TOPSOILS OF AUSTRALIA PTY. LTD.

Manual for
operators

Compost Plant

Written by Faye Milroy, Prior Training. (03) 9386 8145

Technical assistance was provided by John Karounos, Brian Jeffrey, and John Cowey from
Geelong Wool Combing Ltd and Topsoils of Australia Pty Ltd.

July 2003

Contents
Section 1: Introduction
1.1
The training program
1.2
Operator tasks
1.3
The top-making process at GWC
1.4
Overview of the composting process
1.5
The Environmental Management System
1.6
Word list

1
1
2
3
5
6
7

Section 2: Occupational Health and Safety

2.1
Personal protective equipment
2.2
Safety in the compost plant

9
9
10

Section 3: Compost plant equipment and functions

12

3.1

Blending plant

12

3.2

Rolling stock

15

Section 4: Operating procedures

4.1
Suggested shift routine
4.2
Operating procedures for the compost blending plant
4.3
Operating the sludge collection system
4.4
Management of windrows
4.5
Compost stock level reporting
4.6
Sampling and testing procedures
4.7
Loading trucks

16
16
21
22
24
26
28
30

Section 5: Documentation

31

Section 6: Maintenance and troubleshooting

6.1
Regular maintenance and cleaning
6.2
Normal operating conditions
6.3
Using the SCADA to monitor operations

32
32
34
35

Section 7: Assessment
7.1
The assessment procedure
7.2
Checklist of operator tasks
7.3
Oral questions Compost plant operator

37
37
38
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Compost Plant Operator Manual

Section 1:
1.1

Introduction

The training program

The purpose:
To train you to operate and monitor the Compost Plant efficiently and safely, with little
supervision in accordance with company enterprise agreements.
Training objectives:
At the end of this training the operator will be able to:
1. explain the function of the compost plant
2. explain and demonstrate the major duties of the compost plant operator, including
a. materials handling
b. documentation and communication
c. monitoring compost plant functions
d. monitoring quality and taking samples
e. operating and adjusting composting equipment
f. chemicals handling
g. following safety procedures
h. performing basic maintenance

Assessment methods:
1. practical demonstration of competency on the compost plant equipment, according
to the checklist at the back of this manual
2. satisfactory answers to oral test questions relating to compost plant operations and
the monitoring of composting functions

Note that a compost plant operator needs to have:

a heavy truck licence (manual)

a loader permit

a forklift licence

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1.2

Operator tasks

The duties for the compost plant operator include:

1.

Conducting materials handling

operate a truck, loader, tractor, water cart, windrow turner and fork lift
handle bulk materials, such as fertiliser, sawdust, fresh / mature compost

2.

Working with documentation (paper and electronic)

read and maintain compost records
record despatch dockets
maintain vehicle log books
maintain plant fault log

3.

Communicating with others

explain compost functions and operations
talk to delivery personnel and visitors
communicate with ETP and other operators

4.

Working without supervision

plan and prioritise own work

5.

Interpreting and monitoring compost plant technology

SCADA computer screens

6.

Operating and adjusting compost plant equipment

process all bio-sludge and GWC waste streams to correct ratio
maintain level in feedstock hoppers
remove fresh compost to windrow area daily
maintain sawdust supplies
clean up and dispose of general waste
load compost into trucks
ensure proper running and maintenance of conveyors

7.

Managing the windrows

monitor and record windrow temperatures weekly
turn and water windrows weekly
maintain, and ensure access in, windrow area (fill in pot-holes, etc)
maintain leachate dams

8.

Performing basic maintenance

regular cleaning and maintenance of rolling stock
fixing basic problems with equipment
ensure regular inspection / service on rolling stock and plant equipment

9.

Monitoring compost quality

regular sampling and testing of compost
monitoring temperature and moisture levels

10. Following safe work practices

use appropriate personal protective equipment
observe plant safety procedures
refer to and follow Material Safety Data Sheets (MSDS)
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Compost Plant Operator Manual

1.3
1.

6.

7.

The top-making process at GWC our raw material supplier

Receivals/Wool Store
Bale specifications are checked.
Bale lots stacked together.

2.

Gilling (3 stages)
Blends a number of slivers together.
Makes the fibres parallel.
Forms a sliver of even thickness.
Forms a sliver of desired weight.

5.

Combing
Removes short fibres and small tangles
(neps).
Removes remaining vegetable matter.
Blends many slivers into one.
Makes fibres parallel.

8.

Opening and blending

Compacted bales are opened.
Wool bales are blended into lots.
Dust, dirt and seeds sent to storage
bins for compost

3.

Carding
A machine with a series of rollers
covered with metal pins.
Untangles clumps of wool into
individual fibres.
Removes vegetable matter and dust.
Begins to make fibres parallel.
Forms wool into a continuous sliver.

Finishing (2 stages)
Completes process of blending and
making fibres parallel.
Forms sliver of desired weight and
evenness.
Winds sliver into a top or bump.

Scouring
Wool is washed in detergent to remove
grease, sweat (suint) and dirt.
Wool is rinsed and dried.
Wool blended and anti-static oil added

4.

