or 310 in the Aerobic
Tank.
The operator determines the Concentratio n of Oxygen in the Aerobic Tank

Parameter Auto Mode 2 Advised Value Range High TSS Value Low TSS Value
DO Set point for AIT304 2 mg/l 2 - 2.5 mg/l ↑ ↓
DO Set point for AIT310 3 mg/l 3 - 3.5 mg/l ↑ ↓

Auto Mode 1

Auto Mode 2

To choose which DO
Required % opening of
measure to use
main air valve on
manual mode

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5.2.1.4. Settings of Instrumentation

Temperature Meter: TIT302 TIT304

472A/B/C/D _TIT302 HH: 35°C HH: 35°C
472A/B/C/D _TIT304 LL: 20°C LL: 20°C
AIT304 AIT310 AIT301
Oxymeter
HH: 5.0 mg/L HH: 5.0 mg/L HH: 5.0 mg/L
472A/B/C/D _AIT304
H: 3.0 mg/L H: 3.0 mg/L H: 3.0 mg/L
472A/B/C/D _AIT310
L: 1.5 mg/L L: 1.5 mg/L L: 1.5 mg/L
472A/B/C/D _AIT301
LL: 1.0 mg/L LL: 1.0 mg/L LL: 1.0 mg/L
HH: 4 mg/L
TSS Meter H: 3 mg/L
472A/B/C/D _AIT306 L: 2 mg/L
LL: 1 mg/L

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5.2.1.5. Feeding Air Valve

Feeding air valve is controlled by the pop-up:

Aeration air feed valve control: Operation according to the hour and of the Air Flow injected in the seco nd part of the
Aerobic Tank.

The starting of the air flow is determined by a table of 24 values, its values corresponding per hour (expressed in HH:MM)
of starting, the Process to be desired (DN = Denitrification, N = Nitrification).

DN corresponds to the starting of Air Flow,

N corresponds to the stopping of Air Flow.

In case of high Value of NO 3 - →N

In case of low Value of NO 3 - → DN

This mode has to be used only under the responsibility of the process engineer.

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5.2.2. Aeration tank mixed liquor recirculation (internal recirculation)

Each of the train is equipped with two tube pumps (one in operation, one as stand by) at the outlet of aeration tank, to
raise liquors to a gravity channel feeding back at the outlet of the anaerobic zone.
Each of the pumps is inverter controlled and the flow is adjusted by the operator according to the process re quirement
Aeration tank Mixed Liquor is controlled by the pop -up:

Automatic conditions:
The velocity will be adjusted as per inlet biological flow 406A_FQ301 and the quantity of aeration tank in operation.
It is possible to recirculate from 50 to 400% of the inlet flow.

Calculation of flow entering an aeration tank = total incoming flow to the biological treatment (406A_FIT301 +
406B_FIT301) / Number of Aeration tank in operation (chosen on SCADA through virtual switch).

The flow of recirculation is thus equal to X% of the entering flow:

Wq = X x (406A_FIT 301 + 406B_FIT 301) / (Number of Aer ation tank in operation x 100 )

Analogue flow 472x_FIT303 Regulate Regulation speed pump

Wq PID Flow 472xPO104A/B

Manual Mode pump

instruction Automatic control and conditions (see
previously) or Ask operator
= manual speed pump instruction

In case of flow failure (472x_FIT303 or 406A_FIT301 or 406B_FIT301), automatically, switching in manual mode.

With:
Wq: Pump flow set point (m 3 /h).

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NO 3 - too High
Parameter
Advised Value Range outlet
Auto Mode
aeration tank
X Factor 250% 100 – 400% ↑

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5.2.3. Secondary Settling Tank

5.2.3.1. SCADA view presentation and settings

Blower Spraying Level in the Penstock for sludge

pump sump recirculation flow

Scum removal
pump

This pop-up allows to reduce or increase the speed of the bridge

This pop-up allows choosing the period/duration of the sludge suction process.
This setting must changed only under the supervision of the process engineer.

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5.2.4. Activated Sludge Recirculation

5.2.4.1. SCADA View Presentation

 Recirculation pumping station 488A

Recirculation Extracted
Recirculated Extraction Extracted sump
pumps sludge flow
sludge flow pumps

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5.2.5. External recirculation pump control on 488A

There are 5 submersible pumps within the activated sludge pumping station 488A, one being as stand by.
Each of the pumps is inverter controlled and the flow is adjusted by the operator according to the process requirement.

The recirculation pump is controlled by the pop-up:

These pumps control the activated sludge recirculation flow to the aeration tanks distribution 471 488A_FIT301A/B
according to the instructions given by the operator at SCADA/HMI.

If only one pump is required, an automatic rotation will be carried out all X hours, adjustable by the operator

If more than one pump is required, one pump 488A _PO101A/B/C of tank A and one pump 488A_PO101E/F of the tank
B will be started

2 automatic operating modes will be used: Auto 1 / Auto 2 determine the calculation mode of the sludge recirculation
flow instruction in auto: Wqras1.

Auto Mode 1:
The sludge recirculation flow instruction Qr is determined by a chart of preset daily instructions (receipts), adjustable
by the operator and composed of :
- A 24 pairs of values chart;
- Current hours of the day (e.g. 03:00h, 21:00 h);
- Flow instruction Wqras1 in the hour in m³/h;
On failure of flow meter 488A_FIT301A/B: default value is used to control the speed of the pump.

This mode has to be used only under the responsibility of the process Engineer.

Auto Mode 2:
The speed of the pump is proportional to the incoming flow to the biological treatment (Flow Meter 406A_FIT301 +
406B_FIT301) according to the rate of recirculation Tr :

The flow set point of activated sludge to be recirculated is thus equal to X% of the entering flow:
Wqras2 = Tr x (406A_FIT 301 + 406B_FIT 301) / 1 00 )

Note: Load shedding action: If powered under Genset, the maximum value of Wqras2 will be limited at 150% instead
of 400% of the inlet flow.

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In case of flow failure 406A_FIT301 or 406B_FIT301, automatically, switching mode 2 in mode 1.

With:
Wqras1: Pump flow set point (m 3 /h) in mode Auto 1.
Wqras2: Pump flow set point (m 3 /h) in mode Auto 2.

A number of pumps to be stopped/started:

The number of pump is according to the exit of the PID controller:

Addition of one pump:

If the exit of the PID controller is at the maximum (100%) for more than X1 minutes (adjustable by the operator), then
one additional pump must start;
At this time, the speed of pumps is fixed at an instruction “ MIN START” speed during Y1 seconds, (adjustable by
operator) and the regulator is initialized and must set out again at the end of this timer.

Subtraction of one pump:

If the output of the PID controller is at the minimum (0%) for more than X2 minutes (adjustable by the operator), then
one of the pumps under operation is stopped;
At this time, the speed of pumps is fixed at an instruction “ MAXI START” speed during Y2 seconds, (adjustable by
operator) and the regulator is initialized and must be set out again at the end of this timer.

The minimum of pump under operat ion is one

Auto Mode 1

Auto Mode 2

Parameter Auto Mode 2 Advised Value Range

X1 120s -
X2 120s -
Y1 60s -
Y2 60s -
MAX START 50% -
MIN START 25% -
100 to 150%
TR 120%
Refer to 6. Troubleshooting and Repair

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5.2.6. Extraction pump control

There are 3 submersible pumps within the activated sludge pumping station, one being as stand by.
Each of the pumps is inverter controlled and the flow is adjusted by the operator according to the process requirement.
The pump might also operate on a time/sequence basis.
The Extraction pump control is controlled by the pop-up:

Automatic conditions: These pumps control the activated sludge extraction flow
to the storage of liquid sludge 488A_FIT303 in accordance with the instructions
given by the operator at SCADA/HMI

2 automatic operating modes will be used: Auto 1 / Auto 2 determine the

calculation mode of the sludge extraction volume instruction in auto. In the two
modes, the number of pumps to be started and speed are determined by the
operator on the SCADA.

Auto Mode 1: mode frequency volume

A volume Qsas1 (duration) and a Period timer (freq1) are adjustable from SCADA.

Time frequency Time frequency

t
Sludge
extraction
volume
Set point
QSAS1

0
m3
Sludge extraction
volume

When a drive is requested to run, the following sequence is initiated:

 Start the motor; launch the volume and the period timer,
 When the volume is elapsed, the motor is stopped,
 When the period time is elapsed, the sequence starts again.

On failure of the flow meter 488A_FIT303, the volume is replaced by a running timer RTime (refer to DGT-W-NP-000-
101-xx_PLC-01)

Parameters will be adjusted according to the process engineer and analysis results.

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Auto Mode 2: mode volume

The principle is to extract a volume from sludge according to the volume of water incoming to the biological treatment.
All X m 3 (Qiwb) of water (406A_FQ301+ 406B_FQ301), it is ext ract Ym 3 (Qsas2) from sludge 488A_FQ303

Inlet water
volume
Volume
set point
Qiwb

0
m3
Inlet water volume
Sludge
extraction
volume
Set point
Qsas2

0
m3
Sludge extraction
volume

On failure of sludge flow meter 488A_FIT303, the volume ( Qsas2) is replace by running timer RTime (refer to DGT-W-
NP-000-101-xx_PLC-01).

On failure of water flow meter (406A_FIT301or 406B_FIT301), automatically , switching in mode AUTO1

This Mode has to be used under the responsibility of the process Engineer.

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5.3. Secondary treatment line – S2

5.3.1. Aeration Tanks Distribution chamber – 471B

5.3.1.1. SCADA view presentation

5.3.1.2. Parameters
 General operation
The motorized isolating penstocks to aeration tanks distribution 471B (406DVM402 and 406EVM403) are opened
continuously as soon as they are in automatic mode.

 Startup of the aeration tanks

When the operator puts an aeration tank in service:
o When it is the first aeration tank in service,
The control valve 471x_VZ403 opens at its maximum opening and stays in this position as long as it’s
the only aeration tank in service.
o When one or more aeration tanks are already in service:
The PID of the control valve is first forced at th e percentage of the most opened valve 471xVZ403 of
the tanks in service and then starts to control the position of the valve.

 Flow control to the aeration tanks

After start-up, a PID control function 471xVZ403_PID manages the flow of each aeration tank thr ough the
471x_VZ403 motorized penstocks.

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With

𝑄𝑟𝑎𝑠∗471𝑥_𝑋
471x_QSP = 471x_X * Q pretreated water +
𝑆𝑢𝑚 _471_𝑋

Where:

471x_QSP Flow setpoint for each aeration tank (x=E,F,G or H)

471x_X Aeration tank pretreated water flow percentage setpoint (x=E,F,G or H)

Q pretreated water Pretreated water flow

𝑄𝑟𝑎𝑠 Activated sludge flow recirculated
Sum_471_X Sum of 47x_X (x=E,F,G or H)

If the very high level 471LIT320_LSHH is reached or if the pre -treated flow Q pret reated wat er increases too much over
the time (calculated through an evolution rate function EVOLRATE), all the control motorized penstocks 471xVZ403,
which aeration tank is started and available, are opened at their maximum opening 471xVZ403_MAXOPN % during
471_EVOLRATE_DURATION.

Degraded:

If the aeration tank distribution flowmeter 471xFIT301 is in fault, the position set point of the motorized penstock
is equal to the average setpoint of the other motorized penstocks in operation of which the flowmeter is available.

 Accessibility

Penstocks PID controller is controlled by the pop-up:

In manual mode, the operator can set the opening set point of
the penstock.
In auto mode, the percentage setpoint is displayed in the
checkbox “manual setpoint”.

With this switch button, operator can control the PID mode
(auto or manual).

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 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION /U TILITY

Aeration tank E/F/G/H pretreated water
471E/F/G/H_X 12.5 % 0 – 100
flow percentage setpoint
Activated sludge recirculation rate
471AS_X 90 % 0 - 300
setpoint
471E/F/G/HVZ403_MSP 25 % 0 – 100 PID manual value
Evolution rate parameter to wide open all
471xVZ403 penstocks
471_EVOL_RATE 90 % 0 – 100 If Q pretreated water is above this valueduring
10 sec, Force the penstocks to maximum
opening value
Duration parameter to wide open all
471_EVOLRATE_DURATION 300 sec 0 - 3600
471xVZ403 penstocks
Number of elements for calculating the
471_FIFO_X 20 - 1 - 60 moving average of the total distributed
flow to tanks E, F, G H
Evolution time parameter to wide open all
471_EVOL_T 20 min 1 - 60
471xVZ403 penstocks
GlobalFlow_HH 26000 m3/h 0-30000 Global inlet flow very high
Extension5Flow_HH 13000 m3/h 0-30000 Extension 5 inlet flow very high
Motorized controlled penstocks to
471E/F/G/HVZ403_MAXOPN 30 % 0 – 100
aeration tanks maximum opening

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5.3.2. Aeration Tanks

5.3.2.1. SCADA view – Aeration tanks E/F/G/H Overview

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5.3.2.2. SCADA view - Aeration tanks

 SCADA view Aeration Tank E

Blower for
degasing chamber

Valve for connection

to clarifier I&J (From
aeration tanks F/G/H)
Aeration Tank Mixed
liquor Pump

 SCADA views Aeration Tanks F/G/H (similar views)

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5.3.2.3. Parameters
 Mixing in the aeration tanks
When an aeration tank is in operation, its mixers / aerator -mixers are running continuously:
- mixers 472F/G/HQG103 (pre-anaerobic zone)
- mixers 472F/G/HQG103A/B (anaerobic zone)
- mixers 472F/G/HQG102_ (anoxic zone)
- aerators-mixers 472F/G/HAA101A/B/C/D/E/F/G/H (aeration zone)

 Air injection in the aerated zone - 711xVZ403

The aeration operating principle depends on the Auto mode selector AUTO 1: “Time Basis” / AUTO 2: “Oxygen
control” in order to position the air control valve.

o AUTO 1: “Time Basis”: Virtual Selector on “AUTO 1” position

Air flow rate set-point depends on the time of day where 24 adjustable set -points (1 per hour slot) are available on
the SCADA screen. The air flow rate set-point is supplied from the daily chart by comparing the time of day and the
time slots where the corresponding adjustable air flow r ate set-points are.
A time period ends at the start time for another time period.

