Op Kubd PS

STUDY, DESIGN & CONSTRUCTION, OPERATION & MAINTENANCE OF PUMPING STATION, WASTE WATER TREATMENT PLANT & PRESSURE
MAINS IN SOUTH OF AMGARA & SOUTH OF NEW JAHRA SCRAP AREA CONTRACT NO. SE/100
KUBD WWTP OPERATION PHILOSOPHY
Document Version: 1.0 Date Last Updated: 04/02/2010
Title: Project : Doc Number:
KUBD OPERATION PHILOSOPHY SE-100 MFG 020801-KOP-001 Issue Date: Modified Date: 4/2/10
Table of Contents
1. INTRODUCTION ........................................................................................ 5
1.1. 1.2. 1.3. 1.4. 2.1. 2.2. 3.1. 3.2. 3.3. 4.1. 4.2. 5.1. 5.2. 5.3. 6.1. 6.2. 7.1. PURPOSE ....................................................................................................... 5 ABBREVIATIONS ................................................................................................ 5 UNIT ............................................................................................................ 5 REFERENCE DOCUMENT ...................................................................................... 6 EQUIPMENT DESCRIPTION .................................................................................... 7 OPERATION SEQUENCE ....................................................................................... 8 GENERAL ....................................................................................................... 9 NORTH VLR DISC ............................................................................................10 SOUTH VLR DISC.............................................................................................11 EQUIPMENT DESCRIPTION ...................................................................................12 OPERATION ...................................................................................................13 GENERAL ......................................................................................................14 RAS PUMP OPERATION ......................................................................................14 SAS PUMP OPERATION ..........................................................................................15 EQUIPMENT DESCRIPTION ...................................................................................16 OPERATION OF DISC FILTER AND BACKWASH PUMP .......................................................16 GENERAL ......................................................................................................18
2. INLET WORKS ......................................................................................... 7
3. VLR SYSTEM ................................................... ERROR! BOOKMARK NOT DEFINED.
4. CLARIFIERS .......................................................................................... 12
5. RAS/SAS PUMPS .................................................................................... 14
6. DISK FILTER .................................................... ERROR! BOOKMARK NOT DEFINED.
7. UV SYSTEM ........................................................................................... 18 8. EFFLUENT STORAGE RESERVOIR ............................................................. 19 9. TANKER WASTE FACILTIY ....................................................................... 20
9.1. 9.2. GENERAL ......................................................................................................20 PUMP OPERATION ............................................................................................20
10.
SLUDGE THICKNER SYSTEM.................................................................. 22

GENERAL ...................................................................................................22 OPERATION MODE .........................................................................................22 INTERLOCKS ................................................................................................22 SEQUENCE OF OPERATION................................................................................22 FAULT CONDITION: ........................................................................................23 GENERAL ...................................................................................................24 OPERATION MODE .........................................................................................24 INTERLOCKS ................................................................................................24 SEQUENCE OF OPERATION................................................................................24 FAULT CONDITION: ........................................................................................25 EQUIPMENT DESCRIPTION ................................................................................26
Page 2 of 2
10.1. 10.2. 10.3. 10.4. 10.5.
11.
SLUDGE DEWATERING SYSTEM ............................................................. 24
11.1. 11.2. 11.3. 11.4. 11.5.
12.
AEROBIC DIGESTOR ............................................................................ 26
12.1.
Version 1.0/Release Date 6/2/10
Title: Project : Doc Number: 12.2.
OPERATION ................................................................................................26 EQUIPMENT DESCRIPTION ................................................................................27 GENERAL ...................................................................................................29 BLOWER OPERATION ......................................................................................29 INLET SCUM PUMP STATION ..............................................................................31 SECONDARY SCUM PUMP STATION ......................................................................31 PUMP OPERATION .........................................................................................31 GENERAL ...................................................................................................33 PUMP OPERATION .........................................................................................33 GENERAL ...................................................................................................35 PUMP OPERATION .........................................................................................35 INLET WORKS ODOR CONTROL ...........................................................................36 SLUDGE ODOR CONTROL .................................................................................40
13. 14.
CHLORINATION SYSTEM ....................................................................... 27 AIR BLOWERS .................................................................................... 29
13.1. 14.1. 14.2.
15.
SCUM PUMPING STATION...................................................................... 31
15.1. 15.2. 15.3.
16.
RETURN LIQUOR PUMPING STATION ....................................................... 33
16.1. 16.2.
17.
WASH WATER PUMPING STATION .......................................................... 35
17.1. 17.2.
18.
ODOR CONTROL SYSTEM- INLET AND SLUDGE ......................................... 36
18.1. 18.2.
Page 3 of 3
Revision History This Sheet Issue No. A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Revision Level B C D 0

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
This Sheet Issue No. A 31 32 33 34 35 36 37 38 39 40 41
Revision Level B C D 0
X
X X X X X X X X X X
Page 4 of 4
1. INTRODUCTION
1.1. PURPOSE
The Purpose of the document is to describe the area wise Operation of the KUBD WWTP .
1.2. ABBREVIATIONS
The following abbreviations are used in the document
DCS I/Os RIO IL VLR RLP WWP
DISTRIBUTED CONTROL SYSTEM INPUTS AND OUTPUTS REMOTE INPUT /OUTPUT INLET WORKS VERTICAL LOOP REACTOR RETURN LIQUOR PUMP WASH WATER PUMPS
1.3. UNIT
Description
Units
Symbol
Flow Volume Pressure Temperature Energy Power Voltage Current Frequency Power factor Motor Speed Level pH Humidity Conductivity
M /Hr M3 Bar
Degree Centigrade
M3/Hr M3 Bar C kWH kW V A Hz RPM M pH % s

Page 5 of 5
Kilo Watt Hour Kilo Watt Volt Ampere Hertz RPM Meter potential of Hydrogen Percentage Micro siemens
ORP (oxidation-reduction potential) DO ( dissolved Oxygen) Vibration Turbidity Weight Residual Chlorine
Milli Volt Parts per million mm/sec or inch/sec NTU Kilo gram Parts per million
mV ppm mm/sec or inch/sec NTU Kg ppm
1.4. REFERENCE DOCUMENT

P&ID : KBD- PID-01 to KBD-PID-23
Page 6 of 6
2. INLET WORKS
2.1. EQUIPMENT DESCRIPTION
The Raw Sewage from JAHRA PS will be conveyed into the Inlet chamber of KUBD WWTP through SG 100 and SG 101. One Channel including one bar screen and one grit chamber, can be isolated for maintenance, while the other three bar screen and three grit chamber can cope up with peak flow of the isolated bar screen and grit chamber. There are four Bar Screens (SCR 1 to 4) and are operating as 3 working and 1 standby. The Bar Screens operate based on the Timer settings and Differential level (level transmitter LDT103 to 105). The Bar Screen timer settings will be overridden by differential level high (LAH 103 to 105). The timer setting for operation of Bar Screens will be from Inlet works PLC Panel. Bar Screens will be started only after starting the Spiral conveyor and Compactor. Captured screening from SCR 1 and SCR 2 will go to Spiral Conveyor (SC1) and screening from SCR 3 and SCR 4 will go to Spiral Conveyor (SC 2) located at High level of the Preliminary treatment works and discharging into the chute inlet hopper of the compactors. The Grit collection system consist of Vortex Grit Chamber (GRC 1 to 4), Grit pump (GP 1 to 8) and Grit classifiers (GRCL 1 and GRCL 2). There are four Vortex Grit Chamber (GRC 1 to 4) and are operating as 3 working and 1 standby. The Grit chambers operate on duty channel based on Run hours of the grit unit. Each Grit Chamber is equipped with 2 grit pumps (one duty, one standby). All pumps discharge into a common header leading to two classifiers, one duty and one standby. Before starting the grit pumps, the wash water is supplied for an operator settable /adjustable time period (0-5min) to the Grit Chamber and fluidizes the suction line and grit chamber. Then return back to grit pump position and grit pumps will start. The duty /stand by will be as per the run hour. Least run pump shall assume duty. In case the duty pump fails the standby pumps will start and run. The motorized valves (MOV 131&132) feeding to the grit classifiers inlet will be open/close according to Duty classifier. Grit pumps will be allowed to run only if grit classifier is in operation .Classifier shall stop after time delay of stop of all duty grit pumps. Washed grit from the classifiers is collected in container for hauling away by trucks. Wash water from the screenings compactors and the grit classifiers is drained to the wet well of the tankered wastes lift station and conveyed back to the tankered waste discharge chamber. Screened and de gritted sewage from the grit chambers is distributed to an oil skimming tank with separators to form 8 long channels. Oil accumulated at the surface is collected by two slotted pipe trough skimmers, for removal of oil. Skimmed by the scraps and discharge into a gravity line leading to a scum pumping station. According to timer at Inlet works PLC panel or the level setting the Oil Skimmer mechanism will work. The data transfer from Inlet works PLC and DCS is through redundant Profibus
Version 1.0/Release Date 6/2/10 Page 7 of 7
communication.
2.2. OPERATION SEQUENCE