9.

Effluent treatment
Wool grease is extracted for lanolin.
Sludge is removed for compost.
Clean water is recycled or released to
sewer.

Pressing
The tops are compressed into bales for
despatch.
Waste by-products are also pressed into
bales for sale.

10. Despatch to customers

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1.4

Overview of the composting process

A typical bale of greasy wool might contain only wool fibre:

wool fibre 55-65%
moisture 5-10%

wool grease 12-15%

suint 5-8%
dirt, soil 10%
vegetable matter 2-5%

All of these impurities must be removed from the wool. Most of the dirt, suint and grease
is removed during the scouring process. The remaining dirt and vegetable matter is
removed during opening, carding, gilling and combing.
Traditionally, the wool grease is recovered and sold as a by-product as is the noil (short
fibres). The rest of the waste (dust, dirt, vegetable matter) used to be disposed of to the
rubbish tip, for which we paid a dumping fee.
GWC became the first early stage wool processor to develop a system to recycle this waste
and turn it into a saleable by-product compost.
The compost plant receives GWC waste from three main sources:

When the compacted wool bales are opened and blended, the dust, dirt and seeds
that are removed are transported by cyclone to a large storage bin.

The liquor from the scour contains dirt, sweat, wool wax and vegetable matter.
The wool wax is separated and removed in grease recovery. The ETP treats the
remaining liquor and recycles some water back to the scour, while the sludge
passes through the bio-decanter before arriving at the compost plant.

The dust and airborne waste from carding is also cycloned to a storage bin.

Other dry feedstock such as sawdust is sourced externally and stored in bins on site.
During production, the dry material from hoppers 1 & 2 and the sludge from the bio all
feed into the mixer. The ratio (weight) of each material in the blend is preset via the
controller according to the required recipe. For some blends extra nutrients are also fed
into the mixer from hopper 3.
After mixing, the fresh compost is arranged in long heaped mounds called windrows. It
takes about 4 months for the compost to mature, during which time the windrows are
turned weekly. This ensures adequate oxygen levels to support the microbial activity.
Moisture levels, pH and temperatures are also carefully monitored to make sure the
composting process is optimised to ensure client satisfaction.
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Flow chart of the compost process

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Compost Plant Operator Manual

1.5

The Environmental Management System

GWC was the first wool processor in the world to obtain certification to the Environmental
Standard ISO 14001 on the 22nd January 1998.
Why is GWC/Topsoil concerned about environmental management?

Legal Requirements
There are various agreements and regulations relating to the environment which
have to be followed so that GWC/Topsoil can lawfully carry on its activities at
Lara.

Marketing Demands
Certain clients require GWC/Topsoil to offer proof that our operations are carried
out in a manner that does not harm the environment.

Cost Savings
Reduction in waste and recycling should deliver cash savings.

Neighbourhood Relations
GWC/Topsoil can have an effect on neighbours from the emission of noise, dust
or odours. We have procedures in place to monitor each of these impacts.

Several environmental procedures and work instructions cover the compost plant. Your
trainer will take you through the procedures and work instructions related to your job.
It is your responsibility to follow these procedures, and to immediately report any
environmental accident or incident.

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1.6

Word list

Aerobic

A microbial process that uses oxygen to break down

substances.

Anaerobic

A microbial process that breaks down substances without

oxygen, but produces odours.

Ausplume odour
modelling

A method of determining the environmental impact of odour

emissions generated by composting.

Australian Standard
AS 4454

The quality standard that applies to composts, soil

conditioners and mulches used by Topsoils.

Bio-aerosols

Small air-borne particles which may contain bacteria or fungi

spores.

Bio-sludge

The resulting sludge from the biological treatment of scouring

liquors once the wool grease has been recovered.

Bulk Density

A factor used to convert compost production tonnes into

cubic metres (m3).
Example:
0.5 tonne fresh compost will fill a container measuring 1m3
therefore the BD is 0.5(tonne) divided by 1(m3) = 0.5.
So in a day's compost production of 120 tonnes divided by a
BD of 0.5 = 240m3.

Compost

Partially decomposed organic matter produced by microbial

activity, and suitable for improving soil quality.

EC

Electrical Conductivity - a measurement of the salinity in

soils and composts.

Friable

The term given to soil or compost that has a loose, crumbly

texture.

Heavy metals

A group of metals such as Lead and Mercury which are

dangerous to humans and cannot be degraded by composting.

ISO 14001

Environmental Management System (standards) followed by

Topsoil.

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Compost Plant Operator Manual

Leachate

Excess water that has run off or through the composting

material.

MSDS

Material Safety Data Sheet

Pasteurized compost

Compost which has been subjected to a minimum

temperature of 550C for at least three consecutive days.

Pathogens

Harmful bacteria or viruses usually associated with sewage.

Pesticide residues

Harmful chemicals sometimes found in soils and sludges,

resulting from sprays used by farmers for controlling lice and
other pests on sheep and livestock.

pH

A measurement of the acidity or alkalinity of soil or compost.