The daily chart can be adjusted on request by the operator from the SCADA.
The daily chart is composed of 24 pairs of values:
- Current hour of the day,
- Air flow rate set-point in the hour.

This daily chart can be adjusted on request by the operator from the SCADA and is composed of 24 * 3 values:
- Hour
- Minute
- Air flow rate set-point

Daily Chart:
Instructions Hour:Minutes Air flow set point – Nm 3 /h
711xAUTO1_SP
H1 00:00 to 01:00 9000
H2 01:00 to 02:00 9000
H3 02:00 to 03:00 9000
H4 03:00 to 04:00 9000
H5 04:00 to 05:00 9000
H6 05:00 to 06:00 9000
H7 06:00 to 07:00 9000
H8 07:00 to 08:00 9000
H9 08:00 to 09:00 9000
H10 09:00 to 10:00 9000
H11 10:00 to 11:00 9000
H12 11:00 to 12:00 9000
H13 12:00 to 13:00 9000
H14 13:00 to 14:00 9000
H15 14:00 to 15:00 9000
H16 15:00 to 16:00 9000
H17 16:00 to 17:00 9000
H18 17:00 to 18:00 9000
H19 18:00 to 19:00 9000
H20 29:00 to 20:00 9000
H21 20:00 to 21:00 9000
H22 21:00 to 22:00 9000
H23 22:00 to 23:00 9000
H24 23:00 to 24:00 9000

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o AUTO 2: “Oxygen Control”: Virtual Selector on “AUTO 2” position

Air flow rate setpoint is controlled based on the dissolved oxygen measurement value 472F/G/H_AIT304_ or
472F/G/H_AIT310_ (selectable switch on SCADA).
The air flow rate setpoint is calculated in order to maintain constant the dissolved oxygen measurement.

Note: The air flow setpoint PID is a slow control

Degraded:
- In case of fault of the active oxygen measurement p robe, the second probe is used for the air control.
- In case of fault on all dissolved oxygen probes, the PLC changes to Auto 1 mode and an alarme is raised.
- On failure of flow meter 711xFIT307, the default value is used to control the position of the valve .

In all AUTO modes, the air flow rate PID set -point 711xVZ403_SP is always checked and must be included between
minimum and maximum adjustable set-point values (711xVZ403MIN_SP & 711xVZ403MAX_SP air flow rate
measurement set-points). If not, then the air flow rate set-point is limited to these values.

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 Accessibility

Air regulation is controlled by the pop-up:

With this switch button, Operator can adjust the current

operator can select the auto hour of the day and the air flow
mode control. rate set point of the daily chart.

With this switch button, Air flow start set-point or Auto

Common air flow rate and valve
operator can select which mode 2 can be set by the
position set-points can be set by
dissolved oxygen analyser is operator. the operator.
active in order to control the
air regulation valve

 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION / UTILITY

472F/G/HAIT304_HH 2.5 mg/L 0 - 10 Alarm
If active
Dissolved
Dissolved
oxygen
472F/G/HAIT304_H 2 mg/L 0 - 10 oxygen probe,
measurement
adjust the air
set point
regulation
472F/G/HAIT304_M 1 mg/L 0 - 10 valve -
472F/G/HAIT304_L 0.75 mg/L 0 - 10 472xVZ403 -
472F/G/HAIT304_LL 0.5 mg/L 0 - 10 Alarm
472F/G/HAIT310_HH 5 mg/L 0 - 10 Alarm
If active
472F/G/HAIT310_H 4 mg/L 0 - 10 Dissolved -
oxygen probe,
Dissolved
adjust the air
oxygen
472F/G/HAIT310_M 3 mg/L 0 - 10 regulation
measurement
valve
set point
472xVZ403
472F/G/HAIT310_L 2 mg/L 0 - 10 -

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472F/G/HAIT310_LL 1 mg/L 0 - 10 Alarm

-500 -
472F/G/HAIT301_HH 400 mV
500
-500 -
472F/G/HAIT301_H 300 mV 500

-500 - Redox measurement

472F/G/HAIT301_M 200 mV 500
-500 -
472F/G/HAIT301_L 100 mV
500
-500 -
472F/G/HAIT301_LL 50 mV
500
472F/G/HAIT306_HH 4 mg/L 0 - 10 Alarm
472F/G/HAIT306_H 3.5 mg/L 0 - 10 Suspended -
472F/G/HAIT306_M 2.7 mg/L 0 - 10 solids -
measurement
472F/G/HAIT306_L 2 mg/L 0 - 10 -
472F/G/HAIT306_LL 1 mg/L 0 - 10 Alarm
472F/G/HTIT306_HH 38 °C 0 - 50 Dissolved Alarm
472F/G/HTIT306_H 35 °C 0 - 50 oxygen -
472F/G/HTIT306_M 30 °C 0 - 50 measurement -
472F/G/HTIT306_L 25 °C 0 - 50 probe -
temperature
472F/G/HTIT306_LL 20 °C 0 - 50 measurement Alarm
711F/G/HAUTO1_SP[01] Array of
Auto mode 1, 24 air flow set-
711F/G/HAUTO1_SP[02] 24
9000 Nm3/h points daily chart adjustment
… elements
(Flow)
711F/G/HAUTO1_SP[24] 0-20000
711F/G/HAUTO1_HH[01] [0,1,2,3, Array of Auto mode 1, 24 air flow set-
711F/G/HAUTO1_HH[02]
… h 24 points daily chart adjustment
…
elements (Hour)
711F/G/HAUTO1_HH[24]
23]
711F/G/HAUTO1_MIN[01] [0,1,2 Array of
Auto mode 1, 24 air flow set-
711F/G/HAUTO1_MIN[02] 24
… min points daily chart adjustment
… elements
(Minute)
711F/G/HAUTO1_MIN[24] 0-59
58,59]
711F/G/HVZ403_T1 Air flow rate mini/maxi setpoint
1 h 0 - 1000
AIR FLOW RATE LIMIT limitation for a long period
Auto mode 1: Minimum air flow
711FVZ403MIN_SP
1000 Nm3/h 0-6500 rate measurement setpoint
Qair min
adjustment
Auto mode 1: Maximum air flow
711FVZ403MAX_SP
15000 Nm3/h 0-20000 rate measurement setpoint
Qair max
adjustment

711F/G/HVZ403_MSP 25 % 0 – 100 PID manual value

711F/G/HVZ403MIN_POS
18 % 0 - 100 Minimum opening percentage
MIN.VALVE OPENING
711F/G/HVZ403_DVP
Default value position when
POS.WHEN FAULT 18 % 0 – 100
711FFIT307 is in fault
711F/G/HFIT307

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 Air injection in the second aerated zone - 711xVM405 (Nitrification/Denitrification)

The air injection isolating motorized valves 711xVM405 controls the air flow rate to the second aerated zone of the
aeration tank in accordance with the instructions given by the operator in the SCADA. It is used for the sequence of
Nitrification (aeration) and Denitrification (no aeration). The sequence is given by a chart of 24 pairs of values:
- Current hour of the day
- Nitrification / Denitrification

o 711xVM405 valve
If the selector for the selection of the Dissolve Oxygen probe is in 472xAIT310 position and the aeration in AUTO2
then the 711xVM405 valve is opened continuously.

Otherwise:
The 711xVM405 is opened when:
- The nitrification is selected at the current time and the dissolve oxygen is low:
711xVM405_MODE=0 AND 472xAIT310_ASL
- The denitrification is selected at the current time and the redox measure is low:
711xVM405_MODE=1 AND 472xAIT301_ASL

The 711xVM405 is closed when:

- The nitrification is selected at the current time and the dissolve oxygen is high:
711xVM405_MODE=0 AND 472xAIT310_ASH
- The denitrification is selected at the current time and the redox measure is high:
711xVM405_MODE=1 AND 472xAIT301_ASH

Degraded:
The valve 711xVM405 opens:
- If the Dissolve Oxygen 472xAIT310 is in fault AND the nitrification is selected.
- Or If the redox 472xAIT301 is in fault AND the denitrification is selected.

Chart of nitrification/denitrification:

H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12

H:Min 00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00
Sequence N N N N N N N N N N N N
H13 H14 H15 H16 H17 H18 H19 H20 H21 H22 H23 H24
H:Min 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00
Sequence N N N N N N N N N N N N

The PLC scans every minute the chart to extract to corresponding setpoint: Nitrification or Denitrification.
A time period ends at the start time for another time period.

 Accessibility

Air injection in the second aerated zone is controlled by the pop-up:

Operator can adjust the current hour of the day and the sequence D (Denitrification – no
aeration) or N (Nitrification – aeration) of the daily chart.

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 Control Action

D EFAULT F UNCTION / UTILITY

P ARAMETER U NIT R ANGE
VALUE
472F/G/HAIT310_HH 5 mg/L 0 - 10 Alarm
In Nitrification
472F/G/HAIT310_H 4 mg/L 0 - 10 mode: close air
valve VM405
Dissolved oxygen
472F/G/HAIT310_M 3 mg/L 0 - 10 -
measurement
In Nitrification
472F/G/HAIT310_L 2 mg/L 0 - 10 mode: open air
valve VM405
472F/G/HAIT310_LL 1 mg/L 0 - 10 Alarm
472F/G/HAIT301_HH 400 mV -500 - 500 -
In Denitrification
472F/G/HAIT301_H 300 mV -500 - 500 mode: close air
valve VM405
472F/G/HAIT301_M 200 mV -500 - 500 Redox measurement -
-500 - 500 In Denitrification
472F/G/HAIT301_L 100 mV mode: open air
valve VM405
472F/G/HAIT301_LL 50 mV -500 - 500 -
711F/G/HAUTO2.START_SP
13000 Nm3/h 0 - 20000 Air flow start setpoint
AIR FLOW START SETPOINT

 Mixed liquor recirculation

The mixed liquor recirculation canister pump 472xPO104A or B runs continuously when the train x is in operation.
The mixed liquor recirculation canister pumps 472xPO104A or B are controlled according to:
- a mixed liquor recirculation rate 47 2x_XML defined by the operator,
- the aeration tank flow measurement 471xFIT301,
- and the mixed liquor recirculation flow measurement 472xFIT303.

The mixed liquor recirculation flow set point for one aeration tank 472x_QML is calculated by multiplying the
pretreated water flow entering the aeration tank with mixed liquor recirculation rate 472x_XML (defined by the
operator):
472x_QML = Q x pretreated water * 472x_XML

A PID regulation function 472xPO104_PID allows the flow control of mixed liquor recirculation:

If the flow setpoint 472x_QML is lower or equal to 0, the pumps are stopped.

In case of failure of a pump 472xPO104A or B, there is an automatic switch over with the stand -by pump. The pump in
duty runs continuously as long as the maximum running time for changeover is not elapsed.

Degraded:

In case of fault on the inlet flowmeter 472xFIT301 (or in case of loss of communication between the PLC#1 and the
PLC#4 for the tank E) or recirculation mixed li quor 472xFIT303, the PID controlling the mixed liquor recirculation pump
switches automatically in manual mode and the pump is operated on a preset manual set point.

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 Accessibility

Duty and stand-by pump is controlled by the pop-up:

Pumps PID controller is controlled by the pop-up:

With this switch button,

operator can select the PID
mode (Auto / manual).

Manual PID set point for pump

speed command can be set.

Operator can define the mixed

liquor recirculation rate taken
into account in order to
determine the mixed liquor
recirculation flow.

 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION /U TILITY

472F/G/HFIT303_HH 6000 m3/h 0 - 7200 -
472F/G/HFIT303_H 5000 m3/h 0 - 7200 -
472F/G/HFIT303_M 3000 m3/h 0 - 7200 -
472F/G/HFIT303_L 1000 m3/h 0 - 7200 -
m3/h 0 - 7200 After 30 sec, Stop the running pump
472F/G/HFIT303_LL 500 and automatic switchover to the
other pump
472F/G/H_XML Adjust Mixed liquor recirculation
Recirculation Rate 175 % 0 - 400 depending of the aeration tank flow
Tank F/G/H measurement
472F/G/HPO104_MSP 50 % 0 - 100 PID manual value

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5.3.3. Air Production for Aeration 711B

5.3.3.1. SCADA view presentation

5.3.3.2. Parameters

Fans

No fans (711CV102F/G/H // 103F/G/H) are requested to run if the related blower 711CP101F/G/H is stopped.