Screening System: The Inlet gates Open Feedback is provided from DCS to Inlet works PLC panel. Once the open feedback is available if differential Level is more or based on Timer setting in PLC, the Screening system is started from the Inlet Works PLC System. Based on the duty selection Chute 1 or 2 is started. If chute 1 is duty 1 it is started first then based on the position feedback after a 1 sec time delay Compactor 1 is started. After starting the compactor 1 based on run feedback and 2 sec time delay the conveyor is started. Based on the run feedback of Compactor and Conveyor the Bar Screen is started. When the differential level is normal then bar screen is first stopped and based on the stop feedback and 2 sec time delay the conveyor is stopped. Based on the stop feedback of the conveyor and 2 sec time delay the compactor is stopped. In case of fault of any equipment the system is stopped completely and then restarted with the standby equipment. The duty selection the screening system equipments are based on their run hours. Grit Washer: The Inlet gates Open Feedback is provided from DCS to Inlet works PLC panel. Once the open feedback is available and a after a 3 sec time delay the Grit chamber is started based on the duty. Once Grit chamber is started based on the start feedback and after 2 sec time delay Grit classifier is started. The Grit classifier is started based on duty .If Grit classifier 1 is duty 1 then it is started based on the start feedback Motorized gate MOV 131 is opened from DCS and feedback is provided to the Inlet works PLC system. Once gate open feedback is available and after a time delay of 5 sec based on the duty selection for the grit pumps one grit pump is started. While stopping the Grit Pump is stopped first and based on the feedback and 3 sec time delay the MOV is closed and then based on the feedback and after 3 sec the grit classifier is stopped.
Page 8 of 8
3. AERATION TANK
3.1. GENERAL
The VertiCel aeration process is a hybrid aeration process using mechanical aeration upfront and diffused aeration in the second half. This arrangement of aeration equipment maximizes the PAE of both types of aeration devices - resulting in reduced power costs. A looped reactor, such as an Orbal channel or a VLR tank, is the most optimum reactor for maintaining aerated anoxic conditions. First, applied air is swept away from the aerator such that only mixed liquor with depleted DO enters the aerator. Second, since mixing is always in a unidirectional pattern, the mixing requirements are greatly reduced. This allows the oxygen delivery to be turned down during low load periods without concerns that there will not be enough energy for mixing. Thus, auxiliary type equipment, like non-aerated mixers, is not needed. The VertiCel design for KUBD is set up to achieve an average de nitrification rate of 80% without internal recycle. This performance rate is achieved through a high degree of simultaneous nitrification-de nitrification in the VLR tanks and a small degree of simultaneous nitrification-de nitrification in the first fine bubble cell. In the VertiCel design the first half of the process is kept under aerated anoxic conditions. This is important to the BNR benefits of the process. The large aerated anoxic fraction ensures a large amount of simultaneous nitrification-de nitrification. The fact that nitrification occurs in (aerated) anoxic reactors has been well documented. It has even been established that specific types of nitrifies (Nitrospirea) are cultivated under these conditions. It has also been established that the actual nitrification-de nitrification pathway has been shortened in the de nitrification step. This pathway requires less Carbon for overall de nitrification than the normal pathway. In the VertiCel design the first fine bubble reactor is designed for low DO (0.5 mg/l). This reactor becomes an aerated anoxic reactor during high load. Having the majority of the biomass kept under aerated anoxic conditions sometimes even 75% of the biomass - does not result in poor settling conditions or to conditions that led to sludge bulking. On the contrary, systems operating with sludge ages in the range of 6 -12 days, using have better sludge settling - with SVI levels usually below 100. Bio-P removal also occurs in the VertiCel systems. This is accomplished by keeping a large portion of the biomass (50%) under a strong oxygen deficit condition. This establishes a large fraction of the biomass in the aerated anoxic reactors being kept under anaerobic conditions (neither DO nor chemical oxygen available). To maximize Bio-P removal the first VLR reactor can be operated at a lower oxygen delivery rate than the second. The VertiCel system, having multiple chambers, is well suited for biomass shifting. If a sludge bulking situation ever occurred and there was a concern of the sludge blankets in the clarifiers rising too high, changing the entry point of the influent will result in reduced solids load to the clarifiers and a decrease in the sludge blankets. This has been successfully demonstrated at many plants and is an important benefit of the VertiCel system.
Page 9 of 9
3.2. NORTH VLR DISC

3.2.1 General: In North VLR Prefabricated gates PG122 to PG125 is provided to control the inflow to the VLRS. In North VLR the Disc aerators NVD1 to NVD12, probes AE 486 to AE 489, the D.O. probes AE490 to AE 493 are provided in the Aeration Cells and the D.O. probes AE 494 & AE 495 are provided in the RAS Aeration tanks. The North VLR Disc aerators NVD1 to NVD 4 are continuous in operation, NVD5 to NVD 8 are VFD controlled, based on ORP probes set points and NVD9 to NVD12 are ON/OFF controlled, based on ORP probes set points. NVD 5 & 9 is controlled by ORP probe AE 486, NVD 6 & 10 is controlled by ORP probe AE 487, NVD 7 & 11 are controlled by ORP probe AE 488 and NVD 8 & 12 are controlled by ORP probe AE 489. The air to the aeration tanks are controlled by Modulating valves (MOV 480 to 485).The modulating valves are controlled by the D.O. values. 3.2.2 Operation: When selected in Remote from MCC Panel the NVDs can be Operated from DCS. When selected in Local from MCC each NVD can be operated from LCP or MCC. In Remote Mode the NVDs can be Operated in two ways , Remote Auto Mode: When NVD 1 to 4 are placed in Auto Mode from DCS they start Running Continuously. When NVD 5 to 12 are placed in Auto Mode from DCS they Operate based on the respective analyzers (i.e. when AIT value reaches high set point the respective NVD starts), the Speed of the pump increases based on the AIT value and once the NVD reaches Rated speed the next associated NVD starts (Eg: 7 & 11 are working based on AIT 488). The NVDs are stopped when AIT value becomes low or Trip Feedback from MCC. The Modulating Valves MOV 480 to MOV 485 are controlled through respective DO values ,I.e. when the DO values are high the Valve starts opening and the percentage opening increases based on the DO value . The valves close when DO value is becomes low. Remote Manual Mode: In Manual Mode from DCS the Operator can individually Start/Stop the NVD as desired.
Page 10 of 10
3.3. SOUTH VLR DISC