PH is measured on a scale from 1 to 14, with 7 being neutral.
The pH becomes more alkaline as it rises above 7, and more
acid as it falls below 7. The pH of the soil or compost affects
the uptake of nutrients by plants

Plant propagules

Weed seeds.

SCADA

Supervisory Control and Data Acquisition; a computer

programme used to monitor the batching process and retrieve
information for making production and stock reports.

Scouring

Washing out the dirt, sweat and wool grease from wool.

Suint

Sweat produced by sheep that is removed during scouring and

consists of Potassium salts.

Thermophilic process

Aerobic microbial activity which produces heat between 440C

- 800C during the composting maturation phase.

Water retention

Ability of soils to hold moisture, affected by the level of

organic matter (compost).

Windrow

A row of heaped composting material.

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Section 2:
2.1

Occupational health and safety

Personal protective equipment (PPE)

Hearing protection must be worn in the production areas, to protect
your ears from machinery noise.
Sound can damage your ears if it is too loud, too high in frequency, or
you are exposed too often.
With some noise your ears will hurt straight away, with other noise
the damage to your ears will happen gradually over time.
You will not "get used to the noise."
You will get used to your loss of hearing!
Remember, once your ears are damaged they never get better.

Rigger's gloves are provided where required for manual work.

Rubber safety gloves are provided when handling certain
chemicals and harmful substances.

Certain tasks require eye protection or breathing protection, or

both.
For example, eye and breathing protection must be worn while
performing any cleaning task that causes fibres, aerosols or
dust to circulate in the air.

Face protection may also be necessary when handling certain

chemicals, to prevent being splashed or breathing in fumes.

Steel cap boots must be worn in all production areas.

Long hair should be tied back or covered when working near

machinery.

Safety vests must be worn around the compost plant so that

you are visible to drivers

Sunglasses, hat and sunscreen for sun/outdoor work

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Compost Plant Operator Manual

2.2

Safety in the Compost Plant

Drive safely when using any vehicles around the plant.

Do not exceed 15 km/h

look out for pedestrians

make sure other drivers are aware of speed limits

be aware of extra hazards around wet areas

Because of vehicle hazards, monitor access of people to the plant.

all visitors must report to office first

drivers must be alert that other people around the work

site

Use channel 7 on the hand held (CB) radio and notify all
drivers if visitors or staff are nearby

Chemicals

Know the hazards associated with the chemicals you use

in the compost plant

Refer to the MSDS for each chemical for safe handling

procedures

Maintain a high standard of hygiene, particularly around food.

always wash your hands before eating

Emergency stops

Know where the lanyards, on/off and emergency stop

buttons are located, in case of emergency.

Lock out procedure

Isolation of equipment will be in accordance with Tag

Out and Lock Out Procedure, SAF- 001.

Make sure all equipment is tagged out/locked out before

any cleaning or maintenance work

Do not start up any equipment that is locked out.

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Compost Plant Operator Manual

Heavy lifting

Keep your back straight and let your legs do the lifting

Slips, falls

Take care when moving around the plant. Wet floors and
steps can be slippery.

Always face machine when entering/exiting machine and

have a firm grip of the handrail.

Compost Plant emergency procedures (Refer to work instruction)

The following procedures outline what to do in the case of emergencies such as power
failure and fire. These procedures are only to be followed if it is safe to do so.
Do not put yourself at risk to carry out these procedures.
Power failure

If safe to do so:

Turn off power and air

Turn off and lock all machinery and rolling stock

Keep the keys on your person

Proceed to the assembly area.

Resumption of power

Reset the plant.

Return all keys to designated location

Complete incident report

In case of fire hazard hit the group emergency switch.

If time permits follow the steps under power failure, do not put yourself at
risk.

Proceed to the assembly area.

Fire

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Compost Plant Operator Manual

Section 3:
3.1

Compost plant equipment & functions

Blending plant
Hopper 1
Sludge silo

Discharge
conveyor

Hopper 2

Hopper 1

Collects and stores waste from the wool opener, the cards and
cyclone system such as dust, dirt and vegetable matter premixed
with sawdust.

Hopper 2

Collects and stores sawdust.

Hopper 3

Adds fertiliser in specified blend for Pine Gro mix

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Compost Plant Operator Manual

Sludge silo

Collects and stores bio-sludge from the effluent treatment plant

(ETP).

Monopump

Pumps the bio-sludge from the ETP to the silo. Fitted with a
protection device to prevent it running dry.

Mixer

Combines material from the hoppers and silo. Functions such as

feedstock ratios (by weight) and mixing times are centrally
controlled. Total batch weight not to exceed 1,200kg.

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Compost Plant Operator Manual

Conveyors

Conveyor belts feed material from the hoppers to the mixer. A

discharge conveyor transfers the mixer contents to a concrete
hardstand.

Gravity fed air

valve

Enclosed transport for biosludge into mixer

Testing equipment

To test pH, temperature and moisture (Refer to section 4.6)

SCADA

Controls all aspects of mixing plant including mixing time and

mixing ratio.