Only 1 fan (711CV102F/G/H or 711CV103F/G/H) is requested to run if the related blower 711CP101F/G/H is
running.

Both fans are requested to run if the rela ted blower 711CP101F/G/H is running and if the corresponding high
temperature switch 711TISH305F/G/H is activated for the duration of an adjustable timer 711TISH305F/G/H_X.

After the stop of the blower the fan(s) in operation continues to run during a timer 711CV102F/G/H_X before
stopping.

Cooling system

If the cooling system is used, opening 922VY422F/G/H on running confirmation of the associated blower
711CP101F/G/H. Closing after an adjustable temporization 922 VY422F/G/H_X, on stopping confirmation of the
associated blower .

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 Accessibility

Blowers flow is controlled by the pop-up:

Operator can set the minimum

air flow setpoint and timer
before stopping the blower.

Blower’s data can be consulted by the pop-up:

On this pop-up the operator can consult all the data settled in the Continental PLC.

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 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION /U TILITY

711PIT351A_HH
711PIT351B_HH
900 mbar 0 – 1000 Alarm
(Redundant measure)

711PIT351A_H
711PIT351B_H 900 mbar 0 – 1000 -
(Redundant measure)
711PIT351A_M
Pressure measurement setpoint
711PIT351B_M 840 mbar 0 – 1000
Set on the Continental skid HMI
(Redundant measure)
711PIT351A_L
711PIT351B_LL 750 mbar 0 – 1000 -
(Redundant measure)
711PIT351A_LL
711PIT351B_LL 750 mbar 0 - 1000 Alarm
(Redundant measure)
711TISH305F/G/H_X
Timer setpoint for high temperature
High Temp. Reached 60 sec 0 - 300
reached confirmation
Timer
922VY422F/G/H_X
60 sec 0 – 120 Timer setpoint before closing valve
Closing Timer Valve
Minimum air flow before stopping
711CP101_MinFlow the blower
9500 Nm3/h 0 - 20000
SP Minimum air flow If sum of the air flow readings is
lower, stop the blowers
711CP101_T
Timer for minimum air flow before
Timer minimum air 2 min 0 – 15
stopping the blower
flow
711CV102F/G/H_X Timer setpoint before stopping the
60 sec 0 - 900
Stop Timer Fan fans

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5.3.4. Deaeration of Activated Sludge – 481B

5.3.4.1. SCADA view presentation

5.3.4.2. Parameters

One Degassing air blower 481BCS101A or B (one duty and one stand-by with cyclic permutation every
481BCS101_X minutes between the 2 air blowers) is continuously running for the degassing process of the inlet
water within the distribution structure.

The degassing air blower enclosure fan 481BCV102A/B runs continuously when the corresponding blower runs.
It stops 481BCS102_T minutes after the stopping of the corresponding blower.

In case of failure of the duty blower 481BCS101A/B or a low flow 481BPISL303 or the unavailability of the
corresponding fan, there is an automatic switch over with the stand -by blower.

 Accessibility

The set point for cyclic permutation can be set:

The timer to stop the fan can be set:

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 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION /U TILITY

481BCS101_X Setpoint for cyclic permutation
1440 min 0-43200
Change over timer between the 2 air blowers
481BCV102_T
10 min 0-120 Timer to stop the fan
Prolongation timer

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5.3.5. Secondary Settling Tanks

5.3.5.1. SCADA view presentation

SCADA views are similar for S ST M-N & SST O-P

5.3.5.2. Parameters

A local switch with 3 positions “Normal”, “Stop” and “Adjustment” makes it possible to the operator to define the
possibilities of access to the scraper bridge.

Bridge:

In "Normal" position:

The scraper bridge 482xQP101 runs permanently.

In “Stop” position:

The bridge 482xQP101 continues to run as long as it is not detected in front of the gate. When the bridge is in
front of the gate (482xZS101 = 1), it stops and the operator can go up on the bridge. It can then be restarted by
the operator with a local START/STOP push -button. The operator brings into operation the bridge when he goes
down from there and turns the switch in "normal" position.

In “Adjustment” position:

The bridge 482xQP101 continues to run as long as it is not detected in front of the gate. When the bridge is in
front of the gate, it stops and the operator can go up on the bridge. The operator can then bring into operation

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the bridge, the blower 482xCS103 and the anti-scum pump 482xPO102 by the embarked push buttons. The bridge
stops in front of the gate by switch 482xZS101 after a turn.

At any moment, the operator can stop the bridge, the blower and the anti -scum pump and then to start again it,
thanks to the embarked push buttons. The operator brings in to operation the bridge when he goes down from
there and turns the switch in "normal" position.

Blowers:

In “Normal” position:
Blower for air-lift sludge suction 482xCS103 is discontinuously running ( 482x_T4 period / 482x_T3 duration
operation).

In “Adjustment” position:
Blower for air-lift sludge suction 482xCS103 is discontinuously running ( 482x_T4 period / 482x_T3 duration
operation) until 482xZS101 is reached and it can then be restarted by the operator with a local START/STOP
push-button.

In “Stop” position:
Blower for air-lift sludge suction 482xCS103 is discontinuously running ( 482x_T4 period / 482x_T3 duration
operation) until 482xZS101 is reached.

Pump for floating matters sprayers:

In “Normal” position:
Pump for floating matters sprayers 482xPO10 2 is discontinuously running (482x_T6 period / 482x_T5 duration
operation).

In “Adjustment” position:
Pump for floating matters sprayers 482xPO102 is discontinuously running ( 482x_T6 period / 482x_T5 duration
operation) until 482xZS101_ is reached and it c an then be restarted by the operator with a local START/STOP
push-button.

In “Stop” position:
Pump for floating matters sprayers 482xPO102 is discontinuously running ( 482x_T6 period / 482x_T5 duration
operation) until 482xZS101 is reached.

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Activated sludge transfer:

Motorized penstock (482K/L/M/N/O/PVM401) control for activated sludge recirculation.

Closing:

When the activated sludge recirculation flow decreases, the level in the suction pit increases:

 If the high redundancy level threshold of the sludge recirculation tank 488CLIT301/3_LSH is reached, the
motorized controlled penstock for sludge recirculation closes of 488 K/L/M/N/O/P_X1% to reduce the
flow from the clarifier.

 If the high redundancy level threshold of the sludge recirculation tank 488CLIT 301/3_LSH remains reached
for 488 K/L/M/N/O/P_Y1 time, the motorized controlled penstock for sludge recirculation closes again
of 488 K/L/M/N/O/P_X1%.

Opening:

When the activated sludge recirculation flow increases, the level in the suction pit decreases:

 If the low redundancy level threshold of the sludge recirculation tank 488CLIT301/3_LSL is reached, the
motorized controlled penstock for sludge recirculation opens of 488 K/L/M/N/O/P_X2% to increase the
flow from the clarifier.

 If the low redundancy level threshold of the sludge recirculation tank 488CLIT301/3_LSL remains reached
for 488 K/L/M/N/O/P_Y2 time, the motorized controlled penstock for sludge recirculation opens again
of 488 K/L/M/N/O/P_X2%.

Stationary:

 If the redundancy level measurement of th e sludge recirculation tank 488CLIT301/3 is between LSL
and LSH, the motorized controlled penstock for sludge recirculation does not move.

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 Accessibility

Blowers, pumps and bridge setpoints are controlled by the pop up:

Motorized penstocks and

sludge recirculation tank level
timer set points can be set.

Blower & pump timer set

points can be set.

Scaper bridge speed set point

can be set.

 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION /U TILITY

Secondary settling tank scraper
482K/L/M/N/O/P_T2 60 min 0-180
bridge position detection timer
Blower for air-lift sludge suction
482K/L/M/N/O/P_T3 25 min 0-10000
running timer
Blower for air-lift sludge suction
482K/L/M/N/O/P_T4 30 min 0-10000
operating period timer
Pump for floating matters sprayers
482K/L/M/N/O/P_T5 10 min 0-10000
running timer
Pump for floating matters sprayers
482K/L/M/N/O/P_T6 30 min 0-10000
operating period timer
Secondary settling tank scraper
482K/L/M/N/O/PQP101_S 50 % 0 – 100
bridge speed setpoint
Motorized controlled penstocks for
482K/L/M/N/O/P_X1 3 % 0-100
sludge recirculation closing rate
Sludge recirculation tank high level
482K/L/M/N/O/P_Y1 2 min 0-1000
timer
Motorized controlled penstocks for
482K/L/M/N/O/P_X2 3 % 0-100
sludge recirculation opening rate
Sludge recirculation tank low level
482K/L/M/N/O/P_Y2 2 min 0-1000
timer
488CLIT303_HH
Redundant with 7 m 0 - 10 Activated Alarm
488CLIT301_HH sludge
488CLIT303_H 0 - 10 recirculation Motorized
Redundant with 6.8 m 488C - penstocks
488CLIT301_H recirculation closing
488CLIT303_M 0 - 10 tank level
Redundant with 5 m measurement -
488CLIT301_M

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488CLIT303_L 0 - 10 Motorized
Redundant with 4.8 m penstocks
488CLIT301_L opening
488CLIT303_LL 0 - 10
Redundant with 4 m Alarm
488CLIT301_LL

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5.3.6. Activated Sludge Recirculation

5.3.6.1. SCADA View presentation of RAS pumping station – 488B

Recirculated
sludge flow

Recirculation Recirculation
pump pumping
station level

5.3.6.2. SCADA View presentation of RAS pumping station – 488C

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5.3.6.3. Parameters

a) Activated Sludge recirculation flow and recirculation pump control

The activated sludge recirculation pumps 488CPO101A/B/C/D/E control the activated sludge recirculation
flow 488CFIT302A/B to the aeration tanks distribution in accordance with the instructions given by the
operator in the SCADA.

In auto modes, the activated sludge recirculation pump flows are calculated through a PID control algorithm
in order that the measured activated sludge recirculation flow 488CFIT302A/B is equal to the calculated
activated sludge recirculation pump flow setpoint according to one of the automatic mode described below.

A virtual switch on the SCADA allows the operator to choose between 2 automatic modes “Auto 1 / Auto 2”
for the activated sludge recirculation pump flow set -point calculation.

Auto 1 “Time basis”:

The activated sludge recirculation flow set point depends on the time of day where 24 adjustable set -points
(1 per hour slot) are available on the SCADA. The activated sludge recirculation flow set point is supplied
from the daily chart by comparing the time of day and the time slots where the corresponding adjustable
activated sludge recirculation flow set points are.

This daily chart can be adjusted on request by the operator from the SCADA and is composed of 24 * 3
values:

 Hour
 Minute
 Activated sludge recirculation flow rate set-point

Daily Chart:
Instructions Hour:Minutes Flow set point – m 3 /h

H1 00:00 to 01:00 2500

H2 01:00 to 02:00 2500
H3 02:00 to 03:00 2500
H4 03:00 to 04:00 2500
H5 04:00 to 05:00 2500
H6 05:00 to 06:00 2500
H7 06:00 to 07:00 2500
H8 07:00 to 08:00 2500
H9 08:00 to 09:00 2500
H10 09:00 to 10:00 2500
H11 10:00 to 11:00 2500
H12 11:00 to 12:00 2500
H13 12:00 to 13:00 2500
H14 13:00 to 14:00 2500
H15 14:00 to 15:00 2500
H16 15:00 to 16:00 2500
H17 16:00 to 17:00 2500
H18 17:00 to 18:00 2500
H19 18:00 to 19:00 2500
H20 29:00 to 20:00 2500
H21 20:00 to 21:00 2500
H22 21:00 to 22:00 2500
H23 22:00 to 23:00 2500
H24 23:00 to 24:00 2500

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Auto 2 “Flow control”:

The operator defines in the SCADA the activated sludge recirculation rate: 471AS_X (%). The flow of the
activated sludge recirculation from the existing clarifiers I and J is not pumped by the new activated sludge
pumps but is measured on the new flowmeters. Therefore, t he activated sludge recirculation flow set point
for the pumps is calculated as follows.

 When the selector (located on SCADA view – AERATION TANK DISTRIBUTION 471B) for motorized
penstock is in “OPENING” position:

488CAUTO2_SP = [(471AS_X*(471F_X+471G_X+4 71H_X))*Q pretr eated water ]- 488B2_FIT303

 When the selector is in “INLET” position:

488CAUTO2_SP = [(471AS_X*((471F_FLOW_SP/ Q pr etr eated water ) + (471G_FLOW_SP/ Q pr etreatedwa ter ) +

(471H_FLOW_SP/ Q pretreatedwa ter ))) * Q pretreatedwater ] - 488B2_FIT303

Then the PLC compares this calculated activated sludge recirculation flow set point with the sliding average
of activated sludge recirculation flow measurement AVR_SW(488C_FIT302A+B) and controls the speed and
numbers of pumps accordingly.