In South VLR Prefabricated gates PG112 to PG115 is provided to control the inflow to the VLRS. In South VLR the Disc aerators SVD1 to SVD12 are provided. In South VLR the ORP probes AE 406 to AE 409, the D.O. probes AE410 to AE 413 are provided in the Aeration Cells and the D.O. probes AE 414 & AE 415 are provided in the RAS Aeration tanks. The South VLR Disc aerators SVD1 to SVD 4 are continuous in operation, SVD5 to SVD 8 are VFD controlled based on ORP probes and SVD9 to SVD12 are ON/OFF controlled, based on ORP probes set points. SVD 5 & 9 is controlled by ORP probe AE 406, SVD 6 & 10 is controlled by ORP probe AE 407, SVD 7 & 11 are controlled by ORP probe AE 408 and SVD 8 & 12 are controlled by ORP probe AE 409. The air to the aeration tanks are controlled by Modulating valves MOV 400 to 405.The modulating valves are controlled by the D.O. values. The prefabricated gates PG126 to PG 131 are installed to control the RAS flow from the RAS pump station to VLRs. The prefabricated gates PG116 to PG 121 are installed to control the RAS flow from the RAS pump station to VLRs. The Operation of SVD is as same as NVD as explained earlier in Section 3.2 .2.
Page 11 of 11
4. CLARIFIERS
A high solids removal efficiency and stable operation of the Final Settlement Tank, FST is particularly important. The final clarifiers are sized in order to achieve less than 15 mg/l SS in the effluent. FST surface area and depth are calculated to achieve the aforementioned clarification efficiency even with bad settling sludge (design SVI = 150 ml/l). Six (6) no. Rim-Flo Tow-Bro circular clarifiers, each 46m diameter and 5.5 m (5 m SWD) deep are provided. Rim-Flo: Peripheral feed and peripheral effluent launder system for optimizing hydraulic distribution and maximizing overflow rates in secondary clarifiers. Tow-Bro: Unitube hydraulic sludge removal header system for optimizing sludge removal and maximizing mass loading in secondary clarifiers The Rim-Flo Clarifiers peripheralfeed peripheral-overflow design has been proven to be capable of maintaining excellent effluent suspended solids quality at high overflow rates and mass loadings at competitive costs. The Rim-Flo Clarifier design introduces flow into the tank by means of the inlet raceway, which carries the flow round the entire periphery. The raceway floor contains orifices, which are sized and spaced in proper relation to channel friction losses for uniform distribution. The raceway cross section narrows in proportion to the flow to maintain a constant velocity. Flow through the orifices is dispersed by target baffles behind an annular flocculating skirt hung beneath the effluent launder. Flow enters the clarifier zone near the bottom of the tank and diffuses gently inward and upward. The improved performance of the Rim-Flo Clarifier design may be attributed to the substantial difference in the inlet velocities. Velocity at the inlet of the clarifier zone is been shown to be 5 to 10 times greater in centre feed tanks. The substantially greater inlet area of the peripheral feed design reduces the amount of energy, which must be dissipated in the clarification zone. Rim-Flo eliminates the short circuiting caused by the upturn in flow at the sidewall of centre-feed tanks. Centre feed tanks show an inherent decrease in hydraulic efficiency with increasing overflow rates. In the peripheral feed design flow is away from the weirs. Convergence of the flow is at the centre of the tank - the furthest point possible away from the weirs. Unique to the peripheral feed design is an increase in hydraulic efficiency with increasing overflow rates. This may be partly attributed to the comparatively small increase in the velocity head at the inlet to the clarification zone. This results in better performance under surge loads. Rim-Flo clarifiers can handle overflow rates 50% higher than conventional designs. Siemens Tow-Bro Unitube header design assures an active biomass is returned to the aeration tank of activated sludge plants at the highest possible concentration. Field observations indicate a Tow-Bro header can produce return solids concentration 50% to 100% higher than scraper clarifiers and 50% to 75% higher than competitive hydraulic removal devices. This results in a volumetric reduction in sludge pumped of 25% to 50% for an equivalent amount of solids returned. Further, rapid sludge removal reduces air requirements in the activated sludge process and limits rising solids problems associated with nitrogen gas release when solids sit too long in the final clarifier. This minimizes the amount of scum build-up on the surface of the secondary clarifier. Rapid sludge
removal offers the additional benefit of limiting phosphate release to the final effluent. Clarified effluent shall be collected by peripheral overflow weirs. The tank floors will be sloped (approx. 0.50%) in order to assist tank draining and sludge will be hydraulically removed by a unitube suction header, hang from a rotating bridge and transported to a sludge collection manifold. The sludge shall be removed from the centrally positioned manifolds through bell mouth valves. Each clarifier shall be equipped with a dual scum removal system. The main scum removal system, consist of a scraper in the influent distribution channel of the Rim-Flo Tow-bro system. A second backup scum removal system is installed in the main body of the clarifier. Both scum collections will be collected in a scum pit from where the scum is pumped to the sludge drying beds. The Peripheral drive has control to alarm and stop by torque switches. The sludge shall be transported by pipes to the RAS - SAS pumping station.
4.2. OPERATION
The signals from the Clarifiers are hardwired to the DCS and the equipment are monitored and controlled from DCS directly. Each clarifier equipped with Torque switch which on high high will shutdown the clarifier and the clarifier can be started again after a manual reset in the field. High torque switch is provided for warning, warning alarm is annunciated at DCS. The Operation of the clarifiers is either from local or remote. When selected in local the clarifiers are operated from the Local control panels kept near the clarifier. When selected in Remote the clarifiers can be operated in Remote Auto or Remote Manual. In Remote auto mode upon operator selecting Auto sequence start the clarifiers which are available in Auto start sequentially (with time delay) and keep running continuously. In Remote auto mode upon operator selecting Auto sequence stop the clarifiers which are available in Auto stop sequentially (with time delay) and keep running continuously. In Remote Manual Mode the clarifier can be started or stopped by operator from DCS individually from Operator Station.
Page 13 of 13
5. RAS/SAS PUMPS
5.1. GENERAL
RAS Pumps There are 4 Submersible RAS pumps in RAS/SAS Pumping station. For dry run protection of pumps one low low level float switch with low low alarm is provided at Tank 2 and Tank 3. The signals from the RAS pumps will be hardwired to the MCC and they are monitored and controlled from DCS through these signals. A Local control panel (LCP-RASP) is provided with Individual Local /Remote selection switch, Start, Stop Push button and Emergency Lockout Push button. The RAS Pumps Operate as 3 duty and 1 standby. The pump duties are assigned based on the run hours of the pump. The least run pump is assigned duty 1 and next run pump is duty 2 and most run pump as standby. Alternatively manual entry of Duty can be done from the Priority setting available in DCS Operator Station. SAS Pumps There are 2 SAS pumps in RAS/SAS Pumping station. For dry run protection of pumps one low low level float switch with low low alarm is provided at Tank 2 and Tank 3. The signals from the SAS pumps will be hardwired to the DCS and they are monitored and controlled from DCS through these signals. A Local control panel (LCP-SASP) is provided with Individual Local /Remote selection switch, Start, Stop Push button and Emergency Lockout Push button. The SAS Pumps Operate as 1 duty and 1 standby. The pump duties are assigned based on the run hours of the pump. The least run pump is assigned duty 1 and most run pump as standby. Alternatively a duty change button is provided in the DCS Operator Station for changing duty between 2 pumps.
5.2. RAS PUMP OPERATION

When selected in Local from the Local/Remote selector switch in the MCC the pump is operated from the respective push buttons provided at the Local control panel. In local mode shall be started /stopped individually from the Local control panel and will stop automatically on low low level float alarm. In local mode the pump status and alarm will be displayed in the DCS and no operation can be done from DCS. When selected in Remote from the Local/Remote selector switch in the MCC the pump can be operated from DCS. In Remote Mode pump can be operated in two ways Remote auto or Remote Manual. An Auto/Manual selection is provided in the DCS OS for this purpose. In remote auto mode the Pump is operated based on the Flow set point configured in the DCS.
Whenever Flow Demand is available the first Duty Pump starts Operating and its speed increases to full speed. Based on the demand after a time delay the second duty pump starts and followed by the third duty pump. In case of failure of running pump the standby pump starts. Once the failed pump becomes normal it will remain in standby until the next duty cycle change over. A Duty reorder in hours is provided in the OS for reordering duty pumps after the set time. In Remote manual mode the pumps can be operated individually from DCS OS station.
5.3.
SAS PUMP OPERATION
When selected in Local from the Local/Remote selector switch in the MCC the pump is operated from the respective push buttons provided at the Local control panel. In local mode shall be started /stopped individually from the Local control panel and will stop automatically on low low level float alarm. In local mode the pump status and alarm will be displayed in the DCS and no operation can be done from DCS. When selected in Remote from the Local/Remote selector switch in the MCC the pump can be operated from DCS. In Remote Mode pump can be operated in two ways Remote auto or Remote Manual. An Auto/Manual selection is provided in the DCS OS for this purpose. In remote auto mode the Pump is operated based on the Flow set point configured in the DCS.
Page 15 of 15
6. FILTRATION
The effluent from the clarifiers passes through the clarifier collection chamber to the Disc filter influent channel. The overflow from this chamber will flow to the overflow pipe line and the overflow quantity will be measured by ultrasonic flow meter (FIT 102). The summation of flow meters FIT 101 & 102 will show the total overflow quantity for Kubd WWTP. Eight (8) rotating disc filters (DFL-1 to DFL-8) will be installed for the final polishing of the effluent. The filtration media will be Polyester with a pore size of 10 m. Each filter unit consists of a rotating drum onto which are assembled the filter disc panels. Filtration occurs from the inside of the filtration panels and towards the outside. The wastewater is fed by gravity to the inside of the drum and into each filtration panel. The suspended solids are retained on the inside of the filter panels while the filtrate discharges into the chamber. As the solids accumulate on the filter panels, a head loss starts to develop. The filter panels are continuously cleaned by backwashing with filtrate water. The filtration process is continuous even during backwash. The disc filter is provided with Back wash pumps (BWP-1 to BWP 8). The Level switches are provided in the influent channel for the backwash control. The prefabricated gates (PG140 to PG147) are provided to open/close the individual filters. The turbidity Analyzer (AE610) is installed in the inlet of the Disc filters to monitor the turbidity levels. Disc filter control Panel consist of a PLC controlling both Drum drive and Backwash pumps As the filter media collects solids, the water level in the influent chamber of the disc filter rises. If the level reaches the High level switch (LSH) the backwash cycle will start, ie the backwash pump will start and with time delay the discs will start. The Backwash will end till the low level (LSL) switch activated or the timer (KQIC 630) activated. To avoid the multiple filters backwashing at the same time, every start of backwash cycle of each filter will sent a request to DCS for permissive to Backwash and it will allow the Disc filter to carry out the backwash as per the level set limits. The extended backwash cycle option will be provided in the disc filter PLC for every 20th backwash cycle. The backwash water is conveyed to the Return Liquor Pumping Station.
6.2. OPERATION OF DISC FILTER AND BACKWASH PUMP