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Compost Plant Operator Manual

3.2

Rolling stock

Windrow turner

Fitted with purpose-built device to turn outer material to the inside

of the windrow. Weekly turning maintains the necessary oxygen,
temperature and moisture levels.

Front-end loader

Fitted with a bucket of certified volume (5.2m), used to add

feedstock to the hoppers, to load trucks and to measure windrow
stock levels.

Skip truck

To pick up feedstock and transport compost.

Tractor

To pull the water cart and windrow turner along windrows.

Forklift

To fill the nutrient hopper.

Water cart

To maintain moisture level in compost.

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Compost Plant Operator Manual

Section 4:
4.1

Operating procedures

Suggested shift routine

A large part of the compost plant operators job is monitoring, that is checking that the
equipment is running correctly and that the material is up to quality standards. To do this
efficiently you will need to work to a routine so that problems can be quickly identified.
An effective routine would include:

regular visual inspection of the equipment and windrows

regular checking of the SCADA screens

conducting temperature, pH and moisture tests at specified times

accurately completing compost records as required

handling deliveries and sales

At the start of your shift

1. check the SCADA screens for anything that needs attention

2. check the vehicle and equipment maintenance logs for any problems
3. carry out a visual inspection of the blending plant
4. start production
5. carry out a visual inspection of the windrow area
6. conduct tests and complete records as required
A suggested route to follow is:
Site office
SCADA

Blending
plant

Blending
plant

Windrow tests
/maintenance

July 2003

Vehicle checks
/maintenance

Windrow area
inspection

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Compost Plant Operator Manual

What to check at each location on your route

Site office:

At start of shift:
1. Check board for any messages/jobs to do.
2. Monitor operations on the SCADA screens:

silo level if low, check with ETP

hopper levels if low, need to top up

make sure everything is shut down from previous shift

3. Check equipment repairs log book.

4. Check vehicle log books.
At other times during shift:
1. Monitor operations on the SCADA screens:

Production/Sales:

trends screens

overview screen

1. Check that mixer is empty before start up (or it will overflow).

2. Check if hoppers need filling.
3. Start up blending plant equipment.
4. Check to see that conveyor is clear of feed stock at all times.
5. Keep blending area clean and free of excessive build up
6. Sales: loading of trucks takes priority.

Vehicle checks

1. Perform checks on all vehicles as per log book.

2. Check loader radiator and air filter are clean.

Windrow
Maintenance

1. Turn and water as per sheet in tractor, weekly.

2. Take temperature with probe and record details, weekly.
3. Construct new windrows as required and record details.
4. Conduct windrow stock level surveys and record details.

Area Maintenance:

1. Maintain work area and surrounds in a clean and safe manner.

2. Fill in pot holes and maintain a level surface.

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Compost Plant Operator Manual

4.2

Operating procedures for compost blending plant

(Refer to work instruction COM-WI-001)

4.2.1 Prestart checks

1. Check compressed air

Check that the compressed air is turned on.

The regulated pressure on hopper 2 and mixer
gauges should be above 600 Kpa.

2. Set batch values

From the main control panel touch screen:

enter Batching Control window through the

Home window

set the desired batching values for hoppers 1

& 2 and sludge silo

The total batch weight should not exceed 1200kg

3. Check sludge silo setting In the Sludge Silo Batching Control window,
make sure that the time/weight cell (top right hand
corner) reads weight.
4. Set batch run time

Enter Run Features window, set the Batch Time

value to 10-20 seconds.

5. Reset alarms

Reset any alarms that are being reported in the

Safety Alarms window.

6. Fill hoppers

Fill hoppers 1 and 2 to maximum level.

7. Check area is clear

Check that all personnel are clear from the

equipment.

4.2.2 Mixer load

The mixer load increases as the ingredients blend. To protect it against overload,
the mixer is fitted with a load monitor. Should the mixer reach 95% of its rated
load, the discharge door will open immediately and empty the mixer contents.
Check the following:
1. Batch weights

The preset batch weights must be set correctly and

not exceed 1200kg.

2. Discharge time

The discharge time must be sufficient to empty the

contents of each batch.

3. Mixer is empty

Make sure the mixer is empty before starting up, as

the contents will upset the batch weights.

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Compost Plant Operator Manual

4.2.3 Blending system start-up - Local Touch Screen

(refer to attached Flow Diagram 1)

1. Turn key ON

Turn the Master Control key to the on position.

Note: #1 and #2 'Ready to Fill' lights should be lit, not
flashing. Check to see that mixer is empty.

2. Select product

Usually Topsoil or GWR

3. Select manual

Enter the Manual window and select Manual mode.

4. Select Auto

In the 'Manual' window select 'auto' to start the batching

process.
Enter the 'auto mode' screen and ensure that:
i) the 'Automatic' cell is flashing
ii) the 'Resume/Suspend' cell is reading 'Suspend'.
Note: if the batching plant does not start tap the 'Reset'
cell followed by the 'Start Cycle' cell.