Speed and numbers of pumps:

The number of pumps is given according to the output of the PID controller:

o Addition of one pump:

If the output of the PID controller is at the maximum (100%) for more 488CPO101_X1 seconds (adjustable by the
operator) then one additional available pump is started.

At this time, the speed of the pumps is fixed at an adjustable speed 488CPO101_MINSTART during 488CPO101_Y1
seconds and the PID control is initialised to this value and must start again at the end of this timer.

o Decreasing of one pump:

If the output of the PID controller is at the minimum (0%) for more 488CPO101_X2 minutes (adjustable by the
operator) then one of the running pumps is stopped.

At this time, the speed of the pumps is fixed at an adjustable speed 488CPO101_MAXSTART speed dur ing
488CPO101_Y2 seconds and the PID control is initialised to this value and must start again at the end of this
timer. The minimum number of running pumps is one

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Output of the
PID controller

100 %

0%
X1 X1 t
X2

3
Number of
pumps
2

Speed set point

100 %
Max to start

Min to start
0%
Y1 Y1 Y2

o The pumps will perform cyclic permutation at each start and au tomatic changeover in case of fault

o If only one pump is required, an automatic rotation will be carried out every 488CPO101_X hours,
adjustable by the operator.

o If more than one pump is required, at least one pump 488CPO101A/B/C of first tank and one pump
488CPO101D/E of the second tank will be started .

The flow setpoint in mode auto 2 to control the existing activated sludge recirculation pumps of clarifier I and
J (488BPO101A/B) will be modified in PLC#1:

ZN488B_PO101_WQRAS2 := (471AS_X * 471E_QSP) / (1 + 471AS_X)

If the aeration tank E is not in operation, the setpoint will be equal to 0. The pumps will be stopped in case of
high level switch in the discharge channel 488CLSH302.

Degraded:

 In case of one flow measurement failure (471E/F/G/HFIT301 or 488B2_FIT303), Auto 2 mode is automatically
switched into Auto 1 mode.

 If one flowmeter 488CFIT302A/B is in fault, the recirculation flow rate will be equal to 2 times the value from
the remaining flowmeter in service.

 If both flowmeter 488CFIT302A/B are in fa ult, the number of pumps in operation will not change as well as
the speed setpoint of the pump.

 In case of loss of communication between PLC#1 and PLC#4, the existing activated sludge recirculation pumps
of clarifier I and J will be put in Auto 1 .

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 Accessibility

Activated sludge recirculation flow is controlled by the pop -up:

With this switch button, Operator can adjust the current

operator can select the auto hour of the day and the air flow
mode control. rate set point of the daily chart.

Activated sludge recirculation pump is controlled by the pop -up:

Activated sludge recirculation

pump set-points can be set
here.

With this pop-up, operator can

access to the PID controller
window.

Activated sludge recirculation pump PID is controlled by the pop-up:

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With this switch button, operator

can control the PID mode (auto
or manual).

 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION /U TILITY

488CAUTO1_SP[01]
Array of 24 24 sludge recirculation flow set-points
488CAUTO1_SP[02]
2500 m3/h elements daily chart adjustment
…
0-30000 For Auto mode 1 (Flow)
488CAUTO1_SP[24]
488CAUTO1_HH[01] [0,1,2,3, 24 sludge recirculation flow set-points
488CAUTO1_HH[02] Array of 24
… h daily chart adjustment
… elements
For Auto mode 1 (Hour)
488CAUTO1_HH[24]
23]
488CAUTO1_MIN[01] [0,1,2,3, Array of 24 24 sludge recirculation flow set-points
488CAUTO1_MIN[02]
… min elements daily chart adjustment
…
0-59 For Auto mode 1 (Minute)
488CAUTO1_MIN[24]
59]
488CPO101_MSP 25 % 0 - 100 PID manual value
488CPO101_X1 Activated sludge recirculation pump
30 s 0-3600
Max Time in 100% SP Max Time in 100% SP
488CPO101_Y1 Activated sludge recirculation pump
30 s 0-3600
Min Force Time SP Min force Time SP
488CPO101_X2 Activated sludge recirculation pump
30 s 0-3600
Max Time in )% SP Max Time in 0% SP
488CPO101_Y2 Activated sludge recirculation pump
30 s 0-3600
Max Force Time SP Max force Time SP
488CPO101_MINSTART Activated sludge recirculation pump
20 % 0 - 100
Min Speed to Start SP Min speed to start SP
488CPO101_MAXSTART Activated sludge recirculation pump
80 % 0 - 100
Max Speed to stop SP Max speed to stop SP
Activated sludge recirculation
488CPO101_N 2 - 0-5 pumps number when PID in manual
mode
Automatic rotation every X hours
488CPO101_X 8 h 0-1000
when one pump is running

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Number of elements for calculating

488_FIFO_X 1 - 1-60 the moving average of the activated
sludge recirculation
488CFIT302A/B_HH 10000 m3/h 0 - 15000 -
488CFIT302A/B_H 8000 m3/h 0 - 15000 -
488CFIT302A/B_M 5000 m3/h 0 - 15000 Activated sludge -
488CFIT302A/B_L m3/h 0 - 15000 recirculation If at least 2
488C - pumps are
1000 Recirculation running, Stop
flow the pumps and
measurement change over
488CFIT302A/B_LL m3/h 0 - 15000 Stop the pump
500
and change over

b) Pump the surplus activated sludge

In Auto mode, the PLC maintains, through a PID, the level of the 610B SAS Balancing Tan k by controlling the
pumps 488CPO102A/B/C (two on duty, one on stand-by) with the following principles :

 If the medium level threshold of the tank level measurement (610B1LIT350/610B2LIT350) is not
reached:

 The PID flow set-point is start with the 488CPO102_START_SP;

 If the tank level decrease, the 488CPO102_ADJUST set -point is added to the actual PID flow set-
point;

 If the tank level increase, the PID flow set-point does not change;

 If the medium level threshold of the tank level measurement is reached, t he PID flow set-point is
equal to the sum of calculated set-point of GBT feeding and dilution pumps:

488CSAS_PID_FLOW _SP = ∑600B_QS + 610PO161A/B/C/D/E_Q

The number of pumps is given according to the output of the PID controller:

Addition of one pump:

If the output of the PID controller is at the maximum (100%) for more than 488CPO102_X1 seconds) then one
additional available pump is started.

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At this time, the speed of the pumps is fixed at an adjustable 488CPO102_MINSTART speed during
488CPO102_Y1 seconds and the PID control is initialised and must set out again at the end of this timer.

Decreasing of one pump:

If the output of the PID controller is at the minimum (0%) for more than 488CPO102_X2 seconds then one of
the running pumps is stopped.

At this time, the speed of the pumps is fixed at an adjustable 488CPO102_MAXSTOP speed during
488CPO102_Y2 seconds and the PID control is initialised and must set out again at the end of this timer.

The minimum number of running pumps is one. If only one pump is required, an automatic rotation will be
carried out every 488CPO102_X hours .

Output of the
PID controller

100 %

0%
X1 t
X2

2
Number of
pumps
1

Speed set
point

100 %
Max to start

Min to start
0%
Y1 Y2

Degraded:

If the level measurement 610B1LIT350 / 610B2LIT350 on the SAS Balancing Tank 610B are not available, the
PID is automatically set in manual mode and therefore the speed and number ( 488CPO102_N setpoint) of
running pumps are fixed by the operator.

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 Accessibility

Activated sludge extraction pump is controlled by the pop -up:

Activated sludge extraction

pump set-points can be set
here.

With this pop-up, operator can

access to the PID controller
window.

Activated sludge extraction pump PID is controlled by the pop -up:

In manual mode, the operator can set the speed set point of the
pumps and the number of pumps in operation.

With this switch button, operator can control the PID mode
(auto or manual).

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 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION /U TILITY

488CPO102_X1 Activated sludge recirculation SAS
30 s 0-3600
Max Time in 100% SP pump Max Time in 100% SP
488CPO102_Y1 Activated sludge recirculation SAS
30 s 0-3600
Min Force Time SP pump Min force Time SP
488CPO102_X2 Activated sludge recirculation SAS
30 s 0-3600
Max Time in 0% SP pump Max Time in 0% SP
488CPO102_Y2 Activated sludge recirculation SAS
30 s 0-3600
Max Force Time SP pump Max force Time SP
Activated sludge recirculation SAS
488CPO102_MINSTART
25 % 0-100 pump Min speed when starting a
Min Speed to start SP
new pump SP
Activated sludge recirculation SAS
488CPO102_MAXSTOP
50 % 0-100 pump Max speed when stopping a
Max Speed to Stop SP
pump SP
488CPO102_X
Automatic rotation Automatic rotation every X hours
8 h 0 – 100
every X hours of when one SAS pump is running
pumps
488CPO102_N Activated sludge recirculation SAS
SAS pumps number in 1 - 0-2 pumps number when PID in manual
PID manual mode mode
488CPO102_MSP 25 % 0-100 PID manual value
488CPO102_START_SP
Starting flow SP when
250 m3/h 0 – 1000 PID flow starting set-point
the tank is above
medium level
488CPO102_ADJUST
15 m3/h 0 – 100 PID flow set-point increase
Adjustement flow SP
488CFIT301_HH 700.0 m3/h 0 - 1000 -
488CFIT301_H 600.0 m3/h 0 - 1000 -
488CFIT301_M 300.0 m3/h 0 - 1000 -
488CFIT301_L m3/h 0 - 1000 Operator action is required to make
200.0
changeover
If other pump available, stops the
488CFIT301_LL 100.0 m3/h 0 - 1000 pump in operation and permutation
of the pump in operation

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5.4. Shock chlorination

5.4.1.1. SCADA View presentation

5.4.1.2. Parameters

When injection for Shock-chlorination is selected (by positioning manual valves 851VH564/544/554), the
Sodium Hypochlorite dosing pump runs continuously at the speed calculated (refer below to Speed
conversion).

It can also run in Frequency/Duration if it’s selected by the operator (851NaOCl_Mode_581=1) and if
injection in the BT is selected (851NaOCl_MODE=2).

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 Accessibility

The sodium hypochlorite dosing pumps are controlled by the pop up:

With this switch button, With this switch button, operator can With this switch button,
operator can set the dosing select the dosing mode for shock- operator can enable or disable
to RAS or Balancing tank. chlorination to Balancing tank. the calculation mode for shock-
chlorination to RAS.

The sodium hypochlorite for

balancing tank flow set point
is manually entered by the
operator on the SCADA.
Timers for
frequency/duration mode can
also be settled.

The sodium hypochlorite on

RAS flow set point is either
manually entered by the
operator on the SCADA
(disable mode) or it is
calculated using the
equations detailed below
(enable mode).

qmin and qmax are defined

as per the tests of the
pump; these values shall
not be changed.

Calculation according to these settings

Sodium hypochlorite for shock-chlorination to RAS dosing pump flow set point

The Sodium Hypochlorite for shock-chlorination on RAS 488A and 488C flow set-point (851NaOCl_Q_488) is either
manually entered by the operator on the Scada or can be calculated using the Equation here below taken into
consideration the biomass in the system (biological treatment) in kg of VS.