L/O/R selector switch is provided in the Vendor control Panel for Operation of Disc Filter. The Disk Filter VFD speed control is done using a potentiometer type arrangement provided in the disk filter control panel. The Disk filter is operated based on the flow requirement and adjustable timer in the Disk filter Supplier control panel. L/O/R selector switch is provided in the Disk filter Supplier control Panel for operation of Backwash Pump. Backwash is initiated based on the level high signal or timer settings in the Disk filter Supplier control panel.
Page 16 of 16
When selected in Local the Backwash Pumps operate directly from the Disk filter Supplier control panel. In remote mode the backwash Pumps operate based on permissive provided from the DCS for starting backwash from Disk filter Supplier control Panel. In remote mode to decide the permissive an Auto/Manual selector switch is provided in the DCS. When selected in Remote Manual the operator can provide or reject permissive to start backwash directly as and when the request comes. When selected in Remote Auto mode the permissive for backwash is provided automatically based on the flow range set points, availability of filters and number of filtration required. A Table as shown below will be used to decide the number of filters require infiltration. NUMBER OF FILTRATION 1 2 3 4 5 6 7 8 (The range is Operator Settable) Based on number of filtrations required and availability of filters the Backwash permissive is provided to the Disk filter Supplier control panel, as and when backwash request comes to start backwash. Suppose there is requirement of filtration based on flow in a particular filter but a backwash request comes for that filter, the filter continues to be in filtration until the filtration demand is available. Once there is no filtration demand for the filter it goes in to backwash. The Backwash request will be first come first serve basis if more than one filter is requested for backwash. The Operator can override the Remote Auto operation of backwash permissive by selecting in Remote manual mode for backwash permissive.
FLOW RANGE RANGE 1 RANGE 2
Page 17 of 17
7. UV SYSTEM
7.1. GENERAL
The UV System is equipped with dedicated PLC System to Control and Monitor the UV System. The datas from this UV PLC is sent to DCS through a Profibus DP Communication Link. Detail Operation of UV System is as explained in Document (FD South Amghara Rev 1).
Page 18 of 18
8. EFFLUENT STORAGE RESERVOIR

The effluent from UV System is flown into Overflow chamber. From the overflow chamber effluent is transferred to Effluent collection chamber. The effluent to effluent collection chamber from overflow chamber is controlled through motorized gate valve. The Motorized gate valve is opened based on the Level of effluent in the Effluent collection chamber. A flow meter (FIT 732) is used to measure the outlet flow from Effluent collection chamber to DMC.
Page 19 of 19
9. TANKER WASTE FACILTIY

9.1. GENERAL
The Tankered waste lift station consists of a well with three submersible pumps (TWP1 to TWP3) controlled by using an ultrasonic level measurement system. The Pumps collect flow from Tankered Waste Screening System and pumps it into Inlet head works influent chamber. For dry run protection of pumps one low low level float switch provided with low low alarm. Flow monitoring is provided at the outlet of the pumping station to measure the outlet flow. A Pump control panel (PCP-TWP) is provided with Individual Local /Remote selection switch, Start, Stop Push button and Status Indication lamps. The signals from the TW pumps will be hardwired to the PCP TWP. Necessary signals are then retransmitted to DCS by hardwired line for monitoring and automatic controls. The dry run protection float switch is connected to the Pump Control panel and from there it is duplicated to DCS for alarm and shutdown of pumps. Moisture and Temperature switches are provided for pump protection. The running pump trips upon receiving Temperature or Moisture high.
9.2. PUMP OPERATION

The Pumps Operate as 2 duty and 1 standby. The pump duties are assigned based on the run hours of the pump. The least run pump is assigned duty 1 followed by next least run pump as duty 2 and most run pump as standby. Also Pump duties can be assigned manually by the Operator from the Priority setting available in DCS Operator Station. When selected in Local from the Local/Remote selector switch in the Pump control panel the pump is operated from the respective push buttons provided at the Pump control panel. Pump will stop automatically on low low level float alarm. In local mode the pump status and alarm will be displayed in the DCS and no operation can be done from DCS. When selected in Remote from the Pump control panel the pump can be operated from DCS in Remote manual or Remote Auto mode through the Auto/Manual selection on DCS faceplate. In Remote Manual Mode pump can be started or stop using start/Stop selection in DCS faceplate. In Remote auto mode the Pump is operated based on the Level set points configured in the DCS. The Pump Operation is as shown in table below
Page 20 of 20
LEVEL LSH LSHH LSL LSLL
OPERATION Start duty 1 pump Start duty 2 pump Stop running Pumps Dry Run Protection
The On and off range can be entered from DCS Operator Station. In case of failure of one running pump the standby pump starts Operating. The standby pump continues to run even after the failed pump becomes available. In the next duty cycle the pumps get altered.
Page 21 of 21
10.
10.1.GENERAL
SLUDGE THICKNER SYSTEM
The plant is composed by three streams of thickeners GBT 3000 Optima.
10.2.OPERATION MODE
The following sequence is suggested and applies to one line. The others are just the same. The operator can choose, by local selectors, the operating mode of each equipment:
manual mode stop automatic mode

In manual mode the operator can start and stop individually each equipment of the plant. This operation mode is recommended for maintenance and service only. In manual mode all the safety controls stay active. In automatic mode all the equipment starts and stops automatically depending by some conditions. The automatic mode is subject to a general start stop selection opera rated by the touch screen interface on front page, previous setting on the automatic mode for each equipment and the status of the ancillary services of the plant, as following described.
10.3.INTERLOCKS
Before the start in automatic mode the operator has to take care to check the ancillary services are ready to operate: Polyelectrolyte unit PPU - 1 and 2 running. All safety interlocks and/or sensor must be in safety condition (i.e. emergency rope switch on the gravity table, emergency mushroom, and so on) washing water available
10.4.SEQUENCE OF OPERATION
After that the startup follows the sequence below: 1. Starts discharge sludge pump TSLP-1 if the level LSH763 is covered. This pump keep running until the minimum level LSL763 is reached. In case of fault over temperature TSH763 reached, overpressure PSH763 reached, over level LSHH763 reached or motor circuit breaker shut-off, all the upstream equipment will stop too. 2. If the operations above are satisfied the solenoid valvePCV762 opens and after a pre settable time the washing pump TWBP-1 starts too. When the pump is running the pressure switch PSL762 is continuously monitored and, if it is missing for a pre settable time in seconds, generates the stop of the washing pump and, after some seconds, the closure of the valve at the same time all the equipment upstream the washing pump (including gravity table) will stop too after until empty.
3. After a preset time the washing pump TWBP-1 is running the gravity table starts. The gravity keep running until one or more of the following conditions are satisfied: a. If LSH763 covered stops the gravity table motor until the LSL763 is uncovered and a preset time has elapsed. This condition stop temporarily the sludge inlet upstream the gravity table. b. Rope emergency switch HS760A or HS760B. This intervention is equivalent to an emergency stop that means that all the equipment of the line must be stopped immediately c. Belt misalignment ZS760A or ZS760B. In case of intervention of the sensors the gravity table wills stops immediately together all the upstream equipment including washing pump and mixer. This condition require an operator inspection on site before to restart the operations d. LSH760 and LSHH760. The fist level limit indicates to the operator that the level of the sludge on the belt is greater then the maximum allowed. If no action are took and LSHH760 is reached than the gravity table will stops immediately together all the upstream equipment including washing pump and mixer. This condition requires an operator inspection on site before to restart the operations. e. If the minimum sludge level on the belt LSL760 stay under the minimum allowed for a preset time (this condition is signalled to the operator) then the sludge feeding line needs to be checked to find the possible cause. If the the LSL760 remains the gravity table will be stopped together all the upstream equipment including washing pump and mixer. This condition requires an operator inspection on site before to restart the operations. 4. Both mixers TMXR1 A&B start only if the sludge pump STFP1 and polyelectrolyte pump PDP1 are running. 5. Sludge pump STFP1 and polyelectrolyte pump PDP1 start together after the conditions above are satisfied. Both pumps must running together, in case of fault of one pump (or missing of the running enables) the other one stops too. Sludge pump starts if the sludge minimum level of holding tank is covered. During the running of the pump the over temperature TSH754, overpressure PSH754 are continuously monitored and, in case of intervention, stops immediately both the pump PDP1 and STFP1. Polyelectrolyte pump starts if the minimum level inside the polyelectrolite preparation unit is covered and if the unit is not in fault. During the running of the pump the over temperature TSH751, overpressure PSH751 are continuously monitored and, in case of intervention, stops immediately both the pump PDP1 and STFP1. 6. the discharge screw TSLP1 is running controlled by LS 763 levels system. 7. The Controls of the Sludge thickner System is from dedicated Sludge thickner PLC and data are monitored from DCS thorugh Profibus Communication.
10.5.FAULT CONDITION:
In case of intervention of the motor circuit breaker of one of the equipment, all the equipment upstream the fault must be stopped too. The sludge and the polyelectrolyte pumps, powered with VFD, are in a closed loop with corresponding flow measurement instrument. This keeps the presetting flow rate for the polyelectrolyte and sludge line. The PID for the closed loop is implemented directly on the PLC software. Following an example for the sludge pump: The manual set indicate the flow rate of the sludge to keep.
Page 23 of 23
11.
11.1.GENERAL
SLUDGE DEWATERING SYSTEM
The plant is composed by three streams of belt presses: BPF 3000 Optima
11.2.OPERATION MODE
The following sequence is suggested and applies to one line. The others are just the same. The operator can choose, by local selectors, the operating mode of each equipment:
manual mode stop automatic mode