5. Alarm

A local audio alarm, warning automatic start-up of the

batching hoppers, will sound 10 seconds before every
new batching cycle.

6. Filling hoppers

The filling of hoppers 1 & 2 can only be done when the

Ready To Fill light is lit. Do not attempt to fill the
hoppers unless the 'Ready to Fill' lights are lit or
flashing.
Should the contents of H1/H2/Silo become less than
their preset batch weights, the relevant Ready to Fill
light will flash. Further blending will stop until the
condition is fixed.
The contents of hoppers 1 & 2 should be maintained at a
good level to avoid excessive action of the electric
vibrators mounted on the sides of each hopper.

7. Mixer discharge

An alarm will sound between 5-10 seconds before

automatic start-up of the mixer discharge conveyor.

8. Skip truck

Skip is to catch the discharge at all times so that it can

be taken to the windrows

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Compost Plant Operator Manual

START AUTO
BATCHING

Flow Diagram 1

MIXER DISCH GATE

CLOSE

MIXER RUN
TIME DELAY
CHECK MINIMUM
BATCH WEIGHT
H1/H2/SILO

NOTE 1

ABOVE MIN
EXTINGUISH H1/H2
'READY TO FILL'
LIGHT

AUTO STARTUP
AUDIO ALARM
TIME DELAY
CONV 1 RUN

BRIDGE BREAKER
RUN
AUGER DISCH
GATE OPEN

HOPPER 1 OPEN
VIBRATOR RUN
DROP PRESET
BATCH WEIGHT

TIME DELAY
SLUDGE SILO
AUGER RUN

DROP PRESET
BATCH WEIGHT

AUGER DISCH
GATE CLOSE

SLUDGE SILO
AUGER STOP

BRIDGE BREAKER
STOP

HOPPER 1 CLOSE

VIBRATOR STOP

CONV 2 RUN

ILLUMINATE H1
'READY TO FILL'
LIGHT

HOPPER 2 OPEN

VIBRATOR RUN

DROP PRESET
BATCH WEIGHT

ILLUMINATE H2 '
READY TO FILL'
LIGHT

HOPPER 2 CLOSE
VIBRATOR STOP

BATCH TIMER

TIME DELAY
MIXER LOAD
MONITOR

AUTO STARTUP
AUDIO ALARM
ENABLED

CONV 2 STOP

TIME DELAY
TIME DELAY

DISCHARGE CONV
START

MIXER DISCH
DOOR OPEN

CONV 1 STOP

TIME DELAY
MIXER DISCH GATE
CLOSE
TIME DELAY
DISCHARGE CONV
STOP

July 2003

NOTE 1: H1/H2/SILO 'READY TO FILL'

LIGHTS WILL FLASH IMMEDIATELY
IF THE RESPECTIVE HOPPER/SILO
CONTENTS FALL BELOW THE
MINIMUM BATCH WEIGHT.

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Compost Plant Operator Manual

4.2.4 Blending system shutdown

1. Select Manual

When the last batch is discharging enter 'Manual'

mode in 'Manual' window
The mixer discharge door will close and the mixer
will continue to run.

2. Open discharge door

Open the discharge door using the touch screen to

discharge all of the mixer contents.

3. Turn off

Turn everything off. Turn the 'Master Control' key

to off then remove it to the site office keyboard.

Fresh compost

As each skip is filled with fresh compost, it should be moved to the windrow area. Form
the windrows in numerical order by batch number, according to the Windrow Layout
Report Sheet.

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Compost Plant Operator Manual

4.3

Operating the sludge collection system

(refer to attached Flow Diagram 2).

The Monopump sludge collection system works independently of the Compost Blending
Plant. It pumps bio-sludge from the Effluent Treatment Plant (E.T.P.) to the sludge silo at
the eastern side of the blending plant.
The sludge silo has a nominal capacity of 27,000 kgs.
The Monopump is located on the north wall of the E.T.P.
4.3.1 Automatic Control

1.

From the Compost Main Control Panel touch screen enter the Monopump
window and select ON for normal operation.

2.

The pump control will automatically place the Monopump in standby mode
when the sludge level in the Monopump hopper falls to the low position.

3.

When the silo reaches a capacity of 23,000 kgs the Silo Full alarms are
enabled in the E.T.P. The operator can then hold back the bio-sludging.

4.3.2 Manual Control

1.

The monopump manual control push button is located adjacent to the hopper
outside the E.T.P.

4.3.3 Monopump protection

The monopump is fitted with a pressure monitoring device to protect the pump
from running dry. Biosludge will require between 2-10 bar to pump it into the
sludge silo.
If the pump pressure falls below the pre-set pressure for 60 seconds, the monopump
system will automatically shut down into stopped mode. This is indicated by a
flashing red light in the ETP control room and above the North exit door.
Check that the monopump level sensor is clean, free of wet sludge and that the
level in the monopump hopper is about 10%. Restart the monopump from the
manual control push button located adjacent to the monopump hopper, or from the
touch screen in the compost batching plant.
4.3.4 By-Pass

When filling the sludge silo in decanter by-pass mode, the batching system must be
turned OFF. This is for two reasons:

To maintain accuracy of the daily sludge tally

To prevent overfilling of the mixer with biosludge

The by-pass system fills the silo in 1 2 hrs (27,000 kgs).