Equation
851𝑁𝑎𝑂𝐶𝑙_𝐷_488 × 851NaOCl_B_488
851𝑁𝑎𝑂𝐶𝑙_𝑄_488 =
24 × 851𝑁𝑎𝑂𝐶𝑙_𝐶_488

Where:

851NaOCl_Q_488 Sodium Hypochlorite dosing pump Shock-chlorination calculated l/h

flow rate set-point
851NaOCl_D_488 Sodium Hypochlorite for shock chlorination dosing rate g Cl2/kg VS/d

851NaOCl_B_488 Mass of biomass in the system (data entered manually by the Kg VS

operator)

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851NaOCl_C_488 Sodium Hypochlorite commercial solution concentration g/l

Shock-chlorination pump flow to speed conversion

 Shock-chlorination to RAS selected: 851NaOCl_Q_Shock:=851NaOCl_Q_488;

 Shock-chlorination to Balancing tank selected: 851NaOCl_Q_Shock:=851NaOCl_Q_581 ;

 No shock-chlorination selected: 851NaOCl_Q_Shock:=0

The set point speed sent to the speed inverter is calculated according to the table below :

851NaOCl_Q_Shock < 851PO120_QMin

851PO120_SPEED:=851PO120_VMin %

851PO120_QMin < 851NaOCl_Q_Shock < 851PO120_QMax

851NaOCl_Q_Shock − 851PO120_𝑄𝑀𝑖𝑛
∗ (851PO120_𝑉𝑚𝑎𝑥 − 851PO120_𝑉𝑀𝑖𝑛 ) + 851PO120_𝑉𝑀𝑖𝑛 %
851PO120_𝑄𝑀𝑎𝑥 − 851PO120_𝑄𝑀𝑖𝑛

851NaOCl_Q_Shock > 851PO120_QMax

851PO120_SPEED:=851PO120_VMax %

 Control Action

P ARAMETER D EFAULT VALUE U NIT R ANGE F UNCTION /U TILITY

Sodium Hypochlorite dosing to
851NaOCl_Q_488 600 l/h 0 – 3600
RAS flow rate setpoint
g
Sodium Hypochlorite to 488
851NaOCl_D_488 4 Cl2/kg 0–4
dosing rate
VS/d
Sodium Hypochlorite commercial
851NaOCl_C_488 110 g/l 0 – 150
solution concentration
851NaOCl_B_488 260 000 Kg VS 100000 - 400000 Mass of biomass in the system
Dosing pump for shock
851PO120_QMin 200 l/h 0 – 900 chlorination – minimum flow at
VMin speed
Dosing pump for shock
851PO120_QMax 700 l/h 0 - 900 chlorination – maximum flow at
VMax speed
Maximum injection time
851PO120_TMax 1440 min 0 - 10000
After this timer, stop the pump
Dosing pump for shock
851PO120_MSP 50 % 0 - 100
chlorination manual set point
851FIT321_HH 800 l/h 0 - 1000 -
851FIT321_H 700 l/h 0 - 1000 -
851FIT321_M 500 l/h 0 - 1000 -
851FIT321_L 200 l/h 0 - 1000 Stop the pump
851FIT321_LL 50 l/h 0 - 1000 -

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6. Routine Tasks and First level Maintenance

The purpose of the operator’s preventive maintenance schedule is both to keep the equipment ready and to detect any signs of equipment malfunction du ring operation and
scheduled maintenance checks

6.1. Sub Station 930F

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

Level (more than half)

SUB STATION 930 F

Clean Check absence of leakage
FUEL TANK FOR GENERATOR

Visual Inspection Fuel Tank

Check there is no leak of fuel, water

Clean the Area
around the generator
SUB STATION 930 F

Oil Level Checking (once a week) Fuel circuit should be always opened

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6.2. Aeration Tanks

Aeration Tanks A/B/C/D

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

Ensure presence brown colour (≈ milk

chocolate)

Smelt (≈ humus Odour)

Clean the Area
Flocs aspect

Aeration Tank
Check absence of foam

Vibration

Clean the Invent Motor Temperature

470 - AERATION TANKS
Noise
INVENT Mixer
Sludge concentration > 2 g/l
472A/B/C/D _AE306
Oxygen meter 1 > 1.5 mg O 2 /l
Cleaning Sensor, 472A/B/C/D_AE304
Refer to P-OM-020-470 First Other oxygen meter > 2 mg O 2 /l
level Maintenance of sensor of 472A/B/C/D _AE310
the aeration tank
Redox > 100 mV
Sensor

Records temperature

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EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

Check there is a flow and clean of Canal (no

obstruction)
Cleaning Area Internal recirculation is running (1 pump is
ON)
470 - MIXING LIQUOR INTERNAL RECIRCULATION 472A to D_PO104A or B
Record Mixing Recirculation Flow (6 am)
472A_FIT303
To clean Flow-meter 472B_FIT303
472C_FIT303
472D_FIT303 Internal Recirculation

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Aeration Tanks 472E/F/G/H

EQUIPMENT FIRST MAINTENANCE FREQUENCY ROUTINE TASK FREQUENCY PICTURES

Ensure presence brown colour (≈

Daily
milk chocolate)
Smelt (≈ humus Odour) Daily
Flocs aspect Daily
Clean the Area Weekly
Check absence of foam and normal
Daily
size of bubbles

Check that the 12 mixers INVENT are

Clean the Invent Motor Weekly running and check Vibration, noise Daily
and temperature
472E/F/G/H – AERATION
TANKS

Check that:
- Sludge concentration > 2 g/l
472E/F/G/H_AE306
- Oxygen meter 1 > 1.5 mg O2/l
472E/F/G/H_AE304
Cleaning Sensor, - Oxygen meter > 2 mg O 2 /l
Refer to P-OM-020-470 First level 472E/F/G/H_AE310
Daily
Maintenance of sensor of the aeration - Redox > 100 mV
tank 472E/F/G/H_AIT301_
If a parameter is out of range, warn
the hierarchy
Record all the previous results and
tank temperature
(472E/FG/H_TIT304_ )

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Check there is a flow and the

Daily
cleanness of Canal (no obstruction)
Cleaning Area Weekly Check Internal recirculation is
472E/F/G/H - MIXING running (1 pump is ON) Daily
LIQUOR INTERNAL 472E to H_PO104A or B
RECIRCULATION Record Mixing Recirculation Flow (6
am)
To clean Flow-meter Weekly Daily
472E_FIT303 / 472F_FIT303
472G_FIT303 / 472H_FIT303

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6.3. Deaeration of activated Sludge

Degassing chamber 481

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

This is the first area where biological foaming
can be detected (filamentous Bacteria)
Cleaning area
Check there is no foam, If there is foam, warn
481 DEGASSING CHAMBER process engineer
Remove Floating Material Flocs Aspect
Refer to Procedure:
P-OM-008-481 Floating Material
Disposal Floating material Degassing Chamber

Noise, vibration, temperature

Cleaning Motor
481A_PO101
Ensure absence of leakage
481 DEGASSING CHAMBER SCUM PIT

Cleaning Level switch at least

once a week

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Degassing chamber 481B

EQUIPMENT FIRST MAINTENANCE FREQUENCY ROUTINE TASK FREQUENCY PICTURES

This is the first area where
biological foaming can be detected
(filamentous Bacteria)
Cleaning area Weekly Daily
481B & 472E DEGASSING Check there is no foam, If there is
CHAMBER foam, warn process engineer
Remove Floating Material
Flocs Aspect Daily
Refer to Procedure:
Daily
P-OM-008-481 Floating
Floating material Daily
Material Disposal
BLOWERS FOR DEGASSING
CHAMBERS 481B-& 472E
On blowers, check the state of
481B_CS101A Weekly On blowers, check DP < 45mbar Daily
the filter
481B_CS101B
472_CS102A

481B - DEGASSING Noise, vibration, temperature of

Cleaning Motor 481B_PO101 Weekly Daily
CHAMBER SCUM PIT the pump

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6.4. Conventional Secondary Settling

Settling tanks 482 A to H

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

Ensure that water is overflowing at weir penstock

To ensure Black Color of the clarifier mirror

Cleaning Area No flocs going out clarifier

No Floating Material

No Floating material Spillway Settling Tank

482A to H - CLARIFIERS

Ensure the equal flow repartition between the 3 pipes (bridge clarifier)

Settling Tank Extraction Flow

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Settling tanks 482 I to P

EQUIPMENT FIRST MAINTENANCE FREQUENCY ROUTINE TASK FREQUENCY PICTURES

Ensure that water is overflowing at weir penstock Daily

To ensure Black Color of the clarifier mirror Daily

482 I to P - No flocs going out clarifier Daily

Cleaning Area and Through Weekly
CLARIFIERS
No Floating Material Daily

No Floating material Spillway Daily

Ensure the equal flow repartition between the 3
Daily
pipes (bridge clarifier)

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SCUM reception from SST 482 A to H

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

To refer Procedure:
P-OM-007-480 Scum Disposal Maximum
Level

SCUM RECEPTION TANKS Check the Level

Cleaning Level switch at least

once a week

Scum Reception Tank

Noise

Cleaning Temperature

482_PO106_
SCUM PUMPS Vibration
482_PO107_
482_PO108_
482_PO109_ Oil Level

Scum Pump
Ensure absence of Leakage

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SCUM reception from SST 482 I to J

EQUIPMENT FIRST MAINTENANCE FREQUENCY ROUTINE TASK FREQUENCY PICTURES

To refer Procedure:
P-OM-007-480 Scum When needed
Disposal

SCUM RECEPTION TANKS Check the Level Daily

Cleaning Level switch at
Weekly
least

Check the noise, temperature

Daily
and vibration
Cleaning the motor
Check the oil Level Daily
482_PO108I
SCUM PUMPS Weekly
482L_PO104_
482M_PO104
Ensure absence of Leakage Daily
482P_PO104_

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6.5. Air Production for Aeration in Biological Tanks

Air blowers A/B/C/D/E

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

Oil level more than half

Clean the Motor

Temperature, Noise, Vibration

Oil Pot 1 and 2

AIR BLOWERS Ensure that Air fan is running

711__KE101A/B/C/D/E

Fan
Clean the Area

30 < Clogging of Fan < 50

If it not the case, air filter is clogged
Warn the Maintenance team

Manometer

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Air blowers E/F/G

EQUIPMENT FIRST MAINTENANCE FREQUENCY ROUTINE TASK FREQUENCY PICTURES

Check the oil level more than half on

Daily
Pot 1 / On Pot 2

Clean the Motor Weekly

Check Temperature, Noise, Vibration Daily

AIR BLOWERS Oil pots 1 & 2

711B__KE101F/G/H

Ensure that Air fan is running Daily

Clean the Area Weekly

30 < Clogging of Fan < 50

If it not the case, air filter is clogged Daily
Warn the Maintenance team

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6.6. MCC Room

MCC Room 488 & 711

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

Check there is absence of trip Condition (orange

Cleaning Area
Light)

Push the test lamp button once

a week and warn the
Check A/C is running
maintenance team to replace
488 – MCC ROOM
defected light MCC Room
711 – MCC ROOM

Check if filter are clogged by beating (carefully)

Cleaning filters every week
on them.

MCC Filter
VFD of the blower E Check the VFD Check the absence of alarm on the VFD panel

MCC Room 488C & 711B

EQUIPMENT FIRST MAINTENANCE FREQUENCY ROUTINE TASK FREQUENCY PICTURES

Check there is absence of trip Condition

Cleaning Area Weekly Daily
(orange Light)

Push the test lamp button and warn the

488C – MCC ROOM Weekly Check A/C is running Daily
maintenance team to replace defected light

711B – MCC ROOM

Check if filter are clogged by beating

Cleaning filters Weekly Daily
(carefully) on them.

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Clean the system Weekly

Ensure there is no Fire Alarm and no false
Fire Alarm system Daily
Alarm
Check the Alarm System Power is ON Weekly

6.7. Sodium Hypochlorite

Sodium Hypochlorite storage for shock chlorination is located in the storage building 539. The routine tasks related to this reagent is detailed in the Operator Manual P -OM-001-
005 Ultrafiltration.

6.8. Ferric Chloride Injection Part two

EQUIPMENT FIRST MAINTENANCE ROUTINE TASK PICTURES

Clean the Dosing Pumps To check absence of leakage
821_PO103A
Pump Vibration
821_PO103B
821_PO103C Pump Noise
821_PO103D
821_PO103E Pump Temperature
Ferric Chloride Dosing Pump
821A - FERRIC INJECTION ROOM
If pump is running, verify flow meter > 0
L/h
Clean the Area 821A_FIT304A 821A_FIT304E
821A_FIT304B 821A_FIT304F
821A_FIT304C 821A_FIT304G
821A_FIT304D 821A_FIT304H Flow Meter

Check absence of leakage

821A - FERRIC CHLORIDE TANK
Cleaning
821__RF201A/B
Level meter (right and left tank)
821A_LIT302B
Ferric Chloride Tank
821A - SAFETY SHOWER Cleaning Ensure water presence for shower

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924_KE203_

Ensure water presence for eyes rinse

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7. Operation Procedures
7.1. P-OM-012-821A Starting of Ferric Chloride Injection

INJECTION IN INLET WORKS 410

Ferric chloride is corrosive: wear safety goggles and safety gloves

Check that safety shower is operational

Check valves in 410 building:

1) Check that at least one of the following valves are opened upstream of the circulation pumps:
- 411_VH423
- 411_VH422
2) Check that at least one of the following valves is opened downstream of the pumps:
- 411_VH405A
- 411_VH405B
3) Check that isolation valves of the circulation pumps are opened:
- 411_VH403A/B
- 411_VH404A/B
4) Check that ferric chloride injection valve 821A_VH410 is open.

Check valves in 821A building:

1) Check that storage tank valves are open:

- 821A1VH401A
- 821A2VH401A

2) Check that 3 way valves are in the right position for pumping:
- 821A_VH440A/B/C/D
- 821A_VH411A/B/C/D

3) Check that discharge valve of ferric chloride pump is open:

- 821A_VH414A/B/C/D

Start Pumps:

1) Start one circulation pump 411_PO103 A or B.

2) Start ferric chloride pump 821A_PO101 A/B/C/D.
3) Check the ferric chloride flow on flowmeter 821A_FIT305
4) If flow = 0 L/h:
- Check if the ferric chloride pump is primed,
- Check the position of the valve,
- Check the level in the ferric chloride tank (level must be higher than pump level) – at least 10 m 3
of product.
5) If flow is > 0 L/h, adjust the ferric chloride flow reading the procedure 821A - Adjustment of ferric chloride
flow

Remark: Never run the ferric chloride pump if the circulation pump is not running

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INJECTION IN AERATION TANKS 472 F/G/H

Ferric chloride is corrosive: wear safety goggles and safety gloves

Check that safety shower is operational

The installation is composed of 5 pumps. Each pump is used for one or two aeration tanks:
o Pump A for aeration tanks A and F;
o Pump B for aeration tanks B and G;
o Pump C for aeration tanks C and H;
o Pump D for aeration tank D;
o Pump E for aeration tanks E.