In manual mode the operator can start and stop individually each equipment of the plant. This operation mode is recommended for maintenance and service only. In manual mode all the safety controls stay active. In automatic mode all the equipment starts and stops automatically depending by some conditions. The automatic mode is subject to a general start stop selection operarated by the touch screen interface on front pane, previous setting on the automatic mode for each equipment and the status of the ancillary services of the plant, as following described.
11.3.INTERLOCKS
Before the start in automatic mode the operator has to take care to check the ancillary services are ready to operate: Polyelectrolyte unit PPU - 1 and 2 running. All safety interlocks and/or sensor must be in safety condition (i.e. emergency rope switch on the gravity table, emergency mushroom, and so on) washing water available
11.4.SEQUENCE OF OPERATION
After that, the startup follows the sequence below: 1. Start of the air compressor AD2 (normally this could be required a manual command by the operator). 2. Starts the belt conveyors CNV2 & 3 3. If the operations above are satisfied the solenoid valve SV837 opens and after a pre settable time the washing pump TWBP4 starts too. When the pump TWBP4 is running the pressure switch PSL837 is continuously monitored and, if it is missing for a pre settable time in seconds, generates the stop of the washing pump and, after some seconds, the closure of the valve SV837. At the same time all the equipment upstream the washing pump (including belt press) will stop too.
Page 24 of 24
4. After a preset time the washing pump TWBP4 is running the belt press BFP1 starts. The press keep running until one or more of the following conditions are satisfied: a. Rope emergency switch HS835A or HS835B. This intervention is equivalent to an emergency stop that means that all the equipment of the line must be stopped immediately b. Belt misalignment ZS2835A or ZS2835B. In case of intervention of the sensors, the belt press will stop immediately together all the upstream equipment including washing pump and mixer. This condition require an operator inspection on site before to restart the operations c. LSH835 and LSHH835. The first threshold indicates to the operator that the level of the sludge on the belt is greater then the maximum allowed. If no action is taken and LSHH835 is reached the belt press will stop immediately together with all the upstream equipment including washing pump and mixer. This condition requires an operator inspection on site before to restart the operation. d. If the minimum sludge level on the belt LSL835 stay under the minimum allowed for a preset time (this condition is signalled to the operator) the sludge feeding line needs to be checked to find the possible cause. If the the LSL835 remains all the upstream equipment including washing pump and mixer. This condition require an operator inspection on site before to restart the operations 5. Mixer DMXR1 starts only if the sludge pump DSLP1 and polyelectrolyte pump PDP4 are running. 6. Sludge pump DSLP1 and polyelectrolyte pump PDP4 start together after the conditions above are satisfied. Both pumps must running together, in case of fault of one pump (or missing of the running enables) the other one stops too. During the running of the pump DSLP1 the overtemperature switch TSH823 ( dry running protection ) , overpressure PSH823 are continuously monitored and, in case of intervention, stops immediately both the pump DSLP1 and PDP4 Polyelectrolyte pump starts if the minimum level inside the polyelectrolyte preparation unit is covered and if the unit is not in fault. During the running of the pump DSLP1 the overtemperature TSH820 (dry running protection). Overpressure PSH820 are continuously monitored and, in case of intervention, stops immediately both the pump DSLP1 and PDP4. 7. The Controls of the Sludge thickner System is from dedicated Sludge dewatering PLC and data are monitored from DCS thorugh Profibus Communication.
11.5.FAULT CONDITION:
In case of intervention of the motor circuit breaker of one of the equipment, all the equipment upstream the fault must be stopped. The sludge and the polyelectrolyte pumps, powered with VFD, are in a closed loop with corresponding flow measurement instrument. This keeps the presetting flow rate for the polyelectrolyte and sludge line. The PID for the closed loop is implemented directly on the PLC software.
Page 25 of 25
12.
AEROBIC DIGESTOR
12.1.EQUIPMENT DESCRIPTION
Thickened SAS will be stabilized in continuous flow aerobic digesters. Eight (8) no. aerobic digesters shall be constructed. Aeration and mixing will be provided by 2 surface aerators per digester (SAER 1 to SAER 16). Operation of the aerators shall be usually continuous. The digested sludge will be conveyed through a system of pipes, to the Digested Sludge Pumps located in the Sludge Dewatering Building.
12.2.OPERATION
The signals from the Aerobic digesters will be hardwired to the DCS and they are monitored and controlled from DCS through these signals. When selected in Local Mode in the MCC the surface aerators can be operated from the Local Control panels near the equipment or from the MCC. In Remote mode the equipment can be operated from the DCS either in Remote Auto or Remote Manual. In Remote Auto mode the aerobic digesters available in Auto will be running sequentially after a time delay continuously upon selection of Auto sequence. Remote Manual it can be operated individually from DCS OS.
Page 26 of 26
13.
CHLORINATION SYSTEM
The Liquid containers will be placed on the weighing scale and the weight of each container will be seen on the local display. The liquid chlorine is to be withdrawn from the chlorine containers and to facilitate this manifolds are connected to the chlorine cylinders. The liquid chlorine will flow from this manifold to the switch over system. Liquid chlorine varies its pressure based on the atmospheric temperature i.e. as the temperature increases the pressure in the manifold increases and vice versa. To protect the chlorine from over expansion, expansion chambers will be connected into the liquid chlorine manifold. The expansion chamber consists of a chamber and a pressure gauge with electrical contact installed on the top of it and a rupture disc is installed at the bottom of the expansion chamber. In the event of over pressure in the manifold or if the liquid chlorine is trapped in between two liquid chlorine valve, the rupture disc installed at the bottom of the expansion chamber will break and liquid chlorine will enter the expansion chamber thus displaying the chlorine pressure on the pressure gauge of the expansion chamber and at the same time providing an signal into the main control panel of problem in the manifold. Chlorine change over Unit (CCU): Motorized valve are installed connecting two manifolds. As the chlorine is getting consumed from the container the pressure into the switchover unit will reduce and at a set point of 1 bar (Set point to be set manually) a relay will activate and close the motorized valve of the line which is empty and at the same time it will open the other motorised valve which has the line full of chlorine and thus allowing the chlorine to pass through it into the evaporator. Manual reset at CCU is required after replacing empty chlorine container. The indication of which line is working and which is not is shown in the switchover panel by LED lights. The signals are retransmitted to DCS for monitor chlorine leak in evaporator and/or chlorinator area. Both MOV close automatically upon detection of chlorine leak. This liquid chlorine will be travelling into the evaporator where in the liquid chlorine will be heated to the gas phase under controlled conditions. The temperature in the evaporator is set between 68 -71 Deg .C. The heaters are 5KW and will be manually kept in on position. Water is allowed by opening the solenoid valve; the evaporator has a water level switch which will automatically allow water into the evaporator by opening the solenoid valve. The water bath temperature is maintained to above set limits by a contact thermometer, which also indicates the temperature for safety purpose and additional thermostats are provided which alarms at temperatures below 60 deg and above 80 deg which closes the evaporator discharge side MOV. If any of the above parameters is out of order the evaporator will fail. There are also pressure gauges with electrical contact is installed on the evaporator which will control the motorized valve installed on the delivery line after the evaporator. If the pressure in the evaporator increases more than 8 bars the Motorized valve will close and will not allow any chlorine to pass through it. The indication of the same will be shown in the panel. The liquid chlorine after conversion into the gas chlorine will be travelling into the
pressure reducing valve where the pressure is reduced to the 1 bar and then it is fed into the chlorinator and then into the ejector based on the vacuum the ejector generates. The booster pump is designed to deliver 78m3/hr of water into the chlorine ejector. This water during its passage into the ejector will create vacuum and this action will allow the chlorine to flow into the chlorinator. If the booster pumps stops then the entire chlorination systems stops and thus no chlorine can leak out of the system. In case of any chlorine gas leak in evaporator/chlorinator area , motive water pumps will shut down after a time delay. The chlorinators are automatic with manual overdrive. The Chlorine flow rate can be set manually. The chlorinator houses it control valve which is powered by 24V Dc. This control valve is programmed to accept 4-20mA external signal and it will control the flow rate of chlorine from the chlorinator based on the signal it receives from the external source. Chlorine residual analyzer will be fed the chlorinated water after the Chlorine is injected into the overflow chamber. The distance between the injection point and take off point for the analyzers is 60times pipe diameter. The analyzer will receive the disinfected water analyze it and feed the signals to the chlorinator for it to adjust the chlorine flow based on the set point one feeds into the analyzer. Fault annunciation is provided in the Local control Panel and all the signals are duplicated to DCS. Signals from Chlorination System are hardwired to the DCS Chlorination RIO Panel.
Page 28 of 28
14.
14.1. GENERAL
AIR BLOWERS
As the blower curves the flow in Nm3/h is proportional to the power, the program will calculate the flow according motor shaft absorbed power. The system is built with a Siemens Redundant system, so in case of problem on the running PLC, the second one will immediately controls the blowers so no impact on the WWTP work. The Blower parameters are monitored in the DCS through a Redundant Profibus Communication.
14.2. BLOWER OPERATION