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Compost Plant Operator Manual

Flow Diagram 2
AUTOMATIC CONTROL
SELECT
MONOPUMP 'ON'

SILO LEVEL
ABOVE 27000KG

ALARMS
FAST FLASH
'MONOPUMP
STOPPED' LIGHT IN
ETP

SILO LEVEL
BELOW
27000KG

FLASH 'SILO FULL'

LIGHT IN E.T.P/
SILO
'ACKNOWLEDGE
SIREN' PUSH
BUTTON

FAST FLASH
'MONOPUMP
STOPPED' LIGHT IN
ETP

SELECT
MONOPUMP 'OFF'

AUTO CHECK
MONOPUMP
HOPPER LEVEL

CONSTANT 'SILO
FULL' LIGHT IN
E.T.P/SILO

'ACKNOWLEDGE
SIREN' PUSH
BUTTON
SILENCE 'SILO
FULL' SIREN IN
E.T.P.

SILO LEVEL
BELOW 27000KG

MONOPUMP
HOPPER LEVEL
ABOVE 80%

EXTINGUISH 'SILO
FULL' LIGHT IN
E.T.P/SILO

MONOPUMP RUN
PUMP PRESSURE
BELOW 5 BAR FOR
60 SECONDS

SOUND 'SILO FULL'

SIREN IN E.T.P.

MONOPUMP
HOPPER LEVEL
BELOW 10%
MONOPUMP
STANDBY

MANUAL CONTROL
LOCAL MONOPUMP
MANUAL CONTROL
PUSHBUTTON

MONOPUMP RUN

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4.4

Management of windrows

Good windrow management ensures correct oxygen, moisture and temperature levels are
maintained during the maturation period.
4.4.1 Windrow shape

1.

The windrow is constructed with a parabolic (curved) profile.

The initial size of 1.7m high x 5.5m wide at the base gives maximum natural
ventilation through the mix.
1.7m

5.5m
2.

Each windrow will be either 200m or 300m in length running east/west.

Allow 8.0m between windrow centres for machinery access.

8.0m

3.4m

3.

A layout identifying each windrow and its age will be maintained in the
Topsoil spreadsheet.

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4.4.2 Windrow turning

1.

To maintain the oxygen level for the thermophilic (bacteria) process

windrows must be turned once per week.

2.

Windrow moisture level must be kept between 40% - 60%. Direct a jet of
water into the top of the windrow along its length, prior to turning. This will
avoid leaching.

3.

Windrows are turned using a windrow turner fitted with an inverter conveyor.
This ensures that the material on the outside of the windrow is turned to the
inside each turning.

Above: Windrow turning

Below: Windrow survey

Separate stockpile

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4.5

Compost stock level reporting

4.5.1 Windrow Survey Method

A loader fitted with a bucket of certified volume (5.2m) will be used to survey the
stock level of a windrow. (Check ISO procedure)

1. Remove 52m3

Mark the start of the windrow you are surveying.

(10 buckets)

Using the loader, move 52m3 (10 buckets) of

compost material from the end of a windrow. Form
the removed compost into a separate stockpile.

Measure the distance of the space left from the

material you have removed.

Calculate the volume factor (m3 per linear metre).

Example: 52m3 removed, leaving a space of 8 metres

52
8
2. Calculate stock level

= 6.5 m3 per linear metre

Measure the original length of the windrow. (i.e. the

length before you removed the 10 buckets)

Calculate the full windrow stock level by

multiplying the volume factor by the original
length of the windrow.

Example: length of complete windrow is 250 metres

Windrow volume = 6.5 x 250 = 1,625 m3

3. Repeat for other
windrows

Use this method to determine the stock level on all

batches 4 months old and over.
This survey method is used on all applicable batches to
report compost stock levels at the end of each month
until the batch is exhausted.

4. Adjust stock levels

Include batch numbers on each despatch docket so that

stock adjustments can be made and reported on a batchby-batch basis at the end of each month.
Subtract the docket book stock level from the surveyed
stock level to calculate any discrepancies.

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4.5.2 Reduction Factor

The reduction factor is calculated automatically by computer on all batches 4

months old and over. This is done by dividing the surveyed stock level by the fresh
compost produced.
The typical reduction factor is between 30-35%, due to biological activity and wind
loss. A higher reduction factor must be reported as this would not be due to
natural factors.
A log will be kept of the age and reduction factor for each batch so that the
historical reduction factor can be monitored.
The reduction factor of all batches at 4 months old will be averaged every 12
months, and used to correct the stock level of all batches under 4 months old.
4.5.3 Feedstock Bulk Density

The moisture content in the sawdust feedstock markedly affects volume when
converting the fresh compost from tonnes to cubic metres. To compensate when
sawdust is noticeably wet or dry, apply the measured bulk density to the days
production tally instead of the 0.5 average.