Initial conditions
Check level in ferric chloride tank 821A_LIT302B - at least 10 m 3
Check valves on aeration tank in aeration tank 472X
- Ensure that at least one of the following valves are opened :
- 821X_VH472
- 821X_VH402
Check that storage tank valves are open:
- 821A1VH401B
- 821A2VH401B
Check that 3 way valves are in the right position for pumping:
- 821A_VH442A/B/C/D/E
- 821A1VH420A/B/C/D/E
- 821A2VH420A/B/C/D/E
Check that discharge valve of ferric chloride pump is open:
- 821A1VH423A/B/C/D/E
- 821A2VH423A/B/C/D/E

Actions
1) Open the aeration tank X feeding manual valve
- 821A_VH418X
2) Start ferric chloride pump 821A_PO103A/B or C
3) Check the ferric chloride flow on flowmeter 821A_FIT304X
4) Check on site the injection of ferric chloride either in internal
recirculation or at the aeration tank outlet

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7.2. P-OM-012-821A Adjustment of ferric chloride

Ferric chloride is corrosive: wear safety goggle s and safety gloves

Check that safety shower is operational

1) Check the total inlet flow on the inlet flowmeter

2) Ask to the process engineer what is the dosing rate of ferric chloride

3) Adjust the position of the stroke of the pump according to this table :

BE CAREFUL: NEVER CHANGE THE STROKE POSITION IF PUMP IS NOT RUNNING (risk of damages)

STROKE SETTING

Dosing rate (ppm)

15 20 25 30
1000 11 14 18 22

1500 16 22 27 32

Stroke position (%)

Inlet flow (m 3 /h)

2000 22 29 36 43

2500 27 36 45 54

3000 32 43 54 65

3500 38 50 63 75

4000 43 57 72 86

Stroke position (%)

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4) When the stroke is adjusted, control the flow on the ferric chloride flowmeter

FLOWMETER - EXPECTED VALUES

Dosing rate (ppm)

15 20 25 30
1000 50 67 83 100

FeCl 3 pump flow (L/h)

1500 75 100 125 150
Inlet flow (m 3 /h)

2000 100 133 167 200

2500 125 167 208 250

3000 150 200 250 300

3500 175 233 292 350

4000 200 267 333 400

FeCl 3 pump flow (L/h)

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7.3. P-OM-009-711 Control of air blowers

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TAG NUMBER: 711__KE101A/B/C/D/E & 711B__KE101F/G/H

1. Check every 2 hours if there is no alarms on blowers:

- If there is an fix orange light or a flashing orange light

 Check alarm List on panel using the button

 Check bearing temperature especially blower outlet bearing (alarm: 110°C, failure: 120°C)
 Warn the hierarchy if any alarm is present

 Panel for blowers A/B/C/D

 Panel for blowers E (back of panel for blower A/B/C/D)

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 Panel for blowers F/G/H

2. Record the panel data each 1 day – use the “Routine sheet for Aeration”

Air flow
Air Pressure
Motor T°

Blower T°

Vibration

List of alarms

Fan side
Motor T°

Shaft side

Vibration
Blower T°

Inlet T°
BLOWER 1 (A)

Outlet T°

Air Flow

Air Pressure

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3. Check running hours. => .

If running hours is near 3000 hrs, warn the maintenance team for:
- Changing of oil of the 2 bearings
- Greasing of the motor

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7.4. P-OM-008-481 Disposal of floating material in scum Pit

DEGASSING CHAMBER 481A

 If high level is reached:

1) Stop activated sludge extraction pump 488A_PO102A/B/C

2) Start activated sludge scum pump 481A _PO101_
3) Check the level every 10 minutes, when elbow is visible = stop scum pump
4) Restart activated sludge extraction pump

 if high level is not reached

1) Check one air valve is open
2) Start air blower
3) Remove floating sludge from 481:
a) Open air valve A
b) Close air valves B/C/D
c) Open overflow of chamber A
d) Remove the floating sludge
e) Close overflow of chamber A

f) Open air valve B

g) Close air valve A
h) Open overflow of chamber B
i) Remove the floating sludge
j) Close overflow of chamber B

k) Open air valve C

l) Close air valve B
m) Open overflow of chamber C
n) Remove the floating sludge
o) Close overflow of chamber C

p) Open air valve D

q) Close air valve C
r) Open overflow of chamber D
s) Remove the floating sludge
t) Close overflow of chamber D

4) Stop air blower

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DEGASSING CHAMBER 481B

 If high level is reached:

1) Stop activated sludge extraction pump 488C_PO102A/B/C

2) Start activated sludge scum pump 481B_PO101_
3) Check the level every 10 minutes, when elbow is visible = stop scum pump
4) Restart activated sludge extraction pump

 if high level is not reached

5) Check one air valve is open
6) Start air blower 481B_CS101A/B
7) Remove floating sludge from 481B:
a) Open air valve 481B_VH401A
b) Close air valves 481B_VH401B/C/D
c) Open overflow of chamber 481B_VH408
d) Remove the floating sludge
e) Close overflow of chamber 481B_VH408

f) Open air valve 481B_VH401B

g) Close air valve 481B_VH401A
h) Open overflow of chamber 481B_VH407
i) Remove the floating sludge
j) Close overflow of chamber 481B_VH407

k) Open air valve 481B_VH401C

l) Close air valve 481B_VH401B
m) Open overflow of chamber 481B_VH406_
n) Remove the floating sludge
o) Close overflow of chamber 481B_VH406_

p) Open air valve 481B_VH401D

q) Close air valve 481B_VH401C
r) Open overflow of chamber 481B_VH409_
s) Remove the floating sludge
t) Close overflow of chamber 481B_VH409_

u) Open air valve 481B_VH401E

v) Close air valve 481B_VH401D
w) Open overflow of chamber 481B_VH401_
x) Remove the floating sludge
y) Close overflow of chamber 481B_VH401_

z) Open air valve 481B_VH401F

aa) Close air valve 481B_VH401E
bb) Open overflow of chamber 481B_VH404_
cc) Remove the floating sludge
dd) Close overflow of chamber 481B_VH404_
ee) Close air valve 481B_VH401F

8) Stop air blower

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7.5. P-OM-007-480 Disposal of Scum in Clarifiers Scum Pit in manual

CLARIFIERS A TO J
 If high level is reached:

1) Call operator in SCADA room

2) Ask him to start lobe pump (482_PO10XX) in remote manual (function o f clarifier)

Secondary settling tank 480 B/C Lobe Pump 482 PO106

Secondary settling tank 480 A/D Lobe Pump 482 PO107

Secondary settling tank 480 E/H Lobe Pump 482 PO109

Secondary settling tank 480 F/G Lobe Pump 482 PO109

Secondary settling tank 480 I/J Lobe pump 482 PO109I

3) At the same time, check the level of the tank

4) When low level is reached (elbow is visible), ask to operator in SCADA room to stop lobe pump .

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CLARIFIERS K TO P
 If high level is reached:

1) Call operator in SCADA room

2) Stop activated sludge extraction pump 488C_PO102A/B/C
3) Start activated sludge scum pump 482L/M/P_PO104_ in remote manual

Secondary settling tank 480 K/L Lobe pump 482L__PO104_

Secondary settling tank 480 M/N Lobe pump 482M__PO104_

Secondary settling tank 480 O/P Lobe pump 482P__PO104_

4) At the same time, check the level of the tank

5) When low level is reached (elbow is visible), ask to operator in SCADA room to stop lobe pump
6) Restart activated sludge extraction pump 488C_PO102A/B/C

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7.6. P-OM-001-000 Resetting of one tripped equipment

NEVER OPEN AN ELECTRICAL PANEL IF YOU ARE NOT AUTHORIZED

IF YOU ARE AUTHORIZED, WARN THE HIERARCHY AND APPLY CRISIS MANAGEMENT
PROCEDURE GSS 5.1P2 (Safety Operator Manual)

PROBLEM: If you find an equipment failed (TRIP in the MCC room = Orange light)

FIRST CHECKINGS:
1) Check that equipment is not locked-up (look for tag, safety lock…)

2) Have a visual inspection of the equipment on site (check there is no blockage, no debris in it, nobody
working in the area…)

3) Check there is no emergency stop on site

4) Check there is no emergency stop on the MCC

5) Record on log-book that equipment is failed and after resetting, informs the hierarchy that equipment has
been failed.

HOW TO RESTART:

6) Push the “RESET” button (black)

- If the orange light does not disappears then:

a. Shut down the panel (OFF)
b. Wait for all the displays shut down (VFD,
current indicator…)
c. Restart the panel (ON) and wait for all the
displays are started

- If the orange light disappears then, push the “START” button (green)

Equipment is restarted if green light is “ON”

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IF RESTARTING IS NOT POSSIBLE,

DO NOT RETRY THIS PROCEDURE TWICE.
IF SAME EQUIPMENT FAILED TWICE IN ONE DAY
WARN THE HIERARCHY OR AN ELECTRICIAN.

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7.7. P-OM-020-470 First Level Maintenance of the sensor of Aeration Tank

PROTECT YOUR SELF WITH GLOVES AND OVERALLS

WASH YOUR HANDS AFTER WORKING ON THE BIOLOGICAL TANK

Redox sensors 472A/B/C/D/E/F/G/H_AE301:

Operation: Cleaning
Frequency: Every Week

1. Clean the exterior of the sensor with a stream of water. If any remaining debris remove loose contaminate buildup
by carefully wiping the entire measuring end of the sensor (process electrode, concentric metal ground electrode,
and salt bridge) with a soft clean cloth. Rinse the sensor wit h clean, warm water.
2. Prepare a mild soap solution of warm water and dish detergent or other non -abrasive soap that does not contain
lanolin such as laboratory glass cleaner.
Note: Lanolin will coat the glass process electrode and can adversely affect se nsor performance.
3. Soak the sensor for 2 to 3 minutes in the soap solution.
4. Use a small soft bristle brush (such as a toothbrush) and scrub the entire measuring end of the sensor, thoroughly
cleaning the electrode and salt bridge surfaces.

Dissolved Oxygen sensors 472A/B/C/D/E/F/G/H _AE304 and 472A/B/C/D/E/F/G/H _AE310:

Operation: Cleaning
Frequency: Every Week

Clean the exterior of the sensor with a soft, wet cloth.

If the sensor cap is removed from the sensor body, do not leave the interior of th e cap exposed to sunlight. Sun
exposure to the interior of the cap can adversely affect the performance of the sensor. Degradation from sunlight
is only an issue if the sensor cap is off the sensor body and the interior of the sensor cap is exposed to sunl ight.

TSS concentration sensors 472A/B/C/D/E/F/G/H_AE306:

Operation: Visual inspection and cleaning

Frequency: Every Week

Take the sensor out of mixed liquor and have a visual inspection.
The windows are made of quartz glass. If necessary, they can be c leaned with any conventional cleaning agent and
a cloth.

Ask to the laboratory to check the measured value by the sensor. To adjust the calibration factor, refer to supplier
documentation.

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7.8. P-OM-023-470 Filamentous Bacteria Crisis

Purpose

Dysfunctions such as filamentous growth and bulking can lead the process in vicious circles causing:

 High level of sludge blanket in the clarifiers

 Foam overflowing from the tanks
 High TSS concentration of the clarified water
 Non-compliance of the treatment

Mains steps:

1) Identify type of filamentous bacteria by a microscopic analysis (Process engineer or laboratory staff).
2) Identify cause of SVI crisis or foaming of aeration tanks, the process shall be examined very quickly:

a) Operating process has been modified? → Adjust parameters

b) Aeration problem? → Check air supply and oxygen sensor (calibration of DO

meters (fix and portable)
→ Check if the mixers are working properly

c) Sludge Stagnation in the clarifier? → Check that there are no sludge deposits by using an
appropriate sample bottle
→ Increase Sludge Recirculation
→Check suction pipes flow

d) Age Sludge too high? → Increase Sludge Extraction

e) Recirculation Flow from clarifier is the same for each → Check data and adjust it
one?

f) Raw Water Quality

Sulfides presence? → Inject ferric Chloride in 410
High Concentration BOD5, TSS, COD? → Decrease Inlet Flow

g) pH too low? → Inject lime or caustic soda

h) Hydraulic problem? →Check Equipment (mixers, pumps…)

AFTER THIS QUICK PROCESS ADJUSTMENT, IF THE SITUATION DOES NOT IMPROVE, CONTACT THE EXPERTS IN
RUEIL (DEGREMONT SA MAIN OFFICE) FOR GUIDANCE

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1 2 3

4 5
Biological foam evolution, Nocardia genus

Actions

1) Resolve process problem as soon as po ssible

2) For foaming problem, spray foam with sodium hypochlorite
3) Increase aeration is generally recommended
4) Increase sludge extraction in order to reduce sludge age
5) Clean or empty whenever it is possible foam from degassing chamber (481)
6) Treat or remove all other foam stagnation

Repeat the actions above until biological tank rehabilitation

Regarding sodium hypochlorite injection, do not spray stainless steel

equipement in order to avoid corrosion.
Rinse with industrial water stainless steel equipment after use of sodium
hypochlorite

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Chlorination of Sludge

Where:

In each RAS pumping stations 488A & 488C, at the overflow of the external recirculation in order to have a good mixing.