A. Automatic mode / constant pressure regulation On the HMI (located on the Control cabinet) the operator will put the Automatic mode ON The blowers in parallel operation will supply a common pipe 2 pressure transmitters must be installed and wired but only one will be used for the regulation. The second one is a standby. The air quantity distributed by this common pipe to several aeration zones will be regulated according to the process requirements. The differential pressure in the Common pipe must be as constant as possible. The blowers must therefore supply the air quantity necessary to maintain this pressure. Only one blower must be regulated according to the pressure. The additional blower working in parallel will produce a flow considered as fixed. The atmospheric conditions and in particular the ambient air temperature have an influence on the blowers performances. In order to handle these variations the Design flow of the blowers will not be imposed by a fixed position of the inlet valve but will be defined by a regulation at fixed power . The startup/stop of the blowers will be managed through Blower PLC System. In order to distribute the working periods between each blower the blower with the longest standstill will be the next one to be started up . B. Flow blower mode The manual selector (one for each blower) must indicate the Flow mode position A specific program will adjust the position of the blower inlet valve to keep a constant power (it means a constant flow) the securities and the start up and stop procedures will remain active. In this mode the pressure is not regulated so the customer must open the basin valves at the good position to prevent a surge defect from one or more running blowers C.Maintenance mode The manual selector (one for each blower) will indicate the maintenance position. It is necessary to have a blower working independently from the regulation system in order to carry out the checking relating to its maintenance. So a specific program will be integrated into the PLC. Each Local panel will be provided with buttons & selector to move valves and start/stop
motor for maintenance checking. The safeties and the start up and stop procedures will remain active. In this mode the pressure is not regulated so the customer must open the basin valves at the good position to prevent a surge defect from one or more running blowers D.Safety The following parameters are provided as safety interlock for Blower Operation: Motor Power is checked continuously ( From VFD through Profibus Link ) Blower Bearing Temperature (2 Probes for each Blower), in this two parameters are checked alarm level at 110 deg Celsius and stop level at 120 deg Celsius. Blower Vibration ( 1 probe located at each bearing so totally 2 for each Blower ) , in this two parameters are checked alarm level at 5mm/s and stop level at 7mm/s. The differential pressure on the filter is checked continuously per a Differential pressure Switch. In case of clogging (dry contact) => alarm, the filter must be cleaned or changed Motor Bearing Temperature (2 Probes for each motor), in this two parameters are checked alarm level at 90 deg Celsius and stop level at 110 deg Celsius. Motor Winding Temperature (3 Probes for each motor located on motor wires) The inlet air temperature will be measure. This measure will be used for calculation of the blower speed set-point.
Page 30 of 30
15.
SCUM PUMPING STATION
15.1.INLET SCUM PUMP STATION

The Inlet Scum Pump station consists of a well with two submersible pumps (SCP1 to SCP2) controlled by using an ultrasonic level measurement system. The Pumps collect flow from Inlet oil separator and pumps it into Sludge drying beds. For dry run protection of pumps one low low level float switch provided with low low alarm. A Pump control panel (PCP-ISPS) is provided with Individual Local /Remote selection switch, Start, Stop Push button and Status Indication lamps. The signals from the Scum pumps will be hardwired to the PCP- ISPS . Necessary signals are then retransmitted to DCS by hardwired line for monitoring and automatic controls. The dry run protection float switch is connected to the Pump Control panel and from there it is duplicated to DCS for alarm and to shutdown running pumps when operated from DCS. Moisture and Temperature switches are provided for pump protection. The running pump trips upon receiving Temperature or Moisture high.
15.2.SECONDARY SCUM PUMP STATION

The Secondary Scum Pump station consists of a well with two submersible pumps (SCP3 to SCP4) controlled by using an ultrasonic level measurement system. The Pumps collect flow from Inlet oil separator and pumps it into Sludge drying beds. For dry run protection of pumps one low low level float switch provided with low low alarm. A Pump control panel (PCP-SSPS) is provided with Individual Local /Remote selection switch, Start, Stop Push button and Status Indication lamps. The signals from the Scum pumps will be hardwired to the PCP- SSPS . Necessary signals are then retransmitted to DCS by hardwired line for monitoring and automatic controls. The dry run protection float switch is connected to the Pump Control panel and from there it is duplicated to DCS for alarm and to stop running pumps when operated from DCS. Moisture and Temperature switches are provided for pump protection. The running pump trips upon receiving Temperature or Moisture high.
15.3.PUMP OPERATION
The Pumps Operate as 1 duty and 1 standby. The pump duties are assigned based on the run hours of the pump. The least run pump is assigned duty and most run pump as standby. Also a duty change button is provided in the DCS OS from Manual Duty change over.
When selected in Local from the Local/Remote selector switch in the Pump control panel the pump is operated from the respective push buttons provided at the Pump control panel. Pump will stop automatically on low low level float alarm. In local mode the pump status and alarm will be displayed in the DCS and no operation can be done from DCS. When selected in Remote from the Pump control panel the pump can be operated from DCS in Remote manual or Remote Auto mode through the Auto/Manual selection on DCS faceplate. In Remote Manual Mode pump can be started or stop using start/Stop selection in DCS faceplate. In Remote auto mode the Pump is operated based on the Level set points configured in the DCS .The Pump Operation is as shown in table below LEVEL LSHH LSH LSL LSLL OPERATION Hi Hi Level alarm Start duty 1 pump Stop duty 1 pump Dry Run Protection
The above parameters can be set from the DCS Operator Station. In case of failure of one running pump the standby pump starts Operating. The standby pump continues to run even after the failed pump becomes available. In the next duty cycle the pumps get altered.
Page 32 of 32
16.
16.1.GENERAL
RETURN LIQUOR PUMPING STATION
The Return liquor Pump station consists of a well with three submersible pumps (RLP1 to RLP3) controlled by using an ultrasonic level measurement system. Pumps collect return liquor and drain flows from the Filters Backwashing System, the Sludge Thickeners, the Sludge Dewatering Facility, the Sludge Drying beds, and the Sludge Treatment Odor Control Facility and pumps it to Aeration distribution chamber. For dry run protection of pumps one low low level float switch provided with low low alarm. A Pump control panel (PCP-RLP) is provided with Individual Local /Remote selection switch, Start, Stop Push button and Status Indication lamps. The signals from the RL pumps will be hardwired to the PCP RLP. Necessary signals are then retransmitted to DCS by hardwired line for monitoring and automatic controls. The dry run protection float switch is connected to the Pump Control panel and from there it is duplicated to DCS for alarm and to stop running pumps when operated from DCS. Moisture and Temperature switches are provided for pump protection. The running pump trips upon receiving Temperature or Moisture high.
16.2.PUMP OPERATION
The Pumps Operate as 2 duty and 1 standby. The pump duties are assigned based on the run hours of the pump. The least run pump is assigned duty 1 followed by next least run pump as duty 2 and most run pump as standby. Also Pump duty can be set manually from the Priority setting of pumps. When selected in Local from the Local/Remote selector switch in the Pump control panel the pump is operated from the respective push buttons provided at the Pump control panel. Pump will stop automatically on low low level float alarm. In local mode the pump status and alarm will be displayed in the DCS and no operation can be done from DCS. When selected in Remote from the Pump control panel the pump can be operated from DCS in Remote manual or Remote Auto mode through the Auto/Manual selection on DCS faceplate. In Remote Manual Mode pump can be started or stop using start/Stop selection in DCS faceplate. In Remote auto mode the Pump is operated based on the Level set points configured in the DCS .The Pump Operation is as shown in table below
Page 33 of 33
LEVEL LSHH LSH1 LSH2 LSL LSLL
OPERATION Hi Hi Level alarm Start duty 1 pump Start duty 2 pump Stop running pumps Dry Run Protection
The above ranges can be set from DCS Operator Station. In case of failure of one running pump the standby pump starts after a time delay. The standby pump continues to run even after the failed pump becomes available. In the next duty cycle the pumps get altered.
Page 34 of 34
17.
17.1.GENERAL
WASH WATER PUMPING STATION
The WWPS consists of a wash water sump, four pumps (WWP1 to WWP4) and four media filters. The Pumps collect water from UV collection chamber and sends it to Wash water distribution system. For dry run protection of pumps one low low level float switch provided with low low alarm. The Pumps Operate based on the Common header pressure transmitter (PIT 1080) when operated from DCS and based on the Pressure switches (PS 1061 PS 1063) when operated from PCP. A Pump control panel (PCP-WWPS) is provided with Local /Remote selection switch, Individual Hand/Auto selector switch, Individual Start, Individual Stop Push button and Status Indication lamps. The signals from the WWPs will be hardwired to the PCP -WWP. Necessary signals are then retransmitted to DCS by hardwired line for monitoring and automatic controls. The dry run protection float switch is connected to the Pump Control panel and from there it is duplicated to DCS for alarm and shutdown of pumps. The status of the media filters provided after the wash water pumps are monitored in the DCS.
17.2.PUMP OPERATION
The Pumps Operate as 3 duty and 1 standby. The pump duties are assigned based on the run hours of the pump. The least run pump is assigned duty 1 followed by next least run pump as duty 2 followed by next least run pump as duty 3 and most run pump as standby. When selected in Local from the Local/Remote selector switch in the Pump control panel the pump is operated from the PCP. In PCP each Pump is has one Hand/Auto selector switch when selected in auto the pumps operate based on the PS 1061- 1063 and when selected in Hand the pumps are operated from the push buttons provided in the panel. When selected in Remote from the Pump control panel the pump can be operated from DCS in Remote manual or Remote Auto mode through the Auto/Manual selection on DCS faceplate. In Remote Manual Mode pump can be started or stop using start/Stop selection in DCS faceplate. In Remote auto mode the Pump is operated based on the Pressure set points (set from DCS OS) Whenever the Pressure becomes low the first duty pump starts and the Pressure is not build over a period of time the second duty pump starts followed by the third pump. As the pressure increases the Pumps stop in the reverse order of starting. In case of failure of one running pump the standby pump starts after a time delay. The standby pump continues to run even after the failed pump becomes available. In the next duty cycle the pumps get altered.
Page 35 of 35
18.
ODOR CONTROL SYSTEM- INLET AND SLUDGE
18.1.INLET WORKS ODOR CONTROL A. PROCESS DESCRIPTION :