4.5.4

Stockpiling Mature Compost

Should space constraints or weather conditions make it necessary to stockpile

mature compost, each batch will be kept in discrete stockpiles prior to despatch.
All windrows from the same batch are formed into one stockpile. The relevant
batch number can then be recorded in the despatch docket book.

4.5.5 Batch Hopper Calibration

Yearly calibration checks are done on all batch hoppers and silos fitted with
weighing capability, to ensure accurate recording of input feedstock. The
frequency of these checks is detailed in Environmental Monitoring Programme,
GWC-240. Certification is recorded in the Environmental Management
Programme.

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Compost Plant Operator Manual

4.6

Sampling and testing procedures

Sample or test

Windrow core temperature

Weekly.

Method

1. Heat within the windrow indicates the level of

thermophilic microbe activity. It is important that
all windrow material is kept for long periods above
55oC.
2. Temperature is recorded at about 50m intervals
along one side of the windrow, starting at least 10m
from the end. This is done prior to turning, and
recorded on the Weekly Windrow Layout Report.
3. Insert the length of the temperature probe at least
1m horizontally, approximately half way up the
windrow height. The probe should reach the hot
centre of the windrow.

Windrow moisture level

Weekly.

1. Insert your arm into the windrow up to the elbow

and grab a handful of compost.
2. Squeeze the sample in your hand and visually
check its consistency. If it sticks together and forms
a clump without water escaping between the
fingers, the moisture level is OK.
3. If the compost is crumbly it will need watering.

Compost moisture content

Follow standard test procedure.

Carried out when required by

customer.

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Compost Plant Operator Manual

Compost pH test

Follow standard test procedure.

Carried out when required by

customer.

Compost stock levels

(Windrow survey)

End of the month. (Refer to section 4.5.1)

Compost trials

When required, to trial new methods and/or materials.

Compost quality tests

When required, to check compost quality meets

Australian Standard AS4494

Soil in windrow area

An external contractor will sample the soil within the

windrow area, to monitor the impact of the operation.

Three groundwater bores

An external contractor will sample water from three

bores, one upstream and two downstream located in a
triangular configuration, to monitor the groundwater.

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4.7

Loading trucks

Trucks are to be loaded at windrows unless the area is too soft due to
weather conditions.

If windrow area too soft, compost is to be stockpiled at loading ramp to load

trucks efficiently

Drivers are to remain in the truck or the site office at all times.

A docket is to be written out and given to the driver detailing the following
information:
- Company name
- Date
- Batch and type
- Drivers name
- Quantity of material taken
- pH if required by customer

Be courteous at all times - the drivers are our customers or represent our
customers.

If a dispute arises immediately refer the situation to your supervisor.

Loading trucks and attending to customers is a priority over other duties.

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Compost Plant Operator Manual

Section 5:

Documentation

Document

Compost Plant Computer Log

Purpose

Up to date records for each batch kept

automatically by computer:

recipe

windrow locations

age and reduction factor

stock levels

Compost Production Report.

The daily production figures are kept

automatically by the computer. They can be
accessed through the SCADA system.

Weekly Windrow Layout Report

Prior to turning, take and record windrow

temperatures at intervals of 50m. Indicates
microbe activity.

Vehicle Maintenance Log Book

Separate book for each vehicle. Record daily

safety and maintenance checks on all rolling stock.

Maintenance Job Sheet

(Repairs Log)

Use to record equipment problems for the

attention of maintenance department.

Despatch Dockets

Completed for outgoing materials. Must include

batch number so that stock level records can be
updated, in addition to the date, client, volume,
and product type.

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Compost Plant Operator Manual

Section 6
6.1

Maintenance and troubleshooting

Regular maintenance and cleaning

Equipment

Loader

Action

Check the radiator and air filter are clean 3-4 times
daily to ensure efficient cooling

Remove material build-up from bucket galleries to

prevent failure of cylinders and linkages.

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During operation and after batching, visually

check all moving parts for obvious defects.
Report any problems to the maintenance
department by completing a Maintenance Job
Sheet.

Conduct routine daily cleaning of material spillage

around equipment when it is safe to do so during
production.

Conveyor rollers and associated

structures

Clean daily to prevent build-up. Make sure the

equipment is shut down and tagged out per Tag
Out and Lock Out Procedure, SAF-001.

Production equipment

Hose down in the normal course of operation,

including the hopper loading apron. Make sure
that all resulting waste water will drain to the
Biological Treatment Plant.

Rolling stock

Conduct daily maintenance checks and record in

log book.

Maintain water and oil levels.

Grease as per manufacturers specifications.

Collect and place in the Waste oils depository

located in the Grease and Lubricants shed.

Batching plant

Waste oils and lubricants

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6.2

Normal operating conditions

As a competent Compost Plant operator you should know the optimum operating
conditions for the equipment, so that you can recognise abnormal conditions and respond
quickly with the appropriate action.
These functions can be monitored via the SCADA computer program or the blending plant
control panel.
Function/Parameter

Air pressure

Normal range

Corrective action

Above 600Kpa

Check gauges at hopper 2 and mixer.