Calculation:

Sodium Hypochlorite for shock-chlorination on RAS 488A and 488C flow set-point (851NaOCl_Q_488) is either manually
entered by the operator on the SCADA or can be calculated using the Equation here below taken into consideration
the biomass in the system (biological treatment) in kg of VS:

𝑁𝑎𝐶𝑙𝑂 𝑑𝑜𝑠𝑖𝑛𝑔 𝑟𝑎𝑡𝑒 ∗ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑏𝑖𝑜𝑚𝑎𝑠𝑠 𝑖𝑛 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚

𝑁𝑎𝐶𝑙𝑂 𝑓𝑙𝑜𝑤 𝑠𝑒𝑡 𝑝𝑜𝑖𝑛𝑡 =
𝑁𝑎𝐶𝑙𝑂 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛

With:
- NaClO flow set point – l/h
- Mass of biomass in the system – KgVS (entered manually by the operator)
- NaClO for shock chlorination dosing rate – gCl2/KgVS/d
- NaClO commercial solution concentration – g/l

Data for calculation:

- NaClO for shock chlorination dosing rate : 2 kgCl 2 /Tons SS/day in the aeration tank
- NaClO commercial solution concentration : 110 g/l
- Volume of tank : 19 000 m 3

Extra Analysis:

In case of the following parameters are out of range check the chlorination:
- Mixing
- Actual dosing rate (VS theorical dosing rate)
- Sludge recirculation rate
- etc…

Type Frequency Parameter Normal Comments

If no presence warn
Protozoa Presence
hierarchy
Microscopic 2 / day
Floc aspect Should be intact If no warn hierarchy
Filamentous Should reduce and disappear
If increasing warn
Clarified water 1 / day TSS Should be stable
hierarchy
If increasing 
Treated water 1 / day NH 4 Concentration stable
nitrification inhibited
If < 80 ml/g, stop
chlorination
Sludge 2 / day SVI 80 ml/g
Else stop chlorination
after 10 days

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7.9. P-OM-024-771 Resetting of air blowers valve due to a power failure

In case of power failure, a discrepancy appears between the opening of the valve and his setting.
The following procedure need to be followed in order to reset properly the air blowers regulating valve.

1) Put the panel on “local” (1)

2) Start the valve opening (2)

3) Wait for the complete opening of valve (3)

4) Close the valve (4)

5) Wait for the complete closing of the valve (3)

6) Put the panel in remote control (5)

7) This procedure has to be done two times and for each blower.

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7.10. P-OM-000-472 Emptying an Aeration Tanks X (= F/G/H)

Purpose

It is to empty the 19 000 m 3 aeration tank X in order to:

 Inspect all the mixers located in each zone of the aeration tank 472X;
 Perform the repair of the broken mixers;
 Perform the repair of the broken internal recirculation pumps;
 Quick inspection of the coating;
 Removal of sludge and cleaning.

To be carried out by

Process Manager / Process Engineer / Technician Operator

Safety

 Safety Shoes
 Helmet
 Yellow Jacket
 Coverall
 Goggles
 Cartridge Mask
 H 2 S gas detector
 Barricading and signs

Material Required

 Dewatering pumps (approx 300 m 3 /h flow): 2 pumps

 Small submersible pump (approx 60 m 3 /h flow): 1 pump (If necessary)
 Plastic Green hoses: 50 meter long, 6’’, 3 hoses , 4” 30m

Operation

1) Before emptying the tank, decrease the MLSS concentration to 2.5 g/l.

For all the duration of the isolation of the tank,

operators and helpers have to wear a cartridge mask. High concentration of H 2 S!

2) Signalize the area of work in order to avoid people from entering this are a.
3) Close on site the isolating manual penstock 471X_VH402 in the distribution
chamber 471B CARTRIDGE MASK
- Apply a LOTO consignment. COMPULSORY
4) Close the regulation penstock 471X_VZ403 on SCADA
5) From SCADA, put the aeration tank in OUT OF SERVICE
The tank will be discharge in the tank on a side.
- Install the small pump in the anoxic zone with the discharge hose in the
anoxic zone of the next tank
- Install the two big pumps in the aerobic zone with the discharge hose in the
aerobic zone of the next tank
6) Start the pumps
7) Monitor the level in the tank
- In the Anoxic zone

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- In the Aerobic zone

8) From SCADA, set the opening of the air inlet valve 711__VM403X at 15%. (To
maintain DO more than 4 ppm)
9) Apply a LOTO consignment on the recirculation pumps 472X_P O104A/B.
10) Apply a LOTO consignment on the ferric chloride injection valve
821A_VH418X
11) Continue to run all the mixers available.
12) Directly remove the DO probes. Store them into a bucket full of water. The
bucket has to be full of water at all time. Or R emove it and keep in safe place
13) Once the level reaches 5 m in aerobic zone, set from SCADA the opening of
the air inlet valve 711_VM403X at 10%
14) Check every hour that the flow pumped out by the pumps is not decreasing.
15) Once the level in the anoxic zone reaches 2 m, stop the following mixers and
apply the LOTO:
- In pre-anaerobic zone: 472X_QG103
- In anaerobic zone: 472X_QG103A/B
- In anoxic zone: 472X_QG102
16) Once the level in the aerobic zone reaches <2 m:
- Close the air valve 711_VM403X and apply LOTO
- Stop the mixers 472X_AA101A/B/C/D/E/F/G/H and apply LOTO consignment
17) Once the level is too low for the pumps to run, lift up the pumps. Clean the
pumps and send it back to store.
18) Perform the final emptying with the small submersible pump.

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7.11. P-OM-001-472 Filling an Aeration Tanks X (= F/G/H)

Purpose

It is to fill the 19 000 m 3 aeration tank X after inspection, reparation, cleaning operation or emptying of another
aeration tank

To be carried out by

Process Manager / Process Engineer / Technician Opera tor

Safety

 Safety Shoes
 Helmet
 Yellow Jacket
 Coverall
 Goggles
 H 2 S gas detector

Operation

1) Before filling a tank, increase the MLSS concentration to 3.2 g/l in the tanks
in operation.

For all the duration of the starting of the tank,

operators and helpers have to wear a cartridge mask. High concentration of H 2 S!

2) Signalize the area of work in order to avoid people from entering this area.
3) Ensure absence of any debris in each zone of the aeration tank and in the
recirculation channel
4) Remove the LOTO consignment on the isolating manual penstock
471X_VH402 in the distribution chamber 471B and open it
5) Open the regulation penstock 471X_VZ403 on SCADA
6) From SCADA, put the aeration tank IN SERVICE
7) Monitor the level in the anoxic zone
8) Once the level in the anoxic zone reaches 2 m, remove the LOTO consignment
on the mixers.
- Start the mixers:
- In pre-anaerobic zone: 472X_QG103
- In anaerobic zone: 472X_QG103A/B
- In anoxic zone: 472X_QG102
9) Monitor the level In the anoxic and aerobic zones
10) Once the level in the aerobic zone reaches 2 m, remove the LOTO
consignment on the mixers.
- Start the mixers in aerobic zone 472X_AA101A/B/C/D/E/F/G/H
- Ensure that the mixers runs properly
11) Put back in place the DO probes (DO must have been calibrated before)
12) Remove the LOTO consignment on the air valve 711_VM403X and open it
13) Control the dissolved oxygen in the aerobic zone (3 mg/l).
14) Remove the LOTO consignment on the recirculation pumps 472X_PO104A/B
and start the pumps. Ensure that the pumps runs properly

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15) Remove the LOTO consignment on the ferric chloride injection valve
821A_VH418X without opening the valve (only in case of physical
dephosphatation needed)
16) Check for
- Present of brown color of the water
- A good smelt (= humus odour)
- A good aspect of the flocs
- Absence of foam
17) Ensure that
- Sludge concentration > 2 g/l (472X_AIT306)
- Oxygen meter > 1.5 mg O2/l (472X_AIT304)
- Oxygen meter > 2 mg O2/l (472X_AIT310)
- Redox > 100 mV (472X_AIT301)

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7.12. P-OM-069-480 Stop of clarifier (X = F to H)

Purpose

These instructions are intended to be used as a guide for stopping a clarifier in case of any problems regarding the
clarifiers and its equipment.

To be carried out by

Process Manager / Process Engineer / Technician Operator

Safety

 Safety Shoes
 Helmet
 Yellow Jacket
 Coverall
 Goggles

Material Required

 Dewatering pumps
 Hose

Operation

Initial Conditions (x = F/G or H)

 The dedicated stop logs are not installed:
SST K 481B_XZ413_ & 481B_XZ414_
SST L 481B_XZ411_ & 481B_XZ412_
SST M 481B_XZ405_ & 481B_XZ406_
SST N 481B_XZ421_ & 481B_XZ422_
SST O 481B_XZ419_ & 481B_XZ420_
SST P 481B_XZ417_ & 481B_XZ418_
 The penstock 482x_VM401_ is open
 The bridge 482x_QP101_ is in running condition
 The Blower 482x_CV103_ is in running condition
 The Pump 482x_PO102_ is in running condition

Actions
1) Signalize the area of work in order to avoid people from entering this
area.
2) Stop the Air Blower 482x_CV103_ and apply a LOTO consignment.
3) From SCADA, stop the bridge 482x_QP101_
4) From SCADA, stop the pump 482x_PO102_
5) Install the dedicated stop logs
SST K 481B_XZ413_ & 481B_XZ414_
SST L 481B_XZ411_ & 481B_XZ412_
SST M 481B_XZ405_ & 481B_XZ406_
SST N 481B_XZ421_ & 481B_XZ422_
SST O 481B_XZ419_ & 481B_XZ420_
SST P 481B_XZ417_ & 481B_XZ418_
-
6) Install the pump in the clarifier and hose in the repartition chamber 481B
7) Start the dewatering pump
8) When the clarifier is empty , stop the pumps

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7.13. P-OM-068-480 Restarting of clarifier (X = F to H)

Purpose

These instructions are intended to be used as a guide to plant commissionin g and operation which take precedence
in the event of any problems with the equipment in question.

Scope

All operations linked to Restarting of Clarifier .

To be carried out by

Process Manager / Process Engineer / Technician Operator

Safety

 Safety Shoes
 Helmet
 Yellow Jacket
 Coverall
 Goggles

Material Required

 Pump
 Flexible Hose

Procedure

Follow the specific procedure regarding the clarifier to be restart.

- Procedure for clarifiers A to E;
- Procedure for clarifiers F to H.

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PROCEDURE FOR CLARIFIERS A TO E

Preliminary Actions

Check the structures for cleanliness, corrosion and especially the inside of the clarifier sludge cone.

Ensure absence of any debris in the clarifier.

Check electrical connections (with power off) to the manifold, speed red uction motor, load limiter and earth.

Check oil and grease levels:

Oil level and vent plugs on the speed reduction motor,

Grease the slewing ring,
Grease the bearings.

Check the operating direction and power consumption for all electric motors (pumps a nd blower). The operating
direction is sometimes shown by an arrow on the housing.
Check that the blower can rotate freely before energising it.

Check protections in the electric’s cabinet as well as the operation of the safety devices (mushroom head butt on –
load limiter).

Clarifier Filling

Initial Conditions (x = A/B/C/D or E)

 The stop logs 481A1V_401x & 481A2V_401x are installed

 The penstock 482x_VM405_ is closed
 The bridge 482x_QP101_ is in stop Condition
 The Blower 482x_CV102_ is in Stop Condition
 The Pump 482x_PO103_ is in stop condition

Actions

Fill the Clarifier with Clear Water (80% of the total volume of the Clarifier) .

Start the Air Blower, Check that the entire air -lift system is operating correctly.

Check the outlet pipes (3) located in the middle of the clarifier, ensure equal flow between these pipes (if not,
regulate the air flow via the air ball valves).

Start the bridge 482x_QP101_, ensure with SCADA operator that during the operation, the bridge did not meet any
problem (torque).

Fill the Clarifier with sludge from degassing chamber at normal flow:
Clarifiers A to E: remove the stop logs 481A1V_401x & 481A2V_401x (the 2 stop log MUST be removed in order to
get a good degassing).
AVOID OVERFLOW by re installation of the 2 stop logs.

Wait 1 hour for sludge settling and sludge bed formation .

Open the penstock 482x_VM405_.

Remove the stop logs 481A1V_401x & 481A2V_401x

Follow up the process with accuracy (TSS in Clarified Water) .

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PROCEDURE FOR CLARIFIERS F TO H

Preliminary Actions

Check the structures for cleanliness, corrosion and especially the inside of the clarifier sludge cone.

Ensure absence of any debris in the clarifier.