All channels, screens, grit chamber, screening conveyor, screen treatment, grit classifiers grit treatment, and wet wells are covered and provided with air ducting system to convey foul air to the Odor Control Unit. An Odor Control Facility is provided comprised of a 3-stage LO/PRO chemical scrubber followed by a dual bed activated carbon adsorber filled high capacity carbon media. The intention of the carbon adsorber is to provide final polishing of any residual odors that escape the chemical scrubber and to provide backup odor control during periods when the scrubber system is undergoing maintenance. Hydrogen sulfide laden air passes through ductwork to the LO/PRO odor control scrubber. The system utilizes Sodium Hydroxide (NaOH) and Sodium Hypochlorite (NaOCl) to react with and remove the odorous compounds present in the airstream. The chemistry of the system is as follows: under alkaline conditions and with the presence of excess NaOCl, H2S is oxidized to form sulfuric acid. This sulfuric acid is then neutralized by NaOH to form the stable byproduct sodium sulfate. In order to compensate for the consumption of NaOH and NaOCl in the system the pH and Oxidation Reduction Potential (ORP or Redux) are continuously monitored by pHand ORP probes and controllers. Chemical dosing pumps maintain the pH and ORP levels automatically, receiving signals from the pH and ORP PID controllers. Siemens Water Technologies LO/PRO odor control system is a "once-through", three stage absorption system consisting of three vertical counter-current gas absorption sections. The exhaust fan pulls the odorous air from the H2S producing areas and through the LO/PRO odor control system. The foul air first enters a pre-conditioning stage (Stage 1) where it is contacted with liquid from the Stage 1 sump in a countercurrent arrangement. The Stage 1 sump consists of a solution of Sodium Hydroxide (NaOH) at a pH between 10-10.5. The first stage removes approximately 70% of the inlet H2S. In the second stage, the partially treated air is contacted with additional Sodium Hydroxide solution. In the second stage, an additional 70% of the remaining H2S is removed. In this way approximately 90% of the H2S is removed in the first two stages. This configuration minimizes chemical costs by significantly reducing the amount of Hydrogen Sulfide that reacts with Sodium Hypochlorite in Stage 3. In the counter-current final stage, the remaining 10% of the inlet H2S, and any residual organic odors are contacted with a solution of NaOH and NaOCl. The final stage assures the remaining odorous compounds are oxidized. The scrubbed air is discharged from the system through a mist eliminator. A polypropylene packing media is used to allow the necessary chemical reaction of H2S with NaOCl and NaOH to occur in the system. The packing is designed to allow the maximum amount of surface area while minimizing the amount of pressure drop. This configuration is critical to maximize the amount of liquid to gas contact in the system, thereby maximizing the removal efficiency of the system and minimizing chemical consumption. The chemical reactions in the system create byproducts, including sodium sulfate,
sodium chloride, and minute amounts of water. In order to optimize the performance and minimize the maintenance of the system, the salt byproducts must be removed from the process. To accomplish this, fresh water is continuously injected into the sumps, controlled by a flow meter and gate valve. The salt byproducts, dissolved in the sump liquid, overflow out of the system at the same rate at which the makeup water is added. There is an overflow above the liquid level that assures that each chemical sump can never be overfilled. A low level alarm, set at below the designed sump level provides system warning. A pressure differential gauge is provided indicate normal flow conditions, and to provide a warning of solids buildup in the packing. The chemical sumps and absorption stages are housed in a single FRP chamber with access ports for easy and quick access to any part of the system. The spray nozzles in each section are easily removable. After treatment by the LO/PRO, the scrubbed air passes the exhaust fan and is pushed through a single carbon adsorbers for final polishing. The RJC Carbon Adsorber Odor Control System is a once-through chemical and adsorption system. Odorous compounds (H2S and malodorous organics) are removed from the air stream through adherence to the activated carbon porous surface, and a catalytic reduction of the H2S to elemental sulfur. The necessary equipment for each activated carbon adsorption process consists of a volume control damper, activated carbon bed, and a grounding rod. Foul air containing residual odors pass into a carbon adsorber, and through two densely packed parallel media beds. Each bed consists of 3 feet of carbon media. The activated carbon removes the hydrogen sulfide and other odor causing organic constituents. The activated carbon catalytically converts hydrogen sulfide to elemental sulfur and water by the following reaction: 2 H2S (g) + O2 (g) 1/4 S8 (s) + 2 H2O (g) The sulfur produced is adsorbed on the internal surface of the activated carbon while the water is mainly lost to the flowing air gas stream. The flowing air stream dissipates the heat. The adsorption process continues until the activated carbon pores are filled-up. The cleaned air continues through the vessel and into the exhaust ductwork. The adsorber is equipped with a carbon-grounding rod that is used to remove any static charge that might build up in the carbon media. A differential pressure gauge is used across each carbon bed to provide an indication of changes in the airflow through the adsorber. Carbon sample valves allow the extraction of representative carbon samples or air samples from the carbon bed. The duct dampers are provided with limit switches to monitor the status. An on line H2S monitor will be provided in the outlet of one of the exhaust stacks to monitor the H2S. In addition, sample ports will provide at the scrubber inlet and outlet and one hand held H2S monitor will be provided to allow for periodic measurement of inlet concentration.
B. ODOUR CONTROL SYSTEM OPERATION

The control system contained in the packaged scrubber system ECP will provide control and monitoring functions required for the operation and monitoring of the scrubber system only.
Placing any selector switch in the Off position will disable that piece of equipment. Placing any selector switch in the Hand position will manually operate that piece of equipment. Placing the System Switch in the Auto position will operate any piece of equipment in the Auto position. Placing a selector switch in Auto will place that piece of equipment in standby mode, and it will not operate until the System Switch is placed in Auto.
B.1 EXHAUST FAN OPERATION

In Hand, the fan will manually operate. In Auto, the fan will start and the Fan Running light will illuminate when there is a start command from the System Switch. In Auto Mode the Exhaust Fan will operate from DCS. The Exhaust fan will be running continuously and after every (set time) minutes the running Fan will stop and the standby fan resumes duty. The Duty for the exhaust fan is set from DCS OS. The Differential Pressure Switch is used to indicate a low pressure from the lead fan. If a low pressure condition is sustained for more than 10 continuous seconds, the Fan Low Pressure light for the Lead Fan shall illuminate, and the Lag Fan shall start. Similarly, if the motor starter thermal overload trips for the lead fan, the lead fan will stop running and there will be a low pressure condition. After 10 seconds of the low pressure alarm, the Fan Low Pressure light shall illuminate, and the Lag Fan shall start. If the fan start command is given and the fan does not start, the 10 second time delay for the differential pressure switch shall trip, the Fan Low Pressure light shall illuminate, and the Lag Fan shall start. In Hand mode, the low pressure alarm will have no affect. With the hand switch in OFF, the respective Off Light shall illuminate. Interlocks shall be provided to prevent both fans from simultaneously operating in any mode.
B.2 RECIRCULATION PUMP OPERATION (TYPICAL FOR EACH OF THE THREE STAGES)
The recirculation pumps are controlled by their respective hand switches. The Pump Running light will illuminate when there is a start command from the System Switch. The Pressure Switch is used to indicate a low pressure from the pump. If a low pressure condition is sustained for more than 10 continuous seconds, the Pump Low Pressure light shall illuminate. Similarly, if the motor starter thermal overload trips for the pump, the pump will stop running and there will be a low pressure condition. After 10 seconds of the low pressure alarm, the Pump Low Pressure light shall illuminate. A Low Level alarm in any of the three scrubber sumps shall prevent the recirculation pump for that stage from operating in Auto. Placing a pump into Hand will override any level alarm. In Hand mode, the low pressure alarm will have no affect. With the hand switch in OFF, the respective Off Light shall illuminate. In Auto Mode the Recirculation Pumps are operated from DCS OS . In Auto Mode the recirculation pumps continue to Run
Page 38 of 38
B.3 CHEMICAL METERING PUMPS

For each chemical metering pump, a Hand/Off/Auto selector switch and Running indicator is provided. A PID single loop controller is provided in the LCP for each pair of chemical metering pumps. The PID controller provides a 4-20 mA signal to the DC speed controller of the pump. The DC speed controller drives the metering pump and the appropriate speed. The metering pumps are controlled by their respective hand switches. In Hand, the pump will manually operate at a speed determined by the PID controller. In Auto, the pump will start when there is a start command from the System Switch and the PID controller for that chemical in that stage directs the pump to operate. The Pump Running light will illuminate when the pump is in Auto and the System Switch is in Auto. A Low Level alarm in any of the three scrubber sumps shall prevent the chemical metering pumps for that stage from operating in Auto. A Low Level alarm in any of the chemical storage tanks (if provided) shall prevent the chemical metering pumps for that chemical from operating in Auto. Placing a pump into Hand will override any level alarm. In Hand mode, the low flow alarm will have no effect. With the hand switch in OFF, the respective Off Light shall illuminate. Interlocks shall be provided to prevent a metering pump from operating in Auto for any stage for which a recirculation pump is not operating.
B.4 PH AND ORP CONTROLS:

PID controllers are mounted on the face of the ECP, which receive a signal from the pH and ORP probes mounted on the scrubber. The output of the PID controller is sent to the respective chemical metering pump DC Speed Controller to control the flow of the chemical to the scrubber. The controllers are programmed to execute the P, I, D control functions as required to reach the desired pH/ORP set points of the scrubber solution.
B.5 SCRUBBER SUMP LEVEL:

Each of the three scrubber sumps is provided with float-type low and high level switches. Upon activation of a low- or high-level, the respective Level light will illuminate. The light will remain illuminated until the condition is corrected AND the Alarm Reset pushbutton is depressed. A low level condition in a sump will inhibit the recirculation and metering pumps for that sump from operating in Auto.
D.6 DAMPER STATUS

Status lights are provided for each control damper and shall illuminate when the respective damper is Open.
B.7 ALARM RESET PUSHBUTTON

All alarm lights shall latch on once an alarm condition is realized. The lights shall remain illuminated until acknowledged by an operating by pushing the Alarm Reset pushbutton. The illuminated alarm lights will re-light unless the alarm condition has been corrected.
18.2.SLUDGE ODOR CONTROL A.PROCESS DESCRIPTION

All channels, screens, grit chamber, screening conveyor, screen treatment, grit classifiers, grit treatment, and wet wells are covered and provided with air ducting system to convey foul air to the Odor Control Unit. An Odor Control Facility is provided comprised of a 2-stage LO/PRO chemical scrubber followed by a single bed activated carbon adsorber filled high capacity carbon media. The intention of the carbon adsorber is to provide final polishing of any residual odors that escape the chemical scrubber and to provide backup odor control during periods when the scrubber system is undergoing maintenance. Hydrogen sulfide laden air passes through ductwork to the LO/PRO odor control scrubber. The system utilizes Sodium Hydroxide (NaOH) and Sodium Hypochlorite (NaOCl) to react with and remove the odorous compounds present in the airstream. The chemistry of the system is as follows: under alkaline conditions and with the presence of excess NaOCl, H2S is oxidized to form sulfuric acid. This sulfuric acid is then neutralized by NaOH to form the stable byproduct sodium sulfate. In order to compensate for the consumption of NaOH and NaOCl in the system the pH and Oxidation Reduction Potential (ORP or Redux) are continuously monitored by pH and ORP probes and controllers. Chemical dosing pumps maintain the pH and ORP levels automatically, receiving signals from the pH and ORP PID controllers. Siemens Water Technologies LO/PRO odor control system is a "once-through", two stage absorption system consisting of two vertical counter-current gas absorption sections. The exhaust fan pulls the odorous air from the H2S producing areas and through the LO/PRO odor control system. The foul air first enters a pre-conditioning stage (Stage 1) where it is contacted with liquid from the Stage 1 sump in a counter-current arrangement. The Stage 1 sump consists of a solution of Sodium Hydroxide (NaOH) at a pH between 10-10.5. The first stage removes approximately 70% of the inlet H2S. In the counter-current third stage, the remaining 30% of the inlet H2S, and any residual organic odors are contacted with a solution of NaOH and NaOCl. The final stage assures the remaining odorous compounds are oxidized. The scrubbed air is discharged from the system through a mist eliminator. A polypropylene packing media is used to allow the necessary chemical reaction of H2S with NaOCl and NaOH to occur in the system. The packing is designed to allow the maximum amount of surface area while minimizing the amount of pressure drop. This configuration is critical to maximize the amount of liquid to gas contact in the system, thereby maximizing the removal efficiency of the system and minimizing chemical consumption. The chemical reactions in the system create byproducts, including sodium sulfate, sodium chloride, and minute amounts of water. In order to optimize the performance and minimize the maintenance of the system, the salt byproducts must be removed from the process. To accomplish this, fresh water is continuously injected into the sumps, controlled by a flow meter and gate valve. The salt byproducts, dissolved in the sump liquid, overflow out of the system at the same rate at which the makeup water is added.
There is an overflow above the liquid level that assures that each chemical sump can never be overfilled. A low level alarm, set at below the designed sump level provides system warning. A pressure differential gauge is provided indicate normal flow conditions, and to provide a warning of solids buildup in the packing. The chemical sumps and absorption stages are housed in a single FRP chamber with access ports for easy and quick access to any part of the system. The spray nozzles in each section are easily removable. After treatment by the LO/PRO, the scrubbed air passes the exhaust fan and is pushed through a single carbon adsorber for final polishing. The RJC Carbon Adsorber Odor Control System is a once-through chemical and adsorption system. Odorous compounds (H2S and malodorous organics) are removed from the air stream through adherence to the activated carbon porous surface, and a catalytic reduction of the H2S to elemental sulfur. The necessary equipment for each activated carbon adsorption process consists of a volume control damper, activated carbon bed, and a grounding rod. Foul air containing residual odors pass into a carbon adsorber, and through one densely packed media bed. The bed consists of 3 feet of carbon media. The activated carbon removes the hydrogen sulfide and other odor causing organic constituents. The activated carbon catalytically converts hydrogen sulfide to elemental sulfur and water by the following reaction: 2 H2S (g) + O2 (g) 1/4 S8 (s) + 2 H2O (g) The sulfur produced is adsorbed on the internal surface of the activated carbon while the water is mainly lost to the flowing air gas stream. The flowing air stream dissipates the heat. The adsorption process continues until the activated carbon pores are filled-up. The cleaned air continues through the vessel and into the exhaust ductwork. The adsorber is equipped with a carbon-grounding rod that is used to remove any static charge that might build up in the carbon media. A differential pressure gauge is used across the carbon bed to provide an indication of changes in the airflow through the adsorber. Carbon sample valves allow the extraction of representative carbon samples or air samples from the carbon bed. The duct dampers are provided with limit switches to monitor the status. An on line H2S monitor will be provided in the outlet of the exhaust stack to monitor the H2S. In addition, sample ports will provide at the scrubber inlet and outlet and one hand held H2S monitor will be provided to allow for periodic measurement of inlet concentration.
B. ODOR CONTROL SYSTEM OPERATION

The odor control System Operation is as explained in section B in 18.1.
Page 41 of 41

Op Kubd PS

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Op Kubd PS

Uploaded by

Copyright:

Available Formats

STUDY, DESIGN & CONSTRUCTION, OPERATION & MAINTENANCE OF PUMPING STATION, WASTE WATER TREATMENT PLANT & PRESSURE

KUBD WWTP OPERATION PHILOSOPHY

Document Version: 1.0 Date Last Updated: 04/02/2010

Title: Project : Doc Number:

2. INLET WORKS ......................................................................................... 7

3. VLR SYSTEM ................................................... ERROR! BOOKMARK NOT DEFINED.

5. RAS/SAS PUMPS .................................................................................... 14

6. DISK FILTER .................................................... ERROR! BOOKMARK NOT DEFINED.

SLUDGE THICKNER SYSTEM.................................................................. 22

10.1. 10.2. 10.3. 10.4. 10.5.

SLUDGE DEWATERING SYSTEM ............................................................. 24

11.1. 11.2. 11.3. 11.4. 11.5.

AEROBIC DIGESTOR ............................................................................ 26

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number: 12.2.

CHLORINATION SYSTEM ....................................................................... 27 AIR BLOWERS .................................................................................... 29

13.1. 14.1. 14.2.

SCUM PUMPING STATION...................................................................... 31

15.1. 15.2. 15.3.

RETURN LIQUOR PUMPING STATION ....................................................... 33

WASH WATER PUMPING STATION .......................................................... 35

ODOR CONTROL SYSTEM- INLET AND SLUDGE ......................................... 36

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

Revision History This Sheet Issue No. A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Revision Level B C D 0

This Sheet Issue No. A 31 32 33 34 35 36 37 38 39 40 41

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

DCS I/Os RIO IL VLR RLP WWP

M3/Hr M3 Bar C kWH kW V A Hz RPM M pH % s

Title: Project : Doc Number:

mV ppm mm/sec or inch/sec NTU Kg ppm

1.4. REFERENCE DOCUMENT

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

Title: Project : Doc Number:

2.2. OPERATION SEQUENCE

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

3.2. NORTH VLR DISC

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

3.3. SOUTH VLR DISC

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

Title: Project : Doc Number:

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

5.2. RAS PUMP OPERATION

Title: Project : Doc Number:

SAS PUMP OPERATION

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

6.2. OPERATION OF DISC FILTER AND BACKWASH PUMP

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

FLOW RANGE RANGE 1 RANGE 2

Version 1.0/Release Date 6/2/10

Title: Project : Doc Number:

Version 1.0/Release Date 6/2/10