Hopper 1

Fill to maximum

Add material when Ready to fill

light flashes. Blending will stop.

Hopper 2

Fill to maximum

Add material when Ready to fill

light flashes. Blending will stop.

23,000kg

When silo full alarm activated,

contact ETP operator immediately.

Sludge silo

(27,000kg capacity)
Batch time

2-10 seconds

Set via Run features window or

computer.

Total batch weight

1,400kg max.

Set via Batching control window or

computer.

2-10 bar

Monopump will shutdown if pressure

falls below pre-set pressure for 60
seconds.

Monopump pressure

Clean sensor and make sure hopper

level at least 10%. Restart.
Windrow
(initial formation)

1.7m high

Reform windrow to correct size.

5.5m wide
200-300m long
Run east/west
8.0m between centres

Windrow core
temperature during
maturation stage

Above 55C

Windrow moisture

45-60%

July 2003

If temperature is low, check age,

moisture and oxygen levels.
Check windrow moisture as per 4.6.

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6.3

Using the SCADA to monitor operations

The SCADA screens can be used to:

display current production data (Mimics)

display graphs of equipment operation over time (Trends)

provide data on past production events/alarms. (Historical alarms)

These functions are selected from the main menu screen:

The overview mimic screen

This screen displays:

what product is being blended

the current levels in the hoppers and silos

the equipment set points

the daily production figures

It also allows you to enable/disable the biosludge monopump.

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The trend screens

The trend screens give a graphic display of how various functions are running. Different
coloured lines are used for the various functions.
The screens below show the Batch trends. The top screen shows normal operation, while
the bottom screen displays a problem with mixer motor load.

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Compost Plant Operator Manual

Section 7:
7.1

Assessment

The assessment procedure

There are two parts to the assessment of a trainee:

a checklist to monitor the progress of the trainee and assess their competence
in all areas of operation.

a set of oral questions related to quality maintenance, workplace

communication, and occupational health and safety.

The checklist

The checklist sets out all major areas of compost plant operation and the related sub-tasks.
The trainer will check off each task:

as it is explained to the trainee.

as the trainee is observed in the task during normal operation (practice

without assessment).

as the trainee demonstrates the task while observed by the assessor for
assessment.

when the trainee has mastered all the sub-tasks and is therefore competent in
the major area of operation.

when the trainee answers the oral questions to the satisfaction of the assessor.

Note: The checklist does not set out the tasks in order of teaching.
The training program will determine in what order to teach the tasks, and trainers should
also take advantage of situations that occur in normal daily operations
(e.g. occurrence of problems and faults).
Oral test

This will take place in the training room and in the workplace during the training period.
Sample questions are included in section 7.3 of this manual.

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7.2

Checklist of operator tasks

Your trainer will initial each item on the checklist as you go
through your training program. You can then keep track of what
you know, and what you still have to learn.

Trainee assessed
as competent

Major tasks/areas of operation

Individual skills/sub-tasks

Trainee can perform

task under normal
conditions

Compost Plant

Trainee observed by
trainer in practice

Task explained by
trainer

Note that you will not necessarily learn things in this order.

Explain composting process

Identify plant equipment and describe function
Explain general safety procedures and PPE
Identify hazards of compost plant and equipment
Operate loader safely (to above 4m height)
Carry out vehicle pre-operation checks
Operate windrow turner safely
Operate tractor and bucket safely
Operate forklift safely
Start up and shut down blending plant
Enter batching program settings
Operate sludge collection system
Interpret SCADA screens
Construct windrows
Turn and water windrows
Take windrow temperatures
Survey windrow stock levels
Carry out pH test
Carry out moisture level test
Maintain production records for each batch
Complete sales dockets accurately
Clean and maintain batching plant
Clean and maintain vehicles
Clean and maintain windrow area

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7.3

Oral questions Compost Plant operator

These are questions that a workplace assessor might ask you in order to assess your
competence as a compost plant operator.
Explain the function of the Compost Plant by answering questions 1 to 3.
1. What goes into the compost, and where does this material come from?
2. How long does it take for the compost to mature?
3. What are the essential elements for the thermophilic process?
Describe the major duties of the compost plant operator by answering questions 4 to 7
4. What materials handling is the operator required to do? What equipment is used,
and what are the hazards the operator needs to consider?
5. List each item of documentation the operator has to complete (paper and
electronic), and its purpose.
6. List the people with whom the operator has to communicate, and the type of
information communicated.
7. Describe the main operator duties involved in running the compost plant,
including:
a) Starting up the blending plant
b) Operating the sludge collection system
c) Constructing windrows
d) Maintaining windrows to optimise composting process
e) Surveying windrow stock levels
f) Cleaning and maintaining vehicles
Explain the safety procedures to be followed in the compost plant by answering questions
8 to 10.
8. What is the vehicle speed limit in the compost area, and why is this necessary?
9. What personal protective equipment must be used, and why are these items
important?
10. Explain the Lock out/Tag out procedure, and when it is used.

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