Check electrical connections (with power off) to the manifold, speed reduction motor, load li miter and earth.

Check oil and grease levels:

Oil level and vent plugs on the speed reduction motor,

Grease the slewing ring,
Grease the bearings.

Check the operating direction and power consumption for all electric motors (pumps and blower). The opera ting
direction is sometimes shown by an arrow on the housing.
Check that the blower can rotate freely before energising it.

Check protections in the electric’s cabinet as well as the operation of the safety devices (mushroom head button –
load limiter).

Clarifier Filling

Initial Conditions (x = F/G or H)

 The dedicated stop logs are installed:

SST K 481B_XZ413_ & 481B_XZ414_
SST L 481B_XZ411_ & 481B_XZ412_
SST M 481B_XZ405_ & 481B_XZ406_
SST N 481B_XZ421_ & 481B_XZ422_
SST O 481B_XZ419_ & 481B_XZ420_
SST P 481B_XZ417_ & 481B_XZ418_
 The penstock 482x_VM401_ is closed
 The bridge 482x_QP101_ is in stop Condition
 The Blower 482x_CV103_ is in Stop Condition
 The Pump 482x_PO102_ is in stop condition

Actions

Fill the Clarifier with Clear Water (80% of the total volume of the Clarifier).

Start the Air Blower, Check that the entire air -lift system is operating correctly.

Check the outlet pipes (3) located in the middle of the clarifier, ensure equal flow between these pipes (if not,
regulate the air flow via the air ball valves).

Start the bridge 482x_QP101_, ensure with SCADA operator that during the operation, the bridge did not meet any
problem (torque).

Fill the Clarifier with sludge from degassing chamber at normal flow:
Clarifiers K to P: remove the dedicated stop logs (the 2 stop log MUST be removed in order to get a good degassing).
SST K 481B_XZ413_ & 481B_XZ414_
SST L 481B_XZ411_ & 481B_XZ412_
SST M 481B_XZ405_ & 481B_XZ406_
SST N 481B_XZ421_ & 481B_XZ422_

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SST O 481B_XZ419_ & 481B_XZ420_

SST P 481B_XZ417_ & 481B_XZ418_
AVOID OVERFLOW by re installation of the dedicated 2 stop logs.

Wait 1 hour for sludge settling and sludge bed formation .

Open the penstock 482x_VM401_.

Remove the 2 dedicated stop logs.

Follow up the process with accuracy (TSS in Clarified Water).

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8. Troubleshooting and Repair

The following troubleshooting guide is provided for quick reference only. For detailed troubleshooting of system
components, consult the Vendor Data.

Be sure to consult all necessary safety information prior to troubleshoot. Ensure that only qualified personnel
troubleshoot system components.

Mechanical or electrical maintenance should only be performed by qualified personnel . In the event of any
differences between this manual and the supp lied Vendor Data, the supplied Vendor Data should always take
precedence. It is up to the operator to follow the correct safety procedures when doing any type of troubleshooting.

8.1. Important Remarks

It is important to note that the disorders of operation, w hich appear in the biological treatment, could not be solved
immediately: sometimes it requires several days after the intervention, for the expected changes to be visible.

Many parameters are to be taken into account on a biological treatment; this expla ins the multiple causes of possible
dysfunctions.
The first thing is to inform its hierarchy in case of doubt.

To judge "the health" of the biological treatment, the first significant parameters to take into account are:
▫ The odour
▫ The colour
▫ The appearance

8.2. Biological Tank

8.2.1. Disturbance of the aerobic condition

The quality of mixed sludge can be influenced by the inlet water quality of the treatment (presence of harmful
products, septic liquor…) and also by the equipment which intervenes in the process:
 Equipment of air production (blowers)
 Regulating valves,
 Aerators/Mixers equipment,
 Instruments of measures and regulation,
 Recirculation pumping

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Hydraulic

The operator have to observe the hydraulic movements in the Aeration tank

 Effects of the recirculated sludge and/or of inlet water

 Effects of mixing
 Effects of the air insufficiency

Parts from phenomena related to the structure design, the hydraulic disorders are detected by observing an unusual
circulation of mixed sludge in the structure. In this case it is impe rative to check the operation for each equipment
and to analyze them.

Non Uniform Aeration

Good Aeration

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Mixing

Bad mixing could be sometimes due to too low minimum air flow. In this
case the set point should be increased.

Cracked sludge: dead zones (preferential

passage)

Mixing liquor recirculation

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8.2.2. Filamentous Bacteria

Generally: the consequences of the bulking phenomenon on the clarifier maybe limited if the recirculation rate
can be increased.

Bulking may also be reduced by adding mineral matter such as lime or, if available, digested sludge.

Causes

9) Hydraulics

Consequence: Sediments appear in the dead zones (on the surface as at the bottom): sludge rotted because of the
bad mixing and filamentous bacteria appear. This phenomenon is likely to increase quickly until
becoming irreversible if no solution is brought.

Solution: Control the SVI, if SVI > 150 cm 3 .g -1 → Bulking Beginning

Warn the hierarchy and find the nest of infection (sediments) Re -establish the conditions of mixing and
aeration.
If necessary carry out Chlorine injections

10) Recirculation and extraction

Solution: Increase extraction (check before that the sludge treatment is correct) for decreasing sludge age.

Increase the recirculation and aeration.

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8.2.3. Odour

Earthy odour

This odour (odour of under wood) implies a “good he alth” of the biological tank.

Putrid odour

Such an odour (odour of vase) for the sludge is abnormal.

This anomaly can be due to dysfunctions on the conditions of aeration and/or of mixing.
Moreover this dysfunction is frequently accompanied by the presence of filamentous bacteria within the activated
sludge.

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8.2.4. Colour

Brown chocolate sludge

This colour implies a correct operation of the biological treatment.

Yellowish sludge

An effluent change or a preferential passage involving a bad contact with the biomass, involv e the appearance of
such a colour.

Black sludge

A black sludge is often related to a bad aeration. But if this colour lasts, the origin can be due to a deposit.

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8.2.5. Appearance

White Foam

Cream Foam

Another type of foam (thick, greasy and of a creamy aspect) may also be found
accidentally.

Detergents have the property of dissolving part of the greases, which thus
cannot be trapped in the pre-treatment units. These detergents are
subsequently biodegraded by the biological treatment, and thus release the
greases, which then cause the foam to thicken and to float.

At present, no efficient remedy is available against this type of foam.

Accidental Foaming

Brown Foam

A viscous, brown foam that covers the aeration basins and secondary clarifier
has produced many problem in activated sl udge plants. The foam is associated
with a slow-growing filamentous organism of actinomycete group, usually of the
Nocardia genus (see pictures).

Brown foam

Nota: to refer P-OM-023-470 Biologic Foam Removal in case of problem

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8.3. Clarifier

The quality of sludge and its capacity to settled can be influenced by various parameters like:
 Oxygen supply,
 Recirculation ratio
 Gas development,

8.3.1. Colour

It is necessary to observe the surface of clarifier.

Black reflection
This color implies a good treatment.

Yellowish reflection
This color implies a bad treatment.

8.3.2. Appearance

Small Flakes

Small flakes (centimetres) or sludge which looks like chocolate mousse and which rejects no reprehensible odour.
The sludge flakes rise due to a denitrification phenomenon following a nitrification stage (low sludge loading
coefficient and high oxygen content) associated or not with an insufficient recirculation rate.

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Sludge Block rises

Sludge block rises due to sludge deposits in the unit resulting from an insufficient recirculation of the sludge which
turns to an anaerobic condition; gases released during fermentation will drive the sludge blocks to the surface.
- This sludge is blackish colour and releases evil smell.
- Increase the oxygen input if its percentage is too low in the aeration tank.

Sludge Block rises

Whole surface of the clarifier covered with sludge

Whole surface covered with

sludge

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9. Appendices
9.1. Details Supplier

Invent Mixers/Aerator

Supplier: INVENT

INVENT Umwelt- und

Verfahrenstechnik AG
Am Weichselgarten 36
91058 Erlangen – GERMANY
Contact: Matthias ERTL MErtl@invent-uv.de 09131 69098-24
Phone: +49/0 91 31/6 90 98-0
Fax: + 49/0 9131/6 90 98-99
E-mail: invent@invent-uv.de
Website: www.invent-uv.de

Drive, automation and motor

Supplier: FLENDER

FLENDER TÜBINGEN GMBH

Bahnhofstr. 40-44
D-72072 Tübingen – GERMANY
Phone: +49 (0) 70 71-707 0
Fax: +49 (0) 70 71-707 400
E-mail: sales-motox@flender-motox.com
Website: www.flender.com

Dosing Pump

Supplier : MILTON ROY

MILTON ROY EUROPE (DOSAPRO)

10 Grande rue
27360 Pont Saint Pierre – France
Phone : 0033 2 32 68 30 00
Fax : 0033 2 32 68 30 93
E-mail: contact@miltonroy-europe.com
Website: www.miltonroy-europe.com

Air blowers for aeration tanks

Supplier: CONTINENTAL

CONTINENTAL INDUSTRIE
Route de Baneins
01990 Saint Trivier sur Moignans – FRANCE
Contact: Jérôme MONNERON (Project engineer): j.monneron@continental -industrie.com
Jean-François Chavigner (Quality manager): jf.chavigner@continental -industrie.com
Phone: + 33 (0)4 74 55 88 77
Fax France: + 33 (0)4 74 55 86 04 / Ext 5: + 33 4 74 55 92 29
Fax Export: + 33 (0)4 74 55 80 15
E mail: info@continental-industrie.com
Website: www.continental-industrie.com

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Air blowers for dearation

Supplier: AERZEN FRANCE SAS

Z.I. - 10, Avenue Léon Harmel

F- 92 168 Antony – FRANCE
Tel.: +33.(0)1.46.74.13.00
Fax: +33.(0)1.46.66.00.61
E-mail: aerzen@aerzen.fr
Website: www.aerzener.com

Clarifier (bridge)
Extension 3&4 Extension 5

Supplier: COSME Supplier: COSME

COSME Machines for waste water treatment COSME Machines for waste water treatment
Via del lavoro, 14 Via Longare, 80
36050 Quinto Vicentino (VI) – ITALIA 36040 Torri di Quartesolo (VI) – ITALIA
Phone: 0444/356835 Phone: 0444/356835
Fax: 0444/356897 Fax: 0444/356897
Contact: Giuseppe MENEGHETTI Contact: Mrs.Katia SEGATO
Website: www.cosmeitalia.com/eng/index.asp Email: cosme@cosmeitalia.com
export.sales2@cosmeitalia.com

Internal recirculation Tube pumps

Extension 3&4 Extension 5

Supplier: GRUNDFOS Supplier: GRUNDFOS

United Arab Emirates POMPES GRUNDFOS DISTRIBUTION

GRUNDFOS Gulf Distribution Parc d'activité de Chesne
P.O. Box 16768 57, Rue de Malacombe
Jebel Ali Free Zone F-38070 Saint Quentin Fallavier - FRANCE
DUBAI Phone: +33 4 74 82 15 15
Phone: +971 48 815 166 Fax: + 33 4 74 94 10 51
Fax: +971 48 815 136 Contact: Alain RETZIGNAC
Website: www.grundfos.com Email: commercial-fr@grundfos.com
aretzignac@grundfos.com

External recirculation and extraction pump s

Extension 3&4 Extension 5

Supplier: GRUNDFOS Supplier: SULZER

United Arab Emirates SULZER WASTEWATER France SAS

GRUNDFOS Gulf Distribution 26 Allée du plateau
P.O. Box 16768 93250 Villemomble – FRANCE
Jebel Ali Free Zone Contact: Didier PARCHAP
DUBAI Phone: +33 1 49 35 24 55
Phone: +971 48 815 166 Email: didier.parchap@sulzer.com
Fax: +971 48 815 136
Website: www.grundfos.com

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Lobe Pump

Supplier: BORGER

BORGER FRANCE S.A.R.L

9 rue des pres
67670 Wittersheim – FRANCE
Contact: Mrs SCHEER
Phone: 0033 3 88 54 68
Fax: 0033 3 88 5154 13
Mail: info@borger.fr
Website: http://www.borger.fr

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9.2. Acronyms

BOD Biochemical Oxygen Demand

BP Back Pulse
BW Back Wash
CCT Chlorine Contact Tank
COD Chemical Oxygen Demand
DO Dissolve Oxygen
FM Flow Meter
FeCl 3 Ferric Chloride
GBT Gravity Belt Thickener
LCP Local Control Panel
MC Maintenance Cleaning
MCC Motor Control Center
ML Mixing Liquor
ND Nominal Diameter
NaClO Sodium Hypochlorite
OCU Odour Control Unit
ORP Oxygen Redox Potential
PLC Programmable Logic Controller
PS Pumping Station
RAS Recirculated Activated Sludge
RC Recovery Cleaning
SAS Surplus Activated Sludge
SCADA Supervisory Control and Data Acquisition
SP Set Point
SST Secondary Settling Tank
TSE Treated Sewage Effluent
TSS Total Suspended Solids
UF Ultra-Filtration
VFD Variable Frequency Drive

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